Remove/install liquid-cooled charge air cooler

AR09.41-P-0105RF

Remove/install liquid-cooled charge air cooler

20.12.2018

Engine

651 in model 253

1

Charge air cooler

2

Fitting

3

Screws

4

Screws

5

Screw

6

Screw

7

Clamp

8

Charge air pipe downstream of charge air cooler

9

Bracket

B17/8

Charge air temperature sensor

 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 pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Drain coolant from low-temperature circuit.

AR09.41-P-6834LW

 Installation: Do not install upper engine cover until after the leak test.

 Installation: Only install front and center lower engine compartment lining after leak test.

2

Remove fan unit.

AR20.40-P-5050RF

3

Remove screw/bolts (3).

 Bolt, charge air cooler to bracket A/C compressor/bracket

*BA09.41-P-1003-03C

4

Remove screws (4).

 Bolt, charge air cooler to bracket A/C compressor/bracket

*BA09.41-P-1003-03C

5

Unscrew screws (5, 6) and remove bracket (9).

 Installation: Check for unstressed assembly of charge air pipe downstream of charge air cooler (8).

 Bolt, bracket for charge air cooler/charge air line

*BA09.41-P-1004-03C

6

Remove coolant hoses from fittings (2).

AR20.20-P-7441-01RQ

7

Release clamp (7).

8

Disconnect electrical connector on charge air temperature sensor (B17/8).

9

Remove charge air cooler (1) from the charge air pipe downstream of the charge air cooler (8).

10

Check sealing ring on charge air pipe downstream of charge air cooler (8) for damage.

If there are problems,



Replace sealing ring.

11

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

12

Check for leak tightness when engine is running.

 Perform visual inspection only.

13

Install the front and lower center engine compartment lining.

AR61.20-P-1105LW

14

Install upper engine cover.

 Charge air cooler

Number

Designation

Engine 651 in model 253

BA09.41-P-1003-03C

Bolt, charge air cooler to bracket A/C compressor/bracket

Nm

8

 Charge air cooler

Number

Designation

Engine 651 in model 253

BA09.41-P-1004-03C

Bolt, bracket for charge air cooler/charge air line

Nm

8