174019 Removing And Installing Oil/water Heat Exchanger - Turbo
WM 174019 Removing and installing oil/water heat exchanger - Turbo
Tools
Technical values
Preliminary work
1. Raise the vehicle.
=> 4X00IN01 Lifting the vehicle.
2. Remove air cleaner housing.
=> 242519 Removing and installing air cleaner housing - Turbo - section on "Removing".
3. Remove tailpipe covers.
=> 263519 Removing and installing tailpipe cover - section on "Removing".
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
Information
- It may only be supported over a large area at the oil pan.
- Localised loading is not permitted.
Information
- When lowering, the engine must not rest on the rear axle cross member.
4. Lower the engine.
4.1. Support the engine at the oil pan using the hydraulic jack HH2 WE 1033 and transmission jack plate of transmission jack V.A.G 1383 A WE 1082.
4.2. Alternative to transmission jack plate:
Screw on the mounting peg 9163/2 in the middle using a wooden board (40 x 30 cm) and use it as a support.
Mounting peg
4.3. Loosen two special M12 nuts (internal Torx, screw insert T55) -1- on the engine mounting (hydraulic mount) at the left and right.
Engine carrier to engine mounting on cylinder bank 4-6 (view from below)
4.4. Slowly lower the engine with the hydraulic jack.
5. Remove (centre) intake-air distributor and intake-air distributor for cylinder bank 4-6.
=> 244619 Removing and installing intake-air distributor - Turbo - section on "Removing"
Component information
Overview of oil/water heat exchanger
Removing oil/water heat exchanger
Information
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E.) for external Torx, (T.) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)
1. Unclip positive crankcase ventilation line -1- ( -2- ) and set it aside.
Clip position of positive crankcase ventilation line
2. Release, pull off and remove the secondary-air line -1-.
Secondary-air line
WARNING
Hot fluid
- Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
3. Remove two coolant hoses -1- at the oil/water heat exchanger.
Coolant hoses for oil/water heat exchanger
3.1. Place a cloth under the coolant hoses.
3.2. Remove four spring band clamps and pull off and remove coolant hoses.
3.3. Soak up drops of fluid with a cloth.
WARNING
Danger of injury and material damage when using Pentosin.
- Risk of skin irritation and damage to skin.
- Damage to hoses and wiring.
-> Wear protective gloves and goggles.
-> In the event of contact (eyes or skin), wash immediately with water.
-> Collect emerging Pentosin.
-> Use caps to protect the wiring against soiling and damage.
-> Clean hoses and wiring immediately.
4. Remove hydraulic return line.
4.1. Remove Pentosin from the hydraulic supply tank using a suction and pressure syringe Nr.194.
Hydraulic return line
4.2. Disconnect hydraulic return line at the reservoir for the hydraulic pump (release and pull it out at the same time).
Disassembly tool, universal NR.21
If you do not have a special tool to hand, press the circlip backwards using two plastic spatulas or an open-ended wrench (a/f 12) and pull the hydraulic return line forward at the same time.
4.3. Pull hydraulic return line -3- out of the holder on the oil/water heat exchanger and set it aside.
Hydraulic lines
4.4. Soak up drops of fluid with a suitable cloth.
5. Affix a warning sign to the vehicle.
Warning sign for naked flames!
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
6. Remove the high-pressure connecting line.
High-pressure line between fuel collection pipes
6.1. Place a cloth underneath the plug connections to collect emerging fuel.
6.2. Loosen holder for the high-pressure connecting line -1- by unscrewing two external Torx screws (E10, M6 x 16) -2, 3-.
6.3. Loosen and unscrew union nuts -4- on the high-pressure connecting line at the fuel collection pipes.
6.4. Remove the high-pressure connecting line.
7. Remove oil/water heat exchanger.
Fastening screws for oil/water heat exchanger
7.1. Unscrew six internal Torx screws (T30, M6 x 20) -2- and remove the heat exchanger -1-.
7.2. Collect any drops of fluid with a clean cloth and clean the sealing faces.
7.3. Close off oil ducts using suitable stoppers.
Installing oil/water heat exchanger
1. Remove stoppers.
2. Clean sealing faces and replace sealing rings (2 ea.).
3. Install oil/water heat exchanger.
Fastening screws for oil/water heat exchanger
3.1. Fit oil/water heat exchanger -1- on bracket for oil/water heat exchanger.
3.2. Fit and tighten six internal Torx screws (T30) M6 x 20 -2-.
=> Tightening torque: 10 Nm (7.5 ftlb.)
Information
- Always perform a leak test in the high-pressure area after opening the fuel system.
- This is particularly important if components are disassembled and replaced.
- The threaded connections of the fuel lines must be coated with OKS 1710 lubricant (Part No. 000.043.303.27) before being screwed back on again.
- Always allow a drying time of 60 minutes for the lubricant!
- Blow residual fuel out of the lines and high-pressure pump (into a fuel-resistant container or cloth) using compressed air before installation.
- The tightening specifications must be strictly observed.
4. Install high-pressure connecting line.
Observe tightening specifications:
=> 243019 Removing and installing fuel collection pipe with fuel injectors - Turbo - section on "Installing"
High-pressure line between fuel collection pipes
4.1. Position the high-pressure connecting line -1- between the fuel collection pipes.
4.2. Fit and tighten union nuts -4-.
=> Tightening torque: 20 Nm (15 ftlb.)
4.3. Secure holder for the high-pressure connecting line by screwing in and tightening two external Torx screws (E10, M6 x 16) -2, 3-.
=> Tightening torque: 10 Nm (7.5 ftlb.)
5. Fit hydraulic return line.
5.1. Insert hydraulic return line -3- into the holder on the oil/water heat exchanger.
Hydraulic lines
5.2. Connect hydraulic return line to the reservoir for the hydraulic pump -arrow-.
Hydraulic pump return line
Information
- Grease O-rings, hoses and lines in the cooling system with Kluber plus Gel (Part No. 000.043.205.93).
6. Fit two coolant hoses -1- at the oil/water heat exchanger.
Coolant hoses for oil/water heat exchanger
6.1. Secure four spring band clamps.
7. Install secondary-air line -1-.
7.1. Clip in line at the secondary-air valves and connect hose to the secondary-air pump.
Secondary-air line
8. Route and clip in positive crankcase ventilation line -1- ( -2- ).
Clip position of positive crankcase ventilation line
Subsequent work
1. Install (centre) intake-air distributor and intake-air distributor for cylinder bank 4-6.
=> 244619 Removing and installing intake-air distributor - Turbo - section on "Installing"
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
2. Raise the engine.
2.1. Support the engine at the oil pan using the hydraulic jack HH2 WE 1033 and transmission jack plate of transmission jack V.A.G 1383 A WE 1082.
2.2. Alternative to transmission jack plate:
Mounting peg
Screw on the mounting peg 9163/2 in the middle using a wooden board (40 x 30 cm) and use it as a support.
=> Mounting peg
2.3. Slowly lift the engine with the hydraulic jack.
Engine carrier to engine mounting on cylinder bank 4-6 (view from below)
2.4. Tighten two special M12 nuts (internal Torx, screw insert T55) -1- on the engine mounting (hydraulic mount) at the left and right.
=> Tightening torque: 85 Nm (63 ftlb.)
3. Install tailpipe covers.
=> 263519 Removing and installing tailpipe cover - section on "Installing"
4. Install air cleaner housing.
=> 242519 Removing and installing air cleaner housing - Turbo - section on "Installing"