J 603500 Fan Housing, Replace (Y 17 DT, with AC,
RHD)
1. Open bonnet
Caution!
On vehicles from model year 04 with ESP - the steering angle
sensor loses its basic adjustment each time the battery is
disconnected. It must be recalibrated.
2. Disconnect battery
3. Remove air cleaner housing (1)
- Remove wiring harness plug for hot film mass air flow meter
(3)
- Release in direction of arrow
- Remove air intake hose (4)
- Remove bolt (2)
|
|
4. Raise vehicle
5. Remove ribbed V-belt cover
- Remove 3 bolts (1)
- Remove clip (arrow).
|
|
6. Remove ribbed V-belt
- Tension ribbed V-belt tensioner in direction of arrow
- Using KM-913-A at fastening bolt (1)
- Note! Mark running direction
|
|
7. Detach pressure switch wiring
harness plug (1)
|
|
8. Detach centre charge air pipe
- Release lower clamp (2)
- Remove lower bolt (1)
|
|
9. Detach air intake pipe
10. Detach fan motor wiring harness
11. Release fan housing
12. Remove charge air hose
- From intercooler
- Release clamp
13. Drain coolant
- Place collecting basin underneath.
- Open drain bolt
|
|
14. Lower vehicle
15. Detach centre charge air pipe
- Remove upper bolt (1)
- Remove charge air hose
- Loosen clamp (2)
|
|
16. Remove wiring harness plug for engine management
- Engine control unit wiring harness plug (1)
- Release in direction of arrow
- Disconnect combination plug (2) (grey)
- Disconnect combination plug (5) (black)
17. Remove air intake hose (3)
- Remove 2 bolts
- Detach engine vent hose (4)
- Detach air intake pipe from turbocharger
- Unclip wiring harness
|
|
18. Unclip lower coolant hose
19. Unclip fan housing wiring harness
20. Detach upper coolant hose
21. Remove fan housing
- Unscrew right bolt
- Unclip air conditioning wiring harness
- Disconnect compressor wiring harness plug
22. Detach fan motor
- Unscrew 3 nuts (arrows)
- Detach fan thermostatic switch
- Unclip wiring harness
|
|
23. Attach fan motor
- Tighten nuts (5 Nm / 3.7 lbf. ft.)
- Attach fan thermostatic switch
- Attach wiring harness
24. Install fan housing
- Attach wiring harness
- Connect compressor wiring harness plug
- Tighten 2 bolts (5 Nm / 3.7 lbf. ft.)
25. Connect upper radiator hose
26. Fasten lower radiator hose
27. Install air intake pipe
- Tighten 2 bolts
- Attach engine vent hose
- Attach wiring harness
28. Attach engine control unit wiring
harness plug
29. Attach centre charge air pipe
- Install charge air hose
- Fasten clamp (3.5 Nm / 2.6 lbf. ft.)
- Screw in upper bolt
30. Raise vehicle
31. Tighten coolant drain bolt
32. Install centre charge air pipe
- Install lower bolt
- Fasten clamp (3.5 Nm / 2.6 lbf. ft.)
33. Attach fan motor wiring harness
34. Attach charge air hose
- To charge air cooler
- Tighten clamp (3.5 Nm / 2.6 lbf. ft.)
35. Attach pressure switch wiring
harness plug
36. Install ribbed V-belt
- Note! Observe running direction and installation position
- Release ribbed V-belt tensioner
37. Attach ribbed V-belt cover
- Screw in bolts
- Install clip
38. Lower vehicle
39. Install air cleaner housing
- Tighten bolt
- Fasten air intake hose.
- Tighten hose clamp (3.5 Nm / 2.5 lbf. ft.)
- Connect wiring harness plug to hot film mass air flow
meter
40. Connect battery
41. Calibrate steering angle sensor
Note: Rotate the
steering wheel one time from its right-hand to its left-hand
stop.
42. Top up coolant
- Note! Top up and bleed cooling system – see operation
"Top up and bleed cooling system"
- Observe specified coolant quantity
43. Program volatile memories
44. Close bonnet
|