W09.40-1187-09
1 | Turbocharger | 5 | Crankcase breather line | 9 | Compressed-air line | ||
2 | Air intake hose | 6 | Charge air pipe | 10 | Engine brake cylinder | ||
3 | Air intake hose (only on vehicles with code Z90 (vehicle, capable of fording up to 1,195 mm) or code Z69 (vehicle, capable of fording up to 1,500 mm)) | 7 | Shield | G2 | Alternator | ||
4 | Air filter | 8 | Clamp (only on vehicles with code MS5 (BlueTec 5)) |
W09.40-1188-09
1 | Turbocharger | 15 | Control lever | 20 | Oil return line | ||
10 | Engine brake cylinder | 16 | Injection line (only on vehicles with code MS5(BlueTec 5)) | 21 | Oil return hose | ||
11 | Exhaust pipe | 17 | Exhaust manifold | 22 | Engine brake valve fitting | ||
12 | Clip | 18 | Oil pressure line | A | Distance | ||
13 | Bracket | 19 | Bracket | Pfeil | End stop | ||
14 | Clip |
| Remove/install | ||
Topical note | Notes on self-locking nuts and bolts | ||
1 | Disconnect ground line from battery | ||
2 | Open engine hood and raise to vertical position | ||
Installation: Only close the engine hood after the leak test. | |||
3 | Remove right front fender liner | ||
4 | Remove air filter (4) with carrier | ||
Bolt, frame sections to frame | |||
5 | Remove air intake duct for fresh-air intake | ||
6 | Remove charge air pipe (6) from exhaust gas turbocharger (1) to charge air cooler | ||
7 | Remove crankcase breather line (5) from air intake hose (2) | ||
8 | Remove air intake hose (2) from the exhaust gas turbocharger (1) | ||
9 | Remove air intake hose (3) from alternator (G2) | Only on vehicles with code Z90 (vehicle, capable of fording up to 1,195 mm) or code Z69 (vehicle, capable of fording up to 1,500 mm). | |
10 | Remove clamp (8) from shield (7) | Only on vehicles with code MS5 (BlueTec 5). | |
Installation: Install pulley beneath the clamp (8). | |||
Bolt, shield to turbocharger and engine brake valve fitting | |||
11 | Remove compressed-air line (9) from engine brake cylinder (10) | ||
12 | Remove shield (7) | Bolt, shield to turbocharger and engine brake valve fitting | |
13 | Remove injection line (16) of the exhaust aftertreatment system. | ||
Only on vehicles with code MS5 (BlueTec 5). | |||
Installation: A new injection line (16) must be installed after every removal. | |||
14 | Remove engine brake cylinder (10) from bracket (19) | Nut, engine brake cylinder to bracket | |
15 | Unfasten bracket (19) of the engine brake cylinder (10) from the engine brake valve fitting (22) and swivel it to the side | Bolt, engine brake cylinder bracket to engine brake valve fitting | |
16 | Remove oil pressure line (18) from exhaust gas turbocharger (1) | Catch escaping and engine oil and seal bores. | |
Installation: Before installing the oil pressure line (18), the bearing of the exhaust gas turbocharger (1) must be filled with engine oil through the oil pressure bore. Rotate exhaust gas turbocharger shaft by hand during this step so that bearing points are provided with a film of oil. | |||
Union nut, oil pressure line to turbocharger | |||
17 | Remove oil return hose (21) from the cylinder crankcase | Catch escaping and engine oil and seal bores. | |
18 | Remove clamp (12) of the exhaust pipe (11) from the bracket (13) | Bolt, clamp to bracket | |
19 | Remove exhaust pipe (11) from the engine brake valve fitting (22) and press it to the rear | Installation: Observe the installation position of clamp (14). There must be a distance (A) of min. 20 mm between the bolt head on the clamp (14) and the end stop (arrow) of the adjusting lever (15). | |
Bolt, clamp to exhaust pipe on valve fitting for engine brake/exhaust fitting | |||
20 | Remove the exhaust gas turbocharger (1) from the exhaust manifold (17) | Nut, turbocharger to exhaust manifold | |
21 | Remove the exhaust gas turbocharger (1) with engine brake valve fitting (22) | ||
22 | Remove engine brake valve fitting (22) from the exhaust gas turbocharger (1) and seal the bores | Only if replacing turbocharger (1). | |
Nut, engine brake flap fitting to turbocharger | |||
23 | Remove oil return line (20) from exhaust gas turbocharger (1) | Only if replacing turbocharger (1). | |
Bolt, oil return flow line to turbocharger | |||
24 | Install in the reverse order | ||
25 | Check engine oil level with oil dipstick or on display, add oil if necessary | ||
Notes on engine oil | |||
Observe engine oil grade set in maintenance system or Specifications for Operating Fluids. | |||
Warning | Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | |
26 | Start engine and run it at varying rpms | ||
27 | Stop the engine and the check the area of the exhaust gas turbochargers (1) for leaktightness | Visual inspection. |
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