AR09.40-P-6020PP | Remove/install turbocharger | 27.3.00 |
ENGINE 611.962 in MODEL 203.004 /006 /204 /206 /706
ENGINE 612.962 in MODEL 203.016 /216
ENGINE 612.967 in MODEL 209.316
P09.40-2030-09
4/2 Air intake hose
4/3 Air intake scoop
9 Wiring
13 Support
22 Hose clamp
23 Sealing cone
110/5 Charge air hose
110/6 Charge air pipe
111 Catalytic converter
120/1 Pre-catalytic converter
Y31/5 Charge pressure control vacuum transducer
32 Hose clamp
33 Sealing cone
110 Turbocharger
110/3 Oil feed line
110/4 Oil drain line
Modification notes
14.8.03 | Value changed from 22 Nm to 9 Nm | Value in BA09.40-P-1005-01C modified on engine 611.962 | |
14.8.03 | Value changed from 22 Nm to 9 Nm | Value in BA09.40-P-1005-01C modified on engine 612.962/967 |
| Remove/Install | ||
1 | Remove bottom section of sound-proofing capsule | ||
2 | Remove air cleaner | ||
3 | Disconnect vacuum supply lines (9) at boost pressure control vacuum transducer (Y31/5) | ||
4 | Separate charge air hose (110/5) from charge air pipe at charge air cooler | Installation: Replace O-ring, in order to avoid leakage. | |
5 | Unbolt charge air pipe (110/6) at turbocharger (110) and at generator | ||
6 | Remove collar clamp (32) of turbocharger (110) to pre-catalytic converter (120/1) | Installation: Replace sealing cone (33), in order to avoid leakage. | |
7 | Unbolt oil feed line (110/3) at crankcase and at turbocharger | Installation: Replace gaskets, in order to avoid leakage. | |
Oil feed line to turbocharger | |||
Bolt of oil feed line to cylinder head. | |||
8 | Unbolt support (13) at bottom of turbocharger | Installation: Slacken bottom bolt at support (13) and install free of stress. | |
Bolt of support to turbocharger | |||
Bolt of turbocharger support to crankcase | |||
9 | Remove collar clamp (22) of pre-catalytic converter (120/1) to catalytic converter (111) | Installation: Replace sealing cone (23), in order to avoid leakage. | |
10 | Detach pre-catalytic converter (120/1) at crankcase | ||
11 | Unscrew bolts of turbocharger at manifold | Flange connection of exhaust manifold to turbocharger | |
12 | Take out turbocharger (110) together with oil drain line (110/4) toward top | ||
13.1 | Unscrew oil drain line (110/4) from turbocharger (110) | Only when replacing turbocharger (110) or leakage of full face gasket or sealing rings. Installation: Replace full face gasket. Check sealing ring, replace if necessary, in order to avoid leakage. | |
Collect feathering-out oil in a suitable vessel, in order to avoid environment contamination. | |||
Bolt of oil outlet line to turbocharger. | |||
14 | Install in the reverse order | ||
15 | Check fluid level, correct if necessary | ||
Danger! | Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns | Secure vehicle to prevent it from moving. | |
16 | Run engine and inspect for oil leaks |
Turbocharger
Number | Designation | Engine 611.962 | Engine 612.962/ | ||
BA09.40-P-1001-01C | Flange connection of exhaust manifold to turbocharger | Nm | 30 | 30 | |
BA09.40-P-1003-01C | Bolt of oil outlet line to turbocharger | Nm | 9 | 9 | |
BA09.40-P-1004-01C | Oil feed line to turbocharger | Screw socket | Nm | 30 | 30 |
Banjo bolt | Nm | 18 | 18 | ||
BA09.40-P-1005-01C | Bolt of oil feed line to cylinder head | Nm | 9 | 9 | |
BA09.40-P-1006-01C | Bolt of support to turbocharger | Nm | 30 | 30 | |
BA09.40-P-1007-01C | Bolt of turbocharger support to crankcase | Nm | 20 | 20 | |
Referenced documents
- ar0910p1050c Remove/install air filter
- ar9430p5300p Remove/install bottom parts of soundproofing
- as0000z000501a 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.