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

ENGINES 157 in MODEL 463 

Shown on right-hand side 

Fig 1: Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Right-Hand Side

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Drain engine oil
	Remove left turbocharger (1) with exhaust manifold
2	Remove engine with front axle carrier		AR01.10-P-2401GW
3	Detach low-pressure line to A/C compressor	Install new sealing ring.
			*BA83.55-P-1003-01R
4	Detach vacuum hose for boost pressure control valve on turbocharger (1)
5	Remove left charge air ducts	Plug openings.	AR09.41-P-8620GW
			Fig 2
6	Remove coolant lines for left turbocharger (1)	Plug openings.	AR20.20-P-7440GW
			Fig 3
7	Remove Hall sensor for left exhaust camshaft		AR15.10-P-2000GW
8	Detach upper oil line to turbocharger (1)	Plug openings.	AR18.30-P-6850GW
			Fig 3
9	Detach lower oil line on oil pan	Plug openings.	AR18.30-P-6850GW
			Fig 3
10	Remove exhaust pipe downstream of turbocharger (1)		AR49.10-P-5532GW
11	Remove shield on turbocharger (1) and on lower oil line		*BA09.40-P-1007-01R
			*BA09.40-P-1002-01R
12	Remove locking plates (3) on turbocharger (1)	Replace lock washer (3).
13	Unscrew nuts (1a, 1b) on turbocharger (1)		*BA09.40-P-1001-01R
14	Remove turbocharger (1) from cylinder head	Replace exhaust manifold gasket.
	Remove right turbocharger (1) with exhaust manifold
15	Open engine hood and raise to vertical position		AR88.40-P-1000GG
16	Attach cooler guard plate to cooler
	Guard plate for radiator/condenser		WF58.50-P-0110-01A
17	Remove insulation over right cylinder head cover
18	Remove right air filter housing		AR09.10-P-1150GW
19	Remove intake air ducts upstream of air filter
20	Remove poly-V belt		AR13.20-P-0001GW
21	Detach coolant feed line between charge air cooler and additional low-temperature cooler or transmission cooler from oil dipstick guide tube	To do this detach clamp from oil dipstick guide tube.
			*BA09.40-P-1009-01R
22	Remove Hall sensor for right exhaust camshaft		AR15.10-P-2000GW
23	Detach upper oil line to turbocharger (1)	Plug openings.	AR18.30-P-6850GW
			Fig 3
24	Remove shield on turbocharger (1) and on lower oil line		*BA09.40-P-1007-01R
			*BA09.40-P-1002-01R
25	Detach lower oil line to turbocharger (1)	Plug openings.	AR18.30-P-6850GW
			Fig 3
26	Remove right charge air ducts	Plug openings.	AR09.41-P-8620GW
			Fig 2
27	Mount engine suspension lug		AR33.10-P-0105-01GW
			*BA01.30-P-1006-01X
			Fig 4
28	Detach bracket for low temperature line between low temperature circuit expansion reservoir and low-temperature cooler from timing case cover		*BA09.40-P-1005-01R
29	Drain coolant		AR20.00-P-1142GW
	Notes on coolant		AH20.00-N-2080-01A
30	Remove coolant lines for right turbocharger (1)	Plug openings.	AR20.20-P-7440GW
			Fig 3
31	Remove air plenum chamber		AR83.10-P-9998GW
32	Remove both exhaust pipes downstream of turbocharger (1)		AR49.10-P-5532GW
33	Detach vacuum hose for boost pressure control valve on turbocharger (1)
34	Remove screw/bolts for both engine mount from the vehicle frame		*BA22.10-P-1001-01K
35	Remove single-pipe engine vibration damper on vehicle frame		AR22.10-P-1152GW
36	Remove right wheel		AP40.10-P-4050G
37	Remove right wheel housing paneling
38	Remove locking plates (3) on turbocharger (1)	Replace lock washer (3).
39	Unscrew nuts (1a, 1b) on turbocharger (1)		*BA09.40-P-1001-01R
40	Remove turbocharger (1) from cylinder head	Replace exhaust manifold gasket.
41	Raise engine at front engine suspension lug	Ensure that no lines are overstretched and that the engine and its detachable parts do not touch the body. Load regulator
42	Remove turbocharger (1)
43	Install in the reverse order
44	Check engine oil level; correct if necessary
	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
45	Carry out engine test run, checking the engine for proper operation and leaks

REFRIGERANT COMPRESSOR

Number	Designation		Model 463
BA83.55-P-1003-01R	Screw/bolt, refrigerant lines to refrigerant compressor	Nm	20

TURBOCHARGER

Number	Designation			Engine 157
BA09.40-P-1001-01R	Nut, turbocharger/exhaust manifold to cylinder head	M7	Nm	15
		M8	Nm	20
BA09.40-P-1002-01R	Stud bolt on turbocharger		Nm	10
BA09.40-P-1005-01R	Screw/bolt, coolant line to turbocharger/oil filter/coolant pump/timing case cover		Nm	9
BA09.40-P-1007-01R	Screw/bolt, shield to turbocharger/cylinder head		Nm	9
BA09.40-P-1009-01R	Screw/bolt, coolant line clamp to bracket		Nm	9

CYLINDER HEAD

Number	Designation		Engine 157
BA01.30-P-1006-01X	Screw/bolt, lifting eye to cylinder head	Nm	14

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation		Engine 157
BA22.10-P-1001-01K	Screw/bolt, front engine mount to frame	Nm	70

Fig 2: Identifying Set Of Protective Covers (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Lifting Eye (278 589 00 40 00)

Courtesy of MERCEDES-BENZ USA