11 61 550 Removing and installing/replacing intake plenum (N57 Diesel)

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 work:

Remove INTAKE SILENCER HOUSING .
Remove THROTTLE VALVE at intake plenum.

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

Fig 1: Identifying Cable Clamps

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Disconnect plug connection (1) from the electric changeover valve (2) of the engine mount.

Detach the electric changeover valve (2) in direction of arrow and lay to one side.

Disconnect plug connections (3) on preheating control unit.

Release screw (4) on guide tube (oil dipstick).

Disconnect plug connection (5).

Fig 2: Identifying Electric Changeover Valve, Screws, And Plug Connections

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Release screws (1).

Remove cable channel (2) from the cylinder head cover. To do this unlock and detach connectors (3) and (4).

Slide cable channel to one side.

Fig 3: Identifying Cable Channel, Connectors And Screws

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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 4: Identifying Battery Cable, Nut Plug Connection, And Cable Clamps

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

Fig 5: Identifying Screws On Exhaust-Gas Recirculation Cooler

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Release screws (1).

Remove intake system upwards.

Graphic shows N47T.

Fig 6: Identifying Intake System And Screws

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

Fig 7: Removing Exhaust-Gas Recirculation Pipe

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Installation note:

Replace O-ring (1).

Replace beaded metal gasket (2).

Fig 8: Identifying Beaded Metal Gasket And O-Ring

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Installation note:

Replace gaskets (1).

NOTE: Graphic shows N47.

Fig 9: Identifying Gaskets

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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: Identifying Drive Unit For Swirl Flaps, Connecting Lever, And Guide Lever

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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 12: Identifying Connecting Lever And Guide

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

Fig 13: Identifying Adjustment Lever On Swirl Flap Drive

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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 14: Identifying Adjustment Lever, Connecting Lever, And Guide Groove On Intake Plenum

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

Fig 15: Identifying Actuator Drive And Screws

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Graphic shows N47T.

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 16: Identifying Air Intake System Fastening Order

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Graphic shows N47T.

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 17: Air Intake System Bolts Tightening/Loosening Sequence

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Assemble engine.

Check air intake system for leaks.

Check function of DDE.