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Home >> Mercedes Benz >> 2021 >> GT 43 AMG >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Air Intake, Turbocharging -- 290 Chassis >> Testing & Repair >> Remove/Install Charge Air Cooler - AR09.41-P-6817MNI

Remove/Install Charge Air Cooler - AR09.41-P-6817MNI

Engine 177.9 in model 290 

MODIFICATION NOTES

10.05.2023 Document completely revised.    
G16557401Courtesy of MERCEDES-BENZ USA
G16557402Courtesy of MERCEDES-BENZ USA
G16557403Courtesy of MERCEDES-BENZ USA
WARNING 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
WARNING 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
CAUTION 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
Notice  Notes on threaded connections with aluminum screws/bolts   AH00.00-P-0006-01RM
  Notes on coolant level   AH20.00-P-1142-01CW
REMOVINGINSTALLING Remove/install     
1 Discharge air conditioning system.   AR83.30-P-1760FR
2 Remove left air filter housing.   AR09.10-P-1151MNI 
    INSTALLATION IMPORTANT Do not install upper engine cover until after the leak test.  
3 Remove right air filter housing.   AR09.10-P-1152MNI 
4 Disconnect refrigerant lines (24, 25) at separating point and seal openings with suitable stop plugs. INSTALLATION IMPORTANT Replace sealing rings.
Moisten sealing rings with compressor oil.		  
    TORQUE SPECIFICATION Nut/bolt, connecting point for refrigerant line *BA83.30-P-1004-01S 
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Record plug Fig 3
5 Remove cooler module.   AR20.20-P-3865MNI
    IMPORTANT Remove refrigerant line (25) together with cooler module  
    INSTALLATION IMPORTANT Only install lower engine compartment lining after leak test.  
6 Disconnect bleed line at separating point (3), remove from coolant expansion reservoir and seal with suitable stop plugs.   AR20.20-P-7441-01RQ
    TORQUE SPECIFICATION Record plug Fig 3
7 Release and disconnect electrical connector (7).    
8 Release and disconnect electrical connector (12).    
9 Release and disconnect electrical connector (22).    
10 Unclip engine wiring harness (2) from charge air coolers (13, 14).    
11 Remove cable ducts (23) from cylinder head covers. TORQUE SPECIFICATION Screw, cable duct to cylinder head cover/charge air cooler/heat shield, right *BA15.18-P-1003-01G 
12 Remove brackets (1). TORQUE SPECIFICATION Screw, holder for upper charge air cooler to charge air cooler/chain case cover/cylinder head *BA09.41-P-1006-01X 
13 Unscrew screw (4). TORQUE SPECIFICATION Screw, bleed line to charge air cooler *BA01.20-P-1013-01J 
14 Unscrew screw (5). TORQUE SPECIFICATION Screw, purge line to holder for oil separator/boot/holder *BA01.20-P-1010-01J 
15 Unclip bleed line (8), remove from charge air cooler (13) and seal with suitable stop plugs.   AR20.20-P-7441-01RQ
    SPECIAL TOOL Record plug Fig 3
16 Loosen clamps (6). TORQUE SPECIFICATION Clamp, boot to exhaust gas turbocharger/air filter *BA01.20-P-1003-01J 
17 Remove coolant hose (21) from coolant pump and expansion reservoir and seal openings with protective covers.   AR20.30-P-4950MNI
      AR20.20-P-7441-01RQ
    SPECIAL TOOL Set of protective covers Fig 4
18 Remove coolant hose (18) from charge air cooler (14) and seal openings with protective covers. SPECIAL TOOL Set of protective covers AR20.20-P-7441-01RQ
      Fig 4
19 Remove coolant hose (19) from charge air cooler (14) and seal openings with protective covers. SPECIAL TOOL Set of protective covers Fig 4
    SPECIAL TOOL Hose clamp pliers Fig 2
20 Disconnect coolant hose (19) from control unit and remove.   AR20.20-P-7441-01RQ
21 Remove coolant hose (9) from charge air cooler (13) and seal openings with protective covers.   AR20.20-P-7441-01RQ
    SPECIAL TOOL Set of protective covers Fig 4
22 Remove coolant hose (10).   AR20.20-P-7441-01RQ
INSPECT Check     
23 Check alignment of left boot between left throttle valve actuator (M16/60) and left charge-air distributor.    
