Overhaul
WM 244619 Removing and installing DFI intake-air distributor
Technical values
Preliminary work
1. Remove engine compartment cover. => 700219 Removing and installing front cover (engine compartment) - section on "Removing"
2. Pull design cover off the throttle valve.
3. Remove intake manifold. => 243519 Removing and installing air box for throttle housing on DFI engines (intake pipes upstream of throttle valve) - section on "Removing"
4. Remove air-cleaner element and air cleaner housing cover. => 242419 Removing and installing air-cleaner element on DFI engines - section on "Removing"
5. Loosen the drive belt from the generator. For details, see => 137819 Removing and installing drive belt on V6 DFI engines
6. Remove belt tensioner. Unscrew the three screws on the drive belt and remove drive belt.
7. Loosen the generator and tilt it towards the air cleaner housing. Remove upper screw and only loosen the lower screw. => Removing generator
Removing generator
Information
Component overview
Intake-air distributor
Intake distributor, bottom
Intake distributor, side
Removing intake-air distributor
WARNING
Toxic substances
- Danger of poisoning or suffocation
-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
CAUTION
Dirt on injection system components (intake manifold injection and direct fuel injection system)
- Material damage
- Rough-running engine
- Bad exhaust emissions
-> Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.
-> Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
-> Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.
-> Only install clean parts. Do not take spare parts out of the packaging until just before installation.
-> Never use compressed air when the system is open. Do not move the vehicle.
WARNING
Leaking fuel supply lines
- Emerging fuel
- Risk of fire
-> Perform leak test.
Information
- Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting.
Information
- The ignition must be switched off when working on the fuel system.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurised before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
1. Remove connections and accessories on intake-air distributor.
Intake-air distributor connections
1.1. Screw off oil filler cover. -1-
1.2. Remove eyelet. Loosen two screws. -2-
1.3. Disconnect throttle valve and expose cable. -3-
1.4. Loosen tank ventilation line and release it from the intake-air distributor. -6-
1.5. Loosen positive crankcase ventilation line and release it from the intake-air distributor. -5-
1.6. Disconnect crankcase heater. -4-
2. Remove upper screw on sheetmetal holder. -Top arrow-
Heat protection panel on exhaust manifold
3. Pull vacuum line out of the intake-air distributor. Use a screwdriver to prise it off if necessary. -arrow-
Vacuum line
4. Expose throttle housing cable -1-. Remove screw on intake-air distributor. -2-
Throttle valve
5. Remove rear screw on intake-air distributor. -1-
Fastening screw on intake-air distributor
6. Press the two coolant hoses aside and remove screw on oil dipstick. Pull out oil dipstick. -1-
Coolant hoses
7. Pull off vacuum line on vacuum unit for intake-air distributor -1-. Unclip change-over valve, disconnect it and set it aside. -2 and 3-
Vacuum lines
8. Loosen water tube. To do this, remove the screw on the intake-air distributor -1- and press the water tube forward -arrow-. Take the water tube out of the notches and press it down -arrow-.
Water tube
9. Disconnect cable plug for high-pressure sensor. Remove high-pressure pump. => 246319 Removing and installing DFI high-pressure pump - section on "Removing"
10. Remove high-pressure line between the fuel distributor pipes. To do this, loosen the union nuts and remove line. -1 and 2- See illustration -21-.
View of threaded connections in high-pressure system
DFI injection system, 3.6 l
11. Loosen three screws on the intake-air distributor at the sides in the centre of the intake-air distributor. Use a thin Torx socket (e.g. Klann KL-4041-240) to do this. => Intake-air distributor screws These three screws are integrated in the intake-air distributor so that they cannot be lost.
Intake-air distributor screws
12. Remove one front screw at the side of the intake-air distributor. => Side screws on intake-air distributor
Side screws on intake-air distributor
Information
- The lower fuel distribution pipe also secures the intake-air distributor.
- Always open the fuel high-pressure system when removing the intake-air distributor.
- The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6
13. Loosen lower fuel distributor pipe (for cylinders 2, 4 and 6). To do this, insert a suitable extension in between the water tube and remove the three screws using a multiple-tooth socket => Accessing screws on lower fuel distributor pipe. Other illustration, see -19-.
Accessing screws on lower fuel distributor pipe
14. Lift off the intake-air distributor complete with the lower fuel distributor pipe. To do this, first raise the intake-air distributor on the exhaust side and tilt it -1- , then lift it off the cylinder head on the intake side. -2-
Removing intake-air distributor
Installing intake-air distributor
WARNING
Toxic substances
- Danger of poisoning or suffocation
-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
CAUTION
Dirt on injection system components (intake manifold injection and direct fuel injection system)
- Material damage
- Rough-running engine
- Bad exhaust emissions
-> Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.
-> Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
-> Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.
-> Only install clean parts. Do not take spare parts out of the packaging until just before installation.
-> Never use compressed air when the system is open. Do not move the vehicle.
WARNING
Leaking fuel supply lines
- Emerging fuel
- Risk of fire
-> Perform leak test.
Information
- Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting.
