Remove/Install Turbocharger With Exhaust Manifold - AR09.40-P-6025GQC

ENGINE 276.8 in MODEL 166, 251, 292 

Shown on left ATL on model 166 with engine 276.8 

Shown on left ATL on model 166 with engine 276.8 

	Risk of death  when touching components on vehicles with high-voltage on-board electrical system	Do not touch damaged or defective components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers) must not carry out any work on high-voltage on-board electrical systems.	AS54.00-Z-0001-01A
	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
	Note on high-voltage on-board electrical system		AH54.00-P-0010-01A
	Evaluation of high-voltage components		AH54.00-P-6500-01SXH
	Remove/install
1	Perform enable for the high voltage on-board electrical system	Engine 276.8 in model 166.063 When removing the left ATL (1).	AR54.10-P-1150GQA
2	Drain air conditioning system	Engine 276.8 in model 166, 292 with code 468 (ACTIVE CURVE SYSTEM)	AR83.30-P-1760CW
3	Drain off coolant	Engine 276.8 in model 166, 292	AR20.00-P-1142GQ
		Engine 276.8 in model 251	AR20.00-P-1142GZC
4	Remove partition wall between wheel wells	Engine 276.8 in model 251	AR62.30-P-2400RT
5	Remove windshield wiper system	Engine 276.8 in model 251	AR82.30-P-6400RT
6	Remove upper engine cover
7	Remove left-hand air filter housing	Engine 276.8 in model 166, 292 When removing the left ATL (1).	AR09.10-P-1150GQC
8	Remove right air filter housing	Engine 276.8 in model 166, 292 When removing the right ATL (1).	AR09.10-P-1150GQC
9	Detach refrigerant line at upper connecting point on engine compartment	Engine 276.8 in model 166, 292 with code 468 (ACTIVE CURVE SYSTEM) When removing the left ATL (1). Nut, high-pressure line to condenser/engine compartment connecting point/expansion valve	*BA83.30-P-1009-01J
10	Remove left and right air filter housing	Engine 276.8 in model 251	AR09.10-P-1150GQC
11	Detach hydraulic line at hydraulic pump and turn to the side	Engine 276.8 in model 166, 292 with code 468 (ACTIVE CURVE SYSTEM) When removing the left ATL (1).	AR32.34-P-0030GQ
12	Unclip vacuum line at soundproofing on the rail	Engine 276.8 in model 166.063 When removing the left ATL (1).	AR43.10-P-0355GQ
13	Disconnect vacuum line from electrical vacuum pump and place to one side	Engine 276.8 in model 166.063 When removing the left ATL (1).
14	Remove electrical vacuum pump from bracket and place with attached electrical line to one side	Engine 276.8 in model 166.063 When removing the left ATL (1).	AR43.05-P-0001GQA
15	Remove left rail insulation	When removing the left ATL (1).
16	Remove right rail insulation	When removing the right ATL (1).
17	Remove screw/bolt (3) on left ATL (1) and place line to one side	When removing the left ATL (1).
18	Remove screw/bolt (3) on right ATL (1) and place line to one side	When removing the right ATL (1).
19	Detach clamp (6) on left CAT	When removing the left ATL (1). Replace clamp (6) and seal. The dowel pin on the exhaust gas outlet 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.	AR49.10-P-5500GQC
20	Detach clamp (6) on right CAT	When removing the right ATL (1). Replace clamp (6) and seal. The dowel pin on the exhaust gas outlet 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.	AR49.10-P-5500GQC
21	Remove screw/bolts (5) on left charge air pipe (4) and take off left charge air pipe (4)	When removing the left ATL (1).	AR09.41-P-8620GQC
22	Remove screw/bolts (5) on right charge air pipe (4) and take off right charge air pipe (4)	When removing the right ATL (1).	AR09.41-P-8620GQC
23	Disconnect electrical connection at left divert air switchover valve (Y101/1)	When removing the left ATL (1).
24	Disconnect electrical connection at right divert air switchover valve (Y101/1)	When removing the right ATL (1).
25	Detach purge hose at divert air switchover valve (Y101/1)	Engine 276.8 in model 166, 292 with code 468 (ACTIVE CURVE SYSTEM) When removing the left ATL (1).
26	Remove heat shields (14, 15, 16) from left ATL (1)	When removing the left ATL (1).
27	Remove heat shields (14, 15, 16) from right ATL (1)	When removing the right ATL (1).
28.1	Remove screw/bolts (11, 18) at left coolant feed pipe (13) and place left coolant feed pipe (13) to one side	Engine 276.8 in model 166, 251, 292 (except 292.364) When removing the left ATL (1). Replace seal. Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
