Remove/install compressor

AR09.50-P-4705TZ

Remove/install compressor

2.11.11

 

Remove/install

1

Switch ignition off, remove ignition key (transmitter key)

 On vehicles with code 889 Keyless-Go: Press Keyless-Go start/stop button repeatedly until the ignition is switched off.

Remove Keyless Go transmitter card or transmitter key from the vehicle and store beyond transmitter range (min. 2 m).

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

2

Open engine hood

AR88.40-P-1000TX

3

Remove right and left engine intake air duct

4

Remove top engine cover

5

Remove air filter housing (1).

 Removal: When removing air filter housing (1) ensure that intake hose is not twisted since improper removal of air filter housing (1) can deform the steel ring in intake hose and this can loosen while engine is running.

AR09.10-P-1150TZ

 Removal: Carefully raise air filter housing (1) and detach crankcase ventilation hose (2) at fitting (3) of intake line (4).

 Installation: Ensure that catch (5) on intake line (4) does not break off when bottoming on throttle valve actuator (M16/6) since the broken off catch (5) can be sucked in by engine and cause engine damage.

 Installation: Moisten sealing ring, throttle valve actuator (M16/6) with antifriction agent.

Lubricant paste

*BR00.45-Z-1002-06A

6

Remove top charge air distributor (110/6)

 Installation: Pay attention to different lengths of screw/bolt. Cover over openings with a fluffy rag.

AR09.41-P-1320TZ



*BA09.41-P-1001-01C

7

Remove the throttle valve actuator (M16/6)

 Removal: The throttle valve actuator (M16/6) plug (6) of must not be removed, because it is bonded. For removal, disconnect electrical connector (13) at throttle valve actuator (M16/6)

AR07.51-P-1401TY

 Removal: The connector (13) of throttle valve actuator (M16/6) and connector (14) of recirculated air flap actuator are identical and therefore can be mixed up. The wiring harness of the throttle valve actuator (M16/6) is marked with blue insulation tape (arrow). If this is not the case, mark the wiring harness before disconnecting the connector.

Screw on throttle valve actuator

*BA07.61-P-1001-01A

 Danger!

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

8

Remove fuel distributor

 Installation: Replace O-rings of injection valves.

AR07.03-P-1451TY

Fuel feed line on fuel rail

*BA07.52-P-1001-01A

 Bolt, fuel distributor to bottom part of charge air distributor

*BA07.52-P-1003-01A

 Pressure hose

*119589046300

 Set of stop plugs

*129589009100

9

Remove bolt (7) of purge line (8) to cylinder head cover (9)

 Detach hose on engine side and place purge line (8) to the side.

 Cylinder head cover bolt

*BA01.20-P-1001-01E

10

Detach hose (10) for air injection at supercharger (50)

 Hose (10) remains at left aspirator shutoff valve (126/1) and at right aspirator shutoff valve (126/2).

11

Detach hose (11) for air injection at supercharger (50)

12

Detach vacuum line (12) at left aspirator shutoff valve (126/1) and at right aspirator shutoff valve (126/2).

13

Detach crankcase venting hose (15) on right and left on cylinder head cover (9)

14

Detach vacuum line (16) at air pump switchover valve (Y32)

15

Unplug plug of charge air temperature sensor (B17/8)

16

Unplug plug of pressure sensor (B28)

17

Disconnect connector (14) from recirculated air flap actuator

 Removal: The connector (13) of recirculated air flap actuator (M16/6) and connector (14) of throttle valve actuator are identical and therefore can be mixed up. The wiring harness of the throttle valve actuator (M16/6) is marked with blue insulation tape (arrow). If this is not the case, mark the wiring harness before disconnecting the connector.

 Installation: Absolutely coat pins of connector with contact fluid.

Contact fluid

*BR00.45-Z-1001-14A

18

Unplug plug of supercharger magnetic clutch (Y2/1)

 Disconnect plug carefully because plug housing on supercharger magnetic clutch (Y2/1) is not damaged.

19

Remove poly-V belt for compressor (50)

 Mark running direction of poly-V belt.

