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

ENGINES 642 in MODEL 251 

Fig 1: Identifying Turbocharger Remove/Install Components

Courtesy of MERCEDES-BENZ USA

Turbocharger without coolant cooling 

Fig 2: Identifying Turbocharger And Screw

Courtesy of MERCEDES-BENZ USA

Turbocharger without coolant cooling 

Turbocharger with coolant cooling 

Fig 3: Identifying Coolant Line, Screw And Clamp

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	Risk of injury  to skin and eyes caused by handling hot or glowing objects.	Wear safety gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
1	Remove partition wall between wheel wells		AR62.30-P-2400RT
2	Remove engine trim panel		AR01.10-P-2405RTB
3	Remove water deflector over wiper system		AR83.25-P-1406RT
4	Remove wiper system		AR82.30-P-6400RT
5	Remove right air filter housing		AR09.10-P-1150RTC
6	Remove engine air intake duct downstream of the air filter (1)		AR09.10-P-8130GZB
7	Remove engine charge air duct (2) upstream of charge air cooler		AR09.41-P-8623GZB
8	Remove engine charge air duct (2) from turbocharger (14)	Seal opening on turbocharger (14).	AR09.41-P-8622GZB
			Fig 4
			Fig 5
9	Remove heat shield (3) from turbocharger (14)
10	Disconnect connector on exhaust back pressure sensor (B60)	With code 474 Particulate filter
11	Remove exhaust back pressure sensor (B60)	With code 474 Particulate filter
12	Remove left exhaust gas recirculation positioner (Y27/9)		AR14.20-P-1020GZB
13	Disconnect electrical connector from charge pressure positioner (Y77/1)
14	Remove hose clamp (7) at exhaust pipe (5)
15	Remove screw (6)	Remove top bolt (6) but only loosen bottom bolt (6) as the flange is slotted. Replace seal and bolts (6).
			*BA09.40-P-1012-01K
16	Remove exhaust pipe (5)
17	Remove exhaust gas recirculation pipe (8)	Replace gaskets and bolts. On engine with coolant-cooled turbocharger (14), check clamp (17), replace if required.
		Exhaust gas recirculation pipe to charge air distribution line	*BA14.20-P-1003-01G
		Exhaust gas recirculation pipe to exhaust collector	*BA14.20-P-1004-01G
		Clamp, exhaust gas recirculation pipe to exhaust collector pipe	*BA14.20-P-1013-01G
18	Remove bolts (9)	Replace gaskets and bolts (9).
			*BA14.10-P-1001-01L
19	Drain coolant	For a turbocharger (14) with coolant cooling	AR20.00-P-1142GZB
	Notes on coolant		AH20.00-N-2080-01A
20	Remove bolt (16) for coolant line (13)	For a turbocharger (14) with coolant cooling
			*BA09.40-P-1013-01K
21	Remove bolts (11) from carrier (bolts connecting carrier to crankshaft housing)		*BA09.40-P-1007-01K
22	Remove bolts (12) from the oil supply connection fitting		*BA09.40-P-1010-01K
23	Remove bracket (4)
24.1	Remove screw (15)	For a turbocharger (14) without coolant cooling
			*BA09.40-P-1009-01K
24.2	Disconnect electrical connector from temperature sensor upstream of turbocharger (B19/11)	For a turbocharger (14) with coolant cooling
25	Remove turbocharger (14)	Close off openings on turbocharger (14). Clean turbocharger (14) and primary catalytic converter free of sealant residues. Close off openings on a removed oil supply connection fitting. Replace seal on oil supply connection fitting and align according to hole pattern while ensuring that the oil supply channel is not concealed. On engines with coolant-cooled turbocharger (14), replace seal for coolant line (13).
			Fig 4
			Fig 5
			Figure
26	Replace seal between turbocharger (14) and exhaust collector (10)	Only replace in the event of leaks between turbocharger (14) and exhaust collector (10). To achieve tension-free installation and to prevent subsequent damage to exhaust manifold, a provisional installation should be carried out to establish positioning of exhaust collector (10) at turbocharger (14). Install new bolts.	AR09.40-P-6024-15A
			*BA09.40-P-1011-01K
27	Install in the reverse order
	Checking
28	Check engine oil level	In order to avoid measurement errors, vehicle must be parked on an even surface. Shut off engine once it has reached operating temperature and wait approx. 5 minutes before checking engine oil level.	AR18.00-P-3035-01PI
		Without particulate filter	*BF18.00-P-1001-01A
		With code 474 Particulate filter	*BF18.00-P-1001-01S
	Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
29	Conduct engine test run and check engine for leaks while it is running

Fig 4: Identifying Set Of Protective Covers (001 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA