Remove/Install Right Water-Cooled Charge Air Cooler - AR09.41-P-6828MNH
Engine 177.### ## as of 081179 in model 205, 253
Fig 1: Right Water-Cooled Charge Air Cooler Component Location - Model 205 With Engine 177 Up To 081179
| 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. | Engine 177.### ## as of 081179 in model 205 | AR83.30-P-6540LWA |
| Engine 177.### ## as of 081179 in model 253 | AR83.30-P-6540MNG | ||
| 2 | Remove lower coolant expansion reservoir for low-temperature circuit. | AR09.41-P-0060MNH | |
| 3 | Remove left and right air filter housing. | Engine 177.### ## as of 081179 in model 205 | AR09.10-P-1150MNA |
| Remove/install left air filter housing Engine 177.### ## as of 081179 in model 253 | AR09.10-P-1151MNG | ||
| Remove/install right air filter housing Engine 177.### ## as of 081179 in model 253 | AR09.10-P-1152MNG | ||
| 4 | Remove hoses (5). | Fig 2 | |
| 5 | Remove upper coolant expansion reservoir for low-temperature circuit. | AR09.41-P-0050MNG | |
| 6 | Remove bleed line (8) from cable duct. | ||
| 7 | Release and disconnect purge lines at connecting points on holder (17) and seal openings with suitable stop plugs. | Fig 3 | |
| 8 | Unscrew screw (14) and remove coolant line (16). | *BA20.20-P-1001-01Q | |
| 9 | Unscrew screws (15) and remove holder (17). | *BA09.41-P-1006-01X | |
| 10 | Unscrew screws (21) and remove holder (20) with differential pressure sensor. | *BA00.10-P-1002-04A | |
| 11 | Remove soundproofing (19) of left rail. | ||
| 12 | Disconnect engine wiring harness (18). | AR15.18-P-1000-03MNA | |
| *BA15.18-P-1003-01G | |||
| *BA15.18-P-1004-01G | |||
| Fig 4 | |||
| 13 | Position engine wiring harness (18) above coolant line (16). | This will result in damage to the electric lines and can impair their function. |
|
| 14 | Remove purge line (9) from charge air cooler (12) and seal openings with suitable stop plugs. | Fig 3 | |
| 15 | Unscrew bolts (11) and remove bracket (10). | *BA09.41-P-1006-01X | |
| 16 | Remove vacuum line (7) from charge air cooler (12). | Fig 4 | |
| 17 | Open screw clamp (2) and remove charge air hose (1) from charge air cooler (12). | *BA09.41-P-1018-01X | |
| 18 | Open screw clamp and remove charge air hose (13) from throttle valve actuator. | *BA09.41-P-1002-01X | |
| 19 | Open hose clamps (3). | Fig 2 | |
| 20 | Remove charge air cooler (12). | ||
| Lubricant, rubber assembly 1 l | *BR00.45-Z-1010-06A | ||
| Check | |||
| 21 | Check elastomer bearings of charge air cooler (12) for damage. | If damage is present: ↓ Replace appropriate elastomer bearing. |
|
| 22 | Remove the throttle valve actuator. | When replacing charge air cooler (12). | |
| Engine 177.### ## as of 081179 in model 205 | AR09.41-P-1330MNA | ||
| Engine 177.### ## as of 081179 in model 253 | AR07.51-P-1402MNG | ||
| 23 | Remove pressure sensor upstream of throttle valve. | When replacing charge air cooler (12). | |
| Engine 177.### ## as of 081179 in model 205 | AR09.41-P-0003MNA | ||
| Engine 177.### ## as of 081179 in model 253 | AR09.41-P-1021MNG | ||
| 24 | Remove overrun mode bypass air switchover valve. | When replacing charge air cooler (12). | |
| Engine 177.### ## as of 081179 in model 205 | AR09.40-P-3000MNA | ||
| Engine 177.### ## as of 081179 in model 253 | AR09.40-P-0008MNG | ||
| 25 | Install in the reverse order. |
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-1018-01X | Screw, clamp for charge air hose to exhaust gas turbocharger/air filter housing/charge air cooler | Nm | 4 |
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 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA15.18-P-1004-01G | Bolt, engine wiring harness to ME-SFI [ME] control unit | Nm | 9 |
RADIATOR, COOLANT HOSES
| Number | Designation | Engine 177 except in model 463 | |
|---|---|---|---|
| BA20.20-P-1001-01Q | Bolt, coolant line on charge air cooler | Nm | 6 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1010-06A | Lubricant, rubber assembly 1 l | A 000 989 03 67 |