Remove/Install Turbocharger With Right Exhaust Manifold - AR09.40-P-6038MND

Engine 276.8 in model 213, 238 

Courtesy of MERCEDES-BENZ USA

Shown on engine 276.823 

Fig 1: Turbocharger With Right Exhaust Manifold Components Location - Engine 276.8 In Model 213 (Shown On Engine 276.823)

Courtesy of MERCEDES-BENZ USA

Shown on engine 276.823 

Shown on engine 276.823 

Courtesy of MERCEDES-BENZ USA

	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  to skin and eyes suffering scalding from contact with hot coolantspray. 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
	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 avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove
1	Remove engine compartment paneling		AR61.20-P-1105LWE
2	Drain off coolant of engine cooling system		AR20.00-P-1142OLC
3	Remove right catalytic converter	Engine 276.853 in model 213	AR49.10-P-5503MND
4	Remove clamp of exhaust gas recirculation line at exhaust gas turbocharger (14)	Engine 276.853 in model 213
5	Remove right air filter housing with clean air line		AR09.10-P-1152MND
6	Remove right rail insulation
7	Remove bolt (21)
8	Remove right charge air pipe		AR09.41-P-1326MND
9	Release and disconnect electrical connection at bypass air switchover valve (13)
10	Remove screw/bolt (6) at right ATL (14) and place coolant feed pipe (8) to one side, close off openings with suitable stop plugs	Record plug	Fig 2
11	Remove inerting system line from heat shields (9) and place to one side	Engine 276.8 in model 213, 238 with code 2U8 (Alternative refrigerant)	AR86.10-P-0319LWE
12	Remove heat shields (1, 9, 10) of exhaust gas turbocharger (14)
13	Remove coolant return line (5) from ATL (14) and seal openings with suitable stop plugs		AR09.41-P-0016MND
		Record plug	Fig 2
14	Remove oil feed line (2) and seal openings with suitable stop plugs		AR09.40-P-0003MND
		Record plug	Fig 2
15	Remove oil return line (7) and seal openings with suitable stop plugs		AR09.40-P-0005MND
		Record plug	Fig 2
16	Remove vacuum hose (4) at vacuum cell (3)
17	Open clamp (15) and disconnect flange connection between exhaust gas turbocharger (14) and exhaust gas line
18	Unscrew nuts (11) of exhaust gas turbocharger (14) at cylinder head in reverse order to tightening procedure of exhaust manifold and remove peg board	Tightening procedure for exhaust manifold	AR14.10-P-3000-01MM
19	Tip out the ATL (14) from terminal rail (16) and vent line (20) and remove upwards and close off openings with suitable stop plugs	Record plug	Fig 2
20	Remove seal from cylinder head
21	Remove seal between exhaust pipe and ATL (14)	Engine 276.853 in model 213
22	Clean sealing surfaces		AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 (400 ml) cleaning spray	*BR00.45-Z-1046-04A
23	Check stud bolts for damage	Stud bolt damaged ↓ Replace stud bolt.
	Install
24	Fasten new seal on cylinder head
25	Fasten new sealing ring on the vent line (20)
26	Remove the stop plug and introduce ATL (14) in terminal rail (16) and vent line (20) and push downwards	Record plug	Fig 2
27	Place peg board on stud bolts
28	Tighten nuts (11) of ATL (14) on cylinder head in the sequence of the tightening procedure of the exhaust manifold	Tightening procedure for exhaust manifold	AR14.10-P-3000-01MM
		Nut, turbocharger peg board to cylinder head	*BA09.40-P-1001-01W
29	Tighten screw (21)	Screw/bolt, vent line from oil separator to turbocharger	*BA01.20-P-1007-01L
30	Connect flange connection between exhaust line and the ATL (14) with a new clamp (15)	The dowel pin on the exhaust line must be set in the notch on the ATL (14). After screwing on clamp (15) to the specified tightening torque, there may no longer be a gap at the clamp lock. Engine 276.8 in model 238Clamp at turbocharger and catalytic converter/front exhaust line	*BA49.10-P-1001-02I
		Engine 276.8 in model 213Clamp at turbocharger and catalytic converter/front exhaust line	*BA49.10-P-1001-02G
31	Attach vacuum hose (4) to vacuum unit (3)
32	Remove stop plug, attach oil feed line (2)		AR09.40-P-0003MND
		Record plug	Fig 2
33	Remove stop plug, attach oil return line (7)		AR09.40-P-0005MND
		Record plug	Fig 2
34	Remove stop plug; attach coolant return line (5) with a new sealing ring on the ATL (14)		AR09.41-P-0016MND
		Record plug	Fig 2
35	Install heat shield (1, 9, 10)	Bolt/nut for shield attachment	*BA09.40-P-1011-01W
36	Remove stop plug; attach coolant feed pipe (8) with a new sealing ring on the ATL (14) and tighten screw/bolt (6)		AR09.41-P-0012MND
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
		Record plug	Fig 2
37	Plug in electrical connection on bypass air switchover valve (13) and lock
38	Install right rail insulation
39	Install right charge air pipe		AR09.41-P-1326MND
40	Install right air filter housing with clean air line	Only install upper engine cover after the leak test.	AR09.10-P-1152MND
41	Attach clamp of EGR line with a new seal to the ATL (14)	Engine 276.853 in model 213 Clamp, exhaust gas recirculation line to turbocharger/exhaust gas recirculation line	*BA14.20-P-1007-01M
42	Attach line of inerting system to heat shield (9)	Engine 276.8 in model 213, 238 with code 2U8 (Alternative refrigerant)	AR86.10-P-0319LWE
43	Install right three way catalytic converter	Engine 276.853 in model 213	AR49.10-P-5503MND
44	Pour coolant into engine cooling system		AR20.00-P-1142OLC
45.1	Check oil level in engine and correct if necessary	Where exhaust gas turbocharger (14) will be reused.	AP18.00-P-1811MP
45.2	Perform engine oil change with oil filter change	Only when replacing ATL (14).	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
46	Perform an engine test run and check engine for proper operation and leak tightness
47	Install lower engine compartment paneling		AR61.20-P-1105LWE
48	Install upper engine cover

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

Courtesy of MERCEDES-BENZ USA