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

ENGINE 270 in MODEL 117, 156, 176, 242, 246.2 

Shown on MODEL 246.242 

Fig 1: Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Model 246.242 (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Turbocharger With Exhaust Manifold Remove/Install Components - Shown On Model 246.242 (2 Of 2)

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. 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		AR20.00-P-1142NKB
2	Detach clamp (21)		AR49.10-P-4816MT
3	Detach bracket (22) on crankcase	Engine 270 in model 156	AR49.10-P-5500NKX
		Engine 270 in model 117, 176, 242, 246.2	AR49.10-P-5500MT
4	Detach bracket (23) from oil pan	Engine 270 in model 156	AR49.10-P-5500NKX
		Engine 270 in model 117, 176, 242, 246.2	AR49.10-P-5500MT
5	Remove upper engine cover
6	Remove engine air intake duct upstream of air filter
7	Remove air intake pipe	Engine 270 in model 117, 156 with code 494 (US version)	AR09.10-P-8131MTU
		Engine 270 in model 117, 156, 176, 242, 246.2 except code 494 (US version)	AR09.10-P-8131MT
8	Unclip electrical connection of electrical line (1) and unclip electrical plug connection from holder
9	Remove bracket (2)
10	Remove bracket (3) on cylinder head	Engine 270 in model 156	AR49.10-P-5500NKX
		Engine 270 in model 117, 176, 242, 246.2	AR49.10-P-5500MT
11	Detach heat shield (4) at cylinder head
12	Remove heat shield (5)	Ensure that clamp (12) on heat shield is seated correctly.
13	Detach CAT at ATL	Replace seal.
		Nut, catalytic converter to turbocharger	*BA09.40-P-1002-01S
14	Remove support brace (6) for ATL	Nut, turbocharger support brace to turbocharger	*BA09.40-P-1010-01S
		Bolt, turbocharger support brace to crankcase	*BA09.40-P-1011-01S
15	Detach vacuum line at aneroid capsule (7)
16	Detach vacuum line (14) at aneroid capsule for coolant pump and detach with spacers (13) at coolant lines for ATL
17	Remove screw/bolt (9s)	Bolt, water line feed line to oil feed line	*BA09.40-P-1009-01S
18	Remove coolant return line (10) and close off openings with stop plugs	Bolt, water line feed line/return line to turbocharger	*BA09.40-P-1008-01S
		Record plug	Fig 3
19	Remove coolant feed pipe (8) and close off openings with stop plugs	Bolt, water line feed line/return line to turbocharger	*BA09.40-P-1008-01S
		Record plug	Fig 3
20	Remove engine oil feed pipe (9) and close off openings with stop plugs	Screw/bolt, oil feed line to turbocharger	*BA09.40-P-1004-01S
		Screw/bolt, oil feed line to cylinder head	*BA09.40-P-1005-01S
		Record plug	Fig 3
21	Remove engine oil return pipe (11) and close off openings with stop plugs	Bolt, oil return flow line to turbocharger	*BA09.40-P-1006-01S
		Bolt, oil return line to crankcase	*BA09.40-P-1007-01S
		Record plug	Fig 3
22	Detach charge air hose at ATL		AR09.41-P-1311-01AL
23	Disconnect electrical connection at bypass air switchover valve (Y101)
24	Unclip engine wiring harness at ATL
25	Detach coolant pipe (15) at cylinder head and crankcase	Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 724
26	Detach ATL at cylinder head	Replace exhaust manifold gasket and nuts.
		Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-01S
	Check
27	Check stud bolts on cylinder head for damage	If damage is present ↓ Replace stud bolts
28	Detach bypass air switchover valve (Y101) at ATL	When replacing the bypass air switchover valve (Y101).
		Bolt, shift valve to turbocharger	*BA09.40-P-1003-01S
29	Install in the reverse order
	Check
30	Check engine oil level and correct if necessary
		Engine 270.910 in model 117, 156, 176, 246.2	AP18.00-P-0101NK
		Engine 270.920 in model 117, 156, 176, 242, 246.2	AP18.00-P-0101NL
	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
31	Carry out engine test run, checking the engine for leaktightness and proper operation

Fig 3: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA