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

ENGINES 642 in MODEL 211 

Fig 1: Identifying Turbocharger Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Turbocharger And Bolt

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

22.6.05

Flange connection, exhaust manifold and front exhaust pipes

Engine 642

*BA14.10-P-1001-01L

	Remove/install
	Risk of injury  to skin and eyes caused by handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses.	AS00.00-Z-0002-01A
	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
1	Remove engine trim panel		AR01.10-P-2405TI
2	Remove engine intake air duct (1) downstream of the air filter		AR09.10-P-8130TI
3.1	Disconnect connector from exhaust back pressure sensor (B60)	Only valid for particulate filter, code 474.
4	Remove engine charge air duct (2) from turbocharger (15)		AR09.41-P-8622TI
5	Remove heat protection (3)
6	Remove bracket (11)
7	Remove exhaust pipe (10)	Remove top bolts (9) but only loosen bottom bolt (9) as the flange is slotted. Installation:  Replace seal and bolts (9).
		Exhaust line to turbocharger	*BA09.40-P-1012-01K
8	Remove exhaust gas recirculation pipe (4)	Installation:  Replace gasket and bolts.
		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
9	Remove bolts (5) from exhaust collector (6)	Flange connection for exhaust manifold on exhaust collector. Installation:  Replace gaskets and bolts (5).	*BA14.10-P-1001-01L
10	Remove bolts (7) from crankshaft housing carrier	Carrier for exhaust collector on crankshaft housing	*BA09.40-P-1007-01K
11	Remove bolts (8) at oil supply connection fittings	Fitted bolt connecting turbocharger to oil supply connection fitting	*BA09.40-P-1010-01K
12	Remove screw (14)	Support brace connecting turbocharger to charge air manifold	*BA09.40-P-1009-01K
13	Disconnect electrical connector from right boost pressure positioner (Y100/1).
14	Remove turbocharger (15)	Installation:  Close off openings on turbocharger (15). Clean turbocharger (15) and primary catalytic converter free of adhesive residues.	Fig 3
		Installation:  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.	Fig 4
15.1	Replace gasket between turbocharger (15) and exhaust collector (6)	Only in the event of leaks between exhaust collector (6) and turbocharger (15) In order to obtain free of tension assembly and to avoid consequential damage at the exhaust manifold a provisional installation is necessary for positioning of the exhaust collector (6) on the turbocharger (15).	AR09.40-P-6024-15A
		Bolt, turbocharger to exhaust collector. Installation:  Install new bolts.	*BA09.40-P-1011-01K
16	Install in the reverse order
	Checking
17	Check engine oil level		AR18.00-P-3035-01TI
18	Check for leaks with engine running

EXHAUST MANIFOLD

Number	Designation			Engine 642
BA14.10-P-1001-01L	Flange connection, exhaust manifold/front exhaust pipes to exhaust collector	Stage 1	Nm	20
		Stage 2	∠°	90

EXHAUST GAS RECIRCULATION

Number	Designation			Engines 642.82/83/85/86/87/886/9
BA14.20-P-1003-01G	Exhaust gas recirculation pipe to charge air distribution line		Nm	13
BA14.20-P-1004-01G	Exhaust gas recirculation pipe to exhaust collector pipe	Stage 1	Nm	10
		Stage 2	∠°	90

TURBOCHARGER

Number	Designation			Engine 642
BA09.40-P-1007-01K	Bolt, exhaust collector pipe support to cylinder crankcase		Nm	20
BA09.40-P-1009-01K	Bolt, turbocharger to charge air manifold		Nm	9
BA09.40-P-1010-01K	Fitted bolt, turbocharger to oil feed fitting	Stage 1	Nm	10
		Stage 2	Nm	30
BA09.40-P-1011-01K	Bolt, turbocharger to exhaust collector pipe	Stage 1	Nm	20
		Stage 2	∠°	90
BA09.40-P-1012-01K	Exhaust line to turbocharger		Nm	20

Fig 3: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.