Remove/Install Charge Air Cooler - AR09.41-P-6817MNJ

Engine 178.9 in model 190.381

Fig 1: Charge Air Cooler Components Location - Engine 178.9 In Model 190.381

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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 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 overpressure. Do not pour coolant into beverage containers.	AS20.00-Z-0001-01A
		Wear protective gloves, protective clothing and safety glasses.
	Risk of injury to skin and eyes due to handling of Engine oil. Risk of poisoning caused by swallowing Engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill Engine oil into beverage containers.	AS18.00-Z-0001-01A
	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
Notice	Notes on working in Engine compartment		AH60.00-P-0042-01RG
Notice	Notes on coolant		AH20.00-P-2080-01KOA
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Remove/install
1	Remove left and right air filter housing.	Right air filter housing	AR09.10-P-1152MNJ
		Left air filter housing	AR09.10-P-1151MNJ
		Do not install upper Engine cover until after the leak test.
2	Remove charge air hoses (5, 10) from the overrun mode bypass air switchover valves (Y101/1, Y101/2), exhaust gas turbochargers and bracket (4).	Hose clamp pliers	Fig 3
3	Remove air intake lines (6, 9) downstream of air filter.	Clamp, boot to exhaust gas turbocharger/air filter	*BA01.20-P-1003-01J
4	Release and disconnect electrical connectors (3, 11), and expose electrical wiring harness.
5	Remove charge air hoses (7, 8).		AR09.41-P-1311-01AL
		Bolt, clamp for charge air hose to charge-air distributor	*BA09.41-P-1002-01X
6	Drain off coolant.		AR20.00-P-1142MNJ
		Do not install lower Engine covers until after the leak test.
7	Drain coolant of low temperature circuit.		AR20.00-P-1144MNJ
		Do not install lower Engine covers until after the leak test.
8	Remove the coolant expansion reservoir.		AR20.30-P-4950MNB
9	Remove the oil expansion reservoir.		AR46.25-P-1000RG
10	Remove the coolant lines (13, 14) from the charge air coolers (1, 2), and place them to one side.		AR20.20-P-7441-01RQ
11	Remove coolant line (17) from the bracket (16).
12	Release and disconnect electrical connector (15), and remove electric line from the bracket (16).	Dismantling tool	Fig 5
13	Remove the bracket (16).	Bolt, charge air cooler bracket to crossmember	*BA09.41-P-1001-01X
14	Remove the coolant hoses (18, 19) from the charge air coolers (1, 2), and place them to one side.		AR20.20-P-7441-01RQ
15	Remove purge line (12) from the left charge air cooler (1), remove from bracket (4), and plug with suitable stop plugs.	Check sealing rings, replace if necessary, and wet with lubricant.
		Lubricant, rubber assembly 1 L	*BR00.45-Z-1010-06A
		Assembly tool	Fig 2
		Record plug	Fig 4
16	Remove holder (4).	Bolt, charge air cooler bracket to crossmember	*BA09.41-P-1001-01X
17	Remove charge air hoses (20, 21) from the charge air coolers (1, 2).	Bolt, clamp for charge air hose to charge-air distributor	*BA09.41-P-1002-01X
18	Release charge air coolers (1, 2).	Coat the charge air coolers (1, 2) with the lubricant.
		Lubricant, rubber assembly 1 L	*BR00.45-Z-1010-06A
19	Remove the charge air coolers (1, 2) upwards together.	Aid of helper required.
20	Remove overrun mode bypass air switchover valves (Y101/1, Y101/2).	When installing new charge air coolers (1, 2).	AR09.40-P-3000MNB
21	Install in the reverse order.
	Finishing activity
	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
	Risk of burn injuries , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out of the danger zone.	AS49.00-Z-0001-01A
22	Perform Engine test run. While doing so, check Engine for proper operation and leak tightness.