Remove/install turbocharger · ar0940s6020b · Mercedes-Benz WIS

AR09.40-S-6020B

Remove/install turbocharger

19.6.98

ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 KW)
with CODE (MQ5) Engine OM611 DE22 LA (90 KW)

ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 KW)

S09.40-2501-06

1 Bolt

2 Air intake hose

3 Bolt

4 Charge air pipe

5 Charge air hose

6 Turbocharger

7 Screw clamp

8 Exhaust plenum chamber

9 Nut

10 Oil feed line

11 Exhaust manifold

12 Banjo bolt

13 Bolt

14 Sealing ring

15 Sealing ring

16 Oil drain line

17 Seal

18 Vacuum line

19 Vacuum reservoir

20 Bolt

21 Bolt

22 Bracket

23 Bracket

24 Nut

25 Bolt

26 Clamp

29 Bolt

27 Exhaust clamp

28 Bolt

Modification notes

29.6.01	Value changed from 30 Nm to 18 (2) Nm	Figure in BA09.40-P-1004-01C for engine 611.980 modified	*BA09.40-P-1004-01C
14.8.03	Value changed from 22 Nm to 9 Nm	Figure in BA09.40-P-1005-01C for engine 611.980 modified	*BA09.40-P-1005-01C

	Remove/install
1	Slacken screw clamp at charge air pipe (4) from hose and detach hose at charge air pipe	 Thoroughly clean connection points otherwise the charge air hoses may be pressed off in operation.
			*WH58.30-Z-1001-06A
2	Slacken screw clamps (7) at charge air hose (5)		*WH58.30-Z-1001-06A
3	Unscrew bolts (3) at charge air pipe (4) from axle/engine subframe and detach toward bottom from charge air hose (5)	 Thoroughly clean connection points otherwise the charge air hoses may be pressed off in operation.
4	Detach charge air hose (5) at turbocharger (6)	 Pay attention to installation position of charge air hose (5). Check condition of hoses and hose clamps (7), replace if necessary.  Thoroughly clean connection points otherwise the charge air hoses may be pressed off in operation.
5	Detach exhaust plenum chamber (8)		AR14.10-S-3920A
6	Detach vacuum hose (18) at vacuum control unit (19)
7	Unscrew nut (24) and bolts (20, 21) from bracket (22, 23) at turbocharger (6) and engine crankcase and remove	 Installation: Ensure assembly free of tension.
			*BA09.40-P-1008-01C
			*BA09.40-P-1009-01C
			*BA09.40-P-1010-01C
			*001589760900
8	Unscrew nut (9) from oil feed line bracket (10) at exhaust manifold (11)		*BA14.10-P-1001-01A
9	Unscrew banjo bolt (12) of oil feed line (10) at turbocharger (6)	 Replace sealing ring (15). Collect engine oil which flows out.
			*BA09.40-P-1004-01C
10	Unscrew bolt (13) of oil feed line (10) at cylinder head and detach oil feed line (10)	 Replace sealing ring (14). Collect engine oil which flows out.
			*BA09.40-P-1005-01C
			*001589760900
11	Detach bolt (28) at oil drain line (16) to engine crankcase	 Installation: Replace gasket (17). Collect engine oil which flows out.
			*BA09.40-P-1005-01C
			*001589760900
12	Unscrew bolts (25) from turbocharger (6) at exhaust manifold (11)	 Hold turbocharger (6).
			*BA09.40-P-1001-01C
13	Unscrew screw clamp from air intake hose (2) at turbocharger (6)	 Thoroughly clean connection points of hose clamps otherwise the charge air hoses may jump off during operation.
		 Pay attention to installation position of air intake hose (2) at turbocharger (6).
			*WH58.30-Z-1001-06A
14	Remove turbocharger (6)
15.1	Detach oil drain line (16) at turbocharger (6)	 Only when replacing turbocharger. Replace gasket.
			*BA09.40-P-1003-01C
16	Install in the reverse order
	Inspect
17	Check fluid level, correct if necessary		AP18.00-D-0101A
 Danger!	Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury. Crushing and burn injuries may result while working on engine during when it is being started or when it is in operation.	Secure vehicle to prevent it from moving. Always wear appropriate work clothing when working on the vehicle.	AS00.00-Z-0005-01A
18	Run engine and inspect for leaks

 Turbocharger

Number	Designation			Series 611.980 engine


BA09.40-P-1001-01C	Flange connection of exhaust manifold to turbocharger		Nm	30
BA09.40-P-1003-01C	Bolt of oil outlet line to turbocharger		Nm	9
BA09.40-P-1004-01C	Oil feed line to turbocharger	Screw socket	Nm	-
		Banjo bolt	Nm	18 (2)
BA09.40-P-1005-01C	Bolt of oil feed line to cylinder head		Nm	9
BA09.40-P-1006-01C	Bolt of support to turbocharger		Nm	-
BA09.40-P-1008-01C	Nut of turbocharger bracket to cylinder head		Nm	20
BA09.40-P-1009-01C	Nut of turbocharger bracket to turbocharger		Nm	30
BA09.40-P-1010-01C	Bolt of turbocharger bracket to generator support		Nm	21

 Exhaust manifold

Number	Designation		Series 611.980 engine


BA14.10-P-1001-01A	Nut to exhaust manifold at cylinder head	Nm	30

External Torx set

001 589 76 09 00

Commercially available tools

Number	Designation
WH58.30-Z-1001-06A	6 mm socket hexagon on flexible shaft for hose clamps with worm drive

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