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

ENGINE 642 in MODEL 166, 292 

Shown on model 166 

	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
	Remove/install
1	Drain coolant at radiator Notes on coolant		AR20.00-P-1142GQ AH20.00-N-2080-01A
2	Remove bulkhead wall
3	Remove windshield wiper system		AR82.30-P-6400GZ
4	Remove engine air intake duct downstream of air filter		AR09.10-P-8130OGR
5	Detach electrical connection (2) from exhaust pressure sensor
6	Remove engine charge air duct on turbocharger (1)		AR09.41-P-8622OGR
7	Remove rear bracket for engine cover	Engine 642 in model 292
8	Remove heat protection (3)
9	Remove engine suspension lug (4) on right cylinder head cover	Bolt, lifting eye to cylinder head	*BA01.30-P-1006-01S
10	Remove exhaust gas recirculation actuator		AR14.20-P-1020OGR
11	Remove oxygen sensor upstream of catalytic converter		AR07.04-P-0080OGR
12	Detach exhaust pipe on ATL (1) and lay outside the working area	When working on the ATL (1), do not bend or turn exhaust pipe. This can result in leakage.	AR49.10-P-5532OGR
13	Remove exhaust gas recirculation line (5)	Replace seals and screw/bolts (6). Check clamp (7) for damage; replace if necessary. EGR line to charge air distributor	*BA14.20-P-1003-01G
		Clamp, EGR line to exhaust collector pipe	*BA14.20-P-1013-01G
14	Remove screw/bolts (8) from exhaust collector pipe (10)	Replace screw/bolts (8). Flange connection, exhaust manifold/front exhaust pipes to exhaust collector pipe	*BA14.10-P-1001-01L
15	Remove screw/bolts (9) from crankcase	Bolt, support for exhaust collector pipe to crankcase	*BA09.40-P-1007-01K
16	Unfasten screw/bolt (11) for coolant line (12)	Bolt, coolant line to exhaust gas turbocharger/charge air distributor	*BA09.40-P-1013-01K
17	Remove screw/bolts (13) from oil supply connection fitting	Fit bolt, turbocharger to oil supply connection fitting	*BA09.40-P-1010-01K
18	Disconnect electrical connection on temperature sensor upstream of ATL (B1911)
19	Disconnect electrical connection from charge pressure positioner (Y77/1)
20	Remove ATL (1) and close off openings with grommet	Replace seal (14) and align according to the hole pattern. Leaks can occur otherwise. Do not cover the oil supply duct. Helper required. Install new seals (15). Replace seal for coolant line (12) on charge air distributor. Record plug	Figure
		Set of protective covers	Figure
21	Remove coolant line (12)	Only when replacing the ATL (1) Replace seal for coolant line (12) on ATL (1).
22	Remove temperature sensor upstream of ATL (B19/11)	Only when replacing the ATL (1) Observe installation position of the temperature sensor upstream of ATL (B19/11); mark it if necessary. If a new temperature sensor is installed upstream of the ATL (B19/11), this must be brought into the same position as the old temperature sensor upstream of ATL (B19/11). Temperature sensor for exhaust gas temperature measurement	*BA14.20-P-1005-01G
		Paste, hot lubrication 1 kg, DBL 6879.20	*BR00.45-Z-1005-06A
23	Detach exhaust collector pipe (10) from ATL (1)	Only if there are leaks between the exhaust collector pipe (10) and ATL (1), or when replacing the ATL (1) Replace seal between ATL (1) and exhaust collector pipe (10) For stress-free assembly, a provisional installation to position the exhaust collector pipe (10) on the ATL (1) is necessary. Consequential damage can occur on the exhaust manifold (16, 17) otherwise. Replace screw/bolts.	AR09.40-P-6024-15A
		Screw/bolt, turbocharger to exhaust collector pipe	*BA09.40-P-1011-01K
	Clean
24	Clean sealing surfaces on exhaust manifold (16, 17) and on the exhaust collector pipe (10)
25	Clean sealing surfaces on turbocharger (1)	When reusing the ATL (1)
26	Install in the reverse order
	Check
27	Connect diagnostic system, read out fault memory, if necessary clear it and perform initialization of the boost pressure regulator (Y77/1)	Only when replacing the ATL (1)	AD00.00-P-2000-04A
28	Check engine oil level	The vehicle must be horizontal and standing on its wheels. This prevents measurement errors. Check engine oil level about 5 min. after switching off warm engine.	AR18.00-P-3035-01SXI
		Engine 642.826 with code 474 (Diesel particulate filter) Engine oil	*BF18.00-P-1001-01S
29	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. Check for leaktightness with engine 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

Fig 1: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA