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Removing and installing throttle valve module
 Remove
| 1. |
Disconnect ground cable from battery
|
| 2. |
Remove air intake manifold
|
| 3. |
Remove engine vent hose from cylinder head cover
|
| 4. |
Detach air intake pipe from air intake hose
|
| 5. |
Detach air intake pipe from turbocharger
| • |
Release clamp (3)
Note: Seal air intake
pipe at turbocharger
|
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| 6. |
Remove air intake pipe
|
|
|
| 7. |
Remove charge air hose (2)
|
|
|
| 8. |
Detach charge air deflection pipe
| • |
Unclip vacuum line from bracket (2)
|
| • |
Remove charge air deflection pipe
|
|
|
|
| 9. |
Drain coolant
| • |
Open drain bolt on radiator (1)
|
|
|
|
| 10. |
Close coolant drain screw
|
| 11. |
Detach throttle body coolant line (2) from throttle body
|
| 12. |
Disconnect throttle body wiring harness plug (1)
|
|
|
Install
| 14. |
Replace throttle body seal rings and attach throttle body
coolant lines to throttle body
|
| 15. |
Install charge air deflection pipe
| • |
Clip vacuum line into bracket
|
|
| 17. |
Connect ground cable to battery
|
| 18. |
Always use antifreeze 19 40 650 / 9194431 (red) and ensure that
the concentration is 50% water and 50% antifreeze. The antifreeze
does not just protect the entire cooling system from freezing, but
also protects all coolant-flushed parts from rust-corrosion/calcium
deposits. It is therefore important to add antifreeze, even in
tropical countries.
|
| 19. |
The water quality also plays an important role in addition to
the mix ratio. Water of drinkable quality usually meets these
requirements. The quality of purified sea water is inadequate!
|
| 20. |
Damage may also be caused to the engine if unauthorised
anti-freeze agent is used!
|
| 21. |
If radiator, cylinder head or cylinder head gasket have been
replaced the old coolant must not be re-used.
|
Important: Vehicles with air
conditioning: switch air conditioning off and set to ECO mode with
ECC
|
| 22. |
Open cooling system
Warning: Cooling system is under
pressure
|
| • |
Unscrew coolant expansion tank cover
|
|
| 23. |
Fill with coolant up to lower venting line (1) at coolant
expansion tank
|
| 24. |
Seal off cooling system
| • |
Screw in coolant expansion tank cover
|
|
| 25. |
Start engine and allow to warm up
| • |
Allow engine to warm up at idling speed of up to 2500 rpm until
first radiator fan setting switches on
|
|
| 26. |
Vent cooling system
| • |
Allow engine to run for approximately 2 minutes at 2000 to 2500
rpm
Note: The air in the
cooling system is removed via the venting lines
|
|
| 27. |
Switch engine off and allow to cool
|
| 28. |
Check coolant level and also top up coolant to "COLD" mark
|
|
|
| 29. |
Re-teach throttle valve module
Note: For engines with
throttle body module (E-Gas) it is necessary to perform a
relearning procedure after throttle body module (E-Gas)
replacement. To do so, turn on ignition and wait at least 10
seconds. Under no circumstances should starting occur during the
waiting period as this would interrupt the relearning
procedure.
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