09 - 6020 Removing and installing turbocharger
1 Flame starting plug | coat with Hylomar SQ 32 M sealant. |
2 Fuel line | |
3 Electrical connection | |
4 Gasket | replace, TOP faces up. |
5 Startpilot injector | 20 Nm. |
6 Charge air manifold 364 A | |
7 Charge air manifold 364 LA | |
8 Hexagon bolt | 25 Nm. |
9 Assembly hook | |
10 Washer | |
11 Hexagon bolt | |
12 Heat shield | |
13 Washer | |
14 Hexagon bolts | |
15 Bowden cable | coat ball socket with Optimol Olista Moly 2 lubricant. |
16 Manifold pressure compensator line | |
17 Seals | replace. |
18 Banjo bolt |
19 Gasket | replace. |
20 Exhaust manifold | |
21 Washer | |
22 Hexagon bolt | 1st stage 60 Nm, 2nd stage 90° angle of rotation, coat with hot lubricating paste. |
23 Intermediate piece 364 A | |
24 Seals 364 A | replace. |
25 Turbocharger | |
26 Locking nut | 30 Nm, replace. |
27 Exhaust pipe | |
28 Locking nut | 30 Nm, replace. |
29 Clip 364 LA | |
30 Seal 364 LA | replace. |
31 Charge air line 364 LA | |
32 Hose clip | |
33 Connection hose | |
34 Intake pipe | |
35 Hexagon bolt | |
36 Washer | |
37 Bracket | |
38 Crankcase breather line | |
39 Air intake hose |
25 Turbocharger | |
40 Banjo bolt | 40 Nm. |
41 Seals | replace. |
42 Oil presure line | |
43 Gasket | replace. |
44 Flange | |
45 Hexagon bolt | 25 Nm, replace. |
46 Gasket | replace. |
47 Hexagon bolt | 25 Nm, replace. |
48 Gasket | replace. |
49 Oil return connection | |
50 Hexagon bolt | 30 Nm, replace. |
51 Oil return hose |
Removal
-------------------------------
1 Detach throttle control linkage or Bowden cable (15) at throttle control lever.
2 Slacken hexagon bolts (11) at heat shield (12) and assembly hook (9).
3 Detach heat shield (12).
4 OM 364 LA
Remove charge air hose.
5 Detach air intake hose and crankcase ventilation line (38) at intake manifold.
6 If flame starting system fitted:
6.1 Separate electrical connection (3) at flame starting plug (1). Unscrew fuel line (2) at flame starting plug (1).
6.2 OM 364 LA
Unscrew flame starting plug (1) at charge air manifold.
7 If startpilot system fitted:
Unscrew injector (5) at charge air manifold.
8 OM 364 LA
Unscrew banjo bolt (18), take off manifold pressure compensator line (16) at charge air manifold together with seals (17).
9 Unscrew locking nut (28).
10 Take off exhaust pipe (27).
Note
Seal turbocharger openings with caps.
11 Slacken hose clip at oil return hose (51).
12 Unscrew hexagon bolts (47) at oil pressure line (42).
13 Unscrew banjo bolt (40) at oil pressure line at crankcase. Remove oil pressure line (42) and seals.
14 Unscrew hexagon bolts (8, 22), take off exhaust manifold (20) and charge air manifold (6, 7) together at cylinder head. Remove gaskets.
15 OM 364 A
Pull intermediate piece (23) out of charge air manifold and turbocharger flange.
15.1 Pull exhaust manifold together with turbocharger (25) and intake pipe complete out of oil return hose (51) and remove.
Note
Seal turbocharger openings with caps.
16 OM 364 LA
Slacken clip (29) at charge air line (31) and turbocharger, push onto charge air line (31).
16.1 Pull turbocharger out of charge air line (31) and oil return hose (51).
16.2 Remove exhaust manifold complete together with turbocharger (25) and intake pipe.
Note
Seal turbocharger openings with caps.
17 OM 364 A
Slacken hose clips (32) at connection hose (33), pull off intake pipe (34) together with bracket at turbocharger connection.
18 Unscrew locking nuts (26), detach turbocharger from exhaust manifold.
Note
Seal turbocharger openings with caps.
19 Unscrew hexagon bolts (45), take off flange (44) and gasket (43) for oil pressure line.
Note
Seal turbocharger openings with caps.
20 Unscrew hexagon bolts (50), take off oil return connection (49) together with gasket (48) at turbocharger.
Installation
-------------------------------
Note
Before attaching the turbocharger, the intake line and flange manifold upstream of the compressor, the exhaust manifold and the exhaust pipe as well as the oil pressure line and oil return hose must be very carefully examined for foreign bodies, impurities and damage. Do not remove the caps on the openings of the turbocharger until just before installing. Before connecting the oil pressure line, fill the bearing housing with fresh engine oil through the oil inlet hole. When doing this, turn the rotating parts by hand so that the bearings are provided with a film of oil.
