Remove/Install Charge Air Cooler - Ar09.41-P-6817Rvk

Engine 113.990 In Model 211.076 /276 

Engine 113.991 In Model 215.374, 220.074 

Shown On Engine 112 

Fig 1: Identifying Charge Air Cooler Remove/Install Components

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of lifting platform and position four support plates at lifting platform support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel.	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
1	Remove engine trim panel (1)	Pull top engine cover (2) upwards at both air filter housings and at bracket.
2	Remove air filter housing (2).		AR09.10-P-1150SVK
3	Remove top charge air distributor (110/6)		AR09.41-P-1320SVK
4	Remove poly-V-belt for supercharger		AR13.21-P-1202RVK
5	Release fuel pressure through service valve (1/1)	Make sure to collect fuel.
		Pressure hose	Figure
6	Unbolt feed line (17/2) at fuel distributor rail (17)	Make sure to collect fuel.
			*BA07.52-P-1001-01A
		Set of plugs	Fig 4
7	Disconnect electrical connectors at fuel injection valves (Y62)	Press together security catches.
8	Remove bolts for fuel distributor rail (17)		*BA07.52-P-1003-01A
			*BA07.52-P-1002-01A
9	Lift fuel distributor rail (17) including fuel injectors (Y62) from bottom charge air distributor (110/8) toward top	Installation:  Check O-ring for damage. Oil O-rings.
10	Detach gray vacuum line at rubber hose	Installation:  Coat gray vacuum line with liquid lubricant.
		Antifriction agent	*BR00.45-Z-1010-06A
11	Unplug connector for throttle valve actuator (M16/6)
12	Unplug connector for pressure sensor (B28)
13	Unplug connector for charge air temperature sensor (B17/8)
14	Detach electrical connector at the supercharger magnetic clutch (6)	Carefully detach connector since the connector housing can be damaged.
15	Detach rear vacuum line at intake manifold
16	Remove lower engine compartment paneling	Model 215, 220	AR61.20-P-1105M
		Model 211	AR61.20-P-1105T
	Risk of injury  to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning  caused by 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
17	Drain coolant from radiator		AR20.00-P-1142RVK
	Notes on coolant	All engines	AH20.00-N-2080-01A
18	Detach coolant hoses (4) at aluminum pipes (5)	Special pliers	*WH58.30-Z-1005-02A
19	Unscrew bolts for bottom charge air distributor (110/8)		*BA09.41-P-1002-01C
20	Bolt bracket on supercharger	Bracket	Fig 3
21	Attach engine hoist to lifting eye of bracket	Engine hoist (self-locking)	*WE58.40-Z-1012-11A
22	Lift out supercharger (50) together with charge air cooler (110/2) and bottom charge air distributor (110/8)
23	Unbolt charge air cooler (110/2) from supercharger (50)		*BA09.50-P-1001-01B
24	Install in the reverse order
25	Inspect cooling system for leaks		AR20.00-P-1010RVK
26	Read out fault memory
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

Fuel Distributor

Charge Air Pipe/Charge Air Cooling

Supercharger

Fig 2: Identifying Pressure Hose (119 589 04 63 00)

Fig 3: Identifying Bracket (112 589 00 62 00)

Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)