13 54 045 Removing And Installing/Sealing A Throttle Assembly (S54)

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Remove fan cowl. Refer to 17 11 031 REPLACING FAN COWL (S54) .

Release nuts, remove idle-speed control valve (1) together with holder from assembly and place to one side.

Fig 1: Removing Idle-Speed Control Valve

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If throttle assembly 1 is to be removed, remove throttle potentiometer. Refer to 13 63 555 REPLACING THROTTLE POTENTIOMETER (S54) .

If throttle assembly 6 is to be removed, remove pulse generator of inlet camshaft. Refer to 12 14 523 REPLACING PULSE GENERATOR ON INLET CAMSHAFT (S54) .

Remove fuel injector rail. This operation is described in 13 64 501 REMOVING AND INSTALLING/REPLACING A FUEL INJECTOR (S54) .

Remove auxiliary air line. Refer to 13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S54) .

Removal: 

Removal of a throttle assembly is described separately from its installation.

Unclip pull rod (1) for throttle actuator on throttle side (long pull rod).

Fig 2: View Of Pull Rod For Throttle Actuator

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Unclip pull rods (1) on all throttle assemblies.

Fig 3: Identifying Pull Rods On Throttle Assemblies

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Release screw connection of actuating lever on long pull rod.

Always grip screw (2) and turn nut (1) in so doing.

Fig 4: View Of Screw Connection Of Actuating Lever On Long Pull Rod

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Release screw connection of actuating lever with actuating shaft on all throttle assemblies.

Always grip screw (2) and turn nut (1) in so doing.

Fig 5: Removing Screw Connection Of Actuating Lever With Actuating Shaft

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Detach lock washer (1) from actuating shaft.

Fig 6: Removing Lock Washer From Actuating Shaft

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Withdraw actuating shaft (1) in direction of arrow from throttle assemblies.

Fig 7: View Of Actuating Shaft From Throttle Assemblies

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Support actuating lever (2) when withdrawing actuating shaft (1).

Fig 8: Locating Actuating Lever

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Release screw connection of corresponding throttle assembly.

Remove throttle assembly.

Fig 9: View Of Screw Connection Of Throttle Assembly

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Installation: 

Removal of a throttle assembly is described separately from its installation.

Clean sealing faces (1). Note correct position of adapter sleeves (2).

Fig 10: Identifying Positions Of Adapter Sleeves

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Clean sealing face of cylinder head.

Replace O-ring (1) in cylinder head.

Fig 11: View Of O-Ring In Cylinder Head

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Position actuating lever (1) in such a way that it is flush with mount (2) for connecting pipe.

Hold actuating lever (2) and insert throttle assembly until it rests against engine block.

Fig 12: Locating Actuating Lever And Throttle Assembly

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Tighten down screw connection of corresponding throttle assembly.

Fig 13: View Of Screw Connection Of Throttle Assembly

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Push actuating shaft into bearings of throttle assemblies. Start on throttle assembly 1.

Feed out actuating lever (3) when pushing actuating shaft (1) into bearings of throttle assemblies (2).

Fig 14: Identifying Actuating Shaft

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Insert fitting screw (1) as illustrated into actuating lever of throttle assembly 1.

Fig 15: Locating Fitting Screw

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Tighten down screw connection of actuating lever with actuating shaft. Observe the following instructions in so doing:

• Use screws and nuts only once.
• Only turn nut (2) and grip screw (1).
• To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft if at all possible. In this way, no torque is exerted on actuating lever.
• Retighten nut to tightening torque of 7 N.m.

Fig 16: View Of Actuating Lever With Actuating Shaft

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Ball ends are turned to each other.

Fig 17: Identifying Actuating Levers

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Insert fitting screw (1) as illustrated into actuating lever (2) of pull rod.

Observe position of actuating lever (2) to actuating lever (3).

Fig 18: Inserting Fitting Screw Into Actuating Lever Of Pull Rod

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Tighten down screw connection of actuating lever on long pull rod. Observe the following instructions in so doing:

• Use screws and nuts only once.
• Only turn nut (2) and grip screw (1).
• To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft if at all possible. In this way, no torque is exerted on actuating lever.
• Retighten nut to tightening torque of 7 N.m.

Fig 19: Locating Actuating Lever On Long Pull Rod

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Insert screw (1) in all other actuating levers and fit nut (2).

Fig 20: View Of Screw In Actuating Lever

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Clip in pull rod (1) for throttle actuator on throttle side (long pull rod).

Fig 21: View Of Pull Rod For Throttle Actuator

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Clip in pull rods (1) on all throttle assemblies.

Fig 22: Identifying Pull Rods On Throttle Assemblies

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Carry out basic throttle adjustment. Refer to 13 54 010 ADJUSTING BASIC THROTTLE SETTING (S54) .

Assemble engine.

• Service functions.
• DME system checks.
• Function test.

Installation: 

Read out fault memory of control unit of Digital Motor Electronics (DME).

Check stored fault messages.

Rectify faults.

Now clear the fault memory.