Remove/Install Turbocharger With Exhaust Manifold - AR09.40-P-6036MLJ

Engine 157, 278 in model 166 

Engine 157, 278 in model 292 

Shown on engine 278 (right side) 

Courtesy of MERCEDES-BENZ USA

Shown on engine 278 (right side) 

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Drain engine oil
		Engine 278 in model 166, 292	AP18.00-P-0101EL
		Engine 157 in model 166, 292	AP18.00-P-0101EWG
2	Remove engine with front axle carrier	Engine 157 in model 166 Engine 278 in model 166	AR01.10-P-2500MLJ
3	Detach clamp (6) on heat shield (7)	When removing the right ATL with exhaust manifold (1)
4	Remove refrigerant line on A/C compressor	When removing the left ATL with exhaust manifold (1)
		Bolt, refrigerant line to refrigerant compressor	*BA83.55-P-1003-01M
5	Remove heat shield (7) on engine support	Bolt, heat shield to engine support	*BA22.10-P-1003-02A
6	Remove heat shield (8) on cylinder head	Ensure correct seating of the clamps (5) on the heat shield (8) and exhaust manifold gasket.
		Bolt, heat shield to exhaust gas turbocharger/cylinder head	*BA09.40-P-1007-01R
7	Detach vacuum hose for boost pressure control valve on ATL with exhaust manifold (1)
8	Remove the charge air line		AR09.41-P-8620MLJ
		Seal openings using protective covers.
		Set of protective caps	Fig 1
9	Detach coolant line for charge air cooler on timing case cover	When removing the right ATL with exhaust manifold (1)
10	Remove coolant lines		AR20.20-P-7440MLJ
11	Detach upper oil line on ATL with exhaust manifold (1)		AR18.30-P-6850MLJ
12	Detach lower oil line on oil pan		AR18.30-P-6850MLJ
13	Remove bracket (9) between exhaust pipe (2) and cylinder head	Bolt, bracket to exhaust line	*BA14.10-P-1004-01E
		Nut, exhaust line holder to cylinder head	*BA14.10-P-1005-01E
14	Remove exhaust pipe (2)	Bolt/nut, exhaust line to turbocharger	*BA14.10-P-1003-01E
15	Remove lock washer (3) on ATL with exhaust manifold (1)	Install new locking plates (3).
16	Unscrew nuts (1a, 1b) on ATL with exhaust manifold (1)	Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-01R
17	Remove ATL with exhaust manifold (1) from cylinder head	Replace exhaust manifold gasket.
18	Install in the reverse order
	Check
19	Check engine oil level; correct if necessary
		Engine 157 in model 166, 292	AP18.00-P-0101EWG
		Engine 278 in model 166, 292	AP18.00-P-0101EL
	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
20	Carry out an engine test run, checking the engine for proper operation and leaktightness

Fig 1: Identifying Set Of Protective Caps (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA