Remove/install charge air cooler - AR09.41-P-6817SVK

ENGINE 112.960 in MODEL 170.466 

ENGINE 112.961 in MODELS 203.065 /265 

ENGINE 113.992 in MODEL 230.474 

ENGINE 113.995 in MODEL 230.472 

Shown on engine 112.960 

Fig 1: Identifying Charge Air Cooler Remove/Install Components - Shown On Engine 112.960

	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 skin and eyes caused by contact with fuel.	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.	AS47.00-Z-0001-01A
		Wear protective clothing when handling fuel.
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 aluminum distribution pipe (3) for air injection	Model 170.466, 203.065 /265
5.1	Remove poly V-belt of supercharger	Model 230.472/ 474	AR13.21-P-1202RVK
5.2	Remove poly-V-belt	Model 170.466, 203.065 /265	AR13.22-P-1202SVK
6	Release fuel pressure through service valve (1/1)	Make sure to collect fuel.
		Pressure hose	Figure
7	Unbolt feed line (17/2) from fuel distributor rail (17)	Make sure to collect fuel.
			*BA07.52-P-1001-01A
		Set of plugs	Figure
8	Disconnect electrical connectors at fuel injection valves (Y62)	Press together security catches.
9	Take off bolts of fuel rail (17)		*BA07.52-P-1003-01A
10	Lift fuel distributor rail (17) including fuel injectors (Y62) upwards from bottom charge air distributor (110/8)	Installation:  Check O-ring for damage. Oil O-rings.
11	Detach gray vacuum line at rubber hose	Installation:  Coat gray vacuum line with liquid lubricant.
		Antifriction agent	*BR00.45-Z-1010-06A
12	Unplug connector of throttle valve actuator (M16/6)
13	Unplug connector of pressure sensor (B28)
14	Unplug connector of charge air temperature sensor (B17/8)
15	Detach electrical connector (6) at supercharger magnetic clutch	Carefully detach connector since the connector housing can be damaged.
16	Detach rear vacuum line at intake manifold
17	Remove lower engine compartment paneling	Model 170	AR61.20-P-1105A
		Model 203	AR61.20-P-1105P
		Model 230	AR61.20-P-1105R
	Risk of injury  to skin and eyes caused by scalding from contact with hot coolant spray. 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
18	Drain coolant from radiator	Model 170	AR20.00-P-1142SV
		Model 203	AR20.00-P-1142PV
		Model 230	AR20.00-P-1142RVK
	Notes on coolant		AH20.00-N-2080-01A
19	Detach coolant hoses (4) for low temperature water cooler at aluminum pipes (5) of charge air cooler (110/2)	Special pliers	*WH58.30-Z-1005-02A
20	Remove bolts for bottom charge air distributor (110/8)		*BA09.41-P-1002-01C
21	Bolt bracket to supercharger	Bracket	Fig 3
22	Attach engine hoist to lifting eye of bracket	Engine hoist (self-locking)	*WE58.40-Z-1012-11A
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)		*BA09.50-P-1001-01B
25	Install in the reverse order
26	Inspect cooling system for leaks	Model 170, 203	AR20.00-P-1010P
		Model 230	AR20.00-P-1010RVK
27	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)