Remove/install turbocharger with exhaust manifold

AR09.40-P-6036MFD

Remove/install turbocharger with exhaust manifold

21.02.2020

Engine

282 in model 118, 177, 247

Modification notes

28.10.2019

Document completely revised.

Shown on model 177 without code ME08 (hybrid drive 75 – 84 KW VARIANT (INCLUDING PLUGIN))

2

Nuts

5

Profiled clamp

3

Bolts

6

Seal

4

Nut

11

Catalytic converter

Shown on model 177 without code ME08 (hybrid drive 75 – 84 KW VARIANT (INCLUDING PLUGIN))

1

ATL with exhaust manifold

8

Electrical connector

7

Electrical connector

9

Electrical connector

Shown on model 177 without code ME08 (hybrid drive 75 – 84 KW VARIANT (INCLUDING PLUGIN))

1

ATL with exhaust manifold

12

Bolts

10

Heat shield

Shown on model 177 without code ME08 (hybrid drive 75 – 84 KW VARIANT (INCLUDING PLUGIN))

1

ATL with exhaust manifold

17

Screw

21

Mounting rail

13

Nut

18

Screw

22

Terminal strip

14

Nut

19

Screw

23

Seal

15

Nut

20

Screw

24

Stud bolts

16

Nut

 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

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.Engine 282 in model 118, 177, 247
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AS00.00-Z-0035-01A

 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 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

Engine 282 in model 118, 177, 247
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AH00.00-Z-0300-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on battery

Engine 282 in model 118, 177, 247
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AH54.10-P-0001-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Remove voltage of high-voltage on-board electrical system.

Engine 282 in model 118, 177, 247
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AR47.70-P-1000MFH

2

Drain off coolant.

AR20.00-P-1142MFC

3

Counterhold stud bolts and remove nuts (2).

 Nut, front exhaust system to stud bolt

*BA49.10-P-1004-02Q

 Stud bolt/bolt, front exhaust system to crankcase

*BA49.10-P-1003-02Q

4

Remove screw/bolts (3).

 Bolt, front exhaust system to center exhaust system

*BA49.10-P-1006-02Q

5

Remove engine air intake duct downstream of air filter housing.

AR09.10-P-8130MFD

6

Disconnect inerting system line in the engine compartment.

Engine 282 in model 118, 177, 247
with code 2U8 (Alternative refrigerant)

AR86.10-P-0119MFD

7

Remove heat shield for firewall.

Engine 282 in model 118, 177, 247
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN))

AR49.10-P-0001MFD

8

Remove charge air pipe from the exhaust gas turbocharger with exhaust manifold (1) to the charge air cooler.

AR09.41-P-1332MFD

 Installation: Only install upper engine cover after the leak test.

9

Release and disconnect lambda sensor electrical connector downstream of the catalytic converter (G3/1).

AR07.04-P-0085MFD

10

Release and disconnect lambda sensor electrical connector upstream of the catalytic converter (G3/2).

AR07.04-P-0086MFD

11

Remove feed line coolant line for the exhaust gas turbocharger with exhaust manifold (1).

AR20.20-P-1000MFD

12

Remove coolant return flow line for the exhaust gas turbocharger with exhaust manifold (1).

AR20.20-P-1050MFD

13

Remove heat shield of the exhaust gas turbocharger with exhaust manifold (1).

AR09.40-P-6020-03MFD

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

*BA09.40-P-1009-02E

14

Remove nut (4) and release profiled clamp (5).

 Commercially available devices/tools
Box wrench bit, 13 mm

 Clamp/nut, front exhaust system to exhaust gas turbocharger

*BA49.10-P-1001-02Q

15

Release catalytic converter (11) from the exhaust gas turbocharger with exhaust manifold (1) and carefully place down on the axle crossmember.

 Installation: Install new seal (6) and profiled clamp (5).

16

Seal catalytic converter (11) and exhaust gas turbocharger with exhaust manifold (1) with protective covers.

 Set of protective covers

*001589039100

17

Release and disconnect electrical connectors (7, 8, 9) from the exhaust gas turbocharger with exhaust manifold (1) and place wiring harness to one side.

18

Remove oil feed line of the exhaust gas turbocharger with exhaust manifold (1).

AR09.40-P-6022MFD

19

Remove oil return feed line of the exhaust gas turbocharger with exhaust manifold (1).

AR09.40-P-6021MFD

20

Remove screws (12) and remove heat shield (10) at the rear from the exhaust gas turbocharger with exhaust manifold (1).

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

*BA09.40-P-1009-02E

21

Remove nuts (13, 14, 15, 16) in reverse order of the tightening procedure.

Tightening pattern for turbocharger

AR09.40-P-6020-10MFD

 Nut, connecting panel for exhaust gas turbocharger to cylinder head

*BA09.40-P-1002-02E

22

Remove screws (17, 18, 19, 20) in reverse order of the tightening procedure.

Tightening pattern for turbocharger

AR09.40-P-6020-10MFD

 Bolt, turbocharger terminal strip to cylinder head

*BA09.40-P-1001-02E

23

Remove mounting rail (21) and terminal strip (22).

24

Remove exhaust gas turbocharger with exhaust manifold (1) upward.

25

Seal exhaust gas turbocharger with exhaust manifold (1) with the stop plug and with clean, lint-free rags.

 Set of plugs

*199589009800

26

Remove seal (23).

 Installation: Install new gasket (23).

27

Unscrew stud bolts (24).

 Installation: Replace stud bolts(24).

 Stud bolt in cylinder head

*BA09.40-P-1008-02E

28

Seal openings in the cylinder head with clean, lint-free rags.

29

Install in the reverse order.



Check

 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. While doing so, check engine for proper operation and leak tightness.

31

Install upper engine cover.



AP01.10-P-2405-01D

 Turbocharger

Number

Designation

Engine 282

BA09.40-P-1001-02E

Bolt, turbocharger terminal strip to cylinder head

Nm

25

 Turbocharger

Number

Designation

Engine 282

BA09.40-P-1002-02E

Nut, connecting panel for exhaust gas turbocharger to cylinder head

Nm

30

 Turbocharger

Number

Designation

Engine 282

BA09.40-P-1008-02E

Stud bolt in cylinder head

Nm

12

 Turbocharger

Number

Designation

Engine 282

BA09.40-P-1009-02E

Bolt, heat shield to exhaust gas turbocharger/cylinder head cover/connecting panel

Nm

8

 Exhaust system

Number

Designation

Model 118 with engine 282

Model 177 with engine 282

BA49.10-P-1001-02Q

Clamp/nut, front exhaust system to exhaust gas turbocharger

Nm

21

21

 Exhaust system

Number

Designation

Model 247 with engine 282

BA49.10-P-1001-02Q

Clamp/nut, front exhaust system to exhaust gas turbocharger

Nm

21

 Exhaust system

Number

Designation

Model 118 with engine 282

Model 177 with engine 282

BA49.10-P-1003-02Q

Stud bolt/bolt, front exhaust system to crankcase

Nm

13

13

 Exhaust system

Number

Designation

Model 247 with engine 282

BA49.10-P-1003-02Q

Stud bolt/bolt, front exhaust system to crankcase

Nm

13

 Exhaust system

Number

Designation

Model 118 with engine 282

Model 177 with engine 282

BA49.10-P-1004-02Q

Nut, front exhaust system to stud bolt

M8

Nm

21

21

 Exhaust system

Number

Designation

Model 247 with engine 282

BA49.10-P-1004-02Q

Nut, front exhaust system to stud bolt

M8

Nm

21

 Exhaust system

Number

Designation

Model 118 with engine 282

Model 177 with engine 282

BA49.10-P-1006-02Q

Bolt, front exhaust system to center exhaust system

M8

Nm

25

25

 Exhaust system

Number

Designation

Model 247 with engine 282

BA49.10-P-1006-02Q

Bolt, front exhaust system to center exhaust system

M8

Nm

25