Removal and installation of the exhaust gas turbocharger - ra09006026020x(6020)

Engines 602.96, 603.96/97 TURBO (Model 463.3: for deviations see introductory notes)

Operation no. of operation texts and work units or standard texts and flat rates: 09-6020

Fig 1: Identifying Exhaust Gas Turbocharger Remove/Install Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Vehicle	drive onto the platform or inspection pit.
Bottom section of noise encapsulation	detach, attach.
Air cleaner	remove, install (09-1051).
Hose clip (144)	slacken and detach, attach intake hose (167).
Partition wall between trap oxidizer and air cleaner	remove, install (9 bolts) of which 6 accessible from above, 3 accessible from below (Figure 4).
Vacuum lines red/violet/brown on ARF valve (60) and red/violet/blue on air recirculation valve	detach, fit on.
Clip (119) on corrugated pipe (61)	slacken, tighten. Tightening torque 45 Nm.
Corrugated pipe (61)	remove, install.
Exhaust gas recirculation valve (60)	remove, install. Tightening torque 25 Nm.
Trap oxidizer (139) on exhaust manifold	unscrew, screw on. Tightening torque 45 Nm.
Supporting bracket	unscrew, screw on and remove at the same time with trap oxidizer.
Charge air connecting line (138a)	remove, install. Renew gasket (138d).
Engine breather	detach, attach.
Mixing pipe (135) with exhaust gas recirculation valve (60)	remove, install.
Oil feed line (141) of turbocharger (137)	unscrew, screw on. Renew seal.
Mounting bracket (134)	unscrew, screw on.
Nuts (134a) (from top and bottom)	slacken, unscrew.
Mounting bracket (177)	remove, install.
Exhaust gas turbocharger (137)	remove, install.

NOTE: The specified tightening torques are reference values.

Removal, installation

NOTE: For the conversion, the car must be driven onto an inspection pit or platform.

1 Remove noise encapsulation complete from below.
2 Remove air cleaner complete.
3 Slacken hose clip (144) from air flow sensor and detach intake hose (167).
4 Remove partition wall (A) (9 bolts), of which 6 (WAF10) accessible from above, 2 (WAF8) and 1 (WAF10) accessible from below.

Fig 2: Identifying Partition Wall
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5 Detach vacuum lines red/violet/brown on ARF valve and red/violet/blue on air recirculation valve.
6 Slacken clips (B) on corrugated pipe, and remove corrugated pipe.

Fig 3: Identifying Corrugated Pipe Slacken Clips
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7 Unscrew trap oxidizer from exhaust manifold, remove trap oxidizer and supporting bracket at the same time.
8 Remove charge air connecting line (138a).

Fig 4: Identifying Charge Air Connecting Line
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9 Detach engine breather hose.
10 Detach mixing pipe (135) with exhaust gas recirculation valve from cylinder head.

Fig 5: Identifying Mixing Pipe
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11 Unscrew oil feed line (141) from turbocharger (renew seal).
12 Slacken both mounting brackets (134) on the exhaust manifold and turbocharger.
13 Slacken bolts of exhaust pipe - accessible from above (arrows).

Fig 6: Identifying Oil Feed Line And Mounting Brackets
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

NOTE: No vibration compensator was installed between Ch. No. 140 134

1A 254265

with engine 603.971 12 014926

and Ch. No. 140 134 1A 290 226

with engine 603.971 12 018 711
14 Slacken bottom bolt of exhaust flange.
15 Unscrew mounting (177) from alternator flange to turbine housing on both components.
16 Withdraw turbocharger.
17 Install corrugated pipe with flange onto new turbocharger.
18 Clean sealing surfaces mechanically.
20 Install new trap oxidizer, insert supporting bracket at the same time and install.
Tightening torque 45 Nm.
21 Install ARF valve together with corrugated pipe.
22 Install partition panel.
23 Connect vacuum line red/violet/brown to ARF valve and vacuum line red/violet/blue to air recirculation valve.
24 Connect intake hose to air flow sensor and tighten hose clip.
25 Install air cleaner complete.
26 Install bottom section of noise encapsulation complete.