Remove/install turbocharger

AR09.40-P-6020MTA

Remove/install turbocharger

05.09.2018

Engine

133 in model 117, 156, 176

Modification notes

27.01.2016

Cover alternator, added.

Operation step 11

27.06.2016

Document completely revised.

1

Screw/bolts

2

Profiled clamp

G3/2

Oxygen sensor upstream of catalytic converter

3

Clamp

4

Elastomer bearing

5

Bracket

6

Catalytic converter

G3/1

Oxygen sensor downstream of catalytic converter

6

Catalytic converter

7

Aneroid capsule

8

Nut

9

Nuts

10

Screw/bolts

11

Bracket

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes on coolant level

AH20.00-P-1142-01CW



Remove

1

Remove engine cover

2

Drain off coolant

AR20.00-P-1142MTA

3

Remove air filter housing

AR09.10-P-1150MTA

4

Expose purge lines on cylinder head cover

5

Detach air intake pipe and place with attached purge lines to one side

AR09.10-P-8131MTA

6

Detach vacuum line from aneroid capsule (7)

7

Release and disconnect electrical connection at electronic wastegate

AR09.40-P-0001MTA

8

Remove heat shield at ATL

9

Detach charge air hose upstream of charge air cooler at ATL

10

Remove screw/bolts (1) and profiled clamp (2)

11

Cover alternator

 When removing the ATL, the alternator must always be covered up to prevent any ingress of coolant or engine oil.

12

Remove oil lines

AR18.30-P-6850MTA

13

Remove coolant lines

AR20.20-P-7440MTA

14

Unclip electrical lines of the oxygen sensor downstream of CAT (G3/1) and oxygen sensor upstream of CAT (G3/2)

AR07.52-P-5303MTA

 Do not disconnect electrical connections.

15

Loosen clamp (3)

16

Place CAT (6) to one side

 The CAT (6) remains in the elastomer bearing (4).

17

Unscrew nut (8) with a suitable tool from below through the opening in heat shield of the exhaust manifold

18

Unscrew nuts (9)

19

Remove screw/bolts (10)

20

Lift ATL up and out

21

Replace seal between exhaust manifold and ATL

22

Detach bracket (11) from ATL

Only if the bracket (11) is replaced.

23

Remove electronic wastegate

Only if ATL is replaced.

AR09.40-P-0001MTA



Check

24

Check stud bolts of the ATL for damage, for firm seating and replace if necessary



Install

25

Install electronic wastegate

Only if ATL is replaced.

AR09.40-P-0001MTA

26

Take off new bracket (11) at ATL

Only if the bracket (11) is replaced.

 Only for a new bracket (11) there are aluminum plates present which serve as an assembly aid.

 Bolt, bracket to turbocharger

*BA09.40-P-1011-01X

27

Install a new seal between ATL and exhaust manifold

28

Install ATL

29

Align bracket (11) on cylinder head

30

Screw in new screw/bolts (10) and tighten

 Bolt, bracket to cylinder head/bracket

*BA09.40-P-1010-01X

31

Remove the aluminum plates

Only if the bracket (11) is replaced.

 The aluminum plates only serve as an assembly aid and must be removed.

32

Tighten new nuts (9)

 Nut, turbocharger to exhaust manifold

*BA09.40-P-1001-01X

33

Tighten down new nut (8) with a suitable tool from below through the opening in heat shield of the exhaust manifold

 Nut, turbocharger to exhaust manifold

*BA09.40-P-1001-01X

34

Install catalytic converter (6)

35

Tighten clamp (3)

 Clamp, front exhaust system to catalytic converter/gasoline particulate filter

*BA49.10-P-1020-01AL

36

Clip in electrical lines of the oxygen sensor downstream of CAT (G3/1) and oxygen sensor upstream of CAT (G3/2)

AR07.52-P-5303MTA

37

Install coolant lines

AR20.20-P-7440MTA

38

Install oil lines

AR18.30-P-6850MTA

39

Cover alternator

40

Install new profiled clamp (2), screw in screw/bolts (1) and tighten

 Clamp, catalytic converter/gasoline particulate filter to exhaust gas turbocharger

*BA49.10-P-1014-01AL

41

Attach charge air hose upstream of charge air cooler at ATL

42

Install heat shield at ATL

 Bolt, heat shield to bracket

*BA09.40-P-1009-01X

43

Connect and lock electrical connection at electronic wastegate

AR09.40-P-0001MTA

44

Attach vacuum line to aneroid capsule (7)

45

Attach air intake pipe

AR09.10-P-8131MTA

46

Attach purge lines at cylinder head cover

 Replace cable tie.

47

Install air filter housing

AR09.10-P-1150MTA

48

Pour in coolant

AR20.00-P-1142MTA

49

Install engine cover



Check

50

Check engine oil level and correct if necessary



AP18.00-P-0101AHH

 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

51

Carry out engine test run and check engine for proper leaktightness and function

 Turbocharger

Number

Designation

Engine 133

BA09.40-P-1001-01X

Nut, turbocharger to exhaust manifold

Nm

21

 Turbocharger

Number

Designation

Engine 133

BA09.40-P-1009-01X

Bolt, heat shield to bracket

Nm

9

 Turbocharger

Number

Designation

Engine 133

BA09.40-P-1010-01X

Bolt, bracket to cylinder head/bracket

Stage 1

Nm

20

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 133

BA09.40-P-1011-01X

Bolt, bracket to turbocharger

Nm

20

 Exhaust system

Number

Designation

Engine 133 in model 117

Engine 133 in model 156

BA49.10-P-1014-01AL

Clamp, catalytic converter/gasoline particulate filter to exhaust gas turbocharger

M8

Nm

20

20

 Exhaust system

Number

Designation

Engine 133 in model 176

BA49.10-P-1014-01AL

Clamp, catalytic converter/gasoline particulate filter to exhaust gas turbocharger

M8

Nm

20

 Exhaust system

Number

Designation

Engine 133 in model 117

Engine 133 in model 156

BA49.10-P-1020-01AL

Clamp, front exhaust system to catalytic converter/gasoline particulate filter

Nm

35

35

 Exhaust system

Number

Designation

Engine 133 in model 176

BA49.10-P-1020-01AL

Clamp, front exhaust system to catalytic converter/gasoline particulate filter

Nm

35