Remove/install turbocharger with exhaust manifold

AR09.40-P-6025MLJ

Remove/install turbocharger with exhaust manifold

18.02.2020

Engine

157, 278 in model 166

Modification notes

14.09.2017

Bolt/nut, exhaust line to turbocharger

Engine 157

BA14.10-P-1003-01E

14.09.2017

Bolt/nut, exhaust line to turbocharger

Engine 278

BA14.10-P-1003-01E

Shown on engine 278 (on right)

2

Exhaust pipe

3

Locking plates

5

Clamps

6

Clamp

7

Heat shield

8

Heat shield

9

Bracket

Shown on engine 278 (on right)

1

ATL with exhaust manifold

1a

Nuts

1b

Nuts

 Warning

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

 Caution

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

 Caution

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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Drain engine oil



Engine 157 in model 166

AP18.00-P-0101EWG



Engine 278 in model 166

AP18.00-P-0101EL

2

Remove engine with front axle carrier

AR01.10-P-2500MLJ

3

Detach clamp (6) on heat shield (7)

 When removing right exhaust gas turbocharger with exhaust manifold (1).

4

Remove refrigerant line at refrigerant compressor and seal exposed connections with stop plugs

 When removing left exhaust gas turbocharger with exhaust manifold (1).

 Bolt, refrigerant line to refrigerant compressor

*BA83.55-P-1003-01M

 Record plug

*129589009100

5

Remove heat shield (7) at engine carrier

 Bolt, heat shield to engine support

*BA22.10-P-1003-02A

6

Remove heat shield (8) on cylinder head

 Installation: Ensure correct seating of the clamps (5) on the heat shield (8) and exhaust manifold gasket.

 Bolt, heat shield to exhaust gas turbocharger/cylinder head

*BA09.40-P-1007-01R

7

Remove vacuum hose of boost pressure control valve at exhaust gas turbocharger with exhaust manifold (1)

8

Remove charge air pipe

AR09.41-P-8620MLJ

9

Remove coolant line of charge air cooler at timing case cover

 When removing right exhaust gas turbocharger with exhaust manifold (1).

10

Remove coolant lines

AR20.20-P-7440MLJ

11

Remove upper oil line at exhaust gas turbocharger with exhaust manifold (1)

AR18.30-P-6850MLJ

12

Remove lower oil line at oil pan

AR18.30-P-6850MLJ

13

Remove bracket (9) between exhaust pipe (2) and cylinder head

 Bolt, bracket to exhaust line

*BA14.10-P-1004-01E

 Nut, exhaust line holder to cylinder head

*BA14.10-P-1005-01E

14

Remove exhaust pipe (2)

Tightening pattern for turbocharger

AR09.40-P-6020-10NMB

 Bolt/nut, exhaust line to turbocharger

*BA14.10-P-1003-01E

15

Remove nuts (1a, 1b) at exhaust gas turbocharger with exhaust manifold (1)

 Nut, turbocharger/exhaust manifold to cylinder head

*BA09.40-P-1001-01R

16

Remove lock washers (3) at exhaust gas turbocharger with exhaust manifold (1)

 Installation: Install new locking plates (3).

17

Remove exhaust gas turbocharger with exhaust manifold (1) from cylinder head

 Installation: Clean sealing surfaces and replace exhaust manifold seal.

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

18

Install in the reverse order



Check

19

Check engine oil level; correct if necessary



AP18.00-P-1811MP

 Warning

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 hazard area.

AS49.00-Z-0001-01A

 Warning

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

Carry out an engine test run, checking the engine for proper operation and leaktightness

 Turbocharger

Number

Designation

Engine 157

Engine 278

BA09.40-P-1001-01R

Nut, turbocharger/exhaust manifold to cylinder head

M7

Nm

15

15

M8

Nm

20

20

 Turbocharger

Number

Designation

Engine 157

Engine 278

BA09.40-P-1007-01R

Bolt, heat shield to exhaust gas turbocharger/cylinder head

Nm

9

9

 Exhaust manifold

Number

Designation

Engine 157

Engine 278

BA14.10-P-1003-01E

Bolt/nut, exhaust line to turbocharger

Stage 1

Nm

15

15

Stage 2

Nm

25

25

 Exhaust manifold

Number

Designation

Engine 157

Engine 278

BA14.10-P-1004-01E

Bolt, bracket to exhaust line

Nm

25

25

 Exhaust manifold

Number

Designation

Engine 157

Engine 278

BA14.10-P-1005-01E

Nut, exhaust line holder to cylinder head

Nm

20

20

 Engine support (engine side)

Number

Designation

Engine 157

Engine 278

BA22.10-P-1003-02A

Bolt, heat shield to engine support

Nm

9

13

 Refrigerant compressor

Number

Designation

Engine 157

Engine 278

BA83.55-P-1003-01M

Bolt, refrigerant line to refrigerant compressor

M8

Nm

20

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09