Remove/install turbocharger

AR09.40-D-6020WE

Remove/install turbocharger

17.10.2016

Engine

651 in model 900

Engine

651.955/957 in model 906

Modification notes

16.12.2014

Work procedure adapted to modified repair method.

Shown on vehicle except code MS3(Engine version EURO 3)

1

Wheel well lining

2

Diesel particulate filter/front muffler

3

Screw/bolts

4

Bracket

5

Nuts (without code MS3 (Engine version EURO 3)

6

ATL

13

Oil return line

20

Screw/bolt

7

Heat shield

14

Screw/bolts

21

Screw/bolt

8

Screw/bolts

15

Screw/bolts

22

Engine support

9

Bracket

16

Screw/bolts

23

Electrical line (for code (H08High-performance A/C))

10

Screw/bolts

17.1

Oil feed line

G2/7

Alternator with LIN bus

11

Electrical wiring harness

18

Screw/bolt

12

Screw/bolt

19

Bracket

Shown on vehicle except code MS3(Engine version EURO 3)

2

Diesel particulate filter/front muffler

29

Screw/bolt

38

Banjo bolt

6

ATL

30

Retaining clamp

39

Clamp

17.1

Oil feed line

31

Electrical line

40

Aneroid capsule

17.2

Oil feed line

32

Union nut

41

Vacuum hose

24

Exhaust manifold

33

Retaining clip

42

Screw/bolts

25

Heat shield

34

Vacuum hose

43

Retaining clamp

26

Screw/bolt

35

Aneroid capsule

44

Vacuum hose

27

Bracket

36

Screw/bolt

B16/13

Temperature sensor upstream of ATL

28

Screw/bolts

37

Banjo bolt

 Danger !

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

 

Remove/install

1

Remove ventilation box

AR83.10-D-0010-03SD

2

Remove air filter housing

AR09.10-D-1150WE

3

Remove engine cover

AR01.10-D-2405WE

4

Remove air intake pipe

AR09.10-D-8131WE

5

Remove alternator with LIN bus (G2/7)

AR15.40-D-5032WE

6

Remove screw/bolts (8) and detach heat shield (7) from engine support (22)

7

Remove screw/bolt (18) for oil feed line (17.1)

 Collect engine oil which flows out in a suitable vessel.

 Bolt, oil line to crankcase

*BA09.40-N-1013-01R

 Set of flexible head wrenches

*001589810900

8

Remove screw/bolts (14) for oil return line (13)

 Collect engine oil which flows out in a suitable vessel.

 Bolt, oil return line to crankcase/turbocharger

*BA09.40-N-1014-01R

 Set of flexible head wrenches

*001589810900

9

Remove screw/bolts (15, 16) and oil return line (13)

 Collect escaping engine oil in a suitable container and seal off bores with  stop plugs.

 Installation: Replace seals.

 Bolt, oil return line to crankcase/turbocharger

*BA09.40-N-1014-01R

 Set of flexible head wrenches

*001589810900

 Record plug

*129589009100

10

Remove screws/bolts (3) at bracket (4)

 Bolt, diesel particulate filter/front muffler to bracket for cylinder crankcase

*BA14.40-N-1006-01B

11

Unscrew nuts (5)

Engine 651 in model 900
Engine 651.955/957 in model 906
except code MS3 (Engine version EURO 3)

 Installation: Replace nuts (5).

 Nut/bolt, bracket to front exhaust system

*BA49.10-N-1003-01I

12

Unclip retaining clamp (43) for electrical line (31) for temperature sensor upstream of ATL (B1613) on bracket (27)

13

Remove screw/bolt (36) and loosen oil feed line (17.1) bracket

 Bolt, oil line to bracket

*BA09.40-N-1012-01R

14

Remove screw/bolt (29) and loosen oil feed line (17.1) retaining clamp (30)

 Bolt, oil line to bracket

*BA09.40-N-1012-01R

15

Remove screw/bolts (26) and remove heat shield (25)

 Screw/bolt, heat shield to cylinder head

*BA14.10-N-1008-01O

16

Remove screw/bolts (28) and bracket (27)

 Screw/bolt, turbocharger oil line bracket to cylinder head

*BA01.30-N-1007-01K

17

Unclip retaining clip (33) on the oil feed line (17.2) and detach vacuum hose (34) on the aneroid capsule (35)

 Installation: Check vacuum hose (34) for damage; replace if necessary.

18

Unscrew union nut (32) and remove oil feed line (17.1)

 Collect engine oil which flows out in a suitable vessel.

 Installation: Replace sealing ring on the oil feed line (17.1).

 Connection for oil lines

*BA09.40-N-1007-01R

19

Remove banjo bolts (37, 38) and remove oil feed line (17.2)

 Seal bores using  stop plugs.

 Installation: Install new sealing rings.

 Banjo bolt, oil line to turbocharger

*BA09.40-N-1004-01R

 Record plug

*129589009100

20

Remove vacuum hose (44) with clamp on ATL (6)

 Installation: Check vacuum hose (44) and clamp for damage; install new if necessary.

