Remove/install right turbocharger

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

Shown on ENGINE 177

1

Right ATL

15

Clamp

18

Oil return line

19

Bolts

20

Heat shield

Shown on ENGINE 177

12

Coolant vent line

13

Charge air hose

14

Mounting clamp

15

Clamp

16

Vacuum hose

25

Coolant feed pipe

Shown on ENGINE 177

6

Electrical line

7

Electrical line

8

Electrical line

9

Electrical line

10

Heat shield

11

Bracket

Shown on ENGINE 177

01

Parallel gauge

Pfeile

Contact surfaces

18

Oil return line

28

Sealing rings

29

Marking

 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