AR09.41-P-6817SVK Remove/Install Charge Air Cooler
Remove/Install Charge Air Cooler
Illustrated On Engine 112.960:
Remove/Install
DANGER:
- Risk of fatal accident from vehicle slipping or toppling off the lift platform
- Align vehicle between the columns of lifting platform and position the four support plates below the support strong points specified by the vehicle manufacturer.
- Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.
- Fire, sparks, open flames or smoking forbidden.
- Pour fuels only into suitable and appropriately marked containers.
- Wear protective clothing when handling fuel.
1 Remove engine compartment panel (1) at top
NOTE: Pull engine compartment panel up and off at both air cleaner boxes and at bracket.
2 Remove air cleaner housing
DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
- No fire, sparks, naked flames or smoking.
- Wear protective gloves, acid-resistant clothing and safety glasses. Pour battery electrolyte only into suitable and appropriately marked containers.
3 Disconnect ground cable of battery
4 Remove top charge air distributor (110/6)
5 Remove aluminium distribution pipe (3) for secondary air injection
6.1 Remove poly V-belt of compressor
6.2 Remove poly V-belt
7 Release fuel pressure through service valve (1/1)
NOTE: Collect fuel
- Pressure hose: See Special Tools below.
8 Unbolt feed line (17/2) of fuel rail (17)
NOTE: Collect fuel
- Disconnect fuel feed line at fuel rail, Engine 112.960/961 = 35 Nm
Engine 113.992 = 38 Nm
- Set of plugs: See Special Tools below.
9 Separate electric plug connection at injector (Y62)
NOTE: Press together security catches.
10 Take off bolts of fuel rail(17)
- Bolt of fuel rail to bottom part of charge air distributor = 9 Nm
11 Lift fuel rail (17) up and off together with injectors from bottom charge air distributor (110/8)
NOTE: Installation: Inspect O-rings for damage. Oil O-rings.
12 Detach grey vacuum line at rubber hose
NOTE:
- Installation: Coat gray vacuum line with rubber assembly lubricant
- Liquid lubricant
13 Unplug connector of throttle valve actuator (M16/6)
14 Unplug connector of charge air pressure sensor (B28/8)
15 Unplug connector of charge air temperature sensor (B17/8)
16 Unplug connector of electromagnetic clutch (Y2/1)
17 Detach rear vacuum line at intake manifold
18 Remove lower engine compartment lining
DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection.
19 Drain coolant from radiator
20 Detach coolant hoses (4) for low temperature water cooler at aluminium pipes (5) of charge air cooler (110/2)
- Special pliers: See Commercially Available Tools below.
21 Unscrew bolts of bottom charge air distributor (110/8)
22 Bolt bracket to supercharger
- Bracket: See Special Tools below.
23 Attach engine hoist to lifting eye of bracket
- Engine hoist (self-locking): See Commercially Available Tools below.
24 Lift out supercharger (50) together with charge air cooler (110/2) and bottom charge air distributor (110/8)
25 Unbolt charge air cooler (110/2) from supercharger (50)
- Bolt of supercharger to charge air cooler = 20 Nm
26 Install in the reverse order
27 Inspect cooling system for leaks
28 Connect STAR DIAGNOSIS and read out fault memory
Special Tools:
Commercially Available Tools:
