Remove/install turbocharger

AR09.40-S-6020PD

25.10.2019

Model	470 with engine 699.304/305
	with code MT2 (Emissions class Euro 6d-TEMP N1 GR.III/N2)
Model	470, 471 with engine 699.301/303

Modification notes

25.10.2019	Method extended	Operation steps 4, 10.2, 11
25.10.2019	Special tool 129 589 00 91 00 set of stop plugs inserted	Operation steps 8, 14, 15
25.10.2019	Engine filling quantity, added.	Operation step 20

Shown with engine 699.301 except code MT2 (emissions class Euro 6d-TEMP N1 GR.III/N2)

1	Charge air pipe
2	Bolts
3	Bracket
4	Nut
5	Bolts
6	Heat shield

S09.40-4557-06

Shown with engine 699.301 except code MT2 (emissions class Euro 6d-TEMP N1 GR.III/N2)

7	Hose
8	Screw
9	Bracket
10	Hose
11	Turbocharger
12	Nuts
13	Oil separator
17	Hose

S09.40-4564-06

11	Turbocharger
14	Screw
15	Screw
16	Hose

S09.40-4559-06

Shown with engine 699.304 and with code MT2 (emissions class Euro 6d-TEMP N1 GR.III/N2)

11	Turbocharger
18	Electrical connector
19	Electrical connector
20	Electrical wiring harness
21	Mounting clip

S09.40-A040-76

 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
 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
 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
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
 	Remove/install
1	Remove air filter housing.		AR09.10-S-1150PD
2	Remove air intake hose.		AR09.10-S-8030PD
		 Plug openings. Use clean rag.
3	Remove charge air pipe downstream of exhaust gas turbocharger (11).		AR09.41-S-1333PD
		 Plug openings. Use clean rag.
4	Disconnect electrical connector (18).	Model 470 with code MT2 (emissions class Euro 6d-TEMP N1 GR.III/N2)
		 To do so, unlock electrical connector (18).
5	Remove charge air pipe (1).	 To do this, remove screws (2).
		 Plug openings. Use clean rag.
		 Installation: Check seals of the charge air pipe (1) for damage.
		 Screw/bolt, boost pressure pipe to exhaust gas turbocharger	*BA09.40-N-1015-02PD
		If damage is present:
		
		Replace seals of charge air pipe (1).
6	Loosen bracket (3).	 To do this, loosen the nut (4).
		 M6	*BA00.10-N-1002-01A
7	Remove heat shield (6).	 To do this, remove the screw/bolts (5).
		 Screw/bolt, heat shield to exhaust manifold	*BA09.40-N-1005-02PD
8	Remove hose (7) from the oil separator (13).	 Plug openings.
		 Record plug	*129589009100
9	Remove bracket (9).	 For this purpose, remove screws (8) and remove electrical wiring harness.
		 M6	*BA00.10-N-1002-01A
10.1	Remove hose (10) from the vacuum cell of the exhaust gas turbocharger (11).	Model 470, 471 except code MT2 (emissions class Euro 6d-TEMP N1 GR.III/N2)
10.2	Disconnect electrical connector (19).	Model 470 with code MT2 (emissions class Euro 6d-TEMP N1 GR.III/N2)
		 To do so, unlock electrical connector (19).
11	Remove electrical wiring harness (20) from the exhaust gas turbocharger (11).	Model 470 with code MT2 (emissions class Euro 6d-TEMP N1 GR.III/N2)
		 To do so, remove retaining clip (21). Check retaining clip (21) for damage.
		If damage is present:
		
		replace retaining clip (21).
12	Remove hose (17) from the vacuum cell of the exhaust gas turbocharger (11).
13	Remove exhaust pipe from exhaust gas turbocharger (11).		AR14.10-S-3919PD
14	Unscrew screw (14).	 Catch oil running out. Plug openings.
		 Banjo bolt, exhaust gas turbocharger oil line to crankcase	*BA09.40-N-1007-02PD
		 Record plug	*129589009100
15	Remove hose (16) from the crankcase.	 Plug openings.
		 Commercially available devices/tools Hose clamp pliers with wire cable
		 Record plug	*129589009100
16	Remove screw (15).	 Bolt, exhaust gas turbocharger bracket to exhaust gas turbocharger	*BA09.40-N-1009-02PD
17	Remove exhaust gas turbocharger (11) upward.	 To do so, remove nuts (12).
		 Plug openings. Use clean rag.
		 Installation: Replace seals.
		 Nut, exhaust gas turbocharger to exhaust manifold	*BA09.40-N-1010-02PD
18	Change oil line of the exhaust gas turbocharger (11).	If the exhaust gas turbocharger (11) is being replaced.
			AR09.40-S-0009PD
19	Install in the reverse order.
	Check
20	Check oil level with oil dipstick.	 Engine oil	*BF18.00-N-1001-01PP
		If the oil level is incorrect,
		
		Correct oil level.
 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
21	Check for leaktightness when engine is running.	 Visual inspection only.

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number	Designation			8.8	10.9
BA00.10-N-1002-01A	M6	Galvanized	Nm	9	13
		Phosphated	Nm	9	12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number	Designation			12.9
BA00.10-N-1002-01A	M6	Galvanized	Nm	16
		Phosphated	Nm	14