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

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ENGINES 157, 278 in MODEL 212, 218

ENGINES 278 in MODEL 207

Shown on right-hand side

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

Courtesy of MERCEDES-BENZ USA

Shown on right-hand side

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

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Drain engine oil		AP18.00-P-0101EW
2	Remove engine with front axle carrier		AR01.10-P-2500ELB
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)
4	Remove refrigerant line on A/C compressor		*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.
6	Remove shield (8) on cylinder head		*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 protective cover.	AR09.41-P-8620ELB
8	Remove charge air ducts		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-7440ELB
11	Detach upper oil line on turbocharger with exhaust manifold (1)		AR18.30-P-6850ELB
12	Detach lower oil line on oil pan		AR18.30-P-6850ELB
13	Remove bracket (9) between exhaust pipe (2) and cylinder head		*BA14.10-P-1004-01E
13			*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-0101EW
	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

TURBOCHARGER

Number	Designation			Engine 157	Engine 278
BA09.40-P-1001-01R	Nut, turbocharger/exhaust manifold to cylinder head	M7	Nm	15	15
BA09.40-P-1001-01R	Nut, turbocharger/exhaust manifold to cylinder head	M8	Nm	20	20
BA09.40-P-1007-01R	Bolt, shield to turbocharger/cylinder head		Nm	9	9

ENGINE SUPPORT (ENGINE SIDE)

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

EXHAUST MANIFOLD

Number	Designation		Engine 157	Engine 278
BA14.10-P-1003-01E	Bolt/nut, exhaust line to turbocharger	Nm	25	25
BA14.10-P-1004-01E	Bolt, bracket to exhaust line	Nm	25	25
BA14.10-P-1005-01E	Nut, exhaust line holder to cylinder head	Nm	20	20

REFRIGERANT COMPRESSOR

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

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

Courtesy of MERCEDES-BENZ USA