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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 |
|
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 |
 |
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 |
|
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 |
| |
Information on preventing damage to electronic components due to electrostatic discharge |
|
AH54.00-P-0001-01A |
| |
Notes on avoiding damage through contamination and foreign objects |
|
AH00.00-P-5000-01A |
  |
Remove/install |
|
|
| 1 |
Drain off coolant. |
|
AR20.00-D-1142TSC |
| 2 |
Remove air intake pipe from exhaust gas turbocharger (3) and place to one side. |
|
AR09.10-D-8131TSC |
| 3 |
Remove the catalytic converter. |
|
AR49.20-D-0100TSC |
| 4 |
Remove screw (6) of bracket (8). |
M8 |
*BA00.10-N-1003-01A |
| 5 |
Remove screws (1), unscrew nut (9), and remove heat shield (2). |
Screw/bolt, heat shield to cylinder head |
*BA09.40-N-1013-02F |
|
Nut, heat shield to turbocharger support brace |
*BA09.40-N-1014-02F |
| 6 |
Remove coolant lines (4a, 4b). |
|
AR09.40-D-6020-18TSC |
|
Screw/bolt, coolant line to cylinder head |
*BA09.40-N-1010-02F |
|
Screw/bolt, coolant line to coolant pump |
*BA09.40-N-1009-02F |
|
Screw/bolt, coolant line to exhaust gas turbocharger |
*BA09.40-N-1008-02F |
| 7 |
Remove oil feed line (5a). |
|
AR09.40-D-6035TSC |
| 8 |
Remove oil return feed line (5b). |
|
AR09.40-D-6021TSC |
| 9 |
Release and disconnect electrical connector of the overrun mode bypass air switchover valve (Y101). |
|
|
| 10 |
Remove electrical wiring harness and electrical connector of the overrun mode bypass air switchover valve (Y101) and place outside of the working area. |
|
|
| 11 |
Remove vacuum hose from the vacuum cell (7). |
|
|
| 12 |
Remove support (10) from exhaust gas turbocharger (3). |
Nut, turbocharger support brace to turbocharger |
*BA09.40-N-1012-02F |
| 13 |
Remove support (10). |
Bolt, turbocharger support brace to crankcase |
*BA09.40-N-1011-02F |
| 14 |
Unscrew nuts (12) and remove exhaust manifold with the exhaust gas turbocharger (3) from the cylinder head. |
: Replace seal (11) and nuts (12). |
|
| |
|
Nut, exhaust manifold with exhaust gas turbocharger to cylinder head |
*BA09.40-N-1001-02F |
| 15 |
Remove exhaust gas turbocharger (3) upward. |
: The exhaust gas turbocharger (3) must be installed with the support (10). |
|
| 16 |
Install in the reverse order |
|
|
 |
Check |
|
|
| 17 |
Check engine oil level, correct if necessary. |
|
|
 |
Specified engine oils (service) - Overview |
|
BB00.40-P-0223-02A |
 |
|
|
AP18.00-D-0101TSC |
|
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 |
|
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 |
| 18 |
Perform engine test run. While doing so, check engine for proper operation and leak tightness. |
|
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