Remove/Install Turbocharger With Left Exhaust Manifold - AR09.40-P-6037MND

Engine 276.8 in model 213, 238 

Courtesy of MERCEDES-BENZ USA

Shown on engine 276.823 

Fig 1: Turbocharger With Left Exhaust Manifold Components Location - Engine 276.8 In Model 213 (Shown On Engine 276.823)

Courtesy of MERCEDES-BENZ USA

Shown on engine 276.823 

Shown on engine 276.823 

Courtesy of MERCEDES-BENZ USA

	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 explosion  caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.	Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained.	AS83.00-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 pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	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  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
	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-N-0005-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove
1	Drain air conditioning system	Engine 276.8 in model 213 except code 1U6 (R744 refrigerant)	AR83.30-P-1760LW
		Engine 276.8 in model 238	AR83.30-P-1760LWO
2	Remove engine compartment paneling		AR61.20-P-1105LWE
3	Drain off coolant of engine cooling system		AR20.00-P-1142OLC
4	Remove left catalytic converter	Engine 276.853 in model 213	AR49.10-P-5502MND
5	Remove clamp of EGR line at the ATL (15)	Engine 276.853 in model 213
6	Remove left air filter housing with clean air line		AR09.10-P-1151MND
7	Remove left rail insulation
8	Remove screw/bolt (23), remove place vent line (22) and place to one side
9	Remove left charge air pipe		AR09.41-P-1327MND
10	Release and disconnect electrical connection (16) at bypass air switchover valve
11	Remove screw/bolt (5)
12	Remove screw/bolt (10) at the ATL (15) and place coolant feed line (7) to one side, close off openings with suitable stop plugs		AR09.41-P-0011MND
		Record plug	Fig 3
13	Remove inerting system line from heat shield (8) and place to one side	Engine 276.8 in model 213, 238 with code 2U8 (Alternative refrigerant)	AR86.10-P-0319LWE
14	Remove heat shields (4, 6, 8) from ATL (15)
15	Remove coolant return line (11), place to one side and close off openings with suitable stop plugs		AR09.41-P-0016MND
		Record plug	Fig 3
16	Remove oil feed line (3) and seal openings with suitable stop plugs		AR09.40-P-0002MND
		Record plug	Fig 3
17	Unfasten clamp of oil return line (9) at hose line and push back		AR09.40-P-0004MND
		Hose clamp pliers	Fig 2
18	Remove vacuum hose (1) at vacuum unit (2)
19	Disconnect refrigerant lines at engine compartment connecting point and close off openings using suitable stop plugs	Record plug	Fig 3
20	Open clamp (14) and disconnect flange connection between ATL (15) and exhaust line
21	Unscrew nuts (12) for ATL (15) on cylinder head in reverse order to the exhaust manifold tightening procedure and remove peg board	Tightening procedure for exhaust manifold	AR14.10-P-3000-01MM
22	Tilt out the ATL (15) from terminal rail (13) and extend to hose line of the oil return line (9), lift out upwards and openings with suitable stop plugs	Record plug	Fig 3
23	Remove the stop plug and modify oil return line (9) on ATL (15) with a new seal	When installing a new exhaust gas turbocharger (15).	AR09.40-P-0004MND
		Record plug	Fig 3
24	Remove seal from cylinder head
25	Remove seal between exhaust pipe and remove the ATL (15)	Engine 276.853 in model 213
26	Clean sealing surfaces on cylinder head		AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 (400 ml) cleaning spray	*BR00.45-Z-1046-04A
27	Check stud bolts for damage	Stud bolt damaged ↓ Replace stud bolt.
	Install
28	Fasten new seal on cylinder head
29	Remove the stop plug and position the ATL (15) on oil return line (9) and push on	Record plug	Fig 3
30	Introduce ATL (15) from terminal rail (13) and push downwards
31	Place peg board on stud bolts
32	Screw nuts (12) of ATL (15) onto cylinder head in sequence of the tightening procedure of the exhaust manifold	Tightening procedure for exhaust manifold	AR14.10-P-3000-01MM
		Nut, turbocharger peg board to cylinder head	*BA09.40-P-1001-01W
33	Position and fasten clamp for hose line of oil return line (9) and fasten		AR09.40-P-0004MND
		Hose clamp pliers	Fig 2
34	Connect flange connection between exhaust line and the ATL (15) with new clamp (14) and seal	The dowel pin on the exhaust line must be set in the notch on ATL (15). After screwing down the clamp (14) using the prescribed tightening torque, there may be no gap anymore on the clamp lock. Engine 276.8 in model 238Clamp at turbocharger and catalytic converter/front exhaust line	*BA49.10-P-1001-02I
		Engine 276.8 in model 213Clamp at turbocharger and catalytic converter/front exhaust line	*BA49.10-P-1001-02G
35	Remove the stop plug of the connecting point of refrigerant lines in engine compartment	Record plug	Fig 3
36	Connect refrigerant lines to connecting point in engine compartment with new sealing rings	Nut/bolt, connecting point for refrigerant line	*BA83.30-P-1004-01R
37	Detach vacuum hose (1) at vacuum unit (2)
38	Remove the stop plug, attach oil feed line (3)		AR09.40-P-0002MND
		Record plug	Fig 3
39	Remove the stop plugs; attach coolant return line (11) at the ATL (15)		AR09.41-P-0016MND
		Record plug	Fig 3
40	Install heat shields (4, 6, 8)	Bolt/nut for shield attachment	*BA09.40-P-1011-01W
41	Tighten bolt (5)	Bolt/nut for shield attachment	*BA09.40-P-1011-01W
42	Position coolant feed line (7) with the new sealing ring on the ATL (15) and tighten screw/bolt (10)		AR09.41-P-0011MND
		Bolt, coolant feed/return line to turbocharger	*BA09.40-P-1008-01W
43	Plug in electrical connection (16) together on bypass air switchover valve and lock
44	Position vent line (22) with new sealing ring and tighten screw/bolt (23)	Screw/bolt, vent line from oil separator to turbocharger	*BA01.20-P-1007-01L
45	Install left rail insulation
46	Install left charge air pipe		AR09.41-P-1327MND
47	Install left air filter housing with clean air line	Only install upper engine cover after the leak test.	AR09.10-P-1151MND
48	Attach clamp of the EGR line with a new seal to the ATL (15)	Engine 276.853 in model 213 Clamp, exhaust gas recirculation line to turbocharger/exhaust gas recirculation line	*BA14.20-P-1007-01M
49	Attach inerting system line to heat shield (8)	Engine 276.8 in model 213, 238 with code 2U8 (Alternative refrigerant)	AR86.10-P-0319LWE
50	Install left catalytic converter	Engine 276.853 in model 213	AR49.10-P-5502MND
51	Pour coolant into engine cooling system		AR20.00-P-1142OLC
52	Charge air conditioning system	Engine 276.8 in model 213 except code 1U6 (R744 refrigerant)	AR83.30-P-1760LW
		Engine 276.8 in model 238	AR83.30-P-1760LWO
53.1	Check oil level in engine and correct if necessary	When reusing the ATL (15).	AP18.00-P-1811MP
53.2	Perform engine oil change with oil filter change	When installing a new exhaust gas turbocharger (15).	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
54	Perform an engine test run and check engine for proper operation and leaktightness
55	Install lower engine compartment paneling		AR61.20-P-1105LWE
56	Install upper engine cover

Fig 2: Identifying Hose Clamp Pliers (003 589 03 37 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA