S09.40-A005-79
1 | Air intake duct upstream of turbocharger | 7 | Differential pressure sensor | 13 | Boost pressure positioner | ||
2 | Electrical connector | 8 | Clip | 14 | Clip | ||
3 | Vent line | 9 | Quick-release coupling | 15 | Screw | ||
4 | Cylinder head cover | 10 | Air intake pipe | 16 | Clip | ||
5 | Electrical connector | 11 | Air intake hose | 17 | Low-pressure turbocharger | ||
6 | Screw | 12 | Electrical line | 18 | Low pressure exhaust gas recirculation line |
S09.40-A006-78
1 | Air intake duct upstream of turbocharger | 20 | Compensating element | |
16 | Clip | 21 | Elastomer bearing | |
19 | O-ring |
7 | Differential pressure sensor |
18 | Low pressure exhaust gas recirculation line |
22 | Clip |
23 | Low pressure exhaust gas recirculation valve |
S14.20-A007-82
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
| Remove | ||
1 | Remove engine cover. | ||
2 | Disconnect electrical connection (2). | ||
3 | Remove bleed line (3) from the air intake line upstream of the exhaust gas turbocharger (1). | ||
4 | Seal air intake line upstream of the exhaust gas turbocharger (1) with a suitable stop plug. | Record plug | |
5 | Remove bleed line (3) from the cylinder head cover (4) and remove upward. | ||
6 | Seal bleed line (3) with protective covers. | Set of protective caps | |
7 | Seal connection on cylinder head cover (4) with a suitable stop plug. | Record plug | |
8 | Disconnect electrical connector (5). | ||
9 | Remove screw/bolt (6). | ||
10 | Remove differential pressure sensor (7) from the air intake line upstream of the exhaust gas turbocharger (1) and place to one side with connected lines. | ||
11 | Open clamp (8). | ||
12 | Open quick-release fastener (9) and detach air intake pipe (10) from the air intake line upstream of the exhaust gas turbocharger (1). | ||
13 | Detach air intake pipe (10) from the air intake hose (11) and remove toward the front. | ||
14 | Seal air intake hose (11) with protective cover. | Set of protective covers | |
15 | Remove electric line (12) from boost pressure regulator (13) and place to one side. | ||
16 | Open clamp (14). | ||
17 | Remove screw (15). | ||
18 | Open clamp (16). | ||
19 | Detach air intake line upstream of the exhaust gas turbocharger (1) from the low-pressure exhaust gas turbocharger (17) until the low pressure exhaust gas recirculation line (18) can be removed. | WIS Service Media | |
20 | Detach low pressure-exhaust gas recirculation line (18) from the air intake line upstream of the exhaust gas turbocharger (1) and remove air intake line upstream of the exhaust gas turbocharger (1) toward the front. | ||
21 | Seal low-pressure exhaust gas turbocharger (17) with protective cover. | Set of protective covers | |
22 | Remove O-ring (19). | Assembly tool | |
23 | Remove compensating element (20). | ||
24 | Remove clamp (16) from the air intake line upstream of the exhaust gas turbocharger (1). | If a new air intake line upstream of the exhaust gas turbocharger (1) is installed. | |
25 | Remove elastomer bearing (21) from the air intake line upstream of the exhaust gas turbocharger (1). | If a new air intake line upstream of the exhaust gas turbocharger (1) is installed. | |
26 | Open clamp (22) and remove low pressure-exhaust gas recirculation line (18) upward. | ||
27 | Seal low pressure-exhaust gas recirculation valve (23) with protective cover. | Set of protective covers | |
| Check | ||
28 | Check clamp (16) for damage. | If damage is identified, | |
| |||
Replace clamp (16). | |||
29 | Check elastomer bearing (21) for damage. | If damage is identified, | |
| |||
replace elastomer bearing (21). | |||
30 | Check quick-release fastener (9) for damage. | If damage is identified, | |
| |||
replace air intake line upstream of the exhaust gas turbocharger (1). | |||
31 | Check O-rings of the bleed line (3) for damage. | If damage is identified, | |
