Remove/install turbocharger with exhaust manifold

AR09.40-S-6036EH

Remove/install turbocharger with exhaust manifold

06.03.2020

Engine

622.8 in model 447

1

ATL with exhaust manifold

4

Bolts

2

Bolts

5

Intake connection fitting

3

Bracket

6

Electrical connector

1

ATL with exhaust manifold

9

Screw

7

Screw

10

Heat shield

8

Bracket

Tightening procedure

1

ATL with exhaust manifold

A

Nut

B

Nut

C

Nut

D

Nut

E

Nut

F

Nut

G

Nut

H

Nut

I

Nut

J

Nut

 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 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove charge air pipe from the exhaust gas turbocharger with exhaust manifold (1) and place charge air pipe to one side.

AR09.41-S-1311EH

2

Remove screws (4) and remove intake connection (5) from the exhaust gas turbocharger with exhaust manifold (1).

 Installation: Replace sealing ring.

 Assembly tool

*000589936300

3

Remove oil return feed line.

AR09.40-S-6021EF

4

Remove oil pressure line.

AR09.40-S-6035EF

5

Remove screws (2) and remove bracket (3).

 M81.25

*BA00.10-N-1005-04A

6

Release and disconnect electrical connector (6) from the exhaust gas turbocharger with exhaust manifold (1).

7

Remove screw (7) and remove bracket (8).

 Screw, holder in exhaust manifold

*BA14.10-N-1006-02E

8

Unscrew screws (9) and remove heat shield (10).

 Screw, heat shield in exhaust manifold

*BA14.10-N-1005-02E

9

Remove nuts (A to J) and carefully guide out of the exhaust gas turbocharger with exhaust manifold (1) and remove.

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Installation: Replace nuts (A to J).
Observe tightening pattern.

 Nut, exhaust manifold to cylinder head

*BA14.10-N-1001-02E

 Stud bolt to cylinder head

*BA14.10-N-1002-02E

If the stud bolt has come loose,



Replace stud bolt.

10

Place exhaust gas turbocharger down with the exhaust manifold (1) onto a suitable base and seal with protective covers.

 Set of protective covers

*001589039100

11

Install new seal of the exhaust gas turbocharger with exhaust manifold (1) for the cylinder head and clean sealing surfaces.

Assembly cleaner

*BR00.45-Z-1028-04A

12

Install in the reverse order.



Check

 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

13

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

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

Number

Designation

8.8

10.9

BA00.10-N-1005-04A

M81.25

Nm

22

32

 Exhaust manifold

Number

Designation

Engine 622.8 in model 447

BA14.10-N-1001-02E

Nut, exhaust manifold to cylinder head

Nm

25

 Exhaust manifold

Number

Designation

Engine 622.8 in model 447

BA14.10-N-1002-02E

Stud bolt to cylinder head

Nm

8

 Exhaust manifold

Number

Designation

Engine 622.8 in model 447

BA14.10-N-1005-02E

Screw, heat shield in exhaust manifold

Nm

10

 Exhaust manifold

Number

Designation

Engine 622.8 in model 447

BA14.10-N-1006-02E

Screw, holder in exhaust manifold

Nm

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01