Remove/install turbocharger

AR09.40-P-6020CDA

Remove/install turbocharger

22.02.2017

Engine

651 in model 166, 172, 204, 207, 212 (except 212.098/298), 218, 221

For sequential turbocharging

1

Boost pressure control flap aneroid capsule

8

Oil pressure line

15

Screw

2

Vacuum hose

9

Bolts

16

Screw

3

Nut

10

Electrical connector

17

Rear ATL support brace

4

Bolts

11

Vacuum hoses

18

Bolts

5

Screw

12

Screw

B19/11

Temperature sensor upstream of turbocharger

6

Air filter housing bracket at the front

13

Bolts

N14/3

Glow output stage

7

Screw

14

Front ATL support brace

 

Remove/install

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove air filter housing

AR09.10-P-1150CD

2

Remove engine air intake duct downstream of air filter

AR09.10-P-8130CD

3.1

Remove boost pressure control flap aneroid capsule (1)

Model 204, 207, 212 (except 212.098/298), 218, 221

AR09.40-P-1002-01CD

 Installation: Adjust boost pressure control flap aneroid capsule (1).

 Bolt, bracket for vacuum cell to exhaust gas turbocharger

*BA09.40-P-1013-01P

 Nut, vacuum unit to turbocharger

*BA09.40-P-1012-01P

"Yellow" locking paint

*BR00.45-Z-1027-07A

 Vacuum tester

*201589132100

 Hand vacuum pump

*001589732100

3.2

Pull off vacuum hose (2)

MODEL 166, 172

4

Unclip electrical wiring harness for temperature sensor upstream of ATL (B19/11) on air filter housing bracket at the front (6) and remove screw/bolt (7)

 Bolt for oil line bracket

*BA09.40-P-1004-01P

5

Remove screw/bolts (9) and take off air filter housing bracket at the front (6)

 Screw/bolt, air filter bracket to cylinder head

*BA09.10-P-1001-01K

6

Disconnect electrical connector (10) for glow output stage (N14/3)

7

Detach vacuum hoses (11)

8

Remove oil line feed line for turbocharger

AR09.40-P-6022CD

 Removal: Only remove the section between cylinder crankcase and bracket.

9

Remove temperature sensor upstream of ATL (B19/11)

AR07.04-P-0071CD

10.1

Remove corresponding underfloor paneling

MODEL 166

AR61.30-P-1001GQ

10.2

Remove bottom sections of soundproofing

Engine 651 in model 172, 204.0/2/3, 207, 212 (except 212.098/298), 218,

MODEL 172.4

AR94.30-P-5300W

MODEL 204.0/2/3, 207, 212 (except 212.098/298), 218

AR94.30-P-5300EW

10.3

Remove engine compartment paneling

MODEL 204.9

AR61.20-P-1105CY

10.4

Remove lower engine compartment paneling

Model 221 except code Z07 (Highest protection)

AR61.20-P-1105SX

11.1

Remove catalytic converter diesel particulate filter unit

Model 166, 172, 204 (except 204.9), 207, 212 (except 212.08/09/28/29), 218, 221

MODEL 166

AR49.10-P-5501GQ

Model 172, 204 (except 204.9), 207, 212 (except 212.08/09/28/29), 218

AR49.10-P-5501CD

MODEL 221

AR49.10-P-5501SXI

11.2

Remove catalytic converter

MODEL 204.9, 212.08/09/28/29

AR49.10-P-5500OMD

12

Remove charge air hose upstream of charge air cooler

AR09.41-P-8619CD

13.1

Loosen alternator and place down to front

Engine 651 in model 166
For sequential turbochargingEngine 651 in model 172, 204, 207, 212 (except 212.098/298), 218, 221 with transmission 722.9 (except 722.96)For sequential turbocharging

MODEL 166

AR15.40-P-5032GR

Model 172, 204, 207, 212 (except 212.098/298), 218, 221 with transmission 722.9 (except 722.96),

AR15.40-P-5032CD

13.2

Remove alternator

Model 204, 212 with transmission 722.96

AR15.40-P-5032CD

14

Remove oil line return for turbocharger

Engine 651 in model 166, 172, 204, 207, 212 (except 212.098/298), 218, 221For sequential turbocharging

Engine 651 in model 204, 207, 212 (except 212.098/298), 218, 221For sequential turbocharging

AR09.40-P-6021CD

 Installation: Replace seal.

15

Remove screw/bolts (12, 13) and take off front turbocharger support brace (14)

 Bolt, turbocharger bracket to turbocharger bypass flap

*BA09.40-P-1007-01P

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

*BA09.40-P-1008-01P

16

Remove screw/bolts (15, 16) and take off rear turbocharger support brace (17)

 Installation: Replace screw/bolts (15, 16).

 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

17

Remove screw/bolts (18)

 Installation: Install new screw/bolts (18) and seal.

 Flange connection, exhaust manifold to exhaust gas turbocharger

*BA09.40-P-1001-01P

18

Remove turbocharger upwards

19

Install in the reverse order



Check

20

Check engine oil level, correct if necessary


The engine oil level 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

21

Perform an engine test run and check engine around the turbocharger for leaktightness

 Air filter

Number

Designation

Engine 651

BA09.10-P-1001-01K

Screw/bolt, air filter bracket to cylinder head

Nm

9

 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-1004-01P

Bolt for oil line bracket

Nm

9

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1007-01P

Bolt, turbocharger bracket to turbocharger bypass flap

M6

Nm

9

 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-1012-01P

Nut, vacuum unit to turbocharger

M6

Nm

9

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1013-01P

Bolt, bracket for vacuum cell to exhaust gas turbocharger

Nm

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1027-07A

"Yellow" locking paint

Lackfabrik Bäder GmbH & Co. KG
Dieselstrasse 34
73734 Esslingen
Germany
Tel.: +49 711 381607
Fax. +49 711 383092