Remove/install turbocharger - AR09.40-P-6020CDB

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ENGINE 651 in MODEL 204, 212 (except 212.098/298)

For single-speed charging

Fig 1: Turbocharger Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Turbocharger Remove/Install Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Disconnect ground line at the on-board electrical system battery	MODEL 204	AR54.10-P-0003CW
1		MODEL 212	AR54.10-P-0003EW
2	Remove air filter housing		AR09.10-P-1150CD
3	Remove engine air intake duct downstream of air filter		AR09.10-P-8130CD
4	Separate noise damper (13) from ATL (1)	M6	*BA00.10-P-1002-01A
5	Disconnect charge pressure positioner electrical connection (Y77/1x1)
6	Remove banjo bolt (5) and screw/bolt (8) and remove lubricating oil line (7) from ATL (1)	Replace seals. Leaks can occur otherwise.
		Banjo bolt, oil line to turbocharger	*BA09.40-P-1005-01P
		Bolt, oil line to cylinder crankcase	*BA09.40-P-1006-01P
7.1	Remove front section from noise encapsulation	MODEL 204 (except 204.9), 212	AR94.30-P-5300EW
7.2	Remove bottom engine compartment paneling at front	MODEL 204.9	AR61.20-P-1105CY
8	Disconnect catalytic converter diesel particulate filter unit from ATL (1)	MODEL 204	*BA49.10-P-1002-01AC
8		MODEL 212	*BA49.10-P-1002-01AE
9	Remove alternator from major assembly carrier and place to the front		AR15.40-P-5032CD
10	Unscrew screw/bolts (9) from oil return line (10)	Replace seal. Leaks can occur otherwise.
10	Unscrew screw/bolts (9) from oil return line (10)	Bolt, oil line to cylinder crankcase	*BA09.40-P-1006-01P
11	Unhook retaining clip (6) and remove ATL bracket (4)	Replace screw/bolt on ATL (1).
		Bolt, rear/center turbocharger bracket to turbocharger	*BA09.40-P-1002-01P
		Bolt, rear/center turbocharger bracket to cylinder crankcase	*BA09.40-P-1003-01P
12	Remove screw/bolts (3) on exhaust manifold	Install new screw/bolts (3) and seal.
12	Remove screw/bolts (3) on exhaust manifold	Flange connection, exhaust manifold to turbocharger	*BA09.40-P-1001-01P
13	Remove ATL (1) upwards
14	Install in the reverse order
	Check
15	Check engine oil level, correct if necessary	The engine oil level must lie between "Min" and "Max". Engine damage can occur otherwise.
16	Teach in charge pressure (Y77/1) with Star Diagnosis
			AD00.00-P-2000-04A
		Menu guidance: CDI control unit Adaptations Teach-in processes
	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
17	Check engine for a running engine for leaktightness

HEADLESS SCREWS: BOLTS AND NUTS, COARSE-PITCH THREAD

Number	Designation				MODEL ALL
BA00.10-P-1002-01A	M6	8.8	Galvanized	Nm	9
		8.8	Phosphated	Nm	9
		10.9	Galvanized	Nm	13
		10.9	Phosphated	Nm	12
		12.9	Galvanized	Nm	16
		12.9	Phosphated	Nm	14

TURBOCHARGER

Number	Designation			ENGINE 651
BA09.40-P-1001-01P	Flange connection, exhaust manifold to turbocharger	Stage 1	Nm	20
BA09.40-P-1001-01P	Flange connection, exhaust manifold to turbocharger	Stage 2	∠°	90

TURBOCHARGER

Number	Designation		ENGINE 651
BA09.40-P-1002-01P	Bolt, rear/center turbocharger bracket to turbocharger	Nm	20

TURBOCHARGER

Number	Designation		ENGINE 651
BA09.40-P-1003-01P	Bolt, rear/center turbocharger bracket to cylinder crankcase	Nm	20

TURBOCHARGER

Number	Designation			ENGINE 651
BA09.40-P-1005-01P	Banjo bolt, oil line to turbocharger	Stage 1	Nm	9
BA09.40-P-1005-01P	Banjo bolt, oil line to turbocharger	Stage 2	∠°	90

TURBOCHARGER

Number	Designation		ENGINE 651
BA09.40-P-1006-01P	Bolt, oil line to cylinder crankcase	Nm	9

EXHAUST SYSTEM

Number	Designation		ENGINE 642, 646, 651 in MODEL 204
BA49.10-P-1002-01AC	Bolt connecting catalytic converter to turbocharger	Nm	20

EXHAUST SYSTEM

Number	Designation		ENGINE 642, 651 in MODEL 212
BA49.10-P-1002-01AE	Bolt connecting catalytic converter to turbocharger	Nm	20