LEMON Manuals: Even more car manuals for everyone
Home >> Smart >> 2015 >> Fortwo Electric Drive, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 72 (Air Intake, Turbocharging - 212 Chassis - 1 Of 2) >> Testing & Repair >> Remove/install turbocharger >> Remove/install turbocharger - AR09.40-P-6020CDA

Remove/install turbocharger - AR09.40-P-6020CDA

WARNING: This page does not describe the selected car, but rather 33 other vehicles, including the 2016 Mercedes-Benz E63 S AMG, 2016 Mercedes-Benz E400, 2016 Mercedes-Benz E350, 2016 Mercedes-Benz E300, and 2016 Mercedes-Benz E250. However, it is still accessible from the selected car via links, so may be relevant.

ENGINE 651 in MODEL 166, 172, 204, 207, 212 (except 212.098/298), 218, 221 

For sequential turbocharging 

Fig 1: Turbocharger Remove/Install Components
G09974879Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A
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
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1 Remove air filter housing   AR09.10-P-1150CD 
2 Remove engine air intake duct downstream of air filter   AR09.10-P-8130CD 
3.1 Remove boost pressure control flap aneroid capsule (1) Model 204, 207, 212 (except 212.098/298), 218, 221  
INSTALLATION IMPORTANT Adjust boost pressure control flap aneroid capsule (1). AR09.40-P-1002-01CD 
TORQUE SPECIFICATION Fastening bolts for turbocharger vacuum unit bracket *BA09.40-P-1013-01P 
TORQUE SPECIFICATION Fastening nut on turbocharger vacuum unit *BA09.40-P-1012-01P 
"Yellow" locking paint *BR00.45-Z-1027-07A 
SPECIAL TOOL Vacuum tester Figure
SPECIAL TOOL Hand vacuum pump Figure
3.2 Pull off vacuum hose (2) Model 166, 172  
4 Unclip electrical wiring harness for temperature sensor upstream of turbocharger (B19/11) on air filter housing bracket at the front (6) and remove screw/bolt (7) TORQUE SPECIFICATION Lubricating oil line bracket fastening bolt *BA09.40-P-1004-01P 
5 Remove screw/bolts (9) and take off air filter housing bracket at the front (6) TORQUE SPECIFICATION Screw/bolt, air filter bracket to cylinder head *BA09.10-P-1001-01K 
6 Disconnect electrical connector (10) for glow output stage (N14/3)    
7 Detach vacuum hoses (11)    
8 Remove oil line feed line for turbocharger   AR09.40-P-6022CD 
IMPORTANTRemoval:  Only remove the section between cylinder crankcase and bracket.  
9 Remove temperature sensor upstream of turbocharger (B19/11)   AR07.04-P-0071CD
10.1 Remove corresponding underfloor paneling MODEL 166 AR61.30-P-1001GQ
10.2 Remove bottom sections of soundproofing ENGINE 651 in MODEL 172, 204.0/2/3, 207, 212 (except 212.098/298), 218  
MODEL 172.4 AR94.30-P-5300W
MODEL 204.0/2/3, 207, 212 (except 212.098/298), 218 AR94.30-P-5300EW
10.3 Remove engine compartment paneling MODEL 204.9 AR61.20-P-1105CY
10.4 Detach lower engine compartment paneling Model 221 except code Z07 (Highest protection) AR61.20-P-1105SX
11.1 Remove catalytic converter diesel particulate filter unit MODEL 166, 172, 204 (except 204.9), 207, 212 (except 212.08/09/28/29), 218, 221  
MODEL 166 AR49.10-P-5501GQ
MODEL 172, 204 (except 204.9), 207, 212 (except 212.08/09/28/29), 218 AR49.10-P-5501CD
MODEL 221 AR49.10-P-5501SXI
11.2 Remove catalytic converter Model 204.9, 212.08/09/28/29./ AR49.10-P-5500OMD
12 Remove charge air hose upstream of charge air cooler   AR09.41-P-8619CD
13.1 Loosen alternator and place down to front ENGINE 651 in MODEL 166
For sequential turbocharging ENGINE 651 in MODEL 172, 204, 207, 212 (except 212.098/298), 218, 221 with TRANSMISSION 722.9 (except 722.96) For sequential turbocharging		  
MODEL 166 AR15.40-P-5032GR
MODEL 172, 204, 207, 212 (except 212.098/298), 218, 221 with TRANSMISSION 722.9 (except 722.96) AR15.40-P-5032CD
13.2 Remove alternator MODEL 204, 212 with TRANSMISSION 722.96 AR15.40-P-5032CD
14 Remove oil line return for turbocharger ENGINE 651 in MODEL 166, 172, 204, 207, 212 (except 212.098/298), 218, 221 For sequential turbocharging  
ENGINE 651 in MODEL 204, 207, 212 (except 212.098/298), 218, 221 For sequential turbocharging AR09.40-P-6021CD 
INSTALLATION IMPORTANT Replace seal.  
15 Remove screw/bolts (12, 13) and take off front turbocharger support brace (14) TORQUE SPECIFICATION Bolt, turbocharger bracket to turbocharger bypass flap *BA09.40-P-1007-01P 
TORQUE SPECIFICATION Bolt, turbocharger bracket to engine support/major assembly carrier *BA09.40-P-1008-01P 
16 Remove screw/bolts (15, 16) and take off rear turbocharger support brace (17) INSTALLATION IMPORTANT Replace screw/bolts (15, 16).  
TORQUE SPECIFICATION Bolt, rear/center turbocharger bracket to turbocharger *BA09.40-P-1002-01P 
TORQUE SPECIFICATION Bolt, rear/center turbocharger bracket to cylinder crankcase *BA09.40-P-1003-01P 
17 Remove screw/bolts (18) INSTALLATION IMPORTANT Install new screw/bolts (18) and seal.  
TORQUE SPECIFICATION Flange connection, exhaust manifold to turbocharger *BA09.40-P-1001-01P 
18 Remove turbocharger upwards    
19 Install in the reverse order    
INSPECT Check     
20 Check engine oil level, correct if necessary NOTES
The engine oil level must lie between "Min" and "Max".
Engine damage can occur otherwise.		  
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
21 Perform an engine test run and check engine around the turbocharger for leaktightness    
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1007-01P Bolt, turbocharger bracket to turbocharger bypass flap M6 Nm 9
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1012-01P Fastening nut on turbocharger vacuum unit M6 Nm 9
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1008-01P Bolt, turbocharger bracket to engine support/major assembly carrier M8 Nm 20
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1001-01P Flange connection, exhaust manifold to turbocharger Stage 1 Nm 20
Stage 2 ∠° 90
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1004-01P Lubricating oil line bracket fastening bolt Nm 9
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1002-01P Bolt, rear/center turbocharger bracket to turbocharger Nm 20
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1003-01P Bolt, rear/center turbocharger bracket to cylinder crankcase Nm 20
AIR FILTER

Number Designation ENGINE 651
BA09.10-P-1001-01K Screw/bolt, air filter bracket to cylinder head Nm 9
TURBOCHARGER

Number Designation ENGINE 651
BA09.40-P-1013-01P Fastening bolts for turbocharger vacuum unit bracket Nm 25
Fig 2: Identifying Hand Vacuum Pump (001 589 73 21 00)
G09974880Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Vacuum Tester (201 589 13 21 00)
G09974881Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1027-07A "Yellow" locking paint Lackfabrik Bader GmbH & Co. KG
scientia non olet · About LEMON Manuals