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

ENGINE 276.8 in model 172

ENGINE 276.8 in model 231

Fig 1: Turbocharger With Left Exhaust Manifold Components Location - Engine 276.8 In Model 172

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 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 on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
Notice	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-N-0005-01A
	Remove/install
1	Drain air conditioning system	ENGINE 276.8 in model 172 with code 580 (Air-conditioning system)	AR83.30-P-1760V
		ENGINE 276.8 in model 172 with code 581 (Automatic air conditioning) ENGINE 276.8 in model 231	AR83.30-P-1760YF
2	Drain off coolant in the low-temperature circuit		AR09.41-P-6834RKA
3	Remove left-hand air filter housing		AR09.10-P-1150RKA
4	Remove left rail insulation
5	Remove screw/bolt (8) and place vent line to one side
6	Remove left charge air pipe		AR09.41-P-1311RKA
7	Release and disconnect electrical connector (6)
8	Detach coolant feed pipe from exhaust gas turbocharger (7) and place to one side		AR20.20-P-7440RKA
9	Unlock and disconnect electrical connector of the Active Body Control (ABC) pump	ENGINE 276.8 in model 231 with code 487 (Active Body Control (ABC))
10	Detach bracket of coolant return line at oil filter housing and exhaust gas turbocharger (7)		AR20.20-P-7440RKA
11	Detach coolant return line from exhaust gas turbocharger (7) and place to one side		AR20.20-P-7440RKA
12	Detach bracket of left CAT on transmission	ENGINE 276.8 in model 172Bolt, exhaust system bracket to transmission	*BA49.10-P-1014-01AI
		ENGINE 276.8 in model 231 Bolt, bracket for front exhaust system to exhaust system/transmission	*BA49.10-P-1002-01AM
13	Detach oil feed line on exhaust gas turbocharger (7)		AR09.40-P-0002WA
14	Detach oil return line on exhaust gas turbocharger (7)		AR09.40-P-0004WA
15	Detach vacuum hose (1) at vacuum unit (2)
16	Disconnect refrigerant line in engine compartment at connecting point	ENGINE 276.8 in model 231 : Replace O-ring. Bolt/nut to connecting point for refrigerant line in engine compartment	*BA83.30-P-1010-01A
17	Open clamp (5) and disconnect flange connection between exhaust gas turbocharger (7) and exhaust pipe	: Replace clamp (5) and seal. : The dowel pin on left exhaust pipe must be set in the notch on the exhaust gas turbocharger (7). After screwing down the clamp (5) using the prescribed torque there should be no further gap on the left clamp lock. ENGINE 276.8 in model 172Bolt, clamp to diesel particulate filter/turbocharger	*BA49.10-P-1006-01AI
		ENGINE 276.8 in model 231 Bolt, flange connection for front exhaust system to exhaust manifold/turbocharger	*BA49.10-P-1001-01AM
18	Unscrew nuts (3) in reverse order to the tightening procedure of exhaust manifold; remove peg board	Tightening procedure for exhaust manifold	AR14.10-P-3000-01MM
		Nut, exhaust manifold to cylinder head	*BA14.10-P-1001-01E
19	Unclip exhaust gas turbocharger (7) from terminal rail (4) and remove upwards	: Replace seal.
20	Install in the reverse order
21.1	Check oil level in engine and correct if necessary	Where exhaust gas turbocharger (7) is reused.	AP18.00-P-1811MP
21.2	Carry out engine oil and filter change	Only when replacing exhaust gas turbocharger (7).	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
22	Perform an engine test run and check engine for proper operation and leaktightness

EXHAUST MANIFOLD

Number	Designation		ENGINE 276.8
BA14.10-P-1001-01E	Nut, exhaust manifold to cylinder head	Nm	20

EXHAUST SYSTEM

Number	Designation		ENGINE 276 in model 231
BA49.10-P-1001-01AM	Bolt, flange connection for front exhaust system to exhaust manifold/turbocharger	Nm	20

EXHAUST SYSTEM

Number	Designation			ENGINE 276 in model 231
BA49.10-P-1002-01AM	Bolt, bracket for front exhaust system to exhaust system/transmission	M8	Nm	25

EXHAUST SYSTEM

Number	Designation		ENGINE 276 in model 172
BA49.10-P-1006-01AI	Bolt, clamp to diesel particulate filter/turbocharger	Nm	17

EXHAUST SYSTEM

Number	Designation		ENGINE 276 in model 172
BA49.10-P-1014-01AI	Bolt, exhaust system bracket to transmission	Nm	25

AIR CONDITIONING

Number	Designation		Model 231
BA83.30-P-1010-01A	Bolt/nut to connecting point for refrigerant line in engine compartment	Nm	8