Removing Intake-Air Distributor, Side 1-3

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws: (E..) for external Torx, (T..) for internal Torx. 
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

1. Attach or set up fire hazard warning sign in a clearly visible position.
   Fig 1: Example Of Warning Sign

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2. Open line connections on left in engine compartment.
   1. 2.1. Pull off coolant vent line -1-  on the reservoir.
   2. 2.2. Disconnect and remove carbon canister line -2-  .
   3. 2.3. Pull off vacuum line -3-  .
      Fig 2: Identifying Left Engine Compartment Hose Connections

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3. Expose lines above the fuel distributor pipe.
   1. 3.1. Unclip the lines from the holders and secure them on the coolant reservoir with a tie-wrap.
      Fig 3: Securing Lines To Coolant Reservoir

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4. Remove fine fuel filter.

   → 206019 REMOVING AND INSTALLING FINE FUEL FILTER  .

   1. Screw-type clamp - check position
   2. Holder
   3. Retaining clip
      Fig 4: Removing Fuel Filter

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5. Remove oil-filter console -1-  .
   1. 5.1. Place a clean cloth under the console and have additional cloths ready for absorbing residual oil.
   2. 5.2. Remove oil filter (due to oil return).
   3. 5.3. Loosen two hexagon socket head bolts (M8 x 16) -2-  on the oil-filter console holder, but only unscrew the top one.
   4. 5.4. Unscrew two external Torx screws (E12, M8 x 25) -3-  at the sides.
   5. 5.5. Remove oil-filter console and replace seal.
   6. 5.6. Plug drain bore.
      Fig 5: Identifying Oil-Filter Console

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6. Remove the generator.

   → 272219 REMOVING AND INSTALLING GENERATOR  .

7. Remove secondary-air pump.

   → 266519 REMOVING AND INSTALLING SECONDARY-AIR PUMP  .

   1. Secondary-air pump
   2. Connecting line on cylinder bank 4-6, top
   3. Fastening screws on holder
   4. Cable plug
      Fig 6: Identifying Secondary-Air Pump

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8. Disconnect intake air line on turbocharger 1-3 and engine compartment bracket.
   IMPORTANT: Intake air line cannot be removed without removing the engine!
   1. 8.1. Unscrew two M6 external Torx screws -arrows-  and one M6 collar nut -1-  . Pull off intake air line with retaining bracket.
      Fig 7: Locating Intake Air Line Flange 1-3

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   2. 8.2. Replace O-ring when assembling and grease with Kluber Syntheso Glep (Part No. 000.043.204.68).
   3. 8.3. Press intake air line up out of the bracket in the engine compartment -arrow-  .
      Fig 8: Locating Intake Air Line Bracket

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9. Remove holder -1-  on intake-air distributor 1-3.
   1. 9.1. Unscrew two external Torx screws (E10, M6 x 12) -2-  .
      Fig 9: Identifying Intake-Air Distributor Holder 1-3

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10. Disconnect wire harness and fuel line from the fuel collection pipe. Soak up emerging residual fuel with a cloth.
    1. 10.1. Carefully pull up the cable rail -3-  on the fuel collection pipe and press it aside.
    2. 10.2. Disconnect cable plugs -arrows-  at the fuel injectors 1-3.
    3. 10.3. Loosen the fuel line connection -2-  (a/f 17) and make sure to counter at the fuel collection pipe while doing this (a/f 19).
       Fig 10: Locating Cable Rail And Fuel Line 1-3

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11. Disconnect fuel collection pipe with fuel injectors.
    1. 11.1. Unscrew two external Torx screws (E10, M6 x 12).
    2. 11.2. Pull off the fuel collection pipe with fuel injectors at the intake-air distributor and set it aside.
12. Remove intake-air distributor -1-  .
    1. 12.1. Unscrew six hexagon socket head bolts (a/f 5, M6 x 25) -3-  and remove the intake-air distributor.
    2. 12.2. Use a 5-mm socket-wrench insert with a ball joint to loosen hidden screws and a bar magnet to pull them out. 
    3. 12.3. Replace molded seals -2-  .
       Fig 11: Identifying Intake-Air Distributor 1-3

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13. Clean fuel injectors in an ultrasound bath.
    1. 13.1. To do this, remove spring clamps and pull the fuel injectors out of the fuel collection pipe one at a time.
    2. 13.2. Before cleaning the fuel injectors, mark them with a water-resistant marker to facilitate re-installation.
14. Replace O-rings on the fuel injectors.