| |||
replace bleed line (3). | |||
32 | Check bleed line (3) for damage. | If damage is identified, | |
| |||
replace bleed line (3). | |||
33 | Check air intake pipe (10) for damage. | If damage is identified, | |
| |||
replace air intake pipe (10) and air intake hose (11). | |||
| Install | ||
34 | Attach new clamp (22) to the new low pressure-exhaust gas recirculation line (18). | The new clamp (22) is designed as a screw clamp. | |
35 | Remove protective cover from the low pressure-exhaust gas recirculation valve (23). | ||
36 | Attach low pressure-exhaust gas recirculation line (18) to the low pressure-exhaust gas recirculation valve (23) and position. | ||
37 | Tighten clamp (22). | Screw, clamp securing low-pressure exhaust gas recirculation line to low-pressure exhaust gas recirculation valve | |
38 | Attach new clamp (14) to the low pressure exhaust gas recirculation line (18). | The new clamp (14) is designed as a screw clamp. | |
39 | Attach elastomer bearing (21) to the air intake line upstream of the exhaust gas turbocharger (1). | If a new air intake line upstream of the exhaust gas turbocharger (1) was installed. | |
40 | Attach clamp (16) to the air intake line upstream of the exhaust gas turbocharger (1). | If a new air intake line upstream of the exhaust gas turbocharger (1) was installed. | |
41 | Install new compensating element (20). | ||
42 | Install new O-ring (19). | Assembly tool | |
43 | Remove protective cover from the low-pressure exhaust gas turbocharger (17). | ||
44 | Position air intake line upstream of the exhaust gas turbocharger (1) in the installation position and attach to low pressure exhaust gas recirculation line (18). | ||
45 | Attach air intake line upstream of the exhaust gas turbocharger (1) to the low-pressure exhaust gas turbocharger (17). | ||
46 | Tighten clamp (16). | Screw, clamp securing air intake line upstream of exhaust gas turbocharger to low-pressure exhaust gas turbocharger | |
47 | Screw in screw (15). | Screw, air intake line upstream of exhaust gas turbocharger to air duct housing | |
48 | Tighten clamp (14). | Screw, clamp securing low-pressure exhaust gas turbocharger to air intake line upstream of exhaust gas turbocharger | |
49 | Attach electric line (12) to the boost pressure regulator (13). | ||
50 | Remove protective cover from air intake hose (11). | ||
51 | Install air intake pipe (10). | ||
52 | Tighten clamp (8). | Screw, clamp securing air intake pipe to air intake hose | |
53 | Attach differential pressure sensor (7) to the air intake line upstream of the exhaust gas turbocharger (1). | ||
54 | Screw in screw(6). | Screw, differential pressure sensor to air intake line upstream of exhaust gas turbocharger | |
55 | Connect electrical connector (5). | ||
56 | Remove stop plug from the cylinder head cover (4). | ||
57 | Remove stop plug from the air intake line upstream of the exhaust gas turbocharger (1). | ||
58 | Remove protective covers from bleed line (3). | ||
59 | Install bleed line (3). | ||
60 | Connect electrical connector (2). | ||
| 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. | |
61 | Perform engine test run and check air intake line upstream of the exhaust gas turbocharger (1) for leak tightness. | ||
62 | Install engine cover. |
000 589 93 63 00
Assembly tool
001 589 03 91 00
Set of protective covers
001 589 01 91 00
Set of protective covers
001 589 00 91 00
Set of protective caps
129 589 00 91 00
Record plug
Referenced documents
- ah0000p500001a Notes on avoiding damage through contamination and foreign objects
- ah5400p000101a Information on preventing damage to electronic components due to electrostatic discharge
- ar0110s2405ea Remove/install engine cover
- ar0910s8130ea Remove/install engine intake air duct downstream of air filter
- as0000z000501a 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.