Remove/install turbocharger with left exhaust manifold

AR09.40-P-6037MND

Remove/install turbocharger with left exhaust manifold

18.02.2020

Engine

276.8 in model 213, 238

Shown on engine 276.823

1

Vacuum hose

7

Coolant feed line

2

Vacuum unit

8

Heat shield

3

Oil feed line

9

Oil return line

4

Heat shield

10

Screw

5

Screw

11

Coolant return line

6

Heat shield

Shown on engine 276.823

12

Nuts

15

Turbocharger

13

Terminal rail

16

Electrical connector

14

Clip

Shown on engine 276.823

22

Vent line

23

Screw

 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

 Danger

Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained.

AS83.00-Z-0001-01A

 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

 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

 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

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1

Drain air conditioning system

Engine 276.8 in model 213
except code 1U6 (R744 refrigerant)

AR83.30-P-1760LW

Engine 276.8 in model 238

AR83.30-P-1760LWO

2

Remove engine compartment paneling

AR61.20-P-1105LWE

3

Drain off coolant of engine cooling system

AR20.00-P-1142OLC

4

Remove left catalytic converter

Engine 276.853 in model 213

AR49.10-P-5502MND

5

Remove clamp of EGR line at the ATL (15)

Engine 276.853 in model 213

6

Remove left air filter housing with clean air line

AR09.10-P-1151MND

7

Remove left rail insulation

8

Remove screw/bolt (23), remove place vent line (22) and place to one side

9

Remove left charge air pipe

AR09.41-P-1327MND

10

Release and disconnect electrical connection (16) at bypass air switchover valve

11

Remove screw/bolt (5)

12

Remove screw/bolt (10) at the ATL (15) and place coolant feed line (7) to one side, close off openings with suitable stop plugs

AR09.41-P-0011MND

 Record plug

*129589009100

13

Remove inerting system line from heat shield (8) and place to one side

Engine 276.8 in model 213, 238
with code 2U8 (Alternative refrigerant)

AR86.10-P-0319LWE

14

Remove heat shields (4, 6, 8) from ATL (15)

15

Remove coolant return line (11), place to one side and close off openings with suitable stop plugs

AR09.41-P-0016MND

 Record plug

*129589009100

16

Remove oil feed line (3) and seal openings with suitable stop plugs

AR09.40-P-0002MND

 Record plug

*129589009100

17

Unfasten clamp of oil return line (9) at hose line and push back

AR09.40-P-0004MND

 Hose clamp pliers

*003589033700

18

Remove vacuum hose (1) at vacuum unit (2)

19

Disconnect refrigerant lines at engine compartment connecting point and close off openings using suitable stop plugs

 Record plug

*129589009100

20

Open clamp (14) and disconnect flange connection between ATL (15) and exhaust line

21

Unscrew nuts (12) for ATL (15) on cylinder head in reverse order to the exhaust manifold tightening procedure and remove peg board

Tightening procedure for exhaust manifold

AR14.10-P-3000-01MM

22

Tilt out the ATL (15) from terminal rail (13) and extend to hose line of the oil return line (9), lift out upwards and openings with suitable stop plugs

 Record plug

*129589009100

23

Remove the stop plug and modify oil return line (9) on ATL (15) with a new seal

When installing a new exhaust gas turbocharger (15).

AR09.40-P-0004MND

 Record plug

*129589009100

24

Remove seal from cylinder head

25

Remove seal between exhaust pipe and remove the ATL (15)

Engine 276.853 in model 213

26

Clean sealing surfaces on cylinder head

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

27

Check stud bolts for damage

Stud bolt damaged



Replace stud bolt.



Install

28

Fasten new seal on cylinder head

29

Remove the stop plug and position the ATL (15) on oil return line (9) and push on

 Record plug

*129589009100

30

Introduce ATL (15) from terminal rail (13) and push downwards

31

Place peg board on stud bolts

32

Screw nuts (12) of ATL (15) onto cylinder head in sequence of the tightening procedure of the exhaust manifold

Tightening procedure for exhaust manifold

AR14.10-P-3000-01MM

 Nut, turbocharger peg board to cylinder head

*BA09.40-P-1001-01W

33

Position and fasten clamp for hose line of oil return line (9) and fasten

AR09.40-P-0004MND

 Hose clamp pliers

*003589033700

34

Connect flange connection between exhaust line and the ATL (15) with new clamp (14) and seal

 The dowel pin on the exhaust line must be set in the notch on ATL (15). After screwing down the clamp (14) using the prescribed tightening torque, there may be no gap anymore on the clamp lock.

 Engine 276.8 in model 238Clamp at turbocharger and catalytic converter/front exhaust line

*BA49.10-P-1001-02I

 Engine 276.8 in model 213Clamp at turbocharger and catalytic converter/front exhaust line

*BA49.10-P-1001-02G

35

Remove the stop plug of the connecting point of refrigerant lines in engine compartment

 Record plug

*129589009100

36

Connect refrigerant lines to connecting point in engine compartment with new sealing rings

 Nut/bolt, connecting point for refrigerant line

*BA83.30-P-1004-01R

37

Detach vacuum hose (1) at vacuum unit (2)

38

Remove the stop plug, attach oil feed line (3)

AR09.40-P-0002MND

 Record plug

*129589009100

39

Remove the stop plugs; attach coolant return line (11) at the ATL (15)

AR09.41-P-0016MND

 Record plug

*129589009100

40

Install heat shields (4, 6, 8)

 Bolt/nut for shield attachment

*BA09.40-P-1011-01W

41

Tighten bolt (5)

 Bolt/nut for shield attachment

*BA09.40-P-1011-01W

42

Position coolant feed line (7) with the new sealing ring on the ATL (15) and tighten screw/bolt (10)

AR09.41-P-0011MND

 Bolt, coolant feed/return line to turbocharger

*BA09.40-P-1008-01W

43

Plug in electrical connection (16) together on bypass air switchover valve and lock

44

Position vent line (22) with new sealing ring and tighten screw/bolt (23)

 Screw/bolt, vent line from oil separator to turbocharger

*BA01.20-P-1007-01L

45

Install left rail insulation

46

Install left charge air pipe

AR09.41-P-1327MND

47

Install left air filter housing with clean air line

AR09.10-P-1151MND

 Only install upper engine cover after the leak test.

48

Attach clamp of the EGR line with a new seal to the ATL (15)

Engine 276.853 in model 213

 Clamp, exhaust gas recirculation line to turbocharger/exhaust gas recirculation line

*BA14.20-P-1007-01M

49

Attach inerting system line to heat shield (8)

Engine 276.8 in model 213, 238
with code 2U8 (Alternative refrigerant)

AR86.10-P-0319LWE

50

Install left catalytic converter

Engine 276.853 in model 213

AR49.10-P-5502MND

51

Pour coolant into engine cooling system

AR20.00-P-1142OLC

52

Charge air conditioning system

Engine 276.8 in model 213
except code 1U6 (R744 refrigerant)

AR83.30-P-1760LW

Engine 276.8 in model 238

AR83.30-P-1760LWO

53.1

Check oil level in engine and correct if necessary

When reusing the ATL (15).



AP18.00-P-1811MP

53.2

Perform engine oil change with oil filter change

When installing a new exhaust gas turbocharger (15).



AP18.00-P-0101CWZ

 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

54

Perform an engine test run and check engine for proper operation and leaktightness

55

Install lower engine compartment paneling

AR61.20-P-1105LWE

56

Install upper engine cover

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 276

BA01.20-P-1007-01L

Screw/bolt, vent line from oil separator to turbocharger

Nm

9

 Turbocharger

Number

Designation

Engine 276.8

BA09.40-P-1001-01W

Nut, turbocharger peg board to cylinder head

M8

Nm

20

 Turbocharger

Number

Designation

Engine 276.8

BA09.40-P-1008-01W

Bolt, coolant feed/return line to turbocharger

Nm

9

 Turbocharger

Number

Designation

Engine 276.8

BA09.40-P-1011-01W

Bolt/nut for shield attachment

M6

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 276.8

BA14.20-P-1007-01M

Clamp, exhaust gas recirculation line to turbocharger/exhaust gas recirculation line

Nm

10

 Exhaust system

Number

Designation

Model 213 with engine 276

BA49.10-P-1001-02G

Clamp at turbocharger and catalytic converter/front exhaust line

Nm

17

 Exhaust system

Number

Designation

Model 238 with engine 276

BA49.10-P-1001-02I

Clamp at turbocharger and catalytic converter/front exhaust line

Nm

17

 Air conditioning

Number

Designation

Model 213
except code 1U6 (R744 refrigerant)

Model 213
with code 1U6 (R744 refrigerant)

BA83.30-P-1004-01R

Nut/bolt, connecting point for refrigerant line

Nm

12

12

 Air conditioning

Number

Designation

Model 238

BA83.30-P-1004-01R

Nut/bolt, connecting point for refrigerant line

Nm

12

Repair materials

Number

Designation

Order number

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09