Remove/install turbocharger · ar0940p6020rtb · Mercedes-Benz WIS

AR09.40-P-6020RTB

Remove/install turbocharger

2.4.12

ENGINES 642 in MODEL 251

P09.40-2224-09

Turbocharger without coolant cooling

1 Engine air intake duct downstream of air filter

2 Engine charge air duct

3 Heat shield

4 Bracket

5 Exhaust pipe

11 Bolts

12 Bolts

B60 Exhaust back pressure sensor

Y27/9 Left exhaust gas recirculation positioner

Y77/1 Charge pressure positioner

6 Screw

7 Clamp

8 Exhaust gas recirculation pipe

9 Bolts

10 Exhaust collector pipe

P09.40-2225-07

Turbocharger without coolant cooling

5 Exhaust pipe

6 Screw

15 Screw

7 Clamp

14 Turbocharger

P09.40-2390-05

Turbocharger with coolant cooling

13 Coolant line

16 Screw

17 Clamp

Modification notes

3.4.12	Value modified: Fitted bolt, turbocharger to oil feed fitting, Stage 1		*BA09.40-P-1010-01K
	Value modified: Fitted bolt, turbocharger to oil feed fitting, Stage 2		*BA09.40-P-1010-01K

 	Remove/install
 Danger!	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
 Danger!	Risk of injury to skin and eyes caused by handling hot or glowing objects.	Wear safety gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
1	Remove partition wall between wheel wells		AR62.30-P-2400RT
2	Remove engine trim panel		AR01.10-P-2405RTB
3	Remove water deflector over wiper system		AR83.25-P-1406RT
4	Remove wiper system		AR82.30-P-6400RT
5	Remove right air filter housing		AR09.10-P-1150RTC
6	Remove engine air intake duct downstream of the air filter (1)		AR09.10-P-8130GZB
7	Remove engine charge air duct (2) upstream of charge air cooler		AR09.41-P-8623GZB
8	Remove engine charge air duct (2) from turbocharger (14)	 Seal opening on turbocharger (14).	AR09.41-P-8622GZB
			*001589009100
			*001589019100
9	Remove heat shield (3) from turbocharger (14)
10	Disconnect connector on exhaust back pressure sensor (B60)	With code 474 Particulate filter
11	Remove exhaust back pressure sensor (B60)	With code 474 Particulate filter
12	Remove left exhaust gas recirculation positioner (Y27/9)		AR14.20-P-1020GZB
13	Disconnect electrical connector from charge pressure positioner (Y77/1)
14	Remove hose clamp (7) at exhaust pipe (5)
15	Remove screw (6)	Remove top bolt (6) but only loosen bottom bolt (6) as the flange is slotted.
		 Installation: Replace seal and bolts (6).
			*BA09.40-P-1012-01K
16	Remove exhaust pipe (5)
17	Remove exhaust gas recirculation pipe (8)	Installation: Replace gaskets and bolts.
		 Installation: On engine with coolant-cooled turbocharger (14), check clamp (17), replace if required.
		Exhaust gas recirculation pipe to charge air distribution line	*BA14.20-P-1003-01G
		 Exhaust gas recirculation pipe to exhaust collector	*BA14.20-P-1004-01G
		 Clamp, exhaust gas recirculation pipe to exhaust collector pipe	*BA14.20-P-1013-01G
18	Remove bolts (9)	 Installation: Replace gaskets and bolts (9).
			*BA14.10-P-1001-01L
19	Drain coolant	For a turbocharger (14) with coolant cooling	AR20.00-P-1142GZB
	Notes on coolant		AH20.00-N-2080-01A
20	Remove bolt (16) for coolant line (13)	For a turbocharger (14) with coolant cooling
			*BA09.40-P-1013-01K
21	Remove bolts (11) from carrier (bolts connecting carrier to crankshaft housing)		*BA09.40-P-1007-01K
22	Remove bolts (12) from the oil supply connection fitting		*BA09.40-P-1010-01K
23	Remove bracket (4)
24.1	Remove screw (15)	For a turbocharger (14) without coolant cooling
			*BA09.40-P-1009-01K
24.2	Disconnect electrical connector from temperature sensor upstream of turbocharger (B19/11)	For a turbocharger (14) with coolant cooling
25	Remove turbocharger (14)	 Installation: Close off openings on turbocharger (14). Clean turbocharger (14) and primary catalytic converter free of sealant residues.
		 Installation: Close off openings on a removed oil supply connection fitting.
		 Replace seal on oil supply connection fitting and align according to hole pattern while ensuring that the oil supply channel is not concealed.
		 Installation: On engines with coolant-cooled turbocharger (14), replace seal for coolant line (13).
			*001589009100
			*001589019100
			*129589009100
26	Replace seal between turbocharger (14) and exhaust collector (10)	 Only replace in the event of leaks between turbocharger (14) and exhaust collector (10).	AR09.40-P-6024-15A
		To achieve tension-free installation and to prevent subsequent damage to exhaust manifold, a provisional installation should be carried out to establish positioning of exhaust collector (10) at turbocharger (14).
		 Installation: Install new bolts.
			*BA09.40-P-1011-01K
27	Install in the reverse order
	Checking
28	Check engine oil level	 In order to avoid measurement errors, vehicle must be parked on an even surface.	AR18.00-P-3035-01PI
		 Shut off engine once it has reached operating temperature and wait approx. 5 minutes before checking engine oil level.
		 Without particulate filter	*BF18.00-P-1001-01A
		 With code 474 Particulate filter	*BF18.00-P-1001-01S
 Danger!	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
29	Conduct engine test run and check engine for leaks while it is running

