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Remove/install turbocharger - AR09.40-P-6020GZB: Notes

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ENGINES 642 in MODEL 251 

Fig 1: Identifying Turbocharger Components - Without Coolant Cooling (1 Of 3)
G06878068Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Turbocharger Components - Without Coolant Cooling (2 Of 3)
G06878069Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Turbocharger Components - Without Coolant Cooling (3 Of 3)
G00544428Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Turbocharger with coolant cooling: 

Fig 4: Identifying Turbocharger Components - With Coolant Cooling
G06878070Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install     
DANGER Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, lift gates or sliding roof Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A
DANGER 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 right air filter housing AR09.10-P-1150GZC 
2 Remove engine air intake duct downstream of the air filter (1)   AR09.10-P-8130GZB 
3 Remove engine charge air duct (2) upstream of charge air cooler   AR09.41-P-8623GZB 
4 Remove engine charge air duct (2) from turbocharger (14)   AR09.41-P-8622GZB 
5 Remove heat shield (3) from turbocharger (14)   AR09.10-P-1150GZC 
6 Remove screw/bolts (16) for partition wall    
6 Remove engine air intake duct downstream of the air filter (1)   AR09.10-P-8130GZB 
7 Remove the right partition wall Installation: Check partition wall on the right (17) for damage. If damage to the partition wall on the right (17) is visible, particularly in the catalytic converter area of the exhaust system, then this must be replaced.  
8 Remove center partition wall (18) The left partition wall (19) remains in the vehicle.  
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) IMPORTANT Seal opening on turbocharger (14). AR09.41-P-8622GZB 
SPECIAL TOOL Fig 5
SPECIAL TOOL Fig 5
9.1 Disconnect connector from exhaust back pressure sensor (B60) With code (474) diesel particulate filter  
9.2 Remove exhaust back pressure sensor (B60) Except code (474) diesel particulate filter  
10 Remove left exhaust gas recirculation positioner (Y27/9)   AR14.20-P-1020GZB
11 Disconnect electrical connector from charge pressure positioner (Y77/1)    
12 Remove hose clamp (7) at exhaust pipe (5)    
13 Remove screw/bolts (6) Remove top screw/bolts (6) but only loosen bottom screw/bolt (6) as the flange is slotted.
Installation:  Replace gaskets and bolts (6).		  
    TORQUE SPECIFICATION *BA09.40-P-1012-01K 
14 Remove exhaust pipe (5)    
15 Remove exhaust gas recirculation pipe (8) IMPORTANTInstallation:  Replace seal and screw/ bolts.
IMPORTANTInstallation:  On engine with coolant-cooled turbocharger (14), check clamp (22), replace if necessary.		  
TORQUE SPECIFICATION Exhaust gas recirculation pipe to charge air distribution line *BA14.20-P-1003-01G 
TORQUE SPECIFICATION Exhaust gas recirculation pipe to exhaust collector *BA14.20-P-1004-01G 
TORQUE SPECIFICATION Clamp, exhaust gas recirculation pipe to exhaust collector pipe *BA14.20-P-1013-01G 
16 Remove bolts (9) IMPORTANTInstallation:  Replace gaskets and bolts (9).  
TORQUE SPECIFICATION *BA14.10-P-1001-01L 
17 Drain coolant For a turbocharger (14) with coolant cooling AR20.00-P-1142GZB
NOTES Notes on coolant AH20.00-N-2080-01A
18 Remove bolt (21) for coolant line (20) For a turbocharger (14) with coolant cooling  
TORQUE SPECIFICATION *BA09.40-P-1013-01K 
19 Remove bolts (11) from carrier (bolts connecting carrier to crankshaft housing) TORQUE SPECIFICATION *BA09.40-P-1007-01K 
20 Remove bolts (12) from the oil supply connection fitting TORQUE SPECIFICATION *BA09.40-P-1010-01K 
21 Remove bracket (4)    
22 Remove bolt (15) TORQUE SPECIFICATION *BA09.40-P-1009-01K 
23 Disconnect electrical connector from temperature sensor upstream of turbocharger (B19/11) For a turbocharger (14) with coolant cooling  
24 Remove turbocharger (14) Replace seal for oil supply connection fitting and align with the hole pattern. Ensure that the oil supply duct is not concealed. Damage can occur on the turbocharger (14) otherwise.
IMPORTANTInstallation:  Close off openings on turbocharger (14). Clean turbocharger (14) and primary catalytic converter free of sealant residues.
IMPORTANTInstallation:  Close off openings on a removed oil supply connection fitting.
NOTES Replace seal on oil supply connection fitting and align according to hole pattern while ensuring that the oil supply channel is not concealed.
IMPORTANTInstallation:  On engines with coolant-cooled turbocharger (14), replace seal for coolant line.		  
SPECIAL TOOL Fig 5
SPECIAL TOOL Fig 6
25 Replace seal between turbocharger (14) and exhaust collector pipe (10) IMPORTANT Only replace in the event of leaks between turbocharger (14) and exhaust collector pipe (10).
NOTES 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).
IMPORTANTInstallation:  Install new bolts.		 AR09.40-P-6024-15A 
TORQUE SPECIFICATION *BA09.40-P-1011-01K 
26 Install in the reverse order    
INSPECT Checking     
27 Check engine oil level NOTES Vehicle must be horizontal and standing on its wheels. Measurement errors can occur otherwise.
IMPORTANT Shut off engine once it has reached operating temperature and wait approx. 5 minutes before checking engine oil level.		 AR18.00-P-3035-01PI
FLUID SPECIFICATION Without diesel particulate filter (code 474) *BF18.00-P-1001-01A 
FLUID SPECIFICATION With diesel particulate filter code 474 *BF18.00-P-1001-01S 
DANGER 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
28 Check for leak-tightness 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 642.82/83/85/86/87/9
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
BA14.20-P-1013-01G Clamp, exhaust gas recirculation pipe to exhaust collector pipe Nm 9
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 20
Stage 2 ∠° 60
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
BA09.40-P-1013-01K Bolt, coolant line to turbocharger/charge air distribution line Nm 9
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642.940/950 with particulate filter Engine 642.820/870/872 with particulate filter
BF18.00-P-1001-01S Engine oil Filling capacity (oil and filter change) Liters 8.5 8.5
Specifications for Operating Fluids Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
Sheet BB00.40-P-0229-31A BB00.40-P-0229-31A
Sheet BB00.40-P-0229-51A BB00.40-P-0229-51A
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642.940/950 without particulate filter Engine 642.820/870/872 without particulate filter
BF18.00-P-1001-01A Engine oil Filling capacity (oil and filter change) Liters 8.5 8.5
Specifications for Operating Fluids Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-05A BB00.40-P-0228-05A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
Sheet BB00.40-P-0229-03A BB00.40-P-0229-03A
Sheet BB00.40-P-0229-31A BB00.40-P-0229-31A
Sheet BB00.40-P-0229-05A BB00.40-P-0229-05A
Sheet BB00.40-P-0229-51A BB00.40-P-0229-51A
Fig 5: Identifying Set Of Protective Covers (001 589 01 91 00)
G06878072Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Set Of Stop Plugs (129 589 00 91 00)
G06878073Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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