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

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

Shown On Engine 112:

Remove/Install

DANGER:
- Lethal injuries are possible if vehicle slips off of lifting platform
- Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support 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 cover (1) at the 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 hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury to eyes and skin suffering caustic burns to eyes and skin suffering caustic burns from battery electrolyte or from contact with damaged lead acid batteries.
- No fire, sparks, open flames or smoking.
- Wear acid-resistant gloves, clothing and 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 poly V-belt of supercharger
6 Release fuel pressure through service valve (1/1)

NOTE: Collect fuel.

- Pressure hose: See Special Tools below.

7 Unbolt feed line (17/2) of fuel rail (17)

NOTE: Collect fuel.

- Fuel feed line to fuel rail = 38 Nm
- Set of plugs: See Special Tools below.

8 Separate electric plug connection at injector (Y62)

NOTE: Press together security catches.

9 Take off bolts of fuel rail (17)
- Bolt of fuel rail to bottom part of charge air distributor = 9 Nm

10 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.

11 Detach grey vacuum line at rubber hose

NOTE: Installation: Coat gray vacuum line with rubber assembly lubricant.

12 Unplug connector of throttle valve actuator (M16/6)
13 Unplug connector of charge air pressure sensor (B28/8)
14 Unplug connector of charge air temperature sensor (B17/8)
15 Disconnect plug from magnetic clutch of mechanical supercharger (Y2/1)

CAUTION: Disconnect plug carefully because the plug housing on the magnetic clutch of the mechanical supercharger may be damaged.

16 Detach rear vacuum line at intake manifold
17 Remove lower engine compartment paneling

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.

18 Drain coolant at radiator
19 Pull coolant hoses (4) off aluminum pipes (5)
- Special pliers: See Commercially Available Tools below.

20 Unscrew bolts of bottom charge air distributor (110/8)
- Bolt of bottom part of charge air distributor to cylinder head = 20 Nm

21 Bolt bracket to supercharger
- Bracket: See Specials tools below

22 Attach engine hoist to lifting eye of bracket
- Engine hoist (self-locking): See Commercially Available Tools below.

23 Lift out supercharger (50) together with charge air cooler (110/2) and bottom charge air distributor (110/8)
24 Unbolt charge air cooler (110/2) from supercharger (50)
- Bolt of supercharger to charge air cooler = 20 Nm

25 Install in the reverse order
26 Inspect cooling system for leaks
27 Connect STAR DIAGNOSIS and read out fault memory


Special Tools

Special Tools:

Commercially Available Tools

Commercially Available Tools: