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

Engine 264 In Model 167 

Fig 1: Turbocharger With Exhaust Manifold Components Location - Engine 264 In Model 167

Courtesy of MERCEDES-BENZ USA

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.  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 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
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
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	Drain off coolant.	: Only install lower engine compartment paneling after leak test.	AR20.00-P-1142MRK
2	Remove air intake pipe (3).	: Only install upper engine cover after the leak test.	AR09.10-P-8131MRK
3	Release the bleed line (10), unclip it and place to one side.	Do not crush or kink or subject lines to tension. This would lead to damage to the lines and can impair their function.
4	Unclip the bleed line (11) and place to one side.	Do not crush or kink or subject lines to tension. This would lead to damage to the lines and can impair their function.
5	Unclip the electrical line (12) from the holder (13).
6	Remove bracket (13).	Screw, right engine cover holder to cylinder head cover	*BA01.20-P-1009-03B
7	Remove the heat shield (14) for the exhaust gas turbocharger (1).	Screw/bolt, heat shield to cylinder head	*BA09.40-P-1013-02C
8	Unscrew the nut (15) from the holder for the ' exhaust gas turbocharger (1) and remove the holder from the catalytic converter and crankcase.	Secure the catalytic converter so that it does not fall. : Replace seal.	AR49.20-P-0100MRK
9	Release and disconnect the electrical connector (2).
10	Remove wide open throttle bleed line from exhaust gas turbocharger (1).		AR01.20-P-0020MRK
11	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
12	Remove coolant return line of exhaust gas turbocharger (1) and seal openings with suitable stop plugs.		AR09.40-P-6020-18MRH
		: Replace sealing ring. 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
13	Remove the coolant supply line from the exhaust gas turbocharger (1) and seal the openings with suitable stop plugs.		AR09.40-P-6020-18MRH
		: Replace sealing ring. Bolt, coolant line feed line to coolant line	*BA09.40-P-1008-02C
		Lubricant, rubber assembly 1 L	*BR00.45-Z-1010-06A
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1007-02C
		Record plug	Fig 2
14	Remove the oil feed line from the exhaust gas turbocharger (1) and seal the 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 crankcase	*BA09.40-P-1004-02C
		Screw/bolt, oil line for oil feed to exhaust gas turbocharger	*BA09.40-P-1003-02C
		Record plug	Fig 2
15	Remove the oil return feed line from the exhaust gas turbocharger (1) and seal the openings with suitable stop plugs.		AR09.40-P-6020-19MRH
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
		Bolt, oil return flow line to turbocharger	*BA09.40-P-1005-02C
		Bolt, oil return line to crankcase	*BA09.40-P-1006-02C
		Record plug	Fig 2
16	Loosen nut (8).	Nut, support brace to turbocharger	*BA09.40-P-1010-02C
17	Loosen screws/bolts (5).	Bolt, support to support/exhaust gas turbocharger	*BA09.40-P-1012-02C
18	Unscrew screw/bolt (6).	Bolt, turbocharger support brace to crankcase	*BA09.40-P-1011-02C
19	Unscrew nuts of exhaust gas turbocharger (1) in reverse order to 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
20	Remove the exhaust gas turbocharger (1) with holders (7).	: Install new seal (9).
21	Remove the holders (7) from the exhaust gas turbocharger (1).	If the exhaust gas turbocharger (1) is replaced.
	Clean
22	Clean sealing surfaces of exhaust gas turbocharger (1) and cylinder head.	Cleaner	*BR00.45-Z-1025-04A
	Check
23	Check stud bolts of exhaust gas turbocharger (1) for damage and replace if necessary.	Stud bolt for exhaust manifold	*BA01.30-P-1004-01BA
24	Install in the reverse order
	Concluding tasks
25	Check engine oil level and correct if necessary.		AP18.00-P-1812SKI
	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
26	Perform engine test run. While doing so, check engine for proper operation and leak tightness

CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number	Designation		Engine 264
BA01.20-P-1009-03B	Screw, right engine cover holder to cylinder head cover	Nm	20

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-1004-02C	Screw/bolt, oil line for oil feed to crankcase	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 L	A 000 989 03 67
BR00.45-Z-1025-04A	Cleaner	A 005 989 19 71