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Home >> Mercedes Benz >> 2021 >> C300 Base, 2D Convertible >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Air Intake, Turbocharging - 205 Chassis >> Testing & Repair >> Remove/Install Turbocharger With Exhaust Manifold - AR09.40-P-6036MRI

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
G14184995Courtesy of MERCEDES-BENZ USA
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
WARNING 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
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
  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
REMOVINGINSTALLING Remove/install     
1 Remove air intake pipe (3). INSTALLATION IMPORTANT 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). TORQUE SPECIFICATION Screw/bolt, heat shield to cylinder head *BA09.40-P-1013-02C 
4 Drain off coolant. INSTALLATION IMPORTANT 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
    IMPORTANT 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). TORQUE SPECIFICATION Screw/bolt, charge air manifold bracket to turbocharger *BA09.41-P-1002-01ZA 
    TORQUE SPECIFICATION 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 
    INSTALLATION IMPORTANT Replace screw/bolts.  
    Lubricant, rubber assembly 1 I *BR00.45-Z-1010-06A 
    TORQUE SPECIFICATION Bolt, coolant return flow line to cylinder head *BA09.40-P-1009-02C 
    TORQUE SPECIFICATION Bolt, coolant feed/return line to turbocharger *BA09.40-P-1007-02C 
    SPECIAL TOOL 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 
    INSTALLATION IMPORTANT Replace screw/bolt.  
    TORQUE SPECIFICATION Bolt, coolant line feed line to coolant line *BA09.40-P-1008-02C 
    Lubricant, rubber assembly 1 I *BR00.45-Z-1010-06A 
    SPECIAL TOOL 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 
       
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils (service) - Overview INSTALLATION IMPORTANT Replace screw/bolt. BB00.40-P-0223-02A
    TORQUE SPECIFICATION Screw/bolt, oil line for oil feed to exhaust gas turbocharger *BA09.40-P-1003-02C 
    PASSENGER CAR Record plug Fig 2
12 Remove oil return feed line of exhaust gas turbocharger (1) at crankcase.   AR09.40-P-6020-19MRH 
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils (service) - Overview   BB00.40-P-0223-02A
    TORQUE SPECIFICATION Bolt, oil return line to crankcase *BA09.40-P-1006-02C 
13 Release nut (8). INSTALLATION IMPORTANT Replace nut (8).  
    TORQUE SPECIFICATION Nut, support brace to turbocharger *BA09.40-P-1010-02C 
14 Loosen bolts (5). INSTALLATION IMPORTANT Replace screw/bolts (5).  
    TORQUE SPECIFICATION Bolt, support to support/exhaust gas turbocharger *BA09.40-P-1012-02C 
15 Remove screw (6). INSTALLATION IMPORTANT Replace bolt (6).  
    TORQUE SPECIFICATION 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 
    INSTALLATION IMPORTANT Replace nuts.  
    TORQUE SPECIFICATION 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. INSTALLATION IMPORTANT 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 
    INSTALLATION IMPORTANT Replace screw/bolt.  
    TORQUE SPECIFICATION Bolt, oil return flow line to turbocharger *BA09.40-P-1005-02C 
CLEAN Clean     
20 Clean sealing surfaces of exhaust gas turbocharger (1) and cylinder head. Cleaner *BR00.45-Z-1025-04A 
INSPECT Check     
21 Check stud bolts of the exhaust gas turbocharger (1) for damage. TORQUE SPECIFICATION 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.    
REFER TO MAINTENANCE     AP18.00-P-1812MKI
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 o the hazard area. AS49.00-Z-0001-01A
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
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)
G11065549Courtesy 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
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