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Service components of an inlet air path
Replacement of a filtering element of an air cleaner Details of installation of components of an inlet air path models equipped with engine series 612
| - Illustrative material for replacing the air filter element models 163.113 (engine 612 series) is represented in the illustration, which includes all the links in the text.
- Remove the trim panel of the cylinder head cover.
- Disconnect the wiring from the sensor MAF (B2 / 5).
- Disconnect the air from the air hose (4/2).
- Remove the air inlet (4/3).
- Turn out fixing bolts and remove the top section of air cleaner housing (4/1).
- Remove the filter element (4/4).
- If necessary, remove the bottom section of air cleaner housing (4/5) - note the padded bottom (from the engine) washers.
- Installation is performed in reverse order - do not forget to replace the defective fixing collars.
- Finally, reset the indicator of the degree of contamination of the filter element (arrow).
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Removal and installation of the intake air temperature sensor (IAT) Details of installation of the IAT sensor models 163.113 (612 series engine)
| - Details of installation of the IAT sensor models 163.113 (engine series 612) are shown in the illustration, which includes all the links in the text.
- Cut tape bandage (1) fixing the holder (3).
- Disconnect the electrical connector (2) sensor IAT (B17).
- Squeeze the brackets together (arrows) and release the sensor (B17) from the holder (3).
- Remove the O-ring (4) that the assembly must be replaced without fail.
- Installation is in the reverse order.
 | Installation of the sensor must be made with the disengagement pin connector, otherwise there is a possibility of damage mounting brackets (arrows) by dragging them! |
- Finally, clean the system memory on-board self-test (see chap. Systems of an electric motor).
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Removing and installing turbocharger Details of installation of the turbocharger models 163.113 (612 series engine)  | |
| - Details of installation of the turbocharger models 163.113 (engine series 612) are shown in the illustration, which includes all the links in the text.
- Remove the lower section of the insulation.
- Remove the air cleaner (see. Above).
- Remove the air hose (4/2).
- Disconnect from the turbocharger (110) duct (110/6).
- Disconnect the vacuum unit (110/10) hose (4).
- Otboltite oil supplying line (110/3) from the turbocharger and engine block - when you release the choke hold turbocharger nuts from turning.
- Remove primary catalytic converter (120/1).
- Otboltite from the crankcase support bracket (3).
- Remove the turbocharger (110) and bracket assembly (3) and oil return line (110/4).
- Disconnect from the turbocharger (110) support bracket (3) and oil return line (110/4) - ready to collect spilled oil.
- Installation is in the reverse order. Do not forget to replace all sealing elements. Tightening the nuts choke oil lines made only after the installation of the turbocharger.
- Finally, check motor oil level, if necessary, make appropriate adjustment (see chap. Power supply system and exhaust).
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Removal and installation of an intermediate cooler charge air tract Details of the installation of an intermediate cooler charge air tract models 163.113 (612 series engine)
| - Details of the installation of an intermediate cooler charge air tract models 163.113 (engine series 612) are shown in the illustration, which includes all the links in the text.
- Open the hood and fix it in an upright position.
- Remove the lens unit (1) with plates (2).
- Remove the front crossmember of the frame (3).
- Disconnect the electrical connector (4) sensor IAT (B17).
- Release fixing collars (5 and 6) and detach the coolant heat exchanger (110/2) air hose (7 and 8).
- Remove the fixing bolts (9) and remove cooler (110/2).
- Installation is in the reverse order.
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Removal and installation of the diffuser Details of installation of the diffuser models 163.113 (612 series engine)  | | |
| - Details Adjustment of air charge air tract models 163.113 (engine series 612) are shown in the illustration, which includes all the links in the text.
- Open the hood and fix it in an upright position.
- Remove the trim panel of the power unit (1 and 2).
- Remove the lower section of the soundproofing.
- Disconnect the negative wire from the battery.
- Drain the cooling system (see chap. Power supply system and exhaust).
- Remove fuel cooler (6).
- Remove the fuel line (21) (see. Section Removal and installation of a fuel distributive highway and injectors).
- Remove the fuel pipe support brackets.
- Otboltite upper support bracket (8) Air Distribution (110/1).
- Pump the oil out of the tank and remove the power steering hydraulic hose from the last - immediately plug the open end of the hose and nozzle.
- Disconnect vacuum line.
- Remove the radiator overflow hose.
- Remove connected to the mixing chamber (5) duct (12).
- Remove the mixing chamber (5).
- Remove the connecting pipe (13).
- Remove the cover of the thermostat (see chap. System of cooling, heating and air conditioner).
- Remove the support bracket (10) mounting the pipe diffuser tube system EGR.
- Liberate from clamps wiring harness laid along the distributor pipe (110/1) - Disconnect the connectors for the oil level sensor (B40), CKP (L5), boost pressure (B28), the terminal switch lock inlet port (S99) and a motor starter ( M1).
