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

ENGINES 157, 278 in MODEL 216, 221 

Engine 157, 278 up to 30. 07. 2010 

Fig 1: Identifying Coolant Lines Remove/Install Components

Courtesy of MERCEDES-BENZ USA

Engine 157, 278 as of 30. 07. 2010 

Fig 2: Identifying 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 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
		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 at radiator		AR20.00-P-1142MM
	Notes on coolant		AH20.00-N-2080-01A
2	Remove charge air ducts from air filter to turbocharger		AR09.41-P-8620MMB
3	Remove poly-V belt		AR13.20-P-0001MMB
	Perform operation steps 4 to 9 just during removal of the left coolant lines (1l, 2l)
4	Remove washer fluid reservoir	Vehicles with AIRmatic
		Model 221 Model 216	AR82.35-P-6000SX
5	Detach and remove double clamp (6) from turbocharger and coolant line (1l, 2l)		*BA09.40-P-1006-01R
			*BA09.40-P-1009-01R
6	Detach and remove bracket (5) for the upper coolant line (1l) from coolant pump	Ensure correct assembly of the bracket (5) and correct routing of the coolant lines (1l, 2l) otherwise damage can occur on the coolant circuit for the turbocharger.
			*BA09.40-P-1005-01R
7	Remove bolts (4) from coolant pump		*BA09.40-P-1005-01R
8	Remove bolt (3) for coolant lines (1l, 2l) to turbocharger		*BA09.40-P-1005-01R
9	Remove coolant lines (1l, 2l) from coolant pump and turbocharger and take out upwards	Replace sealing ring.
	Perform operation steps 10 to 15 just during removal of the right coolant lines (1r, 2r)
10	Detach bracket (8) for the upper coolant line (1r) to coolant pump		*BA09.40-P-1005-01R
11	Remove bolt (7) for upper coolant line (1r) to coolant pump		*BA09.40-P-1005-01R
12	Remove bolt (9) for coolant line (1l, 2l) to turbocharger		*BA09.40-P-1005-01R
13	Remove upper coolant line (1r) from coolant pump and turbocharger and take out upwards	Replace sealing ring.
14	Remove bolt (7) for lower coolant line (2r) on timing case cover		*BA09.40-P-1005-01R
15	Remove lower coolant line (2r) from timing case cover and turbocharger and take out upwards	Plug openings. Replace sealing ring.
			Figure
16	Install in the reverse order
17	Inspect cooling system for leaks		AR20.00-P-1010SX
	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
18	Carry out engine test run, checking the engine for proper operation and leaks

Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA