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Remove/install exhaust manifold - AR14.10-P-3915GZB

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ENGINES 642 in MODEL 164, 251 

Fig 1: Identifying Exhaust Manifold Components
G06878090Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Turbocharger without coolant cooling 

Fig 2: Identifying Turbocharger Without Coolant Cooling
G06878091Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Turbocharger with coolant cooling 

Fig 3: Identifying Turbocharger With Coolant Cooling
G06878092Courtesy 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
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
DANGER Risk of explosion  caused by oxyhydrogen gas. Risk of poisoning and caustic burns  caused by swallowing battery acid. Risk of injury  caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z-0001-01A
1 Detach ground line from battery Model 164 AR54.10-P-0003GZ
    Model 251 AR54.10-P-0003RT
NOTES Notes on battery   AH54.10-P-0001-01A
2 Remove wiper system Model 251 only AR82.30-P-6400RT
3 Remove air filter housing Right side:  
    Model 164 AR09.10-P-1150GZC
    Model 251 AR09.10-P-1150RTC
    Left side:  
    Model 164 AR09.10-P-1150GZB
    Model 251 AR09.10-P-1150RTB
4 Remove heat shield from turbocharger    
5 Disconnect electrical connector from exhaust back pressure sensor (B60) With code 474 Particulate filter  
6 Remove exhaust back pressure sensor (B60) With code 474 Particulate filter  
7 Remove exhaust gas recirculation positioner   AR14.20-P-1020GZB 
8 Unscrew bolts (13) from power steering expansion reservoir (16) IMPORTANT Push power steering expansion reservoir (16) with connected oil lines slightly to one side.  
9 Remove the vacuum line (14) from out of the rubber support (15)    
10 Remove collar clamp (17) TORQUE SPECIFICATION Model 164 except code (U42) BlueTEC (SCR) diesel exhaust treatment *BA49.10-P-1006-01U 
    TORQUE SPECIFICATION Model 164 with code (U42) BlueTEC (SCR) diesel exhaust treatment *BA49.10-P-1021-01U 
    TORQUE SPECIFICATION Model 251 except code (U42) BlueTEC (SCR) diesel exhaust treatment, except code (928) Exhaust treatment with EU5 technology *BA49.10-P-1014-01X 
    TORQUE SPECIFICATION Model 251 with code (U42) BlueTEC (SCR) diesel exhaust treatment, with code (928) Exhaust treatment with EU5 technology *BA49.10-P-1022-01X 
11 Remove the flanged pipe (10) IMPORTANT To do this, remove the top bolts (9) but only loosen bottom bolt (11). The flanged pipe (10) is slotted at the bottom attachment point.  
    TORQUE SPECIFICATION *BA09.40-P-1012-01K 
12 Remove exhaust gas recirculation line (4) IMPORTANT For engines with turbocharger (14b) with coolant cooling a clamp is installed instead of bolts (6) (EGR line (4) on exhaust collector pipe ()).
IMPORTANTInstallation:  Replace the gaskets.		  
    TORQUE SPECIFICATION *BA14.20-P-1003-01G 
    TORQUE SPECIFICATION *BA14.20-P-1004-01G 
    TORQUE SPECIFICATION *BA14.20-P-1013-01G 
13 Remove bolts (5) from exhaust collector (6) TORQUE SPECIFICATION *BA14.10-P-1001-01L 
14.1 Remove primary catalytic converter (12) With code 474 Particulate filter
IMPORTANT Only when removing right exhaust manifold (2).		 AR49.10-P-7100GZB
14.2 Remove exhaust pipe Without particulate filter  
14.3 Remove exhaust pipe on flange pipe (10) from catalytic converter diesel particulate filter particulate filter unit Vehicles with catalytic converter diesel particulate filter unit  
    TORQUE SPECIFICATION *BA49.10-P-1022-01X 
    TORQUE SPECIFICATION *BA49.10-P-1023-01X 
15 Remove shields (1) On vehicles with coolant-cooled turbocharger (14b), the shield (1) consists of two elements.  
16 Unscrew self-locking nuts from right exhaust manifold (2) IMPORTANTInstallation:  Install new self-locking nuts.
IMPORTANTInstallation:  Check studs, replace if necessary.		  
    TORQUE SPECIFICATION *BA14.10-P-1002-01L 
17 Unscrew self-locking nuts from left exhaust manifold (3) IMPORTANTInstallation:  Install new self-locking nuts.
IMPORTANTInstallation:  Check studs, replace if necessary.		  
    TORQUE SPECIFICATION *BA14.10-P-1002-01L 
18 Remove right exhaust manifold along with seal (2) from cylinder head IMPORTANTInstallation:  Clean sealing surfaces and install new seals.  
19 Remove left exhaust manifold along with seal (3) from cylinder head IMPORTANTInstallation:  Clean sealing surfaces and install new seals.  
20 Install in the reverse order    
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
21 Test run engine and check exhaust system for leaks    
TURBOCHARGER

Number Designation Engine 642
BA09.40-P-1012-01K Exhaust line to turbocharger Nm 20
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
BA14.10-P-1002-01L Nut, exhaust manifold to cylinder head Nm 25
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
EXHAUST SYSTEM

Number Designation Engine 642 in model 164 without Code U42
BA49.10-P-1006-01U Bolt, turbocharger hose clamp to primary catalytic converter Nm 20
EXHAUST SYSTEM

Number Designation Engine 642 in model 164 with Code U42
BA49.10-P-1021-01U Bolt, exhaust pipe clamp with flange to exhaust pipe Nm 15
EXHAUST SYSTEM

Number Designation Engine 642 in model 251 without code 928/U42
BA49.10-P-1014-01X Bolt, clamp for turbocharger/exhaust pipe to primary catalytic converter Nm 20
EXHAUST SYSTEM

Number Designation Engine 642 in model 251 with code U42
BA49.10-P-1022-01X Bolt, exhaust pipe clamp with flange to exhaust pipe Nm 15
BA49.10-P-1023-01X Bolt, exhaust pipe clamp to diesel particulate filter Nm 15
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