Remove/install exhaust manifold

AR14.10-D-3915D

Remove/install exhaust manifold

15.2.12

10.3.99

Procedure modified

Step 4 and 15

 

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

All models

AH54.10-P-0001-01A

2

Remove service cover

3

Remove soundproofing at transmission

 Installation: The quick-release fittings must lock in position securely.

4

Take off shield (13) at exhaust manifold

AR14.10-L-3915-02A



*BA09.41-N-1009-01B

Hand riveter

5

Remove charge air manifold

AR09.41-D-8681D

6

Remove charge air pipe

AR09.41-D-1311D

7

Detach exhaust pipe (10) at engine brake flap connection (5) and at transmission and tie up to the side

 Inspect condition of clamp (9), replace if necessary.

AR49.10-D-7140-01D

8

Disconnect compressed-air line (8) from engine brake cylinder

9

Detach oil pressure line (11) at turbocharger (4)

 Carefully bend up oil pressure line (11) until it is no longer touching the turbocharger (4).
Seal hole at turbocharger (4).



*BA09.40-N-1002-01B

10

Unscrew exhaust manifold bolts (3) together with washers at exhaust manifold (2)



*BA14.10-N-1001-01B

11

Tilt exhaust manifold (2), turbocharger (4) and exhaust brake flap connection (5) forward together

12

Slacken hose clamp (7) and pull turbocharger (4) with attached oil return flow hose (6) out of oil return flow connection

 Collect engine oil which flows out.
 Installation: First of all insert turbocharger (4) with oil return hose (6) into oil return fitting and screw hose clamp (7) tight, then install turbocharger (4).
Inspect condition of hose clamp (7), replace if necessary.

13

Lift exhaust manifold (2), turbocharger (4) and engine brake flap connection (5) up and out together

14

Take off gaskets (1)

 Installation: Replace gaskets (1), pay attention to installation position.

15

Detach shield (15) at turbocharger



*BA09.40-N-1004-01B

16

Take off turbocharger (4)

AR09.40-D-6020D



Checking

17

Inspect shank length of exhaust manifold bolts (3)

AR14.10-D-3915-01D

*BE14.10-N-1001-01A

18

Install in the reverse order

19

Adjust engine oil to correct level

AP18.00-D-0101A

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

20

Start engine and observe oil pressure gauge with the engine idling

 Do not increase engine revolutions until oil pressure is displayed.
The oil pressure gage must indicate oil pressure after about 10 seconds.

*BE18.00-N-1001-01C

21

Switch off engine and inspect for leaks

Inspect engine oil level after about 5 minutes and adjust to correct level.

AP18.00-D-0101A

Number

Designation

Engines
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

Engines
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-1002-01B

Bolt, oil pressure line to turbocharger

M8

Nm

40

M6

Nm

10

BA09.40-N-1004-01B

Bolt, shield to turbocharger

Nm

25

Number

Designation

Engine
904.9 in model 668, 670

BA09.41-N-1009-01B

Bolt, shield to charge air manifold

Nm

25

Number

Designation

Engines
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