- Turn out fixing bolts and remove the diffuser pipe (110/1) from the lower support bracket (7).
- Installation is performed in reverse order - do not forget to replace the sealing elements and the failed components.
- Finally, clean the memory module on-board self-test (see chap. Systems of an electric motor).
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Removal and installation of electric actuator overlapping inlet port Details of installation of electric actuator overlapping inlet port models 163.113 (612 series engine)
| - Details of installation of electric drive overlapping inlet port models 163.113 (engine series 612) are shown in the illustration, which includes all the links in the text.
- On models with AT remove diffuser (See above.).
- On models with Manual transmission remove the left front wheel and the wheel arch locker protection.
- Remove the screws (1).
- Release the lever, and carefully remove the support (3) with the ball head (2).
- On models with Manual transmission Disconnect electrical connector (4) an electric motor (M55).
- Remove the electric motor (M55) with the diffuser assembly (5).
- Installation is in the reverse order. Track correctness of landing flap positioning, smooth check their progress. Do not forget to replace the sealing elements.
- Finally, clean the memory module on-board self-test (see chap. Systems of an electric motor).
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Models 163,128 Replacement of a filtering element of an air cleaner The design of the air cleaner models 163.128 (628 series engine)
| - Illustrative material for replacing the air filter element in the models 628 (628 series engine) is shown in the illustration, which includes all the links in the text.
- Throw off the six retainers clips (arrows) securing the cover of the air cleaner (1).
- Remove the cover (1) and remove the casing of the air filter element to be replaced.
- Installation is in the reverse order - track correctness of planting cover.
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Removal and installation of the intake air temperature sensor (IAT) Details of installation of the IAT sensor models 163.128 (628 series engine)
| - Details of installation of the IAT sensor models 163.128 (engine series 628) are shown in the illustration, which includes all the links in the text.
- Open the hood.
- Remove the padded front of the air cleaner hose suction fan motor.
- Disconnect the wiring connector (1) sensor (B17) at the same time retaining brackets (arrows) of the latter.
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Removal and installation of turbochargers Details of the installation of the right turbocharger models 163.128 (628 series engine) Details of the installation of the left turbocharger models 163.128 (628 series engine)  | |
| - Details of the installation of turbochargers models 163.128 (engine series 628) are shown in the illustrations, which include all the links in the text.
- Remove the front wheels and wheel arch lockers protection.
- Remove both inlet duct (left / right) paths charge air (see. Below).
- Remove the lower air ducts of both (left and right) paths charge air (see. Below).
- Give a nut (1) on the support bracket oil supplying line (110/3).
- Remove the bolt (2) and remove the oil supplying line (110/3) from the cylinder head.
- Disconnect the oil supplying line (110/3) of the left turbocharger (110).
- Remove the bolts (3) and disconnect maslovozvratnuyu line (110/4) from the turbocharger and the engine crankcase.
- Release the clamp on the primary catalytic converter to the right turbocharger (110).
- Completely loosen and pull back left three-functional catalytic converter (TWC).
- Remove the bolt (4) on the hinge (5).
- Disconnect from the turbocharger (110) wiring wastegate (7).
- Remove the screws (6) and remove the turbocharger (110) to the engine exhaust manifold.
| Wastegate (Y100 and Y100 / 1) are replaced only in conjunction with the corresponding turbo! |
- Installation is in the reverse order. Do not forget to replace all sealing elements. Tightening the nuts choke oil lines made only after the installation of the turbocharger.
- Finally, check motor oil level, if necessary, make appropriate adjustment (see chap. Power supply system and exhaust).
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Removal and installation of an intermediate cooler charge air tract Details of the installation of an intermediate cooler charge air tract models 163.128 (628 series engine)
| - Details of the installation of an intermediate cooler charge air tract models 163.128 (engine series 628) are shown in the illustration, which includes all the links in the text.
- Open the hood and fix it in an upright position.
- Remove both the lens unit.
- Remove the front crossmember of the frame.
- Disconnect from the right side of the cooler (1) The air tube (2).
- Remove the screws that secure the connecting plate (3) on the left side coolant heat exchanger (1).
- Remove the mounting screws (arrows) and remove cooler (1).
- Installation is performed in reverse order - do not forget to replace the sealing elements.
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Removal and installation of the diffuser Details of installation of the diffuser models 163.128 (628 series engine) Details of installation of the diffuser models 163.128 (628 series engine)  | |
| - Details Adjustment of air charge air tract models 163.128 (engine series 628) are shown in the illustrations, which include all the links in the text.
- Remove the fuel filter (1) complete with support bracket.
- Remove the valve block (2).
- Remove the covers (3) the cylinder head covers and remove the oil return pipe from the injectors.
- Remove the fuel lines (4).
- Remove the bypass duct (5) - only for the lower section (6), - the air ducts (5) are removed in gathering with the upper section of the diffuser (7).
- Disconnect vacuum pump line (8), remove and move in the direction of the bracket (9).
