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Oil Cooler and Seal Replacement
 
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Pelican Technical Article:

Oil Cooler and Seal Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$10

Talent:

**

Tools:

T30 Torx, torque wrench

Applicable Models:

Mercedes-Benz W204 (2008-15)

Parts Required:

Oil cooler seal

Hot Tip:

Clean both surfaces well

Performance Gain:

No leaks

Complementary Modification:

Oil and filter change

The oil filter housing has an oil to water cooler attached to it to help cool the engine oil. While this simple design does a great job of helping control the engine oil temperature it has a tendency to develop leaks over time. This is usually caused by the seal drying out and installing a new seal usually solves the problem.

You will need to drain the coolant from the radiator as the coolant flows through the cooler and needs to be removed before you can replace the seal. Please see our article on coolant drain and flush.

Begin by removing the front engine cover (red arrow) by pulling it straight up and off and the left side air duct (yellow arrow) by compressing it in and off the air filter cover.
Figure 1

Begin by removing the front engine cover (red arrow) by pulling it straight up and off and the left side air duct (yellow arrow) by compressing it in and off the air filter cover. Please see our article on engine cover removal for additional assistance.

The oil cooler is located to the left of the oil filter cap attached to the oil filter housing (red arrow).
Figure 2

The oil cooler is located to the left of the oil filter cap attached to the oil filter housing (red arrow). You will need to remove the power steering reservoir to get access to the mounting bolts on the cooler (yellow arrow). Please see our article on power steering reservoir replacement for further assistance.

With the power steering reservoir removed, move it off to the side with the one hose still connected (red arrow).
Figure 3

With the power steering reservoir removed, move it off to the side with the one hose still connected (red arrow). You may need to remove the connection for one of the sensors to get access to the mounting bolts on the cooler (yellow arrow).

Use a 1/4-inch T30 Torx and remove the five bolts (red arrows).
Figure 4

Use a 1/4-inch T30 Torx and remove the five bolts (red arrows).

If the cooler has never been removed before you may need to gently pry it away from the housing but never pry anything between the two mounting surfaces.
Figure 5

If the cooler has never been removed before you may need to gently pry it away from the housing but never pry anything between the two mounting surfaces.

Thoroughly clean the coolers mounting surface but do NOT use anything metal that could scratch or gouge the surface; Scotch-Brite pads are a good idea to use here.
Figure 6

Thoroughly clean the coolers mounting surface but do NOT use anything metal that could scratch or gouge the surface; Scotch-Brite pads are a good idea to use here.

Pull the old gasket from the housing.
Figure 7

Pull the old gasket from the housing. You may need to use a pick or small flathead screwdriver to get it out but use care not to scratch or gouge the surface (red arrow).

In this photo you can see the channels for the oil (red arrows) and the channels for the coolant (yellow arrows).
Figure 8

In this photo you can see the channels for the oil (red arrows) and the channels for the coolant (yellow arrows). Make sure the housing is clean and free of any old gasket material. Install the new gasket and torque to spec. Installation is the reverse of removal. Do not forget to refill your coolant and power steering fluids.


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