Remove/install turbocharger · ar0940s6020ea · Mercedes-Benz WIS

AR09.40-S-6020EA

Remove/install turbocharger

04.06.2020

Engine

654.9 in model 447

Modification notes

04.06.2020

Work procedure revised

The whole document

S09.40-A010-79

1.1	Low-pressure turbocharger	10	Compressed-air line	20	Bracket
1.2	High-pressure turbocharger	11	Air duct housing	21	Charge air pipe
2	Air intake line	12	Bolts	22	Temperature sensor
3	Electrical connector	13	Vacuum line	23	Electrical line
4	Oil return lines	14	Rear vacuum cell	24	Vacuum line
5	Screw	15	Union nut	25	Front vacuum cell
6	Coolant feed line	16	Pressure line	26	Screw
7	Coolant feed line	17	Diesel particulate filter	28	Clip
8	Top coolant return line	18	Screw	29	Screw
9	Clip	19	Screw

4	Oil return lines
28	Clip
30	Seal
31	O-ring
32	Securing clamp
33	Exhaust manifold

S09.40-A012-76

S09.40-A013-79

1.2

High-pressure turbocharger

Compensating element

Thread

S09.40-A015-79

1.1	Low-pressure turbocharger		5	Screw		39	Screw
1.2	High-pressure turbocharger

S09.40-A046-78

4	Oil return lines	33	Exhaust manifold
11	Air duct housing	37	Bracket
18	Screw

 Warning	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
 Caution	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
 Caution	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
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
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
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove
1	Remove diesel oxidation catalytic converter.		AR49.20-S-0104EA
2	Remove the air intake line (2).		AR09.40-S-0500EA
3	Disconnect electrical connector (3).
4	Release oil return feed lines (4) from low-pressure exhaust gas turbocharger (1.1) and from high-pressure exhaust gas turbocharger (1.2).		AR09.40-S-6020-21EA
5	Remove screw (5).
6	Remove coolant feed line (6) for high-pressure exhaust gas turbocharger (1.2).		AR20.20-S-0004EA
7	Remove coolant feed line (7) for low-pressure exhaust gas turbocharger (1.1).		AR20.20-S-0005EA
8	Remove top coolant return line (8).		AR20.20-S-0007EA
9	Open clamp (9).	 Dispose of clamp (9).
		 Pliers for click clamps	*171589003700
10	Remove compressed-air line (10) from air duct housing (11).
11	Remove screws (12).
12	Remove vacuum line (13) from rear vacuum cell (14).
13	Remove pressure line (16) from diesel particulate filter (17).	 For this purpose, remove union nut (15).
		 Box wrench bit	*000589700300
14	Loosen screw (18).
15	Remove screw (19).
16	Remove charge air pipe (21) from air duct housing (11).
17	Disconnect electrical connector of temperature sensor (22) and expose electric line (23).		AR07.04-S-0244EA
18	Place down electric line (23) on the low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2).
19	Detach vacuum line (24) from the front vacuum cell (25).
20	Remove screw (26).
21	Open clamp (28).	 For this purpose, release screw of clamp (28).
22	Loosen screw (29).
23	Lift low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) with the air duct housing (11) and remove toward the front.	 Helper required.
24	Seal charge air pipe (21) with protective cover.	 Set of protective caps	*001589029100
	Clean
25	Clean flange on high-pressure exhaust gas turbocharger (1.2).	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) will be reused.
		Assembly cleaner	*BR00.45-Z-1028-04A
26	Seal flange on high-pressure exhaust gas turbocharger (1.2) with protective cover.	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) will be reused.
		 Set of protective caps	*001589029100
27	Completely remove screw (29).	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) must be positioned for follow-up work:
		
		Do not yet dispose of screw (29).
28	Remove compensating element (34) from the high-pressure exhaust gas turbocharger (1.2).	 Compensating element (34) is provided with a left-hand thread and must be released in clockwise direction. Threaded connection can otherwise be damaged.
29	Remove O-rings (31) from the oil return feed lines (4).	 Dispose of O-rings (31).
		 Assembly tool	*000589936300
30	Seal oil return feed lines (4) with suitable stop plugs.	 Record plug	*129589009100
31	Remove clamp (28).	 Dispose of clamp (28).
32	Remove seal (30).
33	Remove the safety clip (32).
	Clean
34	Clean flange on the exhaust manifold (33).	Assembly cleaner	*BR00.45-Z-1028-04A
35	Seal flange on the exhaust manifold (33) with a protective cover.	 Set of protective caps	*001589029100
36	Remove O-ring from air duct housing (11).	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) will be reused.
		 Dispose of O-ring.
		 Assembly tool	*000589936300
37	Seal air duct housing (11) with protective cover.	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) will be reused.
		 Set of protective caps	*001589029100
38	Remove temperature sensor (22) from high-pressure exhaust gas turbocharger (1.2).	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) will be replaced.
		 For this purpose, remove union nut of temperature sensor (22).
	Install
39	Install temperature sensor (22).	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) have been replaced.
		 Coat thread of union nut with heat-resistant lubricating paste.
		 Union nut, temperature sensor to ATL	*BA07.04-N-1015-02EA
		Paste, hot lubrication 1 kg, DBL 6879.20	*BR00.45-Z-1005-06A
		 Box wrench bit	*000589690300
40	Remove protective cover from air duct housing (11).	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) will be reused.
		 Set of protective caps	*001589029100
41	Attach new O-ring to the air duct housing (11).	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) will be reused.
		 Assembly tool	*000589936300
	Check
42	Check thread (35) in high-pressure exhaust gas turbocharger (1.2) for ease of movement.	If low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) will be reused.
		If thread (35) is stiff:
		
