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

ENGINE 276.8 in MODEL 166, 251 

MODIFICATION NOTES

28.1.15

Carry out engine oil and filter change, added

Operation step 24.2

Shown on left ATL 

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

Courtesy of MERCEDES-BENZ USA

Shown on left ATL 

Fig 2: Identifying Turbocharger With Exhaust Manifold Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Remove/install
1	Drain off coolant	ENGINE 276.8 in MODEL 166	AR20.00-P-1142GQ
		ENGINE 276.8 in MODEL 251	AR20.00-P-1142GZC
2	Remove partition wall between wheel wells	ENGINE 276.8 in MODEL 251
			AR62.30-P-2400RT
3	Remove windshield wiper system	ENGINE 276.8 in MODEL 251
			AR82.30-P-6400RT
4	Remove upper engine cover
5	Remove left and right air filter housing		AR09.10-P-1150GQC
6	Remove rail insulation
7	Remove screw/bolt (3), detach line and place to one side
8	Disconnect flange connection between ATL (1) and catalytic converter; to do this open the clamp (6)		AR49.10-P-5500GQC
		Replace clamp (6) and seal. The dowel pin on the exhaust gas outlet must be set in the notch on the ATL (1). After screwing down the clamp (6) using the prescribed torque there should be no further gap on the clamp lock.
9	Remove screws/bolts (5) and detach charge air pipe (4)		AR09.41-P-8620GQC
10	Disconnect electrical connection at divert air switchover valve (Y101/1)
11	Remove heat shields (14, 15, 16) from ATL (1)
12	Remove screw/bolts (11, 18), detach coolant feed pipe (13) and place to one side	Replace seal.
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
13	Remove coolant return line (10)	Replace seal.	AR20.20-P-7440GQC
14	Remove oil return line (12) and oil feed line (17) on ATL (1)		AR18.30-P-6850GQC
		Install new sealing rings.
15	Detach CAT bracket at transmission	ENGINE 276.8 in MODEL 166, 251 with TRANSMISSION 722.9
		ENGINE 276.8 in MODEL 166 with TRANSMISSION 722.9	*BA49.10-P-1020-01AK
		ENGINE 276.8 in MODEL 251 with TRANSMISSION 722.9	*BA49.10-P-1001-01X
16	Detach low temperature coolant container holder	When removing the right ATL (1)
			AR09.41-P-0001GQC
17	Detach vacuum hose (9) at vacuum unit (2)
18	Mount engine hoist and raise engine slightly	When removing the left ATL (1)
		ENGINE 276.8 in MODEL 166	AR33.10-P-0105EW
		ENGINE 276.8 in MODEL 251 Only raise engine sufficiently that the engine mounts are not under tension.	AR33.10-P-0100-01RT
		ENGINE 276.8 in MODEL 251	*BA62.30-P-1008-01E
		Adaptation of engine lifting device	Fig 4
		Engine lifting device	Fig 3
19	Detach front engine mount at bottom right and left	When removing the left ATL (1)
			AR22.10-P-1260GQC
20	Detach nuts (7) for ATL (1) on cylinder head and remove peg board	Tighten nuts (7) from the inside to the outside.
		Nut, turbocharger peg board to cylinder head	*BA09.40-P-1001-01W
21	Lift engine a little	When removing the left ATL (1) Pay attention when lifting out engine that no cables and lines are damaged and that engine does not lean against the bulkhead.
22	Tilt ATL (1) downwards and remove upwards out of the terminal rail (8)	Replace seal.
23	Install in the reverse order
	Check
24.1	Check oil level in engine and correct if necessary	When reusing the ATL (1)
			AP18.00-P-1811MP
24.2	Carry out engine oil and filter change	Only when replacing the ATL (1)
		ENGINE 276.8 in MODEL 251	AP18.00-P-0101W
		ENGINE 276.8 in MODEL 166	AP18.00-P-0101GQ
	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
25	Perform an engine test run and check engine for leaktightness

TURBOCHARGER

Number	Designation			ENGINE 276.8
BA09.40-P-1001-01W	Nut, turbocharger peg board to cylinder head	M8	Nm	20

TURBOCHARGER

Number	Designation		ENGINE 276.8
BA09.40-P-1008-01W	Bolt, coolant feed/return line to turbocharger	Nm	9

EXHAUST SYSTEM

Number	Designation		ENGINE 272, 273, 276 in MODEL 251
BA49.10-P-1001-01X	Bolt, catalytic converter bracket to catalytic convertor	Nm	20

EXHAUST SYSTEM

Number	Designation			ENGINE 276 in MODEL 166
BA49.10-P-1020-01AK	Screw/bolt, exhaust system bracket to transmission	Stage 1	Nm	8
		Stage 2	∠°	90

CROSSMEMBER AND FRONT REINFORCEMENT

Number	Designation		MODEL 251
BA62.30-P-1008-01E	Bolt, partition wall reinforcement between wheel well liners to fender	Nm	10

Fig 3: Identifying Engine Lifting Device (240 589 00 61 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Adaptation Of Engine Lifting Device (642 589 00 61 00)

Courtesy of MERCEDES-BENZ USA