Vehicles with a diesel engine.
Removing
1. Disconnect air intake hose 1 (see illustration).
2. Remove the mixer 2 by disconnecting the low pressure hose 3 from the EGR valve, the charge air hose 4 from the mixer, the pipe 5 of the EGR system from the bottom of the mixer (see illustration 9.1).
3. Unscrew four bolts of fastening and disconnect the mixer from the inlet module.
4. Unscrew the fastening bolts (see arrows in illustration) and disconnect the fuel filter 1 from the inlet module 2 without removing the hoses from it.
5. Remove the low-pressure brake booster vacuum hose from the fitting on the right side, when viewed in the direction of travel, by squeezing the side leashes and releasing the hose from the mount on the manifold.
6. Disconnect the low pressure hose from the boost air pressure sensor.
7. Vehicles manufactured since 9/00. Unscrew the mounting bolts 2 of the oil separator 1, mark the attachment points for all hoses, disconnect them and remove the oil separator (see illustration).
8. Unscrew the bolt that secures the oil filler pipe to the intake module.
9. Unscrew three bolts of fastening of a heat-shielding shield.
10. Unscrew the bolts securing the intake module to the cylinder head, removing the engine lifting lugs and marking the mounting position of the engine oil dipstick guide, as well as all holders and wire harness clamps.
11. Remove the air intake tube from the intake module by moving the locking lever 1 first to the right, when viewed in the direction of travel, and then pressing it down (see arrows in illustration).
12. Disconnect the inlet module.
Installation
13. Lay eight new profile sealing gaskets on the cylinder head.
14. Install the intake module, connect the air intake tube to it and fix it with the lever.
15. Fix the inlet module on the cylinder head with bolts with a tightening torque of 14 Nm.
At the same time, install the guide tube of the engine oil level indicator rod by screwing in the bolt of its fastening.
16. Reinstall all holders and wire harness clamps.
17. Install the heat shield with three bolts.
18. Install and secure the oil filler pipe to the inlet module by tightening the mounting bolts to 9 Nm.
19. Vehicles manufactured since 9/00. Install the oil separator, connect the hoses, I guided by the marks made before removal and reference marks (see illustration 9.7).
20. Connect the low pressure hose to the boost air pressure sensor.
21. Fix the low pressure hose of the vacuum booster in the holders on the intake manifold and connect it to the fitting on the manifold.
22. Bolt the fuel filter to the intake module.
23. Reinstall the air mixer after cleaning the sealing surfaces of the intake module and mixer, and installing a new rubber seal.
24. Fix the mixer with bolts on the inlet module, tightening them to 9 Nm.
25. Connect the pipeline of the air recirculation system, tightening it with a force of 9 Nm.
26. Install the boost air hose and secure it with a clamp.
Attention! Before doing this, carefully clean the hose fitting, because over time the hose may break during operation.
27. Connect the low pressure hose to the recirculation valve.
28. Connect the air intake hose.