		Recut thread (35) with a thread tap.
		 M10 designed as a right-hand thread. M18 designed as a left-hand thread.
		 Commercially available devices/tools Thread tap
43	Slightly screw in new compensating element (34) up to end stop at high-pressure exhaust gas turbocharger (1.2) and then unscrew by 90°.	 Compensating element (34) is provided with a left-hand thread and must be screwed in counterclockwise.
44	Screw new screw (29) by two revolutions into compensating element (34).
45	Install old screw (39) in low-pressure exhaust gas turbocharger (1.1) and new screw (5) in high-pressure exhaust gas turbocharger (1.2).
46	Remove stop plugs from the oil return feed lines (4).	 Record plug	*129589009100
47	Attach new O-rings (31) to the oil return feed lines (4).	 Assembly tool	*000589936300
48	Remove protective cover from the flange of the exhaust manifold (33).	 Set of protective caps	*001589029100
49	Install new seal (30).
50	Position new clamp (28) on the flange of the exhaust manifold (33).	 For this purpose, position pins of safety clips (32) in recesses (arrows). Otherwise, the new clamp (28) cannot be installed correctly.
		 Align new clamp (28) centrally in the open delivery state with the flange of the exhaust manifold (33).
51	Remove protective cover from charge air pipe (21).	 Set of protective caps	*001589029100
52	Remove protective cover from the flange on the high-pressure exhaust gas turbocharger (1.2).	 Set of protective caps	*001589029100
53	Position low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2) with the air duct housing (11) on the bracket (37) and on the flange of the exhaust manifold (33).	 In this connection, carefully position oil return feed lines (4) without twisting at low-pressure exhaust gas turbocharger (1.1) and at high-pressure exhaust gas turbocharger (1.2). Otherwise, the O-rings (31) will be damaged and leaks will occur.
		 Helper required.
54	Position new screw (5) and old screw (39) on the thread of the oil return feed lines (4).	 Helper required.
55	Position air duct housing (11) on the screw (18) and position high-pressure exhaust gas turbocharger (1.2) on the flange of the exhaust manifold (33).	 Helper required.
56	Pull up oil return feed lines (4) with the screw (39) onto the low-pressure exhaust gas turbocharger (1.1) and pull up with the screw (5) onto the high-pressure exhaust gas turbocharger (1.2).	 Pull up oil return feed lines (4) carefully and without kinking onto the low-pressure exhaust gas turbocharger (1.1) and onto the high-pressure exhaust gas turbocharger (1.2.). Otherwise, the O-rings (31) will be damaged and leaks will occur.
		 Helper required.
57	Align clamp (28) with the flange of the exhaust manifold (33) and with the flange of the high-pressure exhaust gas turbocharger (1.2) and tighten.	 Helper required.
		 Screw, clamp to high-pressure exhaust gas turbocharger and exhaust manifold	*BA09.40-N-1001-02EA
58	Tighten screw (18).	 Screw, air duct housing to holder	*BA09.40-N-1033-02EA
59	Tighten screw (29).	 Screw/bolt, bracket to turbocharger	*BA09.40-N-1007-02EA
60	Tighten screw (5).	 Screw, oil return line to high-pressure exhaust gas turbocharger	*BA09.40-N-1021-02EA
61	Remove screw (39).
62	Screw in screw (26).	 Screw, holder for front vacuum cell to coolant feed line	*BA09.40-N-1035-02EA
63	Attach vacuum line (24) to the front vacuum cell (25).
64	Lay electric line (23) and connect electrical connector of temperature sensor (22).		AR07.04-S-0244EA
65	Attach charge air pipe (21) to the air duct housing (11).
66	Position bracket (20) at air duct housing (11).
67	Attach pressure line (16) to diesel particulate filter (17) and tighten union nut (15).	 Union nut, pressure line to SCR catalytic converter diesel particulate filter unit	*BA49.20-N-1002-04EA
		 Box wrench bit	*000589700300
68	Screw in screw (19).	 Bolt, charge air pipe to air duct housing	*BA09.41-N-1005-01EA
69	Attach vacuum line (13) to the rear vacuum cell (14).
70	Screw in screws (12).	 Screw, air duct housing to coolant line holder	*BA09.40-N-1034-02EA
71	Slide new clamp (9) onto compressed-air line (10).	 Use commercially available screw clamp.
	Clean
72	Clean compressed-air line (10) and connection fitting of air duct housing (11).	Assembly cleaner	*BR00.45-Z-1028-04A
73	Attach compressed-air line (10) to air duct housing (11).
74	Tighten clamp (9).	 Observe positioning of clamp (9). Leaks can occur otherwise.
75	Install top coolant return line (8).		AR20.20-S-0007EA
76	Install coolant feed line (7) for the low-pressure exhaust gas turbocharger (1.1).		AR20.20-S-0005EA
77	Install coolant feed line (6) for high-pressure exhaust gas turbocharger (1.2).		AR20.20-S-0004EA
78	Connect electrical connector (3).
79	Install air intake line (2).		AR09.40-S-0500EA
80	Install diesel oxidation catalytic converter.		AR49.20-S-0104EA
	Check
 Warning	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
81	Perform engine test run and check leak tightness of the low-pressure exhaust gas turbocharger (1.1) and high-pressure exhaust gas turbocharger (1.2).	 Visual inspection only.

