Remove/install turbocharger with exhaust manifold

AR09.40-S-6036PD

Remove/install turbocharger with exhaust manifold

25.10.2019

Model

470 with engine 699.304/305

with code MT2 (Emissions class Euro 6d-TEMP N1 GR.III/N2)

Model

470, 471 with engine 699.301/303

Modification notes

24.10.2019

Method modified.

Operation step 6

24.10.2019

Method extended

Operation steps 17, 18.2

1

Bolts

4

Switchover valve

7

Bracket

2

Bracket

5

Electrical connector

8

Hose

3

Hoses

6

Electrical wiring harness

Shown with engine 699.301 except code MT2 (emission class Euro 6d-TEMP N1 GR.III/N2)

10

Nut

12

Bolts

14

Heat shield

11

Bolts

13

Heat shield

15

Heat shield

Shown with engine 699.304 and with code MT2 (emission class Euro 6d-TEMP N1 GR.III/N2)

25

Temperature sensor

26

Nut

27

Electrical wiring harness

28

Retaining clamp

Shown with engine 699.301 except code MT2 (emission class Euro 6d-TEMP N1 GR.III/N2)

16

Nuts

19

Stud bolt

22

Electrical wiring harness

17

Stud bolts

20

Electrical connector

23

Exhaust line

18

Nuts

21

Screw

24

ATL with exhaust manifold

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 

Remove/install

1

Drain off coolant.

AR20.00-S-1142P

2

Remove exhaust gas turbocharger.

AR09.40-S-6020PD

3

Remove holder (2).

 To do this, remove screw/bolts (1) .

 M6

*BA00.10-N-1002-01A

4

Remove hoses (3) from switchover valve (4).

 Removal: Mark arrangement of hoses (3).

 Installation: Note markings on hoses (3).

5

Disconnect electrical connector (5) from switchover valve (4).

6

Remove electrical wiring harness (6) from bracket (7).

 Installation: Check retaining clips for damage.

If damage is present:



Replace relevant retaining clip.

7

Remove the bracket (7).

 To do so, remove screws/bolts (12).

 Switchover valve (4) remains on bracket (7).

 M6

*BA00.10-N-1002-01A

8

Remove oil pressure line of exhaust gas turbocharger with exhaust manifold (24).

AR09.40-S-0011PD

 Plug openings.

 Record plug

*129589009100

9

Remove oil line of exhaust gas turbocharger with exhaust manifold (24).

AR09.40-S-0010PD

 Plug openings.

 Record plug

*129589009100

10

Remove screws (11).

 Screw/bolt, heat shield to exhaust manifold

*BA09.40-N-1005-02PD

11

Remove nuts (10).

 M6

*BA00.10-N-1002-01A

12

Remove heat shield (13).


Carefully remove heat shield (13).
This will prevent damage to heat shield (13).

13

Remove heat shield (15).


Carefully remove heat shield (15).
This will prevent damage to heat shield (15).

14

Remove heat shield (14).


Carefully remove heat shield (14).
This prevents damage to heat shield (14).

15

Disconnect electrical connector (20).

16

Unscrew screw (21).

 Screw/bolt, exhaust pressure sensor bracket to cylinder head bracket

*BA09.40-N-1013-02PD

17

Detach electrical wiring harness (27).

Model 470 with code MT2 (emission class Euro 6d-TEMP N1 GR.III/N2)

 To do so, remove electrical wiring harness (27) from retaining clamp (28).

18.1

Remove electrical wiring harness (22) with electrical connector on engine side.

Model 470, 471 except code MT2 (emission class Euro 6d-TEMP N1 GR.III/N2)

 Place electrical wiring harness (22) outside the working area.

18.2

Remove temperature sensor (25) from exhaust gas turbocharger with exhaust manifold (24).

Model 470 with code MT2 (emission class Euro 6d-TEMP N1 GR.III/N2)

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

AH00.00-P-0015-01CW

 For this purpose, remove nut (26).

 Apply heat-resistant lubricant to nut (26) of temperature sensor (25).

 Commercially available devices/tools
14 mm open-end fitting with 9x12 mm square socket

Paste, hot lubrication 1 kg, DBL 6879.20

*BR00.45-Z-1005-06A

 Temperature sensor upstream of exhaust gas turbocharger to exhaust manifold

*BA07.04-N-1005-02PS

19

Remove exhaust gas line (23) from exhaust gas recirculation cooler.

 To do so, remove nuts (18) and unscrew stud bolts (19).

 Stud bolt at exhaust gas recirculation cooler

*BA14.20-N-1002-01PD

 Nut, exhaust line to exhaust gas recirculation cooler

*BA14.20-N-1006-01PD

20

Remove nuts (16).

 Nut, exhaust gas turbocharger with exhaust manifold to cylinder head

*BA09.40-N-1018-02PD

21

Unscrew stud bolts (17).

 Stud bolt, exhaust gas turbocharger with exhaust manifold to cylinder head

*BA09.40-N-1019-02PD

22

Remove hose (8) on vacuum unit.

23

Remove exhaust gas turbocharger with exhaust manifold (24) upwards.

 Installation: Replace seals.

24

Install in the reverse order.



Check

 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

 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

25

Check for leaktightness when engine is running.

 Visual inspection only.

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 Sensors

Number

Designation

Engine 699 in model 470

BA07.04-N-1005-02PS

Temperature sensor upstream of exhaust gas turbocharger to exhaust manifold

Nm

32

 Exhaust gas turbocharger, exhaust pipe, heat shield, exhaust manifold

Number

Designation

Model 470, 471 with engine 699

BA09.40-N-1005-02PD

Screw/bolt, heat shield to exhaust manifold

Nm

10

 Exhaust gas turbocharger, exhaust pipe, heat shield, exhaust manifold

Number

Designation

Model 470, 471 with engine 699

BA09.40-N-1013-02PD

Screw/bolt, exhaust pressure sensor bracket to cylinder head bracket

Nm

10

 Exhaust gas turbocharger, exhaust pipe, heat shield, exhaust manifold

Number

Designation

Model 470, 471 with engine 699

BA09.40-N-1018-02PD

Nut, exhaust gas turbocharger with exhaust manifold to cylinder head

Nm

20

 Exhaust gas turbocharger, exhaust pipe, heat shield, exhaust manifold

Number

Designation

Model 470, 471 with engine 699

BA09.40-N-1019-02PD

Stud bolt, exhaust gas turbocharger with exhaust manifold to cylinder head

Nm

9

 Exhaust gas recirculation valve, exhaust gas recirculation cooler, temperature sensor, exhaust gas recirculation line

Number

Designation

Model 470, 471 with engine 699

BA14.20-N-1002-01PD

Stud bolt at exhaust gas recirculation cooler

Nm

9

 Exhaust gas recirculation valve, exhaust gas recirculation cooler, temperature sensor, exhaust gas recirculation line

Number

Designation

Model 470, 471 with engine 699

BA14.20-N-1006-01PD

Nut, exhaust line to exhaust gas recirculation cooler

Nm

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DBL 6879.20

A 000 989 76 51