Remove/Install Turbocharger With Exhaust Manifold - AR09.40-P-6036MRI

Engine 264 in model 205, 253 

Fig 1: Turbocharger With Exhaust Manifold Components Location - Engine 264 In Model 205

Courtesy of MERCEDES-BENZ USA

	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
	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 pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	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 hazard area.	AS49.00-Z-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove/install
1	Remove air intake pipe (3).	Only install engine cover after the leak test.	AR09.10-P-8131MRI
2	Remove inerting line from exhaust gas turbocharger (1) and place to one side.	Engine 264 in model 205, 253 with code 2U8 (Alternative refrigerant)	AR86.10-P-0419LWE
3	Remove heat shield of exhaust gas turbocharger (1).	Screw/bolt, heat shield to cylinder head	*BA09.40-P-1013-02C
4	Drain off coolant.	Only install engine compartment paneling after leak test.	AR20.00-P-1142MRI
5	Remove catalytic converter from crankcase bracket and the exhaust gas turbocharger (1).		AR49.20-P-0100MRI
		Secure the catalytic converter so that it does not fall.
6	Release and disconnect the electrical connector (2).
7	Remove wide open throttle bleed line from exhaust gas turbocharger (1).		AR01.20-P-0020MRI
8	Remove charge air line (4).	Screw/bolt, charge air manifold bracket to turbocharger	*BA09.41-P-1002-01ZA
		Clamp, charge air line to charge air cooler	*BA09.41-P-1004-03F
9	Remove coolant return line of exhaust gas turbocharger (1) and seal openings with suitable stop plugs.		AR09.40-P-6020-18MRH
		Replace screw/bolts.
		Lubricant, rubber assembly 1 I	*BR00.45-Z-1010-06A
		Bolt, coolant return flow line to cylinder head	*BA09.40-P-1009-02C
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1007-02C
		Record plug	Fig 2
10	Remove coolant feed line from exhaust gas turbocharger (1), place to one side and seal openings with suitable stop plugs.		AR09.40-P-6020-18MRH
		Replace screw/bolt.
		Bolt, coolant line feed line to coolant line	*BA09.40-P-1008-02C
		Lubricant, rubber assembly 1 I	*BR00.45-Z-1010-06A
		Record plug	Fig 2
11	Remove oil feed line from exhaust gas turbocharger (1), place to one side and seal openings with suitable stop plugs.		AR09.40-P-6020-19MRH
	Specified engine oils (service) - Overview	Replace screw/bolt.	BB00.40-P-0223-02A
		Screw/bolt, oil line for oil feed to exhaust gas turbocharger	*BA09.40-P-1003-02C
		Record plug	Fig 2
12	Remove oil return feed line of exhaust gas turbocharger (1) at crankcase.		AR09.40-P-6020-19MRH
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
		Bolt, oil return line to crankcase	*BA09.40-P-1006-02C
13	Release nut (8).	Replace nut (8).
		Nut, support brace to turbocharger	*BA09.40-P-1010-02C
14	Loosen bolts (5).	Replace screw/bolts (5).
		Bolt, support to support/exhaust gas turbocharger	*BA09.40-P-1012-02C
15	Remove screw (6).	Replace bolt (6).
		Bolt, turbocharger support brace to crankcase	*BA09.40-P-1011-02C
16	Remove nuts of exhaust gas turbocharger (1) in the order opposite that in the tightening procedure.	Tightening pattern for turbocharger	AR09.40-P-6020-10MRH
		Replace nuts.
		Nut, exhaust gas turbocharger (exhaust manifold) to cylinder head	*BA09.40-P-1001-02C
17	Remove exhaust gas turbocharger (1) with the brackets (7) and oil return feed line.	Install new seal (9).
18	Remove brackets (7) from exhaust gas turbocharger (1).	Only when replacing ATL (1).
19	Remove oil return feed line from exhaust gas turbocharger (1).	Only when replacing ATL (1).	AR09.40-P-6020-19MRH
		Replace screw/bolt.
		Bolt, oil return flow line to turbocharger	*BA09.40-P-1005-02C
	Clean
20	Clean sealing surfaces of exhaust gas turbocharger (1) and cylinder head.	Cleaner	*BR00.45-Z-1025-04A
	Check
21	Check stud bolts of the exhaust gas turbocharger (1) for damage.	Stud bolt for exhaust manifold If damage is present, ↓ Replace stud bolts of exhaust gas turbocharger (1).	*BA01.30-P-1004-01BA
22	Install in the reverse order.
23	Check engine oil level and correct if necessary.
			AP18.00-P-1812MKI
	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 o the hazard area.	AS49.00-Z-0001-01A
	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
24	Perform engine test run. While doing so, check engine for proper operation and leak tightness
25	Install engine compartment linings.		AR61.20-P-1105LW
26	Install engine cover.		AR01.10-P-2405MRI

CYLINDER HEAD

Number	Designation		Engine 264
BA01.30-P-1004-01BA	Stud bolt for exhaust manifold	Nm	11

TURBOCHARGER

Number	Designation			Engine 264
BA09.40-P-1001-02C	Nut, exhaust gas turbocharger (exhaust manifold) to cylinder head	Stage 1	Nm	15
		Stage 2	Nm	15

TURBOCHARGER

Number	Designation			Engine 264
BA09.40-P-1003-02C	Screw/bolt, oil line for oil feed to exhaust gas turbocharger	Stage 1	Nm	8
		Stage 2	∠°	60

TURBOCHARGER

Number	Designation			Engine 264
BA09.40-P-1005-02C	Bolt, oil return flow line to turbocharger	Stage 1	Nm	8
		Stage 2	∠°	60

TURBOCHARGER

Number	Designation		Engine 264
BA09.40-P-1006-02C	Bolt, oil return line to crankcase	Nm	9

TURBOCHARGER

Number	Designation			Engine 264
BA09.40-P-1007-02C	Bolt, coolant feed/return line to turbocharger	Stage 1	Nm	8
		Stage 2	∠°	60

TURBOCHARGER

Number	Designation			Engine 264
BA09.40-P-1008-02C	Bolt, coolant line feed line to coolant line	Stage 1	Nm	8
		Stage 2	∠°	60

TURBOCHARGER

Number	Designation			Engine 264
BA09.40-P-1009-02C	Bolt, coolant return flow line to cylinder head	Stage 1	Nm	8
		Stage 2	∠°	60

TURBOCHARGER

Number	Designation		Engine 264
BA09.40-P-1010-02C	Nut, support brace to turbocharger	Nm	30

TURBOCHARGER

Number	Designation			Engine 264
BA09.40-P-1011-02C	Bolt, turbocharger support brace to crankcase	Stage 1	Nm	15
		Stage 2	∠°	90

TURBOCHARGER

Number	Designation			Engine 264
BA09.40-P-1012-02C	Bolt, support to support/exhaust gas turbocharger	Stage 1	Nm	15
		Stage 2	∠°	90

TURBOCHARGER

Number	Designation		Engine 264
BA09.40-P-1013-02C	Screw/bolt, heat shield to cylinder head	Nm	9

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 264
BA09.41-P-1002-01ZA	Screw/bolt, charge air manifold bracket to turbocharger	Nm	9

CHARGE AIR COOLER

Number	Designation		Engine 264
BA09.41-P-1004-03F	Clamp, charge air line to charge air cooler	Nm	4

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

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1010-06A	Lubricant, rubber assembly 1 I	A 000 989 03 67
BR00.45-Z-1025-04A	Cleaner	A 005 989 19 71