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

Engine 276.8 in model 205

MODIFICATION NOTES

27.1.15

Carry out engine oil and filter change, added

Operation step 22.2

Fig 1: Identifying Turbocharger With Exhaust Manifold Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Turbocharger With Exhaust Manifold Remove/Install Components (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 off coolant		AR20.00-P-1142LW
2	Remove upper engine cover
3	Remove air filter housing		AR09.10-P-1150MMV
4	Remove soundproofing at both rails
5	Disconnect flange connection between ATL (1) and catalytic converter; to do this open the clamp		AR49.10-P-5500LW
6	Unfasten CAT bracket at transmission		AR49.10-P-5500LW
7	Remove screw/bolt (3) and detach purge line from charge air pipe of ATL (1) and place to one side	Install new sealing rings.
8	Remove the screw/bolts (5) and take out the charge air pipe (4)		AR09.41-P-8620MMV
9.1	Disconnect electrical connection at left divert air switchover valve (Y101/1)	When removing the left ATL (1)
9.2	Disconnect electrical connection at right bypass air switchover valve	When removing the right ATL (1)
10	Remove screw/bolts (11, 18) and detach coolant feed pipe (13) to ATL (1) and place to one side		AR20.20-P-7440MMV
		Replace seal.
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
11	Detach coolant return line (10) at front at ATL (1) from oil filter housing and thermostat housing		AR20.20-P-7440MMV
		Replace seal.
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
12	Remove heat shields (14, 15, 16) from ATL (1)		AR20.20-P-7440MMV
		Bolt/nut for shield attachment	*BA09.40-P-1011-01W
		Bolt, turbocharger shield bracket to cylinder head	*BA09.40-P-1012-01W
13	Remove engine oil return line (12) and engine oil feed line (17)		AR18.30-P-6850MMV
13		Replace seal.
14	Detach vacuum hose (9) at vacuum unit (2) of ATL (1)
15	Unfasten CAT bracket at transmission	Nut, catalytic converter to catalytic converter bracket	*BA49.10-P-1002-02A
16	Disconnect flange connection between ATL (1) and exhaust pipe of catalytic converter; to do this open clamp (6)	Replace clamp (6) and flange gasket. The dowel pin on adapter 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.
16		Engine 276 in model 205Clamp, exhaust line for catalytic converter to turbocharger	*BA49.10-P-1001-02A
17	Unscrew nuts (7) for ATL (1) on cylinder head and remove peg board	Tighten nuts (7) from the inside to the outside.
17		Nut, turbocharger peg board to cylinder head	*BA09.40-P-1001-01W
18	Disconnect A/C compressor refrigerant lines at left wheel arch connecting point	When removing from left ATL (1)
18		When removing from left ATL (1)	AR83.30-P-1760LW
19	Unclip ATL (1) from lower terminal rail (8) and remove upwards	Replace seal.
20	Install in the reverse order
21.1	Check engine oil level and correct if necessary	When reusing the ATL (1)
			AP18.00-P-1811MP
21.2	Carry out engine oil and filter change	Only when replacing the ATL (1)
			AP18.00-P-0101CWZ
	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
22	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

TURBOCHARGER

Number	Designation			Engine 276.8
BA09.40-P-1011-01W	Bolt/nut for shield attachment	M6	Nm	9

TURBOCHARGER

Number	Designation			Engine 276.8
BA09.40-P-1012-01W	Bolt, turbocharger shield bracket to cylinder head	M7	Nm	14

EXHAUST SYSTEM

Number	Designation		Engine 276 in model 205
BA49.10-P-1001-02A	Clamp, exhaust line for catalytic converter to turbocharger	Nm	17

EXHAUST SYSTEM

Number	Designation		Engine 276 in model 205
BA49.10-P-1002-02A	Nut, catalytic converter to catalytic converter bracket	Nm	22