Remove/install turbocharger with exhaust manifold

AR09.40-P-6025MT

Remove/install turbocharger with exhaust manifold

11.10.2018

Engine

270 in model 117, 156, 176, 242, 246.2

Modification notes

27.01.2016

Cover alternator, added.

Operation step 17

18.05.2016

Screw/bolt, oil line feed line to exhaust gas ATL

BA09.40-P-1004-01S

18.05.2016

Screw/bolt, oil line feed line to cylinder head

BA09.40-P-1005-01S

18.05.2016

Screw/bolt, oil return line to ATL

BA09.40-P-1006-01S

18.05.2016

Screw/bolt, oil return line to crankcase

BA09.40-P-1007-01S

18.05.2016

Screw/bolt, coolant line feed line/return line to ATL

BA09.40-P-1008-01S

18.05.2016

Screw/bolt, coolant line feed line to oil line feed line

BA09.40-P-1009-01S

Shown on model 246.242

1

Electrical line

7

Aneroid capsule

12

Clamp

2

Bracket

8

Coolant line

13

Spacer

3

Bracket

9

Oil line

14

Vacuum line

4

Heat shield

9s

Screw

15

Coolant pipe

5

Heat shield

10

Coolant line

Y101

Divert air switchover valve

6

Support brace

11

Oil line

20

Catalytic converter

21

Clip

22

Bracket

23

Bracket

 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

 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

 Warning

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

 

Remove/install

1

Drain off coolant.

AR20.00-P-1142NKB

2

Remove the clamp (21).

Engine 270 in model 117, 156, 246
except code 598 (Gasoline particulate filter (OPF) with sensor system)
Engine 270 in model 176, 242

AR49.10-P-4816MT

Engine 270 in model 117, 156, 246
with code 598 (Gasoline particulate filter (OPF) with sensor system)

AR49.10-P-4816MTA

 Installation: Replace the clamp (21).

3

Remove bracket (22) from crankcase.

Engine 270 in model 156

AR49.10-P-5500NKX

Engine 270 in model 117, 176, 242, 246.2

AR49.10-P-5500MT

4

Remove bracket (23) from the oil pan.

Engine 270 in model 156

AR49.10-P-5500NKX

Engine 270 in model 117, 176, 242, 246.2

AR49.10-P-5500MT

5

Remove upper engine cover.

6

Remove engine air intake duct upstream of air filter.

7

Remove air intake pipe.

Engine 270 in model 117, 156
with code 494 (US version)

AR09.10-P-8131MTU

Engine 270 in model 117, 156, 176, 242, 246.2
except code 494 (US version)

AR09.10-P-8131MT

8

Release and disconnect electrical connector of the electric line (1) and unclip the electrical plug connection from the bracket.

9

Remove holder (2).

10

Remove bracket (3) from cylinder head.

Engine 270 in model 156

AR49.10-P-5500NKX

Engine 270 in model 117, 176, 242, 246.2

AR49.10-P-5500MT

11

Remove heat shield (4) from cylinder head.

12

Remove the heat shield (5).

 Installation: Ensure that clamp (12) on heat shield (5) is seated correctly.

13

Remove catalytic converter (20) from exhaust gas turbocharger.

 Installation: Replace seal.

 Nut, catalytic converter to turbocharger

*BA09.40-P-1002-01S

14

Remove the support (6).

 Nut, turbocharger support brace to turbocharger

*BA09.40-P-1010-01S

 Bolt, turbocharger support brace to crankcase

*BA09.40-P-1011-01S

15

Detach vacuum line from diaphragm capsule (7).

16

Detach vacuum line (14) from diaphragm capsule of the coolant pump and remove with spacers (13) from the coolant lines of the exhaust gas turbocharger.

17

Over alternator with rags.


When removing the exhaust gas turbocharger, cover the alternator.
Otherwise, coolant or engine oil will get in.

18

Remove screw (9s).

 Screw/bolt, coolant feed line to oil feed line

*BA09.40-P-1009-01S

19

Remove coolant lines (8, 10) and seal openings with suitable stop plugs.

 Installation: Replace screw/bolts and seals.

 Bolt, coolant feed/return line to turbocharger

*BA09.40-P-1008-01S

 Record plug

*129589009100

20

Remove oil lines (9, 11) and seal openings with suitable stop plugs.

 Installation: Replace screw/bolts and seals.

 Screw/bolt, oil feed line to exhaust gas turbocharger

*BA09.40-P-1004-01S

 Screw/bolt, oil feed line to cylinder head

*BA09.40-P-1005-01S

 Bolt, oil return flow line to turbocharger

*BA09.40-P-1006-01S

 Bolt, oil return line to crankcase

*BA09.40-P-1007-01S

 Record plug

*129589009100

21

Remove charge air hose from exhaust gas turbocharger.

AR09.41-P-1311-01AL

22

Release and disconnect electrical connector from the overrun mode bypass air switchover valve (Y101).

23

Unclip engine wiring harness from the exhaust gas turbocharger.

24

Remove coolant pipe (15) from the cylinder head and crankcase.

Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 724

25

Remove exhaust gas turbocharger from the cylinder head.

 Installation: Replace seal and nuts.

 Nut, turbocharger/exhaust manifold to cylinder head

*BA09.40-P-1001-01S

26

Check stud bolts on cylinder head for damage.

If damage occurs,



Replace stud bolts.

27

Remove overrun mode bypass air switchover valve (Y101) from exhaust gas turbocharger.

When replacing the bypass air switchover valve (Y101).

 Bolt, shift valve to turbocharger

*BA09.40-P-1003-01S

28

Install in the reverse order.

29

Check engine oil level and correct if necessary.



AP18.00-P-1811MP

 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

30

Perform engine test run; in this connection check engine for leak tightness and proper operation.

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1001-01S

Nut, turbocharger/exhaust manifold to cylinder head

Nm

15

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1002-01S

Nut, catalytic converter to turbocharger

Nm

25

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1003-01S

Bolt, shift valve to turbocharger

Nm

9

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1004-01S

Screw/bolt, oil feed line to exhaust gas turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1005-01S

Screw/bolt, oil feed line to cylinder head

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1006-01S

Bolt, oil return flow line to turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1007-01S

Bolt, oil return line to crankcase

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1008-01S

Bolt, coolant feed/return line to turbocharger

Stage 1

Nm

8

Stage 2

°

60

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1009-01S

Screw/bolt, coolant feed line to oil feed line

Nm

5

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1010-01S

Nut, turbocharger support brace to turbocharger

Nm

30

 Turbocharger

Number

Designation

Engine 270

BA09.40-P-1011-01S

Bolt, turbocharger support brace to crankcase

Stage 1

Nm

15

Stage 2

°

90