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

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:

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, Plug Connections And Screw

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Release all cable clips (1) on the intake plenum.

Release screw (3) of wiring harness on the plenum.

Release nut (4) on alternator.

Tightening torque: 12 52 2AZ .

Remove positive battery cable (5) and lay to one side.

Fig 3: Identifying Cable Clips, Positive Battery Cable, Screw And Nut

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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 and 2).

Remove intake system upwards.

Fig 5: Identifying Intake System 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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Installation note:

Replace gaskets (1).

Fig 8: Identifying Gaskets

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Replace intake plenum.

Release screws (3).

Modify the swirl-flap actuator (2).

Fig 9: 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 10: Lifting Connecting Lever With Screwdriver

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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 11: 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 12: Locating 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 13: Identifying Oil Return Cover And Screws

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

Fig 14: 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 15: Intake Duct Bolts Tightening Sequence

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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 9).

Tightening torque: 11 61 1AZ .

Fig 16: Intake System Bolts Tightening Sequence

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Assemble engine.

Check air intake system for leaks.

Check function of DDE.