Intake Air Duct: Service and Repair

Charge Air Pipe

To remove
1. Remove the upper engine cover.







2. Undo the bolt securing the bypass pipe at the turbocharger intake pipe.
3. Remove the charge air bypass valve from the charge air pipe.
4. Unplug the connector on the charge air pipe for the pressure/temperature sensor.
5. Undo the hose clips at the throttle body and charge air hose.
Man.: Detach the venturi hose from the charge air pipe







6. Unscrew the bolt securing the charge air pipe to the bracket on the cylinder head and remove the pipe. Cover the throttle body and charge air hose.

IMPORTANT: If the charge air pipe is being replaced; first dismantle the pressure/temperature sensor. Then, fit it to the new charge air pipe. Apply petroleum jelly or the equivalent sparingly to the O-rings.

To fit
1. Remove the seal from the throttle body and delivery hose.
2. Carefully connect the charge air pipe to the throttle body and screw it to the bracket on the cylinder head.
Man.: Connect the venturi hose to the charge air pipe.







IMPORTANT:
^ Check the O-ring on the throttle body and replace if necessary. To facilitate fitting the Oring, apply a thin layer of Vaseline or equivalent, part no. 30 06 665
^ To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 30 15 815 Cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.

3. Connect the charge air hose to the pipe. Tighten the hose clip and bolt on the cylinder head.







4. Plug in the pressure/temperature sensor connector.
5. Connect the bypass valve and tighten the bypass pipe on the turbocharger intake pipe. (6 lbf ft)
6. Fit the upper engine cover.