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

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ENGINE 276.8 in MODEL 207, 212, 218

MODIFICATION NOTES

27.1.15

Carry out engine oil and filter change; added

Operation step 18.2

Shown on left ATL

Fig 1: Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Left ATL (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Shown on left ATL

Fig 2: Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Left ATL (2 Of 2)

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	MODEL 212, 218 with ENGINE 276.8	AR20.00-P-1142EL
1	Drain off coolant	MODEL 207 with ENGINE 276.8	AR20.00-P-1142A
2	Remove upper engine cover
3	Remove air filter housing		AR09.10-P-1150ELS
4	Remove rail insulation	Check retaining clamps for insulation for damage and replace if necessary. Ensure correct seating of the retaining clamps and the insulation at the rail.
5	Remove screw/bolt (3), detach line and place to one side	Replace sealing ring.
6	Remove charge air pipe (4)		AR09.41-P-8620ELS
7	Disconnect electrical connection at left divert air switchover valve (Y101/1)
8	Remove heat shields (14, 15, 16) from ATL (1)
9	Remove screw/bolts (11, 18), detach coolant feed pipe (13) and place to one side	Replace seal.
9		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
10	Detach coolant return line (10) on ATL (1), detach bracket (3 pieces) and set coolant return line (10) aside		AR20.20-P-7440ELS
		Replace seal.
11	Remove oil return line (12) and oil feed line (17)		AR18.30-P-6850ELS
		Install new sealing rings.
12	Detach vacuum hose (9) at vacuum unit (2)
13	Detach CAT bracket at transmission	Bolt, exhaust system bracket to transmission	*BA49.10-P-1023-01AE
14	Disconnect flange connection between ATL (1) and exhaust pipe; to do this open the clamp (6)	Replace clamp (6) and seal. 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 .
14		Bolt, pipe clamp to exhaust gas turbocharger	*BA49.10-P-1050-01AE
15	Detach nuts (7) for ATL (1) on cylinder head and remove peg board	Tighten nuts (7) from the inside to the outside.
15		Nut, turbocharger peg board to cylinder head	*BA09.40-P-1001-01W
16	Unclip ATL (1) from terminal rail (8) and remove upwards	Replace seal.
17	Install in the reverse order
18.1	Check oil level in engine and correct if necessary	When reusing the ATL (1)
			AP18.00-P-1811MP
18.2	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
19	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 156, 157, 271, 272, 273, 276, 278 in MODEL 212	ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1023-01AE	Bolt, exhaust system bracket to transmission	Nm	20	20

EXHAUST SYSTEM

Number	Designation		ENGINE 271, 272, 273, 276, 278 in MODEL 207
BA49.10-P-1023-01AE	Bolt, exhaust system bracket to transmission	Nm	20

EXHAUST SYSTEM

Number	Designation		ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212	ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1050-01AE	Bolt, pipe clamp to exhaust gas turbocharger	Nm	15	15

EXHAUST SYSTEM

Number	Designation		ENGINE 271, 272, 273, 276, 278 in MODEL 207
BA49.10-P-1050-01AE	Bolt, pipe clamp to exhaust gas turbocharger	Nm	15