 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
		Stage 2	°	90

 Exhaust gas recirculation

Number	Designation			Engines 642.82/83/85/86/87/ 886/9


BA14.20-P-1003-01G	Exhaust gas recirculation pipe to charge air distribution line		Nm	13
BA14.20-P-1004-01G	Exhaust gas recirculation pipe to exhaust collector pipe	Stage 1	Nm	10
		Stage 2	°	90
BA14.20-P-1013-01G	Clamp, exhaust gas recirculation pipe to exhaust collector pipe		Nm	9

 Turbocharger

Number	Designation			Engine 642


BA09.40-P-1007-01K	Bolt, exhaust collector pipe support to cylinder crankcase		Nm	20
BA09.40-P-1009-01K	Bolt, turbocharger to charge air manifold		Nm	9
BA09.40-P-1010-01K	Fitted bolt, turbocharger to oil feed fitting	Stage 1	Nm	20
		Stage 2	°	60
BA09.40-P-1011-01K	Bolt, turbocharger to exhaust collector pipe	Stage 1	Nm	20
		Stage 2	°	90
BA09.40-P-1012-01K	Exhaust line to turbocharger		Nm	20
BA09.40-P-1013-01K	Bolt, coolant line to turbocharger/charge air distribution line		Nm	9

 Engine lubrication system

Number	Designation			Engine 642.940/950 with particulate filter	Engine 642.820/822/870/872 with particulate filter


BF18.00-P-1001-01S	Engine oil	Filling capacity (oil and filter change)	Liters	8.5	8.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-51A	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-31A	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-51A	BB00.40-P-0229-51A

 Engine lubrication system

Number	Designation			Engine 642.940/950 without particulate filter	Engine 642.820/822/870/ 872 without particulate filter


BF18.00-P-1001-01A	Engine oil	Filling capacity (oil and filter change)	Liters	8.5	8.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-03A	BB00.40-P-0228-03A
			Sheet	BB00.40-P-0228-05A	BB00.40-P-0228-05A
			Sheet	BB00.40-P-0228-51A	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-03A	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-31A	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-05A	BB00.40-P-0229-05A
			Sheet	BB00.40-P-0229-51A	BB00.40-P-0229-51A

001 589 01 91 00

Set of stop plugs

Set of protective covers

001 589 00 91 00

129 589 00 91 00

Referenced documents

ah2000n208001a Notes on coolant
ar0110p2405rtb Remove/install engine cover
ar0910p1150rtc Remove/install air filter housing
ar0910p8130gzb Remove/install engine intake air duct downstream of air filter
ar0940p602415a Replace seal between turbocharger and exhaust collector
ar0941p8622gzb Remove/install engine charge air channel at turbocharger
ar0941p8623gzb Remove/install engine charge air duct upstream of charge air cooler
ar1420p1020gzb Remove/install exhaust gas recirculation positioner
ar1800p303501pi Check oil level
ar2000p1142gzb Drain/fill in coolant
ar6230p2400rt Remove/install partition wall between wheelhouses
ar8230p6400rt Remove/install wiper system
ar8325p1406rt Remove/install water drain above windshield wiper system
as0000z000201a Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
as0000z000501a 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.
as0000z001101a Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.