Remove/install turbocharger with exhaust manifold

AR09.40-P-6025EVO

Remove/install turbocharger with exhaust manifold

22.5.13

ENGINE

271.8 in MODEL 172, 204, 207, 212

1

Turbocharger

5

Bracket

7

Catalytic converter

12

Electrical line

15

Nuts

16

Nut

17

Support brace

2

Combination valve

6

Shields

12

Electrical line

3

Expansion reservoir

9

Coolant hose

13

Boost pressure control hose

4

Coolant return flow hose

10

Air ducting

5

Bracket

11

Charge air ducting

 

Remove/install

1

Detach ground line from battery

ENGINE 271.8 in MODEL 207, 212

AR54.10-P-0003EW

ENGINE 271.8 in MODEL 172

AR54.10-P-0003W

ENGINE 271.8 in MODEL 204

AR54.10-P-0003CW

2

Remove engine compartment paneling

ENGINE 271.8 in MODEL 172

AR61.20-P-1105W

ENGINE 271.8 in MODEL 204, 207, 212

AR61.20-P-1105EW

3

Remove three-way catalytic converter (7)

AR49.10-P-5500EVO

4

Remove combination valve (2)

Only if present

AR14.30-P-7100EVO

5

Detach power steering expansion reservoir (3)

AR46.25-P-1000EVO

 Place expansion reservoir (3) with attached lines to one side.

6

Remove combination valve (2) bracket (5)

Only if present

7

Remove secondary air system pipework

AR14.30-P-7150EVO

 Installation: Replace seal.

8

Remove shield (6) for turbocharger (1)

9

Unscrew nuts (16) as well as screw/bolts on cylinder crankcase and remove support brace (17).

 Bolt, turbocharger holder to crankcase

*BA09.40-P-1003-01Q

 Nut, bracket to turbocharger

*BA09.40-P-1002-01Q

10

Detach air ducting (10) from turbocharger (1)

11

Detach charge air ducting (11) from noise damper

12

Drain coolant at radiator

AR20.00-P-1142CW



Notes on coolant

AH20.00-N-2080-01A

13

Detach coolant hose (9) from turbocharger (1)

14

Remove coolant return hose (4)

15

Remove coolant lines for turbocharger (1)

AR09.40-P-6020-14EVO

 Installation: Replace seals.

 Bolt, coolant return line/oil feed line holder to turbocharger

*BA09.40-P-1009-01Q

 Bolt, coolant feed pipe to crankcase

*BA09.40-P-1006-01Q

 Bolt, coolant return line flange to turbocharger

*BA09.40-P-1005-01Q

16

Detach alternator, place to one side and secure against falling down

AR15.40-P-5032CW

17

Remove oil line for turbocharger (1)

AR09.40-P-6020-13EVO

 Installation: The banjo bolt and seals must be replaced after every disassembly.

 Bolt, oil return flow line to turbocharger

*BA09.40-P-1010-01Q

 Bolt, coolant return line/oil feed line holder to turbocharger

*BA09.40-P-1009-01Q

 Bolt, oil feed line to cylinder head

*BA09.40-P-1008-01Q

 Banjo bolt, oil feed line to turbocharger

*BA09.40-P-1007-01Q

18

Disconnect connector for electrical line (12) to bypass air switchover valve

19

Disconnect boost pressure control hose (13) from boost pressure control pressure transducer (Y31/5) and unclip from right engine suspension lug

 Installation: Replace clamp if necessary.

20

Unscrew nuts (15) and remove turbocharger (1) upwards

 Installation: Replace seal.

 Nut, turbocharger/exhaust manifold to cylinder head

*BA09.40-P-1001-01Q

21

Install in the reverse order

22

Check engine oil level, correct if necessary



AP18.00-P-0101AB

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

AS00.00-Z-0005-01A

23

Carry out an engine test run, checking the engine for proper operation and leaktightness

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1008-01Q

Bolt, oil feed line to cylinder head

Nm

9

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1005-01Q

Bolt, coolant return line flange to turbocharger

Nm

9

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1007-01Q

Banjo bolt, oil feed line to turbocharger

Stage 1

Nm

6

Stage 2

°

90

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1003-01Q

Bolt, turbocharger holder to crankcase

Nm

20

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1010-01Q

Bolt, oil return flow line to turbocharger

Nm

9

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1001-01Q

Nut, turbocharger/exhaust manifold to cylinder head

Nm

15

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1002-01Q

Nut, bracket to turbocharger

Nm

30

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1009-01Q

Bolt, coolant return line/oil feed line holder to turbocharger

Nm

9

 Turbocharger

Number

Designation

ENGINE 271.8

BA09.40-P-1006-01Q

Bolt, coolant feed pipe to crankcase

Nm

9