Remove/install turbocharger with exhaust manifold

AR09.40-P-6036MRT

Remove/install turbocharger with exhaust manifold

18.02.2020

Engine

256.9 in model 222

1

ATL with exhaust manifold

8

Screw

3

Engine air intake duct

9

Heat shield

4

Bolts

10

Electrical connector

5

Support brace

18

Screw

7

Oil feed line

25

Electrical connector

1

ATL with exhaust manifold

14

Screw

11

Nuts

15

Screw

13

Bleed lines

1

ATL with exhaust manifold

22

Coolant feed pipe

16

Boot

24

Oil return line

21

Coolant return line

 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

 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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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

Topical note

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

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove engine air intake duct downstream of air filter (3).

AR09.10-P-8130MRT

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

2

Release right line of inerting system and place to one side.

Engine 256.9 in model 222
with code 2U8 (Alternative refrigerant)

AR86.10-P-0419LF

3

Release and disconnect electrical connectors (10, 25).

4

Remove screw (14), remove bleed lines (13) and seal openings with suitable stop plugs.

 Bolt, breather adapter to exhaust gas turbocharger

*BA01.20-P-1014-01L

 Record plug

*129589009100

5

Remove oil feed line (7).

AR09.40-P-6022MRT

6

Remove oil return line (24) on the exhaust gas turbocharger with exhaust manifold (1).

AR09.40-P-6021MRT

7

Remove coolant feed line (22) and coolant return line (21) on the exhaust gas turbocharger with exhaust manifold (1).

AR20.20-P-1000MRT

8

Remove support (5).

 Installation: First slightly tighten screws (4, 18) by hand and then tighten with specified tightening torque.

 Bolt, bracket to turbocharger/cylinder head

*BA09.40-P-1003-02MRT

9

Remove ignition coil from cylinder 6 

AR15.12-P-2003MRT

10

Unscrew the screw (8) and remove heat shield (9).

 M61

*BA00.10-P-1002-04A

11

Remove screw (15).

 Screw, support to exhaust gas turbocharger/crankcase

*BA09.40-P-1002-02MRT

12

Detach clamps of boot (16).

 Screw clamp, boot to exhaust gas turbocharger

*BA09.41-P-1010-01MRT

13

Remove nuts (11) in reverse order to the tightening procedure and remove peg board.

Tightening pattern for turbocharger

AR09.40-P-6020-10MRT

 Installation: Replace nuts (11).

 Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head

*BA14.10-P-1001-02MRT

14

Pull exhaust gas turbocharger with exhaust manifold (1) together with boot (16) out of lower terminal strips and remove upwards.

 Installation: Replace boot (16) and multi-hole seal.
Observe marking of boot (16) and marking at exhaust gas turbocharger with exhaust manifold (1).



Clean

15

Clean sealing surface on cylinder head.

16

Clean sealing surfaces at exhaust gas turbocharger with exhaust manifold (1).

Where exhaust gas turbocharger with exhaust manifold (1) is reused.

17

Install in the reverse order.



Check

18

Check and correct engine oil level.



AP18.00-P-1812SKI

19

Read out and delete fault memory.



AD00.00-P-2000-04B

 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

20

Carry out engine test run and check engine for proper leaktightness and leaktightness.

21

Install upper engine cover.

AR01.10-P-2405MRT

 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

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 256.9

BA01.20-P-1014-01L

Bolt, breather adapter to exhaust gas turbocharger

Nm

8

 Turbocharger

Number

Designation

Engine 256.9

BA09.40-P-1002-02MRT

Screw, support to exhaust gas turbocharger/crankcase

M8

Stage 1

Nm

20

Stage 2

 0

90

M6

Nm

-

 Turbocharger

Number

Designation

Engine 256.9

BA09.40-P-1003-02MRT

Bolt, bracket to turbocharger/cylinder head

M6

Nm

8

M8

Nm

33

 Charge air pipe/charge air cooling

Number

Designation

Engine 256.9

BA09.41-P-1010-01MRT

Screw clamp, boot to exhaust gas turbocharger

Nm

6

 Exhaust manifold

Number

Designation

Engine 256.9

BA14.10-P-1001-02MRT

Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head

Stage 1

Nm

20

Stage 2

Nm

20