(Remove/Install Charge Air Cooler - AR09.41-P-6817OGW)

Model 213, 238, 253 with engine 642

Courtesy of MERCEDES-BENZ USA

	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
	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
	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	Notes on coolant		AH20.00-N-2080-01A
	Remove/install
1	Remove fan unit	Model 238 with engine 642	AR20.40-P-5050OLA
		Model 213 with engine 642	AR20.40-P-5050OLC
		Model 253 with engine 642	AR20.40-P-5050RF
		: Only install top engine cover after the leak test.
2	Insert protective plate for radiator
			WF58.50-P-0110-01A
3	Drain coolant from low-temperature circuit	Model 253 with engine 642	AR09.41-P-6834LW
		Model 213, 238 with engine 642	AR09.41-P-6834OGW
4	Remove coolant hoses (2) on charge air cooler (1) and close openings with suitable protective covers		AR20.20-P-7441-01RQ
		Set of protective caps	Fig 2
5	Remove screw/bolt (4)	Bolt engine charge air duct for turbocharger to charge air cooler	*BA09.41-P-1015-01J
6	Remove charge air hose downstream of charge air cooler (1) on engine charge air duct and close off openings with protective covers		AR09.41-P-8625OGW
		: Replace sealing ring.
		Set of protective caps	Fig 1
7	Remove screw/bolts (3, 5)	Bolt, charge air cooler to oil pan/bracket	*BA09.41-P-1013-01J
8	Remove charge air cooler (1) with charge air line and charge air hose upwards
9	Remove charge air line from charge air cooler (1)	When replacing the charge air cooler (1).
		: Replace sealing ring.
		Bolt, charge air line to charge air cooler	*BA09.41-P-1012-01J
10	Install in the reverse order
	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
11	Carry out an engine test run, checking the engine for proper operation and leaktightness
12	Install upper engine cover