Remove/install turbocharger with exhaust manifold

AR09.40-P-6036MRM

Remove/install turbocharger with exhaust manifold

24.02.2020

Engine

274.9 in model 167

20

Cover

21

Partition wall

22

Electrical wiring harness

23

Screw

1

Charge air pipe

6

Support brace

11

Nut

3

Turbocharger

7

Seal

12

Nut

4a

Coolant line

8

Nut

13

Nut

4b

Coolant line

9

Nut

14

Nut

5a

Oil line

10

Nut

15

Nut

5b

Oil line

Shown with code 2U8 (Alternative refrigerant)

2

Heat shield

3

Turbocharger

16

Nut

17

Line

18

Electrical connector

19

Vacuum hose

 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 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

Topical note

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

AH00.00-P-0020-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Drain off coolant.

AR20.00-P-1142MRM

 Installation: Only install lower engine compartment paneling after leak test.

2

Remove cover for air/water duct.

AR83.10-P-1411ME

3

Unclip cover (20) (arrows) and remove.

4

Unclip line of the inerting system from the partition (21).

Engine 274.9 in model 167
with code 2U8 (Alternative refrigerant)

5

Unclip electrical wiring harness (22) from the partition (21).

6

Remove screws (23) and remove the partition (21) upward.

 Installation: Ensure that the partition (21) is seated correctly in the lower part of the partition.

 Screw, upper engine compartment partition to lower engine compartment partition

*BA62.30-P-1012-02I

7

Remove air filter housing.

AR09.10-P-1150MRM

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

8

Remove front holder of air filter housing.

 Bolt, front air filter housing holder to cylinder head/cylinder head cover

*BA01.30-P-1009-01Y

9

Remove right rear engine lifting lug and place to one side.

 Bolt, lifting eye to cylinder head/cylinder head cover

*BA01.30-P-1008-01Y

10

Remove nut (16) and place line (17) to one side.

Engine 274.9 in model 167
with code 2U8 (Alternative refrigerant)

 Nut, heat shield to turbocharger support brace

*BA09.40-P-1014-01U

11

Remove heat shield (2).

 Bolt, heat shield to cylinder head/bracket for air filter

*BA09.40-P-1015-01U

12

Remove oil lines (5a, 5b) and seal openings with suitable stop plugs.

AR09.40-P-6020-13MR

 Installation: Replace screw/bolts and seals.

 Screw/bolt, oil line for oil feed to exhaust gas turbocharger

*BA09.40-P-1005-01U

 Screw/bolt, oil line for oil feed to crankcase

*BA09.40-P-1006-01U

 Bolt, oil return flow line to turbocharger

*BA09.40-P-1007-01U

 Bolt, oil return line to crankcase

*BA09.40-P-1008-01U

 Record plug

*129589009100

13

Remove coolant lines (4a, 4b) and seal openings with suitable stop plugs.

AR09.40-P-6020-14MR

 Installation: Replace screw/bolts and seals.

 Bolt, coolant feed/return line to turbocharger

*BA09.40-P-1009-01U

 Bolt, coolant return flow line to cylinder head

*BA09.40-P-1011-01U

 Record plug

*129589009100

 Hose clamp pliers

*454589003700

14

Remove vacuum hose (19) from vacuum cell.

15

Release and disconnect electrical connector (18).

16

Release clamp of air intake pipe on exhaust gas turbocharger (3) and detach air intake pipe from exhaust gas turbocharger (3).

17

Remove charge air pipe (1) from exhaust gas turbocharger (3).

18

Remove catalytic converter from exhaust gas turbocharger (3) and from holder and secure against falling down.

AR49.20-P-0100MRM

19

Remove support (6) from crankcase and exhaust gas turbocharger (3).

 Nut, support brace to turbocharger

*BA09.40-P-1012-01U

 Bolt, turbocharger support brace to crankcase

*BA09.40-P-1013-01U

 Set of flexible head wrenches

*001589810900

20

Remove nuts (8 to 15) in reverse numerical order.

 Installation: Replace nuts (8 to 15) and install in numerical order.

 Nut, turbocharger/exhaust manifold to cylinder head

*BA09.40-P-1001-01U

21

Unfasten exhaust gas turbocharger (3) from cylinder head.

22

Remove exhaust gas turbocharger (3) together with support (6).

 Installation: Replace seal (7).



Clean

23

Clean sealing surfaces of exhaust gas turbocharger (3) and cylinder head.

Cleaner

*BR00.45-Z-1025-04A



Check

24

Check stud bolts of exhaust gas turbocharger (3) for damage.

If there is a problem,



Replace stud bolts of exhaust gas turbocharger (3).

 Stud bolt for exhaust manifold

*BA01.30-P-1004-01Y

25

Install in the reverse order.

26

Check engine oil level in multifunction display 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

27

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

 Cylinder head

Number

Designation

Engine 274

BA01.30-P-1004-01Y

Stud bolt for exhaust manifold

Nm

8

 Cylinder head

Number

Designation

Engine 274

BA01.30-P-1008-01Y

Bolt, lifting eye to cylinder head/cylinder head cover

M8

Nm

20

 Cylinder head

Number

Designation

Engine 274

BA01.30-P-1009-01Y

Bolt, front air filter housing holder to cylinder head/cylinder head cover

M8

Nm

20

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1001-01U

Nut, turbocharger/exhaust manifold to cylinder head

Nm

15

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1005-01U

Screw/bolt, oil line for oil feed to exhaust gas turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1006-01U

Screw/bolt, oil line for oil feed to crankcase

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1007-01U

Bolt, oil return flow line to turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1008-01U

Bolt, oil return line to crankcase

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1009-01U

Bolt, coolant feed/return line to turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1011-01U

Bolt, coolant return flow line to cylinder head

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1012-01U

Nut, support brace to turbocharger

Nm

30

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1013-01U

Bolt, turbocharger support brace to crankcase

Stage 1

Nm

15

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1014-01U

Nut, heat shield to turbocharger support brace

Nm

10

 Turbocharger

Number

Designation

Engine 274

BA09.40-P-1015-01U

Bolt, heat shield to cylinder head/bracket for air filter

Nm

10

 Frond end with reinforcement

Number

Designation

Model 167

BA62.30-P-1012-02I

Screw, upper engine compartment partition to lower engine compartment partition

4

Repair materials

Number

Designation

Order number

BR00.45-Z-1025-04A

Cleaner

A 005 989 19 71