Clean intake ports

CAUTION: Swirling dirt particles caused by compressed air .
Injury hazard!

Collect dirt particles, e.g. when blowing out, use cloth to do so.
Wear safety goggles.

NOTE: RISK OF DAMAGE
Engine damage due to walnut shell granules in the combustion chamber .
If walnut shell granules penetrate the combustion chamber while cleaning the intake ports, engine damage may occur .

Always clean the intake port with valves of the relevant cylinder closed.
Set the piston of the relevant cylinder to the TDC.
If walnut shell granules have entered the combustion chamber: Do not turn or start the engine hand force. Disassemble the cylinder head and clean all components.

Ready the special tool 2 208 034 , the walnut shell granules and a standard vacuum cleaner.

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Have the special tool 2 356 969 ready.
NOTE: TECHNICAL INFORMATION
The front area of the beam probe is marked with two notches. These may additionally be highlighted in color.
During the blasting process, only pull the beam probe out of the jet vacuum adapter until the mark becomes visible.

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Observe the mark (1).
Open the blasting device (1).

Pour in the walnut shell granules (2).

TECHNICAL DATA SPECIFICATION

Walnut shell granules
	Quantity for each blasting process	2 l

Close the blasting device (1).

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Close the valve (1) on the blasting device (2).

Connect compressed air (3).

TECHNICAL DATA SPECIFICATION

Cleaning the intake ports
	Operating pressure	6 bar... 8 bar

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Attach the beam probe (2) to the blasting device (1).

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Connect the vacuum cleaner (1) to the special tool 2 410 274 .

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Prepare 3 standard feeler gauges (1) with a thickness of 0.05 mm.
Cut the 3 feeler gauges (1) to a length of 25 mm.

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NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
Position the prepared feeler gauges (1) on the blow-by-ports of the cylinder head (2).
Ensure that the blow-by ports on the cylinder head (2) are closed by the feeler gauges (1).

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NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
Insert and position the cylinder head covers (1).
Ensure that the feeler gauges (arrows) are correctly positioned between the cylinder head cover (1) and the blow-by ports of the cylinder head (2).

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Position the cylinder head cover (A).
Make sure that the cylinder head cover (A) does not touch the high pressure pump bracket!

Tighten all the screws in the sequence from (1) to (21) hand-tight.

TIGHTENING TORQUES SPECIFICATION

Cylinder head cover to cylinder head
M6X30	Joining torque	8 Nm

Tighten all screws in the sequence (1) to (21).

Fig 1: Cylinder Head Cover Screws Tightening Sequence

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TIGHTENING TORQUES SPECIFICATION

Cylinder head cover to cylinder head
M6X30	tightening torque	11 Nm

Clean the marked areas (1) with a brush.

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NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
Insert special tool 2 410 274 into the tangential port (1) of the cylinder to be cleaned.

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NOTE: TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.
Insert special tool 2 208 033 into special tool 2 410 274 in arrow direction .

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Turn on the vacuum cleaner (1).

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NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
Move and rotate the beam probe in arrow direction.
This removes all contamination in the tangential port.
Open the valve (1).

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Slide the locking lever (1) forward in the arrow direction.
Actuate the valve (2) to release the compressed air.
Actuate valves (1) and (2) to release the walnut shell granules and the compressed air.

Clean the swirl port.

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TECHNICAL DATA SPECIFICATION

Cleaning the intake ports
	Blast duration with walnut shell granules	Approx. 20 s
	Blast duration with pure compressed air for the complete blowing out of walnut shell granules	Approx. 10 s

Close the valve at the beam probe.
» Check the pressure drop at the pressure tester.
Repeat the following work steps consecutively on all other cylinders:
- Turn the piston for the cylinder to be cleaned to the top dead center
- Clean intake ports
Tighten all the screws on the cylinder head cover (A) in the sequence (21) to (1).

Fig 2: Cylinder Head Cover Screws Tightening Sequence
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NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
Feed out and remove the feeler gauges (1) on the blow-by-ports of the cylinder head (2).

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Clean the blow-by channels (2) with an air gun (1).

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Make sure that the blow-by ports (1) are free of walnut shell granules.

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Make sure that the inlet ports (1) are free of walnut shell granules.

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