Remove/Install Left Water-Cooled Charge Air Cooler - AR09.41-P-6827XGA
Engine 176 in model 463
as of model year 2019
Fig 1: Left Water-Cooled Charge Air Cooler Components Location - Engine 176 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 left air filter housing. | AR09.10-P-1151XGA | |
| 2 | Remove right air filter housing. | AR09.10-P-1152XGA | |
| 3 | Remove fan unit. | AR20.40-P-5050XGA | |
| 4 | Remove upper coolant expansion reservoir for low-temperature circuit. | AR09.41-P-0050XGA | |
| 5 | Remove coolant line (8) and seal openings with protective covers. | ||
| *BA00.10-P-1002-04A | |||
| Fig 2 | |||
| Fig 3 | |||
| 6 | Remove coolant hose (21) from charge air coolers (18, 20) and seal openings with protective covers. | Fig 3 | |
| Fig 2 | |||
| 7 | Remove purge lines (11) at separating points (14) and seal openings with protective covers. | Fig 3 | |
| 8 | Release and disconnect electrical connector (13). | ||
| 9 | Remove purge lines (11) with bracket from chain case cover and place to one side. | *BA00.10-P-1002-04A | |
| 10 | Disconnect bleed line (5) at separating point (1) and seal openings with protective covers. | AR20.20-P-7441-01RQ | |
| Fig 3 | |||
| 11 | Unhook bleed line (5) on right charge air cooler (20) and engine cable duct (2) and place to one side. | ||
| 12 | Remove engine cable duct (16) from left cylinder head cover and left charge air cooler (18). | *BA15.18-P-1001-01G | |
| 13 | Remove engine cable duct (2) from right cylinder head cover and right charge air cooler (20). | *BA15.18-P-1001-01G | |
| *BA00.10-P-1002-04A | |||
| 14 | Remove engine cable duct (4) from right cylinder head cover. | *BA15.18-P-1001-01G | |
| 15 | Release and disconnect electrical connector (17). | ||
| 16 | Release and disconnect electrical connector at boost pressure control pressure transducer (Y77/1). | ||
| 17 | Release and disconnect electrical connector of left overrun mode bypass air switchover valve (Y101/1). | ||
| 18 | Release and disconnect electrical connector of right overrun mode bypass air switchover valve (Y101/2). | ||
| 19 | Release and disconnect electrical connector of right intake camshaft Hall sensor (B6/5). | ||
| 20 | Release and disconnect electrical connector of right exhaust camshaft Hall sensor (B6/7). | ||
| 21 | Release and disconnect electrical connector of left intake camshaft Hall sensor (B6/4). | ||
| 22 | Release and disconnect electrical connector of left exhaust camshaft Hall sensor (B6/6). | ||
| 23 | Release and disconnect electrical connector of pressure sensor upstream of left throttle valve (B28/20). | ||
| 24 | Release and disconnect electrical connector of pressure sensor upstream of right throttle valve (B28/21). | ||
| 25 | Release and disconnect electrical connector at pressure sensor downstream of left throttle valve (B28/22). | ||
| 26 | Release and disconnect electrical connector of pressure sensor downstream of right throttle valve (B28/23). | ||
| 27 | Place engine wiring harness outside of working area. | ||
| 28 | Remove bracket (3) from chain case cover. | *BA09.41-P-1006-01X | |
| 29 | Remove bracket (12) from chain case cover. | *BA09.41-P-1006-01X | |
| 30 | Release clamp of boot (22) at right throttle valve actuator (M16/61). | ||
| Lubricant, rubber assembly 1 l | *BR00.45-Z-1010-06A | ||
| *BA09.41-P-1002-01X | |||
| 31 | Release clamp of boot (15) at left throttle valve actuator (M16/60). | ||
| Lubricant, rubber assembly 1 l | *BR00.45-Z-1010-06A | ||
| *BA09.41-P-1002-01X | |||
| 32 | Release charge air hose (7) at right charge air cooler (20). | *BA09.41-P-1002-01X | |
| 33 | Release charge air hose (9) at left charge air cooler (18). | *BA09.41-P-1002-01X | |
| 34 | Release left clamp on boot (19) and slide in direction of right charge air cooler (20). | ||
| Lubricant, rubber assembly 1 l | *BR00.45-Z-1010-06A | ||
| Fig 2 | |||
| 35 | Carefully pry charge air coolers (18, 20) out of elastomer bearings. | Lubricant, rubber assembly 1 l |
*BR00.45-Z-1010-06A |
| 36 | Release and disconnect electrical connector of left throttle valve actuator (M16/60). | ||
| 37 | Remove left charge air cooler (18) in upward direction. | ||
| 38 | Check elastomer bearings of left charge air cooler (18) for damage. | If problems exist, ↓ Replace appropriate elastomer bearing. |
|
| 39 | Remove left throttle valve actuator (M16/60). | When replacing left charge air cooler (18). | AR07.51-P-1402XGA |
| 40 | Remove hose (10). | When replacing left charge air cooler (18). |
Fig 2 |
| 41 | Install in the reverse order. | ||
| 42 |
Read out and delete fault memory. | AD00.00-P-2000-04B | |
| 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 | |
| 43 | Carry out engine test run and check engine for proper leak tightness and leak tightness. | ||
| 44 | Install lower engine compartment lining. | AR61.20-P-1105XG | |
| 45 | Install upper engine cover. | AR01.10-P-2405XGA |
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 176 | |
|---|---|---|---|
| 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 176 | |
|---|---|---|---|
| BA09.41-P-1006-01X | Bolt, upper charge air cooler bracket to charge air cooler/chain case cover | Nm | 9 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA15.18-P-1001-01G | Bolt, engine wiring harness to cylinder head cover | Nm | 9 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1010-06A | Lubricant, rubber assembly 1 | | A 000 989 03 67 |