For M20-6 Mta Transmission
Warning: When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.
Important: When working on the fuel system, pay strict attention to cleanliness as even the smallest particle of dirt may lead to malfunctions in engine operation or the fuel system. Seal opened fuel connections with suitable closure plugs 1) . Closure plugs are intended for single use.
Remove
- 1. Open bonnet
- 2. Remove battery tray
- 3. Detach engine cover
- 4. Detach bulkhead closing part
- 5. Raise vehicle by its full height
- 6. Place collecting pan underneath.
- 7. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt
- 8. Separate wiring harness from oil dipstick guide tube • Detach 2x cable ties
- 9. Detach lower hose (2) from oil separator (1) • Release clamp
- 10. Lower vehicle by its full height
- 11. Detach fuel return line from front fuel return line • Undo quick-release fitting (1) with KM-796-A • Seal with sealing plug KM-6015 • Unclip from bracket (2)
- 12. Detach fuel return line from damper fuel return line (9) • Undo quick-release fitting (8) with KM-796-A • Seal with sealing plug KM-6015
- 13. Detach fuel supply line (1) from fuel filter (3) • Undo quick-release fitting with KM-796-A • Seal with sealing plug KM-807 • Unclip 2x from bracket (2)
- 14. Detach fuel supply line from high pressure pump (3) • Release clamp (2) • Unclip from bracket (1)
- 15. Remove oil dipstick guide tube
- 16. Detach engine management wiring harness (1) from intake manifold • Disconnect 5x wiring harness plugs – Exhaust gas recirculation valve – Fuel pressure regulator – Solenoid, throttle valve – Charge pressure sensor – Fuel pressure sensor • Unclip 5x wiring harness
Note. Only for variant: Fuel pressure regulator on accumulator
- 17. Detach engine vent hose (2) from timing case • Release clamp
- 18. Detach engine venting hose bracket (1) • Unscrew bolt
- 19. Detach charge air pipe (1) from throttle valve housing (3) • Unscrew 2x bolts (2)
- 20. Remove oil separator (1) • Unscrew 2x bolts
- 21. Remove brake force amplifier vacuum line (1) • Disconnect quick-release fitting
- 22. Separate vacuum line vacuum pump (2)
- 23. Remove throttle valve housing (1) • Remove vacuum pipe (2) from solenoid valve • Unscrew 3 bolts
- 24. Detach flange throttle valve module (1) from intake manifold • Unscrew 3x bolts (2)
Important. Apply colour marks for assignment
- 25. Detach 2x coolant hose heating (1) from heater core • Unlatch 2 quick-release fittings (2) using a screwdriver
- 26. Detach 2x coolant hose heating (1) from coolant pipe • Undo 2 clamps
- 27. Detach engine vent hose, cylinder head venting (1) from charge air pipe • Unscrew bolt, thermostat housing bracket (2) • Undo quick-release fitting (3) • Unscrew bolt, bracket on intake manifold top
- 28. Remove coolant hose (1) from thermostat housing • Release clamp • Detach from bracket
- 29. Detach exhaust gas recirculation valve (1) • Detach metal pipe from intake manifold – Release clamp (2) • Detach exhaust gas recirculation valve bracket from cylinder block – Unscrew bolt (3) • Unscrew 2x bolts • Remove assembly valve and radiator exhaust gas recirculation
- 30. Remove intake manifold (1) • Unscrew 9x bolt (2) and (3)
Note. Note different bolt lengths
Install
- 31. Clean sealing surfaces.
- 32. Install intake manifold • Replace 2x seals • Tighten 9x bolts 25 Nm
Note. Note different bolt lengths.
- 33. Install exhaust gas recirculation valve • Use new gasket • Tighten 2x bolt 22 Nm
- 34. Attach exhaust gas recirculation valve to cylinder block • Tighten bolt 22 Nm
- 35. Attach exhaust gas recirculation pipe to intake manifold • Tighten clamp
- 36. Attach coolant hose to thermostat housing. • Fasten clamp • Install in bracket
- 37. Attach engine vent hose, cylinder head venting to charge air pipe • Lock quick-release fitting • Tighten bolt, bracket to thermostat housing • Tighten bolt, bracket to intake manifold
- 38. Attach 2x coolant hose heating to coolant pipe • Attach 2x clamps
- 39. Attach 2x coolant hose heating to heat exchanger • Connect 2 quick release fitting
Note. Note the assignment.
- 40. Install flange, throttle valve module intake manifold • Insert seal ring intake manifold • Tighten 3x bolt 8 Nm
- 41. Attach 2x coolant hose heating to coolant pipe • Attach 2x clamps
- 42. Attach throttle valve housing • Tighten 3x bolt 8 Nm • Attach vacuum pipe to solenoid valve
- 43. Fit charge air pipe at throttle valve module • Replace gasket • Tighten 2x bolts
- 44. Install oil separator • Tighten 2x bolt 9 Nm • Attach lower hose oil separator – Fasten clamp
- 45. Attach engine vent hose to timing case • Fasten clamp • Clip hose into bracket • Fasten bracket bolt
- 46. Attach vacuum line brake servo • Connect quick release fitting
- 47. Attach engine management wiring harness to intake manifold • Connect 5x wiring harness plugs – EGR valve – Fuel pressure control – Solenoid, throttle valve – Boost pressure sensor – Fuel pressure sensor • Clip into bracket
Note. Only for variant: Fuel pressure regulator on accumulator
- 48. Attach dipstick guide tube • Fasten bracket bolt • Attach wiring harness
- 49. Attach fuel supply line to high pressure pump • Fasten clamp • Clip into bracket
- 50. Attach fuel supply line to fuel filter • Connect quick release fitting – Remove sealing plug KM-6015 • Clip into bracket
- 51. Attach fuel return line to bypass fuel return line • Connect 2 quick release fitting – Remove 2x sealing plug KM-6015 • Clip 2x fuel return line into bracket
- 52. Attach fuel return line to damper fuel return line • Connect quick release fitting – Remove sealing plug KM-6015 • Clip into bracket
- 53. Attach bulkhead closing part
- 54. Install engine cover
- 55. Attach battery support
- 56. Top up coolant or ensure correct quantity is present.
- 57. Program volatile memories
- 58. Close bonnet
1
) ; protective caps are available in the parts catalogue