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

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Engine 260 in model 118 up to model year 2022

Engine 260 in model 177, 247 up to model year 2021

Fig 1: Turbocharger With Exhaust Manifold Components Location - Engine 260 In Model 118 Up To Model Year 2022 (Shown On Model 177 Except Code M016)

Courtesy of MERCEDES-BENZ USA

Shown on model 177 with engine except code M016 (Performance-enhanced engine)

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

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 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 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 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 coolant		AH20.00-P-2080-01KOA
Notice	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Notice	Notes on self-locking nuts and bolts		AH00.00-P-0001-01KOA
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Remove/install
1	Drain off coolant.	: Only install lower engine compartment paneling after leak test.	AR20.00-P-1142MFC
2	Remove engine air intake duct upstream of air filter (1).	Engine 260 in model 118 up to model year 2022 except code M016 (Uprated engine) Engine 260 in model 177, 247 up to model year 2021 except code M016 (Uprated engine)
3	Remove charge air hose (2).	Engine 260 in model 118 up to model year 2022 except code M016 (Uprated engine) Engine 260 in model 177, 247 up to model year 2021 except code M016 (Uprated engine)	AR09.41-P-1311-01AL
		Set of protective covers	Fig 4
4	Remove engine air intake duct downstream of air filter (4).	: Do not install upper engine cover until after the leak test.	AR09.40-P-6045MFC
5	Remove heat shields (6) from exhaust gas turbocharger with exhaust manifold (29).		AR09.10-P-8130MFC
6	Release and disconnect electrical connector (10).
7	Unscrew screws (8) and remove lower heat shield (9).	Bolt/nut, heat shield to turbocharger	*BA09.40-P-1009-02G
8	Remove screws (11).	Bolt, coolant return line to oil line	*BA09.40-P-1003-02G
		Bolt, feed line/return line to turbocharger/crankcase	*BA09.40-P-1002-02G
9	Remove coolant lines (13, 31) at exhaust gas turbocharger with exhaust manifold (29) and place to one side.	: Replace seals.
		Assembly tool	Fig 2
		Record plug	Fig 3
10	Unscrew screws (14) and remove oil feed line (15).	: Replace seals.
		Bolt, feed line/return line to turbocharger/crankcase	*BA09.40-P-1002-02G
		Assembly tool	Fig 2
		Record plug	Fig 3
11	Unscrew screws (16) and remove oil return feed line (17).	: Replace seals.
		Bolt, feed line/return line to turbocharger/crankcase	*BA09.40-P-1002-02G
		Assembly tool	Fig 2
		Record plug	Fig 3
12	Remove catalytic converter (30) from engine and at exhaust gas turbocharger with exhaust manifold (29).	The screws from the catalytic converter (30) to the exhaust system remain on the vehicle.	AR49.20-P-0100MFC
13	Remove screw (18) from upper holder (19).	Bolt, holder for heat shield on exhaust gas turbocharger to cylinder head	*BA09.40-P-1007-02G
14	Remove nut (20) and remove upper holder (19).	Nut, holder for heat shield to exhaust gas turbocharger	*BA09.40-P-1006-02G
15	Remove nuts (32 to 39) with retaining plates at exhaust gas turbocharger with exhaust manifold (29) in reverse numerical sequence.	: Replace nuts (32 to 39) with retaining plates. Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-02G
16	Remove nut of support (41) at exhaust gas turbocharger with exhaust manifold (29).	Nut, turbocharger support brace to turbocharger	*BA09.40-P-1004-02G
17	Remove screw (40) and remove support (41).	Bolt, turbocharger support brace to crankcase	*BA09.40-P-1005-02G
18	Slightly press catalytic converter (30) to side and remove exhaust gas turbocharger with exhaust manifold (29).	: Replace seal of catalytic converter (30). Aid of helper required.
19	Remove seal (22) and check stud bolts on cylinder head for damage.	: Replace seal (22). Stud bolt for exhaust manifold If there are problems on the stud bolts on the cylinder head: ↓ Replace stud bolts on cylinder head.	*BA01.30-P-1004-01Y
20	Install in the reverse order.
	Check
21	Check engine oil level and correct if necessary.
		Vehicle must be horizontal and standing on its wheels. Measurement errors occur otherwise. Never pour in engine oil to above the maximum value. Engine damage will occur otherwise.	AP18.00-P-1812MFA
	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
22	Carry out engine test run and check function and leak tightness of the engine.

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-1002-02G	Bolt, feed line/return line to turbocharger/crankcase	Stage 1	Nm	8
BA09.40-P-1002-02G	Bolt, feed line/return line to turbocharger/crankcase	Stage 2	∠°	60

TURBOCHARGER

Number	Designation		Engine 260
BA09.40-P-1003-02G	Bolt, coolant return line to oil line	Nm	5

TURBOCHARGER

Number	Designation		Engine 260
BA09.40-P-1004-02G	Nut, turbocharger support brace to turbocharger	Nm	30

TURBOCHARGER

Number	Designation			Engine 260
BA09.40-P-1005-02G	Bolt, turbocharger support brace to crankcase	Stage 1	Nm	15
BA09.40-P-1005-02G	Bolt, turbocharger support brace to crankcase	Stage 2	∠°	90

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 Assembly Tool (000 589 93 63 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Set Of Protective Covers (001 589 12 91 00)

Courtesy of MERCEDES-BENZ USA