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

ENGINE 642 in MODEL 164, 251 

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 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	Remove upper radiator crossmember	Model 164	AR62.30-P-2300GZ
		Model 251	AR62.30-P-2300RT
2	Remove left and right engine intake air ducts
3	Detach charge air hose upstream of charge air cooler (1)	To prevent leaks, check sealing rings for damage and replace if necessary.	AR09.41-P-8621GZB
4	Detach charge air hose downstream of charge air cooler (1)	To prevent leaks, check sealing rings for damage and replace if necessary.	AR09.41-P-8625GZB
5	Remove front bumper	Model 164	AR88.20-P-2000GZ
		Model 251	AR88.20-P-2000RT
6	Remove bolts (2) from top fan shroud (8)
7	Remove bolts (3) from bottom fan shroud (8)
8	Remove screw (7)
9	Unscrew nuts (6) and pull out bolts (5)	Model 164	*BA62.30-P-1004-02D
		Model 251	*BA62.30-P-1002-02E
10	Remove front cross member (4)	Only detach to the extent that the fan shroud (8) can be removed.
11	Take out fan shroud (8)
12	Unclip charge air cooler (1) from mounts (9) on radiator
13	Remove charge air cooler (1)
14	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
15	Carry out engine test run

FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

Number	Designation		Model 164.1	Model 164.8
BA62.30-P-1004-02D	Bolt, crossmember to crash box	Nm	18	18

FRONT END ASSEMBLY WITH FRONT REINFORCEMENT

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