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

Engine 139 in model 118, 177, 247 

Fig 1: Turbocharger Components Location - Model 118 In Engine 139 (Shown On Model 177)

Courtesy of MERCEDES-BENZ USA

Shown on model 177 

	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
	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 danger zone.	AS49.00-Z-0001-01A
	Risk of injury  to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning  from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	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
	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
Notice	Notes on self-locking nuts and bolts		AH00.00-P-0001-01KOA
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove/install
1	Remove inertization line in engine compartment.	Engine 139 in model 118, 177, 247.7 with code 2U8 (Alternative refrigerant)	AR86.10-P-0119MFA
2	Drain off coolant.		AR20.00-P-1142MFG
3	Remove coolant feed line for exhaust gas turbocharger (1).	: Only install upper engine cover after the leak test.	AR20.20-P-1000MFG
4	Remove battery carrier.		AR54.10-P-0028MFA
5	Remove charge air pipe downstream of exhaust gas turbocharger (1).		AR09.41-P-1333MFG
6	Remove boost pressure control flap actuator (M16/7) from exhaust gas turbocharger (1).		AR09.50-P-8845MFG
7	Remove bolts (5, 6).	Screw, coolant return flow line to exhaust gas turbocharger/holder/heat shield/oil return feed line	*BA09.40-P-1006-01X
		Bolt, oil return line to turbocharger/crankcase/bracket	*BA09.40-P-1004-01X
8	Unscrew screw (7) and remove coolant return line (8) from exhaust gas turbocharger (1).	: Replace seal.
		Screw, coolant return flow line to exhaust gas turbocharger/holder/heat shield/oil return feed line	*BA09.40-P-1006-01X
		Assembly tool	Fig 2
9	Unscrew screw (9) and remove oil return feed line (10).	: Replace seal. Ensure that oil return feed line (10) is seated correctly. Aid of helper required.
		Bolt, oil return line to turbocharger/crankcase/bracket	*BA09.40-P-1004-01X
		Assembly tool	Fig 2
10	Release catalytic converter at its holders until flange on exhaust gas turbocharger (1) is exposed.	: Align catalytic converter such that it is free of tension.	AR49.20-P-0100MFG
11	Remove clamp (2).	: Replace clamp (2) and seal (11).
		Clamp, turbocharger to exhaust system	*BA09.40-P-1002-01X
12	Remove clamp (3).	: replace clamp (3). Clamp (3) is two-piece.
		Clamp, exhaust gas turbocharger to exhaust manifold	*BA09.40-P-1015-01X
13	Remove exhaust gas turbocharger (1).
14	Clean connections of exhaust system of corrosion and contamination.
15	Install in the reverse order.
	Concluding tasks
16	Check engine oil level and correct if necessary.
			AP18.00-P-1812AKI
	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
17	Perform engine test run. While doing so, check engine for proper operation and leak tightness.

Fig 2: Identifying Assembly Tool (000 589 93 63 00)

Courtesy of MERCEDES-BENZ USA