Remove/install turbocharger

AR09.40-P-6020CWI

Remove/install turbocharger

7.12.06

 

Remove/install

 Danger!

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

Align vehicle between columns of lifting platform and position four support plates at lifting platform support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove air filter housing

AR09.10-P-1150TXX

2

Remove shield above turbocharger

3

Loosen catalytic converter-diesel particulate filter device

 To do this remove pipe clamp at turbocharger (5) and

unfasten catalytic converter diesel particulate filter device at transmission holders and at crankcase.



*BA49.10-P-1011-01I



*BA49.10-P-1015-01I



*BA49.10-P-1017-01I

4

Remove bolt (1)



*BA09.40-P-1007-01N

5

Unclip line (2)

6

Remove charge air duct (3) upstream of charge air cooler

7

Remove oil feed line (4)

 Installation: Replace sealing rings, in order to prevent leaks

 To do this, remove bolts (6, 7) at cylinder head and turbocharger (5).



*BA09.40-P-1008-01N



*BA09.40-P-1009-01N

8

Remove support brace (8) on underside of the turbocharger (5)

 Remove bolt (9).

 Installation: In order to be able to install the turbocharger (5) such that it is not under any tension, the bolt of the support brace (8) on the crankcase must be loosened.



*BA09.40-P-1002-01N



*BA09.40-P-1003-01N



*001589011600



*003589050900

9

Pull plug (10) out of boost pressure positioner (Y77/1)

10

Disconnect connector from temperature sensor upstream of turbocharger (B19/11)

11

Remove bolts (11) and turbocharger (5) from exhaust manifold

 Installation: Bolts (11) in the Torx design must be replaced by bolts in the twelve-point design.



*BA09.40-P-1001-01N

12

Remove turbocharger (5) upwards

 The oil drain line (12) must be removed upwards at the same time.

 Collect any oil that flows out in a suitable vessel.

13.1

Remove oil drain line (12) from turbocharger (5)

Only if turbocharger (5) is replaced.

 Installation: Prior to installing the new turbocharger (5), the oil drain line (12) must be positioned at the turbocharger (5). The bolts (13) are not tightened until after the turbocharger (5) has been installed.



*BA09.40-P-1010-01N

14

Install in the reverse order



Checking

15

Check engine oil level

 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

16

Check engine for leaks

 With engine running.

17

Read out fault memory and erase



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine
646.8

BA09.40-P-1001-01N

Flange connection, exhaust manifold to turbocharger

Stage 1

Nm

20

Stage 2

°

90

BA09.40-P-1002-01N

Bolt, support brace to turbocharger

Nm

30

BA09.40-P-1003-01N

Bolt, turbocharger support brace to crankcase

Nm

20

BA09.40-P-1007-01N

Bolt, charge air manifold bracket to charge air manifold

Nm

9

BA09.40-P-1008-01N

Bolt, oil feed line to turbocharger

Nm

18

BA09.40-P-1009-01N

Bolt, oil feed line to cylinder head

Nm

9

BA09.40-P-1010-01N

Bolt, oil drain line to turbocharger

Nm

9

Number

Designation

Engine
646.8

BA49.10-P-1011-01I

Self-locking nut, three way catalytic converter to bracket

Nm

20

BA49.10-P-1015-01I

Bolt connecting catalytic converter hose clamp to turbocharger

Nm

15

BA49.10-P-1017-01I

Self-locking nut connecting diesel particulate filter to bracket at transmission

Nm

20