Air Injection Hose/Tube: Service and Repair

WM 266719 Removing and installing secondary-air line

Tools

Technical values

Preliminary work

1. Remove engine compartment lid.
-> 557819 Removing and installing engine compartment lid 557819 Removing and Installing Engine Compartment Lid.
2. Remove resonance tube.
-> 247419 Removing and installing resonance tube Service and Repair.
3. Remove intake-air distributor for cylinder bank 1-3.
-> 244619 Removing and installing intake-air distributor Service and Repair.
4. Remove rear wheel housing liner.

Only for removing secondary-air line for cylinder bank 4-6:
5. Remove oil filler neck.
-> 171519 Removing and installing oil filler neck Service and Repair.
6. Disconnect negative terminal of the battery.

Removing secondary-air line

Removing secondary-air line for cylinder bank 1-3

1. Unscrew external Torx screw (E10, M6 x 20) -2- on the secondary-air line -1- at the cylinder head.

Secondary-air line at cylinder head

2. Unclip connector for secondary-air pump at the oil filler neck holder.
3. Unscrew external Torx screw (E10, M6 x 30) -2- at the bracket.

Secondary-air line at bracket

4. Unscrew cap screw (a/f 27) -2- on the secondary-air line at the shut-off valve.

Secondary-air line connection at secondary-air pump

5. Pull secondary-air line -1- out of the connection in the cylinder head.

Secondary-air line at cylinder head

6. Guide secondary-air line up out of the engine compartment.
7. Replace two sealing rings on the connecting flange of the secondary-air line.

Removing secondary-air line for cylinder bank 4-6

1. Unscrew external Torx screw (E10, M6 x 20) -2- on the secondary-air line -1- at the cylinder head.

Secondary-air line at cylinder head

2. Release and pull off cable plug -1- on oil pressure sensor.

Connector for oil pressure sensor

3. Remove line connections at the starter.
3.1. Remove protective cap.
3.2. Unscrew M8 hexagon nut (a/f 13) on the solenoid switch for the starter.
3.3. Unscrew M6 hexagon nut (a/f 10) on the solenoid switch for the starter.
3.4. Pull wire harness off the connections and set it aside.
4. Remove coolant hoses at the oil/water heat exchanger.
4.1. Clamp coolant hoses.
4.2. Loosen spring band clamps -1-.
4.3. Place cleaning cloths underneath the connections to collect emerging coolant.
4.4. Pull off coolant hoses.
4.5. Close off connections at the oil/water heat exchanger and coolant hoses with stoppers.

Coolant connections at oil/water heat exchanger

5. Unscrew external Torx screw (E10, M6 x 25) -2- on the secondary-air line -1- at the crankcase.

Screw securing secondary-air line 4-6 to crankcase

6. Unscrew cap screw (a/f 27) -1- on the secondary-air line at the shut-off valve.

Secondary-air line connection at secondary-air pump

7. Pull secondary-air line -1- out of the connection in the cylinder head.

Secondary-air line at cylinder head

8. Guide secondary-air line up out of the engine compartment.
9. Replace two sealing rings on the connecting flange of the secondary-air line.

Installing secondary-air line

Installing secondary-air line for cylinder bank 1-3

1. Position secondary-air line.
2. Guide secondary-air line -1- into the connection in the cylinder head.
3. Fit cap screw (a/f 27) for the secondary-air line at the shut-off valve.

Secondary-air line connection at secondary-air pump

4. Fit and tighten external Torx screw (E10, M6 x 30) -2-.

Secondary-air line at bracket

=> Tightening torque: 13 Nm (9.5 ftlb.)
5. Fit and tighten external Torx screw (E10, M6 x 20) -2- on the secondary-air line -1- at the cylinder head.

Secondary-air line at cylinder head

=> Tightening torque: 13 Nm (9.5 ftlb.)
6. Tighten cap screw (a/f 27) -2- for the secondary-air line at the shut-off valve using special tool open-ended wrench insert, a/f 27 9821 => Special tool for cap screw on secondary-air line.

Secondary-air line connection at secondary-air pump

Special tool 9821:

Special tool for cap screw on secondary-air line

=> Tightening torque: 30 Nm (22 ftlb.)

Installing secondary-air line for cylinder bank 4-6

1. Position secondary-air line.
2. Guide secondary-air line -1- into the connection in the cylinder head.

Secondary-air line at cylinder head

3. Fit cap screw (a/f 27) -1- for the secondary-air line at the shut-off valve.

Secondary-air line connection at secondary-air pump

4. Fit and tighten external Torx screw (E10, M6 x 25) -2- on the secondary-air line -1- at the crankcase.

Screw securing secondary-air line 4-6 to crankcase

=> Tightening torque: 10 Nm (7.5 ftlb.)
5. Fit and tighten external Torx screw (E10, M6 x 20) -2- on the secondary-air line -1- at the cylinder head.

Secondary-air line connection at secondary-air pump

Special tool 9821

Special tool for cap screw on secondary-air line

=> Tightening torque: 30 Nm (22 ftlb.)
7. Push on cable plug -1- for oil pressure sensor.

Connector for oil pressure sensor

8. Fit electric lines at the starter.
-> 276019 Removing and installing starter .
8.1. Fit wire harness at the connections.
8.2. Fit and tighten M6 hexagon nut (a/f 10) on the solenoid switch for the starter.
=> Tightening torque: 6.5 Nm (5 ftlb.)
8.3. Fit and tighten M8 hexagon nut (a/f 13) on the solenoid switch for the starter.
=> Tightening torque: 18 Nm (13 ftlb.)
8.4. Fit protection cap.
9. Fit coolant hoses at the oil/water heat exchanger.
9.1. Remove stoppers from the connections at the oil/water heat exchanger and coolant hoses.
9.2. Push on coolant hoses.
9.3. Position and secure spring band clamps -1-.
9.4. Remove hose clamps.
9.5. Remove cleaning cloths.

Coolant connections at oil/water heat exchanger

Subsequent work

Only for installing secondary-air line for cylinder bank 4-6:
1. Install oil filler neck.
-> 171519 Removing and installing oil filler neck Service and Repair.
2. Install intake-air distributor for cylinder bank 1-3.
-> 244619 Removing and installing intake-air distributor Service and Repair.
3. Install resonance tube.
-> 247419 Removing and installing resonance tube Service and Repair.
4. Install rear wheel housing liner.
-> 536919 Removing and installing rear wheel housing liner Service and Repair.
5. Check engine coolant level and top up coolant if necessary.
6. Install engine compartment lid.
-> 557819 Removing and installing engine compartment lid 557819 Removing and Installing Engine Compartment Lid.
7. Connect negative terminal of the battery.
-> 2X00IN02 Work instructions after disconnecting the battery Work Instructions After Disconnecting the Battery.