Remove/Install Turbocharger - AR09.40-P-6020CDA

ENGINE 651 in MODEL 166, 172, 204, 207, 212 (except 212.098/298), 218, 221 

For sequential turbocharging 

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	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 on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Remove air filter housing		AR09.10-P-1150CD
2	Remove engine air intake duct downstream of air filter		AR09.10-P-8130CD
3.1	Remove boost pressure control flap aneroid capsule (1)	Model 204, 207, 212 (except 212.098/298), 218, 221 Adjust boost pressure control flap aneroid capsule (1).	AR09.40-P-1002-01CD
		Bolt, bracket for vacuum cell to exhaust gas turbocharger	*BA09.40-P-1013-01P
		Nut, vacuum unit to turbocharger "Yellow" locking paint	*BA09.40-P-1012-01P  *BR00.45-Z-1027-07A
		Vacuum tester	Figure
		Hand vacuum pump	Figure
3.2	Pull off vacuum hose (2)	MODEL 166, 172
4	Unclip electrical wiring harness for temperature sensor upstream of ATL (B19/11) on air filter housing bracket at the front (6) and remove screw/bolt (7)	Bolt for oil line bracket	*BA09.40-P-1004-01P
5	Remove screw/bolts (9) and take off air filter housing bracket at the front (6)	Screw/bolt, air filter bracket to cylinder head	*BA09.10-P-1001-01K
6	Disconnect electrical connector (10) for glow output stage (N14/3)
7	Detach vacuum hoses (11)
8	Remove oil line feed line for turbocharger	Removal  : Only remove the section between cylinder crankcase and bracket.	AR09.40-P-6022CD
9	Remove temperature sensor upstream of ATL (B19/11)		AR07.04-P-0071CD
10.1	Remove corresponding underfloor paneling	MODEL 166	AR61.30-P-1001GQ
10.2	Remove bottom sections of soundproofing	Engine 651 in model 172, 204.0/2/3, 207, 212 (except 212.098/298), 218,
		MODEL 172.4	AR94.30-P-5300W
		MODEL 204.0/2/3, 207, 212 (except 212.098/298), 218	AR94.30-P-5300EW
10.3	Remove engine compartment paneling	MODEL 204.9	AR61.20-P-1105CY
10.4	Remove lower engine compartment paneling	Model 221 except code Z07 (Highest protection)	AR61.20-P-1105SX
11.1	Remove catalytic converter diesel particulate filter unit	Model 166, 172, 204 (except 204.9), 207, 212 (except 212.08/09/28/29), 218, 221
		MODEL 166	AR49.10-P-5501GQ
		Model 172, 204 (except 204.9), 207, 212 (except 212.08/09/28/29), 218	AR49.10-P-5501CD
		MODEL 221	AR49.10-P-5501SXI
11.2	Remove catalytic converter	MODEL 204.9, 212.08/09/28/29	AR49.10-P-5500OMD
12	Remove charge air hose upstream of charge air cooler		AR09.41-P-8619CD
13.1	Loosen alternator and place down to front	Engine 651 in model 166 For sequential turbochargingEngine 651 in model 172, 204, 207, 212 (except 212.098/298), 218, 221 with transmission 722.9 (except 722.96) For sequential turbocharging MODEL 166	AR15.40-P-5032GR
		Model 172, 204, 207, 212 (except 212.098/298), 218, 221 with transmission 722.9 (except 722.96),	AR15.40-P-5032CD
13.2	Remove alternator	Model 204, 212 with transmission 722.96	AR15.40-P-5032CD
14	Remove oil line return for turbocharger	Engine 651 in model 166, 172, 204, 207, 212 (except 212.098/298), 218, 221 For sequential turbocharging Engine 651 in model 204, 207, 212 (except 212.098/298), 218, 221 For sequential turbocharging Replace seal.	AR09.40-P-6021CD
15	Remove screw/bolts (12, 13) and take off front turbocharger support brace (14)	Bolt, turbocharger bracket to turbocharger bypass flap	*BA09.40-P-1007-01P
		Bolt, turbocharger bracket to engine support/major assembly carrier	*BA09.40-P-1008-01P
16	Remove screw/bolts (15, 16) and take off rear turbocharger support brace (17)	Replace screw/bolts (15, 16). Bolt, turbocharger bracket to rear/center to turbocharger	*BA09.40-P-1002-01P
		Bolt, bracket for rear/center exhaust gas turbocharger to crankcase	*BA09.40-P-1003-01P
17	Remove screw/bolts (18)	Install new screw/bolts (18) and seal. Flange connection, exhaust manifold to exhaust gas turbocharger	*BA09.40-P-1001-01P
18	Remove turbocharger upwards
19	Install in the reverse order
	Check
20	Check engine oil level, correct if necessary	The engine oil level must lie between "Min" and "Max". Engine damage can occur otherwise.
	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 buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
21	Perform an engine test run and check engine around the turbocharger for leaktightness

Fig 1: Identifying Vacuum Tester (201 589 13 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Hand Vacuum Pump (001 589 73 21 00)

Courtesy of MERCEDES-BENZ USA