24 Remove left front wheel and tire assembly. Only if alignment of left boot corresponds to shown position (arrow A).  
      AR40.10-P-1102A
25 Remove fender liner in left front fender. Only if alignment of left boot corresponds to shown position (arrow A).  
      AR88.10-P-1301FR
26 Release clamps (15). REMOVAL NOTES :
Release clamps (15) at throttle valve actuators (M16/60, M16/61).
Risk of incorrect installation otherwise exists.		  
    IMPORTANT Boot has different diameters at intake side and exhaust side.  
    TORQUE SPECIFICATION Bolt, clamp for charge air hose to charge-air distributor *BA09.41-P-1002-01X 
27 Remove purge lines (11, 20) from charge air coolers (13, 14) and seal openings with suitable stop plugs. SPECIAL TOOL Record plug Fig 3
28 Remove brackets (16). TORQUE SPECIFICATION Bolt, lower charge air cooler bracket to thermostat/crankcase *BA09.41-P-1007-01X 
29 Unclip electric line (17) from charge air coolers (13, 14).    
30 Release and disconnect electrical connector of right pressure sensor upstream of throttle valve (B28/21).   AR09.41-P-1021MNI 
31 Release and disconnect electrical connector of left pressure sensor upstream of throttle valve (B28/20).   AR09.41-P-1020MNI 
32 Release charge air coolers (13, 14). INSTALLATION IMPORTANT Wet lower retaining lugs of charge air coolers (13, 14) with lubricant.  
    Antifriction paste, rubber parts 2.5 kg, DBL 6867.00 *BR00.45-Z-1002-06A 
33 Remove charge air coolers (13, 14) upwards. IMPORTANT Aid of helper required.  
  Align     
34 Release clamp of left boot and turn at charge-air distributor counterclockwise until shown position (arrow B) is reached. Only if alignment of left boot corresponds to shown position (arrow A).  
    TORQUE SPECIFICATION Bolt, clamp for charge air hose to charge-air distributor *BA09.41-P-1002-01X 
35 Install in the reverse order.    
WARNING 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
36 Carry out engine test run and check engine for proper operation and leak tightness.    
37 Install lower engine compartment lining.   AR61.20-P-1105FRX
38 Install upper engine cover.    
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number Designation Engine 177.9
BA01.20-P-1003-01J Clamp, boot to exhaust gas turbocharger/air filter Nm 1, 5
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number Designation Engine 177.9
BA01.20-P-1010-01J Screw, purge line to holder for oil separator/boot/holder Nm 5
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number Designation Engine 177.9
BA01.20-P-1013-01J Screw, bleed line to charge air cooler Nm 6
CHARGE AIR LINE/CHARGE AIR COOLING

Number Designation Engine 177.8 in model 290
Engine 177.9 in model 167, 205, 213, 217, 222, 253, 290
Engine 177.9 in model 463
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 177.8 in model 290
Engine 177.9 in model 167, 205, 213, 217, 222, 253, 290
Engine 177.9 in model 463
BA09.41-P-1006-01X Screw, holder for upper charge air cooler to charge air cooler/chain case cover/cylinder head Nm 8
CHARGE AIR LINE/CHARGE AIR COOLING

Number Designation Engine 177.8 in model 290
Engine 177.9 in model 167, 205, 213, 217, 222, 253, 290
Engine 177.9 in model 463
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
AIR CONDITIONING

Number Designation Model 290
BA83.30-P-1004-01S Nut/bolt, connecting point for refrigerant line Nm 12
Fig 1: Identifying Assembly Tool (000 589 93 63 00)
G16145173Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Hose Clamp Pliers (003 589 03 37 00)
G16145168Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Record Plug (129 589 00 91 00)
G16145009Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Set Of Protective Covers (001 589 12 91 00)
G16145179Courtesy of MERCEDES-BENZ USA
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
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