Remove/Install Right Water-Cooled Charge Air Cooler - AR09.41-P-6828SC
Engine 176 in model 223
MODIFICATION NOTES
| 25.06.2021 | Document completely revised. | Operation steps 1 to 35 |
| 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 | 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 | |
| Remove/install | |||
| 1 | Remove the bottom coolant expansion reservoir for the low-temperature circuit. | AR09.41-P-0060SC | |
| 2 | Remove radiator unit. | AR20.20-P-3871SC | |
| 3 | Remove right air filter housing. | AR09.10-P-1152SC | |
| 4 | Remove left air filter housing. | AR09.10-P-1151SC | |
| 5 | Remove the upper coolant expansion reservoir for the upper low-temperature circuit. | AR09.41-P-0050SC | |
| 6 | Remove hoses (1). | Fig 1 | |
| 7 | Remove coolant hose (3) on charge air cooler (5). | Fig 1 | |
| 8 | Remove coolant hose (9) on charge air cooler (8). | Fig 1 | |
| 9 | Remove coolant line (2). | AR20.20-P-7441-01RQ | |
| 10 | Remove engine wiring harness covers (4). | ||
| 11 | Unclip coolant hose (7) from line duct. | ||
| 12 | Remove return line (10). | *BA00.10-P-1002-04A | |
| Fig 1 | |||
| 13 | Release and disconnect electrical connectors (11, 12, 14). | ||
| 14 | Remove screws (21). | *BA15.18-P-1004-01G | |
| 15 | Release and disconnect the electrical connectors (20). | ||
| 16 | Remove screw (16). | *BA15.18-P-1003-01G | |
| 17 | Remove screws (17). | *BA15.18-P-1001-01G | |
| 18 | Remove purge lines (18) at separating points and place to one side and seal openings with suitable stop plugs. | Fig 2 | |
| 19 | Lift engine wiring harness (6) slightly, release and disconnect electrical connectors (15, 23). | Do not crush or kink or subject lines to tension. This would lead to damage to the lines and can impair their function. |
|
| 20 | Lift engine wiring harness (6) slightly, release and disconnect electrical connector on intake air pressure sensor (B28/1). | ||
| 21 | Release and disconnect electrical connector (19). | ||
| 22 | Move engine wiring harness (6) to rear and fix in place outside of working area with suitable means. | Do not crush or kink or subject lines to tension. This would lead to damage to the lines and can impair their function. |
|
| 23 | Remove bracket (22). | *BA09.41-P-1006-01X | |
| 24 | Loosen charge air hose (25) on throttle valve actuator (M16/6). | *BA09.41-P-1002-01X | |
| 25 | Release clamp of charge air hose on right charge air cooler (8). | *BA09.41-P-1018-01X | |
| 26 | Release clamp (24) from boot. | Fig 1 | |
| 27 | Remove purge line (13) on charge air cooler (8) and seal openings with suitable stop plugs. | Fig 2 | |
| 28 | Carefully pry charge air cooler (8) out of hoses using a suitable tool. | ||
| 29 | Release and disconnect electrical connector of the throttle valve actuator (M16/6). | ||
| 30 | Remove charge air cooler (8) downwards. | Lubricant, rubber assembly 1 L |
*BR00.45-Z-1010-06A |
| Check | |||
| 31 | Check elastomer bearings of charge air cooler (8) for damage. | If damage is present: ↓ Replace appropriate elastomer bearing. Lubricant, rubber assembly 1 L |
*BR00.45-Z-1010-06A |
| 32 | Remove throttle valve actuator (M16/6). | When replacing charge air cooler (8). | AR07.51-P-1403SC |
| 33 | Remove the charge air pressure sensor (B28/31). | When replacing charge air cooler (8). | AR09.41-P-1021SC |
| 34 | Install in the reverse order. | ||
| Check | |||
| 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 | |
| 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 | |
| 35 | Perform engine test run. While doing so, check engine for proper operation and leak tightness. |
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 |
CHARGE AIR LINE/CHARGE AIR COOLING
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA09.41-P-1018-01X | Screw, clamp for charge air hose to exhaust gas turbocharger/air filter housing/charge air cooler | Nm | 4 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA15.18-P-1001-01G | Bolt, engine wiring harness to cylinder head cover | Nm | 9 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 176 | |
|---|---|---|---|
| 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 176 | |
|---|---|---|---|
| BA15.18-P-1004-01G | Bolt, engine wiring harness to ME-SFI [ME] control unit | Nm | 9 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1010-06A | Lubricant, rubber assembly 1 L | A 000 989 03 67 |