Remove/Install Liquid Cooled Charge Air Cooler - AR09.41-P-0105MFC

Engine 260 in model 118, 177, 247

with code M016 (Uprated Engine)

Fig 1: Liquid Cooled Charge Air Cooler Components Location - Engine 260 In Model 247 With Code M016

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

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
	Risk of injury to skin and eyes due to handling of Engine oil. Risk of poisoning caused by swallowing Engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill Engine oil into beverage containers.	AS18.00-Z-0001-01A
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove/install
1	Drain off low-temperature circuit coolant.		AR09.41-P-6834MFC
2	Remove air filter housing.		AR09.10-P-1150MFC
3	Remove the front and side battery cover, voltage dip limiter and fuse and relay module.		AR54.10-P-0005MFA
4	Remove Engine air intake duct downstream of air filter.		AR09.10-P-8130MFC
		Only install upper Engine cover after the leak test.
5	Remove charge air pipe downstream of exhaust gas turbocharger.		AR09.41-P-1333MFC
6	Remove low-temperature circuit expansion reservoir.		AR09.41-P-0001MFC
7	Unclip the coolant line (8) on the charge air cooler (1).
8	Release and disconnect the electrical connector (5), unclip the electric line on the charge air cooler (1) and place to one side.
9	Remove the purge line (4) on the charge air cooler (1) and seal the openings with protective covers.	Set of protective caps	Fig 3
10	Remove the coolant hose (9) on the coolant line to the charge air cooler (1) and seal the openings with protective covers and suitable stop plugs.		AR20.20-P-7441-01RQ
		Set of plugs	Fig 2
		Set of protective covers	Fig 5
11	Remove the vacuum line (2) on the vacuum pump and seal the openings with protective covers.	Set of protective caps	Fig 3
12	Unclip the vacuum line (2) and fuel line (7) on the charge-air distributor (1) and place to one side.
13	Remove soundproofing (3).
14	Remove screw (15).	Screw, charge air cooler holder to cylinder head cover	*BA09.41-P-1005-01KOA
15	Unscrew the screw (13) for the holder of the coolant line (12).	Screw, coolant line holder to charge air cooler	*BA09.41-P-1007-01KOA
16	Open the clamp (14), remove the coolant line (12) from the charge air cooler (1) and seal the openings with suitable stop plugs and protective covers.	Set of plugs	Fig 2
		Set of protective caps	Fig 3
17	Release and disconnect the electrical connector (11) for the lambda sensor.
18	Unclip the subharness (10) on the battery frame and place to one side.
19	Release the hose clamp (16).	Clamp, boot to charge air line/charge air cooler	*BA09.41-P-1003-01KOA
20	Release the charge air cooler (1) from the elastomer bearings and lift it up until you can access the electrical connector (6) on the overrun mode bypass air switchover valve (Y101).	Wet elastomer bearings with lubricant.
		Lubricant, rubber assembly 1	*BR00.45-Z-1010-06A
21	Release and disconnect electrical connector (6).
22	Remove the charge air cooler (1).
23	Check charge air cooler (1) for damage.	If there are problems, ↓ Replace charge air cooler (1).
24	Check the elastomer bearings of the charge air cooler (1) for damage.	If there are problems, ↓ replace the elastomer bearings of the charge air cooler (1).
25	Remove the bleed line (20) from the charge air cooler (1) and seal the openings with protective covers and suitable stop plugs.	When installing a new charge air cooler (1). Commercially available devices/tools Hose clamp pliers
		Set of protective caps	Fig 3
		Record plug	Fig 4
26	Remove the molded hose (17) from the charge air cooler (1) and seal the openings with protective covers.	When installing a new charge air cooler (1).
		Commercially available devices/tools Hose clamp pliers
		Set of protective caps	Fig 6
		Set of protective covers	Fig 5
27	Open the hose clamp (21) and remove the boot from the charge air cooler (1).	When installing a new charge air cooler (1).
		Clamp, boot to charge air line/charge air cooler	*BA09.41-P-1003-01KOA
28	Remove the clamp (23), remove the coolant line (22) and seal the openings with suitable stop plugs and protective covers.	When installing a new charge air cooler (1).
		Set of plugs	Fig 2
		Set of protective covers	Fig 5
29	Remove the pressure and temperature sensor upstream of the throttle valve (B28/26) and seal the openings with suitable stop plugs.	When installing a new charge air cooler (1).
		Pressure and temperature sensor to charge air cooler	*BA09.41-P-1004-01KOA
		Record plug	Fig 4
30	remove the overrun mode bypass air switchover valve (Y101) and seal the opening with a suitable stop plug.	When installing a new charge air cooler (1).
		Replace seal.
		Bolt, solenoid valve to charge air cooler	*BA09.41-P-1001-01KOA
		Set of plugs	Fig 2
31	Unscrew the screws (18) and remove the holder (19).	When installing a new charge air cooler (1).
		Screw, coolant line holder to charge air cooler	*BA09.41-P-1007-01KOA
32	Install in the reverse order.
33	Read out and delete fault memory.
			AD00.00-P-2000-06MFA
	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
34	Perform Engine test run. While doing so, check Engine for proper operation and leak tightness
35	Install upper Engine cover.
			AP01.10-P-2405-01C