Installing the ignition coil of cylinder bank 2

Prerequisite 

Ignition is switched off.

• Insert and install the ignition coil (2).
• Tighten down screw (1).

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• Feed in and install the cable clip (3).
• Tighten down screw (2).

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• Tighten nut (1).

• Connect and lock connectors (arrows).

  The connectors (arrows) must audibly engage.

• Feed the cable (2) into the bracket (arrows).
• Secure clamps (1).

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→ Installing coolant expansion tank 

Check 

• Check if the foam seal on retaining bridge (1) in area (2) is damaged, porous, loose or present.

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  Result 

  » Foam seal (2) is damaged or porous or loose.

  Measure

  • Replace the foam seal (2).

  Parts:  foam

  Measure

  • Clean any foam seal residue or adhesive residue on the bonding surface in area (2) with cleaning agent R2.

  Parts:  Cleaning agent

  Measure

  • Bond foam seal (2).

  Result 

  » Foam seal (2) is not installed.

  Measure

  • Retrofit foam seal (2).

  Parts:  foam

  Measure

  • Clean the bonding surface in area (2) with cleaning agent R2.

  Parts:  Cleaning agent

  Measure

  • Bond the foam with an adhesive.
  NOTE: RISK OF DAMAGE 
  Injectors contaminated with coolant. 
  Damage to and failure of injectors that were coated with coolant for an extended period. 

  • Covering injectors with suitable auxiliary materials before testing or topping up the coolant is mandatory.
  • Covering injectors with suitable auxiliary materials before working on the cooling system in the area of the injectors is mandatory.
  • If necessary, draw off all of the coolant from the coolant expansion tank.
  • Always clean injectors or injector shafts contaminated with coolant (e.g. with compressed air).

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  CAUTION: Swirling dirt particles caused by compressed air. 
  Injury hazard! 

  • Collect dirt particles, e.g. when blowing out, use cloth to do so.
  • Wear safety goggles.
  CAUTION: Materials harmful to health. 
  Contact with fluids harmful to health! 

  • Note and follow safety instructions on containers.
  • Conduct all work in appropriate personal protective equipment only.
  • Check the injector shafts for coolant residues (1).
  • If there are coolant residues (1) in the injector shaft: Clean the injector shafts with an air gun (2).

  Schematic diagram is for example purposes. Some parts may differ in certain details.

  • Illustrated on the S63T4: 
  • Position the coolant expansion tank (2).
  • Connect and lock coolant hose in area (1).

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  NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
  • Illustrated on the S63T4: 
  • Remove the seal plug (1).

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  • Secure clamps (3).
  • Connect connectors (2) and lock.

    The connector (2) must engage audibly.

  • Connect and lock the coolant lines (1).

    Coolant lines (1) must engage audibly.

  • Remove the standard disconnection tool (arrows).

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  NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
  • Illustrated on the S63T4: 
  • Position the coolant expansion tank (2).
  • Clip the fuel lines in area (4) into expansion tank (2).
  • Remove clamping pliers (3).
  • Remove the rubber mat (1).

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  • Connect the holder (4) and lock.

    The holder (4) must engage audibly.

  • Secure the coolant hose (3) on the coolant expansion tank (2).

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  • Check the rubber mount (1) for correct fit.

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  • Equipment specification with gasoline particulate filter: 

  Guide the holder of gasoline particulate filter (2) downwards into the guide.

  • Tighten down screw (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Gasoline particulate sensor to coolant expansion tank
  M6x20 screw	Tightening torque	8 Nm

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  • Equipment specification with gasoline particulate filter: 
  • Position the coolant expansion tank (2).
  • Tighten the screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Coolant reservoir
  M6x20 screw	Tightening torque	11 Nm

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  • Equipment specification with gasoline particulate filter: 

    Press the rear hood seal (2) into the guide.

  • Guide cable (1) into the holders.
  • Check if the rear hood seal (2) and cable (1) fit correctly.

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  • Feed in and install coolant expansion tank (2).

  Tighten down screws (1).

  TIGHTENING TORQUES SPECIFICATION
  
  

  Coolant reservoir
  M6x20 screw	Tightening torque	11 Nm

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  NOTE: TECHNICAL INFORMATION 
  Follow notes for repair work on the cooling system.
  For additional information see:
  INSTRUCTIONS FOR REPAIR WORK ON COOLING SYSTEM .

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  • Top up the coolant expansion tank (1) with coolant up to the maximum mark  (2).
  • Close the sealing cap (1) until the arrows  align.

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  → Installing the control unit bracket for cylinders 5 to 8 

  NOTE: RISK OF DAMAGE 
  Electrostatic discharge. 
  Damage to or destruction of electrical components. 

  • Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
  • Read and comply with user information on using the associated special tool 12 7 060.
  • Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
  • Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
  • For additional information see: NOTES ON ESD (ELECTROSTATIC DISCHARGE) PROTECTION .
  NOTE: TECHNICAL INFORMATION 
  Follow instructions for removing and installing control units.
  For additional information see: 1200... INSTRUCTIONS FOR REMOVAL AND REPLACEMENT OF CONTROL UNITS .
  NOTE: TECHNICAL INFORMATION 
  Disconnecting control units may cause fault code entries and functional limitations. Fault code entries must be read out and deleted if necessary.
  • Guide and install control unit bracket (2) with the DME control unit into holder (3).
  • Tighten down screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Control unit holder
  Hexagon screw	Tightening torque	8 Nm

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  • Fasten all the clamps (2).
  • Connect all connectors (1) and lock.

  The connectors (1) must engage audibly.

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  → Install clean air pipe, top 

  WARNING: Hot surfaces. 
  Risk of burning! 

  • Perform all work only on components that have cooled down.
  • Feed in top clean air pipe (2) and install.
  • Tighten clamps (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Upper clean air pipe to lower clean air pipe
  Hose clamp	Tightening torque	3 Nm

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  → Installing the cover of the left DME control unit 

  • Feed in the cover (1) in the guides and install it.

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Follow-up work 

• Refer to ATTACHING COOLANT EXPANSION TANK .
• Refer to INSTALLING THE CONTROL UNIT BRACKET FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING CLEAN AIR PIPE, TOP .
• Refer to INSTALLING THE COVER OF THE LEFT DME CONTROL UNIT .
• Refer to INSTALLING CONTROL UNIT HOLDER FOR CYLINDERS 1 TO 4 .
• Refer to INSTALLING THE COVER OF THE RIGHT DME CONTROL UNIT .
• Refer to CONNECTING NEGATIVE BATTERY CABLE .