Remove/install turbocharger with exhaust manifold

AR09.40-D-6025SE

Remove/install turbocharger with exhaust manifold

31.5.11

15.1.10

Remove/install bracket from engine support to turbocharger, added

Step 12

Remove/install bracket for wastegate aneroid capsule on turbocharger with exhaust manifold, added

Step 15

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

1

Disconnect battery ground line

AR54.10-D-0003SD

2

Remove oil feed line (3)

AR09.40-D-6022SE

3

Detach hose (5) on wastegate aneroid capsule (6) and hose (14) on wastegate aneroid capsule (13)

 Installation: Check hoses (5, 14) for damage, replace if necessary.

4

Detach clamp (15) at the catalytic converter (12)

 Installation: Check clamp (15) for damage; replace if necessary.



*BA14.40-N-1001-02D

5

Remove oil return line (7) at the turbocharger with exhaust manifold (1)

  Seal holes using suitable plugs.

 Installation: Clean sealing surfaces.
Replace seal and ensure the correct installation position for the seal. The retaining clamps on the seal must point in the direction oil return line (7).



*BA09.40-N-1002-01O

 Set of stop plugs

*129589009100

6

Lift/jack up vehicle

AR00.60-D-1000H

7

Loosen screw clamp (18)

 Installation: Check screw clamp (18) for damage, replace if necessary.

The wide locking lug (arrow B) on the screw clamp (18) must point towards the turbocharger (2).

Tight screw clamp (18) and after approx. one hour waiting time retighten with the check torque.



*BA09.41-N-1009-01M

8

Detach charge air hose (10) at turbocharger (2)

 Installation: Check charge air hose (10) for damage, replace if necessary.

Deoil and clean connector of charge air hose (10) and connection fitting of turbocharger (2).

The marking (arrow A) on the charge air hose (10) must match the opposite arrow edge (arrow C) on the turbocharger (2).

9

Loosen the catalytic converter (12) at the bracket (11) and push back the catalytic converter (12)



*BA14.40-N-1006-02D

10

Detach the carrier (17) at the turbocharger (2) and at the cylinder crankcase



*BA09.40-N-1005-01O

11

Remove the strut (8) at the turbocharger (2) and at the engine support (9)



*BA09.40-N-1007-01O



*BA09.40-N-1009-01O

12

Remove bolts (19) and remove bracket



*BA09.40-N-1012-01O



*BA09.40-N-1013-01O

13

Detach oil return line (16) from turbocharger (2)

 Seal holes.

 Installation: Clean sealing surfaces.
Replace seal and ensure the correct installation position for the seal. The retaining clamps on the seal must point in the direction oil return line (16).



*BA09.40-N-1002-01O

14

Lower vehicle

15

Remove bolts (20) on bracket for wastegate aneroid capsule (13) and swivel wastegate aneroid capsule (13) upwards

16

Detach turbocharger with exhaust manifold (1) together with turbocharger (2) at the cylinder head, and lift it out upwards

 Seal holes with suitable plugs.

 Installation: Clean sealing surfaces. Check stud bolts in the cylinder head and seal ring to the catalytic converter (12) on the turbocharger (2) for damage, replace if necessary.

Do not screw on the nut (4) for the bracket of the oil feed line (3).



*BA09.40-N-1006-01O



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

17

Remove seal of turbocharger with exhaust manifold (1) from cylinder head

 Installation: Clean sealing surface and replace gasket.

18

Detach turbocharger (2) from the turbocharger with exhaust manifold (1)

 Only if the turbocharger with exhaust manifold (1) or the turbocharger (2) is replaced.

AR09.40-D-6028SE

19

Install in the reverse order

 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

20

Perform engine test run and check the engine for leaks in the area of the turbocharger with exhaust manifold (1) and the turbocharger (2)

Number

Designation

Engine
646.986
in model 906

BA09.40-N-1002-01O

Bolt, oil drain line to turbocharger

Nm

8

BA09.40-N-1005-01O

Bolt, turbocharger support to crankcase

Nm

20

BA09.40-N-1006-01O

Exhaust manifold on cylinder head

Nm

30

BA09.40-N-1007-01O

Bolt, support to turbocharger

Nm

30

BA09.40-N-1009-01O

Bolt, turbocharger support brace to engine support

Nm

23

BA09.40-N-1012-01O

Bolt, support for engine support to air duct housing/turbocharger

Nm

20

BA09.40-N-1013-01O

Bolt, charge air pipe or air duct housing to turbocharger

Nm

9

Number

Designation

Engine
646
in model
906

BA09.41-N-1009-01M

Screw clamp, charge air hose to turbocharger

Tightening torque

Nm

4

Control torque (after a waiting time of approx. one hour)

Nm

4

Number

Designation

Engine
646

BA14.40-N-1001-02D

Pipe clamp connecting catalytic converter to turbocharger

Nm

15

BA14.40-N-1006-02D

Nut connecting bracket to catalytic converter

Nm

23