Table of contents: Removal 🠇 Installation 🠇
Removal
Disconnect the battery.
Drain the fluid from the engine cooling system.
Remove:
- protective shield under the engine (depending on the model);
- front bumper (2) (see the corresponding operation);
- front right headlight (1).
Loosen the screws securing the windshield washer reservoir.
Move the washer reservoir aside (without opening the circuit).
Place the car on a lift.
EP6DT/DTS engines
Remove the intake manifold (4) (from above).
Loosen the bolts (5) and remove the air filter unit cover (3).
Unscrew the bolt (9) and remove the intake manifold (8) (lower).
Loosen the bolt (6) and remove the air filter (7).
Disconnect the connector in area "a".
Loosen clamps (10) and (14).
Unscrew bolts (11) and (13) and remove the intermediate tube (12).
Caution: Release the fuel pressure by connecting the end of the tube to the SHRADER fitting and collect the drained fuel in a collecting container (in area "b").
Loosen and disconnect the fuel pipes (15) (in area "c").
Remove the lifting bracket.
Disconnect the air bleed tube (16) (in area "d").
Disconnect the connector (in area "e").
Unscrew the nuts (17).
Disconnect the air conditioning pipes (18) from the air conditioning reducer.
Caution: Quickly close the air conditioner pipes to prevent refrigerant leakage.
Unscrew the nuts (19).
Disconnect the tubes (18) from the air conditioner condenser.
Caution: Quickly close the air conditioner pipes to prevent refrigerant from baking.
Move the accessory drive belt aside.
Disconnect the electrical connectors (21) of the air conditioning compressor (22).
Loosen the bolts (20).
Move aside the cooling compressor (22).
Loosen the bolts (20).
Unscrew the nuts (23).
Disconnect the air conditioning pipes (18) from the air conditioning compressor (22).
Caution: Quickly close the air conditioner pipes to prevent refrigerant leakage.
Disconnect the electrical connector from the air conditioning pressure sensor.
Remove the air conditioner tube retaining bolts.
Disconnect the air conditioning pipes (18).
Remove the high pressure (HP) and low pressure (LP) air conditioner pipes.
Loosen the bolts (24) and remove the air filter unit cover (25).
Engines EP6 / ERZ
Loosen the bolts (27) and remove the air filter unit (26) (intermediate piece).
Loosen the bolt (28) and remove the intake manifold (29) and air filter unit (30) (lower).
Disconnect the fuel hoses (31).
Disconnect the fuel hoses (31) (in area "f").
Remove the lifting bracket (32).
Disconnect the air bleed tube (33) (in area "g").
Unscrew the nuts (34).
Caution: Quickly close the air conditioner pipes to prevent refrigerant leakage.
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Disconnect the air conditioner pipes (35) from the air conditioner reducer.
Unscrew the nuts (36).
Caution: Quickly close the air conditioner pipes to prevent refrigerant leakage.
Disconnect the tubes (35) from the air conditioning compressor.
Unscrew the nuts (37).
Caution: Quickly close the air conditioner pipes to prevent refrigerant leakage.
Disconnect the tubes (35) from the air conditioner condenser.
Disconnect the electrical connector from the air conditioning pressure sensor.
Remove the air conditioner tube retaining bolts.
Disconnect the air conditioning pipes (35).
Remove the high pressure (HP) and low pressure (LP) air conditioner pipes.
Installation
Caution: Check the cleanliness of the hoses before and after the air conditioning system components.
Note: Before installing the A/C tubes, install new gaskets lubricated with A/C compressor oil.
Caution: Observe the required tightening torques (see the corresponding tables).
Install all removed parts in reverse order.