W202 C200 intercooler removal

[dpmstevens]

Hello,
New on here and in need of some advice regarding removing the intercooler on on my 2000 C200K. Does anyone have a how to for this procedure?

I drowned the Merc last week and I'm trying to get all the water out. Of which there is a lot, but I'd like to save the car. Or at least try.

Cheers
Dan

 

[guydewdney]

Just yank off the pipes from behind the bumper and use a vacuum on blow or an airline?

 

[dpmstevens]

That's a good idea - I'll give it a go in the morning and see how it works out. The water is at least six inches up the pipes, so I reckon the intercooler is full of the stuff.
Cheers
Dan

 

[hondo]

Was engine run whilst under water ?

Or was it just parked up wen flood happened ?

 

[Auto-mobile]

It's a bumper removal job to get to the intercooler, if it cut out when you went through water I'd imagine it's to late.

 

[dpmstevens]

It was running when it stopped i.e it was the water that stopped it.

Pulled the plugs and they were wet. Very small amount of water in the sump oil, and quite a lot in the intake manifold. The engine has not locked up. I'm going to dry everything, and then try turning it over. It now has clean oil in it, too, which I will change again before trying to start it.

Then there's the interior to deal with...
Cheers
Dan

 

[guydewdney]

I wouldnt bother changing the oil again - if its hydraulic-d and bent the rods, the engine is scrap. If it starts and runs ok, then the tiny amount of water wont hurt it for a few minutes.

Just disconnect the inlet in pipe and spin it over with no plugs in, then loosely fit the plugs and try to start. OK - it will be in limp mode, but i suspect it will be anyway. If it goes, then its worth all the rest of the hassle of cleaning everything else out.

 

[dpmstevens]

So now I have removed everything I can remove, cleaned and dried all the parts but I'm still unsure how to take the intercooler off. Anyone done this before and are able to give me a quick run down of what's necessary?

It's funny, but I cannot seem to find much detail on some procedures for this engine - I need to have the inlet manifold off, too, but there doesn't seem to be anything on the web. If I find out, I'll post it here.
Cheers
Dan

 

[streethawk]

So now I have removed everything I can remove, cleaned and dried all the parts but I'm still unsure how to take the intercooler off. Anyone done this before and are able to give me a quick run down of what's necessary?

It's funny, but I cannot seem to find much detail on some procedures for this engine - I need to have the inlet manifold off, too, but there doesn't seem to be anything on the web. If I find out, I'll post it here.
Cheers
Dan

Hi well mine's a 230k so not sure if there the same but the intercooler was a bit of a pain with all the lying on back etc. It's been a while since I did mine so I'll try and remember rightly. Once bumper is off you need too remove jubilee clips at each end of cooler which iirc attach to rubber hoses which in turn attach to the aluminum pipe work. You can also remove aluminum pipe on the left hand side looking from front of car for more acsess to see what your doing. Removing clips is a bit of a juggle between acsess from the top and bottom. Now I can't remember if cooler is attached by two plastic dowels which are part of cooler into rubber donuts or bolted because rad and condenser use donuts as I've removed them before so maybe getting confused as I said it was a while ago. Should really become apparent what to do when the bumper is off. Inlet manifold just unbolts and I supported mine with a bungee to bonnet so as I didn't have to remove fuel lines etc. They do recommend new inlet gaskets when replacing which are more like o rings than a traditional gasket. Not sure if yours is the same but while you have inlet off clean out two air jets under it! They have rubber pipes on and there is two but pipes will be brittle no doubt. Just something to do while it's off because it stops oil going out the rocker breather into airbox and oiling up the maf.

 

[dpmstevens]

Thanks for that. I think the 200K intercooler is a bit different - the pipework is all plastic, and it appears to be very much trapped by the radiator, which I think will have to come out. The intercooler has been full of oily water, so I reckon it will be coated on the inside with the remains - everything else was...

I had hoped that by spinning the engine with the supercharger connected to the intercooler it might blow the oily mess out of the outlet pipe. It doesn't.

The thing with the inlet manifold I couldn't work out was what do with the injectors - they seem to be fitted through the manifold. So maybe the manifold lifts off with the injectors still attached...
Cheers
Dan

 

[guydewdney]

i dont think spinning at starter speeds would generate enough oomph to blow an intercooler clear of ikky water.

if it spins over, try firing it up, surely?

 

[grober]

You could try using a Pela type oil extractor to suck out the majority of liquid if you can get the suction tube in far enough. Pela 6000 Vacuum Oil Extractor Pump 6 Litre

 

[dpmstevens]

I'm a bit reluctant to fire it up with all of that oily mess in the intercooler - at some point it's going to find its way into the inlet manifold, and I imagine that coating of liquid on the internal surfaces must impede the intercooler's efficiency. So I'm going to remove it, clean it, and reassemble. If I can work out how to get it off without dismantling the entire car...
Cheers
Dan

 

[dpmstevens]

Right - got it out. You need to remove the radiator, the transmission coolant lines and the air-con condenser. I'll post in more detail when I have some pix.
Cheers
Dan