195919 Removing And Installing Unit Carrier (coolant Distributor Housing) - Turbo

WM 195919 Removing and installing unit carrier (coolant distributor housing) - Turbo

Technical values





Information





Overview of coolant distributor housing






Preliminary work

DANGER

Vehicle can fall down

- Risk of squashing or crushing
- Risk of damage to the vehicle

-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
-> The outer take-up points should be used primarily.

1. Raise the vehicle.
=> 4X00IN01 Lifting the vehicle
2. Place protective covers on the vehicle to avoid damaging the vehicle.
3. Remove air cleaner housing.
=> 242519 Removing and installing air cleaner housing - Turbo - section on "Removing"
4. Remove (centre) intake-air distributor.
=> 244619 Removing and installing intake-air distributor - Turbo - section on "Removing"
5. Relieve and remove the drive belt -1-.
=> 137819 Removing and installing drive belt - section on "Removing"





Relieving drive belt

5.1. Turn the tensioner -3- clockwise at the hexagon (a/f 30) using a ring wrench -2- and remove the drive belt.
5.2. Allow the tensioner to slide back to its initial position.
6. Remove air-conditioning compressor and set it aside. The lines remain connected.
=> 873419 Removing and installing air-conditioning compressor - section on "Removing"
7. Remove hydraulic pump.
=> 489819 Removing and installing hydraulic pump - section on "Removing"
8. Remove the generator.





Generator

8.1. Loosen external Torx screws (E12, M8) -1 and 2- by two to three turns and fit screw insert (E12) with short extension on the screw head.
8.2. Loosen threaded sleeves in the unit carrier by tapping gently with a plastic hammer.
8.3. Unscrew external Torx screw (E12, M8) and swivel the generator up.
=> 272219 Removing and installing generator - section on "Removing"

WARNING

Hot fluid

- Danger of scalding

-> Let the fluid cool down.
-> Wear personal protective gear.

9. Drain coolant.
=> 193817 Draining and filling coolant - section on "Draining"
10. Remove number plate and retainer plate.
11. Remove front silencer.
=> 262519 Removing and installing front silencer - section on "Removing"
12. Remove engine carrier.
=> 103019 Removing and installing engine carrier - section on "Removing"

Removing unit carrier (coolant distributor housing)

1. Remove engine carrier bracket.
1.1. Loosen and unscrew M10 threaded bolts.





Threaded bolts

1.1.1. Screw two M10 nuts -1- onto the M10 threaded bolts -2- to lock them.
1.1.2. Unscrew M10 threaded bolts.
1.2. Remove the engine carrier bracket -3-.
1.3. Clean the threaded bolts and thread in the crankcase (adhesive residue) and remove any traces of grease (using brake cleaner) by blowing out the threaded bore with compressed air.
2. Remove the drive belt -1-.





Drive belt

3. Remove the vibration damper -1-.





Disconnecting vibration damper

=> 137519 Removing and installing vibration damper - Turbo - section on "Removing"
4. Remove water connection piece -3-.





Water connection piece

4.1. Loosen the vacuum line at the water connection piece.
Unscrew one external Torx screw (E10, M6 x 12) -2- on the water connection piece.
4.2. Unscrew three external Torx screws (E10, M6 x 25) -1- on the bracket for the coolant pump -5- and crankcase and remove the water connection piece.
5. Remove thermostat housing lid -1-.





Intake tube and thermostat housing

5.1. Remove coolant hose on the thermostat housing lid by releasing and pulling off the spring band clamp.
5.2. Loosen one external Torx screw (E10, M6 x 40) -2- by two to three turns.
5.3. Loosen and unscrew two external Torx screws (E10, M6 x 12) -4- on the intake coolant pipe -5- at the thermostat housing and high-pressure pump holder.
5.4. Pull the intake coolant pipe out of the thermostat housing.
5.5. Loosen and unscrew three external Torx screws (E10, M6 x 50) -3- on the thermostat housing lid and remove the lid.
5.6. Loosen and unscrew one external Torx screw (E10, M6 x 50) at the bottom of the thermostat housing.
6. Remove bracket for the coolant pump.





Bracket for coolant pump





To remove the external Torx screw -4- , the tensioner must be turned and locked.
6.1. Unscrew external Torx screws -3, 4, 5 and 6-.
6.2. Remove bracket for coolant pump -1-.





Removing bracket for coolant pump

6.2.1. Turn the bracket for the coolant pump slightly until the bars on the bracket for the coolant pump and thermostat housing -7- are exposed -arrow-.
6.2.2. Pull bracket for coolant pump out to the rear.
7. Remove unit carrier (coolant distributor housing)
7.1. Remove coolant connection piece.
7.1.1. Release spring clamps at the Henn coupling and pull off the coolant hose at the coolant connection piece -3-. Make sure that the spring clamp is not overstretched.
7.1.2. Open the spring band clamp and pull it off.
7.1.3. Loosen and unscrew three external Torx screws (E12, M8 x 70) -1- and remove the coolant connection piece.
7.2. Release the cable plug on the coolant temperature sensor and disconnect it.
7.3. Unscrew three external Torx screws (E12, M8 x 50) -4 and 5-.
7.4. Carefully pull the unit carrier -6- off the thermostat housing -7- and remove it.





Unit carrier (coolant distributor housing)






Installing unit carrier (coolant distributor housing)

Information

- Grease O-rings, hoses and lines in the cooling system with Kluber plus Gel (Part No. 000.043.205.93).

1. Replace two seals -3- and two O-rings -8- on the unit carrier. Replace one seal -4- for the coolant connection piece.





Seals on unit carrier

2. Replace moulded seal on the connecting tube -3-.





Thermostat housing and connecting tube for coolant pump

3. Install unit carrier (coolant distributor housing).
3.1. Insert unit carrier -6- into the thermostat housing -7-.
3.2. Screw in and tighten three external Torx screws (E12, M8 x 50) -4 and 5- on the unit carrier.
=> Tightening torque: 33 Nm (24 ftlb.)
3.3. Connect and engage the cable plug on the coolant temperature sensor.
3.4. Install coolant connection piece.
3.4.1. Fit the coolant connection piece -3- and tighten Torx screws (M8 x 70) -1-.
=> Tightening torque: 33 Nm (24 ftlb.)
3.4.2. Fit and secure a spring band clamp on the coolant hose.
3.4.3. Fit coolant hose on the coolant connection piece and secure with a spring clamp on the Henn coupling. Make sure that the Henn coupling locks with an audible click.





Unit carrier (coolant distributor housing)





4. Install bracket for the coolant pump.
4.1. Replace O-rings.
Grease new O-rings with Kluber plus Gel (Part No. 000.043.205.93).
4.2. Fit bracket for coolant pump -1-.





Coolant connection piece

4.2.1. Turn the bracket for the coolant pump slightly and guide into position from the right.
4.2.2. Carefully press the bracket for the coolant pump into the mounting.
4.3. Secure bracket for coolant pump -1-.
4.3.1. Screw in and tighten external Torx screws -3, 4, 5 and 6- first.
4.3.2. Tighten one external Torx screw (E10, M6 x 20).
=> Tightening torque: 13 Nm (9.5 ftlb.)
4.3.3. Tighten one external Torx screw (E12, M8 x 25).
=> Tightening torque: 33 Nm (24 ftlb.).
4.3.4. Tighten two external Torx screws (E12, M8 x 50).
To tighten the external Torx screw, the tensioner must be turned and locked.
=> Tightening torque: 33 Nm (24 ftlb.).





Bracket for coolant pump





5. Install thermostat housing lid -1-.





Intake tube and thermostat housing

5.1. Secure the thermostat housing lid.
5.1.1. Fit and tighten one external Torx screw (E10, M6 x 50) at the bottom of the thermostat housing.
=> Tightening torque: 13 Nm (9.5 ftlb.)
5.1.2. Fit the thermostat housing lid and screw in and tighten three external Torx screws (E10, M6 x 50) -3-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
5.1.3. Tighten one external Torx screw (E10, M6 x 40) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
5.2. Secure intake coolant pipe -5-.
5.2.1. Replace O-rings.
Grease new O-rings with Kluber plus Gel (Part No. 000.043.205.93).
5.2.2. Press the intake coolant pipe into the thermostat housing.
5.2.3. Fit and tighten two external Torx screws (E10, M6 x 12) -4- on the intake coolant pipe.
=> Tightening torque: 13 Nm (9.5 ftlb.)
5.3. Connect the coolant hose to the thermostat housing lid and secure with a spring band clamp.
6. Install water connection piece -3-.





Water connection piece

6.1. Fit water connection piece.
6.2. Fit and tighten six external Torx screws (E10, M6 x 25) -1- on the bracket for the coolant pump -5- and crankcase.
=> Tightening torque: 13 Nm (9.5 ftlb.)
6.3. Secure the vacuum line at the water connection piece.
Fit and tighten one external Torx screw (E10, M6 x 12) -2-.
=> Tightening torque: 13 Nm (9.5 ftlb.)
7. Install vibration damper -1-.





Installing vibration damper

=> 137519 Removing and installing vibration damper - Turbo - section on "Installing"

Information

The threaded bolt on the bracket for the engine carrier must be bonded using Loctite 243 and can only be subjected to pressure after a hardening time of three hours.

8. Install engine carrier bracket.
8.1. Fit the drive belt on the vibration damper.
8.2. Fit the engine carrier bracket -3-.





Threaded bolt (stud)

8.3. Apply Loctite to the threaded bolt (stud) M10 x 120.
8.4. Screw in and tighten threaded bolt (stud) M10 x 120.
Screw two M10 nuts -1- onto the M10 x 120 threaded bolt -2- to lock it and tighten the threaded bolt.
=> Tightening torque: 5 Nm (3.5 ftlb.)

Subsequent work

1. Install engine carrier.
=> 103019 Removing and installing engine carrier - section on "Installing"
2. Install front silencer.
=> 262519 Removing and installing front silencer - section on "Installing"
3. Install number plate and retainer plate.
4. Install the generator.





Generator

Fit the generator and tighten M8 external Torx screws (E12) -1 and 2-.
=> 272219 Removing and installing generator - section on "Installing"
5. Install hydraulic pump.
=> 489819 Removing and installing hydraulic pump - section on "Installing"
6. Install air-conditioning compressor.
=> 873419 Removing and installing air-conditioning compressor - section on "Installing"
7. Fit drive belt -1-.
=> 137819 Removing and installing drive belt - section on "Installing"





Slackening/tensioning the drive belt

7.1. Turn the tensioner -3- clockwise at the hexagon (a/f 30) using a ring wrench -2- and fit the belt.
7.2. Allow the tensioner to slide back to its initial position.
8. Install (centre) intake-air distributor.
=> 244619 Removing and installing intake-air distributor - Turbo - section on "Installing"
9. Install air cleaner housing.
=> 242519 Removing and installing air cleaner housing - Turbo - section on "Installing"
10. Fill in coolant.
=> 193817 Draining and filling coolant (includes bleeding) - section on "Filling"
11. Let the engine run until warm and visually check for leaks.
12. Remove protective covers from the vehicle.