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

ENGINE 271.8 in MODEL 172, 204, 207, 212 

Fig 1: Identifying Turbocharger And Exhaust Manifold Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Turbocharger And Exhaust Manifold Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Detach ground line from battery	ENGINE 271.8 in MODEL 207, 212	AR54.10-P-0003EW
		ENGINE 271.8 in MODEL 172	AR54.10-P-0003W
		ENGINE 271.8 in MODEL 204	AR54.10-P-0003CW
2	Remove engine compartment paneling	ENGINE 271.8 in MODEL 172	AR61.20-P-1105W
		ENGINE 271.8 in MODEL 204, 207, 212	AR61.20-P-1105EW
3	Remove three-way catalytic converter (7)		AR49.10-P-5500EVO
4	Remove combination valve (2)	Only if present
			AR14.30-P-7100EVO
5	Detach power steering expansion reservoir (3)		AR46.25-P-1000EVO
		Place expansion reservoir (3) with attached lines to one side.
6	Remove combination valve (2) bracket (5)	Only if present
7	Remove secondary air system pipework		AR14.30-P-7150EVO
		Replace seal.
8	Remove shield (6) for turbocharger (1)
9	Unscrew nuts (16) as well as screw/bolts on cylinder crankcase and remove support brace (17).	Bolt, turbocharger holder to crankcase	*BA09.40-P-1003-01Q
		Nut, bracket to turbocharger	*BA09.40-P-1002-01Q
10	Detach air ducting (10) from turbocharger (1)
11	Detach charge air ducting (11) from noise damper
12	Drain coolant at radiator		AR20.00-P-1142CW
	Notes on coolant		AH20.00-N-2080-01A
13	Detach coolant hose (9) from turbocharger (1)
14	Remove coolant return hose (4)
15	Remove coolant lines for turbocharger (1)		AR09.40-P-6020-14EVO
		Replace seals.
		Bolt, coolant return line/oil feed line holder to turbocharger	*BA09.40-P-1009-01Q
		Bolt, coolant feed pipe to crankcase	*BA09.40-P-1006-01Q
		Bolt, coolant return line flange to turbocharger	*BA09.40-P-1005-01Q
16	Detach alternator, place to one side and secure against falling down		AR15.40-P-5032CW
17	Remove oil line for turbocharger (1)		AR09.40-P-6020-13EVO
		The banjo bolt and seals must be replaced after every disassembly.
		Bolt, oil return flow line to turbocharger	*BA09.40-P-1010-01Q
		Bolt, coolant return line/oil feed line holder to turbocharger	*BA09.40-P-1009-01Q
		Bolt, oil feed line to cylinder head	*BA09.40-P-1008-01Q
		Banjo bolt, oil feed line to turbocharger	*BA09.40-P-1007-01Q
18	Disconnect connector for electrical line (12) to bypass air switchover valve
19	Disconnect boost pressure control hose (13) from boost pressure control pressure transducer (Y31/5) and unclip from right engine suspension lug	Replace clamp if necessary.
20	Unscrew nuts (15) and remove turbocharger (1) upwards	Replace seal.
		Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-01Q
21	Install in the reverse order
22	Check engine oil level, correct if necessary
			AP18.00-P-0101AB
	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
23	Carry out an engine test run, checking the engine for proper operation and leaktightness

TURBOCHARGER

Number	Designation		ENGINE 271.8
BA09.40-P-1008-01Q	Bolt, oil feed line to cylinder head	Nm	9

TURBOCHARGER

Number	Designation		ENGINE 271.8
BA09.40-P-1005-01Q	Bolt, coolant return line flange to turbocharger	Nm	9

TURBOCHARGER

Number	Designation			ENGINE 271.8
BA09.40-P-1007-01Q	Banjo bolt, oil feed line to turbocharger	Stage 1	Nm	6
		Stage 2	∠°	90

TURBOCHARGER

Number	Designation		ENGINE 271.8
BA09.40-P-1003-01Q	Bolt, turbocharger holder to crankcase	Nm	20

TURBOCHARGER

Number	Designation		ENGINE 271.8
BA09.40-P-1010-01Q	Bolt, oil return flow line to turbocharger	Nm	9

TURBOCHARGER

Number	Designation		ENGINE 271.8
BA09.40-P-1001-01Q	Nut, turbocharger/exhaust manifold to cylinder head	Nm	15

TURBOCHARGER

Number	Designation		ENGINE 271.8
BA09.40-P-1002-01Q	Nut, bracket to turbocharger	Nm	30

TURBOCHARGER

Number	Designation		ENGINE 271.8
BA09.40-P-1009-01Q	Bolt, coolant return line/oil feed line holder to turbocharger	Nm	9

TURBOCHARGER

Number	Designation		ENGINE 271.8
BA09.40-P-1006-01Q	Bolt, coolant feed pipe to crankcase	Nm	9