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

ENGINES 642 in MODEL 221 

Fig 1: Identifying Turbocharger Remove/Install Components - Turbocharger Without Coolant Cooling

Courtesy of MERCEDES-BENZ USA

Turbocharger without coolant cooling 

Fig 2: Identifying Turbocharger Remove/Install Components - Turbocharger With Coolant Cooling

Courtesy of MERCEDES-BENZ USA

Turbocharger with coolant cooling 

Fig 3: Identifying Turbocharger Remove/Install Components - Turbocharger Without Coolant Cooling

Courtesy of MERCEDES-BENZ USA

Turbocharger without coolant cooling 

	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 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
1	Remove engine cover	Ensure correct seating of the engine cover.	AR01.10-P-2405SXI
2	Remove engine air intake duct (1) downstream of the air filter		AR09.10-P-8130SXI
3	Disconnect connector from exhaust back pressure sensor (B60)	Only with code (474) Particulate filter
4	Remove engine charge air duct (2)		AR09.41-P-8622SXI
5	Remove heat protection (3)
6	Remove bracket (11)
7	Remove exhaust pipe (10)	Remove top screw/bolts (9) but only loosen bottom screw/bolt (9) as the flange is slotted. For vehicles with code (U42) BlueTEC (SCR) diesel exhaust treatment, remove the exhaust pipe (10) with attached O2 sensor upstream of CAT and lay outside the working area. Replace seal and screw/bolts (9).
		Exhaust line to turbocharger	*BA09.40-P-1012-01K
8	Remove exhaust gas recirculation pipe (4)	Replace seals and screw/bolts. For vehicles with code (U42) BlueTEC (SCR) diesel exhaust treatment, check the clamp (12) and replace if necessary.
		Exhaust gas recirculation pipe to charge air distribution line	*BA14.20-P-1003-01G
		Exhaust gas recirculation pipe to exhaust collector pipe	*BA14.20-P-1004-01G
		Clamp, exhaust gas recirculation pipe to exhaust collector pipe	*BA14.20-P-1013-01G
9	Remove screw/bolts (5) from exhaust collector pipe (6)	Replace seals and screw/bolts (5).
		Flange connection, exhaust manifold or front exhaust pipes on exhaust collector pipe	*BA14.10-P-1001-01L
10	Remove screw/bolts (7) on exhaust collector pipe support brace	Screw/bolt, exhaust collector pipe support brace to cylinder crankcase	*BA09.40-P-1007-01K
11	Drain coolant	For a turbocharger (15) with coolant cooling	AR20.00-P-1142SXI
	Notes on coolant		AH20.00-N-2080-01A
12	Remove screw/bolt (16) for coolant line (13)	For a turbocharger (15) with coolant cooling
		Screw/bolt, coolant line to turbocharger/charge air distribution line	*BA09.40-P-1013-01K
13	Remove screw/bolts (8) at oil supply connection fittings	Fitted bolt connecting turbocharger to oil supply connection fitting	*BA09.40-P-1010-01K
14.1	Remove screw/bolt (14)	For a turbocharger (15) without coolant cooling
		Support brace connecting turbocharger to charge air manifold	*BA09.40-P-1009-01K
14.2	Unplug electrical connector on temperature sensor upstream of turbocharger (B19/11)	For a turbocharger (15) with coolant cooling
15	Detach electrical connector on right boost pressure control (Y100/1)
16	Remove turbocharger (15)	Close off openings for a removed oil supply connection fitting. Close off openings on turbocharger (15) and the diesel particulate filter. Clean turbocharger (15) and diesel particulate filter free of adhesive residues. Replace seal on oil supply connection fitting in order to avoid leaks. For a turbocharger (15) with coolant cooling replace the seal for coolant line (13).
		Set of stop plugs	Figure
		Set of protective covers	Fig 4
17	Replace seal between turbocharger (15) and exhaust collector pipe (6)	Only in the event of leaks between exhaust collector pipe (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 pipe (6) on the turbocharger (15). Install new screw/bolts.	AR09.40-P-6024-15A
		Screw/bolt connecting turbocharger to exhaust collector pipe	*BA09.40-P-1011-01K
18	Install in the reverse order
	Checking
19	Check engine oil level		AR18.00-P-3035-01SXI
		Filling capacity (oil and filter change)	*BF18.00-P-1001-01S
		Filling capacity (oil and filter change)	*BF18.00-P-1001-01A
20	Check for leaktightness with engine running

Fig 4: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA