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

ENGINE 642 in MODEL 166 

MODIFICATION NOTES

2.4.12	Value altered: turbocharger fit bolt on oil supply connection fitting, stage 1		BA09.40-P-1010-01K
1.1.70	Value altered: turbocharger fit bolt on oil supply connection fitting, stage 2		BA09.40-P-1010-01K
26.4.12	Fit bolt, turbocharger to oil supply connection fitting		BA09.40-P-1010-01K
27.4.12	Fit bolt, turbocharger to oil supply connection fitting		BA09.40-P-1010-01K

Fig 1: Identifying Turbocharger Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Drain coolant at radiator		AR20.00-P-1142GQ
	Notes on coolant		AH20.00-N-2080-01A
2	Remove bulkhead wall
3	Remove wiper system		AR82.30-P-6400GZ
4	Remove engine air intake duct downstream of air filter		AR09.10-P-8130OGR
5	Unplug electrical connector (2) from exhaust back pressure sensor
6	Remove engine charge air duct on turbocharger (1)		AR09.41-P-8622OGR
7	Remove heat protection (3)
8	Remove engine suspension lug (4) on right cylinder head cover	Bolt, lifting eye to cylinder head	*BA01.30-P-1006-01S
9	Remove exhaust gas recirculation actuator		AR14.20-P-1020OGR
10	Remove oxygen sensor upstream of catalytic converter		AR07.04-P-0080OGR
11	Detach exhaust pipe on turbocharger (1) and lay outside the working area		AR49.10-P-5532OGR
		When working on the turbocharger (1), do not bend or turn exhaust pipe. This can result in leakage.
12	Remove exhaust gas recirculation pipe (5)	Replace seals and screw/bolts (6). Check hose clamp (7); replace if necessary.
		Exhaust gas recirculation pipe to charge air distribution line	*BA14.20-P-1003-01G
		Clamp, exhaust gas recirculation pipe to exhaust collector pipe	*BA14.20-P-1013-01G
13	Remove screw/bolts (8) from exhaust collector (10)	Replace screw/bolts (8).
		Flange connection, exhaust manifold/front exhaust pipes to exhaust collector	*BA14.10-P-1001-01L
14	Remove screw/bolts (9) from cylinder crankcase	Screw/bolt, exhaust collector pipe support brace to cylinder crankcase	*BA09.40-P-1007-01K
15	Unfasten screw/bolt (11) for coolant line (12)	Screw/bolt, coolant line to turbocharger/charge air distribution line	*BA09.40-P-1013-01K
16	Remove screw/bolts (13) from oil supply connection fitting	Fit bolt, turbocharger to oil supply connection fitting	*BA09.40-P-1010-01K
17	Disconnect electrical connector on temperature sensor upstream of exhaust gas turbocharger (B1911)
18	Disconnect electrical connector from charge pressure positioner (Y77/1)
19	Remove turbocharger (1)	Replace seal (14) and align according to the hole pattern. Leaks are prevented in this way. Do not cover the oil supply duct. Close off openings on the turbocharger (1). Replace seals (15). Close off openings on the oil supply connection fitting. Replace seal for coolant line (12) on charge air distribution line.
		Record plug	Figure
		Set of protective covers	Fig 2
20	Remove coolant line (12)	Only when replacing the turbocharger (1) Replace seal for coolant line (12) on turbocharger (1).
21	Remove temperature sensor upstream of turbocharger (B19/11)	Only when replacing the turbocharger (1) Observe installation position of the temperature sensor upstream of turbocharger (B19/11); mark it if necessary. If a new temperature sensor is installed upstream of the turbocharger (B19/11), this must be brought into the same position as the old temperature sensor upstream of turbocharger (B19/11).
		Temperature sensor for exhaust gas temperature measurement	*BA14.20-P-1005-01G
		Paste, hot lubrication 1 kg, DB supply specification 6879.20	*BR00.45-Z-1005-06A
22	Remove exhaust collector pipe (10) from turbocharger (1)	Only if there are leaks between the exhaust collector pipe (10) and turbocharger (1), or when replacing the turbocharger (1)
		Replace seal between turbocharger and exhaust collector For stress-free assembly, a provisional installation to position the exhaust collector pipe (10) on the turbocharger (1) is necessary. Damage can occur on the exhaust manifold (16, 17) otherwise.	AR09.40-P-6024-15A
		Replace bolts. Screw/bolt, turbocharger to exhaust collector pipe For the provisional installation and replacement of the seal: ↓	*BA09.40-P-1011-01K
		Replace seal between turbocharger and exhaust collector	AR09.40-P-6024-15A
	Clean
23	Clean sealing surfaces on exhaust manifold (16, 17) and on the exhaust collector pipe (10)
24	Clean sealing surfaces on turbocharger (1)	When reusing the turbocharger (1)
25	Install in the reverse order
	Check
26	Connect Star Diagnosis, read out fault memory, if necessary erase it and perform initialization of the boost pressure regulator (Y77/1) Only when replacing the turbocharger (1)
			AD00.00-P-2000-04A
27	Check engine oil level		AR18.00-P-3035-01SXI
		The vehicle must be horizontal and standing on its wheels. This prevents measurement errors occurring. Inspect engine oil level about 5 min. after switching off warm engine.
		ENGINE 642.826 with CODE 474 (Particulate trap)	*BF18.00-P-1001-01S
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it 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 leaks with engine running

CYLINDER HEAD

Number	Designation		ENGINE 642
BA01.30-P-1006-01S	Bolt, lifting eye to cylinder head	Nm	14

TURBOCHARGER

Number	Designation		ENGINE 642
BA09.40-P-1007-01K	Screw/bolt, exhaust collector pipe support brace to cylinder crankcase	Nm	20

TURBOCHARGER

Number	Designation			ENGINE 642
BA09.40-P-1010-01K	Fit bolt, turbocharger to oil supply connection fitting	Stage 1	Nm	20
		Stage 2	∠°	60

TURBOCHARGER

Number	Designation			ENGINE 642
BA09.40-P-1011-01K	Screw/bolt, turbocharger to exhaust collector pipe	Stage 1	Nm	20
		Stage 2	∠°	90

TURBOCHARGER

Number	Designation		ENGINE 642
BA09.40-P-1013-01K	Screw/bolt, coolant line to turbocharger/charge air distribution line	Nm	9

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		ENGINE 642.82/83/85/86/87/886/9
BA14.20-P-1003-01G	Exhaust gas recirculation pipe to charge air distribution line	Nm	13

EXHAUST GAS RECIRCULATION

Number	Designation		ENGINE 642.82/83/85/86/87/886/9
BA14.20-P-1005-01G	Temperature sensor for exhaust gas temperature measurement	Nm	45

EXHAUST GAS RECIRCULATION

Number	Designation		ENGINE 642.82/83/85/86/87/886/9
BA14.20-P-1013-01G	Clamp, exhaust gas recirculation pipe to exhaust collector pipe	Nm	9

ENGINE LUBRICATION SYSTEM

Number	Designation			ENGINE 642.826/830/832/834/835/836/838/850/852/853/854/856/858/861/862/867/868 with CODE 474 (Particulate trap)
BF18.00-P-1001-01S	Engine oil	Filling capacity (oil and filter change)	Liter	8, 0
		Specification		Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
		Specification		Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1
		Specification		Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
		Specification		Low SPAsh multigrade service engine oils (specification 229.52). See https://bevo.mercedes-benz.com/index.php?language_id=1

Fig 2: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

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