Remove/install turbocharger

AR09.40-P-6020MFF

Remove/install turbocharger

05.02.2020

Engine

654 in model 118, 177, 247

Modification notes

05.12.2019

Document completely revised.

1

Turbocharger

7

Oil return line

2

Clip

8

Electrical line

3

Exhaust aftertreatment unit

13

Screw

4

Screw

B19/11

Temperature sensor upstream of turbocharger

5

Screw

N37/8

NOx sensor control unit downstream of SCR catalytic converter

3

Exhaust aftertreatment unit

6

Clip

7

Oil return line

9

Seal

10

Seal

11

O-ring

12

Exhaust manifold

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Warning

Risk of burns and injury when working on the diesel particulate filter and health hazard from inhalation of soot particles

Wear protective gloves, safety glasses and respiratory protection.

AS49.20-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Drain off coolant.

AR20.00-P-1142MFF

2

Remove air intake line upstream of exhaust gas turbocharger(1).

AR09.40-P-0500MFF

 Installation: Only install upper engine cover after the leak test.

3

Remove temperature sensor upstream of exhaust gas turbocharger (B19/11) from exhaust gas turbocharger (1) and place electric line to one side.

AR49.20-P-0015MFF

4

Remove engine charge air duct at exhaust gas turbocharger(1).

AR09.41-P-8622MFF

5

Remove NOx sensor control unit downstream of SCR catalytic converter (N37/8) and place to one side with exposed electric line (8).

AR49.20-P-2062MFF

6

Remove coolant feed line from exhaust gas turbocharger (1) and place to one side.

AR20.20-P-1000MFF

7

Remove coolant return flow line from exhaust gas turbocharger (1) and place to one side.

AR20.20-P-1050MFF

8

Remove oil feed line from exhaust gas turbocharger (1) and place to one side.

 Engine 654 in model 118, 177, 247
except code M014 (Engine uprated)Screw/nut, exhaust gas turbocharger oil lines

*BA09.40-P-1018-02B

9

Remove O-ring from oil feed line.

 Installation: Replace O-ring.

 Assembly tool

*000589936300

10

Seal openings with suitable stop plug.

 Record plug

*129589009100

11

Release screw (4) by one revolution.

12

Release oil return feed line (7) via a slight tap on head of screw (4).

13

Unscrew bolt (4).

 Engine 654 in model 118, 177, 247
except code M014 (Engine uprated)Bolt, oil return flow line to turbocharger

*BA09.40-P-1008-02B

14

Remove screw (5).

 Installation: Replace screw (5)

 Engine 654 in model 118, 177, 247
except code M014 (Engine uprated)Bolt, exhaust gas turbocharger bracket to exhaust gas turbocharger

*BA09.40-P-1002-02B

15

Remove screw (13).

 Installation: Replace screw (13).

 Clamp/screw, catalytic converter to exhaust gas turbocharger

*BA49.10-P-1001-02V

16

Open clamp(2).

17

Open clamp (6).

 Engine 654 in model 118, 177, 247
except code M014 (Engine uprated)Bolt, turbocharger clamp to exhaust manifold

*BA09.40-P-1001-02B

18

Remove exhaust gas turbocharger (1) upwards.

 Installation: Pin at exhaust gas turbocharger (1) must slide into opening (arrow) at exhaust manifold (12).

19

Remove O-ring (11) from oil return feed line (7).

 Installation: Replace O-ring (11).

 Assembly tool

*000589936300

20

Remove seal (9).

 Installation: Install new seal (9).

21

Remove seal (10).

 Installation: Install new gasket (10).

22

Remove clip (6).

 Installation: Replace clamp (6).
Observe the installation position of clamp (6).

23

Remove clamp (2) from exhaust gas aftertreatment unit (3).

 Installation: Replace clamp (2).

24

Seal openings using protective cover.

 Set of protective covers

*001589039100

25

Install in the reverse order.



Check

26

Read out and delete fault memory.



AD00.00-P-2000-06MFA

27

Check and correct engine oil level.



Check engine oil level with instrument cluster

AP18.00-P-1812MFA

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

28

Perform engine test run and check exhaust gas turbocharger (1) for proper operation and leak tightness.

29

Install upper engine cover.

AR01.10-P-2405MFF

 Turbocharger

Number

Designation

Engine 654 in model all
except code M014 (Engine uprated)

BA09.40-P-1001-02B

Bolt, turbocharger clamp to exhaust manifold

Nm

20

 Turbocharger

Number

Designation

Engine 654 in model all
except code M014 (Engine uprated)

BA09.40-P-1002-02B

Bolt, exhaust gas turbocharger bracket to exhaust gas turbocharger

Stage 1

Nm

20

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 654 in model all
except code M014 (Engine uprated)

BA09.40-P-1008-02B

Bolt, oil return flow line to turbocharger

Nm

10

 Turbocharger

Number

Designation

Engine 654 in model all
except code M014 (Engine uprated)

BA09.40-P-1018-02B

Screw/nut, exhaust gas turbocharger oil lines

Stage 1

Nm

8

Stage 2

°

30

 Exhaust system

Number

Designation

Engine 654 in model 118

Engine 654 in model 177

BA49.10-P-1001-02V

Clamp/screw, catalytic converter to exhaust gas turbocharger

M8

Nm

17

17

 Exhaust system

Number

Designation

Engine 654 in model 247

BA49.10-P-1001-02V

Clamp/screw, catalytic converter to exhaust gas turbocharger

M8

Nm

17