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

ENGINES 642 in MODEL 164 

Fig 1: Identifying Turbocharger Remove/Install Components (1 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Turbocharger Remove/Install Components (2 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Turbocharger Remove/Install Components (3 Of 3)

Courtesy of MERCEDES-BENZ USA

Turbocharger with coolant cooling 

Fig 4: Identifying Turbocharger Remove/Install Components - Turbocharger With Coolant Cooling

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of injury  to skin and eyes caused by handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Risk of injury  caused by fingers being pinched or crushed  when removing, installing or adjustment operations on hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving components.	AS00.00-Z-0011-01A
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)
6	Remove screw/bolts (16) for partition wall
7	Remove the right partition wall (17)	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)	EG The left partition wall (19) remains in the vehicle.
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 boost pressure control (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. Replace seal and screw/bolts (6).
			*BA09.40-P-1012-01K
14	Remove exhaust pipe (5)
15	Remove exhaust gas recirculation pipe (8)	Replace seal and screw/bolts. On engine with coolant-cooled turbocharger (14), check clamp (22), replace if necessary.
			*BA14.20-P-1003-01G
			*BA14.20-P-1004-01G
			*BA14.20-P-1013-01G
16	Remove screw/bolts (9)	Replace seals and screw/bolts (9).
			*BA14.10-P-1001-01L
17	Drain coolant	For a turbocharger (14) with coolant cooling	AR20.00-P-1142GZB
	Notes on coolant		AH20.00-N-2080-01A
18	Remove screw/bolt (21) for coolant line (20)	For a turbocharger (14) with coolant cooling
			*BA09.40-P-1013-01K
19	Remove screw/bolts (11) from carrier (bolts connecting carrier to crankshaft housing)		*BA09.40-P-1007-01K
20	Remove screw/bolts (12) from the oil supply connection fitting		*BA09.40-P-1010-01K
21	Remove bracket (4)
22	Remove screw/bolt (15)		*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. 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. On engines with coolant-cooled turbocharger (14), replace seal for coolant line.
			Fig 5
			Figure
25	Replace seal between turbocharger (14) and exhaust collector pipe (10)	Only in the event of leaks between turbocharger (14) and exhaust collector pipe (10). To achieve tension-free installation and to prevent consequential damage to exhaust manifold, a provisional installation should be carried out to establish positioning of exhaust collector pipe (10) at turbocharger (14). Install new screw/bolts.	AR09.40-P-6024-15A
			*BA09.40-P-1011-01K
26	Install in the reverse order
	Checking
27	Check engine oil level	Vehicle must be horizontal and standing on its wheels. Measurement errors can occur otherwise. Shut off engine once it has reached operating temperature and wait approx. 5 minutes before checking engine oil level.	AR18.00-P-3035-01PI
		Except code (474) diesel particulate filter	*BF18.00-P-1001-01A
		With code (474) diesel 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 from working on the vehicle as it is being started or when the engine is running	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
28	Check for leaktightness with engine running

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