Remove/install turbocharger with exhaust manifold

AR09.40-S-6036PDA

Remove/install turbocharger with exhaust manifold

15.11.2019

Model

470, 471 with engine 699.300/302

1

Electrical connector

6

Hose

10

Bolts

2

Bracket

7

Hoses

11

Electrical wiring harness

3

Electrical wiring harness

8

Switchover valve

12

Bracket

4

Bolts

9

Electrical connector

13

Exhaust pressure sensor

5

Hose

14

Heat shield

15

Bolts

16

Nuts

19

ATL with exhaust manifold

22

Oil return line

17

Exhaust line

20

Screw

23

Oil pressure line

18

Nuts

21

Clip

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove engine cover

AR01.10-S-2405PD

2

Remove air filter housing

AR09.10-S-1150PD

3

Remove air intake hose

AR09.10-S-8030PD

4

Remove air intake pipe

AR09.10-S-8131PD

5

Remove charge air pipe downstream of ATL

AR09.41-S-1333PDA

6

Remove oxygen sensor upstream of catalytic converter

Model 470, 471 with engine 699.300/302
except code MT2 (Emissions class Euro 6d-TEMP N1 GR.III/N2)

AR07.04-S-0086PD

7

Remove electrical wiring harness (3) from bracket (2)

 To do this disconnect electrical connection (1).

8

Remove hose (5)

9

Remove hose (6)

10

Remove hoses (7) from switchover valve (8)

 Removal: Mark assignment of hoses (7).

 Installation: Note markings on hoses (7).

11

Disconnect electrical connection (9) from switchover valve (8)

12

Remove bracket (2)

 For this purpose, remove bolts (4).

 Switchover valve (8) remains on bracket (2).

 M6

*BA00.10-N-1002-01A

13

Remove bracket between exhaust pressure sensor (13) and cylinder head cover

 For this purpose, remove screws (10).

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

*BA09.40-N-1013-02PD

 M6

*BA00.10-N-1002-01A

14

Disconnect electrical connection from exhaust pressure sensor (13)

15

Remove electrical wiring harness (11) from brackets (12)

16

Remove exhaust pipe from exhaust gas turbocharger with exhaust manifold (19)

AR14.10-S-3919PD

17

Remove heat shield (14)

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

 For this purpose, remove screws (15).

 Screw/bolt, heat shield to exhaust manifold

*BA09.40-N-1005-02PD

18

Remove oil pressure line (23) from crankcase

AR09.40-S-0011PDA

19

Remove right front wheel

AR40.10-S-1100P

20

Remove front right fender liner

AR88.10-S-1301P

21

Remove nuts (16)

 Nut, exhaust gas line for exhaust gas recirculation cooler to exhaust manifold

*BA09.40-N-1017-02PD

 Nut, exhaust line to exhaust gas recirculation cooler

*BA14.20-N-1006-01PD

22

Remove exhaust line (17)

 Installation: Replace seals.

23

Remove screw (20)

 Bolt, exhaust gas turbocharger bracket to exhaust gas turbocharger

*BA09.40-N-1009-02PD

24

Unscrew nuts (18)

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

*BA09.40-N-1018-02PD

25

Remove turbocharger with exhaust manifold (19) and oil return line (22) upwards

 To do this, release clamp (21) and remove oil return line (22) from crankcase.

 Installation: Ensure correct positioning of oil return line (22) and oil pressure line (23). Aid of helper required.

 Installation: Check clamp (21).

 Hose clamp pliers

*454589003700

Depending on findings



Replace the clamp (21).

26

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

27

Check for leak tightness with engine 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

 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-1009-02PD

Bolt, exhaust gas turbocharger bracket to exhaust gas turbocharger

Nm

25

 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-1017-02PD

Nut, exhaust gas line for exhaust gas recirculation cooler to exhaust manifold

Nm

25

 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 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