Shown on removed engine |
1 | Exhaust gas recirculation line |
2 | Screw |
3 | Electrical wiring harness |
4 | Oxygen sensor upstream of catalytic converter |
5 | Bolts |
6 | Exhaust pipe |
10 | Exhaust collector pipe |
15 | Seal |
S09.40-4578-76
7 | Electrical connectors |
14 | Turbocharger |
S09.40-4580-76
P09.40-2583-08
8 | Bolts | 11 | Screw | |
9 | Bolts | 12 | Coolant line | |
10 | Exhaust collector pipe | 13 | Bolts |
16 | Wooden block |
17 | Steering gear |
18 | Oil pan |
S09.40-4581-76
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. | |
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. | |
Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on self-locking nuts and bolts | ||
| Remove/install | ||
1 | Remove fan unit. | ||
Installation: Only install upper engine cover after the leak test. | |||
2 | Remove clean air line. | ||
3 | Remove charge air pipe downstream of exhaust gas turbocharger (14). | ||
4 | Remove heat shield from exhaust gas turbocharger (14). | ||
5 | Drain off coolant. | ||
6 | Remove the transmission with torque converter. | ||
7 | Remove exhaust gas recirculation line (1). | ||
8 | Take load off of wooden block (16) between steering gear (17) and oil pan (18) and lay onto flat side. | ||
9 | Carefully support engine on wooden block (16). | ||
10 | Remove screw/bolt (2). | Installation: Replace screw/bolt (2). | |
Bolt, exhaust pipe to turbocharger | |||
11 | Expose electrical wiring harness (3) of lambda sensor upstream of catalytic converter (4). | ||
12 | Remove screws (5). | Installation: Replace screw/bolts (5). | |
Bolt, exhaust pipe to turbocharger | |||
13 | Remove exhaust pipe (6) with lambda sensor upstream of catalytic converter (4) in upward direction. | ||
14 | Remove bolts (8). | Installation: Replace screws (8). | |
Screw/bolt, flange connection of exhaust manifold/front exhaust pipes to exhaust collector pipe | |||
15 | Remove screws/bolts (9). | Bolt, turbocharger support brace to crankcase | |
16 | Remove bolts (13). | Installation: Install new screw/bolts (13). | |
Fit bolt, turbocharger to oil supply connection fitting | |||
17 | Disconnect electrical connectors (7). | ||
18 | Remove exhaust gas turbocharger (14) together with exhaust gas collector pipe (10) and coolant line (12), then seal openings with suitable stop plugs or protective covers. | Installation: | |
Installation: Replace seals (15) and seal between exhaust gas turbocharger (14) and oil supply connection fitting. | |||
Set of protective covers | |||
Record plug | |||
19 | Remove screw (11) and remove coolant line (12). | If exhaust gas turbocharger (14) is replaced. | |
20 | Remove O-ring from coolant line (12). | Installation: Replace O-ring. | |
Assembly tool | |||
21 | Remove temperature sensor upstream of exhaust gas turbocharger (14). | If exhaust gas turbocharger (14) is replaced. | |
22 | Remove exhaust gas collector pipe (10) from exhaust gas turbocharger (14). | If exhaust gas turbocharger (14) is replaced. | |
Installation: Replace seal. | |||
Screw/bolt, turbocharger to exhaust collector pipe | |||
| Clean | ||
23 | Clean sealing surfaces on exhaust manifolds and exhaust gas collector pipe (10). | ||
24 | Clean sealing surfaces on exhaust gas turbocharger (14) with lint-free rag. | If exhaust gas turbocharger (14) is reused. | |
25 | Install in the reverse order. | ||
26 | Read out fault memory and perform initialization of boost pressure regulator. | If exhaust gas turbocharger (14) was replaced. | |
| |||
If there is a fault in the fault memory: | |||
| |||
Erase corresponding fault. | |||
27 | Check engine oil level. | | |
If there is a problem, | |||
| |||
Correct engine oil level. | |||
Engine oil | |||
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. | |
28 | Perform engine test run and check exhaust gas turbocharger (14) for leaks in the process. |
000 589 93 63 00
Assembly tool
129 589 00 91 00
Record plug
001 589 01 91 00
Set of protective covers