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

Engine 256.9 In Model 167

MODIFICATION NOTES

31.07.2019

Remove support of exhaust gas turbocharger.

Operation step 14

Fig 1: Turbocharger With Exhaust Manifold Components Location - Engine 256.9 In Model 167

Courtesy of MERCEDES-BENZ USA

	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 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 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	Remove engine compartment service flap.		AR01.10-P-2405-02MSC
		Nut to wiper arm on front windshield wiper system	*BA82.30-P-1001-01R
		M6 x 1	*BA00.10-P-1002-04A
2	Remove engine air intake duct downstream of air filter.	: Only install upper engine cover after the leak test.	AR09.10-P-8130MSC
3	Remove inerting system line from exhaust gas turbocharger (1) and place to one side.	Engine 256.9 in model 167 with code 2U8 (Alternative refrigerant)	AR86.10-P-0119ME
4	Release and disconnect the electrical connections (2).
5	Remove full load bleed line from exhaust gas turbocharger (1) and place to one side.		AR01.20-P-0020MSC
6	Remove oil feed line.		AR09.40-P-6022MSC
7	Remove exhaust gas aftertreatment unit.		AR49.20-P-1500MSC
8	Remove oil return feed line from exhaust gas turbocharger (1).		AR09.40-P-6021MSC
9	Remove coolant return flow line from exhaust gas turbocharger (1).		AR20.20-P-1050MSC
10	Remove feed line coolant line from exhaust gas turbocharger (1).		AR20.20-P-1000MSC
11	Unscrew screws (4) and remove holder (3).	: First, tighten screws (4) slightly by hand and then tighten with the specified tightening torque. Bolt, bracket to turbocharger/cylinder head	*BA09.40-P-1003-02MRT
12	Remove ignition coil of cylinder 6.		AR15.12-P-2003MSC
13	Remove heat shield (5).	M6X1	*BA00.10-P-1002-04A
14	Unscrew screw (6) and lower screws of support and remove support.	Screw, support to exhaust gas turbocharger/crankcase	*BA09.40-P-1002-02MRT
15	Release clamps of boot (8).	Screw clamp, boot to exhaust gas turbocharger	*BA09.41-P-1010-01MRT
16	Remove nuts (10) in reverse order of tightening procedure and remove peg board (9).	Tightening pattern for turbocharger	AR09.40-P-6020-10MRT
		: Install new nuts (10). Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head	*BA14.10-P-1001-02MRT
17	Release exhaust gas turbocharger (1) from the bottom terminal strips and remove with boot (8).	: Install new boot (8) and seal of the exhaust gas turbocharger (1). Align marking of the boot (8) with the marking on the exhaust gas turbocharger (1). Wet boot (8) with lubricant. Lubricant, rubber assembly 1 L	*BR00.45-Z-1010-06A
18	Remove ball pin (7).	Only when replacing exhaust gas turbocharger (1). Ball pin, engine cover to exhaust gas turbocharger/camshaft housing	*BA01.10-P-1001-01MRT
	Clean
19	Clean sealing surfaces on the cylinder head and exhaust gas turbocharger (1).
20	Install in the reverse order.
	Check
21	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
22	Carry out engine test run and check engine for proper leak tightness and leak tightness.
23	Install upper engine cover.		AR01.10-P-2405MSC

METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143

Number	Designation		8.8	10.9
BA00.10-P-1002-04A	M6x1	Nm	9	13

ENGINE COVER

Number	Designation		Engine 256
BA01.10-P-1001-01MRT	Ball pin, engine cover to exhaust gas turbocharger/camshaft housing	Nm	8

TURBOCHARGER

Number	Designation				Engine 256.9
BA09.40-P-1002-02MRT	Screw, support to exhaust gas turbocharger/crankcase	M8	Stage 1	Nm	20
		M8	Stage 2	∠°	90
		M6		Nm	-

TURBOCHARGER

Number	Designation			Engine 256.9
BA09.40-P-1003-02MRT	Bolt, bracket to turbocharger/cylinder head	M6	Nm	8
BA09.40-P-1003-02MRT	Bolt, bracket to turbocharger/cylinder head	M8	Nm	33

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 256.9
BA09.41-P-1010-01MRT	Screw clamp, boot to exhaust gas turbocharger	Nm	6

EXHAUST MANIFOLD

Number	Designation			Engine 256.9
BA14.10-P-1001-02MRT	Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head	Stage 1	Nm	20
BA14.10-P-1001-02MRT		Stage 2	Nm	20

WINDSHIELD WIPER

Number	Designation		Model 167
BA82.30-P-1001-01R	Nut to wiper arm on front windshield wiper system	Nm	30

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1010-06A	Lubricant, rubber assembly 1 L	A 000 989 03 67