Remove/install turbocharger

AR09.40-S-6020SE

Remove/install turbocharger

3.9.10

22.4.10

Repair method supplemented.

Operation steps 13.2, 22, 24,

 

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

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove front engine cover

AR01.10-S-2405SE

2

Detach vacuum line on vacuum pump and place to one side

3

Remove engine intake air duct (1) downstream of the air filter

AR09.10-S-8130SE

4

Remove rear engine cover

AR01.10-S-2405SE

5

Remove noise damper (2)

AR09.40-S-6920SE

6

Remove shield (3)

Only for engine 642.9



*BA09.40-N-1010-01Q



*BA09.40-N-1011-01Q

7

Remove support brace (12)



*BA09.40-N-1002-01Q

8

Remove fan wheel

 Do not remove fan shroud to do this.

AR20.40-S-5614SE

9

Loosen bolt, condenser to front module

Only for code (HH4) Automatic air conditioning or code (HH9) Regulated air conditioning (Tempmatic)

 Do not remove A/C lines to do this

 Installation: Replace bolt.

10

Remove bottom engine compartment paneling

Only for model 639.7/8 as of VIN 055347

AR61.20-S-1105S

11

Remove charge air hose upstream of charge air cooler

AR09.41-S-8621SE

12

Remove charge air hose downstream of the charge air cooler

AR09.41-S-8625SE

13.1

Remove catalytic converter (10) and place to one side

Only for engine 642.9

AR49.10-S-5500-02SE

 Sufficient room must be allowed for removing/installing the turbocharger (15).



*BA09.40-N-1007-01Q



*BA32.35-N-1003-02B



*BA32.35-N-1006-02B



*BA49.10-N-1002-01N



*BA49.10-N-1005-01N



*BA49.10-N-1006-01N

13.2

Remove exhaust pipe upstream off diesel particulate filter catalytic converter

Only for engine 642.8

AR49.10-S-5529SE

 Sufficient room must be allowed for removing/installing the turbocharger (15).

14

Support engine subframe

 Do not use the lateral fixing arms of adapter.

AR33.10-S-0100-03S

Adaptation

*639589036200

Transmission jack 2.0-7.0 t

gotis://H_00.10_01.0

Jack assembly adapter

gotis://A_25/35/49_03.0

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

15

Lower engine with front axle carrier

Engine without code (ZG2)

AR01.00-S-3000-03SE



*BA31.35-N-1008-01A



*BA46.20-N-1004-01A



Spacer bolts and washers to fasten the lowered front axle carrier

WF58.50-S-0110-06S

16

Remove bolts (7)

 If the exhaust collector pipe (6) or the turbocharger (15) is replaced, both additional bolts on the support brace on the cylinder crankcase are released in order to achieve free of tension installation.

 Loosen bolts on support brace on cylinder crankcase from bottom



*BA09.40-N-1008-01Q

17

Remove exhaust gas recirculation pipe (4)

Installation: Replace gaskets and bolts.



*BA14.20-N-1007-01H



*BA14.20-N-1008-01H

18

Remove bolts (5)

 Do not damage seals to prevent leakage.

 Installation: Replace bolts (5).



*BA14.10-N-1003-01O

19

Remove upper engine wiring harness on front plate

 Installation: Install new cable ties.

20

Remove bolts (8)



*BA09.40-N-1003-01Q

21

Disconnect electrical connector from charge pressure positioner (Y77/4)

22

Disconnect electrical connector for exhaust temperature sensor

Only for engine 642.8

AR07.04-S-0071SE

 Installation: When replacing turbocharger (15), ensure that electrical line is routed correctly.

23

Remove turbocharger (15)

 Close off openings on turbocharger (15) and oil supply connection fitting. Clean turbocharger (15) and catalytic converter (10) free of sealant residues.

 Installation: Replace seal of oil supply connection fitting.

 Set of protective covers

*001589019100

 Set of stop plugs

*129589009100

24

Remove exhaust temperature sensor from turbocharger

 Only with engine 642.8 and only when replacing turbocharger (15).

AR07.04-S-0071SE

25

Remove exhaust collector pipe (6) from turbocharger (15)

 Only if there are leaks between the exhaust collector pipe (6) and turbocharger (15), or if replacing the turbocharger (15).

 Installation: In order to obtain free of tension assembly and to avoid consequential damage at the exhaust manifold a provisional installation is necessary for positioning of the exhaust collector (6) on the turbocharger (15).

 Installation: Install new bolts.

For provisional installation and replacement of the seal see:



Replace seal between turbocharger and exhaust collector

AR09.40-S-6024-15SE



*BA09.40-N-1004-01Q

26

Install in the reverse order



Checking

27

Check engine oil level, correct if necessary



Low SPAsh multigrade service engine oils (specification 228.51)

BB00.40-P-0228-51A

 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

28

Check for leaks with engine running

 Visual inspection only.

Number

Designation

Engine
642
in model
639

BA09.40-N-1002-01Q

Bolt, turbocharger to charge air manifold

Nm

10

BA09.40-N-1003-01Q

Fitted bolt, turbocharger to oil feed fitting

Stage 1

Nm

10

Stage 2

Nm

30

BA09.40-N-1004-01Q

Bolt, turbocharger to exhaust collector pipe

Stage 1

Nm

20

Stage 2

°

90

BA09.40-N-1007-01Q

Bolt connecting catalytic converter to turbocharger

Nm

20

BA09.40-N-1008-01Q

Bolt, turbocharger support brace to crankcase

Nm

20

BA09.40-N-1010-01Q

Bolt, shield to holder

Nm

8

BA09.40-N-1011-01Q

Bolt, shield to exhaust collector pipe

Nm

10

Number

Designation

Engine
642
in model 639

BA14.10-N-1003-01O

Flange connection, exhaust manifold/front exhaust pipes to exhaust collector pipe

Stage 1

Nm

20

Stage 2

°

90

Number

Designation

Engine
642 in model 639

BA14.20-N-1007-01H

Exhaust gas recirculation pipe to charge air distribution line

Nm

13

BA14.20-N-1008-01H

Exhaust gas recirculation pipe to exhaust collector pipe

Stage 1

Nm

10

Stage 2

°

90

Number

Designation

Model
639
without code ZG2
up to VIN
176133

Model
639
without code ZG2
as of VIN
176134

BA31.35-N-1008-01A

Bolt, subframe to longitudinal frame member

Nm

150

172

Number

Designation

Model
636, 639
with engine
272, 642

BA32.35-N-1003-02B

Stabilizer bar on subframe

M8

Stage 1

Nm

-

Stage 2

°

-

M10

Nm

60

BA32.35-N-1006-02B

Bolt, heat shield to bracket

M6

Nm

10

Number

Designation

Model
636, 639

BA46.20-N-1004-01A

Bolt on universal joint

Nm

28

Number

Designation

Engine
642 in model 639

BA49.10-N-1002-01N

Nut, catalytic converter to bracket

Nm

15

BA49.10-N-1005-01N

Bolt, catalytic converter hose clamp to diesel particulate filter or pipe connection

Nm

35

BA49.10-N-1006-01N

Bolt, catalytic converter or exhaust pipe on cylinder head bracket

Nm

17

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51