Procedures

Removing and installing oil filler neck
Removal
1. Disconnect the battery and cover terminal or battery.
2. Remove the complete air cleaner assembly:
2.1. Unclip oil filler neck from upper part of the air cleaner.






2.2. Undo hexagon-head bolt M6 x 34.






2.3. Pull plug off the mass air flow sensor. To do this, push the button and simultaneously pull the plug off. Loosen hose clamp on the throttle body, unclip cable on the air cleaner housing and remove the air cleaner system.
The plug is shown turned to show the button more clearly.






3. Pull plug off the throttle body. Undo 4 hexagon-head bolts (M6 x 40) and remove the throttle body.






4. Release vent line. To release vent line, push the outer unlocking ring (arrows) and simultaneously pull out the line.






5. Remove intake distributor - centre. Loosen inner hose clamps at intake distributor. Loosen fit by swiveling intake distributor.






6. Tighten inner hose clamps again. Loosen outer hose clamps. Swivel to loosen fit.
7. Loosen inner clamp hoses and remove intake distributor.






8. Remove generator from bracket. To do this, relieve drive belt, turn the tensioning roller (wrench size 24 mm) clockwise and simultaneously remove the belt from the tensioning roller. Remove belt from drive wheel of generator.






8.1. Undo upper right-hand fastening screw on generator (1) by approximately 3 turns. A gentle tap on the fastening screw loosens the front fastening bushing in the generator arm. Unscrew fastening screw (2).










8.2. Turn generator clockwise and remove from bracket.






8.3. Set down generator with connected lines.






9. Undo two hexagon-head bolts (a/f 10 mm) on the oil filler neck. Pull oil filler neck out of the crankcase.

Installation
1. Fit new sealing ring (42 x 4) on oil filler neck. Coat new sealing ring, e.g. with tire mounting paste, and fit oil filler neck on crankcase.
2. Secure new micro-encapsulated hexagon-head bolts (M6 x 16). Tightening torque: 10 Nm (7.5 ft. lbs.).






3. Fit intake distributor. Ensure that the vacuum line is seated correctly in the right rubber sleeve.






4. Centre the intake distributor. Push both rubber sleeves onto the intake distributor up to the marking (line). Check distance between intake distributor and support for hydraulic pump, they must be at least 5 mm apart.
Arrow show marking (line) on the intake distributor






5. Fit throttle body. Insert new sealing ring in the correct position.






5.1. Secure 4 hexagon-head bolts (M6 x 40). Tightening torque 10 Nm (7.5 ft. lbs.). Fit plug.






6. Install generator.
Tightening torque of the hexagon-head bolt M10 x 145 (8.8) (No.1) 46 Nm (34 ft. lbs.).
Tightening torque of the hexagon-head bolt M10 x 30 (No.2) 46 Nm (34 ft. lbs.).
7. Fit drive belt.
8. Install air cleaner assembly.

Note;
- Before installation, make sure that the rubber sleeves (2 ea.) are present and properly seated in the transverse lock panel. Clip oil filler neck onto upper part of the air cleaner.

9. Connect battery.
10. Carry out adaptation.
10.1. Switch on ignition.
10.2. Wait one minute. (Do not operate accelerator pedal).
10.3. Switch off ignition for at least 10 seconds.
10.4. Read out fault memory.

Model year as of 2004