Remove/install right turbocharger · ar0940p6027mna · Mercedes-Benz WIS

AR09.40-P-6027MNA

Remove/install right turbocharger

30.09.2019

Engine	176 in model 463
	up to model year 2019
Engine	177 in model 205
Engine	178 in model 190

Shown on ENGINE 177

1	Right ATL
5	Cover
24	Oil feed line
26	Coolant return line
27	Boot

P09.40-2506-06

Shown on ENGINE 177

1	Right ATL
15	Clamp
18	Oil return line
19	Bolts
20	Heat shield

P09.40-2510-06

Shown on ENGINE 177

12	Coolant vent line
13	Charge air hose
14	Mounting clamp
15	Clamp
16	Vacuum hose
25	Coolant feed pipe

P09.40-2508-06

Shown on ENGINE 177

6	Electrical line
7	Electrical line
8	Electrical line
9	Electrical line
10	Heat shield
11	Bracket

P09.40-2507-12

Shown on ENGINE 177

01	Parallel gauge
Pfeile	Contact surfaces

P09.40-2522-06

18	Oil return line
28	Sealing rings
29	Marking

P09.40-2526-03

 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 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 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
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Topical note	Notes on coolant		AH20.00-N-2080-01A
 	Remove/install
1	Remove center and front section of lower engine compartment lining.	Engine 178 in model 190
			AR61.20-P-1105RG
		 Installation: Install front and center sections of lower engine compartment paneling only after the leak test.
2	Drain coolant from low-temperature circuit.	Engine 176 in model 463 up to model year 2019	AR09.41-P-6834MNF
		Engine 178 in model 190	AR09.41-P-6834MNB
		Engine 177 in model 205	AR09.41-P-6834MNA
3.1	Disconnect left and right catalytic converter at separation points of the exhaust system.	Engine 177 in model 205 Engine 178 in model 190.377/378
		Engine 178 in model 190.377/378	AR49.10-P-7142MNB
		Engine 177 in model 205	AR49.10-P-7283MNA
3.2	Remove left and right rear muffler.	Engine 176 in model 463 up to model year 2019
			AR49.10-P-4951GW
3.3	Remove exhaust system.	Engine 178 in model 190.379/380/477/478/479/480
			AR49.10-P-7142MNC
4	Remove front stiffener from frame floor.	Engine 178 in model 190.377/378
		 Bolt, front reinforcement on frame floor assembly	*BA61.10-P-1001-01I
5	Remove bottom bracket of the catalytic converters from the catalytic converters.	Engine 178 in model 190 If installed.
			AR49.10-P-5500MNB
6.1	Remove right air filter housing.	Engine 176 in model 463 up to model year 2019 Engine 177 in model 205
			AR09.10-P-1150MNA
6.2	Remove right intake air duct downstream of the air filter.	Engine 178 in model 190
			AR09.41-P-1311-01AL
7	Remove left air filter housing.	Engine 176 in model 463 up to model year 2019 Engine 177 in model 205
			AR09.10-P-1150MNA
8	Remove cover (5).	 Installation: Pay attention to correct seating of the cover (5).
9	Remove screws (19) and remove heat shield (20) upwards.	 Bolt, upper heat shield to bracket/side heat shield	*BA09.40-P-1006-01ZA
10	Unclip electric lines (6, 7, 8, 9) at heat shield (10).	Engine 177 in model 205
11	Remove bracket (11) from crankcase.	 Bolt, rear heat shield bracket to crankcase	*BA09.40-P-1005-01ZA
12	Remove heat shield (10) of the catalytic converters.	Engine 176 in model 463 up to model year 2019	AR49.10-P-5500MNF
		Engine 177 in model 205	AR49.10-P-5500MNA
13	Remove top bracket of the catalytic converters.	Engine 176 in model 463 up to model year 2019	AR49.10-P-5500MNF
		Engine 178 in model 190	AR49.10-P-5500MNB
		Engine 177 in model 205	AR49.10-P-5500MNA
14	Remove boot (27) from right exhaust gas turbocharger (1) and place to one side.	 Clamp, boot to exhaust gas turbocharger/air filter	*BA01.20-P-1003-01J
15	Remove vacuum hose (16) from right exhaust gas turbocharger (1).
16	Remove coolant return line (26) from right exhaust gas turbocharger (1).		AR20.20-P-1101MNA
17	Remove bracket for coolant feed pipe (25).		AR20.20-P-1100MNA
18	Remove coolant feed pipe (25) from right exhaust gas turbocharger (1).		AR20.20-P-1100MNA
19	Remove oil feed line (24) from right exhaust gas turbocharger (1) and place to one side.		AR09.40-P-6040MNA
20	Remove coolant vent line (12) from right exhaust gas turbocharger (1).		AR20.20-P-1201MNA
21	Remove charge air hose (13) from right exhaust gas turbocharger (1).
22	Remove left catalytic converter from left exhaust gas turbocharger.		AR09.40-P-6018-01MNA
		 Installation: The alignment of the clamp between the left exhaust gas turbocharger and the left catalytic converter must be observed.
		 Engine 178 in model 190Clamp, front exhaust system to turbocharger	*BA49.10-P-1010-01AG
		 Engine 176 in model 463 up to model year 2019Screw/bolt, catalytic converter clamp to exhaust gas turbocharger	*BA49.10-P-1001-02F
		 Engine 177.9 in model 205Clamp, front exhaust system to turbocharger	*BA49.10-P-1001-02E
		 Engine 176 in model 463 up to model year 2019 Bei zweiteiliger SchelleEngine 177 in model 205 Bei zweiteiliger SchelleEngine 178 in model 190Bei zweiteiliger Schelle Caulking bolt	*103589013900
23	Check design of clamp between left exhaust gas turbocharger and left catalytic converter.	If a one-piece clamp is installed,
		
		Replace clamp.
		If a two-piece clamp is installed,
		
		Replace nuts and bolts.
24	Remove right catalytic converter from right exhaust gas turbocharger (1).		AR09.40-P-6018-01MNA
		 Installation: Alignment of mounting clamp (14) between right exhaust gas turbocharger (1) and right catalytic converter must be observed.
		 Engine 178 in model 190Clamp, front exhaust system to turbocharger	*BA49.10-P-1010-01AG
		 Engine 176 in model 463 up to model year 2019Screw/bolt, catalytic converter clamp to exhaust gas turbocharger	*BA49.10-P-1001-02F
		 Engine 177.9 in model 205Clamp, front exhaust system to turbocharger	*BA49.10-P-1001-02E
		 Engine 176 in model 463 up to model year 2019 Bei zweiteiliger SchelleEngine 177 in model 205 Bei zweiteiliger SchelleEngine 178 in model 190Bei zweiteiliger Schelle Caulking bolt	*103589013900
25	Check design of mounting clamp (14) between right exhaust gas turbocharger (1) and right catalytic converter.	If a one-piece mounting clamp (14) is installed
		
		Replace mounting clamp (14).
		If a two-piece mounting clamp (14) is installed
		
		Replace nuts and bolts.
26	Remove clamp (15).	 Installation: Install new hose clamp (15).
		 Installation: To ensure a parallelism of the right exhaust gas turbocharger (1) to the left exhaust gas turbocharger,  install parallel gauge (01) so that flush with contact surfaces (arrows).
		 Bolt, turbocharger clamp to exhaust manifold	*BA09.40-P-1001-01ZA
		 Parallel support	*168589032100
27	Remove right exhaust gas turbocharger (1) with oil return feed line (18) upwards.	 Installation: Ensure that marking (29) on oil return feed line (18) is flush with crankcase. Oil return feed line (18) will otherwise be leaky.
		 Installation: Replace sealing ring on right exhaust manifold.
28	Remove oil return feed line (18) at right exhaust gas turbocharger (1).		AR09.40-P-6043MNA
		 Installation: Replace oil return feed line (18) with sealing rings (28).
29	Install in the reverse order.
	Check
30	Check engine oil level and correct if necessary.
		Engine 177 in model 205 Engine 178 in model 190	AP18.00-P-1811MP
		Engine 176 in model 463 up to model year 2019	AP18.00-P-0101GE
 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
31	Perform engine test run and check engine for leak tightness.
32	Install center and front section of the engine compartment lining.	Engine 178 in model 190	AR61.20-P-1105RG

 Crankcase ventilation system, cylinder head cover

Number	Designation		Engine 176	Engine 177
BA01.20-P-1003-01J	Clamp, boot to exhaust gas turbocharger/air filter	Nm	1,5	1,5

 Crankcase ventilation system, cylinder head cover

Number	Designation		Engine 178
BA01.20-P-1003-01J	Clamp, boot to exhaust gas turbocharger/air filter	Nm	1,5

 Turbocharger

Number	Designation		Engine 176	Engine 177
BA09.40-P-1001-01ZA	Bolt, turbocharger clamp to exhaust manifold	Nm	21	21

 Turbocharger

Number	Designation		Engine 178
BA09.40-P-1001-01ZA	Bolt, turbocharger clamp to exhaust manifold	Nm	21

 Turbocharger

Number	Designation		Engine 176	Engine 177
BA09.40-P-1005-01ZA	Bolt, rear heat shield bracket to crankcase	Nm	9	9

 Turbocharger

Number	Designation		Engine 178
BA09.40-P-1005-01ZA	Bolt, rear heat shield bracket to crankcase	Nm	9

 Turbocharger

Number	Designation		Engine 176	Engine 177
BA09.40-P-1006-01ZA	Bolt, upper heat shield to bracket/side heat shield	Nm	9	9

 Turbocharger

Number	Designation		Engine 178
BA09.40-P-1006-01ZA	Bolt, upper heat shield to bracket/side heat shield	Nm	9

 Exhaust system

Number	Designation			Engine 177 in model 205
BA49.10-P-1001-02E	Clamp, front exhaust system to turbocharger	M6	Nm	8
		M8	Nm	20

 Exhaust system

Number	Designation			Engine 176 in model 463 up to model year 2019
BA49.10-P-1001-02F	Screw/bolt, catalytic converter clamp to exhaust gas turbocharger	M6	Nm	8
		M8	Nm	20

 Exhaust system

Number	Designation		Engine 178 in model 190
BA49.10-P-1010-01AG	Clamp, front exhaust system to turbocharger	Nm	20

 Frame floor assembly

Number	Designation		Model 190
BA61.10-P-1001-01I	Bolt, front reinforcement on frame floor assembly	Nm	50

103 589 01 39 00

Caulking bolt

168 589 03 21 00

Parallel support

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