Remove/Install Coolant Lines - AR20.20-P-7440MLJ

ENGINES 157, 278 in MODEL 166 

Shown on engine 278 

Fig 1: Identifying Coolant Lines Remove/Install Components - Shown On Engine 278

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 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
		Observe assembly sequence for the coolant lines. One must always  first remove the lower coolant lines (2l) and then the upper coolant lines (1l) on the turbocharger.
1	Drain coolant at radiator		AR20.00-P-1142GQ
	Notes on coolant		AH20.00-N-2080-01A
2	Remove charge air ducts from air filter to turbocharger		AR09.41-P-8620MLJ
3	Remove poly-V belt		AR13.20-P-0001MLJ
	Perform operation Operating steps 4 to 8 just during removal of the left coolant lines (1l, 2l)
4	Detach and remove double clamp (6) from turbocharger and coolant lines (1l, 2l)		*BA09.40-P-1006-01R
			*BA09.40-P-1009-01R
5	Detach and remove bracket (5) for upper coolant line (1l, 2l) from coolant pump	Ensure correct assembly of the bracket (5) and correct routing of the coolant lines (1l, 2l). Damage can occur on the coolant circuit the turbocharger otherwise.
			*BA09.40-P-1005-01R
6	Remove screw/bolts (4) 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.
	Only perform operating steps 9 to 14 for removal of the RH coolant line
9	Detach bracket (8) for the upper coolant line (1r) to coolant pump		*BA09.40-P-1005-01R
10	Remove bolt (7) for upper coolant line (1r) to coolant pump		*BA09.40-P-1005-01R
11	Remove screw/bolt (9) for coolant lines (1r, 2r) to turbocharger		*BA09.40-P-1005-01R
12	Remove upper coolant line (1r) from coolant pump and turbocharger and take out upwards	Replace sealing ring.
13	Remove screw/bolt (7) for lower coolant line (2r) on timing case cover		*BA09.40-P-1005-01R
14	Remove lower coolant line (2r) from timing case cover and turbocharger and take out upwards	Plug openings. Replace sealing ring.
			Fig 2
15	Install in the reverse order
16	Inspect cooling system for leaks		AR20.00-P-1010GQ
	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

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

Courtesy of MERCEDES-BENZ USA