Remove/install charge air cooler - AR09.41-P-6817RTB

ENGINES 642.950 in MODEL 251.020/022/122

Fig 1: Identifying Charge Air Cooler Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
1	Open engine hood		AR88.40-P-1000RT
2	Remove upper radiator crossmember		AR62.30-P-2300RT
3	Remove left and right engine intake air ducts
4	Detach charge air hose upstream of charge air cooler	To prevent leaks, check sealing rings for damage and replace if necessary.	AR09.41-P-8621RTB
5	Loosen charge air hose downstream of charge air cooler	To prevent leaks, check sealing rings for damage and replace if necessary.	AR09.41-P-8625RTB
6	Raise vehicle with vehicle lift		AR00.60-P-1000RT
7	Remove front bumper		AR88.20-P-2000RT
8	Remove bolts (2) from top fan shroud (8)
9	Remove bolts (3) from bottom fan shroud (8)
10	Remove screw (7)
11	Unscrew nuts (6) and pull out bolts (5)		*BA62.30-P-1002-02E
12	Remove crossmember (4) at front	Only detach to the extent that the fan shroud (8) can be removed.
13	Take out fan shroud (8)
14	Unclip charge air cooler (1) from mount (9) on the radiator
15	Remove charge air cooler (1)
16	Install in the reverse order
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
17	Carry out engine test run

FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

Number	Designation		Model 251
BA62.30-P-1002-02E	Bolt, crossmember to crash box	Nm	18