Remove/install turbocharger

AR09.40-D-6020WD

Remove/install turbocharger

12.10.11

 

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

Lift/jack up vehicle

AR00.60-D-1000H

2

Unclip and remove right front fender liner (4)

3

Remove alternator

AR15.40-D-5032WD

4

Unclip electrical wiring harness (2) at bracket (3) and remove bracket (3)

5

Unclip electrical wiring harness (11) at support brace (9) and expose it

6

Remove screws/bolts (10) and remove support brace (9)



*BA09.40-N-1002-01R



*BA09.40-N-1003-01R

7

Remove screw/bolt (5) of oil feed line (8)

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

8

Remove screws/bolts (6) of oil return line (7)

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

9

Remove screws/bolts (15) and remove oil return line (7)

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

 Installation: Replace seals.

10

Unscrew nuts (13)

 Installation: Install new nuts (13).



*BA49.10-N-1003-01I

11

Unscrew nuts (14) on diesel particulate filter (12)



*BA14.40-N-1006-01B

12

Remove air intake pipe

AR09.10-D-8131WE

13

Remove screw/bolt of clamp (16) and open clamp (16)

 Installation: Replace sealing ring on turbocharger (1).

Check clamp (16), replace if necessary.



*BA49.10-N-1006-01I

14

Disconnect electrical connector (17) at temperature sensor upstream of turbocharger (B16/13), expose electrical line and place to one side

15

Remove banjo bolt (18) and remove oil feed line (8)

 Installation: Replace sealing rings.



*BA09.40-N-1004-01R

16

Remove screws/bolts (19)

 Installation: Replace screw/bolts (19).



*BA09.40-N-1001-01R

17

Remove turbocharger (1)

 Installation: Clean sealing surfaces and install new gasket.

18

Install in the reverse order

19

Connect Star Diagnosis and perform initialization of boost pressure regulator

 Only when replacing turbocharger (1)

20

Check engine oil level, correct if necessary

 The engine oil level must not be above the maximum mark. This can lead to engine damage.



Low SPAsh multigrade service engine oils (specification 228.51)

Sheet 228.51

BB00.40-P-0228-51A



Multigrade service engine oil Low SPAsh

Sheet 229.31

BB00.40-P-0229-31A

 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

21

Test run engine and check engine for leaks around turbocharger (1)

Number

Designation

Engine
651
in model
906

BA09.40-N-1001-01R

Flange connection, exhaust manifold to turbocharger

Stage 1

Nm

20

Stage 2

°

90

BA09.40-N-1002-01R

Bolt, turbocharger bracket to rear / center to turbocharger

Nm

20

BA09.40-N-1003-01R

Bolt, turbocharger bracket to rear / center to cylinder crankcase

Nm

20

BA09.40-N-1004-01R

Banjo bolt, lubricating oil line to turbocharger

Nm

18

Number

Designation

Engine
651

BA14.40-N-1006-01B

Screw/bolt, diesel particulate filter/front muffler to cylinder crankcase bracket

Nm

23

Number

Designation

Model
906
with engine 651
without code (MS3)

BA49.10-N-1003-01I

Nut/bolt, bracket to front exhaust system

Nm

23

BA49.10-N-1006-01I

Pipe clamp, diesel particulate filter to turbocharger

Nm

15