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

Engine 276.8 in model 217, 222 

Shown on engine 276.8 without code ME05 (HD 80KW-variants (INCLUDING PLUGIN)) on left ATL 

Fig 1: Turbocharger Components Location - Engine 276.8 In Model 222 (Left Side Shown Without Code ME05)

Courtesy of MERCEDES-BENZ USA

Shown on left ATL 

Courtesy of MERCEDES-BENZ USA

	Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
	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
	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
Notice	Notes on self-locking nuts and bolts		AH00.00-P-0001-01KOA
Notice	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment		AH00.00-Z-0300-01A
Notice	Notes on battery		AH54.10-P-0001-01A
	Remove/install
1	Perform enable for the high voltage on-board electrical system	When removing the left ATL (1).
		Engine 276.8 in model 222.163/173	AR54.10-P-1150LF
2	Drain off coolant		AR20.00-P-1142LF
3	Remove upper engine cover	:  Only install upper engine cover after the leak test.
4	Remove relevant air filter housing		AR09.10-P-1150LFA
5	Unclip vacuum line at soundproofing on the rail	Engine 276.8 in model 222.163/173 At left turbocharger (1).
6	Remove soundproofing of rail
7	Unscrew screw/bolt (3), remove line and place to side	:  Install new sealing rings.
8	Remove relevant charge air pipe (4)		AR09.41-P-8620LFA
9	Disconnect electrical connection at left bypass air switchover valve (Y101/1) or right bypass air switchover valve
10	Remove left line of inerting system at turbocharger (1)	At left turbocharger (1).
		Engine 276.8 in model 217, 222 with code 2U8 (Alternative refrigerant)	AR86.10-P-0319LF
11	Remove right line of inerting system at turbocharger (1)	At right turbocharger (1).
		Engine 276.8 in model 217, 222 with code 2U8 (Alternative refrigerant)	AR86.10-P-0419LF
12	Remove heat shields (14, 15, 16) from ATL (1)
13	Unscrew screws/bolts (11, 18), remove coolant feed pipe (13) over relevant turbocharger (1) and place to side	:  Replace seal.
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
14	Remove coolant return line (10) of left turbocharger (1) and place to side		AR20.20-P-7440LFA
		:  Replace seal.
15	Remove oil return line (12) and oil feed line (17) of relevant turbocharger (1)		AR18.30-P-6850LFA
		:  Replace seal.
16	Remove vacuum hose (9) at vacuum control unit (2) at relevant turbocharger (1)
17	Remove catalytic converter bracket at transmission	Engine 276.8 in model 222 Bolt, front exhaust system bracket to transmission	*BA49.10-P-1003-01AN
		Engine 276 in model 217 Bolt, front exhaust system bracket to transmission	*BA49.10-P-1003-02D
18	Disconnect flange connection between relevant turbocharger (1) and exhaust pipe; to do this, open clamp (6)	:  Replace clamp (6) and seal.
		:  Insert dowel pin on intermediate piece between turbocharger (1) and exhaust system into notch on turbocharger (1). After screwing down the clamp (6) using the prescribed torque there should be no further gap on the clamp lock.
		Engine 276.8 in model 222 Bolt, clamp for front/center/rear exhaust system	*BA49.10-P-1006-01AN
		Engine 276 in model 217 Bolt, clamp for front/center/rear exhaust system	*BA49.10-P-1006-02D
19	Unscrew nuts (7) of relevant turbocharger (1) at cylinder head, and remove peg board	:  Tighten nuts (7) from the inside to the outside.
		Engine 276.8 in model 217, 222Nut, turbocharger peg board to cylinder head	*BA09.40-P-1001-01W
20	Tilt relevant turbocharger (1) out of terminal rail (8), and remove upwards	:  Replace seal.
21	Install in the reverse order
22.1	Check oil level in engine and correct if necessary	When reusing relevant turbocharger (1).
			AP18.00-P-1811MP
22.2	Perform engine oil and engine oil filter change	When replacing relevant turbocharger (1).
			AP18.00-P-0101CWZ
	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
23	Perform an engine test run and check engine for leaktightness
24	Install upper engine cover