W09.40-1106-09
1 Adapter piece
2 Sealing ring
3 Shielding
4 Right oil pressure line
5 Right turbocharger
6 Connecting piece
7 Intake manifold
12 Oil return line
13 Gasket
14 Engine brake flap connection
15 Charge air pipe
8 Transverse exhaust pipe
9 Left oil pressure line
10 Left turbocharger
11 Bracket (only with code (K68) muffler(s) vertical behind cab)
W09.40-1107-11
11 Bracket (only with code (K68) muffler(s) vertical behind cab)
16 Compressed air line (only with code (K68) muffler(s) vertical behind cab)
17 Bracket (only if CODE (GS3) "hydraulic" gearshift fitted).
18 Hydraulic lines (only in case of vehicles with code (GS3) gearshift "hydraulic")
19 Steering pressure line (only with code (GS3) gear shift "hydraulic")
20 Steering intake line (only with code (GS3) gear shift "hydraulic")
W09.40-1099-11
Shown at left turbocharger
12 Oil return line
| Remove/Install | ||
| Notes on self-locking nuts and bolts | ||
1 | Remove charge air manifold/charge air housing | ||
2 | Loosen connection piece (6) at intake pipe (7) and at right turbocharger (5) or left turbocharger (10) and push back intake pipe (7) | Do not remove intake pipe (7). | |
3.1 | Remove exhaust cross pipe (8) | When removing right turbocharger (5). | |
3.2 | Remove engine brake flap supports (14) | When removing left turbocharger (10). | |
4 | Remove mounting clamps or bracket for steering pressure line (19), steering intake line (20) and hydraulic lines (18) | Only if CODE (GS3) "hydraulic" gearshift fitted. Do not separate steering pressure line(19), steering intake line (20) and hydraulic lines (18). | |
5 | Remove bracket (17) at crankcase | Only in case of vehicles with code (GS3) gearshift "hydraulic" | |
6 | Remove compressed-air line (16) at bracket (11) | Only on models with code (K68) muffler(s) vertical behind cab | |
7 | Remove right (4) or left (9) oil pressure line | Seal the holes. | |
Installation: check right (4) or left (9) oil pressure line for soiling and damage, where necessary.: | |||
clean or replace right (4) or left (9) oil pressure line. | |||
Fill bearing housing of right (5) or left (10) turbocharger with engine oil via oil fill opening. Whilst doing this, turn the turbocharger shaft. Install new seals. | |||
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| Oil pressure line to exhaust gas turbocharger modified | As of engine end no. 237607 | |
8 | Remove oil return line (12) at right (5) or left (10) turbocharger | Seal the holes. | |
Installation: Check oil pressure line (12) for contamination and damage and replace if necessary. | |||
Clean or replace oil pressure line (12). | |||
Replace gasket (13). Ensure clearance (arrows) of oil return line (12) around flange and compressor housing of right (5) or left (10) turbocharger. | |||
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| Seal oil return line to turbocharger modified | As of engine end no. 156394 | |
9 | Push charge air pipe (15) towards the front | Do not damage charge air hose. | |
Installation: Align intermediate piece (1). | |||
10 | Remove right (5) or left (10) turbocharger at exhaust manifold and pull out at charge air pipe (15) | If the vehicle is equipped with code (GS3) "hydraulic" gear shift, then the hydraulic lines (18) must be lifted to remove the left turbocharger. | |
Plug openings. | |||
Installation: Clean sealing surfaces. | |||
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11 | Pull out intermediate piece (1) | Installation: Replace sealing rings (2). | |
| Intermediate piece charge air housing to turbocharger modified | As of engine end no. 026083 | |
12 | Modify shielding (3) at right (5) or left (10) turbocharger | Only when replacing right (5) or left (10) turbocharger. | |
On vehicles with code (K68) muffler(s) vertical behind cab, the bracket (11) at the left turbocharger (10) must also be modified. | |||
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13 | Check all parts of air intake and charging for foreign bodies, soiling and damage | Clean parts or replace, as necessary. | |
14 | Test turbine and compressor housing on the new right turbocharger (5) or the left turbocharger (10) according to installation position | Only when replacing right (5) or left (10) turbocharger. Only one turbocharger version is available as a replacement part. | |
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15 | Install in the reverse order | ||
Danger! | Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns when working in engine during starting procedure | Secure vehicle to prevent it from moving. | |
16 | Run engine and inspect for leaks |
Crankcase, timing case cover, end cover
Number | Designation | Engine 541.9, 542.9 | ||
BA01.40-N-1011-01D | Oil pressure line for exhaust gas turbocharger to crankcase | M141.5 | Nm | 35 |
Turbocharger
Number | Designation | Engine | ||
BA09.40-N-1001-01C | Bolt, oil pressure line to exhaust gas turbocharger | M8 | Nm | 25 |
BA09.40-N-1003-01C | Bolt, oil return flow line to exhaust gas turbocharger | Nm | 25 | |
BA09.40-N-1005-01C | Nut of turbocharger to exhaust manifold | Nm | 50 | |
BA09.40-N-1006-01C | Bolt of compressor housing to bearing housing | Nm | 15 | |
BA09.40-N-1007-01C | Bolt of turbine housing to bearing housing | Nm | 20 | |
BA09.40-N-1008-01C | Bolt, shielding to exhaust gas turbocharger | M8 | Nm | 20 |
BA09.40-N-1009-01C | Oil pressure line to turbocharger | M141.5 | Nm | 35 |
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