Remove/Install Turbocharger - AR09.40-P-6020SR

ENGINE 281.910 in MODEL 453 (except 453.062/362/462) 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. 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 death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	Notes on coolant		AH20.00-N-2080-01A
	Remove/install
1	Remove maintenance flap
2	Turn cap on engine coolant expansion reservoir a half turn counterclockwise, relieve overpressure and then unscrew the cap
3	Remove covering over engine	Only install covering over engine after the leak test.
4	Remove air intake hose (2)
5	Remove all heat shield over the CAT		AR49.10-P-6905SR
6	Remove safety clamp (3)	Replace safety clamp (3).
7	Remove control rod (4) from exhaust manifold (5)
8	Disconnect electrical connection (6)
9	Disconnect electrical connection (7)
10	Remove coolant hose (8)	Collect escaping coolant in a suitable container. Replace clamp if necessary. Hose clamp pliers	Fig 1
11	Remove coolant hose (9)	Collect escaping coolant in a suitable container. Replace clamp if necessary. Hose clamp pliers	Fig 1
12	Remove screws/bolts (10)	Screw/bolt, oil return flow line to exhaust gas turbocharger	*BA09.40-P-1004-02A
13	Detach oil return line (11) at ATL (1)
14	Lower vehicle with vehicle lift
15	Unscrew nuts (12)
16	Remove bracket (13)
17	Unfasten clamp (14) and take off
18	Remove banjo bolt (15)	Banjo bolt, oil feed line to exhaust gas turbocharger	*BA09.40-P-1003-02A
19	Detach oil feed line (16) at ATL (1)
20	Remove screws/bolts (17)	Screw/bolt, charge air hose to exhaust gas turbocharger	*BA09.40-P-1001-02A
21	Detach charge air hose (18) from ATL (1)	Replace seal.
22	Raise vehicle with vehicle lift
23	Unfasten ATL (1) from exhaust manifold (5) and remove downwards	Ensure that ATL (1) is correctly seated.
24	Install in the reverse order
25	Pour in coolant and bleed cooling system		AR20.00-P-1142SR
	Check
26	Check engine oil level		AP18.00-P-0101S
	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
27	Perform an engine test run and check engine for leaktightness around ATL (1)

Fig 1: Identifying Hose Clamp Pliers (003 589 03 37 00)

Courtesy of MERCEDES-BENZ USA