13 54 045 Removing and installing/sealing a throttle assembly (S54): Installation:

Removal of a throttle assembly is described separately from its installation.

Clean sealing faces (1). Note correct position of adapter sleeves (2).

Fig 1: Cleaning Sealing Faces

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Clean sealing face of cylinder head.

Replace O-ring (1) in cylinder head.

Fig 2: Replacing O-Ring In Cylinder Head

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Position actuating lever (1) in such a way that it is flush with mount (2) for connecting pipe.

Hold actuating lever (2) and insert throttle assembly until it rests against engine block.

Fig 3: Positioning Actuating Lever

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Tighten down screw connection of corresponding throttle assembly.

Fig 4: Tightening Down Screw Connection Of Corresponding Throttle Assembly

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Push actuating shaft into bearings of throttle assemblies. Start on throttle assembly 1.

Feed out actuating lever (3) when pushing actuating shaft (1) into bearings of throttle assemblies (2).

Fig 5: Pushing In Actuating Shaft

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Insert fitting screw (1) as illustrated into actuating lever of throttle assembly 1.

Fig 6: Inserting Fitting Screw

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Tighten down screw connection of actuating lever with actuating shaft. Observe the following instructions in so doing:

• Use screws and nuts only once.
• Only turn nut (2) and grip screw (1).
• To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft if at all possible. In this way, no torque is exerted on actuating lever.
• Retighten nut to tightening torque of 7 N.m.
  Fig 7: Tightening Down Screw Connection Of Actuating Lever

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Ball ends are turned to each other.

Fig 8: View Of Actuating Lever Assembly

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Insert fitting screw (1) as illustrated into actuating lever (2) of pull rod.

Observe position of actuating lever (2) to actuating lever (3).

Fig 9: Inserting Fitting Screw

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Tighten down screw connection of actuating lever on long pull rod. Observe the following instructions in so doing:

• Use screws and nuts only once.
• Only turn nut (2) and grip screw (1).
• To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft if at all possible. In this way, no torque is exerted on actuating lever.
• Retighten nut to tightening torque of 7 N.m.
  Fig 10: Tightening Down Screw Connection On Long Pull Rod

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Insert screw (1) in all other actuating levers and fit nut (2).

Fig 11: Inserting Screw And Fitting Nut

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Clip in pull rod (1) for throttle actuator on throttle side (long pull rod).

Fig 12: Clipping In Pull Rod On Throttle Side

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Clip in pull rods (1) on all throttle assemblies.

Fig 13: Clipping In Pull Rods On Throttle Assemblies

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Carry out basic throttle adjustment. Refer to 13 54 010 Adjusting basic throttle setting (S54)  .

Assemble engine.

• Service functions
• DME system checks
• Function test

Installation: 

Read out fault memory of control unit of Digital Motor Electronics (DME).

Check stored fault messages.

Rectify faults.

Now clear the fault memory.