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Remove/install coolant lines - AR20.20-P-7440ELS

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ENGINE 276.8 in MODEL 207, 212, 218 

Fig 1: Coolant Lines Remove/Install Components (1 Of 2)
G09975365Courtesy of MERCEDES-BENZ USA
Fig 2: Coolant Lines Remove/Install Components (2 Of 2)
G09975366DANGERDANGERREMOVINGINSTALLINGNOTESTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONINSTALLATION IMPORTANTTORQUE SPECIFICATIONSPECIAL TOOLINSTALLATION IMPORTANTTORQUE SPECIFICATIONSPECIAL TOOLTORQUE SPECIFICATIONINSTALLATION IMPORTANTTORQUE SPECIFICATIONSPECIAL TOOLINSTALLATION IMPORTANTTORQUE SPECIFICATIONSPECIAL TOOLSPECIAL TOOLDANGERCourtesy of MERCEDES-BENZ USA
DANGER Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. No parts of the body or limbs should be within the operating area when the components are moving. AS00.00-Z-0011-01A
DANGER 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
REMOVINGINSTALLING Remove/install     
1 Drain coolant MODEL 207 with ENGINE 276.8 AR20.00-P-1142A
NOTES Notes on coolant   AH20.00-N-2080-01A
    MODEL 212, 218 with ENGINE 276.8 AR20.00-P-1142EL 
2 Detach left or right air filter housing   AR09.10-P-1150ELS
3 Detach charge air cooler at both charge air pipes and at throttle valve actuator and pull to the front   AR09.41-P-6819ELS
4 Detach right or left oil line return line (2R or 2L) at connection for coolant hose (3)    
5 Detach heat shield (4) or heat shield (6) TORQUE SPECIFICATION Bolt/nut for shield attachment *BA09.40-P-1011-01W 
TORQUE SPECIFICATION Bolt, turbocharger shield bracket to cylinder head *BA09.40-P-1012-01W 
6 Detach bracket for rights or left coolant return line (2R or 2L) on ATL    
7 Detach bracket for left coolant return line (2L) on oil filter housing and coolant thermostat When removing the left coolant return line (2L)  
TORQUE SPECIFICATION Bolt for coolant line attachment *BA09.40-P-1010-01W 
8 Detach right or left coolant return line (2R or 2L) on ATL and close off openings with suitable grommets INSTALLATION IMPORTANT Replace sealing ring.  
TORQUE SPECIFICATION Bolt, coolant feed/return line to turbocharger *BA09.40-P-1008-01W 
SPECIAL TOOL Record plug Figure
9 Detach right or left coolant return line (2R or 2L) on crankcase and close off openings with suitable grommets INSTALLATION IMPORTANT Replace sealing ring.  
TORQUE SPECIFICATION Bolt, coolant feed line to crankcase *BA09.40-P-1009-01W 
SPECIAL TOOL Record plug Figure
10 Remove right or left coolant return line (2R or 2L)    
11 Detach heat shield (5) ENGINE 276.8 in MODEL 207, 212, 218 without CODE 920 (Direct petrol injection with stratified charging)  
TORQUE SPECIFICATION Bolt/nut for shield attachment *BA09.40-P-1011-01W 
12 Detach right or left coolant feed line (1R or 1L) on ATL and close off openings with suitable grommets INSTALLATION IMPORTANT Replace sealing ring.  
TORQUE SPECIFICATION Bolt, coolant feed/return line to turbocharger *BA09.40-P-1008-01W 
SPECIAL TOOL Record plug Figure
13.1 Detach right or left coolant feed line (1R or 1L) on crankcase and close off openings with suitable grommets ENGINE 276.8 in MODEL 207, 212, 218 without CODE 920 (Direct petrol injection with stratified charging)
INSTALLATION IMPORTANT Replace sealing ring.		  
TORQUE SPECIFICATION Bolt, coolant feed line to crankcase *BA09.40-P-1009-01W 
SPECIAL TOOL Record plug Figure
13.2 Detach hose for right or left coolant feed line (1R or 1L) on exhaust gas recirculation valve and close off with suitable grommets ENGINE 276.8 in MODEL 207, 212, 218 with CODE 920 (Direct petrol injection with stratified charging)  
SPECIAL TOOL Record plug Figure
14 Remove right or left coolant feed line (1R or 1L)    
15 Install in the reverse order    
16 Check engine cooling system for leaktightness MODEL 207 with ENGINE 276.8 AR20.00-P-1010ELA
MODEL 212, 218 with ENGINE 276.8 AR20.00-P-1010EL 
DANGER 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
17 Carry out an engine test run, checking the engine for leaktightness and proper operation    
TURBOCHARGER

Number Designation ENGINE 276.8
BA09.40-P-1008-01W Bolt, coolant feed/return line to turbocharger Nm 9
TURBOCHARGER

Number Designation ENGINE 276.8
BA09.40-P-1009-01W Bolt, coolant feed line to crankcase Nm 9
TURBOCHARGER

Number Designation ENGINE 276.8
BA09.40-P-1010-01W Bolt for coolant line attachment M6 Nm 9
TURBOCHARGER

Number Designation ENGINE 276.8
BA09.40-P-1011-01W Bolt/nut for shield attachment M6 Nm 9
TURBOCHARGER

Number Designation ENGINE 276.8
BA09.40-P-1012-01W Bolt, turbocharger shield bracket to cylinder head M7 Nm 14
Fig 3: Identifying Record Plug (129 589 00 91 00)
G09975367Courtesy of MERCEDES-BENZ USA
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