Remove/install turbocharger

AR09.40-P-6020CDB

Remove/install turbocharger

13.02.2017

Engine

651 in model 204, 212 (except 212.098/298)

For single-speed charging

1

ATL

5

Banjo bolt

9

Screw/bolts

2

Screw/bolt

6

Retaining clamp

10

Oil return line

3

Screw/bolts

7

Lubricating oil line

Y77/1

Boost pressure positioner

4

ATL bracket

8

Screw/bolt

1

ATL

11

Screw/bolts

12

Connecting panel

13

Noise damper

14

Screw/bolts

15

Bracket

Y77/1

Boost pressure positioner

Y77/1x1

Boost pressure positioner electrical connection

 

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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Disconnect ground line at the on-board electrical system battery

MODEL 204

AR54.10-P-0003CW

MODEL 212

AR54.10-P-0003EW

2

Remove air filter housing

AR09.10-P-1150CD

3

Remove engine air intake duct downstream of air filter

AR09.10-P-8130CD

4

Separate noise damper (13) from ATL (1)

 M6

*BA00.10-P-1002-01A

5

Disconnect charge pressure positioner electrical connection (Y77/1x1)

6

Remove banjo bolt (5) and screw/bolt (8) and remove lubricating oil line (7) from ATL (1)

 Installation:
Replace seals.
Leaks can occur otherwise.

 Banjo bolt, oil line to turbocharger

*BA09.40-P-1005-01P

 Bolt, oil line to crankcase

*BA09.40-P-1006-01P

7.1

Remove front section from noise encapsulation

MODEL 204 (except 204.9), 212

AR94.30-P-5300EW

7.2

Remove bottom engine compartment paneling at front

MODEL 204.9

AR61.20-P-1105CY

8

Disconnect catalytic converter diesel particulate filter unit from ATL (1)

 MODEL 204Bolt connecting catalytic converter to turbocharger

*BA49.10-P-1002-01AC

 MODEL 212Bolt, catalytic converter to turbocharger

*BA49.10-P-1002-01AE

9

Remove alternator from major assembly carrier and place to the front

AR15.40-P-5032CD

10

Unscrew screw/bolts (9) from oil return line (10)

 Installation:
Replace seal.
Leaks can occur otherwise.

 Bolt, oil line to crankcase

*BA09.40-P-1006-01P

11

Unhook retaining clip (6) and remove ATL bracket (4)

 Installation: Replace screw/bolt on ATL (1).

 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

12

Remove screw/bolts (3) on exhaust manifold

 Installation: Install new screw/bolts (3) and seal.

 Flange connection, exhaust manifold to exhaust gas turbocharger

*BA09.40-P-1001-01P

13

Remove ATL (1) upwards

14

Install in the reverse order



Check

15

Check engine oil level, correct if necessary

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

16

Teach in charge pressure (Y77/1) with Star Diagnosis



AD00.00-P-2000-04A


Menu guidance:
 CDI control unit
 Adaptations
 Teach-in processes

 Danger !

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

17

Check engine for a running engine for leaktightness

 Headless screws: bolts and nuts, coarse-pitch thread

Number

Designation

Model all

BA00.10-P-1002-01A

M6

8.8

Galvanized

Nm

9

Phosphated

Nm

9

10.9

Galvanized

Nm

13

Phosphated

Nm

12

12.9

Galvanized

Nm

16

Phosphated

Nm

14

 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-1005-01P

Banjo bolt, oil line to turbocharger

Stage 1

Nm

9

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 651

BA09.40-P-1006-01P

Bolt, oil line to crankcase

Nm

9

 Exhaust system

Number

Designation

Engine 642, 646, 651 in model 204

BA49.10-P-1002-01AC

Bolt connecting catalytic converter to turbocharger

Nm

20

 Exhaust system

Number

Designation

Engine 642, 651 in model 212

BA49.10-P-1002-01AE

Bolt, catalytic converter to turbocharger

Nm

20