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

ENGINE 157, 278 in MODEL 231 

MODIFICATION NOTES

17.06.2015

Screw holder to exhaust pipe

Motor 278

BA14.10-P-1004-01E

Shown on right-hand side 

Fig 1: Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Right-Hand Side (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Right-Hand Side (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	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 engine oil
		Engine 157 in model 231	AP18.00-P-0101EWG
		Engine 278 in model 231	AP18.00-P-0101EW
2	Remove engine with front axle carrier		AR01.10-P-2500RKB
3	Remove clamp (6) on shield (7)
4	Remove refrigerant line from refrigerant compressor (A9)	When removing the left ATL with exhaust manifold (1) Bolt, refrigerant line to refrigerant compressor	*BA83.55-P-1003-01M
5	Remove shield (7) on engine support	Bolt, heat shield to engine support	*BA22.10-P-1003-02A
6	Remove shield (8) at cylinder head	Ensure correct seating of the clips (5) on the shield (8) and exhaust manifold gasket. Bolt, heat shield to exhaust gas turbocharger/cylinder head	*BA09.40-P-1007-01R
7	Detach vacuum hose for boost pressure control valve from ATL with exhaust manifold (1)
8	Remove charge air ducts		AR09.41-P-8620RKB
9	Remove coolant line for charge air cooler on timing case cover	When removing the right ATL with exhaust manifold (1)
10	Remove coolant lines		AR20.20-P-7440RKB
11	Remove oil lines on ATL with exhaust manifold (1)	Oil line removal and installation	AR18.30-P-6850RKB
12	Remove bracket (9) for exhaust pipe (2) at cylinder head	Nut, exhaust line holder to cylinder head	*BA14.10-P-1005-01E
		Bolt, bracket to exhaust line	*BA14.10-P-1004-01E
13	Remove exhaust pipe (2)	Bolt/nut, exhaust line to turbocharger	*BA14.10-P-1003-01E
14	Remove lock washer (3) on ATL with exhaust manifold (1)	Install new locking plates (3).
15	Unscrew nuts (1a, 1b) on ATL with exhaust manifold (1)	Observe tightening procedure.	AR14.10-P-3000-01MM
		Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-01R
16	Remove ATL with exhaust manifold (1)	Replace exhaust manifold gasket.
17	Install in the reverse order
	Check
18	Check engine oil level; correct if necessary
		Engine 157 in model 231	AP18.00-P-0101EWG
		Engine 278 in model 231	AP18.00-P-0101EW
	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
19	Perform a function and leak test

TURBOCHARGER

Number	Designation			Engine 157	Engine 278
BA09.40-P-1001-01R	Nut, turbocharger/exhaust manifold to cylinder head	M7	Nm	15	15
		M8	Nm	20	20

TURBOCHARGER

Number	Designation		Engine 157	Engine 278
BA09.40-P-1007-01R	Bolt, heat shield to exhaust gas turbocharger/cylinder head	Nm	9	9

EXHAUST MANIFOLD

Number	Designation		Engine 157	Engine 278
BA14.10-P-1003-01E	Bolt/nut, exhaust line to turbocharger	Nm	25	25

EXHAUST MANIFOLD

Number	Designation		Engine 157	Engine 278
BA14.10-P-1004-01E	Bolt, bracket to exhaust line	Nm	25	25

EXHAUST MANIFOLD

Number	Designation		Engine 157	Engine 278
BA14.10-P-1005-01E	Nut, exhaust line holder to cylinder head	Nm	20	20

ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Engine 157	Engine 278
BA22.10-P-1003-02A	Bolt, heat shield to engine support	Nm	9	13

REFRIGERANT COMPRESSOR

Number	Designation			Engine 157	Engine 278
BA83.55-P-1003-01M	Bolt, refrigerant line to refrigerant compressor	M8	Nm	20	20