Cooling System: Service and Repair
Removing and installing coolant distributor housing
Information
Overview
Overview of distributor housing
1 - Coolant distributor housing
4 - Screw
5 - Screw
6 - Sealing ring
7 - Sealing ring
8 - Sealing ring
Preliminary Work
1. Disconnect the battery.
2. Remove pressure pipe.
3. Remove air cleaner housing.
4. Detach and swivel out air conditioning compressor.
5. Remove oil-filter console.
6. Remove the generator.
Warning
Hot pressurized coolant.
Danger of scalding and burning.
- Only work on the coolant system when the engine is "cool".
- Wear protective clothes, gloves and goggles.
7. Drain coolant.
8. Remove hydraulic pump with reservoir.
Danger
Parts of the exhaust system become extremely hot!
Danger of burns
Permanent scarring of the skin
- Do not begin work until the exhaust system has cooled down completely.
- If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-resistant protective gear.
9. Remove rear silencer.
Removing coolant distributor housing
1. Remove unit carrier.
1.1. Remove coolant flange -5-.
Unscrew screw -4- on cable rail.
Unscrew screws -3- and remove cooling water flange -5-.
1.2. Unscrew screws -1- on the unit carrier and remove it.
Removing and installing unit carrier
Warning
Coolant is corrosive and hazardous to health.
Risk of skin and eye irritation.
- Wear protective gloves and goggles.
- If you come into contact with coolant, wash off immediately with plenty of warm water.
2. Remove upper coolant distributor housing.
2.1. Loosen coolant supply hose. To do this, loosen the spring clamp -1- on the Henn coupling and pull off coolant hose -2-.
Coolant supply hose and left Henn coupling
2.2. Disconnect coolant hoses.
Coolant hoses on distributor housing
Loosen spring band clamps -2, 5- and pull off coolant hoses -3, 4-.
Danger
Risk of engine falling down.
Danger of fatal injury, material damage.
- Support the engine with the prescribed tool.
3. Remove engine carrier.
Support the engine with a transmission jack and retainer plate P 9592.
Engine carrier
4. Remove oil return lines.
Oil return line 4-6
4.1. Remove oil return line 4-6.
4.2. Remove oil return line 1-3.
Oil return line 1-3
5. Remove coolant distributor housing.
Carefully press off distributor housing -1- and remove it.
Removing and installing distributor housing
Installing coolant distributor housing
Danger
Risk of engine falling down.
Danger of fatal injury, material damage.
- Support the engine with the prescribed tool.
1. Install coolant distributor housing.
Information
Replace O-rings.
Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68).
1.1. Replace sealing rings -6 and 7-.
1.2. Fit coolant distributor housing and press it into the joining socket.
Overview of distributor housing
1 - Coolant distributor housing
4 - Screw
5 - Screw
6 - Sealing ring
7 - Sealing ring
8 - Sealing ring
2. Install oil return lines.
Oil return line 4-6
2.1. Install oil return line 4-6.
2.2. Install oil return line 1-3.
Oil return line 1-3
3. Install engine carrier.
3.1. Support the engine with a transmission jack and retainer plate P 9592.
- Tightening torque: 85 Nm (63 ftlb.)
- Tightening torque: 65 Nm (48 ftlb.)
Engine carrier
Information
Replace O-rings.
Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68).
4. Install unit carrier.
Sealing rings on unit carrier
4.1. Replace all sealing rings.
4.2. Fit unit carrier -2- and screw in and tighten screws.
4.3. Position coolant flange -5- and screw in and tighten screws -3-.
- Tightening torque: 10 Nm (7.5 ftlb.)
4.4. Screw in and tighten screw -4- on cable rail.
- Tightening torque: 10 Nm (7.5 ftlb.)
Unit carrier
Subsequent Work
1. Install rear silencer.
2. Install hydraulic pump with reservoir.
3. Install the generator.
4. Install oil-filter console.
5. Install air conditioning compressor.
6. Install air cleaner housing.
7. Install pressure pipe.
8. Connect the battery.
9. Fill in coolant and bleed the system.