AR13.21-P-1202TZ

Running diagram of compressor poly-V belt

AR13.21-P-1202-01TZ



Check visible area of poly-V belt for wear

AP13.22-P-1352TZ

20

Remove poly-V belt

 Mark running direction of poly-V belt.

AR13.22-P-1202TZ

Routing diagram of poly V-belt

AR13.22-P-3902-02TZ



Check visible area of poly-V belt for wear

AP13.22-P-1352TZ

 Danger!

Risk of death caused by vehicle slipping or tilting off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

21

Remove lower engine compartment paneling

AR61.20-P-1105TX

 Danger!

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



Notes on coolant

All engines

AH20.00-N-2080-01A

22

Drain coolant at radiator

AR20.00-P-1142TY



*BF20.00-P-1001-02K

23

Disconnect coolant hoses at coolant drain line (17) and coolant feed line (18)

 Close coolant hoses.

24

Remove bolt (19) of coolant drain line bracket (17) and coolant feed line (18)

25

Remove left aspirator shutoff valve (126/1) and right aspirator shutoff valve (126/2)

 Bolt, bottom part of charge air distributor to cylinder head

*BA09.41-P-1002-01C

26

Remove screw/bolt (20) of charge air distributor bottom section to cylinder head

 Installation: Pay attention to different lengths of screw/bolt. The bolt (21) has a length of 35 mm. The screw/bolt (20) have a length of 30 mm.

 Bolt, bottom part of charge air distributor to cylinder head

*BA09.41-P-1002-01C

27

Screw bracket (22) onto compressor (50)

 Bracket

*112589006200

28

Attach engine hoist in the lifting eye of the bracket (22)

Load regulator
gotis://H_00.12_04.0

29

Lift out supercharger (50) together with charge air cooler and bottom charge air distributor (110/10)

 Installation: Use dowel bolt (arrow) for exact positioning of supercharger (50) with charge air cooler and bottom charge air distributor (S110/10) as well as for centering the gasket (110/9).

 Set of dowel bolts

*112589026200

30

Remove charge air cooler

 No dirt particles should be able to find their way into the charge air cooler while cleaning the sealing surfaces since these could destroy the compressor (50).

AR09.41-P-6817TZ

 Installation: No excess sealant should be allowed to find its way into the compressor (50) since this could destroy the compressor (50).

 Installation: Moisten sealing ring on air recirculation flap actuator with liquid lubricant.

 Bolt, compressor to charge air cooler

*BA09.50-P-1001-01B

Lubricant paste

*BR00.45-Z-1002-06A

31

Install in the reverse order

32

Inspect cooling system for leaks

AR20.00-P-1010TX

33

Read out fault memory and erase if necessary



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

Number

Designation

Engine 113

BA01.20-P-1001-01E

Cylinder head cover bolt

Stage 1

Nm

9

Stage 2

°

-

Number

Designation

Engine 113.990/
991

BA07.52-P-1001-01A

Fuel feed line to fuel distributor

Nm

38

BA07.52-P-1003-01A

Bolt, fuel distributor to bottom part of charge air distributor

Nm

9

Number

Designation

Engine
112, 113

BA07.61-P-1001-01A

Bolt at throttle valve actuator

Nm

10

Number

Designation

Engine
113.990/
991

BA09.41-P-1001-01C

Bolt, upper part of charge air distributor to bottom part of charge air distributor

Nm

9

BA09.41-P-1002-01C

Bolt, bottom part of charge air distributor to cylinder head

Nm

20

Number

Designation

Engine
113.990

BA09.50-P-1001-01B

Bolt, supercharger to charge air cooler

Nm

20

Number

Designation

Engine
113.990

BF20.00-P-1001-02K

Cooling system

Total filling capacity

Liters

13.2

Capacity of anticorrosion/antifreeze agent down to -37°C

Liters

6.6

Filling capacity of anticorrosion/ antifreeze down to -45°C

Liters

7.3

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

Number

Designation

Order number

BR00.45-Z-1002-06A

Antifriction paste, rubber parts 2.5 kg, DB supply specification 6867.00

A 000 989 01 60

BR00.45-Z-1001-14A

Contact fluid

A 008 989 55 71