Remove/install turbocharger with exhaust manifold - AR09.40-P-6025MR

ENGINE 274 in MODEL 172, 204, 207 

Fig 1: Identifying Turbocharger With Exhaust Manifold Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Drain off coolant		AR20.00-P-1142MR
2	Remove air intake pipe	Engine 274 in model 172	AR09.10-P-8131MRE
3.1	Remove oxygen sensor upstream of catalytic converter (G3/2)	Engine 274 in model 172, 204.0/2/3, 207
			AR07.52-P-5303MR
3.2	Remove catalytic converter	Engine 274 in model 172, 204.9
		Engine 274 in model 204.9	AR49.10-P-7100MR
		Engine 274 in model 172 Replace CAT clamps on ATL and exhaust system at the rear.	AR49.10-P-7142MRE
4	Remove heat shield (2)	Bolt, heat shield to cylinder head/bracket for air filter	*BA09.40-P-1015-01U
5	Remove lower bracket of exhaust gas recirculation	Engine 274 in model 207 with code 920 (Direct petrol injection with stratified charging)
6	Remove coolant lines (4a, 4b)		AR09.40-P-6020-14MR
		Bolt, coolant return flow line to cylinder head	*BA09.40-P-1011-01U
		Bolt, coolant line feed line to water pump	*BA09.40-P-1010-01U
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1009-01U
7	Remove oil lines (5a, 5b)		AR09.40-P-6020-13MR
		Ensure correct seating of the bracket on cylinder crankcase and the lower seal.
		Bolt, oil return line to crankcase	*BA09.40-P-1008-01U
		Bolt, oil return flow line to turbocharger	*BA09.40-P-1007-01U
		Bolt, oil line, oil feed to crankcase	*BA09.40-P-1006-01U
		Bolt, oil line, oil feed to turbocharger	*BA09.40-P-1005-01U
8	Disconnect electrical connection on divert air switchover valve (Y101) and unclip electrical line (6) on ATL (3)
9	Detach charge air hose (7) at ATL (3)
10	Detach vacuum hose (8) at vacuum unit
11	Disconnect flange connection between ATL (3) and catalytic converter; to do this open the clamp (9)	Engine 274 in model 172, 204.0/2/3, 207 Replace CAT clamp on ATL.
		Bolt, catalytic converter clamp to turbocharger	*BA09.40-P-1002-01U
12	Detach holder (10) at crankcase and ATL (3)	Bolt, turbocharger support brace to crankcase	*BA09.40-P-1013-01U
		Nut, support brace to turbocharger	*BA09.40-P-1012-01U
13	Detach manifold for ATL (3) on cylinder head	Replace seal (11) and nuts (12).
		Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-01U
14	Remove ATL (3) upwards	The ATL (3) must be inserted together with the holder (10).
15	Install in the reverse order
	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
16	Perform an engine test run; in doing so check engine for proper operation and leaktightness

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1001-01U	Nut, turbocharger/exhaust manifold to cylinder head	Nm	15

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1002-01U	Bolt, catalytic converter clamp to turbocharger	Nm	15

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1005-01U	Bolt, oil line, oil feed to turbocharger	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1006-01U	Bolt, oil line, oil feed to crankcase	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1007-01U	Bolt, oil return flow line to turbocharger	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1008-01U	Bolt, oil return line to crankcase	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1009-01U	Bolt, coolant feed/return line to turbocharger	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1010-01U	Bolt, coolant line feed line to water pump	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1011-01U	Bolt, coolant return flow line to cylinder head	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1012-01U	Nut, support brace to turbocharger	Nm	30

TURBOCHARGER

Number	Designation			Engine 274
BA09.40-P-1013-01U	Bolt, turbocharger support brace to crankcase	Stage 1	Nm	15
		Stage 2	∠°	90

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1015-01U	Bolt, heat shield to cylinder head/bracket for air filter	Nm	10