Fuel Cooler: Service and Repair

Removing And Installing Fuel Cooler

Tools







Technical values







Information

Overview







Preliminary work
1. Remove pressure pipe.
2. Remove air cleaner housing.
3. Lower the engine. Lower the engine by max. 40 mm.
3.1. Support the engine with a jack and retainer plate P 9592.
3.2. Loosen collar nuts on engine mounting and unscrew. Carefully lower engine using the jack.

General warning notes

Safety instructions when working on the fuel system

WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion.

- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapours.
- Attach warning sign in a clearly visible position.

WARNING:
Caustic fluid
- Danger of chemical burns.

- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

Removing fuel cooler

CAUTION:
Refrigerant system open during repairs
- Too much moisture entering the refrigerant system
- Risk of damage to air conditioning compressor.

- Do not leave air conditioning system open for more than 24 hours.

INFORMATION:
- It is necessary to remove the refrigerant by suction before removing the fuel cooler.
- The safety regulations must be observed during all work on the refrigerant system.







1. Remove refrigerant by suction.
The connections for the air conditioning -1, 2- are located in the luggage compartment.

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.







2. Undo the fuel supply lines on the fuel cooler.
Loosen union nuts (a/f 17) for fuel lines -1 and 2- at the fuel cooler. Always counter with an open-ended wrench (a/f 14) while doing this. Absorb emerging fuel with a cloth.







3. Undo the refrigerant lines on the fuel cooler.
Unscrew cheese head bolts -2- and pull off refrigerant lines.

3.1. Remove old O-rings.

4. Remove fuel cooler.
Unscrew screw -3- at holding clamp and remove fuel cooler.

Installing fuel cooler







1. Position fuel cooler -1- and screw in screw -3- for holding clamp only slightly.
1.1. Insert new sealing rings for refrigerant lines.
1.2. Connect refrigerant lines at the fuel cooler. Insert screws for refrigerant lines -2- and tighten.
Tightening torque: 23 Nm (17 ftlb.)

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.







2. Connect fuel lines at the fuel cooler.
2.1. Tighten union nuts (a/f 17) for fuel lines -1 and 2- at the fuel cooler. Always counter with an open-ended wrench (a/f 14) while doing this.
Tightening torque: 25 Nm (19 ftlb.)







2.2. Tighten screw for fuel cooler clamp -3-.
Tightening torque: 23 Nm (17 ftlb.)







3. Fill in refrigerant.
The connections for the air conditioning -1, 2- are located in the luggage compartment.

Subsequent work
1. Raise the engine.
1.1. Raise engine in installation position, using retainer plate P 9592 to do this.
1.2. Screw in and tighten collar nuts.
Tightening torque: 85 Nm (63 ftlb.)

2. Install air cleaner housing.
3. Install pressure pipe.