Remove/install turbocharger with exhaust manifold

AR09.40-P-6025SB

Remove/install turbocharger with exhaust manifold

15.07.2016

Engine

281.910 in model 453.062/362/462

1

ATL

8

Coolant hose

2

Air intake hose

9

Coolant hose

3

Securing clamp

10

Screw/bolts

4

Control rod

11

Oil return line

5

Exhaust manifold

1

ATL

6

Electrical connection

7

Electrical connection

1

ATL

15

Banjo bolt

12

Nuts

16

Oil feed line

13

Bracket

17

Screw/bolts

14

Clamp

18

Charge air hose

 Danger !

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

 Danger !

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger !

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



Notes on coolant

AH20.00-N-2080-01A

 

Remove/install

1

Remove maintenance flap

2

Turn cap on engine coolant expansion reservoir a half turn counterclockwise, relieve overpressure and then unscrew the cap

3

Remove covering over engine

 Installation: Only install covering over engine after the leak test.

4

Remove air intake hose (2)

5

Remove all heat shield over the CAT

AR49.10-P-6905SR

6

Remove catalytic converter

AR49.10-P-5500SRA

7

Disconnect electrical connection (6)

8

Disconnect electrical connection (7)

9

Remove coolant hose (8)

 Collect escaping coolant in a suitable container.

 Installation: Replace clamp if necessary.

 Hose clamp pliers

*003589033700

10

Remove coolant hose (9)

 Collect escaping coolant in a suitable container.

 Installation: Replace clamp if necessary.

 Hose clamp pliers

*003589033700

11

Remove screw/bolts (10)

 Screw/bolt, oil return flow line to exhaust gas turbocharger

*BA09.40-P-1004-02A

12

Unfasten oil return line (11) from ATL (1)

13

Lower vehicle with vehicle lift

14

Remove banjo bolt (15)

 Banjo bolt, oil feed line to exhaust gas turbocharger

*BA09.40-P-1003-02A

15

Unfasten oil feed line (16) from ATL (1)

16

Remove screw/bolts (17)

 Screw/bolt, charge air hose to exhaust gas turbocharger

*BA09.40-P-1001-02A

17

Unfasten charge air hose (18) from ATL (1)

 Installation: Replace seal.

18

Raise vehicle with vehicle lift

19

Unscrew nuts for exhaust manifold (5) on cylinder head

 Installation: Screw on nuts evenly up to stop.

 Nut, exhaust manifold to cylinder head

*BA49.10-P-1002-02C

20

Unfasten ATL (1) together with exhaust manifold (5) and remove downwards

 Installation: Ensure correct seating of the ATL (1) and the exhaust manifold (5).

21

Remove seal and clean sealing surface on cylinder head and on exhaust manifold (5)

 Installation: Replace seal.

22

Install in the reverse order

23

Pour in coolant and bleed cooling system

AR20.00-P-1142SR



Check

24

Check engine oil level



AP18.00-P-0101S

 Danger !

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

Perform an engine test run and check engine for leaktightness around ATL (1) and check the exhaust manifold (5) for leaktightness

 Exhaust gas turbocharger

Number

Designation

Engine 281.910

BA09.40-P-1001-02A

Screw/bolt, charge air hose to exhaust gas turbocharger

Nm

8

 Exhaust gas turbocharger

Number

Designation

Engine 281.910

BA09.40-P-1003-02A

Banjo bolt, oil feed line to exhaust gas turbocharger

Nm

12

 Exhaust gas turbocharger

Number

Designation

Engine 281.910

BA09.40-P-1004-02A

Screw/bolt, oil return flow line to exhaust gas turbocharger

Nm

12

 Exhaust system

Number

Designation

Engine 281.910

BA49.10-P-1002-02C

Nut, exhaust manifold to cylinder head

Nm

35