Intercooler, Replace (Z 20 LEL, Z 20 LER)
Remove
2. |
Disconnect battery
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Detach ground connection from ground terminal
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3. |
Empty climate control system
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Connect service station
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Blue hose to low pressure service connection (1) with small
diameter
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Red hose to high pressure service connection (2) with large
diameter
Note: Read Service
Station operating instructions carefully
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Determine quantity of condenser extracted at the oil separator
of the Service Station
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4. |
Remove radiator grille (2)
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Remove 4x body-bound rivets (1)
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Unclip from front panelling from above
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5. |
Raise vehicle by its full height
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6. |
Place collecting basin underneath.
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7. |
Drain coolant
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Open drain bolt on radiator (1)
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8. |
Place collecting basin underneath.
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9. |
Detach front panelling (3)
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Remove 5x body-bound rivets (2)
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10. |
Place collecting basin underneath.
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11. |
Detach high-pressure headlamp cleaning system hose from
reservoir (2)
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Undo quick-release fitting (1)
Note: Escaping
fluid
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12. |
Lower vehicle by half its height
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13. |
Remove front panelling
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Second man
Note: Push front
panelling upwards at side and pull out of bracket in direction of
arrow
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Detach front panelling from bracket
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Unclip outside temperature sensor
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14. |
Lower vehicle by half its height
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15. |
Detach upper radiator hose from radiator
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16. |
Disconnect charge pressure sensor wiring harness plug (1)
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17. |
Detach charge air hose from intercooler
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18. |
Detach coolant return hose between turbocharger and
radiator
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19. |
Secure radiator at right and left using suitable wire bars
(1)
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Insert 2x wire bars (1)
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20. |
Raise vehicle by half its height
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21. |
Detach charge air hose (3), turbocharger to intercooler
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22. |
Detach refrigerant line (low pressure side)
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23. |
Disconnect pressure switch wiring harness plug (1), air
conditioning system
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24. |
Detach refrigerant line (high pressure side) from condenser
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25. |
Disconnect compressor wiring harness plug (1)
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Unclip compressor wiring harness from refrigerant line
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26. |
Detach air conditioning wiring harness from cooling module
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Unfasten 10x cable ties (4)
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Unclip 2x relays (1) from auxiliary fan housing
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Disconnect auxiliary fan wiring harness plug (3)
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27. |
Raise vehicle by half its height
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28. |
Detach lower radiator hose from radiator
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29. |
Detach fan wiring harness
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Disconnect wiring harness plug (1)
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30. |
Remove bracket, right side of radiator (2)
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31. |
Remove bracket, left side of radiator (1)
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32. |
Lower vehicle by half its height
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33. |
Remove cooling module
Note: Second man
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Remove 2x fuses from bracket
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34. |
Detach intercooler from cooling module
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Unscrew bolt (2) and nut (1)
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Remove intercooler in direction of arrow
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Install
35. |
Attach intercooler to cooling module
Important: Insert bolt nut with
screw locking compound
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Tighten bolt, nut 5 Nm
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36. |
Insert cooling module
Note: Second man
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Insert 2x fuses in bracket
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37. |
Raise vehicle by half its height
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38. |
Install left radiator bracket
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Screw in 2x bolts 20 Nm
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39. |
Install right radiator bracket
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Screw in 2x bolts 20 Nm
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40. |
Attach lower radiator hose to radiator
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41. |
Attach fan wiring harness
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Fix wiring harness plug
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42. |
Lower vehicle by half its height
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43. |
Attach air conditioning wiring harness to cooling module
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Clip 2x relays to auxiliary fan housing
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Connect auxiliary fan wiring harness plug
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44. |
Connect compressor wiring harness plug
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Clip compressor wiring harness to refrigerant line
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45. |
Connect air conditioning system pressure switch wiring harness
plug
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46. |
Attach refrigerant line (high pressure side)
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47. |
Attach refrigerant line (low pressure side)
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48. |
Attach charge air hose between turbocharger and intercooler
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49. |
Insert front panelling
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Second man
Note: Slide side front
panelling into bracket
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Attach front panelling to bracket
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Attach outside temperature sensor
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50. |
Fit front panelling
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Install 5x body-bound rivets
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51. |
Attach high-pressure headlamp cleaning hose to reservoir
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Attach 1 quick-release fitting to windscreen washing system
reservoir
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52. |
Lower vehicle by half its height
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53. |
Remove radiator retainer from bracket
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54. |
Attach coolant return hose from turbocharger to radiator
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55. |
Attach charge air hose to intercooler
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56. |
Connect charge pressure sensor wiring harness plug
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57. |
Attach upper radiator hose to radiator
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58. |
Fill with coolant and correct coolant level
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59. |
Top up climate control system
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Connect service station
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Blue hose to low-pressure service connection with small
diameter
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Red hose to high-pressure service connection with large
diameter
Note: ! Read service
station operating instructions carefully
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Use the Service Station to insert the quantity of new
compressor lubricant into the climate control system that was
extracted when it was emptied.
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Fill air conditioning system with R 134a refrigerant
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Refrigerant quantity 700g
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60. |
Connect battery
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Attach ground connection to ground terminal
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61. |
Programme transient memory
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