Remove/install turbocharger with exhaust manifold

AR09.40-D-6036TSC

Remove/install turbocharger with exhaust manifold

15.01.2019

Engine

274 in model 907

1

Screw

5a

Oil feed line

9

Nut

2

Heat shield

5b

Oil return line

10

Support brace

3

Turbocharger

6

Screw

11

Seal

4a

Coolant line

7

Vacuum unit

12

Nut (8 pcs.)

4b

Coolant line

8

Bracket

Y101

Divert air switchover valve

 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

 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

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Drain off coolant.

AR20.00-D-1142TSC

2

Remove air intake pipe from exhaust gas turbocharger (3) and place to one side.

AR09.10-D-8131TSC

3

Remove the catalytic converter.

AR49.20-D-0100TSC

4

Remove screw (6) of bracket (8).

 M8

*BA00.10-N-1003-01A

5

Remove screws (1), unscrew nut (9), and remove heat shield (2).

 Screw/bolt, heat shield to cylinder head

*BA09.40-N-1013-02F

 Nut, heat shield to turbocharger support brace

*BA09.40-N-1014-02F

6

Remove coolant lines (4a, 4b).

AR09.40-D-6020-18TSC

 Screw/bolt, coolant line to cylinder head

*BA09.40-N-1010-02F

 Screw/bolt, coolant line to coolant pump

*BA09.40-N-1009-02F

 Screw/bolt, coolant line to exhaust gas turbocharger

*BA09.40-N-1008-02F

7

Remove oil feed line (5a).

AR09.40-D-6035TSC

8

Remove oil return feed line (5b).

AR09.40-D-6021TSC

9

Release and disconnect electrical connector of the overrun mode bypass air switchover valve (Y101).

10

Remove electrical wiring harness and electrical connector of the overrun mode bypass air switchover valve (Y101) and place outside of the working area.

11

Remove vacuum hose from the vacuum cell (7).

12

Remove support (10) from exhaust gas turbocharger (3).

 Nut, turbocharger support brace to turbocharger

*BA09.40-N-1012-02F

13

Remove support (10).

 Bolt, turbocharger support brace to crankcase

*BA09.40-N-1011-02F

14

Unscrew nuts (12) and remove exhaust manifold with the exhaust gas turbocharger (3) from the cylinder head.

 Installation: Replace seal (11) and nuts (12).

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

*BA09.40-N-1001-02F

15

Remove exhaust gas turbocharger (3) upward.

 Installation: The exhaust gas turbocharger (3) must be installed with the support (10).

16

Install in the reverse order



Check

17

Check engine oil level, correct if necessary.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A



AP18.00-D-0101TSC

 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

18

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

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

Number

Designation

8.8

10.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

23

32

Phosphated

Nm

21

29

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

Number

Designation

12.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

38

Phosphated

Nm

36

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1001-02F

Nut, exhaust manifold with exhaust gas turbocharger to cylinder head

Nm

15

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1008-02F

Screw/bolt, coolant line to exhaust gas turbocharger

Nm

9

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1009-02F

Screw/bolt, coolant line to coolant pump

Nm

9

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1010-02F

Screw/bolt, coolant line to cylinder head

Nm

9

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1011-02F

Bolt, turbocharger support brace to crankcase

Stage 1

Nm

15

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1012-02F

Nut, turbocharger support brace to turbocharger

Nm

30

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1013-02F

Screw/bolt, heat shield to cylinder head

Nm

10

 Turbocharger

Number

Designation

Engine 274 in model 907

BA09.40-N-1014-02F

Nut, heat shield to turbocharger support brace

Nm

10