Remove/install turbocharger with exhaust manifold

AR09.40-P-6036MSC

Remove/install turbocharger with exhaust manifold

18.02.2020

Engine

256.9 in model 167

Modification notes

31.07.2019

Remove support of exhaust gas turbocharger.

Operation step 14

1

Turbocharger

2

Electrical connector

3

Bracket

4

Bolts

5

Heat shield

6

Screw

7

Ball stud

8

Boot

9

Peg board

10

Nuts

 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

 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

 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

 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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove engine compartment service flap.

AR01.10-P-2405-02MSC

 Nut to wiper arm on front windshield wiper system

*BA82.30-P-1001-01R

 M61

*BA00.10-P-1002-04A

2

Remove engine air intake duct downstream of air filter.

AR09.10-P-8130MSC

 Installation: Only install upper engine cover after the leak test.

3

Remove inerting system line from exhaust gas turbocharger (1) and place to one side.

Engine 256.9 in model 167
with code 2U8 (Alternative refrigerant)

AR86.10-P-0119ME

4

Release and disconnect the electrical connections (2).

5

Remove full load bleed line from exhaust gas turbocharger (1) and place to one side.

AR01.20-P-0020MSC

6

Remove oil feed line.

AR09.40-P-6022MSC

7

Remove exhaust gas aftertreatment unit.

AR49.20-P-1500MSC

8

Remove oil return feed line from exhaust gas turbocharger (1).

AR09.40-P-6021MSC

9

Remove coolant return flow line from exhaust gas turbocharger (1).

AR20.20-P-1050MSC

10

Remove feed line coolant line from exhaust gas turbocharger (1).

AR20.20-P-1000MSC

11

Unscrew screws (4) and remove holder (3).

 Installation: First, tighten screws (4) slightly by hand and then tighten with the specified tightening torque.

 Bolt, bracket to turbocharger/cylinder head

*BA09.40-P-1003-02MRT

12

Remove ignition coil of cylinder 6 .

AR15.12-P-2003MSC

13

Remove heat shield (5).

 M61

*BA00.10-P-1002-04A

14

Unscrew screw (6) and lower screws of support and remove support.

 Screw, support to exhaust gas turbocharger/crankcase

*BA09.40-P-1002-02MRT

15

Release clamps of boot (8).

 Screw clamp, boot to exhaust gas turbocharger

*BA09.41-P-1010-01MRT

16

Remove nuts (10) in reverse order of tightening procedure and remove peg board (9).

Tightening pattern for turbocharger

AR09.40-P-6020-10MRT

 Installation: Install new nuts (10).

 Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head

*BA14.10-P-1001-02MRT

17

Release exhaust gas turbocharger (1) from the bottom terminal strips and remove with boot (8).

 Installation: Install new boot (8) and seal of the exhaust gas turbocharger (1).
Align marking of the boot (8) with the marking on the exhaust gas turbocharger (1).
Wet boot (8) with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

18

Remove ball pin (7).

Only when replacing exhaust gas turbocharger (1).

 Ball pin, engine cover to exhaust gas turbocharger/camshaft housing

*BA01.10-P-1001-01MRT



Clean

19

Clean sealing surfaces on the cylinder head and exhaust gas turbocharger (1).

20

Install in the reverse order.



Check

21

Check engine oil level and correct if necessary.



AP18.00-P-1812SKI

 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

22

Carry out engine test run and check engine for proper leak tightness and leak tightness.

23

Install upper engine cover.

AR01.10-P-2405MSC

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Engine cover

Number

Designation

Engine 256

BA01.10-P-1001-01MRT

Ball pin, engine cover to exhaust gas turbocharger/camshaft housing

Nm

8

 Turbocharger

Number

Designation

Engine 256.9

BA09.40-P-1002-02MRT

Screw, support to exhaust gas turbocharger/crankcase

M8

Stage 1

Nm

20

Stage 2

 0

90

M6

Nm

-

 Turbocharger

Number

Designation

Engine 256.9

BA09.40-P-1003-02MRT

Bolt, bracket to turbocharger/cylinder head

M6

Nm

8

M8

Nm

33

 Charge air pipe/charge air cooling

Number

Designation

Engine 256.9

BA09.41-P-1010-01MRT

Screw clamp, boot to exhaust gas turbocharger

Nm

6

 Exhaust manifold

Number

Designation

Engine 256.9

BA14.10-P-1001-02MRT

Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head

Stage 1

Nm

20

Stage 2

Nm

20

 Windshield wiper

Number

Designation

Model 167

BA82.30-P-1001-01R

Nut to wiper arm on front windshield wiper system

Nm

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67