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

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ENGINE 642 in MODEL 207, 212, 218, 222

ATL without coolant cooling

Fig 1: Turbocharger Remove/Install Components - ATL Without Coolant Cooling

Courtesy of MERCEDES-BENZ USA

ATL with coolant cooling

Fig 2: Turbocharger Remove/Install Components - ATL With Coolant Cooling

Courtesy of MERCEDES-BENZ USA

ATL without coolant cooling

Fig 3: Turbocharger Remove/Install Components - ATL Without Coolant Cooling

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 . 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
	Remove/install
1	Remove engine cover	Ensure correct seating of the engine cover.
2	Remove engine air intake duct (1) downstream of the air filter		AR09.10-P-8130OGE
3	Disconnect electrical connection from exhaust pressure sensor (B60)
4	Remove engine charge air duct (2)	MODEL 222 with ENGINE 642	AR09.41-P-8622LFD
4	Remove engine charge air duct (2)	MODEL 207, 212, 218 with ENGINE 642	AR09.41-P-8622SXI
5	Remove heat protection (3)
6	Remove bracket (11)	MODEL 207, 212, 218 with ENGINE 642 MODEL 222 with ENGINE 642 without CODE M005 (4MATIC)
7.1	Remove catalytic converter (10)	MODEL 207, 212, 218 with ENGINE 642	AR49.10-P-5500OGE
		Remove upper screws/bolts (9) and only loosen lower screw/bolt (9); the flange is slotted. Replace seal and screw/bolts (9).
7.2	Remove exhaust pipe at ATL (15)	MODEL 222 with ENGINE 642	AR49.10-P-5501LFD
		When working on the ATL (15), do not bend or turn exhaust pipe. This can lead to leaks. Replace seal and screw/bolts (9).
8	Remove exhaust gas recirculation pipe (4)	Replace seals and screw/bolts. For ATL (15) with coolant cooling, check the clamp (12) for damage; replace if necessary.
		Exhaust gas recirculation pipe to charge air distribution line	*BA14.20-P-1003-01G
		Exhaust gas recirculation pipe to exhaust collector pipe	*BA14.20-P-1004-01G
		Clamp, exhaust gas recirculation pipe to exhaust collector pipe	*BA14.20-P-1013-01G
9	Remove screw/bolts (5) on exhaust collector pipe (6)	Replace seals and screw/bolts (5).
		Flange connection, exhaust manifold/front exhaust pipes to exhaust collector	*BA14.10-P-1001-01L
		Screw/bolt, turbocharger to exhaust collector pipe	*BA09.40-P-1011-01K
10	Remove screw/bolts (7) on support brace from exhaust collector pipe (6)	Screw/bolt, exhaust collector pipe support brace to cylinder crankcase	*BA09.40-P-1007-01K
11	Unscrew screw/bolt (14) for coolant line (13)	Engine 642 in model 207, 212, 218 MOTOR 642 in model 222 except code M005 (4MATIC) For ATL with coolant cooling
11	Unscrew screw/bolt (14) for coolant line (13)	Screw/bolt, coolant line to turbocharger/charge air distribution line	*BA09.40-P-1013-01K
12	Remove screw/bolts (8) on oil supply connection fittings	Fit bolt, turbocharger to oil supply connection fitting	*BA09.40-P-1010-01K
13	Disconnect electrical connection on temperature sensor upstream of ATL (B1911)
14	Disconnect electrical connection from charge pressure positioner (Y77/1)
15	Remove ATL (15)	Replace seal on oil supply connection fitting. This prevents leaks occurring. Close off openings for a removed oil supply connection fitting using a stop plug. Close off openings for ATL (15) and the CAT (10) with protective covers. Clean ATL (15) and catalytic converter (10) free of sealant residues. For a ATL (15) with coolant cooling replace the seal for coolant line (13).
		Record plug	Figure
		Set of protective covers	Fig 4
16	Replace seal between ATL (15) and exhaust collector pipe (6)	Only in the event of leaks between exhaust collector pipe (6) and ATL (15)
			AR09.40-P-6024-15A
		Attach exhaust collector pipe (6) provisionally for positioning on ATL (15). This ensures free of tension assembly and consequential damage is avoided on the exhaust manifold. Replace screw/bolts.
		Screw/bolt, turbocharger to exhaust collector pipe	*BA09.40-P-1011-01K
17	Install in the reverse order
	Check
18	Check engine oil level	MODEL 222 with ENGINE 642	AR18.00-P-3035-01LFD
		MODEL 207, 212, 218 with ENGINE 642 Vehicle must be horizontal and standing on its wheels. This prevents measurement errors occurring. Check engine oil level about 5 min. after switching off warm engine.	AR18.00-P-3035-01SXI
		Engine oil	*BF18.00-P-1001-01S
	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 leaktightness with engine running

