Remove/Install Charge Air Cooler - AR09.41-P-6817MNM
Engine 177 in model 217, 222
| Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. 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. 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 | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Notice | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| Notice | Notes on threaded connections with aluminum screws/bolts | AH00.00-P-0006-01RM | |
| Notice | Notes on coolant | AH20.00-P-2080-01KOA | |
| Notes on coolant level | AH20.00-P-1142-01CW | ||
| Remove/install | |||
| 1 | Remove left-hand air filter housing | AR09.10-P-1151MNM | |
| 2 | Remove right air filter housing | AR09.10-P-1152MNM | |
| 3 | Drain coolant from low-temperature circuit | AR09.41-P-6834MNM | |
| 4 | Drain off coolant | AR20.00-P-1142MNL | |
| 5 | Remove fan unit | AR20.40-P-5050MNM | |
| 6 | Mount protective plate on radiator | ||
| WF58.50-P-0110-01A | |||
| 7 | Unclip engine wiring harness (2) from charge air coolers (13, 14) | ||
| 8 | Remove brackets (1) | *BA09.41-P-1006-01X | |
| *BA00.10-P-1002-04A | |||
| 9 | Release and disconnect electrical connection (7) | ||
| 10 | Release and disconnect electrical connector (12) | ||
| 11 | Release and disconnect electrical connector (22) | ||
| 12 | Remove screw (4) | ||
| 13 | Remove screw/bolt (5) | ||
| 14 | Remove cable ducts (23) from cylinder head covers | *BA15.18-P-1003-01G | |
| 15 | Unclip bleed line (8) and remove from charge air cooler (13) | AR20.20-P-7441-01RQ | |
| 16 | Disconnect vent line at connecting point (3) | AR20.20-P-7441-01RQ | |
| 17 | Loosen clamps (6) | *BA09.41-P-1002-01X | |
| 18 | Remove coolant hose (21) from coolant inlet fitting and expansion reservoir | AR20.30-P-4949LF | |
| 19 | Remove coolant hose (18) from charge air cooler (14) | AR20.20-P-7441-01RQ | |
| 20 | Remove coolant hose (19) from charge air cooler (14) | Fig 2 | |
| 21 | Remove coolant hose (9) from charge air cooler (13) | AR20.20-P-7441-01RQ | |
| 22 | Remove coolant hose (10) | AR20.20-P-7441-01RQ | |
| 23 | Loosen clamps (15) | ||
| *BA09.41-P-1002-01X | |||
| 24 | Remove purge lines (11, 20) on charge air coolers (13, 14) | ||
| 25 | Remove brackets (16) | *BA09.41-P-1007-01X | |
| 26 | Unclip electric line (17) from charge air coolers (13, 14) | ||
| 27 | Release and disconnect electrical connector of right boost pressure sensor upstream of throttle valve | AR09.41-P-1021MNM | |
| 28 | Release and disconnect electrical connector of left boost pressure sensor upstream of throttle valve | AR09.41-P-1020MNM | |
| 29 | Detach charge air coolers (13, 14) | ||
| Antifriction paste, rubber parts 2.5 kg, DBL 6867.00 | *BR00.45-Z-1002-06A | ||
| 30 | Remove charge air coolers (13, 14) upwards | ||
| 31 | Install in the reverse order | ||
| 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 | |
| 32 | Perform an engine test run and check engine for proper operation and leaktightness | ||
| 33 | Install lower engine compartment paneling | AR61.20-P-1105LF | |
| 34 | Install upper engine cover |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1002-04A | M6X1 | 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 |
CHARGE AIR LINE/CHARGE AIR COOLING
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA09.41-P-1007-01X | Bolt, lower charge air cooler bracket to thermostat/crankcase | Nm | 9 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA15.18-P-1003-01G | Screw, cable duct to cylinder head cover/charge air cooler/heat shield, right | Nm | 9 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1002-06A | Antifriction paste, rubber parts 2.5 kg, DBL 6867.00 | A 000 989 01 60 |