Remove/install charge air hose downstream of liquid-cooled charge air cooler

AR09.41-S-1221CE

Remove/install charge air hose downstream of liquid-cooled charge air cooler

13.05.2019

Engine

608 in model 415

1

Charge air hose

4

Screw

7

Electrical connector

2

Bolts

5

Nut

8

Charge air cooler

3

Bolts

6

Stud bolt

9

Coolant hose

 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove lower crossmember.

AR31.30-S-4115C

2

Remove screws (2, 3).

 Bolt, charge air cooler to lower holder

*BA09.41-N-1004-03CE

3

Lower vehicle.

4

Remove expansion reservoir and place outside working area.

AR20.30-S-4950CD

 Do not extract coolant, do not remove coolant hoses.

5

Remove charge air pipe upstream of charge air cooler (8).

AR09.41-S-1231CE

6

Remove coolant hose (9) at bracket.

 Installation: Check retaining clips

Depending on the findings,



Replace damaged retaining clips.

7

Unscrew bolt (4).

 In this connection, slightly push away coolant hose (9).

 Bolt/nut, charge air cooler to upper holder

*BA09.41-N-1003-03CE

8

Remove nut (5).

 Bolt/nut, charge air cooler to upper holder

*BA09.41-N-1003-03CE

9

Remove stud bolt (6).

10

Detach electrical connector (7).

11

Open coupling of charge air hose (1) at throttle valve actuator.

AR09.41-D-1311-01WE

 For this purpose, slightly pull charge air cooler (8) towards front.

 Assembly tool

*000589936300

12

Remove charge air hose (1).

AR09.41-D-1311-01WE

 For this purpose, turn charge air hose (1) and open coupling of charge air hose (1) at charge air cooler (8).

 Installation: Observe direction of installation of charge air hose (1).

 Assembly tool

*000589936300

13

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

14

Check for leaktightness when engine is running.

 Visual inspection only.

 Charge air cooler

Number

Designation

Engine 608 in model 415

BA09.41-N-1003-03CE

Bolt/nut, charge air cooler to upper holder

Nm

8

 Charge air cooler

Number

Designation

Engine 608 in model 415

BA09.41-N-1004-03CE

Bolt, charge air cooler to lower holder

Nm

8