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

Engine 176 in model 217, 222 

with large 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 Large Lower 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  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 coolant		AH20.00-P-2080-01KOA
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
	Remove/install
1	Remove condenser.		AR83.30-P-6540MNM
2	Remove lower coolant expansion reservoir for low-temperature circuit.		AR09.41-P-0060MNP
3	Remove left and right air filter housing.	Remove/install left air filter housing	AR09.10-P-1151MNL
		Remove/install right air filter housing	AR09.10-P-1152MNL
4	Remove hoses (8).	Hose clamp pliers	Fig 3
5	Remove upper coolant expansion reservoir for low-temperature circuit.		AR09.41-P-0050MNL
6	Remove bleed line of coolant expansion reservoir from cable duct.
7	Release, disconnect purge lines at separating points at bracket (13) and seal openings with suitable stop plugs.	Record plug	Fig 5
8	Open hose clamp (4), remove coolant hose (5 from coolant line (15) and seal openings using suitable protective covers.	Hose clamp pliers	Fig 3
		Set of protective covers	Fig 4
9	Unscrew screw (14) and remove coolant line (15) from charge air cooler (16).	Bolt, coolant line on charge air cooler	*BA20.20-P-1001-01Q
10	Unscrew screws (3) and remove holder (13).	Screw, holder for upper charge air cooler to charge air cooler/chain case cover/cylinder head	*BA09.41-P-1006-01X
11	Remove soundproofing of left rail.
12	Disconnect engine wiring harness.		AR15.18-P-1000-03XGI
		Screw, cable duct to cylinder head cover/charge air cooler/heat shield, right	*BA15.18-P-1003-01G
		Dismantling tool	Fig 2
13	Position engine wiring harness above coolant line (15).	Do not crush or kink or subject electric lines to tension. This will result in damage to the electric lines and can impair their function.
14	Open hose clamp, remove coolant hose (7) from charge air cooler (16) and seal openings using suitable protective covers.	Hose clamp pliers	Fig 3
		Set of protective covers	Fig 4
15	Remove purge line (2) at charge air cooler (16) at bottom and seal openings with suitable stop plugs.	Record plug	Fig 5
16	Open screw clamp (11) and remove charge air hose (1) from charge air cooler (16).	Screw, clamp for charge air hose to exhaust gas turbocharger/air filter housing/charge air cooler	*BA09.41-P-1018-01X
17	Open screw clamp and remove charge air hose (6) from throttle valve actuator.	Bolt, clamp for charge air hose to charge-air distributor	*BA09.41-P-1002-01X
18	Open hose clamps (9, 12).	Hose clamp pliers	Fig 3
19	Remove charge air cooler (16).	:  Wet elastomer bearings and coolant hoses (10, 17) of charge air cooler (16) with lubricant.
		Lubricant, rubber assembly 1 L	*BR00.45-Z-1010-06A
	Check
20	Check elastomer bearings of charge air cooler (16) for damage.	If damage is present: ↓ Replace appropriate elastomer bearing.
21	Remove the throttle valve actuator.	When replacing charge air cooler (16).
			AR07.51-P-1402MNL
22	Remove pressure sensor upstream of throttle valve.	When replacing charge air cooler (16).
			AR09.41-P-1020MNL
23	Remove overrun mode bypass air switchover valve.	When replacing charge air cooler (16).
			AR09.40-P-0007MNL
24	Install in the reverse order.

Fig 2: Identifying Dismantling Tool (000 589 95 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Hose Clamp Pliers (454 589 00 37 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Set Of Protective Covers (001 589 11 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA