Remove/install exhaust manifold

AR14.10-I-3915B

Remove/install exhaust manifold

15.2.12

 

Remove/install

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnecting the battery



Notes on battery

AH54.10-P-0001-01A

2

Remove charge air pipe (4)

AR09.41-I-1311B

3

Remove engine brake flap fitting (12)

AR14.15-I-6302B

4

Detach oil return hose (11) at turbocharger (10)

 Collect engine oil which flows out in a suitable vessel.

5

Remove oil pressure line (7)

 Seal hole on turbocharger (10).

 Installation: Before installation of oil pressure line (7), fill the turbocharger housing through the oil inlet hole with engine oil. Rotate the turbocharger shaft by hand during this step so that the bearing points are provided with a film of oil. Replace sealing rings (8).



*BA09.40-N-1006-01B

6

Detach air intake hose (6) at turbocharger (10)

7

Remove exhaust manifold (2) together with the attached turbocharger (10)



*BA14.10-N-1001-01B

8

Take off gaskets (1)

 Installation: Replace seals (1).

9

Remove turbocharger (10) from
exhaust manifold (2)

 Install new self-locking nuts.

 Seal holes on turbocharger (10) using caps.



*BA09.40-N-1001-01B



Checking

10

Inspect bolts (3)

 Installation: If the maximum shank length (L) is exceeded, the bolt (3) concerned should replaced.

*BE14.10-N-1001-01A

11

Install in the reverse order

12

Check engine oil level, correct as indicated



Specified engine oils (service) - overview

Sheet 223.2

BB00.40-P-0223-02A

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

13

Perform engine test run and check exhaust manifold (2) for leaks

 Crank engine with starter for maximum 90 seconds. Wait at least for about 2 minutes before repeating attempt at starting. Do not rev up the engine if an oil pressure is not indicated. The oil pressure gauge must indicate oil pressure after about 10 seconds.

*BE18.00-N-1001-01C

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BE14.10-N-1001-01A

Exhaust manifold bolts

Thread diameter

M

10

Shank length
when new

mm

47.0

Permissible shank length

mm

47.5

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BE18.00-N-1001-01C

Engine oil pressure at

Idling speed

bar

0.5

maximum speed

bar

2.5

Number

Designation

Engine
900.9, 904.9

BA09.40-N-1001-01B

Nut, turbocharger to exhaust manifold

M8

Nm

30

M10

Nm

50

BA09.40-N-1006-01B

Union nut, oil pressure line to turbocharger

M14

Nm

30

M16

Nm

35

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BA14.10-N-1001-01B

Bolt, exhaust manifold to cylinder head

Stage 1

Nm

10

Stage 2

Nm

55

Stage 3

°

90