2. Remove the air filter housing.
3. Drain the coolant.
4. Loosen the screw (1) securing the turbocharger to the lower part of the exhaust manifold.
5. Remove the EGR mount. (Only for engines with code MS3. Engine version: Euro 3.)
6. Remove the air manifold.
7. Remove the decorative cylinder head panel.
8. Disconnect the clamps (2).
9. Disconnect the coolant hose (3) from the radiator.
10. Disconnect the ventilation hose (4) from the expansion tank.
11. Remove the catalytic converter temperature sensor (Only for engines with code KA 1: presence of a diesel particulate filter, starting from 25.9.06.)
12. Remove the hose (5) connecting the engine to the intake air duct, together with the ventilation hose (6). To do this, remove the clamp from the turbocharger pipe and disconnect the connector of the pressure sensor (14) at the outlet of the air filter. Disconnect the ventilation hose (6) from the oil separator.
13. Disconnect the wiring harness, marking the connection points of the connectors.
(Material created based on the website: MERCEDESMAN.ru)
14. Disconnect the return fuel line from the injectors.
15. Remove the vacuum pump (17) by unscrewing the screws (16).
16. Remove the vacuum accumulator (7). (Only for engines 646.982/983.)
17. Move the vacuum tubes (8) with the vacuum accumulator (7) to the side as far as possible.
18. Remove the high pressure fuel pump (hereinafter referred to as high pressure fuel pump) (see figure VN 2.041).
19. Unscrew the screw (11).
20. Remove the bracket (12).
21. Remove the clamp and disconnect the fuel return line.
VN 2.040
Removing the cylinder head
1. Screw
2. Clamps
3. Cooling system hose
4. Ventilation hose
5. Air duct
6. Crankcase ventilation hose
7. Vacuum accumulator
8. Main vacuum tube
9. Hose
10. Brackets
11. Screw
12. Brackets
13. Screw
14. Air filter outlet pressure sensor (B28/5)
15. Ventilation line heater (R39/1)
Removing the vacuum pump
16. Screw
17. Vacuum pump
VN 2.041
Removing the fuel injection pump
1. Vacuum pump
2. High pressure fuel line
3. Fuel injection pump
4. Fuel lines
5. Screws
6. Sealing ring
7. Fuel injection pump drive shaft
8. Fuel temperature sensor (B50 or B50/3)
9. Fuel supply control valve (Y94 bkb Y94/3)
VN 2.042
1. High pressure fuel lines supplying fuel to the injectors
2. High pressure fuel line for supplying fuel to the high pressure fuel pump
3. Screw
4. Banjo bolt type connector
5. Pressure sensor in the high-pressure fuel pump (B4/6)
6. Fuel pressure regulating valve (Y74)
7. Screw for fastening the high pressure fuel pump
8. Return fuel line
VN 2.043
Removing injectors
1. Impact puller
2. Impact puller screw rod
3. Threaded adapter
4. Camshaft position sensor (B6/17)
23. Move the cylinder head wiring harness to the side.
24. Remove the injectors (see figure VN 2.043).
When installing, the clamp screw should be tightened according to the scheme 7 Nm + 90° + 90°.
25. Remove the oil filler pipe (2) of the automatic transmission (only with automatic transmission) (see figure VN 2.044).
26. Disconnect the coolant hose (1) from the cylinder head by loosening the clamp (4) and moving the hose to the side.
27. Unscrew the screw (5) of the clamp securing the oil dipstick guide tube (6).
28. Remove the oil supply pipe to the turbocharger (see figure VN 2.045).
29. Unscrew the screws (13) (see fig, VN 2.040) fastening the turbocharger to the exhaust manifold.
30. Check the correct initial settings of the camshafts (see, figure VN 2.046) To do this, you need to check the relative position of the camshafts and the relative position of the crankshaft and camshaft system.
VN 2.044
Removing the cylinder head (shown on engine 646.982 starting with number 007338)
1 Coolant hose
2. Automatic transmission oil filler pipe
4. Clamp
5. Screw
6. Oil dipstick guide tube
7. Screws
8. Cylinder head mounting screws
VN 2.045
Removing the oil supply pipe to the turbocharger
1. Engine air inlet duct
2. Oil supply line
3. Clamp
4, 5. Screws
6. Branch pipe
7. Air filter outlet pressure sensor (828/5)
8. Ventilation line heater (R39/1)
VN 2.046
1. Crankshaft pulley
2. Intake valve camshaft
3. Pin fixing the position of the inlet camshaft gear
4. Camshaft bearing
5. Marks on gears