Remove/install turbocharger

AR09.40-P-6020TX

Remove/install turbocharger

22.5.06

 

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

AR49.00-P-1000-01T

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.

AR49.10-P-5501TX

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, the support brace (8) on the crankcase must be loosened.



*BA09.40-P-1002-01N



*BA09.40-P-1003-01N



*001589011600



*003589050900



*WH58.30-Z-1065-06A

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



*WH58.30-Z-1011-11A



*WH58.30-Z-1012-11A

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

 Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

*WH58.30-Z-1048-13A

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

WH58.30-Z-1065-06A

Plug in TORX box wrench

WH58.30-Z-1011-11A

Insert box wrench 9x12

WH58.30-Z-1012-11A

Insert box wrench Torx 9x12

WH58.30-Z-1048-13A

STAR DIAGNOSIS diagnosis system, Compact Passenger Car

6511 1801 00