1.

1 drain coolant (Cooling system)

Explanation

Warning, coolant
■ Coolant is toxic. Avoid prolonged or repeated contact with the skin. In case of contact,
immediately wash the skin with soap and water. In case of eye contact, rinse with plenty of
water. Do not ingest. If swallowed, seek immediate medical attention. Do not induce
vomiting.
■ Do not remove the radiator cap from a hot or running engine. When the coolant is hot, there
is overpressure in the cooling system. It can cause scalding coolant to spray out and cause
serious personal injury. Carefully remove the filler cap to release the overpressure.
If the engine has been operated within the last 30 minutes, be very careful when removing
the radiator cap. Protect face, hands, and arms against escaping fluid and steam by covering
the cap with a large, thick rag while carefully removing it.
■ Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is poisonous. Store it in
the original fluid container only, and always keep it out of the reach of children. • Also, never
remove the cap on the surge tank while the engine is still hot. Wait until the coolant
temperature is below 50°C (120°F). Scalding steam and fluid under pressure may escape
and cause serious personal injuries.

■ In order to avoid damaging the engine block, do not fill up a warm engine with coolant.

Coolant is harmful to the environment. Unused coolant must be stored as a toxic hazardous
substance in leak-
leak-proof containers. Used coolant must be processed as industrial chemical
waste. Please follow HAZMAT guidelines both with used and unused coolants.
M024408 - 03.07.2013
1.5 loosen supply pipe dosing module, fuel (Aftertreatment, eng.)
Explanation

Loosening supply pipe dosing module, fuel

1 2
1. Loosen the union nut of the fuel pipe (2) from the
fuel dosing module (4).

4 3
1

M201966-2

M028059 - 09.20.2011
1.6 loosen coolant pipe (Aftertreatment, eng.)
Explanation

Loosening Coolant Piping

1 2
1. Loosen the banjo bolts (1) from the EAS dosing
module (4) and collect the copper sealing washers.

4 3
1

M201966-2

2. Plug the banjos using the collected copper sealing

washers and two flange bolts and flange nuts.

Tighten the flange bolts and flange nuts

to the torque specified for the banjo bolts
(1).

M202021

M028060 - 12.22.2010
1.7 remove dosing module, fuel (Aftertreatment, eng.)
Explanation

Removing dosing module, fuel

2
1. Loosen the attachment bolts (1) and remove the
dosing module (7). 3
4
1
Discard the attachment bolts (1).

2. Remove the gasket (5) and fiber disc (6).

Discard the gasket (5) and fiber disc (6).

7 6 5
i401992
 M029066 - 07.29.2013
1.8 check fuel delivery dosing module, fuel (Aftertreatment, eng.)
Explanation

Checking fuel delivery dosing module, fuel

A 1 B 2
1. Extend the disconnected wiring harness (2) with a
cable (B), special tool (1809969), and connect it to
the removed dosing module (3).
2. Extend the disconnected fuel pipe (1) with a hose
(A), special tool (1809968), and connect it to the
removed dosing module (3).

Tighten the hose (A) at both ends to the

torque specified for the fuel pipe (1) to
the fuel dosing module (3).
3 C
3. Position the dosing module (3) in a measuring i401774-2

container (C) of at least 0.2 gallons (1 liter).

Cover the measuring container (C) to

prevent fuel spilling.

4. Access the DAVIE application 'Fuel dosing system

override test' and perform the procedure at least 3
times.

■ Each time, record the amount of

fuel that is collected during the test.
■ The average amount of collected
fuel must meet the specifications
displayed by DAVIE.
■ If the average amount does not
meet the specifications, clean the
fuel dosing module (3) according to
the instructions in Engine Rapido
and repeat the test.
■ Do not return the measured fuel to
the fuel tank.
■ For more information, see "Fuel
dosing system override test".

5. After the test, remove the extension hose (A) and

the cable (B).

M029521 - 10.31.2013
1.9 install dosing module, fuel (Aftertreatment, eng.)
 Explanation

Installing dosing module, fuel

2
1. Fit a new gasket (5) and new fiber disc (6) to the
dosing module (7) and position them using two new 3
attachment bolts (1). 1
4

2. Carefully install the fuel dosing module (7) and

tighten the attachment bolts (1) to the specified
torque.

7 6 5
i401992

M031740 - 07.31.2012
1.14.1 fill coolant (Cooling system,chas.)
Explanation

Warning, coolant
■ Coolant is toxic. Avoid prolonged or repeated contact with the skin. In case of contact,
immediately wash the skin with soap and water. In case of eye contact, rinse with plenty of
water. Do not ingest. If swallowed, seek immediate medical attention. Do not induce
vomiting.
■ Do not remove the radiator cap from a hot or running engine. When the coolant is hot, there
is overpressure in the cooling system. It can cause scalding coolant to spray out and cause
serious personal injury. Carefully remove the filler cap to release the overpressure.
If the engine has been operated within the last 30 minutes, be very careful when removing
the radiator cap. Protect face, hands, and arms against escaping fluid and steam by covering
the cap with a large, thick rag while carefully removing it.
■ Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is poisonous. Store it in
the original fluid container only, and always keep it out of the reach of children. • Also, never
remove the cap on the surge tank while the engine is still hot. Wait until the coolant
temperature is below 50°C (120°F). Scalding steam and fluid under pressure may escape
and cause serious personal injuries.

■ In order to avoid damaging the engine block, do not fill up a warm engine with coolant.

Coolant is harmful to the environment. Unused coolant must be stored as a toxic hazardous
substance in leak-
leak-proof containers. Used coolant must be processed as industrial chemical
waste. Please follow HAZMAT guidelines both with used and unused coolants.
M024408 - 03.07.2013
 1.14.3 bleed cooling system (Cooling system,chas.)
Explanation

Warning, coolant
■ Coolant is toxic. Avoid prolonged or repeated contact with the skin. In case of contact,
immediately wash the skin with soap and water. In case of eye contact, rinse with plenty of
water. Do not ingest. If swallowed, seek immediate medical attention. Do not induce
vomiting.
■ Do not remove the radiator cap from a hot or running engine. When the coolant is hot, there
is overpressure in the cooling system. It can cause scalding coolant to spray out and cause
serious personal injury. Carefully remove the filler cap to release the overpressure.
If the engine has been operated within the last 30 minutes, be very careful when removing
the radiator cap. Protect face, hands, and arms against escaping fluid and steam by covering
the cap with a large, thick rag while carefully removing it.
■ Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is poisonous. Store it in
the original fluid container only, and always keep it out of the reach of children. • Also, never
remove the cap on the surge tank while the engine is still hot. Wait until the coolant
temperature is below 50°C (120°F). Scalding steam and fluid under pressure may escape
and cause serious personal injuries.

■ In order to avoid damaging the engine block, do not fill up a warm engine with coolant.

Coolant is harmful to the environment. Unused coolant must be stored as a toxic hazardous
substance in leak-
leak-proof containers. Used coolant must be processed as industrial chemical
waste. Please follow HAZMAT guidelines both with used and unused coolants.
M024408 - 03.07.2013
Bleeding cooling system
1. Set the cabin heater to the maximum temperature.
2. Run the engine at an increased speed (n =1200
rpm) for at least three minutes to bleed the cooling
system
3. Check and top up the coolant level during bleeding.

Top up until the coolant level stabilizes

at the maximum indicator.

4. Check that both hoses connected to the cabin

heater start to warm up.
M039123 - 09.19.2013
This information applies exclusively to the entered chassis number or the selected engine type. Please take into account that this information may change
daily. Therefore the provided information is only valid on 02-11-2015. You cannot derive any rights from the information provided with respect to vehicles
and/or components of another series, with another chassis number, and/or of another date. (CJ296140 / MX_EPA10-MX ENGINE)