Remove/Install Charge Air Cooler - AR09.41-P-6817HH (SL600, SL65 AMG)

Engine 275 In Model 215, 216, 220, 221, 230

Engine 285 In Model 240

Shown On Engine 285

Fig 1: Identifying Charge Air Cooler Components - Shown On Engine 285

Courtesy of MERCEDES-BENZ USA

	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 275.95	AR01.10-P-2405LA
		Engine 275.98	AR01.10-P-2405IM
2	Remove air filter housing	Model 215, 216, 220, 221, 230	AR09.10-P-1150LA
		Model 240	AR09.10-P-1150H
3	Drain coolant from low temperature circuit	Model 215, 216, 220, 221, 230	AR20.00-P-1142HM
		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
			*WH58.30-Z-1002-06A
		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.
			*BA09.41-P-1003-02B
			*WH58.30-Z-1002-06A
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 dismount 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 fitting at the charge air cooler (2). This combination must not be separated, otherwise leakage may occur.
			*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 screws (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.
			*WH58.30-Z-1019-02A
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 of charge air hose at engine charge air channel and at charge air cooler	Nm	3
BA09.41-P-1003-02B	Hose clamp of charge air channel as required charge air cooler at charge air cooler and at 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

Commercially Available Tools

Number	Designation
WH58.30-Z-1019-02A	Hose clamp pliers (length 210 mm, clamping range 80 mm)
WH58.30-Z-1002-06A	7 mm socket hexagon on flexible shaft for hose clamps with worm drive

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