Remove/Install Charge Air Cooler - AR09.41-P-6817XGC
Engine 177 in model 463 as of model year 2019
| 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 pressure. 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 | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Notes on threaded connections with aluminum screws/bolts | AH00.00-P-0006-01RM | ||
| Notes on coolant | AH20.00-N-2080-01A | ||
| Notes on coolant level | AH20.00-P-1142-01CW | ||
| Remove/install | |||
| 1 | Remove low-temperature circuit switchover valve mounting support. | |
AR09.41-P-1240XGC |
| 2 | Remove the coolant expansion reservoir. | AR20.30-P-4950XGC | |
| 3 | Remove fan unit. | AR20.40-P-5050XGC | |
| 4 | Unclip engine wiring harness (11) from charge air coolers (14, 15). | ||
| 5 | Remove engine cable ducts (3) from cylinder head covers. | *BA15.18-P-1003-01G | |
| 6 | Release and disconnect electrical connector (21) and remove from charge air cooler (14). | ||
| 7 | Remove coolant line (10) from charge air cooler (14) and seal openings with suitable stop plugs. | AR09.41-P-1311-01AL | |
| Fig 2 | |||
| 8 | Remove screw (7). | *BA00.10-P-1002-04A | |
| 9 | Disconnect bleed line (5) at connecting point (6) and seal openings with suitable stop plugs. | AR09.41-P-1311-01AL | |
| Fig 2 | |||
| 10 | Release and disconnect electrical connector (12) and remove associated electric line from bracket (4) at charge air cooler (14). | ||
| 11 | Remove brackets (4). | *BA09.41-P-1006-01X | |
| *BA00.10-P-1002-04A | |||
| 12 | Release and disconnect electrical connector (20). | ||
| 13 | Remove screw (9). | *BA00.10-P-1002-04A | |
| 14 | Release clamps (8). | *BA01.20-P-1003-01J | |
| 15 | Remove coolant hose (2) from connection fitting of coolant pump and seal openings with protective covers. | AR20.20-P-7441-01RQ | |
| Fig 4 | |||
| 16 | Remove coolant hose (18) from charge air cooler (15) and seal openings with protective covers. | AR09.41-P-1311-01AL | |
| Fig 3 | |||
| 17 | Remove coolant hose (19) from charge air cooler (15) and seal openings with suitable stop plugs. | Fig 2 | |
| Fig 1 | |||
| 18 | Remove purge lines (13) from charge air coolers (14, 15) and seal openings with suitable stop plugs. | Fig 2 | |
| 19 | Release clamps (1). | *BA09.41-P-1002-01X | |
| 20 | Release and disconnect electrical connector of pressure sensor upstream of right throttle valve (B28/21). | ||
| 21 | Release and disconnect electrical connector of pressure sensor upstream of left throttle valve (B28/20). | ||
| 22 | Release and disconnect electrical connector at left throttle valve actuator (M16/60). | ||
| 23 | Release and disconnect electrical connector at right throttle valve actuator (M16/61). | ||
| 24 | Remove engine wiring harness (16) from charge air coolers (14, 15). | ||
| 25 | Remove brackets (17). | *BA09.41-P-1007-01X | |
| 26 | Release charge air coolers (14, 15). | Antifriction paste, rubber parts 2.5 kg, DBL 6867.00 |
*BR00.45-Z-1002-06A |
| 27 | Remove charge air coolers (13, 14) upwards. | ||
| 28 | 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 | |
| 29 | Carry out engine test run and check engine for proper leaktightness and leaktightness. | ||
| 30 | Install lower engine compartment paneling. | AR61.20-P-1105XG | |
| 31 | Install upper engine cover. | AR01.10-P-2405XGC |
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 |
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA01.20-P-1003-01J | Clamp, boot to exhaust gas turbocharger/air filter | Nm | 1, 5 |
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 |