Remove/Install Charge Air Cooler - AR09.41-P-6817MRI

Engine 264 in model 205, 253

MODIFICATION NOTES

26.02.2019

Method description revised.

Operation steps 2 to 20.

Fig 1: Charge Air Cooler Components Location - Engine 264 In Model 205

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Risk of injury due to fan starting unexpectedly	Do not reach into the rotation or hazard area of the fan. Wear closed and close-fitting work clothes.	AS20.40-Z-0001-01A
	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
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove/install
1	Drain coolant from low-temperature circuit.		AR09.41-P-6834MRI
2	Remove air intake pipe (1).		AR09.10-P-8131MRI
3	Remove vent hose (2) from charge air cooler (3).	Hose clamp pliers	Fig 2
4	Unscrew bolt (4).	Screw, coolant hose clamp to coolant thermostat	*BA20.10-P-1005-01CA
5	Remove coolant hose (5) from charge air cooler (3).		AR20.20-P-7441-01RQ
6	Remove coolant hose (6) from charge air cooler (3).		AR20.20-P-7441-01RQ
7	Release and disconnect overrun mode bypass air switchover valve electrical connector (Y101) and unclip electric line from the charge air cooler (3).		AR09.40-P-3000MRI
8	Remove bracket (15).	Bolt, bracket for charge air cooler to timing case/oil pan	*BA09.41-P-1002-03F
		Screw/bolt, charge air cooler to bracket	*BA09.41-P-1001-03F
9	Remove screws (7) and remove brackets (8).	Bolt, bracket for charge air line to charge-air distributor	*BA09.41-P-1003-01ZA
10	Release clamp (9).	Clamp, charge air line to charge air cooler	*BA09.41-P-1004-03F
11	Remove charge air line (10) with the fitting and place to one side with the connected lines.	Check O-ring and replace if necessary.
12	Remove screw (11) and release bracket (12).	Screw/bolt, charge air manifold bracket to turbocharger	*BA09.41-P-1002-01ZA
13	Release clamp (13).	Clamp, charge air line to charge air cooler	*BA09.41-P-1004-03F
14	Remove right charge air line (14) with the fitting.	Check O-ring and replace if necessary.
15	Remove top purge line from charge air cooler (3).	Check O-ring and replace if necessary.
16	Unclip coolant line (16) from the charge air cooler (3).
17	Unclip retaining clip (17) from the bracket (18) and pull charge air cooler (3) out of the bracket (18).
18	Remove charge air cooler (3) upward.	Wet rubber guides of the charge air cooler (3) with the lubricant. Lubricant	*BR00.45-Z-1032-06A
19	Change overrun mode bypass air switchover valve (Y101).	When replacing the charge air cooler (3).	AR09.40-P-3000MRI
	Check
20	Check rubber guides of charge air cooler (3) for damage.	If complaints are present, ↓ Replace corresponding rubber guide of charge air cooler (3).
21	Install in the reverse order.
	Risk of burn injuries , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out o the hazard area.	AS49.00-Z-0001-01A
	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
22	Perform engine test run. While doing so, check engine for proper operation and leak tightness

CHARGE AIR COOLER

Number	Designation		Engine 264
BA09.41-P-1001-03F	Screw/bolt, charge air cooler to bracket	Nm	9

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 264
BA09.41-P-1002-01ZA	Screw/bolt, charge air manifold bracket to turbocharger	Nm	9

CHARGE AIR COOLER

Number	Designation			Engine 264
BA09.41-P-1002-03F	Bolt, bracket for charge air cooler to timing case/oil pan	M6	Nm	9
BA09.41-P-1002-03F	Bolt, bracket for charge air cooler to timing case/oil pan	M8	Nm	20

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 264
BA09.41-P-1003-01ZA	Bolt, bracket for charge air line to charge-air distributor	Nm	9

CHARGE AIR COOLER

Number	Designation		Engine 264
BA09.41-P-1004-03F	Clamp, charge air line to charge air cooler	Nm	4

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation			Engine 264
BA20.10-P-1005-01CA	Screw, coolant hose clamp to coolant thermostat	M6	Nm	8

Fig 2: Identifying Hose Clamp Pliers (454 589 00 37 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1032-06A	Lubricant	A 000 989 08 60