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

Engine 274.9 in model 205 

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

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Drain off coolant		AR20.00-P-1142LW
2	Remove air filter housing		AR09.10-P-1150MRA
3	Remove expansion reservoir for low temperature circuit and place with attached lines to one side	Engine 274.9 in model 205 except code 494 (US version)
4	Remove air filter housing holder
5	Remove heat shield (2)	Bolt, heat shield to cylinder head/bracket for air filter	*BA09.40-P-1015-01U
6	Remove oil line feed line (5a) and oil line return flow (5b)		AR09.40-P-6020-13MR
		Replace the sealing rings and make sure that it is seated correctly.
		Bolt, oil line, oil feed to turbocharger	*BA09.40-P-1005-01U
		Bolt, oil line, oil feed to crankcase	*BA09.40-P-1006-01U
		Bolt, oil return flow line to turbocharger	*BA09.40-P-1007-01U
		Bolt, oil return line to crankcase	*BA09.40-P-1008-01U
7	Remove coolant return flow line (4a) and coolant feed line (4b)		AR09.40-P-6020-14MR
		Replace seals.
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1009-01U
		Bolt, coolant line feed line to water pump	*BA09.40-P-1010-01U
		Bolt, coolant return flow line to cylinder head	*BA09.40-P-1011-01U
8	Unclip coolant line (1) and remove air filter housing holder	Model 205 with engine 274.9 except code 494 (US version)
9	Disconnect vacuum hose on ATL (3)
10	Detach air intake pipe on ATL (3)		AR09.10-P-8131MRA
11	Remove charge air pipe upstream of charge air cooler
12	Detach CAT bracket at transmission	Nut, bracket for catalytic converter to crankcase bracket	*BA49.10-P-1003-02A
13	Replace clamp (9) for CAT at ATL (3)	Replace clamp (9) CAT at ATL (3).
		Bolt, catalytic converter clamp to turbocharger	*BA09.40-P-1002-01U
14	Disconnect flange connection of ATL (3) and catalytic converter
15	Detach EGR line from ATL (3) with exhaust manifold	Engine 274.9 in model 205 with code 920 (Direct fuel injection with stratified charging) except code 494 (US version) Replace seal, nuts and ensure correct seating of the seal.
16	Detach support brace (10) at crankcase and ATL (3)	Nut, support brace to turbocharger	*BA09.40-P-1012-01U
		Bolt, turbocharger support brace to crankcase	*BA09.40-P-1013-01U
		Set of flexible head wrenches	Fig 2
17	Detach exhaust manifold on cylinder head	Replace seal (11) and nuts (12).
		Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-01U
18	Move exhaust manifold with ATL (3) downwards and remove upwards	The ATL (3) must be inserted together with the support brace (10).
19	Install in the reverse order
	Check
20	Check oil level in engine and correct if necessary
			AP18.00-P-1848U
21	Check engine cooling system for leaktightness		AR20.00-P-1010LW
	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	Carry out an engine test run, checking the engine for proper operation and leaktightness

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1001-01U	Nut, turbocharger/exhaust manifold to cylinder head	Nm	15

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1002-01U	Bolt, catalytic converter clamp to turbocharger	Nm	15

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1005-01U	Bolt, oil line, oil feed to turbocharger	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1006-01U	Bolt, oil line, oil feed to crankcase	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1007-01U	Bolt, oil return flow line to turbocharger	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1008-01U	Bolt, oil return line to crankcase	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1009-01U	Bolt, coolant feed/return line to turbocharger	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1010-01U	Bolt, coolant line feed line to water pump	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1011-01U	Bolt, coolant return flow line to cylinder head	Nm	9

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1012-01U	Nut, support brace to turbocharger	Nm	30

TURBOCHARGER

Number	Designation			Engine 274
BA09.40-P-1013-01U	Bolt, turbocharger support brace to crankcase	Stage 1	Nm	15
		Stage 2	∠°	90

TURBOCHARGER

Number	Designation		Engine 274
BA09.40-P-1015-01U	Bolt, heat shield to cylinder head/bracket for air filter	Nm	10

EXHAUST SYSTEM

Number	Designation		Engine 274 in model 205
BA49.10-P-1003-02A	Nut, bracket for catalytic converter to crankcase bracket	Nm	25

Fig 2: Identifying Set Of Flexible Head Wrenches (001 589 81 09 00)

Courtesy of MERCEDES-BENZ USA