11 61 550 Removing and installing/renewing the intake plenum (N47D20 K/U/O/T 1)

Installation note:

If the air intake plenum is replaced, the stop values for the swirl flaps must be deleted and taught in again.

Follow diagnosis instruction.

Necessary preliminary tasks:

Disconnect negative battery lead.
Remove ACOUSTIC COVER
Remove rear ACOUSTIC COVER /injectors.
REMOVE sound insulation bulkhead upper part, center.
Remove intake silencer housing . See 13 71 000 REMOVING AND INSTALLING/REPLACING INTAKE SILENCER HOUSING (N47 D16/20 K/U/O/T 1) or 13 71 000 REMOVING AND REFITTING/REPLACING INTAKE FILTER HOUSING (N47 D20 O 1 WITH SCR) .
Release electronics box . See 12 14 550 REPLACING ELECTRONICS BOX (N47 D16/20 K/U/O/T 1) or 12 14 550 REPLACING CONTROL UNIT BOX (N47 D20 O 1 WITH SCR) and set aside.
Remove PRESSURE PIPE at throttle body.

Push the cable clamps (1) between the engine and bulkhead on both halves apart and remove the cable from the holder.

Fig 1: Identifying Cable Clamps

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Disconnect plug connection (1 and 2) from the preheating control unit.

Fig 2: Locating Plug Connection From Preheating Control Unit

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Release screw (1) and remove holder (2).

Fig 3: Identifying Holder And Screw

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Loosen screws (1) of the positive battery cable.

Fig 4: Identifying Screws Of Positive Battery Cable

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Loosen all cable clamps (1 and 2) on the intake plenum.

Disconnect plug connection (3) at charge air pressure sensor.

Release nut (4) on alternator.

Tightening torque: 12 52 2AZ

Lay positive battery cable (5) to one side.

Fig 5: Identifying Cable Clamps On Intake Plenum

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Loosen screws (1) on the exhaust-gas recirculation cooler.

Fig 6: Identifying Screws On Exhaust-Gas Recirculation Cooler

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Release screws (1).

Remove the air intake system toward the top.

Fig 7: Identifying Intake System And Screws

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Remove the exhaust-gas recirculation pipe (1) in direction of arrow.

Fig 8: Locating Exhaust-Gas Recirculation Pipe

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Installation note:

Replace O-ring (1).

Replace beaded metal gasket (2).

Fig 9: Identifying Beaded Metal Gasket And O-Ring

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IMPORTANT: The following operations only apply to vehicles with swirl flaps.

Replace intake plenum.

Release screws (3).

Modify the swirl-flap actuator (2).

Fig 10: Identifying Swirl-Flap Actuator And Screws

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Slide the drive unit for swirl flaps (2) forward in direction of arrow.

Lift the connecting lever (1) with a screwdriver in direction of arrow until the guide lever (3) is disconnected from the connecting lever (1).

Fig 11: Locating Swirl Flaps Drive Unit And Guide Lever

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Unclamp retaining clamps (1) from the seal holder.

Fig 12: Identifying Retaining Clamps

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Unclamp retaining clamps (1) from the seal holder.

Remove the seal holders (2) with swirl flaps.

Fig 13: Identifying Retaining Clamps And Seal Holders

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Installation note:

All swirl flaps must be opened to install the seal carrier (1).

This prevents jamming of the seal carrier (1).

Clean the sealing surfaces on the intake plenum (2).

Position the seal holder (1) with open swirl flaps on the intake plenum (2).

Fig 14: Locating Seal Carrier

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Installation note:

Note fixing (2) on the seal holder (1).

Attach the seal holder (1) with the retaining clamps on the air intake system.

Fig 15: Locating Seal Holder With Retaining Clamps On Air Intake System

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Before the swirl flap drive can be installed, the connecting lever (1) must be positioned toward the intake plenum.

Prepare the connecting lever (2) for the guide (1) on the intake plenum.

Fig 16: Locating Guide On Intake Plenum

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The adjustment lever (1) on the swirl flap drive is worked at the marked area.

Fig 17: Locating Adjustment Lever On Swirl Flap Drive Worked

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The adjustment lever (1) on the swirl flap drive must be positioned with the connecting lever (2) of the swirl flaps toward the guide groove (3) on the intake plenum before the swirl flap drive can be attached.

Fig 18: Identifying Adjustment Lever And Swirl Flaps Toward Guide Groove On Intake Plenum

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Secure the actuator drive (1) with screws (3).

Fig 19: Identifying Swirl-Flap Actuator And Screws

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Installation note:

Position the air intake system on the cylinder head.

Tack the air intake system on in the following order (from 1 to 4).

Fig 20: Identifying Air Intake System On Cylinder Head

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Installation note:

To ensure tightness of the air intake system, the tightening sequence must be complied with.

Tighten the air intake system in sequence (1 to 7).

Tightening torque: 11 61 1AZ .

Fig 21: Air Intake System Bolts Tightening/Loosening Sequence

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Assemble engine.

Check differentiated air intake system for leak tightness.

Check function of DDE.