1 Clean sealing surfaces on turbocharger and attached parts and check for even surface.
2 Screw flange (44) and new gasket (43) tight with new hexagon bolts (45), 25 Nm.
3 Screw oil return connection (49) and new gasket (48) tight with new hexagon bolts (50),
25 Nm.
4 Assemble turbocharger and exhaust manifold and screw tight with new locking nuts (26),
30 Nm.
5 Fit intake pipe (34) complete with bracket and connection hose (33) onto the turbocharger connection.
6 Screw hose clips (32) tight.
7 OM 364 A
Install exhaust manifold complete with turbocharger (25). Insert oil return connection into the hose (51).
Note
Also install oil pressure line (42).
8 OM 364 LA
Insert new seal into charge air line, push clip (29) over charge air line (31).
8.1 Install exhaust manifold complete with turbocharger (25) and intake pipe; when doing this, push turbocharger connection over charge air line (31) and introduce oil return connection into the hose (51).
Note
Also install oil pressure line (42).
9 Fit new gaskets to exhaust manifold, screw exhaust manifold tight with hexagon bolts,
1st stage 60 Nm,
2nd stage 90° angle of rotation.
Note
Coat hexagon bolts with hot lubricating paste.
10 OM 364 A
Insert new seals (24) at intermediate piece (23) and push into turbocharger connection. Install intermediate piece (23) in charge air manifold.
11 Clean sealing surfaces, attach charge air manifold (6, 7) with new gaskets (4) TOP facing up.
12 Tighten hexagon bolts (8), 25 Nm.
13 Screw on oil pressure line (42) with new gasket and new hexagon bolts (47), 25 Nm.
14 Screw hose clips tight to oil return hose (51).
15 Screw oil pressure line (42) tight with banjo bolts (40) and new seals, 40 Nm.
16 Attach exhaust pipe (27) and screw tight with new locking nut (28), 30 Nm.
17 Attach crankcase ventilation line (38) and air intake hose.
18 OM 364 LA
Attach charge air hose.
19 Attach heat shield (12) for the turbocharger.
20 Screw heat shield (12) and assembly hook (9) tight with the hexagon bolts (11).
21 Attach throttle control linkage or Bowden cable (15) to throttle control lever.
Note
- Grease ball socket Optimol Olista Moly 2.
- Adjust throttle control (30-1010).
22 OM 364 LA
Attach manifold pressure compensator line (16) with new seals (17) to charge air manifold. Screw banjo bolt (18) tight.
23 If startpilot system fitted
Screw injector (5) to charge air manifold, 20 Nm.
24 If flame starting system fitted
24.1 Screw flame starting plug (1) into charge air manifold.
Note
Seal flame starting plug (1) with Hylomar
SQ 32 M.
24.2 OM 364 A, LA
Create electrical connection (3) at flame starting plug (1).
24.3 Screw fuel line (2) to flame starting plug (1).
25 Adjust engine oil to correct level.
26 Start engine, check for normal operation and leaks.
Note
The starter must not be operated for more than 20 seconds otherwise it will overheat and may be damaged. If no oil pressure is indicated after the first attempt at starting the engine, wait about 1 minute in each case before the next attempt, or start engine and run at idling speed. Keep a check on engine oil pressure gauge. A constant oil pressure must be indicated after about
10 seconds.
Referenced documents
- bb0040p022302a Specified engine oils for Cars, Vans (service) - Overview
- bb0040p026602a Long-life grease (NLGI grade 2)
- ra0003d000200x 0002 - Installation overview Engines 364, 364 A/LA - T2
- ra0003d000400x 0004 - Special tools Engines 364, 364 A/LA - T2
- ra0003d000500z 0005 - Technical data Engines 364, 364 A/LA - T2
- ra0003d000900x 0009 - Repair instructions Engines 364, 364 A/LA - T2
- ra0903d000300x 0003 - Sectional view Engines 364 A/LA - T2
- ra0903d000400x 0004 - Special tools Engines 364 A/LA - T2
- ra0903d000500x 0005 - Technical data Engines 364 A/LA - T2
- ra0903d000900x 0009 - Troubleshooting, Turbocharger Engines 364 A/LA - T2
- ra0903d601300x 6013 - Checking turbocharger (removed from vehicle) Engines 364 A/LA - T2
- ra0903d606300x 6063 - Disassembly and assembly of turbocharger Engines 364 A/LA - T2
- ra3003d101000x 1010 - Adjustment of accelerator control Engines 364, 364 A/LA - T2