21

Remove screw/bolt for clamp (39) and open clamp (39)

 Installation: Replace sealing ring on ATL (6).
Check clamp (39) for damage; replace if necessary.

 Clamp securing diesel particulate filter to turbocharger

*BA49.10-N-1006-01I

 Clamp, front muffler to turbocharger

*BA49.10-N-1011-01I

22

Unhook electrical wiring harness (11) on bracket (9)

23

Expose electrical line (23) on bracket (9)

Engine 651.955/957 in model 906
with code H08 (Roof-mounted air conditioning system, reinforced)

24

Remove screw/bolts (20, 21) and bracket (19)

 Installation:
Place screw/bolts (20, 21) loosely then the ATL (6) must first be fastened with the screw/bolts (42) to the exhaust manifold (24).
Then tighten screw/bolts (10, 12, 20, 21).
Tensions will occur otherwise, which lead to leaks.

 Installation: Observe installation location of screw/bolt (21).

 Flange connection, exhaust manifold to turbocharger

*BA09.40-N-1001-01R

 Bolt, bracket for turbocharger at rear/center to turbocharger

*BA09.40-N-1002-01R

 Bolt, bracket for turbocharger at rear/center to crankcase

*BA09.40-N-1003-01R

 Set of flexible head wrenches

*001589810900

25

Remove screw/bolts (10, 12) and bracket (9)

 Installation: Fit screw/bolts (10, 12) loosely.
Observe installation location of screw/bolt (12).

26

Remove screw/bolts (42) on exhaust manifold (24) and ATL (6)

 Installation:
The screw/bolts (42) are only tightened in combination with the screw/bolts (10, 12, 20, 21).
Tensions will occur otherwise, which lead to leaks.

 Installation: Loosely position screw/bolts (42).
Replace screw/bolts (42).

 Set of flexible head wrenches

*001589810900

27

Remove vacuum hose (41) from aneroid capsule (40)

 Installation: Check vacuum hose (41) for damage; replace if necessary.

28

Remove ATL (6)

 Seal openings using  protective covers.

 Installation: Clean sealing surfaces on diesel particulate filter/front muffler (2), exhaust manifold (24) and ATL (6). Replace seal.

 Set of protective covers

*001589019100

29

Install in the reverse order

30

Check engine oil level, correct if necessary



Low SPAsh multigrade service engine oils (specification 228.51)

BB00.40-P-0228-51A



Low SPAsh multigrade service engine oils (specification 229.31)

BB00.40-P-0229-31A


The engine oil level must not lie above the maximum marking.
Engine damage may occur otherwise.

 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

31

Perform an engine test run and check engine for leaktightness around ATL (6)

 Cylinder head

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA01.30-N-1007-01K

Screw/bolt, turbocharger oil line bracket to cylinder head

Nm

9

9

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1001-01R

Flange connection, exhaust manifold to turbocharger

Stage 1

Nm

20

20

Stage 2

°

90

90

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1002-01R

Bolt, bracket for turbocharger at rear/center to turbocharger

Nm

20

20

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1003-01R

Bolt, bracket for turbocharger at rear/center to crankcase

Nm

20

20

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1004-01R

Banjo bolt, oil line to turbocharger

Stage 1

Nm

9

9

Stage 2

0

90

90

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1007-01R

Connection for oil lines

Nm

22

22

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1012-01R

Bolt, oil line to bracket

Nm

9

9

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1013-01R

Bolt, oil line to crankcase

Nm

9

9

 Turbocharger

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.40-N-1014-01R

Bolt, oil return line to crankcase/turbocharger

Nm

9

9

 Exhaust manifold

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA14.10-N-1008-01O

Screw/bolt, heat shield to cylinder head

M6

Nm

9

9

M8

Nm

20

20

 Diesel particulate filter

Number

Designation

Engine 651 in model 900, 906

BA14.40-N-1006-01B

Bolt, diesel particulate filter/front muffler to bracket for cylinder crankcase

Nm

23

 Exhaust system

Number

Designation

Engine 651 in model 900

Engine 651 in model 906
except code MS3 (Engine version EURO 3)

BA49.10-N-1003-01I

Nut/bolt, bracket to front exhaust system

Nm

23

23

 Exhaust system

Number

Designation

Engine 651 in model 900

Engine 651 in model 906
except code MS3 (Engine version EURO 3)

BA49.10-N-1006-01I

Clamp securing diesel particulate filter to turbocharger

Nm

15

15

 Exhaust system

Number

Designation

Engine 651 in model 906
with code MS3 (Engine version EURO 3)

BA49.10-N-1006-01I

Clamp securing diesel particulate filter to turbocharger

Nm

15

 Exhaust system

Number

Designation

Engine 651 in model 900

Engine 651 in model 906
except code MS3 (Engine version EURO 3)

BA49.10-N-1011-01I

Clamp, front muffler to turbocharger

Nm

15

15

 Exhaust system

Number

Designation

Engine 651 in model 906
with code MS3 (Engine version EURO 3)

BA49.10-N-1011-01I

Clamp, front muffler to turbocharger

Nm

15