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

Engine 256.9 in model 223 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Shown with code M016 (Performance-enhanced engine) 

	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 danger zone.	AS49.00-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 overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-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
	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 avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Notice	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Remove/install
1	Remove engine air intake duct downstream of air filter.	: Do not install upper engine cover until after the leak test.	AR09.10-P-8130SB
	Risk of injury  during testing and repair operations related to pyrotechnical components	Do not expose pyrotechnical component parts to temperatures above 100°C or 212°F. Disconnect current supply when working on such component parts.	AS91.00-Z-0008-01A
2	Remove inerting system line (1) from exhaust gas turbocharger (12) and place to one side.	Engine 256.9 in model 223 with code 2U8 (Alternative refrigerant)
	Information, assessment and legal requirements when working with, handling and storing pyrotechnical components		AH91.00-Z-0000-10A
		Pipe for inerting to engine	*BA86.10-P-1002-03G
3	Release and disconnect electrical connectors (2).
4	Remove wide open throttle bleed line from the exhaust gas turbocharger (12).		AR01.20-P-0020SB
5	Remove oil feed line.		AR09.40-P-6022SB
6	Remove oil return feed line from the exhaust gas turbocharger (12) and place to one side.		AR09.40-P-6021SB
7	Remove coolant feed line from the exhaust gas turbocharger (12) and place to one side.		AR20.20-P-1000SB
8	Remove coolant return flow line from the exhaust gas turbocharger (12) and place to one side.		AR20.20-P-1050SB
9	Remove screws (3) and remove bracket (4).	Bolt, bracket to turbocharger/cylinder head	*BA09.40-P-1003-02MRT
10	Remove the ignition coil (T1/6).		AR15.12-P-2003SB
11	Remove bolts (5) and remove heat shield (6).	Screw, side heat shield to upper heat shield	*BA09.40-P-1014-02MRT
12	Unscrew screws (7) and remove support (8).	Screw, support to exhaust gas turbocharger/crankcase	*BA09.40-P-1002-02MRT
13.1	Remove boot (9) from check valve.	Engine 256.9 in model 223 with code M016 (Uprated engine) Screw clamp, boot to exhaust gas turbocharger	*BA09.41-P-1010-01MRT
13.2	Remove boot (9) from charge air pipe.	Engine 256.9 in model 223 except code M016 (Uprated engine) Screw clamp, boot to exhaust gas turbocharger	*BA09.41-P-1010-01MRT
14	Remove nuts in reverse order to tightening procedure and remove peg board (10).	Tightening pattern for turbocharger : Replace nuts.	AR09.40-P-6020-10MRT
		Nut, exhaust manifold (exhaust gas turbocharger) to cylinder head	*BA14.10-P-1001-02MRT
15	Remove exhaust gas turbocharger (12).	: Install new boot (9) and seal of the exhaust gas turbocharger (12). Align marking of the boot (9) with the marking on the exhaust gas turbocharger (12). Wet boot (9) with lubricant. Lubricant, rubber assembly 1 L	*BR00.45-Z-1010-06A
16	Remove ball pin (13).	If exhaust gas turbocharger (12) is being replaced. Ball pin, engine cover to exhaust gas turbocharger/camshaft housing	*BA01.10-P-1001-01MRT
	Clean
17	Clean sealing surfaces on cylinder head and exhaust gas turbocharger (12).
18	Install in the reverse order.
	Check
19	Check engine oil level and correct if necessary.
			AP18.00-P-1812A
	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	Perform engine test run. While doing so, check engine for proper operation and leak tightness.