Remove/install charge air cooler - AR09.41-P-6817HH

ENGINE 275 in MODEL 215, 216, 220, 221, 230

ENGINE 285 in MODEL 240

Fig 1: Identifying Charge Air Cooler Components

Courtesy of MERCEDES-BENZ USA

Shown on engine 285

	Remove/install
	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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
1	Remove engine trim panel	Engine 275.98	AR01.10-P-2405IM
1	Remove engine trim panel	Engine 275.95, 285	AR01.10-P-2405LA
2	Remove air filter housing	Model 215, 216, 220, 221, 230 without code (P99) Special Model "AMG Black Series"	AR09.10-P-1150LA
2	Remove air filter housing	Model 240	AR09.10-P-1150H
3	Drain coolant from low temperature circuit	Model 215, 216, 220, 221, 230	AR20.00-P-1142HM
3	Drain coolant from low temperature circuit	Model 240	AR20.00-P-1142HN
4	Disconnect charge air hose (1) at charge air cooler (2).	Installation: check charge air hose (1) and hose clamp for damage bad replace if required. Clean and degrease inside of charge air hose (1) as well as its connection fitting at charge air cooler (2).
			*BA09.41-P-1002-02B
		Cleaner from package	*BR00.45-Z-1028-04A
5	Disconnect charge air duct (3) at charge air cooler (2).	Installation: Check charge air duct (3) and hose clamp for damage and replace if required.
5	Disconnect charge air duct (3) at charge air cooler (2).		*BA09.41-P-1003-02B
6	Remove pneumatic line (4a) at charge air cooler (2).	Only when removing from right charge air cooler (2). Installation: Check pneumatic line (4a) and hose clamp for damage; replace if necessary.
7	Disconnect electrical connector at pressure sensor upstream of throttle valve actuator (B28/6) and detach pressure sensor upstream of throttle valve actuator (B28/6) from bracket (5)	Only when removing from right charge air cooler (2). The pneumatic line (4b) is bonded with the support to charge air cooler (2). This combination must not be separated, otherwise leakage may occur.
7			*BA09.41-P-1002-03A
8	Remove pneumatic line (4c) from charge air cooler (2).	Only when removing from right charge air cooler (2). Installation: Install new cable ties.
9	Remove bolts (6)		*BA09.41-P-1001-03A
10	Remove coolant hoses on fitting (2a) for charge air cooler (2)	For better accessibility lift charge air cooler (2) slightly forward. Installation: Check coolant hoses at fitting (2a) and hose clamp for damage; replace if necessary.
11	Take out charge air cooler (2)	Unclip plug connection for O2 sensor from retaining spring at rear of charge air cooler (2).
12	Install in the reverse order
13	Bleed low temperature circuit		AR20.00-P-1145H
14	Inspect cooling system for leaks		AR20.00-P-1010HN

CHARGE AIR DUCT

Number	Designation		Engine 275, 285
BA09.41-P-1002-02B	Hose clamp, charge air hose to engine charge air channel and to charge air cooler	Nm	3
BA09.41-P-1003-02B	Hose clamp, charge air channel as required charge air cooler to charge air cooler and to electronic accelerator actuator	Nm	3

CHARGE AIR COOLER

Number	Designation		Engine 275, 285
BA09.41-P-1001-03A	Bolt, charge air cooler to cylinder head cover	Nm	8
BA09.41-P-1002-03A	Bolt, pressure sensor in front of throttle valve actuator to bracket	Nm	6

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Cleaner from package	Adolf Wurth GmbH & Co. KG Reinhold-Wurth-Str. 12-17 74653 Kunzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000 www.wuerth.de