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Home >> Mercedes Benz >> 2021 >> Metris Van Cargo >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Air Intake, Turbo Charging -- 447 Chassis >> Testing & Repair >> Remove/Install Turbocharger With Exhaust Manifold - AR09.40-S-6036EG

Remove/Install Turbocharger With Exhaust Manifold - AR09.40-S-6036EG

Model 447, 448 with engine 274 

MODIFICATION NOTES

01.12.2023 Screw, heat shield to cylinder head   BA09.40-Z-1013-02KOF
01.12.2023 Screw, oil return line to crankcase   BA09.40-Z-1007-02KOF
01.12.2023 Screw, oil return line to turbocharger   BA09.40-Z-1006-02KOF
01.12.2023 Bolt, oil feed line to crankcase   BA09.40-Z-1005-02KOF
01.12.2023 Bolt, oil feed line to exhaust gas turbocharger   BA09.40-Z-1004-02KOF
25.03.2024 Screw, heat shield to cylinder head   BA09.40-Z-1013-02KOF
29.04.2024 Change notice (AH) document reference, added Information block AR09.40-S-6020-19EG
29.04.2024 Change notice (AH) document reference, added Information block  
G16484739Courtesy of MERCEDES-BENZ USA
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
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 overpressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
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
Notice  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
REMOVINGINSTALLING Remove/install     
1 Drain off coolant.   AR20.00-S-1140E
2 Remove air intake pipe from exhaust gas turbocharger (3) and place to one side.   AR09.10-S-8131EG 
3 Remove engine charge air duct on exhaust gas turbocharger (3).   AR09.41-S-8622EG 
4 Remove the catalytic converter.   AR49.10-S-5500EG
5 Remove bolt (1) from bracket (8). TORQUE SPECIFICATION M8 *BA00.10-Z-1003-01KOA 
6 Unscrew bolts (9) and remove bracket (6). TORQUE SPECIFICATION M8 *BA00.10-Z-1003-01KOA 
7 Unscrew bolts and remove heat shield (2). TORQUE SPECIFICATION Screw, heat shield to cylinder head *BA09.40-Z-1013-02KOF 
8 Remove coolant lines (4a, 4b).   AR09.40-S-6020-18EG 
    TORQUE SPECIFICATION Screw, coolant line to exhaust gas turbocharger *BA09.40-Z-1008-02KOF 
    TORQUE SPECIFICATION Screw, coolant line to coolant pump *BA09.40-Z-1009-02KOF 
    TORQUE SPECIFICATION Screw, coolant line to cylinder head *BA09.40-Z-1010-02KOF 
9 Remove oil lines (5a, 5b).   AR09.40-S-6020-19EG 
    TORQUE SPECIFICATION Screw, oil return line to crankcase *BA09.40-Z-1007-02KOF 
    TORQUE SPECIFICATION Bolt, oil return flow line to turbocharger *BA09.40-Z-1006-02KOF 
    TORQUE SPECIFICATION Bolt, oil feed line to exhaust gas turbocharger *BA09.40-Z-1004-02KOF 
    TORQUE SPECIFICATION Bolt, oil feed line to crankcase *BA09.40-Z-1005-02KOF 
10 Release and disconnect electrical connector of the overrun mode bypass air switchover valve (Y101).    
11 Remove electrical wiring harness and electrical connector of the overrun mode bypass air switchover valve (Y101) and place outside of the working area.    
12 Remove vacuum hose from vacuum cell (7).    
13 Remove support (10) from exhaust gas turbocharger (3). TORQUE SPECIFICATION Nut, turbocharger support brace to turbocharger *BA09.40-Z-1012-02KOF 
14 Remove support (10). TORQUE SPECIFICATION Bolt, turbocharger support brace to crankcase *BA09.40-Z-1011-02KOF 
15 Remove exhaust manifold with exhaust gas turbocharger (3) from cylinder head. INSTALLATION IMPORTANT : Replace seal (11) and nuts (12).
TORQUE SPECIFICATION Nut, exhaust manifold with exhaust gas turbocharger to cylinder head		 *BA09.40-Z-1001-02KOF 
16 Remove exhaust gas turbocharger (3) upward. INSTALLATION IMPORTANT : The ATL (3) must be installed with the support (10).  
17 Install in the reverse order.    
INSPECT Check     
18 Check engine oil level.    
REFER TO CAPACITIES & SPECIFICATIONS Multigrade engine oils (specification 229.5) If oil level is incorrect,
↓
Correct engine oil level.		 BB00.40-P-0229-05A
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
19 Check for leak tightness when engine is running. IMPORTANT Visual inspection only.  
HEADLESS SCREWS/BOLTS: SCREWS/BOLTS AND NUTS, COARSE-PITCH THREAD

Number Designation 8.8 10.9
BA00.10-Z-1003-01KOA M8 Galvanized Nm 23 32
Phosphated Nm 21 29
HEADLESS SCREWS/BOLTS: SCREWS/BOLTS AND NUTS, COARSE-PITCH THREAD

Number Designation 12.9
BA00.10-Z-1003-01KOA M8 Galvanized Nm 38
Phosphated Nm 36
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1001-02KOF Nut, exhaust manifold with exhaust gas turbocharger to cylinder head Nm 15
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1004-02KOF Bolt, oil feed line to exhaust gas turbocharger Stage 1 Nm 8
Stage 2 ∠° 60
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1005-02KOF Bolt, oil feed line to crankcase Stage 1 Nm 8
Stage 2 ∠° 60
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1006-02KOF Bolt, oil return flow line to turbocharger Stage 1 Nm 8
Stage 2 ∠° 60
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1007-02KOF Screw, oil return line to crankcase Stage 1 Nm 8
Stage 2 ∠° 60
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1008-02KOF Screw, coolant line to exhaust gas turbocharger Nm 9
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1009-02KOF Screw, coolant line to coolant pump Nm 9
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1010-02KOF Screw, coolant line to cylinder head Nm 9
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1011-02KOF Bolt, turbocharger support brace to crankcase Stage 1 Nm 15
Stage 2 ∠° 90
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1012-02KOF Nut, turbocharger support brace to turbocharger Nm 30
TURBOCHARGER

Number Designation Engine 274 in model 447, 448
BA09.40-Z-1013-02KOF Screw, heat shield to cylinder head Nm 8
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