Removing and installing / replacing non-return valve (cylinder bank 1-6) (M73) Compress retainer (2) and push off connector (1).

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1 Removing and installing / replacing non-return valve (cylinder bank 1-6) (M73) Compress retainer (2) and push off connector (1). Open clips (1). Unfasten hose clip (2) from inlet hose for air pump. Remove hose. Disconnect plug connection (3). Unfasten hose clip (4). Remove complete top right section of intake filter housing. Remove fan coupling with fan wheel, refer to Unclip and remove oil drip tray.

2 1. Non-return valve for cylinder bank 1 to 6 2. Non-return valve for cylinder bank 7 to 12 Unfasten hose clip (1) to non-return valve for cylinder bank 7 to 12 and remove pressure hose. Unfasten hose clip on non-return valve for cylinder bank 1 to 6 and remove pressure hose.

3 Unclip bracket (1) for coolant vent hose. Unfasten screws in non-return valve (1) for cylinders 1 to 6 to pressure pipe (2) and remove non-return valve. Replace gasket. Unfasten hose clip on pressure pipe for air pump. Remove hose.

4 Unfasten pressure pipe (1) from brackets and remove. The spacer disc (2) must be fitted under the bracket (1) to the water pump to prevent the pressure pipe from being subjected to tension.

5 Removing and installing/replacing water pump (M73) Remove non-return valve for cylinder bank 1-6, refer to Remove left heat baffle plate from front axle support. Unfasten drain plug for coolant on engine left. Drain off coolant and dispose of correctly. Replace sealing ring Tightening torque, refer to Technical Data AZ Top up coolant. Bleed cooling system and check for water leaks, refer to Completely remove coolant expansion tank, refer to Remove complete fan shroud, refer to Remove drive belt from air conditioning compressor, refer to Unfasten screw and disconnect coolant hose from water pump. Remove coolant hose.

6 Loosen hose clamp. Pull hose off. Remove bracket(1), then remove hose to coolant expansion tank Unfasten plug connection from temperature sensor for coolant temperature.

7 Remove complete fan wheel, refer to Unfasten screws and remove pulley from water pump. Remove vibration damper, refer to Remove vent hose from hose bracket (1) and unfasten hose clip on water pump. Unfasten screws.

8 Insert three screws in threaded bore provided and evenly press water pump off engine. Replace O-rings and coat with antifriction agent for ease of assembly.

9 Replacing all injector valves (M73) Switch off ignition. Unfasten engine wiring harness on engine, lift upwards and secure to the hood, refer to Up to 9/97: Open bracket (1). Unfasten hose clips. Remove hoses. Caution! Fuel is pressurised (approx. 3.5 bar): Carefully pull off fuel hoses to release pressure. Catch escaping fuel in suitable container. Always replace hose clips and fuel hoses! Up to 9/97: Unfasten hose clips and remove hoses. Caution! Catch escaping fuel in suitable container. Always replace hose clips and fuel hoses! 1 Bright-coloured line = fuel delivery line 2 Dark line = fuel return line

10 From 9/97: Pull supply air hoses (1) for air-contained injection valves off injection valve strips (2). From 9/97: Loosen hose clips (1 and 2) and pull off injection valve strips. Caution! Fuel is pressurised (approx. 3.5 bar): Carefully pull off fuel hoses to release pressure. Catch escaping fuel in suitable container. Replace hose clips. Unfasten screws, remove injection valve strip complete with injection valves. Unclip and remove circlip. Remove injector valves. Check seals on injector valves and replace if necessary.

11 Before installing injector valves, coat seals with acid-free grease. Check injector valves for leaks and clean, refer to

12 Removing and installing / replacing intake air manifold for cylinders 1-6 (M73) Switch off ignition. Remove complete injection pipe with injector valves, refer to Disconnect plug connection (1). Unfasten screws, remove throttle body and place to one side. Hoses remain connected. Replace gasket between manifold and throttle body. Mark routing of lines for knock sensors (1 and 2 ) on manifold.

13 Unfasten screws and remove noise insulation strip. Unfasten nut and place ignition wiring harness (1) to one side. Unfasten manifold with special tool

14 Unfasten screws (1) and remove control valve for engine venting. Note: Installation is described in section on sealing and replacing left control valve for engine venting, refer to If necessary, remove vent pipe (1). Installation position of vent pipe (1) in manifold (2).

15 Clip rubber mount (1) of vent pipe (2) in manifold on rotary shaft. Lug (1) on vent pipe must locate in bore (2) of manifold.

16 Removing and installing / replacing air intake manifold from cylinders 7-12 (M73) Note instructions on connecting and disconnecting battery, refer to General Data MG12 Switch off ignition. Disconnect battery ground wire. Remove complete injection pipe with injection valves, refer to Disconnect plug connection (1). Unfasten screws, remove throttle body and place to one side: hoses remain connected. Replace gasket between manifold and throttle body. Mark line routing on knock sensors (1 and 2 ) on manifold.

17 Unfasten screws and remove noise insulation strip. Unfasten nuts and remove ignition wiring harness (1). Unfasten screws in manifold using special tool

18 Unfasten screws (1) and remove control valve for engine venting. Note: Installation is described in section on sealing / replacing control valve for venting left side of engine, refer to If necessary, remove vent pipe (1). Installation position of vent pipe (1) in manifold (2).

19 Clip rubber mount (1) of vent pipe (2) to rotary shaft in manifold. Lug (1) on vent pipe must engage in bore (2) of manifold.

20 Removing and installing / sealing coolant connection pipe(s) (M73) Remove intake air manifold from cylinder bank 1 to 6, refer to Remove intake air manifold from cylinder bank 7 to 12, refer to Remove water pump, refer to Unfasten hose clip (1). Remove coolant hose. Unfasten hose clip. Remove coolant hose.

21 Unfasten screw, Remove coolant pipes (1 and 2). Replace O-rings in back of coolant manifold and in water pump. Coat O-rings with anti-friction agent.

22

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