TURBOCHARGER

Number	Designation		ENGINE 642
BA09.40-P-1007-01K	Screw/bolt, exhaust collector pipe support brace to cylinder crankcase	Nm	20

TURBOCHARGER

Number	Designation			ENGINE 642
BA09.40-P-1010-01K	Fit bolt, turbocharger to oil supply connection fitting	Stage 1	Nm	20
BA09.40-P-1010-01K	Fit bolt, turbocharger to oil supply connection fitting	Stage 2	∠°	60

TURBOCHARGER

Number	Designation			ENGINE 642
BA09.40-P-1011-01K	Screw/bolt, turbocharger to exhaust collector pipe	Stage 1	Nm	20
BA09.40-P-1011-01K	Screw/bolt, turbocharger to exhaust collector pipe	Stage 2	∠°	90

TURBOCHARGER

Number	Designation		ENGINE 642
BA09.40-P-1013-01K	Screw/bolt, coolant line to turbocharger/charge air distribution line	Nm	9

EXHAUST MANIFOLD

Number	Designation			ENGINE 642
BA14.10-P-1001-01L	Flange connection, exhaust manifold/front exhaust pipes to exhaust collector	Stage 1	Nm	20
BA14.10-P-1001-01L		Stage 2	∠°	90

EXHAUST GAS RECIRCULATION

Number	Designation		ENGINE 642.82/83/85/86/87/886/9
BA14.20-P-1003-01G	Exhaust gas recirculation pipe to charge air distribution line	Nm	13

EXHAUST GAS RECIRCULATION

Number	Designation			ENGINE 642.82/83/85/86/87/886/9
BA14.20-P-1004-01G	Exhaust gas recirculation pipe to exhaust collector pipe	Stage 1	Nm	10
BA14.20-P-1004-01G	Exhaust gas recirculation pipe to exhaust collector pipe	Stage 2	∠°	90

EXHAUST GAS RECIRCULATION

Number	Designation		ENGINE 642.82/83/85/86/87/886/9
BA14.20-P-1013-01G	Clamp, exhaust gas recirculation pipe to exhaust collector pipe	Nm	9

ENGINE LUBRICATION SYSTEM

Number	Designation			ENGINE 642.826/830/832/834/835/836/838/850/852/853/854/856/858/861/862/867/868 with CODE 474 (Diesel particulate filter)
BF18.00-P-1001-01S	Engine oil	Filling capacity (oil and filter change)	Liter	8, 0
		Specification		Low SPAsh multigrade service engine oils (specification 228.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
		Specification		Low SPAsh multigrade service engine oils (specification 229.31). See https://bevo.mercedes-benz.com/index.php?language_id=1
		Specification		Low SPAsh multigrade service engine oils (specification 229.51). See https://bevo.mercedes-benz.com/index.php?language_id=1
		Specification		Low SPAsh multigrade service engine oils (specification 229.52). See https://bevo.mercedes-benz.com/index.php?language_id=1

Fig 4: Identifying Set Of Protective Covers (001 589 01 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA