Remove/Install Turbocharger - Ar09.40-D-6020SG

ENGINES 642.896 /898 /993 in MODEL 906

Fig 1: Turbocharger Remove/Install Component Location - Shown on engine 642.896

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Turbocharger Remove/Install Components (Shown On Engine 642.896)

Courtesy of MERCEDES-BENZ USA

REMOVE/INSTALL TURBOCHARGER - ENGINES 642.896 /898 /993 IN MODEL 906

	Remove/install
	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 trim panel on right cylinder head cover		AR01.20-D-5015SF
2	Remove right bracket for air filter housing from firewall		AR09.10-D-1150-03SF
3	Remove noise damper on turbocharger (6)		AR09.40-D-6920SG
4	Remove rear exhaust gas recirculation pipe (9) from exhaust reticulation pipe (10) to exhaust gas recirculation bypass flap	Engine 642.896/898 Press rear exhaust gas recirculation pipe (9) toward rear only, do not remove.	AR14.20-D-1060SD
5	Remove bracket (2) from rail (1)	On engine 642.896/898
6	Disconnect electrical connector (3) for temperature sensor upstream of exhaust gas turbocharger (B16/11)	On engine 642.896/898
7	Expose electrical line (5) for temperature sensor upstream of exhaust gas turbocharger (B16/11)	On engine 642.896/898
8	Disconnect electrical connector (4) from charge air actuator (Y77/1, Y77/8)
9	Unscrew bolts (8) and remove support (7)
10	Remove bolts (11)	Installation: Replace seals (16) and bolts (11).

			Figure
11	Remove bolts (14)	Unscrew bolts (14) from bottom Installation: Replace bolts (14).
11	Remove bolts (14)
12	Remove bolts (15)	Installation: Replace bolts (15).
13	Lift turbocharger (6) up and out	To prevent damage caused by soilage, close off openings on turbocharger (6), left exhaust manifold (12), right exhaust manifold (13) and on oil supply connection fitting using suitable stop plugs. Collect escaping engine oil and remove soiling if necessary. Installation: Install a new sealing ring (17) and seal (18). Replace seals (16) and fix seals (16) in place with four new bolts (11) on exhaust collector pipe (10) before inserting exhaust gas turbocharger (6)
			Figure
			Fig 5
14	Unscrew temperature sensor upstream of exhaust gas turbocharger (B16/11) from exhaust gas turbocharger (6)	On engine 642.896/898, if exhaust gas turbocharger (6) is replaced. Installation: When tightening temperature sensor upstream of exhaust gas turbocharger (B16/11), ensure that electrical line (5) is routed correctly. The heat protection hose (arrow) must be located in the area of the exhaust gas turbocharger (6).

		Paste
15	Replace seal between turbocharger (6) and exhaust collector (10)	Only if installing new turbocharger (6) or in the case of leakage between exhaust collector pipe (10) and turbocharger (6).	AR09.40-S-6024-15SE
15
	Clean
16	Clean sealing surfaces on right exhaust manifold (12), left exhaust manifold (13) and exhaust collector pipe (10)
17	Clean sealing surfaces on exhaust gas turbocharger (6)	Only if exhaust gas turbocharger (6) is not replaced.
18	Install in the reverse order
19	Connect Star Diagnosis, read out fault memory, delete if necessary and perform initialization of charge air actuator (Y77/1 or Y77/8)	When replacing exhaust gas turbochargers (6).
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-D-2000-04SD
20	Check engine oil level, correct if necessary	The engine oil level must not be above the maximum mark. This can lead to engine damage. Engine oil specifications for opening fluids
	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 engine for leaks around turbocharger (6)

EXHAUST TEMPERATURE SENSOR ON TURBOCHARGER TORQUE SPECIFICATIONS - ENGINES 642.896/.898

Number	Designation		Engine 642.898
BA07.04-N-1011-01G	Exhaust temperature sensor on exhaust gas turbocharger	Nm	45

TURBOCHARGER TORQUE SPECIFICATIONS - ENGINE 642 IN MODEL 906

Number	Designation			Engine 642 in model 906
BA09.40-N-1002-01Q	Bolt, turbocharger to charge air manifold		Nm	10
BA09.40-N-1003-01Q	Fitted bolt, turbocharger to oil feed fitting	Stage 1	Nm	10
BA09.40-N-1003-01Q	Fitted bolt, turbocharger to oil feed fitting	Stage 2	Nm	30
BA09.40-N-1004-01Q	Bolt, turbocharger to exhaust collector pipe	Stage 1	Nm	20
BA09.40-N-1004-01Q	Bolt, turbocharger to exhaust collector pipe	Stage 2	Degrees	90
BA09.40-N-1006-01Q	Bolt, support brace to exhaust collector		Nm	30

EXHAUST MANIFOLD/FRONT EXHAUST PIPES TO EXHAUST COLLECTOR PIPE TORQUE SPECIFICATIONS - ENGINE 642 IN MODEL 906

Number	Designation			Engine 642 in model 906
BA14.10-N-1003-01O	Flange connection, exhaust manifold/front exhaust pipes to exhaust collector pipe	Stage 1	Nm	20
BA14.10-N-1003-01O		Stage 2	Degrees	90

ENGINE OIL CAPACITY & SPECIFICATIONS - ENGINE 642 IN MODEL 906

Number	Designation			Engine 642 in model 906 without particulate filter	Engine 642 in model 906 with particulate filter
BF18.00-N-1001-01L	Engine oil	Filling capacity (oil and filter change)	Liters	12.5	12.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-03A	-
			Sheet	BB00.40-P-0228-05A	-
			Sheet	BB00.40-P-0228-51A	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-03A	-
			Sheet	BB00.40-P-0229-05A	-
			Sheet	BB00.40-P-0229-31A	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-51A	BB00.40-P-0229-51A

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Flexible Head Wrench Set (001 589 81 09 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS - LUBRICATION PASTE

Number	Designation	Order number
BR00.45-Z-1005-06A	Paste, hot lubrication 1 kg, DB supply specification 6879.20	A 000 989 76 51