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

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Engine 260 in model 118 as of model year 2023

Engine 260 in model 177, 247 as of model year 2022

Fig 1: Turbocharger With Exhaust Manifold Components Location - Model 118 In Engine 260 (As Of Model Year 2023)

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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 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 danger zone.	AS49.00-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 overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-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
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Notice	Notes on self-locking nuts and bolts		AH00.00-P-0001-01KOA
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Notice	Notes on coolant	AH20.00-P-2080-01KOA Notes on safety-relevant components	AH00.00-Z-0019-01A
	Remove/install
1	Remove engine air intake duct downstream of air filter.		AR09.10-P-8130MFC
2	Release catalytic converter from exhaust gas turbocharger (1) and crankcase.		AR49.20-P-0100MFC
3	Remove oil return feed line from exhaust gas turbocharger (1).		AR09.40-P-6021MRX
4	Remove coolant return flow line from exhaust gas turbocharger (1) and swivel to one side.		AR20.20-P-1050MFA
5	Release, disconnect electrical connector (2) and expose electrical wiring harness.	: Ensure that electrical wiring harness is routed properly.
		Dismantling tool	Fig 4
6	Unscrew screw (3) and remove holder from exhaust gas turbocharger (1).
7	Remove screws (4) and remove heat shield (5).	Bolt/nut, heat shield to turbocharger	*BA09.40-P-1009-02G
8	Remove nut (6).	Nut, holder for heat shield to exhaust gas turbocharger	*BA09.40-P-1006-02G
9	Remove nut (7).	Bolt/nut, heat shield to turbocharger	*BA09.40-P-1009-02G
10	Unscrew screw (8) and remove bracket (9).	Bolt, holder for heat shield on exhaust gas turbocharger to cylinder head	*BA09.40-P-1007-02G
11	Remove nuts (10), sliding strips (11) and the exhaust gas turbocharger (1).
			GF09.40-P-8451-10MFH
		Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-02G
		Record plug	Fig 3
		Set of protective caps	Fig 5
		Set of protective covers	Fig 2
	Clean
12	Clean sealing surface at exhaust manifold and exhaust gas turbocharger (1).
	Check
13	Remove seal (12) and check stud bolt (13) on cylinder head for damage.	: Install new seal (12). Stud bolt for exhaust manifold If defects are present on the stud bolts (13) on the cylinder head: ↓ Replace stud bolts (13) on the cylinder head.	*BA01.30-P-1004-01Y
14	Install in the reverse order.
	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
15	Carry out engine test run and check engine for proper operation and leak tightness.

CYLINDER HEAD

Number	Designation		Engine 260
BA01.30-P-1004-01Y	Stud bolt for exhaust manifold	Nm	11

TURBOCHARGER

Number	Designation		Engine 260
BA09.40-P-1001-02G	Nut, turbocharger/exhaust manifold to cylinder head	Nm	15

TURBOCHARGER

Number	Designation		Engine 260
BA09.40-P-1006-02G	Nut, holder for heat shield to exhaust gas turbocharger	Nm	30

TURBOCHARGER

Number	Designation		Engine 260
BA09.40-P-1007-02G	Bolt, holder for heat shield on exhaust gas turbocharger to cylinder head	Nm	20

TURBOCHARGER

Number	Designation		Engine 260
BA09.40-P-1009-02G	Bolt/nut, heat shield to turbocharger	Nm	8

Fig 2: Identifying Set Of Protective Covers (001 589 03 91 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Dismantling Tool (000 589 95 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Set Of Protective Caps (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA