Remove/Install Turbocharger With Exhaust Manifold - AR09.40-P-6036MSA
Engine 256.9 in model 213, 238, 257, 290
MODIFICATION NOTES
| 29.09.2022 | Remove screws from lower support and remove support, added. | Operation step 13 | |
| 24.01.2023 | Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head | Engine 256.9 | BA14.10-P-1001-02MRT |
| 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 overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. |
AS20.00-Z-0001-01A | |
| 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 danger zone. | AS49.00-Z-0001-01A | |
| 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 | |
| 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 | |
| Notice | Notes on coolant | AH20.00-P-2080-01KOA | |
| Notice | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| Notice | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| Remove/install | |||
| 1 | Remove engine air intake duct downstream of air filter. | AR09.10-P-8130MSA | |
| 2 | Remove inerting system line from exhaust gas turbocharger (1) and place to one side. | Engine 256.9 in model 213, 238 with code 2U8 (Alternative refrigerant) | AR86.10-P-0119LWO |
| Engine 256.9 in model 257, 290 with code 2U8 (Alternative refrigerant) | AR86.10-P-0119FR | ||
| 3 | Release and disconnect electrical connectors (2). | ||
| 4 | Remove full load bleed line from exhaust gas turbocharger (1) and place to one side. | AR01.20-P-0020MSA | |
| 5 | Remove oil feed line. | AR09.40-P-6022MSA | |
| 6.1 | Remove the catalytic converter. | Engine 256.9 in model 213, 238 up to model year 2020 Engine 256.9 in model 257 except code 961 (Exhaust system with OPF, generation 2.0) except code 999 (Exhaust system with OPF, generation 3.0) Engine 256.9 in model 290 except code 961 (Exhaust system with OPF, generation 2.0) except code 999 (Exhaust system with OPF, generation 3.0) |
AR49.20-P-0100MSA |
| 6.2 | Remove exhaust gas aftertreatment unit. | Engine 256.9 in model 213, 238 as of model year 2020 Engine 256.9 in model 257, 290 with code 961 (Exhaust system with OPF, generation 2.0) Engine 256.9 in model 257, 290 with code 999 (Exhaust system with OPF, generation 3.0) Engine 256.9 in model 213, 238 as of model year 2020 |
AR49.20-P-1500MSA |
| Engine 256.9 in model 257 with code 961 (Exhaust system with OPF, generation 2.0) Engine 256.9 in model 257 with code 999 (Exhaust system with OPF, generation 3.0) Engine 256.9 in model 290 with code 961 (Exhaust system with OPF, generation 2.0) Engine 256.9 in model 290 with code 999 (Exhaust system with OPF, generation 3.0) |
AR49.20-P-1500SA | ||
| 7 | Remove oil return feed line from exhaust gas turbocharger (1). | AR09.40-P-6021MSA | |
| 8 | Remove coolant line from exhaust gas turbocharger (1). | AR20.20-P-1050MSA | |
| 9 | Remove feed line coolant line from exhaust gas turbocharger (1). | AR20.20-P-1000MSA | |
| 10 | Remove screws (4) and remove support (3). | *BA09.40-P-1003-02MRT | |
| 11 | Remove cylinder 6 ignition coil. | AR15.12-P-2003MSA | |
| 12 | Remove the heat shield (5). | *BA09.40-P-1004-02MRT | |
| *BA09.40-P-1014-02MRT | |||
| 13 | Unscrew screw (6) and lower screws of support and remove support. | *BA09.40-P-1002-02MRT | |
| 14 | Release clamps of boot (8). | *BA09.41-P-1010-01MRT | |
| 15 | Remove nuts (10) in reverse order of tightening procedure and remove peg board (9). | Tightening pattern for turbocharger |
AR09.40-P-6020-10MRT |
| *BA14.10-P-1001-02MRT | |||
| *BA14.10-P-1002-02MRT | |||
| *BA09.40-P-1018-02MRT | |||
| 16 | Release exhaust gas turbocharger (1) from the bottom terminal strips and remove with boot (8). | Align marking of the boot (8) with the marking on the exhaust gas turbocharger (1). Wet boot (8) with lubricant. Lubricant, rubber assembly 1 L |
*BR00.45-Z-1010-06A |
| 17 | Remove ball pin (7). | Only when replacing ATL (1). |
*BA01.10-P-1001-01MRT |
| Clean | |||
| 18 | Clean the sealing surfaces on cylinder head. | ||
| 19 | Clean sealing surfaces on exhaust gas turbocharger (1). | If exhaust gas turbocharger (1) is reused. | |
| 20 | Install in the reverse order. | ||
| Check | |||
| 21 | Check engine oil level and correct if necessary. | ||
| Engine 256.9 in model 213, 238, 290 | AP18.00-P-1812MKI | ||
| Engine 256.9 in model 257 | AP18.00-P-1812BKI | ||
| 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 | |
| 22 | Perform engine test run. While doing so, check engine for proper operation and leak tightness. |
ENGINE COVER
| Number | Designation | Engine 256 | |
|---|---|---|---|
| BA01.10-P-1001-01MRT | Ball pin, engine cover to exhaust gas turbocharger/camshaft housing | Nm | 8 |
TURBOCHARGER
| Number | Designation | Engine 256 | |||
|---|---|---|---|---|---|
| BA09.40-P-1002-02MRT | Screw, support to exhaust gas turbocharger/crankcase | M8 | Stage 1 | Nm | 20 |
| Stage 2 | ∠° | 90 | |||
| M6 | Nm | - | |||
TURBOCHARGER
| Number | Designation | Engine 256 | ||
|---|---|---|---|---|
| BA09.40-P-1003-02MRT | Bolt, bracket to turbocharger/cylinder head | M6 | Nm | 8 |
| M8 | Nm | 33 | ||
TURBOCHARGER
| Number | Designation | Engine 256 | |
|---|---|---|---|
| BA09.40-P-1004-02MRT | Nut/screw, heat shield to exhaust gas turbocharger/heat shield | Nm | 8 |
TURBOCHARGER
| Number | Designation | Engine 256 | |
|---|---|---|---|
| BA09.40-P-1014-02MRT | Screw, side heat shield to upper heat shield | Nm | 8 |
TURBOCHARGER
| Number | Designation | Engine 256 | |
|---|---|---|---|
| BA09.40-P-1018-02MRT | Nut, peg board/exhaust gas turbocharger to cylinder head | Nm | - |
CHARGE AIR PIPE/CHARGE AIR COOLING
| Number | Designation | Engine 256 | |
|---|---|---|---|
| BA09.41-P-1010-01MRT | Screw clamp, boot to exhaust gas turbocharger | Nm | 6 |
EXHAUST MANIFOLD
| Number | Designation | Engine 256.9 | ||
|---|---|---|---|---|
| BA14.10-P-1001-02MRT | Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head | Stage 1 | Nm | 21 |
| Stage 2 | Nm | 21 | ||
| Stage 3 | Nm | 21 | ||
EXHAUST MANIFOLD
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA14.10-P-1002-02MRT | Screw, exhaust manifold (exhaust gas turbocharger) strip clamp to cylinder head | Nm | 20 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1010-06A | Lubricant, rubber assembly 1 L | A 000 989 03 67 |