Remove/Install Oil Return Flow Line Of Turbocharger - AR09.40-P-6021MSA

Engine 256.9 in model 213, 238, 257, 290 

MODIFICATION NOTES

13.07.2020	Addition of an operation step variant for removing/installing the catalytic converter/exhaust gas aftertreatment unit	Operation step 1.1/1.2
31.07.2020	Special tool 000 589 93 63 00 assembly tool added	Operation steps 3 and 5

Fig 1: Turbocharger Oil Return Line Component Location - Engine 256.9 In Model 257

Courtesy of MERCEDES-BENZ USA

	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 injury  to skin and eyes due to	Wear protective gloves, protective clothing	AS18.00-Z-0001-01A
	handling of engine oil. Risk of poisoning  caused by swallowing engine oil	and safety glasses. Do not fill engine oil into beverage containers.
	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
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove/install
1.1	Remove the catalytic converter.	Engine 256.9 in model 213, 238 up to model year 2020 Engine 256.9 in model 257, 290
		Do not install upper engine cover until after the leak test.	AR49.20-P-0100MSA
1.2	Remove exhaust gas aftertreatment unit.	Engine 256.9 in model 213, 238 as of model year 2020
		Do not install upper engine cover until after the leak test.	AR49.20-P-1500MSA
2	Remove heat shield (2).	Bolt, heat shield to timing case	*BA22.10-P-1005-02A
		Bolt, heat shield to engine support	*BA22.10-P-1003-02A
		Screw, heat shield to crankcase/catalytic converter bracket/engine mount heat shield	*BA22.10-P-1004-02A
3	Unscrew screw s (3), place coolant feed pipe (4) to one side, and close off openings using suitable stop plugs.	Replace sealing ring.
		Bolt, coolant feed pipe to crankcase	*BA15.40-P-1010-02MRT
		Assembly tool	Fig 2
		Record plug	Fig 4
4	Remove screws (5, 6, 7).	Bolt, oil return line to turbocharger/crankcase	*BA09.40-P-1008-02MRT
5	Remove oil return feed line (8) and seal openings with protective covers and suitable stop plugs.	Install new sealing rings.
		Assembly tool	Fig 2
		Set of protective caps	Fig 3
		Record plug	Fig 4
6	Install in the reverse order.
	Check
7	Check engine oil level and correct if necessary.
		Engine 256.9 in model 213, 238, 290	AP18.00-P-1812MKI
		Engine 256.9 in model 257	AP18.00-P-1812BKI
	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 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
8	Perform engine test run. While doing so, check engine for proper operation and leak tightness

TURBOCHARGER

Number	Designation			Engine 256.9
BA09.40-P-1008-02MRT	Bolt, oil return line to turbocharger/crankcase	Stage 1	Nm	8
		Stage 2	∠°	60

STARTER-ALTERNATOR

Number	Designation		Engine 256
BA15.40-P-1010-02MRT	Bolt, coolant feed pipe to crankcase	Nm	8

ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Engine 256
BA22.10-P-1003-02A	Bolt, heat shield to engine support	Nm	12

ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Engine 256
BA22.10-P-1004-02A	Screw, heat shield to crankcase/catalytic converter bracket/engine mount heat shield	Nm	8

ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Engine 256
BA22.10-P-1005-02A	Bolt, heat shield to timing case	Nm	8

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA