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

ENGINE 133 in MODEL 117, 156, 176 

MODIFICATION NOTES

27.01.2016 Cover alternator, added. Operation step 11  
27.06.2016 Document completely revised.    
Fig 1: Turbocharger Remove/Install Components (1 Of 3)
G11065596Courtesy of MERCEDES-BENZ USA
Fig 2: Turbocharger Remove/Install Components (2 Of 3)
G11065597Courtesy of MERCEDES-BENZ USA
Fig 3: Turbocharger Remove/Install Components (3 Of 3)
G11065598Courtesy of MERCEDES-BENZ USA
DANGER Risk of injury  to skin and eyes due to handling of engine oil. Risk of poisoning  caused by swallowing engine oil Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.		 AS18.00-Z-0001-01A
DANGER 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
DANGER Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from swallowing coolant. Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
DANGER Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
NOTES Notes on coolant   AH20.00-N-2080-01A
NOTES Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
IMPORTANT Notes on coolant level   AH20.00-P-1142-01CW
REMOVING Remove     
1 Remove engine cover    
2 Drain off coolant   AR20.00-P-1142MTA
3 Remove air filter housing   AR09.10-P-1150MTA 
4 Expose purge lines on cylinder head cover    
5 Detach air intake pipe and place with attached purge lines to one side   AR09.10-P-8131MTA 
6 Detach vacuum line from aneroid capsule (7)    
7 Release and disconnect electrical connection at electronic wastegate   AR09.40-P-0001MTA 
8 Remove heat shield at ATL    
9 Detach charge air hose upstream of charge air cooler at ATL    
10 Remove screw/bolts (1) and profiled clamp (2)    
11 Cover alternator IMPORTANT When removing the ATL, the alternator must always be covered up to prevent any ingress of coolant or engine oil.  
12 Remove oil lines   AR18.30-P-6850MTA
13 Remove coolant lines   AR20.20-P-7440MTA
14 Unclip electrical lines of the oxygen sensor downstream of CAT (G3/1) and oxygen sensor upstream of CAT (G3/2)   AR07.52-P-5303MTA
IMPORTANT Do not disconnect electrical connections.  
15 Loosen clamp (3)    
16 Place CAT (6) to one side IMPORTANT The CAT (6) remains in the elastomer bearing (4).  
17 Unscrew nut (8) with a suitable tool from below through the opening in heat shield of the exhaust manifold    
18 Unscrew nuts (9)    
19 Remove screw/bolts (10)    
20 Lift ATL up and out    
21 Replace seal between exhaust manifold and ATL    
22 Detach bracket (11) from ATL Only if the bracket (11) is replaced.  
23 Remove electronic wastegate Only if ATL is replaced.  
  AR09.40-P-0001MTA 
INSPECT Check     
24 Check stud bolts of the ATL for damage, for firm seating and replace if necessary    
INSTALLING Install     
25 Install electronic wastegate Only if ATL is replaced.  
  AR09.40-P-0001MTA 
26 Take off new bracket (11) at ATL Only if the bracket (11) is replaced.
IMPORTANT Only for a new bracket (11) there are aluminum plates present which serve as an assembly aid.		  
TORQUE SPECIFICATION Bolt, bracket to turbocharger *BA09.40-P-1011-01X 
27 Install a new seal between ATL and exhaust manifold    
28 Install ATL    
29 Align bracket (11) on cylinder head    
30 Screw in new screw/bolts (10) and tighten TORQUE SPECIFICATION Bolt, bracket to cylinder head/bracket *BA09.40-P-1010-01X 
31 Remove the aluminum plates Only if the bracket (11) is replaced.
IMPORTANT The aluminum plates only serve as an assembly aid and must be removed.		  
32 Tighten new nuts (9) TORQUE SPECIFICATION Nut, turbocharger to exhaust manifold *BA09.40-P-1001-01X 
33 Tighten down new nut (8) with a suitable tool from below through the opening in heat shield of the exhaust manifold TORQUE SPECIFICATION Nut, turbocharger to exhaust manifold *BA09.40-P-1001-01X 
34 Install catalytic converter (6)    
35 Tighten clamp (3) TORQUE SPECIFICATION Clamp, front exhaust system to catalytic converter *BA49.10-P-1020-01AL 
36 Clip in electrical lines of the oxygen sensor downstream of CAT (G3/1) and oxygen sensor upstream of CAT (G3/2)   AR07.52-P-5303MTA
37 Install coolant lines   AR20.20-P-7440MTA
38 Install oil lines   AR18.30-P-6850MTA
39 Cover alternator    
40 Install new profiled clamp (2), screw in screw/bolts (1) and tighten TORQUE SPECIFICATION Clamp, catalytic converter to turbocharger *BA49.10-P-1014-01AL 
41 Attach charge air hose upstream of charge air cooler at ATL    
42 Install heat shield at ATL TORQUE SPECIFICATION Bolt, heat shield to bracket *BA09.40-P-1009-01X 
43 Connect and lock electrical connection at electronic wastegate   AR09.40-P-0001MTA 
44 Attach vacuum line to aneroid capsule (7)    
45 Attach air intake pipe   AR09.10-P-8131MTA 
46 Attach purge lines at cylinder head cover IMPORTANT Replace cable tie.  
47 Install air filter housing   AR09.10-P-1150MTA 
48 Pour in coolant   AR20.00-P-1142MTA
49 Install engine cover    
INSPECT Check     
50 Check engine oil level and correct if necessary    
REFER TO MAINTENANCE     AP18.00-P-0101AHH
DANGER 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
51 Carry out engine test run and check engine for proper leaktightness and function    
TURBOCHARGER

Number Designation Engine 133
BA09.40-P-1001-01X Nut, turbocharger to exhaust manifold Nm 21
TURBOCHARGER

Number Designation Engine 133
BA09.40-P-1009-01X Bolt, heat shield to bracket Nm 9
TURBOCHARGER

Number Designation Engine 133
BA09.40-P-1010-01X Bolt, bracket to cylinder head/bracket Stage 1 Nm 20
Stage 2 ∠° 90
TURBOCHARGER

Number Designation Engine 133
BA09.40-P-1011-01X Bolt, bracket to turbocharger Nm 20
EXHAUST SYSTEM

Number Designation Engine 133 in model 117 Engine 133 in model 156
BA49.10-P-1014-01AL Clamp, catalytic converter to turbocharger M8 Nm 20 20
EXHAUST SYSTEM

Number Designation Engine 133 in model 176
BA49.10-P-1014-01AL Clamp, catalytic converter to turbocharger M8 Nm 20
EXHAUST SYSTEM

Number Designation Engine 133 in model 117 Engine 133 in model 156
BA49.10-P-1020-01AL Clamp, front exhaust system to catalytic converter Nm 35 35
EXHAUST SYSTEM

Number Designation Engine 133 in model 176
BA49.10-P-1020-01AL Clamp, front exhaust system to catalytic converter Nm 35
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