Remove/install coolant lines - AR20.20-P-7440GW

ENGINES 157 in MODEL 463

Fig 1: Coolant Lines Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	Risk of injury from grazing or abrasion injury of body parts on sharp-edged 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
		Observe assembly sequence for the coolant lines. One must always first remove the lower coolant lines (2r, 2l) and then the upper coolant lines (1r, 1l) on the turbocharger.
1	Drain coolant		AR20.00-P-1142GW
	Notes on coolant		AH20.00-N-2080-01A
2	Remove upper charge air ducts from air filter to turbocharger		AR09.41-P-8620GW
3	Remove poly-V belt		AR13.20-P-0001GW
	Perform operation steps 4 to 8 to remove the left coolant lines (1l, 2l)
4	Detach and remove double clamp (6) from turbocharger and coolant line (1l, 2l)		*BA09.40-P-1006-01R
4			*BA09.40-P-1009-01R
5	Detach and remove bracket (5) for the upper coolant line (1l) from oil filter housing	Ensure correct assembly of the bracket (5) and correct routing of the coolant lines (1l, 2l). Damage can occur on the turbocharger coolant circuit otherwise.
5			*BA09.40-P-1005-01R
6	Remove screw/bolts (4a, 4b) from coolant pump		*BA09.40-P-1005-01R
7	Remove screw/bolt (3) for coolant lines (1l, 2l) to turbocharger		*BA09.40-P-1005-01R
8	Remove coolant lines (1l, 2l) from coolant pump and turbocharger and take out upwards	Replace sealing ring.
	Perform operation steps 9 to 13 to remove the right coolant lines (1l, 2l)
9	Detach screw/bolts (7) on coolant pump		*BA09.40-P-1005-01R
10	Remove screw/bolt (8) for coolant line (1l, 2l) to turbocharger		*BA09.40-P-1005-01R
11	Remove upper coolant line (1r) from coolant pump and turbocharger and take out upwards	Replace sealing ring.
12	Remove screw/bolt (4) for lower coolant line (2r) on timing case cover		*BA09.40-P-1005-01R
13	Remove lower coolant line (2r) from timing case cover and turbocharger and take out upwards	Plug openings. Replace sealing ring.
13			Figure
14	Install in the reverse order
15	Pour in coolant		AR20.00-P-1142GW
16	Inspect cooling system for leaks		AR20.00-P-1010GW
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
17	Carry out engine test run, checking the engine for proper operation and leaks

TURBOCHARGER

Number	Designation		Engine 157
BA09.40-P-1005-01R	Screw/bolt, coolant line to turbocharger/oil filter/coolant pump/timing case cover	Nm	9
BA09.40-P-1006-01R	Screw/bolt, coolant line bracket to water pump/turbocharger	Nm	9
BA09.40-P-1009-01R	Screw/bolt, coolant line clamp to bracket	Nm	9

Fig 2: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA