turbo intercooler replacement

[Benton]

I have a turbo intercooler that is leaking. I verified it is not the hose. I'm not sure of the best way to get the dang thing out. I've removed the wheel well, bottom dust covers, electric fan, and it seems that the best way to acces the cooler is removing the bumper cover? I don't know how the cooler is positioned or secured. Is it just clipped to the radiator?

Also, it looks like I can get a new intercooler for about $140. Does that sound right?
This is on my 2005 E320 CDI.

Cheers

 

[Westheath]

I have a turbo intercooler that is leaking. I verified it is not the hose. I'm not sure of the best way to get the dang thing out. I've removed the wheel well, bottom dust covers, electric fan, and it seems that the best way to acces the cooler is removing the bumper cover? I don't know how the cooler is positioned or secured. Is it just clipped to the radiator?

Also, it looks like I can get a new intercooler for about $140. Does that sound right?
This is on my 2005 E320 CDI.

Cheers

 

[JBell]

It is probably the seals underneath that have gone bad, they look like 1920's glasses

It is a common fault on that engine and the early 350CDi, the seals are about $5 each and 6-8 hours of labour to replace

 

[Benton]

It is probably the seals underneath that have gone bad, they look like 1920's glasses

It is a common fault on that engine and the early 350CDi, the seals are about $5 each and 6-8 hours of labour to replace

Actually, it appears to be the plastic housing on the end of the radiator. I could put my hand on it and feel exactly where it is cracked. I'll confirm once I get the darn thing off. Looks like I probably need to pull the bumpber cover to access it well enough to remove. I might be able to pull it from underneith...anyway, don't think it is the seals.

 

[Westheath]

Erm theres a vid

Looks like I probably need to pull the bumpber cover to access it well enough to remove.
I might be able to pull it from underneith...anyway, don't think it is the seals.

I posted a YT link on how to remove it in this thread above.

turbo intercooler replacement

 

[Benton]

Erm theres a vid


I posted a YT link on how to remove it in this thread above.

turbo intercooler replacement

I did see the video, thank you. It is clear that the bumper needs to be removed. Thanks for the reply.

 

[Westheath]

I did see the video, thank you. It is clear that the bumper needs to be removed. Thanks for the reply.

Nope its left on.

 

[Benton]

Nope its left on.

Optical illusion I guess. No wheels and angle. I'm going to try and remove it this evening. Hope it is as easy as the video shows. Thanks again for sending.

 

[Westheath]

Optical illusion I guess. No wheels and angle. I'm going to try and remove it this evening. Hope it is as easy as the video shows. Thanks again for sending.

Good luck and watch the plastic clips and bits, they can ping off and break easily.

 

[Benton]

Got the intercooler out last night. Not easy, but not too bad. Helped knowing that removing the bumper cover was not needed. When I pulled it out, there was a 7" long crack on the top of it. Weird place to crack, but I do recall my son bumping a car a while back. no obvious damage on the outside, but right where the plastic end of the intercooler is located. Anywho...I JB welded the hell out of it...yeah...JB weld. I'll be reinstalling it this evening. Looks and feels very solid at this piont. Maybe I'l get a picture for anyone interested.

 

[Benton]

JB weld held up great, long enough for my new intercooler to arrive. Now that I am familiar with the clips and process, it only took me about 30 minutes to remove the damaged intercooler, and replace it with the new one. It is such good feeling when the car doesn't have a warning light flashing at me. I'm sure something else will happen in the next few weeks. That just seems to be something you can count on with Mercedes.

 

[Steve@Avantgarde]

On the E320CDI's you have to remove the front bumper..you won't get it out in situ...have tried.

 

[Benton]

On the E320CDI's you have to remove the front bumper..you won't get it out in situ...have tried.

That is strange being that I just did it on my E320CDI, 2 times...

 

[Steve@Avantgarde]

That is strange being that I just did it on my E320CDI, 2 times...

Straight or V6?

 

[Westheath]

I will say this as, I originally said leave the bumper cover on,
sometimes its easier to tackle the job if you have ramp access and air tools,
and can quickly whip off wheels etc and go into "auto mode" stripping down
because it make everything easier.

For someone struggling at home the more practical way is to remove at least as possible,
and less chance not having the tools and damaging associated parts removing more than they need to.

 

[V6Matty]

05 211 Steve would make me think IL6

 

[Benton]

Straight or V6?

It's a straight 6. The first time I removed the passenger side wheel, wheel well, and the electric fan, and the under covers.
The second time, I only removed the under covers. It was not too bad. I could pry the very bottom of the bumper cover outward with enough room to drop the intercooler. Installing it takes some finesse, and/or someone to hold the other side up while you align the tabs on your side.

 

[MarkCan]

Can someone please confirm that this procedure works for the V6 OM642.
I plan on cleaning the intercooler internals but not really looking forward to the bumper off part.
Thank you

 

[mioba]

Without answering your question, why are you cleaning the internals.