Remove/Install Turbocharger With Exhaust Manifold - AR09.40-P-6025MLJ

ENGINE 157, 278 in MODEL 166 

Shown on engine 278 (on right) 

Shown on engine 278 (on right) 

	Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. 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  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 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/install
1	Drain engine oil
		Engine 157 in model 166	AP18.00-P-0101EWG
		Engine 278 in model 166	AP18.00-P-0101EL
2	Remove engine with front axle carrier		AR01.10-P-2500MLJ
3	Detach clamp (6) on heat shield (7)	When removing right exhaust gas turbocharger with exhaust manifold (1).
4	Remove refrigerant line at refrigerant compressor and seal exposed connections with stop plugs	When removing left exhaust gas turbocharger with exhaust manifold (1). Bolt, refrigerant line to refrigerant compressor	*BA83.55-P-1003-01M
		Record plug	Figure
5	Remove heat shield (7) at engine carrier	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	Remove vacuum hose of boost pressure control valve at exhaust gas turbocharger with exhaust manifold (1)
8	Remove charge air pipe		AR09.41-P-8620MLJ
9	Remove coolant line of charge air cooler at timing case cover	When removing right exhaust gas turbocharger with exhaust manifold (1).
10	Remove coolant lines		AR20.20-P-7440MLJ
11	Remove upper oil line at exhaust gas turbocharger with exhaust manifold (1)		AR18.30-P-6850MLJ
12	Remove lower oil line at 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)	Tightening pattern for turbocharger	AR09.40-P-6020-10NMB
		Bolt/nut, exhaust line to turbocharger	*BA14.10-P-1003-01E
15	Remove nuts (1a, 1b) at exhaust gas turbocharger with exhaust manifold (1)	Nut, turbocharger/exhaust manifold to cylinder head	*BA09.40-P-1001-01R
16	Remove lock washers (3) at exhaust gas turbocharger with exhaust manifold (1)	Install new locking plates (3).
17	Remove exhaust gas turbocharger with exhaust manifold (1) from cylinder head	Clean sealing surfaces and replace exhaust manifold seal. Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
18	Install in the reverse order
	Check
19	Check engine oil level; correct if necessary		AP18.00-P-1811MP
	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 hazard area.	AS49.00-Z-0001-01A
	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 Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA