Remove/install turbocharger

AR09.40-P-6020EH

Remove/install turbocharger

02.12.2019

Engine

651.9 in model 212.098/298

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

19

Turbocharger

6

Air filter housing bracket at the front

13

Bolts

B19/11

Temperature sensor upstream of turbocharger

7

Screw

14

Front ATL support brace

N14/3

Glow output stage

 

Remove/install

 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

 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

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove power electronics with power distributor

AR08.10-P-0011EH

2

Remove boost pressure control flap aneroid capsule (1)

AR09.40-P-1002-01CD

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

 Nut, vacuum unit to turbocharger

*BA09.40-P-1012-01P

"Yellow" locking paint

*BR00.45-Z-1027-07A

 Hand vacuum pump

*001589732100

 Vacuum tester

*201589132100

3

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

4

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

5

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

6

Detach vacuum hoses (11)

7

Remove oil line feed line for ATL (19)

AR09.40-P-6022CD

 Only remove the section between cylinder crankcase and bracket.

8

Remove temperature sensor upstream of ATL (B19/11)

AR07.04-P-0071CD

9

Remove oil line return for ATL (19)

AR09.40-P-6021CD

 Installation: Replace seal.

10

Remove screw/bolts (12, 13) and take off front ATL 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

11

Remove screw/bolts (15, 16) and take off rear ATL 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

12

Remove bolts (18)

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

 Flange connection, exhaust manifold to exhaust gas turbocharger

*BA09.40-P-1001-01P

13

Remove turbocharger (19) upwards

14

Install in the reverse order

15

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

AS00.00-Z-0005-01A

16

Perform an engine test run and check engine for leaks around turbocharger (19)

 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

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