Remove/install turbocharger

AR09.40-T-6020BA

Remove/install turbocharger

15.2.12

 

Remove/install

1

Open rear left maintenance flap

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

2

Remove batteries

AR54.10-T-0005BA



Notes on battery

All models

AH54.10-P-0001-01A

3

Remove air filter housing

AR09.10-T-1150C

4

Remove partition to engine compartment

 Danger!

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

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

AS00.00-Z-0002-01A

5

Remove flap connection (1)

AR14.15-T-6302BA

6

Remove air intake hose

AR09.10-T-8030BA

7

Slacken clamps of charge air hose



*BA09.41-N-1001-01H



*001589752100

8

Remove charge air hose

 For easier removal of the turbocharger (4), loosen the clamp (2) and remove the charge air pipe together with the charge air hose.

9

Detach oil pressure line (3) from turbocharger (4)

 For flange connections, unscrew flange connection bolts, for annular connection, unscrew banjo bolt.

 Installation: Clean sealing surfaces and replace seal or sealing rings.



*BA09.40-N-1001-01I



*BA09.40-N-1012-01I



*000589642100

10

Detach oil pressure line (3) from crankcase

 Installation: Clean sealing surfaces and install new sealing rings .



*BA09.40-N-1002-01I



*000589642100

11

Detach oil return flow line (5) at connection fitting

12

Remove the turbocharger (4)

 Seal off all openings at turbocharger (4) with caps.

 Installation: Prior to installing the turbocharger (4), all connection points and parts to be connected should be inspected for foreign bodies, contaminants and damage and cleaned or replaced if necessary, otherwise engine damage could occur.

 Installation: Clean sealing surfaces, install new gasket. Install new self-locking nuts.



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A



*BA09.40-N-1004-01I



*000589642100



Check

13

Check turbocharger (4)

AR09.40-T-5910BB

14

Install in the reverse order

Number

Designation

Engine 457.9

BA09.40-N-1001-01I

Bolt connecting oil pressure line to turbocharger

Nm

25

BA09.40-N-1002-01I

Banjo bolt connecting oil pressure line to crankcase

Nm

35

BA09.40-N-1004-01I

Nut connecting turbocharger to exhaust manifold

Nm

50

BA09.40-N-1012-01I

Banjo bolt connecting oil pressure line to turbocharger

Nm

35

Number

Designation

Engine
457.9

BA09.41-N-1001-01H

Clamp connecting charge air hose to charge air pipe

M5

Nm

8

M6

Nm

10