Remove/install charge air cooler

AR09.41-D-6817TSM

Remove/install charge air cooler

19.03.2020

Engine

654.9 in model 907.1/2/6

1

Charge air cooler

2

Coolant hose

3

Coolant line

4

Retaining clips

5

Bracket

6

Electrical wiring harness

7

Bolts

1

Charge air cooler

13

Screw

8

Tab

14

Mounting bar

9

Air cleaner housing

15

Charge air pipe

10

Electrical wiring harness

16

Coolant hose

11

Vent line

17

Charge air temperature sensor

12

Electrical connector

1

Charge air cooler

2

Coolant hose

5

Bracket

17

Charge air temperature sensor

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Drain off coolant.

AR20.00-D-1142TSM

 Engine 654.9 in model 907.1/2/6
with code XM1 (Noise reduction)
Installation: Only install engine compartment paneling below after leak test.

2

Remove the throttle valve actuator.

AR07.70-D-0005TSM

 Installation: Only install upper engine cover after the leak test.

3

Remove coolant hose (2) from coolant line (3).

 Hose clamp pliers

*454589003700

4

Seal openings using suitable protective covers.

 Set of protective covers

*001589019100

5

Unclip retaining clips (4) from bracket (5) and place electrical wiring harness (6) to the side.

6

Remove bolts_(7).

 Bolt, bracket for charge air cooler to charge air cooler/crankcase

*BA09.41-N-1003-03EA

7

Press shackle (8) back on the air filter housing (9), remove electrical wiring harness (10), and place to one side.

8

Separate electrical connector (12).

9

Remove bleed line (11) from the charge air cooler (1) and place to one side.

 Hose clamp pliers

*454589003700

10

Seal openings with suitable stop plug.

 Record plug

*129589009100

11

Remove coolant hose (16) from charge air cooler (1).

12

Seal openings using suitable protective covers.

 Set of protective covers

*001589019100

13

Remove screw (13).

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

*BA09.41-N-1002-03EA

14

Turn mounting bracket (14) in direction of arrow (arrow A) and remove.

15

Detach charge air cooler (1) from charge air pipe (15) and remove.

 Installation: Replace seal at charge air pipe (15) with  assembly tool.

 Assembly tool

*000589936300

16

Seal openings using suitable protective covers.

 Set of protective caps

*001589029100

17

Remove holder (5).

If the charge air cooler (1) is replaced.

 Bolt, bracket for charge air cooler to charge air cooler/crankcase

*BA09.41-N-1003-03EA

18

Remove coolant hose (2).

If charge air cooler (1) and/or coolant hose (2) will be replaced.

 Hose clamp pliers

*454589003700

19

Remove charge air temperature sensor (17).

If the charge air cooler (1) is replaced.

AR09.41-D-2009TSM

20

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

21

Perform engine test run.

 Charge air cooler

Number

Designation

Engine 654.9 in model 907

BA09.41-N-1002-03EA

Bolt, bracket for charge air line to charge air cooler

Nm

6

 Charge air cooler

Number

Designation

Engine 654.9 in model 907

BA09.41-N-1003-03EA

Bolt, bracket for charge air cooler to charge air cooler/crankcase

Stage 1

Nm

8

Stage 2

°

30