Remove/install charge air cooler

AR09.41-S-6817PS

Remove/install charge air cooler

07.11.2019

Engine

642 in model 470, 471

Modification notes

07.11.2019

Method extended

Operation steps 3, 4, 5

07.11.2019

Method adapted

Operation steps 6, 7

1

Center bumper carrier

4

Charge air cooler

6

Electrical wiring harness

2

Air duct segments

5

Cover

7

Engine hood cable

3

Charge air hoses

 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

Remove front bumper.

AR88.20-S-2000P

2

Remove center bumper bracket (1).

AR88.20-S-2010P

3

Remove cover (5).

 To do this, remove cover (5) from the catch hook.

4

Remove electrical wiring harness (6).

 To do this, remove electrical wiring harness (6) from the right air duct segment (2).

5

Remove hood cable (7).

 To do this, remove hood cable (7) from the left air duct segment (2).

6

Remove screws from the air duct segments (2).

 Screw, air duct segment to upper front crossmember/headlamp mount

*BA09.41-N-1001-03PS

7

Remove air duct segments (2) with air intake hoses toward the front.

AR09.10-S-8030PS

8

Remove charge air hoses (3) from the charge air cooler (4).

AR09.41-D-1311-01WE

 Plug openings.

 Assembly tool

*000589936300

 Set of protective caps

*001589029100

9

Pull charge air cooler (4) out of the elastomer bearings and remove upward.



Check

10

Check elastomer bearings for correct installation position and damage.

If damage is identified,



replace damaged elastomer bearing.

If the installation position of an elastomer bearing is not correct,



Rectify the installation position.

11

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

12

Check charge air cooler (4) for leak tightness with the engine running.

 Visual inspection only.

 Charge air cooler

Number

Designation

Engine 642 in model 470, 471

BA09.41-N-1001-03PS

Screw, air duct segment to upper front crossmember/headlamp mount

Nm

8