Procedures
Crankcase ventilation and electronic throttle module (ETM), cleaning
Note! Some variation in the illustrations may occur, but the essential information is always correct.
Removing
Remove:
- the battery negative cable. Refer to: Battery, disconnecting Battery Disconnecting
- the auxiliaries belt. Use999 7109 Wrench 999 7109 Wrench
- the inlet hose for inlet hose to the control module, if applicable.
Remove the oil dipstick pipe.
Remove:
- the screw for the charge air pipe over the engine
- the clamp for the delivery pipe to the power steering pump from the intake manifold
- the charge air hose from the charge air cooler (CAC)
- the charge air pipe from the hose on the turbocharger (TC).
Remove the charge air pipe.
If the vehicle has lock brackets
Remove:
- the lock bracket (2) by removing the screw (1)
- the pipe nipple at the pump.
Place paper towels under the power steering pump to absorb any power steering pump fluid.
Install a hose clamp on the power steering pump hose.
Remove the pressure line from the power steering pump. Plug the power steering pump and pipe using rubber plugs.
Disconnect the connector from the belt cover above the power steering pump.
Remove the power steering pump's 3 x mounting screws through the pulley holes.
Remove:
- the servo hoses and the engine coolant hoses from their holders/clips. Remove the tie strap for the servo hose by the suspension turret
- the servo reservoir from its mounting on the expansion tank for coolant
- the connector and place the servo reservoir on the engine.
Place the power steering pump on the engine.
Removal of alternator
Remove:
- the upper screw for the generator
- the screws common to the generator and the compressor.
Slacken off the lower screws for the compressor (so that there is some clearance).
Rest the generator against the radiator and the A/C compressor.
Removing the fan shroud
Remove the inlet pipe to the air cleaner (ACL) housing.
Disconnect both the connectors for the engine cooling fan (FC).
Remove:
- The evaporative emission system (EVAP) valve from the engine cooling fan (FC) shroud
- the 4 x tie straps that hold the cable harness secure at the fan shroud.
Note! Certain vehicles have three tie straps and a clip holding the cable harness at the fan shroud.
Lift out the hose for the expansion tank from the holders on top of the fan shroud
Remove the 2 x screws holding the fan shroud.
Carefully lift up the engine cooling fan (FC).
Removing the throttle body
Slacken off the hose clamp for the charge air pipe on the throttle body (TB).
Remove the charge air pipe from the throttle body.
Remove the 4 x screws for the throttle body.
Cleaning
Note! For tightening torques, see: Tightening torque Tightening Torque
Cleaning the throttle body
Lift up the throttle body and position it between the radiator and the intake manifold.
Position paper underneath the throttle body.
Clean the throttle and the air duct according to the following method.
Note! Do not use compressed air when cleaning the throttle body.
Clean the throttle body (TB) using cleaning agent 1161826 and apply using a brush or similar.
Ensure that all deposits are removed from the surfaces marked in the illustration.
Carefully wipe clean the inside of the air channel on both sides of the throttle disc. Also wipe clean the edge of the throttle disc.
Installing the throttle body
Install:
- the throttle body. Use a new gasket
- the 4 x screws to contact.
Cleaning crankcase ventilation
Remove the pipe screws from intake manifold.
Disconnect the hose (1) from the nipple.
Remove the oil filler cap.
Blow the hose (1) clean with compressed air.
Clean the hose with an electrical cable - 2.0 mm.
Note! If the hose is clogged, use a welding rod (max - 2.0 mm , approximately 250 mm long) to clean the hose.
Clean the nipple using a - 2.0 mm drill bit or a welding rod.
Install:
- the hose on the nipple
- the pipe screws with new gaskets
- the oil filler cap.
Raise the vehicle.
Remove the splashguard under the engine.
Tighten:
- the pipe screws.
- the four screws for the throttle body (TB).
Install the splashguard under the engine.
Lower the vehicle.
Installing
Install the charge air hose to the throttle body and tighten the clamp.
Installing alternator
Install:
- the generator in the correct position
- the upper screw, but do not tighten
- the 2 x screws common to the generator and A/C compressor, but do not tighten.
Tighten:
- the upper screw. Tighten to 24 Nm
- the lower screws for the A/C compressor.
- the 2 x screws common to the generator and the A/C compressor.
Installing the fan shroud
Carefully lower the fan shroud and align with the holders. Route the cable harness behind the holder (3).
Tighten the 2 x mounting screws.
Press the hose down from the expansion tank into the holder on the fan shroud
Secure the cable harness by the fan shroud using tie straps (1) and (2), see the illustration.
Install the evaporative emission system (EVAP) valve.
Connect the engine cooling fan (FC) connectors.
Install:
- the charge air pipe to the turbocharger (TC) and the charge air cooler (CAC).
- the intake manifold to the air cleaner (ACL) housing.
Install:
- the power steering pump in the correct position
- the 3 x screws through the pulley.
Install the delivery pipe on the power steering pump. Use a new O-ring on the pressure line.
Remove the hose clip.
If the vehicle has lock brackets
Install the lock bracket (2).
Tighten the screw (1).
Note! There may be a gap (3) of a few millimetres between the pipe coupling and the power steering pump. Bend the bracket so that the twelve edged mounting on the bracket is on the nut.
Install:
- the auxiliaries belt. Use999 7109 Wrench 999 7109 Wrench
- the servo reservoir in its mounting on the expansion tank
- the tie strap around the servo hose at the spring strut turret
- the servo hose in the holder on the belt cover on the power steering pump
- the connector with holder on the power steering pump.
Install:
- the charge air hose on the charge air cooler (CAC).
- the screw for the charge air pipe above the engine and clamp for power steering pump delivery lines from the intake manifold
- cold air inlet hose to control module.
Check the level in the servo reservoir and top up if necessary.
Install:
- the battery negative cable. Refer to: Battery, disconnecting Battery Disconnecting
Start the engine and check for leakage.