28.2	Remove screw/bolt (11) and place left coolant feed pipe (13) to one side	Engine 276.8 in model 292.364 When removing the left ATL (1). Replace seal. Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
29.1	Remove screw/bolts (11, 18) at right coolant feed pipe (13) and place right coolant feed pipe (13) to one side	Engine 276.8 in model 166, 251, 292 (except 292.364) When removing the right ATL (1). Replace seal. Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
29.2	Remove screw/bolt (11) and place right coolant feed pipe (13) to one side	Engine 276.8 in model 292.364 When removing the right ATL (1). Replace seal. Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
30	Remove left coolant return line (10)	When removing the left ATL (1).	AR20.20-P-7440GQC
31	Remove right coolant return line (10)	When removing the right ATL (1).	AR20.20-P-7440GQC
32	Remove left oil return line (12) and left oil feed line (17) on ATL (1)	When removing the left ATL (1).	AR18.30-P-6850GQC
33	Remove right oil return line (12) and right oil feed line (17) on ATL (1)	When removing the right ATL (1).	AR18.30-P-6850GQC
34	Detach bracket of left oil lines on transmission	When removing the left ATL (1). Engine 276.8 in model 166, 292 with transmission 722.9 Engine 276.8 in model 166.063 with transmission 724.2 Bolt, exhaust system bracket to transmission	*BA49.10-P-1020-01AK
		Engine 276.8 in model 251 with transmission 722.9 Bolt, catalytic converter bracket to catalytic converter	*BA49.10-P-1001-01X
35	Detach bracket of right CAT on transmission	When removing the right ATL (1). Engine 276 in model 166.063 with transmission 724.2 Engine 276.8 in model 166, 292 with transmission 722.9 Bolt, exhaust system bracket to transmission	*BA49.10-P-1020-01AK
		Engine 276.8 in model 251 with transmission 722.9 Bolt, catalytic converter bracket to catalytic converter	*BA49.10-P-1001-01X
36	Expansion reservoir carrier for low-temperature circuit expansion reservoir and place to one side	When removing the right ATL (1).	AR09.41-P-0002GQC
37	Detach vacuum hose (9) at left vacuum unit (2)	When removing the left ATL (1).
38	Detach vacuum hose (9) at right vacuum unit (2)	When removing the right ATL (1).
39	Mount engine hoist and raise engine slightly	When removing the left ATL (1). Engine 276.8 in model 251 Only raise engine sufficiently that the engine mounts are not under tension.	AR33.10-P-0100-01RT
		Engine 276.8 in model 251 Bolt, partition wall reinforcement between wheel well liners to fender	*BA62.30-P-1008-01E
		Adaptation of engine lifting device	Fig 2
		Engine lifting device	Fig 1
40	Detach front engine mounts on front axle carrier	Engine 276.8 in model 251 When removing the left ATL (1).	AR22.10-P-4330GQC
41	Detach nuts (7) for link ATL (1) on cylinder head and remove peg board	When removing the left ATL (1). Tighten nuts (7) from the inside to the outside. Nut, turbocharger peg board to cylinder head	*BA09.40-P-1001-01W
42	Detach nuts (7) for right ATL (1) on cylinder head and remove peg board	When removing the right ATL (1). Tighten nuts (7) from the inside to the outside. Nut, turbocharger peg board to cylinder head	*BA09.40-P-1001-01W
43	Lift engine a little	Engine 276.8 in model 251 When removing the left ATL (1). Pay attention when lifting out engine that no cables and lines are damaged and that engine does not lean against the bulkhead.
44	Tilt left ATL (1) downwards and remove upwards out of the terminal rail (8)	When removing the left ATL (1). Replace seal.
45	Tilt right ATL (1) downwards and remove upwards out of the terminal rail (8)	When removing the right ATL (1). Replace seal.
46	Install in the reverse order
	Check
47.1	Check oil level in engine and correct if necessary	When reusing the ATL (1).	AP18.00-P-1811MP
47.2	Carry out engine oil and filter change	Only when replacing ATL (1).
		Engine 276.8 in model 251	AP18.00-P-0101W
		Engine 276.8 in model 166, 292	AP18.00-P-0101GQ
	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 buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
48	Perform an engine test run and check engine for leaktightness

Fig 1: Identifying Engine Lifting Device (240 589 00 61 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Adaptation Of Engine Lifting Device (642 589 00 61 00)

Courtesy of MERCEDES-BENZ USA