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

Engine 260 in model 118, 177, 247 

Courtesy of MERCEDES-BENZ USA

Shown on model 177 with Engine without code M016 (performance-enhanced Engine) 

Fig 1: ATL/Turbocharger With Exhaust Manifold Components Location - Engine 260 In Model 247 (Shown On Model 177)

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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 o 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 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.		AR20.00-P-1142MFC
		Only install lower Engine compartment paneling after leak test.
2	Remove Engine air intake duct upstream of air filter (1).	Engine 260 in model 118, 177, 247 except code M016 (Uprated Engine)
3	Remove charge air hose (2) and seal openings with protective covers.	Engine 260 in model 118, 177, 247 except code M016 (Uprated Engine)
			AR09.41-P-1311-01AL
		Set of protective caps	Fig 4
4	Remove Engine air intake duct downstream of air filter (4).		AR09.10-P-8130MFC
		Do not install upper Engine cover until after the leak test.
5	Remove heat shields (6) from exhaust gas turbocharger with exhaust manifold (29).		AR09.40-P-6045MFC
6	Release and disconnect electrical connector (10).
7	Unscrew screws (8) and remove lower heat shield (9).	Bolt, heat shield to exhaust gas 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) from exhaust gas turbocharger with exhaust manifold (29), place to one side and seal openings with suitable stop plugs.	Replace seals.
		Assembly tool	Fig 2
		Record plug	Fig 3
10	Remove screws (14), remove oil feed line (15) and seal openings with suitable stop plugs.	Replace seals.
		Bolt, feed line/return line to turbocharger/crankcase	*BA09.40-P-1002-02G
		Record plug	Fig 3
11	Remove screws (16), remove oil return feed line (17), and seal openings with suitable stop plugs.	Replace seals.
		Bolt, feed line/return line to turbocharger/crankcase	*BA09.40-P-1002-02G
		Record plug	Fig 3
12	Remove catalytic converter (30) from Engine and at exhaust gas turbocharger with exhaust manifold (29).		AR49.20-P-0100MFC
		The screws from the catalytic converter (30) to the exhaust system remain on the vehicle.
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 a 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 screw (40) and remove support (41).	Bolt, turbocharger support brace to crankcase	*BA09.40-P-1005-02G
17	Press catalytic converter (30) to side slightly, remove exhaust gas turbocharger with exhaust manifold (29), and seal openings with clean, lint-free rags.	Replace seal of catalytic converter (30).
		Aid of helper required.
18	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
19	Install in the reverse order.
	Check
20	Check Engine oil level and correct if necessary.
			AP18.00-P-1812MFA
		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.
	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
21	Carry out Engine test run and check function and leak tightness of the Engine.
22	Install lower Engine compartment lining.	Engine 260 in model 118, 177, 247 with code M016 (Uprated Engine)	AR61.20-P-1105MFR
		Engine 260 in model 118, 177, 247 except code M016 (Uprated Engine)	AR61.20-P-1105MFA
23	Install upper Engine cover.
			AP01.10-P-2405-01C

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 Caps (001 589 02 91 00)

Courtesy of MERCEDES-BENZ USA