Rapido Page 1 of 8

1.1.1 disconnect battery clamp, negative pole

Explanation

Warning, battery clamp and negative terminal

■ Do not disconnect the vehicle batteries until the DEF dosing system has
completed the purge cycle.
■ Before beginning to remove and/or disconnect any components, wait at least 5
minutes after the key switch is turned OFF for the aftertreatment DEF dosing
system to purge DEF from the system.
■ The purge cycle is an automatic process and does not require active
intervention. The aftertreatment DEF dosing unit creates an audible pumping
noise during the purging process.

■ Electrical shock hazard: Never disconnect the battery clamp when the engine is
running.
■ Disconnecting the battery clamps while the engine is running may result in
death, personal injury, or equipment damage from electrical arching or damage
to electronic components.
■ Turn off the engine and place the ignition switch in the OFF position before
disconnecting the battery clamps.
■ Do not place any tools or other materials on top of or close to the batteries. This
can cause a dangerous high-
high-current short circuit and, in the worst case, a
battery explosion. Keep all objects away from the battery terminals.
■ Always break the contact between the battery clamp and the negative terminal
before working on the vehicle. Working on a vehicle while the battery is
connected may result in electrical injury or damage.
■ Always disconnect the battery at the negative terminal when performing service
procedures.

■ Battery acid can cause chemical burns.

■ If you come into contact with battery acid: flush your skin with water and/or apply
baking soda or lime to help neutralize the acid.
■ If battery acid comes into contact with the eyes, flush immediately with water and
seek medical attention.
■ Wear protective clothing when handling any part of the battery.

M024327 - 05.03.2010
1.1.2 drain coolant (Cooling system)
Explanation

Warning, coolant

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Rapido Page 2 of 8

■ 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
1.1.5 loosen coolant pipe, turbo return (Cooling system)
Explanation

Loosening Coolant Piping, Turbo Outlet

6
1. Loosen the union nut (5), and put aside the
bleed pipe (6). 5 7
4
8
2. Remove the banjo bolt (4), and collect the
copper sealing washers. 3
3. Remove bolts (1) and (3), and carefully pull
2
out the coolant outlet piping (2).
9

1 10

11
8

M201965-2

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Rapido Page 3 of 8

M028056 - 06.04.2010
1.1.6 loosen coolant pipe, turbo supply (Cooling system)
Explanation

Loosening Coolant Piping, Turbo Supply

6
1. Remove the banjo bolt (7), and collect the
copper sealing washers. 5 7
4
8
2. Loosen the attachment bolt (11), and
carefully pull out the coolant supply piping 3
(8).
2
9

1 10

11
8

M201965-2

M028503 - 06.04.2010
1.1.7 remove VTG turbocharger actuator (Inlet/exhaust elem.)
Explanation

Removing the VTG Actuator

1. Disconnect the VTG actuator (3).

2. Cut the clamping straps and loosen the
wiring harness.
3. Loosen the attachment bolts (1) and remove 1
the VTG actuator (3).
4. Remove the gasket.

3
i401769

M029472 - 09.21.2010
1.2.1 connect battery clamp, negative pole
Explanation

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Rapido Page 4 of 8

Warning, battery clamp and negative terminal

■ Do not disconnect the vehicle batteries until the DEF dosing system has
completed the purge cycle.
■ Before beginning to remove and/or disconnect any components, wait at least 5
minutes after the key switch is turned OFF for the aftertreatment DEF dosing
system to purge DEF from the system.
■ The purge cycle is an automatic process and does not require active
intervention. The aftertreatment DEF dosing unit creates an audible pumping
noise during the purging process.

■ Electrical shock hazard: Never disconnect the battery clamp when the engine is
running.
■ Disconnecting the battery clamps while the engine is running may result in
death, personal injury, or equipment damage from electrical arching or damage
to electronic components.
■ Turn off the engine and place the ignition switch in the OFF position before
disconnecting the battery clamps.
■ Do not place any tools or other materials on top of or close to the batteries. This
can cause a dangerous high-
high-current short circuit and, in the worst case, a
battery explosion. Keep all objects away from the battery terminals.
■ Always break the contact between the battery clamp and the negative terminal
before working on the vehicle. Working on a vehicle while the battery is
connected may result in electrical injury or damage.
■ Always disconnect the battery at the negative terminal when performing service
procedures.

■ Battery acid can cause chemical burns.

■ If you come into contact with battery acid: flush your skin with water and/or apply
baking soda or lime to help neutralize the acid.
■ If battery acid comes into contact with the eyes, flush immediately with water and
seek medical attention.
■ Wear protective clothing when handling any part of the battery.

M024327 - 05.03.2010
1.2.3 install VTG turbocharger actuator (Inlet/exhaust elem.)
Explanation

Installing VTG actuator

1. Clean the mounting surfaces of the turbo

housing and VTG actuator.
2. Clean the sector gear (4) and its surrounding
area.

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3. Install the special tool (1903024) (A)

4. Check the free movement of the sector gear
(4):
■ The first movement might require some
extra force due to soot on the VTG
mechanism.
1 4
■ In the counterclockwise direction, the left 2
side must align with the mark (1) on the
special tool (A). A

■ In the clockwise direction, the right side

must align with mark (2) on the special
tool (A).
i402149-2

If the sector gear does not

reach both marks on the
gauge card, the complete
turbo charger must be 1 4
replaced.
2
5. Grease the sector gear teeth, and align the
right side with mark (2) of the special tool (A) A

6. Make sure that the sector gear (4) does not

move before installing the actuator (3). I402150-3

The prealigned sector gear (4) can

now be meshed with the actuator
gear (5).

7. Connect the VTG actuator (3).

8. Prealign the actuator gear (5) using DAVIE: 3

■ Contact Engine Support Center to obtain

the "Service level key". 5

■ Access the DAVIE application 'turbo

actuator replacement' and follow the
procedure.
■ To avoid injury, do not touch the
actuator gear (5) during the procedure. i401770

■ The actuator gear (5) must not move

before installation.

9. Fit two attachment bolts (1), as shown, to

position the gasket (2) on the actuator (3).
10. Carefully install the actuator (3) onto the
turbo housing, and fit the remaining two
attachment bolts (1).
11.

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Tighten the attachment bolts (1) crosswise to

the specified torque.
12. Secure the wiring harness using the blue 1
plastic clamping straps.
■ Position the clamping strap in 2
the recess within the engine
wiring harness. 3
■ Do not overtighten the
clamping strap. 1
i401773

13. Continue the DAVIE application 'turbo

actuator replacement' and follow the
procedure.

3
i401769

M029473 - 10.16.2013
1.2.8.1 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

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Rapido Page 7 of 8

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
1.2.8.3 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.

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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 06-03-2015. 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.
(CD153911 / MX_EPA10-MX ENGINE)

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