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Home >> Mercedes Benz >> 2017 >> GT AMG >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Air Intake, Turbocharging -- 190 Chassis >> Testing & Repair >> Remove/Install Turbocharger >> Remove/Install Left Turbocharger - AR09.40-P-6026MNJ

Remove/Install Left Turbocharger - AR09.40-P-6026MNJ

Engine 178.9 in model 190.381 

G16681461Courtesy of MERCEDES-BENZ USA
G16681462Courtesy of MERCEDES-BENZ USA
G16681463Courtesy of MERCEDES-BENZ USA
WARNING 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
WARNING 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
WARNING Risk of burn injuries  , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning  caused by skin contact with solid components of the exhaust. Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. AS49.00-Z-0001-01A
CAUTION 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
CAUTION 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
Topical note  Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
REMOVING Remove     
1 Drain off coolant.   AR20.00-P-1142MNJ
2 Remove left and right air filter housing. Left air filter housing AR09.10-P-1151MNJ 
    Right air filter housing AR09.10-P-1152MNJ 
3 Remove catalytic converters and place to one side.   AR49.10-P-5500MNB
4 Unclip purge line (11) and bleed line (12) and place outside of working area.    
5 Remove charge air hose (8) from left exhaust gas turbocharger (1) and seal opening with a suitable rag. SPECIAL TOOL Hose clamp pliers Fig 2
6 Remove vacuum line (2) from left, right vacuum cell and from switchover valve.    
7 Release clamp on left exhaust gas turbocharger (1) and remove clean air lines (10) from the left exhaust gas turbocharger (1).    
8 Remove boot (3) from left exhaust gas turbocharger (1).    
9 Remove charge air hose (9) to the charge air cooler from the left exhaust gas turbocharger (1) and seal opening with a suitable rag.    
10 Remove oil feed line (4).   AR09.40-P-6040MNJ 
11 Remove coolant circuit return line.   AR20.20-P-1101MNA
12 Remove coolant feed pipe (5) from right exhaust gas turbocharger (6) and seal openings with suitable stop plugs. SPECIAL TOOL Record plug Fig 4
13 Remove coolant feed pipe (5) from cylinder head and seal openings with suitable stop plugs. SPECIAL TOOL Record plug Fig 4
14 Remove clamp (14).    
15 Remove left exhaust gas turbocharger (1) upwards and seal all openings with suitable rags.    
16 Remove oil return feed line (18) from left exhaust gas turbocharger (1). Only when replacing left exhaust gas turbocharger (1). AR09.40-P-6043MNA 
17 Remove coolant feed pipe (5) from left exhaust gas turbocharger (1) and seal openings with suitable stop plugs. Only when replacing left exhaust gas turbocharger (1).  
    SPECIAL TOOL Record plug Fig 4
INSTALLING Install     
18 Remove stop plug from coolant feed pipe (5) and fit to left exhaust gas turbocharger (1). Only when replacing left exhaust gas turbocharger (1).  
    IMPORTANT Install new sealing rings.
Wet sealing rings with lubricant.		  
    TORQUE SPECIFICATION Bolt, coolant line to turbocharger/cylinder head *BA09.40-P-1004-01ZA 
    Lubricant, rubber assembly 1 L *BR00.45-Z-1010-06A 
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Record plug Fig 4
19 Attach oil return feed line (18) with sealing rings (28) at left exhaust gas turbocharger (1). Only when replacing left exhaust gas turbocharger (1).  
    IMPORTANT Replace oil return line (18) and sealing rings (28).
Wet sealing rings (28) with lubricant.		 AR09.40-P-6043MNA 
    TORQUE SPECIFICATION Bolt, oil return line to turbocharger/crankcase *BA09.40-P-1003-01ZA 
    Lubricant, rubber assembly 1 L *BR00.45-Z-1010-06A 
    SPECIAL TOOL Assembly tool Fig 1
20 Position clamp (14) on left exhaust manifold and align according to assembly specifications.   AR09.40-P-6017-01MNE 
    IMPORTANT Install new clamp (14).  
21 Remove rags from the openings and install left exhaust gas turbocharger (1). IMPORTANT Install new seal on left exhaust manifold.  
22 Install template at left exhaust gas turbocharger (1) and right exhaust gas turbocharger (6) and tighten screws for securing oil feed line (4). SPECIAL TOOL Template Fig 3
23 Tighten clamp (14). TORQUE SPECIFICATION Bolt, turbocharger clamp to exhaust manifold *BA09.40-P-1001-01ZA 
24 Remove template from left exhaust gas turbocharger (1) and right exhaust gas turbocharger (6). SPECIAL TOOL Template Fig 3
25 Remove stop plug from the coolant feed pipe (5). SPECIAL TOOL Record plug Fig 4
26 Install coolant feed pipe (5) at cylinder head. IMPORTANT Replace sealing rings and coat with lubricant.  
    TORQUE SPECIFICATION Bolt, coolant line to turbocharger/cylinder head *BA09.40-P-1004-01ZA 
    Lubricant, rubber assembly 1 L *BR00.45-Z-1010-06A 
    SPECIAL TOOL Assembly tool Fig 1
27 Remove stop plug from the coolant feed pipe (5). SPECIAL TOOL Record plug Fig 4
28 Attach coolant feed pipe (5) to the right exhaust gas turbocharger (6). IMPORTANT Replace sealing rings and coat with lubricant.  
    TORQUE SPECIFICATION Bolt, coolant line to turbocharger/cylinder head *BA09.40-P-1004-01ZA 
    Lubricant, rubber assembly 1 L *BR00.45-Z-1010-06A 
    SPECIAL TOOL Assembly tool Fig 1
29 Install coolant circuit return line.   AR20.20-P-1101MNA
30 Install oil feed line (4).   AR09.40-P-6040MNJ 
31 Remove rag from opening and attach charge air hose (9) to charge air cooler at left exhaust gas turbocharger (1). TORQUE SPECIFICATION Bolt, clamp for charge air hose to charge-air distributor *BA09.41-P-1002-01X 
32 Install boot (3) at left exhaust gas turbocharger (1). TORQUE SPECIFICATION Clamp, boot to exhaust gas turbocharger/air filter *BA01.20-P-1003-01J 
33 Attach clean air lines (10) at left exhaust gas turbocharger (1). TORQUE SPECIFICATION Clamp, boot to exhaust gas turbocharger/air filter *BA01.20-P-1003-01J 
34 Install vacuum line (2) at left, right vacuum cell and switchover valve. IMPORTANT Install new vacuum line (2).  
35 Remove rag from opening and attach charge air hose (8) at left exhaust gas turbocharger (1). SPECIAL TOOL Hose clamp pliers Fig 2
36 Clip in purge line (11) and bleed line (12).    
37 Attach catalytic converters.   AR49.10-P-5500MNB
    IMPORTANT Only install lower Engine compartment lining after leak test.  
38 Install left and right air filter housing. Left air filter housing AR09.10-P-1151MNJ 
    Right air filter housing AR09.10-P-1152MNJ 
    IMPORTANT Do not install upper Engine cover until after the leak test.  
39 Fill in coolant.   AR20.00-P-1142MNJ
INSPECT Check     
40 Check Engine oil level and correct if necessary.    
REFER TO MAINTENANCE     AP18.00-P-1811MP
WARNING 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
41 Perform Engine test run. While doing so, check Engine for proper operation and leak tightness.    
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number Designation Engine 178
BA01.20-P-1003-01J Clamp, boot to exhaust gas turbocharger/air filter Nm 1, 5
TURBOCHARGER

Number Designation Engine 178
BA09.40-P-1001-01ZA Bolt, turbocharger clamp to exhaust manifold Nm 21
TURBOCHARGER

Number Designation Engine 178
BA09.40-P-1003-01ZA Bolt, oil return line to turbocharger/crankcase Nm 9
TURBOCHARGER

Number Designation Engine 178
BA09.40-P-1004-01ZA Bolt, coolant line to turbocharger/cylinder head Nm 9
CHARGE AIR LINE/CHARGE AIR COOLING

Number Designation Engine 178
BA09.41-P-1002-01X Bolt, clamp for charge air hose to charge-air distributor Nm 7
Fig 1: Identifying Assembly Tool (000 589 93 63 00)
G12939678Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Hose Clamp Pliers (454 589 00 37 00)
G12939525Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Template (177 589 00 23 00)
G13656309Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Record Plug (129 589 00 91 00)
G09975019Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 L A 000 989 03 67
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