4000 Hours Service

Maintenance to be performed every 4000 hours of operation.

1.Cooling system

If necessary, the cooling system should be cleaned more often.

1.1.External cleaning, at least every 4th year 5*

1.Clean externally the radiator fins and hoses. 2.Check that the radiator is not blocked on the air side and that the fins are not damaged. 3.Carefully scrape the deposit away from the radiator fins. If necessary, a paraffin-based engine cleaner may be used. 4.Check the fins, rubber hoses, clamps and pipes for corrosion, damage and leakages. 5.Bent fins can be carefully straightened, e.g. using a steel wire brush.

CAUTION

The cooling system must not be cleaned using caustic soda. It can damage aluminium parts.

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1.2 Internal cleaning, at least every 4th year 5*

Removing deposits

1.If possible, run the engine until it is warm and then drain the cooling system, see changing coolant, item 1.4 2.Remove the thermostats (1). 3.Fill the system with clean, hot water mixed with one of the commercially available radiator cleaners based on sulphamin acid and containing dispersing agents. Follow the manufacturer's instructions (on the packaging) for mix ratios and cleaning times. 4.Run the engine for the specified time. 5.Drain the cooling system by removing a low hose or pipe (2). Do not use the drain cocks, the loosened

deposits can clog them!

6.Refit the hose which was used as drain hose.

7Fill the system again with hot water and run the engine for about 20 -30 minutes.

8.Drain the water from the cooling system in the usual way, use the drain cocks.

9.Refit the thermostats.

10.Fill the system with coolant as described in the specifications in item 1.3 at 2000 hours service.

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WARNING

When handling cleaners for the cooling system: Study the warning on the packaging.

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1. Charge air cooler housing with element 2. O-ring 3. Gasket 4. Intake manifold

1 Maintenance to be performed every 4000 hours of operation.

1.3.Charge air cooler 5*

1.Drain the coolant from the engine, see changing coolant, item 1.4.

2.Detach the intake manifold from the turbo.

3.Detach the charge air cooler's inlet and outlet connections.

4.Unbolt the charge air cooler assembly from the intake manifold. The charge air element is integrated into the housing.

Take care not to damage the element's water connections.

5.Clean the outside of the element. Use a paraffin-based engine cleaner. 6.Change gasket (3). 7.Bolt the charge air cooler back in place. Tighten the bolts to 42 Nm.

8.Refit inlet and outlet connections with new O-rings. 9.Refit the delivery pipe clamps. 10.Connect the intake manifold from the turbo.

11.Fill coolant as described in the specifications in item 1.3 at 2000 hours service.

1.4 Change coolant, at least every 4th year 5*

1.Remove the filler cap (1) from the expansion tank. 2.Drain the coolant in two places: • the "lowest point" on the engine block (2), right hand side. • the "lowest point" of the cooling system (3), under the oil cooler on left hand side. The engine belly plate must be removed to reach the drain cock.

3.Close the cocks.

4.Fill with correct mixture, pre-mixed coolant through the expansion tank filler hole. See item 1.3 at 2000 hours service.

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