Remove/install turbocharger

AR09.40-S-6020E

Remove/install turbocharger

14.03.2016

Model

447 with engine 651

Modification notes

14.10.2015

Method extended

Operation steps 6.2, 14.2

Shown with transmission 722.9

1

Nut

3

Rubber

5

Screw/bolt

2

SCR catalytic converter

4

Bracket

6

Bracket

Shown without CODE ZG2 (Permanent all-wheel drive)

7

Return line

9

Screw/bolt

11

Diesel particulate filter

8

ATL

10

Screw/bolt

12

Heat shield

8

ATL

14

Vacuum hose

13

Feed line

15

Vacuum hose

 Danger !

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

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

AS00.00-Z-0002-01A

 

Remove/install

1

Remove ground line from battery

AR54.10-S-0003E

2

Remove engine cover

AR01.10-S-2405E

3

Remove air intake pipe for ATL (8)

AR09.10-S-8131E

4

Remove charge air hose upstream of charge air cooler from ATL (8)

AR09.41-D-1311-01WE

5

Unscrew nut (1)

 M8

*BA00.10-N-1003-01A

6.1

Unfasten SCR catalytic converter (2)

Model 447.### 1# with engine 651
except code MF4 (Low-emission vehicle Euro 4 Gr. III)
except code ZG2 (Permanent all-wheel drive)

 To do this remove rubber (3).

6.2

Loosen diesel particulate filter (11) on undercarriage

Model 447.### 1# with engine 651
with code ZG2 (Permanent all-wheel drive)
except code MF4 (Low-emission vehicle Euro 4 Gr. III)
Model 447.### 2# with engine 651
except code MF4 (Low-emission vehicle Euro 4 Gr. III)

AR14.40-S-1000EA

 The diesel particulate filter (11) is not completely removed.

7

Remove bracket (4)

 Bolt, bracket for turbocharger at rear/center to turbocharger

*BA09.40-N-1002-01R

 Bolt, bracket for turbocharger at rear/center to crankcase

*BA09.40-N-1003-01R

8

Remove screw/bolt/bolts (5)

 Model 447 with transmission 711.680Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01F

 Model 447 with transmission 722.9Bolt, transmission housing to engine

*BA27.10-N-1003-04B

9

Remove alternator

AR15.40-S-5032E

10

Remove bracket (6) from crankcase

 The holder (6) remains on the ATL (8).

 Bolt, bracket for turbocharger at rear/center to crankcase

*BA09.40-N-1003-01R

11

Remove return lines (7) from ATL (8)

 Return lines (7) remains on crankcase.

 Installation: Replace seals.

 Bolt, oil return line to crankcase/turbocharger

*BA09.40-N-1014-01R

12

Remove screw/bolt (9)

13

Remove screw/bolt (10)

 Screw/bolt, differential pressure sensor to bracket for differential pressure sensor

*BA07.04-N-1009-01F

14.1

Remove diesel particulate filter (11) from ATL (8) and push somewhat to the rear

Model 447.### 1# with engine 651
except code ZG2 (Permanent all-wheel drive)

 Installation: Replace sealing ring.

 Clamp securing diesel particulate filter to turbocharger

*BA49.10-N-1006-01I

14.2

Remove catalytic converter

Model 447 with engine 651
with code MF4 (Low-emission vehicle Euro 4 Gr. III)
Model 447.### 1# with engine 651
with code ZG2 (Permanent all-wheel drive)
Model 447.### 2# with engine 651
except code MF4 (Low-emission vehicle Euro 4 Gr. III)

AR49.10-S-5500EA

15

Remove heat shield (12)

 Screw/bolt, heat shield to cylinder head

*BA14.10-N-1008-01O

16

Separate feed line (13)

 Connection for oil lines

*BA09.40-N-1007-01R

17

Remove vacuum hoses (14, 15) from the vacuum unit

18

Remove ATL (8)

 Installation: Replace seal.

 Flange connection, exhaust manifold to turbocharger

*BA09.40-N-1001-01R

19

Install in the reverse order



Check

 Danger !

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

20

Check for leaktightness with engine running

 Visual inspection only.

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

23

32

Phosphated

Nm

21

29

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

38

Phosphated

Nm

36

 Sensors, transmitters

Number

Designation

Engine 651 in model 447

BA07.04-N-1009-01F

Screw/bolt, differential pressure sensor to bracket for differential pressure sensor

Nm

9

 Turbocharger

Number

Designation

Engine 651 in model 447

BA09.40-N-1001-01R

Flange connection, exhaust manifold to turbocharger

Stage 1

Nm

20

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 651 in model 447

BA09.40-N-1002-01R

Bolt, bracket for turbocharger at rear/center to turbocharger

Nm

20

 Turbocharger

Number

Designation

Engine 651 in model 447

BA09.40-N-1003-01R

Bolt, bracket for turbocharger at rear/center to crankcase

Nm

20

 Turbocharger

Number

Designation

Engine 651 in model 447

BA09.40-N-1007-01R

Connection for oil lines

Nm

22

 Turbocharger

Number

Designation

Engine 651 in model 447

BA09.40-N-1014-01R

Bolt, oil return line to crankcase/turbocharger

Nm

9

 Exhaust manifold

Number

Designation

Engine 651 in model 447

BA14.10-N-1008-01O

Screw/bolt, heat shield to cylinder head

M6

Nm

9

M8

Nm

20

 Manual transmission, complete

Number

Designation

Model 447 with transmission 710.510, 711.680

BA26.10-N-1001-01F

Screw/bolt, manual transmission to engine

Nm

38

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1003-04B

Bolt, transmission housing to engine

Nm

38

 Exhaust system

Number

Designation

Engine 651 in model 447

BA49.10-N-1006-01I

Clamp securing diesel particulate filter to turbocharger

Nm

15