Remove/Install Right Water-Cooled Charge Air Cooler - AR09.41-P-6828MNG
Engine 177 in model 253
| Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from 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 | |
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| 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 | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Notes on threaded connections with aluminum screws/bolts | AH00.00-P-0006-01RM | ||
| Notes on coolant | AH20.00-N-2080-01A | ||
| Notes on coolant level | AH20.00-P-1142-01CW | ||
| Remove/install | |||
| 1 | Remove left-hand air filter housing | AR09.10-P-1151MNG | |
| 2 | Remove right air filter housing | AR09.10-P-1152MNG | |
| 3 | Remove fan unit | AR20.40-P-5050MNG | |
| 4 | Remove hoses (4) and seal openings with protective covers | Fig 3 | |
| Fig 2 | |||
| 5 | Remove upper coolant expansion reservoir for low-temperature circuit | AR09.41-P-0050MNG | |
| 6 | Remove coolant line (11) and seal openings with protective covers | ||
| *BA00.10-P-1002-04A | |||
| Fig 2 | |||
| Fig 1 | |||
| 7 | Disconnect purge lines (7) at separating points (10) and seal openings with protective covers | Fig 1 | |
| 8 | Release and disconnect electrical connection (8) | ||
| 9 | Remove purge lines (7) with bracket from chain case cover and place to one side | *BA00.10-P-1002-04A | |
| 10 | Release and disconnect electrical connector at boost pressure control pressure transducer (Y77/1) | ||
| 11 | Disconnect bleed line (2) at separating point (1) and seal openings with protective covers | AR20.20-P-7441-01RQ | |
| Fig 1 | |||
| 12 | Detach bleed line (2) at right charge air cooler (16) and at engine cable duct and place to one side | ||
| 13 | Remove coolant hose (18) at right charge air cooler (16) and seal openings with protective covers | Fig 2 | |
| Fig 1 | |||
| 14 | Disconnect engine wiring harness and place | Left engine wiring harness | AR15.18-P-1000-07MNG |
| Right engine wiring harness | AR15.18-P-1000-06MNG | ||
| *BA15.18-P-1001-01G | |||
| *BA15.10-P-1003-05F | |||
| 15 | Remove bracket (3) from chain case cover | *BA09.41-P-1006-01X | |
| 16 | Remove bracket (9) from chain case cover | *BA09.41-P-1006-01X | |
| 17 | Release clamp of boot (17) at right throttle valve actuator (M16/61) | ||
| Lubricant, rubber assembly 1 l | *BR00.45-Z-1010-06A | ||
| *BA09.41-P-1002-01X | |||
| 18 | Detach clamp of boot (13) at left throttle valve | ||
| Lubricant, rubber assembly 1 l | *BR00.45-Z-1010-06A | ||
| *BA09.41-P-1002-01X | |||
| 19 | Release charge air hose (5) at right charge air cooler (16) | *BA09.41-P-1002-01X | |
| 20 | Release charge air hose (6) at left charge air cooler (14) | *BA09.41-P-1002-01X | |
| 21 | Release right clamp of boot (15) and slide in direction of left charge air cooler (16) | ||
| Lubricant, rubber assembly 1 l | *BR00.45-Z-1010-06A | ||
| Fig 2 | |||
| 22 | Carefully pry charge air coolers (14, 16) out of elastomer bearings | ||
| 23 | Remove right charge air cooler (16) upwards | ||
| Lubricant, rubber assembly 1 l | *BR00.45-Z-1010-06A | ||
| 24 | Check elastomer bearings of right charge air cooler (16) for damage | If a problem arises ↓ Replace relevant elastomer bearing(s). |
|
| 25 | Remove right throttle valve actuator (M16/61) | When replacing right charge air cooler (16). | AR07.51-P-1402MNG |
| 26 | Install in the reverse order | ||
| 27 | Read out and erase fault memory | ||
| AD00.00-P-2000-04B | |||
| Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | AS00.00-Z-0005-01A | |
| 28 | Perform an engine test run and check engine for proper operation and leaktightness | ||
| 29 | Install lower engine compartment paneling | AR61.20-P-1105LW |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1002-04A | M6 X 1 | Nm | 9 | 13 |
CHARGE AIR LINE/CHARGE AIR COOLING
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA09.41-P-1002-01X | Bolt, clamp for charge air hose to charge-air distributor | Nm | 6 |
CHARGE AIR LINE/CHARGE AIR COOLING
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA09.41-P-1006-01X | Bolt, upper charge air cooler bracket to charge air cooler/chain case cover | Nm | 9 |
GROUND STRAP
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA15.10-P-1003-05F | Bolt, engine wiring harness ground to cylinder head cover | Nm | 9 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA15.18-P-1001-01G | Bolt, engine wiring harness to cylinder head cover | Nm | 9 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1010-06A | Lubricant, rubber assembly 1 l | A 000 989 03 67 |