Remove/install charge air cooler

AR09.41-D-6817R

Remove/install charge air cooler

30.05.2018

Engine

646 in model 909

Shown on vehicle with code MS9(Engine version EURO 4)

1

Charge air cooler

2

Lock crossmember

6

Cooling pipe

1a

Charge air hose

4

Condenser

1b

Clip

5

Radiator

Shown on vehicle with code MP5 (Engine version Euro 5)

1

Charge air cooler

2

Lock crossmember

1a

Charge air hose

3

Screw

1b

Clip

5

Radiator

1c

Catch hook

6

Cooling pipe

 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

Remove lock crossmember (2).

AR88.00-D-2302F

2

Remove front bumper.

Engine 646 up to 2/28/18 in model 909

AR88.20-D-2000F

3

Remove additional fan.

Engine 646 in model 909
with code HH9 (Air conditioner, automatic heater control)

AR83.30-D-5610R

4

Remove condenser (4) and place to one side with connected lines.

Engine 646 in model 909
with code HH9 (Air conditioner, automatic heater control)

AR83.30-D-6540F

5

Remove screws (3) and cooling pipe (6) of the steering from the charge air cooler (1) and place to one side with the connected lines.

 Remove cooling pipe (6) of the steering together with the brackets from the charge air cooler (1).

6

Remove charge air hoses (1a) from the charge air cooler (1).

 Installation: Replace clamps (1b) and replace if necessary.

 Clamp, charge air hose to charge air cooler/throttle valve actuator

*BA09.41-N-1010-01M

7.1

Press catch hooks (1c) downward with a suitable tool on both sides of the charge air cooler (1) and extend the charge air cooler (1) out of the mount on the cooler (5).

Engine 646 in model 909
with code MP5 (Engine version Euro 5)

7.2

Remove screws of the charge air cooler (1) from the cooler (5).

Engine 646 in model 909
with code MS9 (Engine version Euro 4)

8

Remove charge air cooler (1).

 Engine 646 in model 909
with code MP5 (Engine version Euro 5)
Installation: Ensure correct seating of the charge air cooler (1) in the mounts (5).

9

Install in the reverse order.



Check

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 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

10

Perform engine test run and check charge air system in the area of the charge air cooler (1) for leak tightness.

 Charge air pipe/charge air cooling

Number

Designation

Engine 646.7 in model 909

BA09.41-N-1010-01M

Clamp, charge air hose to charge air cooler/throttle valve actuator

Nm

5,5