2013 Mercedes-Benz Sprinter 3500

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Adrian Hamilton
5 years ago
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Fig. 23: Identifying Exhaust Collector Pipe

Install new seal between exhaust collector

1 Fig. 23: Identifying Exhaust Collector Pipe Bolt & Exhaust Gas Turbocharger Flange Fig. 24: Replacing Seal Between Turbocharger & Exhaust Collector 4. Install new seal between exhaust collector and turbocharger. Observe installation position of hole pattern on seal.

2 5. Screw in bolts (2, 3) finger-tight. It must be possible to move the exhaust gas turbocharger in the direction of the exhaust collector pipe. 6. Install exhaust gas turbocharger with old seal on oil supply connection fitting 7. Screw exhaust collector pipe alternately on right and left exhaust manifold to old seal hand-tight. 8. Tighten bolts (2) fully. Displacement between exhaust collector pipe and exhaust gas turbocharger leads to tension which can cause considerable engine damage 9. Loosen bolts between exhaust collector pipe and exhaust manifold again. 10. Remove exhaust gas turbocharger from oil supply connection fittings. 11. Carefully remove turbocharger with exhaust collector. Displacement between exhaust collector pipe and exhaust gas turbocharger leads to tension which can cause considerable engine damage 12. Clamp exhaust collector pipe with exhaust gas turbocharger on flange (1) into vise and carefully tighten bolt (3). Displacement between exhaust collector pipe and exhaust gas turbocharger leads to tension which can cause considerable engine damage Helper required and observe tightening torque. 13. Remove exhaust gas turbocharger with exhaust collector pipe from vise. Aid of helper required. BOLT PLAN FOR CHARGE AIR MANIFOLD - AR09.41-D S CHARGE AIR PIPE/CHARGE AIR COOLING Number Designation Engine 642 BA09.41-N O Bolt, charge air distribution line to cylinder Nm 16 head 1. Tighten all bolts (1 to 19) finger-tight to charge air manifold (20). Screw on lifting eye (21) when screwing on bolts (7 and 10). 2. Tighten bolts (1 to 19) according to bolt plan, start with bolt (1).

3 3. Tighten bolts (1 and 11) again. Fig. 25: Identifying Charge Air Manifold Bolts Tightening Sequence BOLT PLAN FOR CHARGE AIR MANIFOLD - AR09.41-D SG CHARGE AIR DISTRIBUTION LINE TO CYLINDER HEAD BOLT TORQUE SPECIFICATION - ENGINE 642 Number Designation Engine 642 BA09.41-N O Bolt, charge air distribution line to cylinder head Nm 16

4 Fig. 26: Identifying Flexible Head Wrench Set ( ) Shown on engine Screw all bolts (1 to 19) finger-tight to charge air manifold (20), except bolts (2 and 11). Screw on lifting eye (22) when screwing on bolts (7 and 10) 2. Remove clamp (21) from charge air manifold (20). 3. Tighten bolts (1 to 19) according to bolt plan, start with bolt (1). 4. Tighten bolts (1 and 11) again.

5 Fig. 27: Identifying Charge Air Manifold Bolt Tightening Sequence REMOVE/INSTALL CHARGE AIR MANIFOLD - AR09.41-D-1310SG ENGINES /898 in MODEL 906

6 Fig. 28: Charge Air Manifold Remove/Install Component Location

Fig. 29: Charge Air Manifold Remove/Install Component Location (Shown On Engine 642.896) Fig. 30: Charge Air Manifold Remove/Install Component Location (Only On Engine 642.

7 Fig. 29: Charge Air Manifold Remove/Install Component Location (Shown On Engine ) Fig. 30: Charge Air Manifold Remove/Install Component Location (Only On Engine ) REMOVE/INSTALL CHARGE AIR MANIFOLD - ENGINES /898 IN MODEL 906 Remove/install Risk of injury to skin and Do not open cooling system AS20.00-Z A eyes caused by scalding unless coolant temperature is from contact with hot below 90 C. Open cap coolant spray. Risk of slowly and release the poisoning caused by pressure. Do not pour swallowing coolant. coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel Notes about Common-Rail components No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. AS47.00-Z A AH07.16-P SM 1 Drain coolant AR20.00-D-1140SD 2 Remove trim panel on right AR01.20-D-5015SF cylinder head cover 3 Remove oil supply AR09.40-S-6023SE

AR01.30-P-5800PK Remove/install cylinder head

Page 1 of 10 AR01.30-P-5800PK Remove/install cylinder head 7.6.00 ENGINE 111.955 in MODEL 203.045 /245 /745 P01.30-2081-09 1 Air filter housing 2 Air recirculation flap actuator 3 Top engine trim panels