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

Engine 274.9 in model 205 

Engine 274.9 in model 253 

Courtesy of MERCEDES-BENZ USA

Shown on engine 274.9 in model 205 with code 2U8 (Alternative refrigerant) 

Courtesy of MERCEDES-BENZ USA

	Risk of burn injuries  , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning  caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.	AS49.00-Z-0001-01A
	Risk of injury  to skin and eyes due to handling of engine oil. Risk of poisoning  caused by swallowing engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers.	AS18.00-Z-0001-01A
	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
	Notes on coolant		AH20.00-N-2080-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove/install
1	Drain off coolant	: Only install front and center lower engine compartment paneling after leak test.	AR20.00-P-1142LW
2	Remove air filter housing	: Only install upper engine cove after the leak test.	AR09.10-P-1150MRA
3	Remove expansion reservoir for low-temperature circuit and place with attached lines to one side		AR09.41-P-0001MRA
4	Unclip coolant line (1) from front holder from the air filter housing
5	Remove air filter housing holder	M8 X 1	*BA00.10-P-1004-04A
6	Unscrew nut (13) and place line (14) to one side	Engine 274.9 in model 205 with code 2U8 (Alternative refrigerant) Engine 274.9 in model 253 with code 2U8 (Alternative refrigerant)
		Nut, heat shield to turbocharger support brace	*BA09.40-P-1014-01U
7	Remove heat shield (2)	Bolt, heat shield to cylinder head/bracket for air filter	*BA09.40-P-1015-01U
8	Remove oil lines (5a, 5b) and close off openings with suitable stop plugs	: Replace screw/bolts and seals.	AR09.40-P-6020-13MR
		Screw/bolt, oil line for oil feed to exhaust gas turbocharger	*BA09.40-P-1005-01U
		Screw/bolt, oil line for 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
		Record plug	Fig 2
9	Remove coolant lines (4a, 4b) and close off openings with suitable stop plugs	: Replace screw/bolts and seals.	AR09.40-P-6020-14MR
		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
		Record plug	Fig 2
10	Detach vacuum hose (16) from vacuum unit
11	Release and disconnect electrical connector (15)
12	Remove air intake pipe from ATL (3)		AR09.10-P-8131MRA
13	Remove charge air pipe from ATL (3)	M6 X 1	*BA00.10-P-1002-04A
14	Remove bracket for CAT		AR49.10-P-5500LW
15	Remove CAT from ATL (3) and secure against falling down		AR49.10-P-5500LW
16	Remove EGR line from ATL (3)	Engine 274.9 in model 205 with code 920 (Direct petrol injection with stratified charging)
		: Replace seal and nuts.
		Bolt/nut, connecting point for exhaust pipe	*BA14.20-P-1003-01O
17	Remove holder (10) from 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 1
18	Unscrew nuts (12)	Tightening pattern for turbocharger Installation:  Replace nuts (12).	AR09.40-P-6020-10MRD
		Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-01U
19	Unfasten ATL (3) from cylinder head
20	Remove ATL (3) together with support (10)	Installation:  Replace seal (11).
	Clean
21	Clean sealing surfaces of ATL (3) and cylinder head
	Check
22	Check stud bolts of ATL (3) for damage and replace if necessary	Stud bolt for exhaust manifold	*BA01.30-P-1004-01Y
23	Install in the reverse order
24	Check engine oil level and correct		AP18.00-P-1811MP
	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
25	Perform an engine test run and check engine for proper operation and leaktightness
26	Install front and center engine compartment paneling		AR61.20-P-1105LW
27	Install upper engine cover

Fig 1: Identifying Set Of Flexible Head Wrenches (001 589 81 09 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA