Remove/install turbocharger with exhaust manifold

AR09.40-P-6036MRD

Remove/install turbocharger with exhaust manifold

13.03.2018

Engine

274.9 in model 213

Engine

274.9 in model 238

1

Charge air pipe

4b

Coolant line

10

Support brace

3

Turbocharger

5a

Oil line

11

Seal

4a

Coolant line

5b

Oil line

12

Nuts

Shown on engine 274.9 in model 213 with code 2U8 (Refrigerant alternative)

2

Heat shield

3

Turbocharger

13

Nut

14

Line

15

Electrical connector

16

Vacuum hose

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Drain off coolant

AR20.00-P-1142OLC

 Installation: Only install lower engine compartment paneling after leak test.

2

Remove air filter housing

AR09.10-P-1150MRD

 Installation: Only install upper engine cover after the leak test.

3

Remove air filter housing holder

 M81

*BA00.10-P-1004-04A

4

Unscrew nut (13) and place line (14) to one side

Engine 274.9 in model 213
with code 2U8 (Alternative refrigerant)
Engine 274.9 in model 238
with code 2U8 (Alternative refrigerant)

 Nut, heat shield to turbocharger support brace

*BA09.40-P-1014-01U

5

Remove heat shield(2)

 Bolt, heat shield to cylinder head/bracket for air filter

*BA09.40-P-1015-01U

6

Remove oil lines (5a, 5b) and close off openings with suitable stop plugs

AR09.40-P-6020-13MR

 Installation: Replace screw/bolts and seals.

 Screw/bolt, oil line for oil feed to exhaust gas turbocharger

*BA09.40-P-1005-01U

 Screw/bolt, oil line for oil feed to crankcase

*BA09.40-P-1006-01U

 Bolt, oil return flow line to turbocharger

*BA09.40-P-1007-01U

 Bolt, oil return line to crankcase

*BA09.40-P-1008-01U

 Record plug

*129589009100

7

Remove coolant lines (4a, 4b) and close off openings with suitable stop plugs

AR09.40-P-6020-14MR

 Installation: Replace screw/bolts and seals.

 Bolt, coolant feed/return line to turbocharger

*BA09.40-P-1009-01U

 Bolt, coolant line feed line to water pump

*BA09.40-P-1010-01U

 Bolt, coolant return flow line to cylinder head

*BA09.40-P-1011-01U

 Record plug

*129589009100

8

Detach vacuum hose (16) from vacuum unit

9

Release and disconnect electrical connector (15)

10

Remove air intake pipe from ATL (3)

AR09.10-P-8131MRD

11

Remove charge air pipe (1) on ATL (3)

 M61

*BA00.10-P-1002-04A

12

Remove bracket for CAT

AR49.10-P-5500MRD

13

Remove CAT from ATL (3) and secure against falling down

AR49.10-P-5500MRD

14

Remove EGR line from ATL (3)

Engine 274.9 in model 213
with code 920 (Direct petrol injection with stratified charging)
Engine 274.9 in model 238
with code 920 (Direct petrol injection with stratified charging)

 Installation: Replace seal and nuts.

 Bolt / nut, connecting point for exhaust pipe

*BA14.20-P-1003-01O

15

Remove holder (10) from crankcase and ATL (3)

 Nut, support brace to turbocharger

*BA09.40-P-1012-01U

 Bolt, turbocharger support brace to crankcase

*BA09.40-P-1013-01U

 Set of flexible head wrenches

*001589810900

16

Unscrew nuts (12)

Tightening pattern for turbocharger

AR09.40-P-6020-10MRD

 Installation: Replace nuts (12).

 Nut, turbocharger/exhaust manifold to cylinder head

*BA09.40-P-1001-01U

17

Unfasten ATL (3) from cylinder head

18

Remove ATL (3) together with support (10)

 Installation: Replace seal (11).



Clean

19

Clean sealing surfaces of ATL (3) and cylinder head



Check

20

Check stud bolts of ATL (3) for damage and replace if necessary

 Stud bolt for exhaust manifold

*BA01.30-P-1004-01Y

21

Install in the reverse order

22

Check engine oil level and correct



AP18.00-P-1811MP

 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.

AS00.00-Z-0005-01A

23

Perform an engine test run and check engine for proper operation and leaktightness

24

Install lower engine compartment paneling

AR61.20-P-1105LWE

25

Install upper engine cover

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1004-04A

M81

Nm

23

33

 Cylinder head

Number

Designation

Engine 274

BA01.30-P-1004-01Y

Stud bolt for exhaust manifold

Nm

8

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1001-01U

Nut, turbocharger/exhaust manifold to cylinder head

Nm

15

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1005-01U

Screw/bolt, oil line for oil feed to exhaust gas turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1006-01U

Screw/bolt, oil line for oil feed to crankcase

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1007-01U

Bolt, oil return flow line to turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1008-01U

Bolt, oil return line to crankcase

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1009-01U

Bolt, coolant feed/return line to turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1010-01U

Bolt, coolant line feed line to water pump

Nm

9

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1011-01U

Bolt, coolant return flow line to cylinder head

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1012-01U

Nut, support brace to turbocharger

Nm

30

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1013-01U

Bolt, turbocharger support brace to crankcase

Stage 1

Nm

15

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1014-01U

Nut, heat shield to turbocharger support brace

Nm

10

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1015-01U

Bolt, heat shield to cylinder head/bracket for air filter

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 274

BA14.20-P-1003-01O

Bolt / nut, connecting point for exhaust pipe

Nm

9