- Disconnect the vacuum line (10) the inlet port of the isolation valve.
- Remove the belt band (11) fixing the transport pipeline.
- Remove the bolts (12).
- Remove the bolts (13) securing cooling EGR.
- Disconnect from the line (15) of the cooling hoses tract (14).
- Remove and move aside the line of the cooling path (15).
- Remove the support brackets (16), left and right positioners EGR.
- Remove the mounting bolts (17) and remove the upper section of the diffuser (7) assembly with a bypass sleeve (5).
- Installation is performed in reverse order - do not forget to replace the sealing elements and the failed components.
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Removal and installation of the inlet tract charge air hoses Details of the installation of the left sleeve of the inlet charge air tract models 163.128 (628 series engine) Details of the installation of the right sleeve of the inlet charge air tract models 163.128 (628 series engine) Details of the installation of the intake charge air hoses tract models 163.128 (engine series 628) are shown in the illustrations, which include all the links in the text. The left sleeve | - Remove the left front wheel and the wheel arch locker protection.
- Disconnect the hose from the inlet diffuser.
- Remove the bolts (2) of the flange (3).
- Remove the bolt (5) on the cylinder head cover.
- Release the clip (4) and remove the inlet sleeve (1).
- Installation is in the reverse order.
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Right sleeve | - Disconnect the hose from the inlet diffuser.
- Disconnect the electrical wiring from the boost pressure sensor.
- Remove the bolt (2) on the cylinder head cover.
- Release the clip (3) and remove the inlet sleeve (1).
- Installation is in the reverse order.
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Removal and installation of the lower charge air hoses tract  | Details of installation of the lower left sleeve tract charge air models 163.128 (628 series engine) |
 | Details of installation of the lower left sleeve tract charge air models 163.128 (628 series engine) |
 | Details of the installation of the right lower arm tract charge air models 163.128 (628 series engine) |
 | Details of the installation of the right lower arm tract charge air models 163.128 (628 series engine) |
Details of installation of the lower charge air hoses tract models 163.128 (engine series 628) are shown in the illustrations, which include all the links in the text. The left sleeve | - Remove the lower section of the soundproofing.
- Remove the charge air hose tract (3).
- Remove the screws (1).
- Release upper screw connection plate (5) on the inlet flange (4) of the turbocharger (6).
- Remove the bottom screw the plate (5) on the air hose (2).
- Disconnect the hose (2) from the flange (4) of the turbocharger (6) and remove it from the engine by pulling down.
- Installation is performed in reverse order - do not forget to replace the O-ring.
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Right sleeve | - Disconnect the negative wire from the battery.
- Remove the lower section of the soundproofing.
- Remove the protective cover electric lines (6 and 7), a starter (M1) - ?��?�� terminals 30 and 50.
- Remove the starter mounting bolts to the dome of the transmission.
- Release upper screw the connecting plate (5) on the inlet flange of the turbocharger (4).
- Remove the bottom screw the plate (5) on the air hose (1).
- Disconnect the hose (2) of the duct (1).
- Remove the support brackets (3) with the lower section of the sump and the duct (1).
- Remove the top bracket (arrow) of the duct to the crankcase.
- Move aside the starter and ATF lines and disconnect the air hose from the turbocharger inlet flange.
- Pass the sleeve forward and remove it from the engine compartment.
- Installation is performed in reverse order - do not forget to replace the O-ring.
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Removal and installation of the bypass duct Details of installation of the bypass duct models 163.128 (628 series engine) Details of installation of the bypass duct models 163.128 (628 series engine) Details of installation of the bypass duct models 163.128 (628 series engine)
| - Details of installation of the bypass duct models 163.128 (engine series 628) are shown in the illustrations, which include all the links in the text.
- Remove the trim panel of the power unit.
- Disconnect the wiring from the sensor (3).
- Release the line cooling path of the bracket (2).
- Detach the air hose (4) from the bypass sleeve (1).
- Detach the air hose from the power steering line (6).
- Separate pipe EGR (8) of the connecting flange of the cylinder head (arrow).
- Disconnect the bypass hose from the connecting pipes (5 and 7) and remove them from the engine.
- Installation is performed in reverse order - do not forget to replace sealing elements.
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Removing and installing intermediate couplers Details of the installation of intermediate connecting pipes Air intake Series 628
| - Details of installation of the intermediate duct models 163.128 (engine series 628) are shown in the illustration, which includes all the links in the text.
- Lift the cover of the power unit.
- Remove the bypass duct (see. Above).
- Remove the fuel filter (3).
- Remove the screws (5) and remove the right connecting pipe (1).
- Remove the rod (9) vacuum unit overlapping inlet port (8).
- Remove the screw (7) and move towards a vacuum unit (8).
- Remove the screws (6) and remove the left connecting pipe (2).
- Installation is performed in reverse order - do not forget to replace the O-rings (10 and 11).
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