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

ENGINES 157, 278 in MODEL 166 

Shown on engine 278 (right side) 

Fig 1: Identifying Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Engine 278

Courtesy of MERCEDES-BENZ USA

Shown on engine 278 (right side) 

Fig 2: Identifying Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Engine 278

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Drain engine oil		AP18.00-P-0101GQ
2	Remove engine with front axle carrier		AR01.10-P-2500MLJ
3	Detach clamp (6) on shield (7)	When removing the right turbocharger with exhaust manifold (1)
4	Remove refrigerant line on A/C compressor	When removing the left turbocharger with exhaust manifold (1)
			*BA83.55-P-1003-01M
5	Remove shield (7) on engine support		*BA22.10-P-1003-02A
6	Remove shield (8) on cylinder head	Ensure correct seating of the clips (5) on the shield (8) and exhaust manifold gasket.
			*BA09.40-P-1007-01R
7	Detach vacuum hose for boost pressure control valve on turbocharger with exhaust manifold (1)
8	Remove charge air ducts	Seal openings using a set of protective covers.	AR09.41-P-8620MLJ
			Fig 3
9	Detach coolant line for charge air cooler on timing case cover	When removing the right turbocharger with exhaust manifold (1)
10	Remove coolant lines		AR20.20-P-7440MLJ
11	Detach upper oil line on turbocharger with exhaust manifold (1)		AR18.30-P-6850MLJ
12	Detach lower oil line on oil pan		AR18.30-P-6850MLJ
13	Remove bracket (9) between exhaust pipe (2) and cylinder head		*BA14.10-P-1004-01E
			*BA14.10-P-1005-01E
14	Remove exhaust pipe (2)		*BA14.10-P-1003-01E
15	Remove lock washer (3) on turbocharger with exhaust manifold (1)	Replace lock washer (3).
16	Unscrew nuts (1a, 1b) on turbocharger with exhaust manifold (1)		*BA09.40-P-1001-01R
17	Remove turbocharger with exhaust manifold (1) from cylinder head	Replace exhaust manifold gasket.
18	Install in the reverse order
19	Check engine oil level; correct if necessary		AP18.00-P-0101GQ
	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
20	Carry out engine test run, checking the engine for proper operation and leaks

Fig 3: Identifying Set Of Protective Covers (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA