Remove/Install Left Water-Cooled Charge Air Cooler - AR09.41-P-6827MNL

Engine 176 in model 217, 222 

with small lower coolant expansion reservoir for low-temperature circuit 

Fig 1: Left Water-Cooled Charge Air Cooler Components Location - Engine 176 In Model 222 With Low-Temperature Circuit Lower Small Reservoir

Courtesy of MERCEDES-BENZ USA

	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-1151MNL
		:  Do not install upper engine cover until after the leak test.
2	Remove right air filter housing		AR09.10-P-1152MNL
3	Drain coolant from low-temperature circuit		AR09.41-P-6834MNL
		:  Only install lower engine compartment lining after leak test.
4	Remove fan unit		AR20.40-P-5050MNL
5	Mount protective plate on radiator
			WF58.50-P-0110-01A
6	Remove right and left upper engine compartment lining
7	Remove coolant hose (20) from charge air coolers (18, 21)	Hose clamp pliers	Fig 2
8	Unclip coolant hose (20)
9	Remove engine cable duct (9) from cylinder head cover and left charge air cooler (18)	M6X1	*BA00.10-P-1002-04A
10	Remove engine cable duct (3) from cylinder head cover and right charge air cooler (21)	M6X1	*BA00.10-P-1002-04A
11	Remove engine cable duct (5) from cylinder head cover	M6X1	*BA00.10-P-1002-04A
12	Remove coolant hose (14) from return line (11)	Hose clamp pliers	Fig 2
13	Disconnect bleed line (2) at separating point (1)		AR20.20-P-7441-01RQ
14	Remove purge lines at separating points (13)
15	Release and disconnect electrical connector of left bypass air switchover valve (Y101/1)		AR09.40-P-0007MNL
16	Release and disconnect electrical connector of right bypass air switchover valve (Y101/2)		AR09.40-P-0008MNL
17	Release and disconnect electrical connector (17)
18	Release and disconnect electrical connection of boost pressure control pressure transducer (Y77/1)
19	Remove bleed line (16) from left charge air cooler (18)
20	Release and disconnect electrical connectors of position sensors of left camshafts		AR15.12-P-2148MNL
21	Release and disconnect electrical connector of left pressure sensor upstream of throttle valve		AR09.41-P-1020MNL
22	Release and disconnect electrical connector of right pressure sensor upstream of throttle valve		AR09.41-P-1021MNL
23	Release and disconnect electrical connector of left pressure sensor downstream of throttle valve		AR09.41-P-1030MNL
24	Remove upper coolant expansion reservoir for low-temperature circuit		AR09.41-P-0050MNL
25	Remove lower coolant expansion reservoir for low-temperature circuit		AR09.41-P-0060MNL
26	Place engine wiring harness to one side
27	Remove return line (11)	M6X1	*BA00.10-P-1002-04A
28	Remove bracket (12)	Bolt, upper charge air cooler bracket to charge air cooler/chain case cover	*BA09.41-P-1006-01X
		M6X1	*BA00.10-P-1002-04A
29	Remove bracket (4) from cylinder head cover	Bolt, upper charge air cooler bracket to charge air cooler/chain case cover	*BA09.41-P-1006-01X
30	Release clamp of boot (15) from left throttle valve actuator (M16/60)	Bolt, clamp for charge air hose to charge-air distributor	*BA09.41-P-1002-01X
31	Release clamp of boot (23) from right throttle valve actuator (M16/61)	Bolt, clamp for charge air hose to charge-air distributor	*BA09.41-P-1002-01X
32	Open clamp (19) and slide in direction of right charge air cooler (21)	Hose clamp pliers	Fig 2
33	Detach clamps of boots (7, 8) at charge air coolers (18, 21)	Bolt, clamp for charge air hose to charge-air distributor	*BA09.41-P-1002-01X
34	Lift charge air coolers (18, 21) out of elastomer bearings
35	Release and disconnect electrical connector of left throttle valve actuator (M16/60)
36	Remove left charge air cooler (18)
37	Check elastomer bearings of left charge air cooler (18) for damage	If a problem arises ↓ Replace appropriate elastomer bearing.
38	Remove left throttle valve actuator (M16/60)	When replacing left charge air cooler (18).
			AR07.51-P-1402MNL
39	Remove hose (10)	When replacing left charge air cooler (18).
		Hose clamp pliers	Fig 2
40	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
41	Perform engine test run and check engine for proper operation and leak tightness
42	Install lower engine compartment paneling		AR61.20-P-1105LF
43	Install upper engine cover

Fig 2: Identifying Hose Clamp Pliers (003 589 03 37 00)

Courtesy of MERCEDES-BENZ USA