Remove/install turbocharger

AR09.40-I-6020B

Remove/install turbocharger

15.2.12

 

Remove/install

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnecting the battery



Notes on battery

AH54.10-P-0001-01A

2

Remove engine brake flap connection

AR14.15-I-6302B

3

Remove charge air pipe (5)

AR09.41-I-1311B

4

Remove crankcase ventilation hose (3) on air intake hose (2)

5

Detach air intake hose (2) at turbocharger (1)

6

Detach oil return line (4) at turbocharger (1)

 Collect oil which flows out in a suitable vessel.

Use suitable plugs to seal the openings.

 Installation: Install new gasket



*BA09.40-N-1003-01B

7

Detach oil pressure line (6) at turbocharger (1)

 Collect oil which flows out in a suitable vessel.

Use suitable plugs to seal the openings.

 Installation: Before installation of oil pressure line (6), fill the turbocharger bearing housing (1) through the oil inlet hole with engine oil. Rotate the turbocharger shaft by hand during this step so that the bearing points are provided with a film of oil.



*BA09.40-N-1006-01B

8

Unscrew nut (8) on exhaust manifold (7) and remove turbocharger (1)

 The turbocharger (1) is attached by four nut (8) to exhaust manifold (7).

Close off openings on turbocharger (1) using suitable plugs.

 Replace self-locking nuts (8).



*BA09.40-N-1001-01B

9

Install in the reverse order

10

Check engine oil level, correct if necessary

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

11

Start engine and observe engine oil pressure gauge with the engine idling

 Start engine using the starter for a maximum of 90 seconds repeating the starting procedure after a pause of about 2 minutes if necessary.
Do not rev engine if no engine oil pressure is indicated otherwise there is danger of incurring engine damage.

*BE18.00-N-1001-01C

 The engine oil pressure display must indicate the oil pressure after about 10 seconds.

12

Turn off engine and check area of turbocharger (1) for leaks

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BE18.00-N-1001-01C

Engine oil pressure at

Idling speed

bar

0.5

maximum speed

bar

2.5

Number

Designation

Engine
900.9, 904.9

BA09.40-N-1001-01B

Nut, turbocharger to exhaust manifold

M8

Nm

30

M10

Nm

50

BA09.40-N-1003-01B

Bolt, oil return flow line to turbocharger

Nm

10

BA09.40-N-1006-01B

Union nut, oil pressure line to turbocharger

M14

Nm

30

M16

Nm

35