11 61 550 Removing and installing/replacing air intake plenum (N47 D20 O1)

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 cable. See NEGATIVE BATTERY LEAD .
Remove acoustic cover. See 13..... REMOVE ACOUSTIC COVER (N47 D20 O/T1) .
Remove lower section of microfilter housing (only E9x, E84).
Remove pressure pipe at throttle body.

Push the cable clamps (1) on both halves apart and pull them off the holder.

Fig 1: Identifying Cable Clamps

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

Disconnect plug connection (3) from the electric changeover valve (4) of the engine mount.

Detach the electric changeover valve (4) in direction of arrow and lay to one side.

Fig 2: Identifying Plug Connection From Electric Changeover Valve

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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 3: Identifying Cable Clamps On Intake Plenum

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

Fig 4: Identifying Screws On Exhaust-Gas Recirculation Cooler

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Release screws (1).

Remove the air intake system toward the top.

Fig 5: Identifying Intake System And Screws

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

Fig 6: Locating Exhaust-Gas Recirculation Pipe

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Installation note:

Replace O-ring (1).

Replace beaded metal gasket (2).

Fig 7: Identifying Beaded Metal Gasket And O-Ring

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Replace intake plenum.

Release screws (3).

Modify the swirl-flap actuator (2).

Fig 8: 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 9: Identifying Swirl Flaps Drive Unit And Guide Lever

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Unclamp retaining clamps (1) from the seal holder.

Fig 10: Identifying Retaining Clamps

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Unclamp retaining clamps (1) from the seal holder.

Remove the seal holders (2) with swirl flaps.

Fig 11: Identifying Retaining Clamps And Seal Holders

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Installation note:

Open all swirl flaps to install the seal holder (1). This prevents jamming the seal holder (1).

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

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

Fig 12: Identifying Sealing Ring On Intake Plenum

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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 13: Identifying 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 14: Identifying Guide On Intake Plenum

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

Fig 15: Identifying Adjustment Lever

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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.

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

Fig 16: Identifying Adjustment Lever And Swirl Flaps Toward Guide Groove On Intake Plenum

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Fig 17: Identifying Actuator Drive 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 18: 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 19: Air Intake System Bolts Tightening/Loosening Sequence

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Assemble engine.

Check air intake system for leaks.

Check function of DDE.