 Sensors

Number	Designation		Engine 654.9 in model 447
BA07.04-N-1015-02EA	Union nut, temperature sensor to ATL	Nm	45

 Turbocharger

Number	Designation		Engine 654.9 in model 447
BA09.40-N-1001-02EA	Screw, clamp to high-pressure exhaust gas turbocharger and exhaust manifold	Nm	20

 Turbocharger

Number	Designation			Engine 654.9 in model 447
BA09.40-N-1007-02EA	Screw/bolt, bracket to turbocharger	Stage 1	Nm	35
		Stage 2	°	90

 Turbocharger

Number	Designation			Engine 654.9 in model 447
BA09.40-N-1021-02EA	Screw, oil return line to high-pressure exhaust gas turbocharger	Stage 1	Nm	8
		Stage 2	°	30

 Turbocharger

Number	Designation		Engine 654.9 in model 447
BA09.40-N-1033-02EA	Screw, air duct housing to holder	Nm	8

 Turbocharger

Number	Designation		Engine 654.9 in model 447
BA09.40-N-1034-02EA	Screw, air duct housing to coolant line holder	Nm	8

 Turbocharger

Number	Designation		Engine 654.9 in model 447
BA09.40-N-1035-02EA	Screw, holder for front vacuum cell to coolant feed line	Nm	8

 Charge air pipe/charge air cooling

Number	Designation		Engine 654.9 in model 447
BA09.41-N-1005-01EA	Bolt, charge air pipe to air duct housing	Nm	8

 SCR catalytic converter diesel particulate filter unit

Number	Designation		Engine 654.9 in model 447
BA49.20-N-1002-04EA	Union nut, pressure line to SCR catalytic converter diesel particulate filter unit	Nm	20

000 589 93 63 00

Assembly tool

129 589 00 91 00

Record plug

171 589 00 37 00

Pliers for click clamps

000 589 70 03 00

Box wrench bit

000 589 69 03 00

Box wrench bit

001 589 02 91 00

Set of protective caps

Repair materials

Number	Designation	Order number
BR00.45-Z-1005-06A	Paste, hot lubrication 1 kg, DBL 6879.20	A 000 989 76 51
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01

Referenced documents

ah0000n000101a Notes on self-locking nuts and bolts
ah0000p001501cw Note on calculation of tightening torque when using insertion or socket tools with various effective lengths
ah0000p002001a Notes on threaded connections fastened using a tightening angle-based tightening process
ah0000p500001a Notes on avoiding damage through contamination and foreign objects
ah5400p000101a Information on preventing damage to electronic components due to electrostatic discharge
ar0704s0244ea Remove/install temperature sensor upstream of turbocharger
ar0940s0500ea Remove/install air intake duct upstream of turbocharger
ar0940s602021ea Disconnect oil return feed lines from exhaust gas turbocharger
ar2020s0004ea Remove/install coolant feed line for high-pressure exhaust gas turbocharger
ar2020s0005ea Remove/install coolant feed line for low-pressure exhaust gas turbocharger
ar2020s0007ea Remove/install upper coolant return line for exhaust gas turbocharger
ar4920s0104ea Remove/install diesel oxidation catalytic converter
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.
as0000z001701a Risk of injury caused by scraping or cutting body parts on sharp vehicle parts
as1800z000101a Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil
as4900z000101a 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.