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

Engine 264 in model 213, 238, 257 

Fig 1: Turbocharger With Exhaust Manifold Components Location - Engine 264 In Model 213

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
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-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 upper engine cover after the leak test.	AR09.10-P-8131MRH
2	Remove inerting line from exhaust gas turbocharger (1) and place to one side.	Engine 264 in model 213, 238, 257 with code 2U8 (Alternative refrigerant)	AR86.10-P-0419LWE
3	Remove exhaust gas turbocharger heat shield (1).	Screw/bolt, heat shield to cylinder head	*BA09.40-P-1013-02C
4	Drain off coolant.	Engine 264 in model 213, 238	AR20.00-P-1142MRH
		Engine 264 in model 257 Only install lower engine compartment paneling after leak test.	AR20.00-P-1142MSB
5	Remove catalytic converter from crankcase bracket.		AR49.20-P-0100MRH
6	Remove catalytic converter from exhaust gas turbocharger (1) and secure against falling down.		AR49.20-P-0100MRH
7	Release and disconnect electrical connector (2).
8	Remove full load bleed line from exhaust gas turbocharger (1).		AR01.20-P-0020MRH
9	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
10	Remove coolant return line of exhaust gas turbocharger (1) and seal openings with suitable stop plugs.		AR09.40-P-6020-18MRH
		Lubricant, rubber assembly 1 l	*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
11	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
		Lubricant, rubber assembly 1 l	*BR00.45-Z-1010-06A
		Record plug	Fig 2
12	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		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
13	Remove oil return feed line of exhaust gas turbocharger (1) from 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
14	Loosen nut (8).	Nut, support brace to turbocharger	*BA09.40-P-1010-02C
15	Loosen screws/bolts (5).	Bolt, support to support/exhaust gas turbocharger	*BA09.40-P-1012-02C
16	Remove screw/bolt (6).	Bolt, turbocharger support brace to crankcase	*BA09.40-P-1011-02C
17	Unscrew nuts of exhaust gas turbocharger (1) in reverse order to 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
18	Remove exhaust gas turbocharger (1) with brackets (7) and oil return feed line.	Install new seal (9).
19	Remove brackets (7) from exhaust gas turbocharger (1).	Only when replacing ATL (1).
20	Remove oil return feed line from exhaust gas turbocharger (1).	Only when replacing ATL (1).	AR09.40-P-6020-19MRH
		Bolt, oil return flow line to turbocharger	*BA09.40-P-1005-02C
	Clean
21	Clean sealing surfaces of exhaust gas turbocharger (1) and cylinder head.
	Check
22	Check stud bolts of exhaust gas turbocharger (1) for damage and replace if necessary.	Stud bolt for exhaust manifold	*BA01.30-P-1004-01BA
23	Install in the reverse order.
24	Check and correct engine oil level.
		Engine 264 in model 238	AP18.00-P-1812EKI
		Engine 264 in model 213	AP18.00-P-1812MKI
		Engine 264 in model 257	AP18.00-P-1812BKI
	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
25	Carry out engine test run and check engine for proper leaktightness and leaktightness.
26	Install lower engine compartment lining.	Engine 264 in model 257	AR61.20-P-1105FR
		Engine 264 in model 213, 238	AR61.20-P-1105LWE
27	Install upper engine cover.		AR01.10-P-2405MRH

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-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 l	A 000 989 03 67