Oil Cooler: Service and Repair
Removing and installing oil/water heat exchanger
Information
Overview
Overview of oil/water heat exchanger
1 - Large oil/water heat exchanger
2 - Small oil/water heat exchanger
3 - Sealing rings
Preliminary Work
1. Disconnect battery.
2. Remove pressure pipe.
3. Remove air cleaner housing.
4. Remove fuel filter.
Danger
Risk of engine failing down.
^ Danger of fatal injury, material damage.
- Support the engine with the prescribed tool.
5. Lower engine.
Lower the engine by max. 40 mm.
Support the engine using a jack with retainer plate P 9592.
Loosen and screw off M12 collar nuts on the engine mounting. Carefully lower the engine using the jack.
6. Remove left intake-air distributor.
7. Drain coolant.
Removing oil/water heat exchanger
Removing large oil/water heat exchanger
1. Disconnect lines from the oil/water heat exchanger.
Disconnecting and connecting oil/water heat exchanger
1.1. Move fuel line with plastic mounting -2- in the direction of the arrow and lay it to one side.
Vent lines on oil/water heat exchanger
1.2. Pull off coolant vent lines -1- from the oil/water heat exchanger.
Removing and installing cycle valve
1.3. Remove cycle valve -2- for active carbon filter.
1.4. Remove hose from clip and lay to one side.
2. Remove oil/water heat exchanger.
Information
Oil and coolant will flow out when the oil/water heat exchanger is removed.
Place a cloth underneath the heat exchanger and cover the generator to prevent contamination and subsequent damage to engine components.
Large oil/water heat exchanger
2.1. Remove screws -1-. Lift large oil/water heat exchanger and remove it.
Removing small oil/water heat exchanger
Information
Oil and coolant will flow out when the oil/water heat exchanger is removed.
Place a cloth underneath the heat exchanger and cover the generator to prevent contamination and subsequent damage to engine components.
1. Remove cycle valve for active carbon filter.
Removing and installing cycle valve
1.1. Pull off cable plug -3- and vacuum line -2-. Pull cycle valve for active carbon filter -1- out of the bracket and remove it.
2. Disconnect lines from the oil/water heat exchanger.
Oil breather hose
2.1. Disconnect oil breather hose -2- from the oil tank.
Vent lines on oil/water heat exchanger
2.2. Pull off coolant vent lines -1- from the oil/water heat exchanger.
Information
Oil and coolant will flow out when the oil/water heat exchanger is removed.
Place a cloth underneath the heat exchanger and cover the generator to prevent contamination and subsequent damage to engine components.
3. Remove oil/water heat exchanger.
Small oil/water heat exchanger
3.1. Unscrew screws -1- and remove oil/water heat exchanger -2-.
Installing oil/water heat exchanger
Installing large oil/water heat exchanger
1. Replace O-rings.
1.1. Clean sealing faces for large oil/water heat exchanger, remove escaping oil and coolant from the engine housing.
Insert O-rings -1- and grease with Kluber Syntheso Glep (Part No. 000.043.204.68).
O-rings for oil/water heat exchanger
2. Install oil/water heat exchanger (cleanliness is essential).
2.1. Lift large oil/water heat exchanger and insert it in installation position. Fit and tighten screws -1-.
Large oil/water heat exchanger
- Tightening torque: 10 Nm (7.5 ftlb.)
3. Connect lines to the oil/water heat exchanger.
3.1. Connect coolant vent lines -1- to the oil/water heat exchanger.
Vent lines on oil/water heat exchanger
Removing and installing cycle valve
3.2. Install cycle valve -1- for active carbon filter.
3.3. Press hose into the clip.
Fuel line on oil/water heat exchanger
3.4. Place fuel line on oil/water heat exchanger -1- and move plastic mounting -2- in the direction of the arrow.
Installing small oil/water heat exchanger
1. Replace O-rings.
1.1. Clean sealing faces for the small oil/water heat exchanger, remove escaping oil and coolant from the engine housing.
Insert O-rings -2- and grease with Kluber Syntheso Glep (Part No. 000.043.204.68).
O-rings for oil/water heat exchanger
2. Install oil/water heat exchanger (cleanliness is essential).
2.1. Position oil/water heat exchanger -2-. Fit and tighten screws -1-.
Small oil/water heat exchanger
- Tightening torque: 10 Nm (7.5 ftlb.)
3. Connect lines to the oil/water heat exchanger.
Oil breather hose
3.1. Connect oil breather hose -2- to the oil tank.
3.2. Connect coolant vent lines -1- to the oil/water heat exchanger.
Vent lines on oil/water heat exchanger
4. Install cycle valve for active carbon filter.
Removing and installing cycle valve
4.1. Push on cable plug -3- and vacuum line -2-. Insert cycle valve for active carbon filter -1 into the bracket.
Subsequent Work
1. Install left intake-air distributor.
2. Raise the engine.
Lift the engine using a jack and retainer plate P 9592 in the assembly position.
Screw in and tighten M12 collar nuts.
- Tightening torque: 85 Nm (63 ftlb.)
3. Install fuel filter.
4. Install air cleaner housing.
5. Install pressure pipe.
6. Fill in coolant and bleed the system.