Remove/install exhaust manifold

AR14.10-S-3006EA

Remove/install exhaust manifold

15.04.2020

Engine

654.9 in model 447

Modification notes

16.01.2020

Information added.

Operation steps 7, 9

AR09.40-S-6020-20EA

08.04.2020

Work procedure revised.

The whole document

AR09.40-S-6020-20EA

08.04.2020

Work procedure revised

The whole document

1

Nut

9

Nut

2

Nut

10

Exhaust manifold

3

Nut

11

Screw

4

Nut

12

Screws

5

Nut

13

Coolant line

6

Nut

14

Screw

7

Nut

15

Screws

8

Nut

16

Exhaust gas recirculation line

13

Coolant line

16

Exhaust gas recirculation line

17

Seal

17.1

Heat shield

18

Seal

19

Seal

20

O-ring

21

Seal

22

Stud bolts

 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 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

Topical note

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

AH00.00-P-0020-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove oil return feed line of the exhaust gas turbocharger.

AR09.40-S-6021EA

2

Remove holder for the exhaust gas turbocharger.

AR09.40-S-6020-20EA

 Screw/bolt, support to cylinder head

*BA09.40-N-1009-02EA

 Bolt, bracket to crankcase

*BA09.40-N-1006-02EA

3

Remove coolant feed line.

AR20.20-S-0006EA

4

Remove bottom coolant return line for the exhaust gas turbocharger.

AR20.20-S-0008EA

5

Remove screws (11).

 Bolt, coolant line to crankcase

*BA14.20-N-1003-01EA

6

Remove coolant line (13).

 To do so, remove screws (12).
Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Installation: Replace O-ring (20) and seal (21) on coolant line (13).

 Bolt, coolant line to high pressure exhaust gas recirculation valve

*BA14.20-N-1004-01EA

 Assembly tool

*000589936300

 Record plug

*129589009100

7

Remove screws (14).

 Bolt, high pressure exhaust gas recirculation line to exhaust manifold

*BA14.20-N-1021-01EA

8

Remove exhaust gas recirculation line (16).

 For this purpose, remove screws (15).

 Installation: Replace seal (18, 19) on exhaust gas recirculation line (16).

 Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve

*BA14.20-N-1006-01EA

9

Remove nuts (1 to 9).

 Installation: Attach nuts (1 to 9) in numerically ascending sequence.

 Nut, exhaust manifold to cylinder head

*BA14.10-N-1001-02EA

10

Remove exhaust manifold (10).

 Installation: Install new seal (17) with the heat shield (17.1).



Check

11

Check exhaust manifold (10) for damage.

If damage is detected:



Replace new exhaust manifold (10).

12

Check coolant line (13) for damage.

If damage is detected:



Install new coolant line (13).

13

Check exhaust gas recirculation line (16) for damage.

If damage is detected:



Replace exhaust gas recirculation line (16).

14

Check stud bolts (22) for damage.

If damage is detected:



Replace corresponding stud bolt (22).

 Stud bolt, exhaust manifold to cylinder head

*BA14.10-N-1002-02EA

15

Check stud bolts (22) for tight seating.

If stud bolts (22) are loose:



Tighten corresponding stud bolt (22).

 Stud bolt, exhaust manifold to cylinder head

*BA14.10-N-1002-02EA



Clean

16

Clean sealing surface on cylinder head.

Assembly cleaner

*BR00.45-Z-1028-04A

17

Clean sealing surface on exhaust manifold (10).

If the exhaust manifold (10) is reused.

Assembly cleaner

*BR00.45-Z-1028-04A

18

Clean sealing surfaces on the exhaust gas recirculation line (16).

If exhaust gas recirculation line (16) is reused.

Assembly cleaner

*BR00.45-Z-1028-04A

19

Clean sealing surface on the coolant line (13).

If the coolant line (13) is reused.

Assembly cleaner

*BR00.45-Z-1028-04A

20

Install in the reverse order.

 Turbocharger

Number

Designation

Engine 654.9 in model 447

BA09.40-N-1006-02EA

Bolt, bracket to crankcase

Nm

20

 Turbocharger

Number

Designation

Engine 654.9 in model 447

BA09.40-N-1009-02EA

Screw/bolt, support to cylinder head

Stage 1

Nm

20

Stage 2

°

90

 Exhaust manifold

Number

Designation

Engine 654.9 in model 447

BA14.10-N-1001-02EA

Nut, exhaust manifold to cylinder head

Stage 1

Nm

15

Stage 2

Nm

15

 Exhaust manifold

Number

Designation

Engine 654.9 in model 447

BA14.10-N-1002-02EA

Stud bolt, exhaust manifold to cylinder head

Nm

15

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1003-01EA

Bolt, coolant line to crankcase

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1004-01EA

Bolt, coolant line to high pressure exhaust gas recirculation valve

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1006-01EA

Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1021-01EA

Bolt, high pressure exhaust gas recirculation line to exhaust manifold

Stage 1

Nm

12

Stage 2

°

90

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01