S09.41-A046-79
1 | Screw | 5 | Electrical wiring harness | 9 | Vacuum valve | ||
2 | Temperature sensor | 6 | Electrical connector | 10 | Hose | ||
3 | Exhaust gas recirculation line | 7 | Hoses | 11 | Bracket | ||
4 | Charge air distributor | 8 | Vacuum valve | 12 | Hose |
S09.41-A047-79
13 | Retaining clips | 16 | Bolts | 19 | Nut | ||
14 | Stud bolt | 17 | Electrical connector | 20 | Bolts | ||
15 | Nut | 18 | Stud bolt |
Warning | Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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. | |
Caution | Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. | |
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
| Remove | ||
1 | Remove coolant pipe. | ||
2 | Remove screw/bolt (1). | ||
3 | Remove temperature sensor (2) from exhaust gas recirculation line (3) and charge-air distributor (4). | ||
4 | Remove the alternator | ||
5 | Remove electrical wiring harness (5) at charge-air distributor (4). | To do this, detach the retaining clip. | |
6 | Disconnect the glow plug connectors from the glow plugs. | ||
Mark assignment of glow plug connector to respective cylinder. | |||
7 | Disconnect electrical connectors (6). | To do so, release electrical connectors (6). | |
8 | Remove hoses (7) from vacuum valves (8, 9). | Mark assignment of hoses (7) to vacuum valves (8, 9). | |
9 | Remove hose (10) from vacuum valve (9) and bracket (11) of charge-air distributor (4). | ||
10 | Remove hose (12) from vacuum valve (8) and charge-air distributor (4). | Hose (12) is fastened to charge-air distributor (4) with retaining clips (13). | |
11 | Remove EGR line (3) from charge air distributor (4). | ||
12 | Remove the throttle valve actuator. | ||
13 | Detach exhaust gas recirculation cooler downstream of exhaust gas recirculation. | ||
To do this, remove the exhaust gas recirculation cooler downstream of exhaust gas recirculation until stud bolt (14) and nut (15) are accessible. | |||
14 | Remove nut (15). | ||
15 | Remove stud bolt (14). | ||
16 | Remove screw (16). | ||
17 | Disconnect electrical connector (17) at boost pressure sensor downstream of throttle valve. | To do so, unlock electrical connector (17). | |
18 | Remove nut (19). | ||
19 | Remove stud bolt (18). | ||
20 | Remove bolts (20). | ||
21 | Remove charge-air distributor (4) upwards. | Dispose of seal. | |
| Install | ||
22 | Install new seal on charge-air distributor (4). | To do this, use two cable ties to fasten the seal to charge-air distributor (4). | |
23 | Position charge-air distributor (4) on cylinder head. | ||
24 | Screw in stud bolts (14, 18). | Stud bolt, charge-air distributor to cylinder head | |
25 | Remove cable ties. | To do this, cut the attached cable ties and remove from charge-air distributor (4). | |
26 | Fasten charge-air distributor (4) in place. | ||
To do this, screw in bolts (16, 20) and attach nuts (15, 19). | |||
Bolt, charge air distributor to cylinder head | |||
Nut, charge air distributor to cylinder head | |||
27 | Screw in screw (1). | M8 | |
28 | Install exhaust gas recirculation cooler downstream of exhaust gas recirculation. | ||
29 | Install the throttle valve actuator. | ||
30 | Install exhaust gas recirculation line (3). | ||
31 | Remove temperature sensor (2) from exhaust gas recirculation line (3) and attach to charge-air distributor (4). | ||
32 | Connect electrical connector (17) to boost pressure sensor downstream of throttle valve. | ||
33 | Attach hose (12) to vacuum valve (8) and charge-air distributor (4). | Check retaining clips (13) for damage. | |
If damage is present: | |||
| |||
Replace damaged retaining clips (13). | |||
34 | Attach hose (10) to vacuum valve (9) and bracket (11) of charge-air distributor (4). | Check holder (11) for damage. | |
If holder (11) is damaged, | |||
| |||
install new bracket (11). | |||
35 | Attach hoses (7) to vacuum valves (8, 9). | Note markings on hoses (7) to vacuum valves (8, 9). | |
36 | Establish the electrical connections (6). | ||
37 | Connect the glow plug connectors to the glow plugs. | ||
Observe marks of glow plug connectors. | |||
38 | Attach electrical wiring harness (5) to charge-air distributor (4). | | |
Check retaining clips for damage. | |||
If the retaining clip is damaged, | |||
| |||
Replace retaining clip. | |||
39 | Install alternator. | ||
40 | Install coolant pipe. | ||
| Check | ||
Warning | Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | |
41 | Check for leaktightness when engine is running. | Visual inspection only. |
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