W09.40-1112-09
Shown on model 944 without code MS4 (BlueTec 4) or without code MS5 (BlueTec 5)) |
1 | Heat shield | 8 | Front muffler with exhaust pipe and exhaust flex pipe | 14 | Engine brake cylinder | ||
2 | Turbocharger | 9 | Tensioning strap | 15 | Engine brake valve fitting | ||
3 | Charge air pipe | 10 | Lifting eye | 16 | Exhaust manifold | ||
4 | Charge air hose | 11 | Exhaust pipe | 17 | Oil pressure line | ||
5 | Clip | 12 | Clip | 18 | Oil return line | ||
6 | Air intake hose | 13 | Compressed-air line | 19 | Fitting | ||
7 | Soundproofing at top |
2 | Turbocharger |
18 | Oil return line |
20 | Bracket |
21 | Engine wiring harness |
22 | Union nut |
23 | Bracket (only for code MS4 (BlueTec 4) or for code MS5 (BlueTec 5)) |
24 | Clamp (only with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5)) |
25 | Wastegate line (only for code MS4 (BlueTec 4) or for code MS5 (BlueTec 5)) |
Pfeil | Contact surface |
W09.40-1166-06
| Remove/install | ||
Topical note | Notes on self-locking nuts and bolts | ||
Warning | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut. | |
1 | Tilt cab | ||
Topical note | Notes on tilting the cab | ||
Installation: Only tilt back cab after the leak test. | |||
Danger | Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC. | No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers. | |
2 | Disconnect ground line from battery | ||
Topical note | Notes on battery | ||
3 | Remove soundproofing at top (7) from frame on right and soundproofing at bottom center and right | ||
4 | Remove heat shield (1) | Engine 457.9Bolt, heat shield to turbocharger and engine brake flap fitting | |
5 | Remove tensioning strap (9) | ||
6 | Remove clamp (12) from the rear lifting eye (10) | ||
7 | Remove premuffler with exhaust pipe and exhaust flex pipe (8) from the engine brake valve fitting (15), push it back to the rear, and connect it with a cable tie | ||
8 | Remove air intake hose (6) | Installation: Check condition of air intake hose (6), replace it if necessary. | |
Air intake hose clamp on air intake pipe and turbocharger | |||
9 | Remove charge air hose (4) from charge air pipe (3) | Installation: Check condition of charge air hose (4), replace it if necessary. | |
Clamp, charge air hose to charge air housing/charge air pipe and charge air cooler | |||
10 | Take off clamp (5) | Clamp, charge air pipe to turbocharger | |
11 | Unscrew the screw from the bracket and remove the charge air pipe (3) | Seal bores at exhaust gas turbocharger (2). | |
12 | Remove oil pressure line (17) | Catch escaping and engine oil and seal bores. | |
Installation: Before attaching the oil pressure line (17), fill the bearing housing of the exhaust gas turbocharger (2) with engine oil through the oil inlet hole. Rotate exhaust gas turbocharger shaft by hand during this step so that bearing points are provided with a film of oil. | |||
Engine 457.9Banjo bolt, oil pressure line to turbocharger | |||
Engine 457.9Banjo bolt, oil pressure line to crankcase | |||
13 | Remove compressed-air line (13) at engine brake cylinder (14) | ||
14 | Remove injection line for exhaust aftertreatment system | ||
Only in vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5). | |||
Installation: Replace injection line after each removal. | |||
15 | Loosen electrical engine wiring harness (21) on the bracket (20) | ||
16 | Remove the oil return line (18) from the cylinder crankcase | Counterhold the fitting (19) when loosening the oil return line (18). | |
Installation: Lubricate contact surface (arrow) on collar and thread of union nut (22) using engine oil. | |||
Engine 457.9Nut, oil return line to cylinder crankcase fitting | |||
17 | Remove bracket (23) | Only in vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5). | |
Engine 457.9Bolt, turbocharger on retaining bracket/crankcase | |||
18 | Remove the exhaust gas turbocharger (2) from the exhaust manifold (16) and take it out | Seal bores at exhaust gas turbocharger (2). | |
Engine 457.9Nut, turbocharger to exhaust manifold | |||
19 | Remove the engine brake valve fitting (15) from the exhaust gas turbocharger (2) | Only if replacing exhaust gas turbocharger (2). | |
Nut, valve fitting of engine brake to exhaust gas turbocharger | |||
20 | Remove clamp (24) from the Wastegate line (25) | Only in vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5)) if the exhaust gas turbocharger (2) is being replaced. | |
21 | Remove oil return line (18) from exhaust gas turbocharger (2) | Only if replacing exhaust gas turbocharger (2). | |
Engine 457.9Bolt, oil return flow line to turbocharger | |||
22 | Install in the reverse order | ||
23 | Check engine oil level with oil dipstick or on display, add oil if necessary | ||
Notes on engine oil | |||
Observe oil grade set in maintenance system or Specifications for Operating Fluids. | |||
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. | |
24 | Start engine and allow to run in idle; oil pressure must have built up after about 10 s, then run the engine at varying rpms | ||
25 | Turn off engine and check area of exhaust gas turbocharger (2) for leaktightness | Visual inspection. | |
26 | Synchronize time between tachograph disk and display |