Contents: Removal ↡ Installation ↡
Removal
1. Disconnect the negative cable from the battery.
2. Remove the service cover.
3. Remove the gearbox protective cover.
4. Remove shield 13 of the exhaust manifold (figure 3.4).
5. Remove the compressed air supply pipe and inlet manifold.
6. Disconnect the exhaust pipe 10 from the engine brake valve 5 and from the gearbox and secure it to the side.
7. Disconnect the compressed air supply pipe 8 from the engine brake cylinder.
8. Disconnect oil injection pipe 11 from turbocharger 4.
9. Unscrew bolts 3 securing exhaust manifold 2 together with gaskets.
10. Tilt forward together the exhaust manifold 2, turbocharger 4 and exhaust pipe flap 5.
11. Loosen clamp 7 and lower turbocharger 4 with oil drain line 6 attached.
12. Lift and remove together the exhaust manifold 2, turbocharger 4 and the valve in the exhaust pipe 5.
13. Remove gasket 1.
14. Disconnect shield 15 from turbocharger.
15. Remove turbocharger 4.
16. Check the bolts 3 securing the exhaust manifold. Thread diameter: M10. New bolt length: 47 mm. Allowable length: 47.5 mm.
Installation
17. Installation is carried out in the reverse order of removal. Adjust the engine oil level. Start the engine and check the oil pressure. Oil pressure at: idle speed: 0.5 bar, maximum speed: 2.5 bar.
Figure 3.4. Exhaust manifold: 1 - Gaskets; 2 - Exhaust manifold; 3 - Exhaust manifold mounting bolts; 4 - Turbocharger; 5 - Exhaust manifold flap (engine brake); 6 - Oil drain line; 7, 9 - Clamps; 8 - Compressed air supply tube; 10 - Exhaust pipe; 11 - Oil injection line; 13, 15 - Shields.