Remove/Install Turbocharger - Ar09.40-P-6020Mc: Notes

Engine 275 In Model 215, 216, 220, 221, 230

Illustrated On Right Turbocharger

Fig 1: Identifying Turbocharger Remove/Install Components (1 Of 4)

Fig 2: Identifying Turbocharger Remove/Install Components (2 Of 4)

Fig 3: Identifying Turbocharger Remove/Install Components (3 Of 4)

Fig 4: Identifying Turbocharger Remove/Install Components (4 Of 4)

Modification Notes

22.11.05

Remove model 230 with front axle carrier, added

Step 1.2

	Remove/install
1.1	Remove engine	Model 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07
		Model 215, 220 without special protection version, light armoring or top protection	AR01.10-P-2400MC
1.2	Remove engine with front axle carrier	Model 216, 221	AR01.10-P-2500SZ
		Model 230	AR01.10-P-2500RC
2	Mount engine onto assembly stand	Model 215, 220
3	Remove right air filter housing.		AR09.10-P-1150LA
4	Remove intercooler		AR09.41-P-6817HH
5	Remove engine charge air channel upstream of charge air cooler		AR09.41-P-8623H
6	Remove ignition coil module		AR15.12-P-1100LA
7	Remove support (1) from turbocharger (2)		*BA09.40-P-1009-01H
			*BA09.40-P-1010-01H
8	Remove engine supports (3)		*BA22.10-P-1001-02A
9	Remove coolant feed line (4) from crankcase to turbocharger (2)	Installation: Install new sealing rings.
			*BA09.40-P-1005-01H
			*BA09.40-P-1007-01H
10	Remove oil return line (5) from turbocharger (2)	Installation: Replace gasket and sealing ring.
			*BA09.40-P-1004-01H
			*BA09.40-P-1006-01H
11	Dismount pneumatic lines (6) from deceleration air valve (7) and from vacuum cell (8)	Installation: Check condition of pneumatic lines (6) and hose clamps; replace if necessary.
12	Unscrew bolts (9) of oil feed line (10) and of coolant return line (11) at turbocharger (2)	Installation: Replace gaskets and sealing rings.
			*BA09.40-P-1002-01H
			*BA09.40-P-1003-01H
13	Remove shields (12) at turbocharger (2)		*BA09.40-P-1012-01H
14	Unscrew bolts (13) of coolant line (14) at cylinder head (15)		*BA09.40-P-1001-01H
15	Mount assembly tool (16) with 4 bolts (bolt M8x20) onto turbocharger (2)	Turbocharger and exhaust manifold are one unit and must not be disassembled, as this can lead to leakage. Assembly tools (16) serve to fix the flexible exhaust manifold parts in place.
			Figure
16	Unscrew nuts (17) at exhaust manifold	Installation: Observe torque diagram.	AR09.40-P-6020-11MC
			Fig 6
			Fig 7
			*BA09.40-P-1011-01H
17	Remove turbocharger (2) with exhaust manifold from cylinder head (15)	Installation: Replace seal.
18	Install in the reverse order

Turbocharger

Number	Designation		Engine 275
BA09.40-P-1001-01H	Coolant line to cylinder head	Nm	9
BA09.40-P-1002-01H	Bolt, oil feed line to turbocharger	Nm	8
BA09.40-P-1003-01H	Bolt, coolant return flow line to turbocharger	Nm	8
BA09.40-P-1004-01H	Bolt, oil return flow line to turbocharger	Nm	8
BA09.40-P-1005-01H	Bolt connecting coolant feed line to turbocharger	Nm	8
BA09.40-P-1006-01H	Bolt, oil return flow line to crankcase	Nm	8
BA09.40-P-1007-01H	Banjo bolt, coolant feed line to crankcase	Nm	25
BA09.40-P-1009-01H	Bolt, support to turbocharger	Nm	30
BA09.40-P-1010-01H	Bolt, turbocharger support to crankcase	Nm	20
BA09.40-P-1011-01H	Exhaust manifold to cylinder head	Nm	15
BA09.40-P-1012-01H	Shield to turbocharger	Nm	9

Engine Support (Engine Side)

Number	Designation			Engine 275
BA22.10-P-1001-02A	Bolt, engine support to crankcase	Stage 1	Nm	20°
BA22.10-P-1001-02A	Bolt, engine support to crankcase	Stage 2	∠°	90

Fig 5: Identifying Assembly Arm (285 589 00 61 00)

Fig 6: Identifying Box Wrench Bit (285 589 00 03 00)

Fig 7: Identifying Torque Wrench (001 589 87 21 00)