Remove/install turbocharger

AR09.40-P-6020OLF

Remove/install turbocharger

22.02.2017

Engine

651 in model 222

1

ATL

11

Screw/bolt

2

Clamp

12

Screw/bolt

3

Vacuum hose

13

Rear support

4

Vacuum line

14

Front support

5

Vacuum hose

15

Screw/bolt

6

Screw/bolt

16

Bracket

7

Bracket

17

Screw/bolt

8

Screw/bolt

18

Screw/bolt

9

Screw/bolt

B19/11

Temperature sensor upstream of ATL

10

Screw/bolt

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Warning

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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 

Remove/install

1

Remove air filter housing

AR09.10-P-1150OLF

2

Remove engine air intake duct downstream of air filter

AR09.10-P-8130OLF

3

Remove temperature sensor (B19/11)

 Installation: Coat thread of the temperature sensor (B19/11) with heat-resistant lubricant.

Paste, hot lubrication 1 kg, DBL 6879.20

*BR00.45-Z-1005-06A

 Exhaust temperature sensor in manifold

*BA15.60-P-1002-01D

4

Detach clamp (2) and disconnect CAT-DPF unit from ATL (1)

 Installation: Replace sealing ring between CAT-DPF unit from ATL (1).
Check clamp (2) for damage.

 Installation: Align components of the exhaust system before tightening the clamp (2) free of tension.

 Bolt, clamp for oxicat

*BA49.10-P-1011-01AN

5

Detach clamp (3) and pull vacuum hose (3) off the ATL (1)

 Installation: Check vacuum hose (3) and clamp for damage.

6

Detach vacuum line (4) from aneroid capsule

 Installation: Check vacuum line (4) for damage.

7

Detach vacuum hose (5) from aneroid capsule

 Installation: Check vacuum hose (5) for damage.

8

Remove rear and center section of lower engine compartment paneling

AR61.20-P-1105LF

9

Remove alternator

AR15.40-P-5032OLF

10

Remove screw/bolt (6) and remove bracket (7)

 Installation: First mount the alternator, then tighten the screw/bolt (6).

 Bolt, turbocharger bracket to engine support/major assembly carrier

*BA09.40-P-1008-01P

11

Remove oil feed lines

AR09.40-P-6022OLF

12

Remove oil return line

AR09.40-P-6021OLF

13

Detach electrical line from front support (14)

14

Remove screw/bolts (8, 9)

 Only loosen the screw/bolt (9) and place rear support (13) to one side.

 Installation: Replace screw/bolt (8).

 Bolt, turbocharger bracket to rear / center to turbocharger

*BA09.40-P-1002-01P

 Bolt, bracket for rear/center exhaust gas turbocharger to crankcase

*BA09.40-P-1003-01P

15

Remove screw/bolts (10, 11, 12)

 Only loosen the screw/bolt (12) and place front support (14) to one side.

 Installation: Replace screw/bolt (10).

 Bolt, turbocharger bracket to rear / center to turbocharger

*BA09.40-P-1002-01P

 Bolt, bracket for rear/center exhaust gas turbocharger to crankcase

*BA09.40-P-1003-01P

16

Remove screw/bolt (15)

 Installation: Replace screw/bolts (15) and seal between ATL (1) and exhaust manifold.

 Flange connection, exhaust manifold to exhaust gas turbocharger

*BA09.40-P-1001-01P

17

Remove ATL (1) upwards

 Installation: Ensure that the rear support (13) is not pinched.

18

Remove aneroid capsule

Only when replacing the ATL (1)

AR09.40-P-1002OLF

19

Remove screw/bolts (17, 18) and bracket (16)

Only when replacing the ATL (1)

 Installation: Replace screw/bolts (17, 18).

 Bolt, bracket for vacuum cell to exhaust gas turbocharger

*BA09.40-P-1013-01P

If the screw/bolts (17) round Allen head bolts:



Replace screw/bolts (17) by heat-resistant hexagon head bolts.



Clean

20

Clean sealing surfaces on CAT-DPF-unit, exhaust manifold and ATL (1)

21

Install in the reverse order



Check

22

Check engine oil level, correct if necessary



AP18.00-P-1811MP


The oil level of the engine must lie between "Min" and "Max".
Engine damage can occur otherwise.

 Warning

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 buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

23

Carry out an engine test run, checking the engine for proper operation and leaktightness

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1001-01P

Flange connection, exhaust manifold to exhaust gas turbocharger

Stage 1

Nm

20

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1002-01P

Bolt, turbocharger bracket to rear / center to turbocharger

Nm

20

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1003-01P

Bolt, bracket for rear/center exhaust gas turbocharger to crankcase

Nm

20

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1008-01P

Bolt, turbocharger bracket to engine support/major assembly carrier

M8

Nm

20

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1013-01P

Bolt, bracket for vacuum cell to exhaust gas turbocharger

Nm

25

 Temperature sensor

Number

Designation

Engine 651

BA15.60-P-1002-01D

Exhaust temperature sensor in manifold

Nm

45

 Exhaust system

Number

Designation

Engine 651 in model 222

BA49.10-P-1011-01AN

Bolt, clamp for oxicat

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DBL 6879.20

A 000 989 76 51