Information
- The ignition must be switched off when working on the fuel system.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurised before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
Information
- The lower fuel distribution pipe also secures the intake-air distributor.
- Always open the fuel high-pressure system when removing the intake-air distributor.
- The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6
1. Replace intake-air distributor gaskets.
2. Replace the gaskets between the fuel injectors and fuel distributor pipe (for cylinders 2, 4 and 6) and coat them with clean engine oil.
3. Only complete the following step if screws are defective: To replace the integrated screws for the intake-air distributor, carefully drill out the three openings using a 13-mm drill bit. When doing so, make sure the drill holes do not exceed a max. depth of 15 mm. => Drilling out to allow access to screws
Drilling out to allow access to screws
4. Insert the lower fuel distributor pipe (for cylinders 2, 4 and 6) into the removed intake-air distributor. => Pre-fitting lower fuel distributor pipe
Pre-fitting lower fuel distributor pipe
5. Fit intake-air distributor complete with the lower fuel distributor pipe. To do this, first guide it in on the intake side -1- , then tilt it to the cylinder head on the exhaust side. -2-
Installing intake-air distributor
6. Screw in screws on intake-air distributor. Use a thin Torx socket (e.g. Klann KL-4041-240) to tighten the screws hand-tight. => Intake-air distributor screws => Side screws on intake-air distributor
Intake-air distributor screws
Side screws on intake-air distributor
Information
- The lower fuel distribution pipe also secures the intake-air distributor.
- Always open the fuel high-pressure system when removing the intake-air distributor.
- The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6
7. Good lighting is essential when working in confined spaces. Fit lower fuel distributor pipe (for cylinders 2, 4 and 6) together with the intake-air distributor. To do this, press the lower fuel distributor pipe correctly onto the injectors. Move fuel distributor pipe into installation position. Fit screws and tighten by hand. To do this, insert a suitable extension in between the water tube and fit the three screws using a multiple-tooth socket => Accessing screws on lower fuel distributor pipe.
Accessing screws on lower fuel distributor pipe
8. Tighten screws on the intake-air distributor and fuel distributor pipe. => Tightening torque: 30 Nm (22 ftlb.) , then => Torque angle: 90° => Tightening torque: 8 Nm (6 ftlb.)
9. Fit high-pressure line between the fuel distributor pipes. To do this, fit union nuts loosely. -1 and 2- See illustration -21-.
View of threaded connections in high-pressure system
DFI injection system, 3.6 l
10. Fit high-pressure pump. => 246319 Removing and installing DFI high-pressure pump - section on "Installing" Connect cable plug for high-pressure sensor.
11. Fit water tube. To do this, insert the water tube into the latch on the intake-air distributor and slide it back towards the plenum panel -arrows-. Fit the screw into the intake-air distributor -1-.
Fitting coolant pipe
12. Connect vacuum line to the vacuum unit of the intake-air distributor -1-. Clip on change-over valve and fit cable plugs. -2 and 3-
Vacuum lines
13. Press the two coolant hoses onto the intake-air distributor and fit screw on oil dipstick. Insert dipstick. -1-
Coolant hoses
14. Fit rear screw on intake-air distributor. -1- => Tightening torque: 20 Nm (15 ftlb.)
Fastening screw on intake-air distributor
15. Insert vacuum line into the intake-air distributor. Grease connection and seal -2- with Kluber Syntheso Glep 1 as required. -arrow-
Vacuum line
16. Fit throttle housing cable -1-. Fit screw on intake-air distributor. -2- => Tightening torque: 20 Nm (15 ftlb.)
Throttle valve
17. Fit upper screw on sheetmetal holder. -Top arrow- => Tightening torque: 20 Nm (15 ftlb.)
Heat protection panel on exhaust manifold
18. Fit connections and accessories on intake-air distributor.
Intake-air distributor connections
18.1. Screw on oil filler cover. -1-
18.2. Fit eyelet. Tighten two screws. -2- => Tightening torque: 23 Nm (17 ftlb.)
18.3. Connect cable plug for throttle valve. -3-
18.4. Fit tank vent line. -6-
18.5. Fit positive crankcase ventilation line. -5-
18.6. Connect cable plug for crankcase heater. -4-
19.Subsequent work
1. Place the generator in installation position -arrow- and secure with the fastening screws -arrows 3-. For details, see => 272219 Removing and installing generator - section on "Installing"
Securing the generator
2. Fit belt tensioner. Tighten the three screws on the belt tensioner. => Tightening torque: 25 Nm (19 ftlb.)
3. Fit drive belt. For details, see => 137819 Removing and installing drive belt on V6 DFI engines
4. Fit air-cleaner element and air cleaner housing cover. => 242419 Removing and installing air-cleaner element on DFI engines - section on "Installing"
5. Install intake manifold. => 243519 Removing and installing air box for throttle housing on DFI engines (intake pipes upstream of throttle valve) - section on "Installing"
6. Press design cover onto the throttle valve.
7. Fit engine compartment cover. => 700219 Removing and installing front cover (engine compartment) - section on "Installing"