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Home >> Mercedes Benz >> 2012 >> Sprinter 2500, Van Crew Extended >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Air Intake, Turbo Charging -- Model 906 (Engine 642) >> Testing & Repair >> Remove/Install Charge Air Cooler - Ar09.41-D-6817SD

Remove/Install Charge Air Cooler - Ar09.41-D-6817SD

ENGINES 642.896 /898 /992 /993, 646.984 /985 /986 /989 /990 in MODEL 906 

Fig 1: Charge Air Cooler Remove/Install Component Locations - Shown on engine 646.984
G08211433Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CHARGE AIR COOLER - ENGINES 642.896 /898 /992 /993, 646.984 /985 /986 /989 /990 IN MODEL 906

REMOVINGINSTALLING Remove/install     
1 Raise vehicle   AR00.60-D-1000H
2 Remove fan shroud (1) Engine 642 AR20.40-D-6800SF
3.1 Open screw clamps and remove charge air hoses (2) from charge air cooler (3) Engine 646 and 642.992/993
IMPORTANT Seal connectors with SPECIAL TOOL protective covers.
 
TORQUE SPECIFICATION Engine 646  
SPECIAL TOOL Set of protective covers Figure
3.2 Open Henn coupling and remove charge air hoses (2) on charge air cooler (3) Engine 642.896/898
IMPORTANT Seal connectors with SPECIAL TOOL protective covers.
 
IMPORTANTInstallation:  Replace sealing ring. AR09.41-P-1311-01AL 
SPECIAL TOOL Set of protective covers Figure
4 Remove additional fan unit Vehicles with engine 642.992/993, 646 and code (HH9) Regulated air conditioning, (Tempmatic) AR83.30-D-5610SD
5 Remove plate under front grille For vehicles without code (ZX8) Trademark scope-Dodge or without code (ZX9) Trademark scope-Freightliner (FTL) and without code (HH9) Regulated air conditioning, (Tempmatic)   AR88.00-D-2200SD
6 Remove front grille For vehicles with code (ZX8) Trademark scope-Dodge or with code (ZX9) Trademark scope-Freightliner (FTL) and without code (HH9) Regulated air conditioning, (Tempmatic) AR88.00-D-2115SE
7 Unclip condenser (4) at front module and raise until bolts are accessible (arrows) For vehicles with code (HH9) Regulated air conditioning, (Tempmatic)  
8 Unscrew bolts (arrows).    
9 Remove charge air cooler (3) downwards    
10 Install in the reverse order    
Fig 2: Identifying Set Of Protective Covers (001 589 01 91 00)
G08211434Courtesy of MERCEDES-BENZ USA