Remove/Install Charge Air Cooler - AR09.41-P-6817MNP
Engine 177 In Model 167
| 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 | |
| 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 | |
| Notice | Notes on coolant | AH20.00-P-2080-01KOA | |
| Notes on coolant level | AH20.00-P-1142-01CW | ||
| Remove/install | |||
| 1 | Remove left-hand air filter housing. | AR09.10-P-1151MNP | |
| 2 | Remove right air filter housing. | AR09.10-P-1152MNP | |
| 3 | Drain off low-temperature circuit coolant. | AR09.41-P-6834MNP | |
| 4 | Drain off coolant. | AR20.00-P-1142MNP | |
| 5 | Remove fan unit. | AR20.40-P-5050MNP | |
| 6 | Mount protective plate on cooler. | ||
| WF58.50-P-0110-01A | |||
| 7 | Unclip engine wiring harness (2) from the charge air coolers (13, 14). | ||
| 8 | Remove brackets (1). | *BA09.41-P-1006-01X | |
| *BA15.18-P-1008-01G | |||
| 9 | Release and disconnect electrical connector (7). | ||
| 10 | Release and disconnect electrical connector (12). | ||
| 11 | Release and disconnect electrical connector (22). | ||
| 12 | Unscrew bolt (4). | ||
| 13 | Remove screw (5). | ||
| 14 | Remove cable ducts (23) from cylinder head covers. | *BA15.18-P-1003-01G | |
| 15 | Unclip bleed line (8) and remove from the charge air cooler (13). | AR20.20-P-7441-01RQ | |
| 16 | Disconnect bleed line at separating point (3). | AR20.20-P-7441-01RQ | |
| 17 | Loosen clamps (6). | *BA09.41-P-1002-01X | |
| 18 | Remove coolant hose (21) from the coolant inlet fitting and the expansion reservoir. | AR20.20-P-7441-01RQ | |
| 19 | Remove coolant hose (18) from charge air cooler (14). | AR20.20-P-7441-01RQ | |
| 20 | Remove coolant hose (19) from charge air cooler (14). | Fig 2 | |
| 21 | Remove coolant hose (9) from charge air cooler (13). | AR20.20-P-7441-01RQ | |
| 22 | Remove coolant hose (10). | AR20.20-P-7441-01RQ | |
| 23 | Release clamps (15). | *BA09.41-P-1002-01X | |
| 24 | Remove purge lines (11, 20) from the charge air coolers (13, 14) and seal with suitable stop plugs. | Fig 3 | |
| 25 | Remove brackets (16). | *BA09.41-P-1007-01X | |
| 26 | Unclip electric line (17) from the charge air coolers (13, 14). | ||
| 27 | Release and disconnect electrical connector o pressure sensor upstream of right throttle valve (B28/21). | AR09.41-P-1021MNP | |
| 28 | Release and disconnect electrical connector o pressure sensor upstream of left throttle valve (B28/20). | AR09.41-P-1020MNP | |
| 29 | Release charge air coolers (13, 14). | Lubricant, rubber assembly 1 L |
*BR00.45-Z-1010-06A |
| 30 | Remove charge air coolers (13, 14) upward. | ||
| 31 | Remove pressure sensor upstream of the right throttle valve (B28/21) and pressure sensor upstream of the left throttle valve (B28/20). | When installing new charge air coolers (13, 14). Boost pressure sensor upstream of the left throttle valve (B28/20) |
AR09.41-P-1020MNP |
| Boost pressure sensor upstream of the right throttle valve (B28/21) | AR09.41-P-1021MNP | ||
| 32 | Install in the reverse order. | ||
| Check | |||
| Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. | Wear protective clothing and safety glasses. Use the extraction system. Move people out of the danger zone. | AS49.00-Z-0001-01A | |
| 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 | |
| 33 | Perform engine test run. While doing so, check engine for proper operation and leak tightness |
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 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA15.18-P-1008-01G | Screw, engine wiring harness to charge air cooler holder | Nm | 8 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1010-06A | Lubricant, rubber assembly 1 L | A 000 989 03 67 |