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.
   Fig 1: Identifying Positive Crankcase Ventilation Line Clip Position

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2. Release, pull off and remove the secondary-air line -1-  .
   Fig 2: Identifying Secondary-Air Line

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   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.
   Fig 3: Identifying Oil/Water Heat Exchanger Coolant Hoses

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   1. 3.1. Place a cloth under the coolant hoses.
   2. 3.2. Remove four spring band clamps and pull off and remove coolant hoses.
   3. 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.
   1. 4.1. Remove Pentosin from the hydraulic supply tank using a Suction And Pressure Syringe Nr.194  .
      Fig 4: Removing Hydraulic Return Line

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   2. 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.

   3. 4.3. Pull hydraulic return line -3-  out of the holder on the oil/water heat exchanger and set it aside.
      Fig 5: Identifying Hydraulic Lines

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   4. 4.4. Soak up drops of fluid with a suitable cloth.
5. Affix a warning sign to the vehicle.
   Fig 6: Caution: Danger Of Fire Or Explosion

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   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 vapors.

   → Attach warning sign in a clearly visible position.

6. Remove the high-pressure connecting line.
   1. 6.1. Place a cloth underneath the plug connections to collect emerging fuel.
   2. 6.2. Loosen holder for the high-pressure connecting line -1-  by unscrewing two external Torx screws (E10, M6 x 16) -2, 3-  .
   3. 6.3. Loosen and unscrew union nuts -4-  on the high-pressure connecting line at the fuel collection pipes.
   4. 6.4. Remove the high-pressure connecting line.
   Fig 7: Identifying High-Pressure Line

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7. Remove oil/water heat exchanger.
   1. 7.1. Unscrew six internal Torx screws (T30, M6 x 20) -2-  and remove the heat exchanger -1-  .
   2. 7.2. Collect any drops of fluid with a clean cloth and clean the sealing faces.
   3. 7.3. Close off oil ducts using suitable stoppers.
      Fig 8: Identifying Oil/Water Heat Exchanger Fastening Screws

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   Information 

   • When the work is complete, check that all aids and foreign objects (e.g. cloths, tools) are removed from the engine compartment. 
8. Make sure there are no tools, foreign objects or aids in the engine compartment.