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

Engine 642 in model 166, 292 

Fig 1: Turbocharger Components Location - Engine 642 In Model 166

Courtesy of MERCEDES-BENZ USA

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.		AR20.00-P-1142GQ
	Notes on coolant		AH20.00-N-2080-01A
2	Remove bulkhead.
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 connector (2) from exhaust pressure sensor.
6	Remove engine charge air duct at exhaust gas 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 lifting lug (4) on right cylinder head cover.	Bolt, lifting eye to cylinder head	*BA01.30-P-1006-01S
10	Remove exhaust gas recirculation actuator.	Engine 642 in model 166, 292 with code 927 (EU6 emissions standard)	AR14.20-P-1020OGS
		Engine 642 in model 166, 292 except code 927 (EU6 emissions standard)	AR14.20-P-1020OGR
11	Remove oxygen sensor upstream of catalytic converter.		AR07.04-P-0080OGR
12	Remove exhaust pipe from exhaust gas turbocharger (1) and lay outside the working area.		AR49.10-P-5532OGR
		When working on the ATL (1), do not bend or turn exhaust pipe. This can result in leakage.
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 screws (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 screws (13) at oil supply connection fitting.	Fit bolt, turbocharger to oil supply connection fitting	*BA09.40-P-1010-01K
18	Disconnect electrical connector on temperature sensor upstream of exhaust gas turbocharger (B19/11).
19	Disconnect electrical connection from charge pressure positioner (Y77/1).
20	Remove exhaust gas turbocharger (1) and close off openings with a suitable 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	Fig 2
		Set of protective covers	Fig 3
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 exhaust gas turbocharger (B19/11).	Only when replacing the ATL (1)
		Observe installation position of temperature sensor upstream of exhaust gas turbocharger (B19/11); mark it if necessary. If a new temperature sensor is installed upstream of exhaust gas turbocharger (B19/11), bring this into the same position as the old temperature sensor upstream of exhaust gas turbocharger (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	Remove exhaust collector pipe (10) from exhaust gas turbocharger (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)	AR09.40-P-6024-15A
		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.
		Screw/bolt, turbocharger to exhaust collector pipe	*BA09.40-P-1011-01K
	Clean
24	Clean sealing surfaces on exhaust manifold (16, 17) and on exhaust collector pipe (10).
25	Clean sealing surfaces on exhaust gas 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 boost pressure regulator (Y77/1).	Only when replacing the ATL (1)
			AD00.00-P-2000-04A
28	Check engine oil level.		AR18.00-P-3035-01SXI
		The vehicle must be horizontal and standing on its wheels. In order to avoid measurement errors. Check engine oil level about 5 min. after switching off warm engine.
		Engine oil	*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
29	Check for leaktightness when engine is running.

Fig 2: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA