Remove/install liquid-cooled charge air cooler

AR09.41-S-0105CE

Remove/install liquid-cooled charge air cooler

09.05.2019

Engine

608 in model 415

1

Charge air cooler

2

Coolant hose

3

Charge air hose

4

Coolant hose

5

Coolant line

6

Bracket

 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

 Warning

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

 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 off coolant.

AR20.00-S-1142CE

2

Remove coolant hose (2).

 Clamp engages in opened position. Clamp is attached to coolant hose (2). Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Record plug

*129589009100

 Hose clamp pliers

*454589003700

3

Remove charge air hose (3).

AR09.41-S-1221CE

4

Remove coolant hose (4).

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Record plug

*129589009100

 Hose clamp pliers

*454589003700

5

Remove coolant line (5).

 For this purpose, release lock and remove coolant line (5). Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Record plug

*129589009100

 Set of protective caps

*001589009100

6

Remove charge air cooler (1) upwards.

7

Transfer bracket (6).

When installing a new charge air cooler(1).

8

Install in the reverse order.



Check

 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

9

Check for leaktightness when engine is running.

 Visual inspection only.