12 12 011
Remove and install / replace all spark plugs \PREMIUM
GRA-SYM-GRCI0000-10-WARNING
WARNING
Hot surfaces.
Risk of burning!
Perform all work only on components that have cooled down.
Preliminary Work
1 – Removing the acoustic cover
GRA-SYM-GRCI0000-10-NOTICE
RISK OF DAMAGE
Damage to the acoustic cover.
Jerky movements during disassembly and excessive application of force during installation may result in breakage of the acoustic cover.
Disassemble or mount the acoustic cover carefully.
Disassemble or mount snap-lock couplings of the ball pivots one after the other.
Disassemble or mount acoustic cover only at temperatures >20 °C.
Use only distilled water as an auxiliary material during installation, no lubricants.
GRA-PIX-GRRB-12-014-32
Pull the acoustic cover (1) up and out of rubber mounts and remove it.
2 – Remove left and right upper section of intake filter housing
GRA-SYM-GRCI0000-10-NOTICE
NOTICE
Description is for left component only. Procedure on the right side is identical.
▶ Remove upper section of intake filter housing
Prerequisite
Ignition is switched off.
GRA-PIX-GRRB-13-002-56
Unlock and pull off the connector (1) on the hot film air mass meter.
Unfasten clamp (2).
Release screws along line (3).
Release clean air pipe (4) from intake filter housing.
Remove the upper section of the intake filter housing (5).
3 – Release expansion tank for the charge air cooler and place to one side
GRA-PIX-GRRB-12-014-28
Loosen screw (1).
Release expansion tank (2) for the charge air cooler from the bracket and place to one side.
4 – Release oil reservoir for hydraulic steering and place to one side
GRA-PIX-GRRB-12-014-30
Loosen screws (1).
Release oil reservoir (2) for hydraulic steering and place to one side.
5 – Release DME control unit for the cylinders 1 to 4 from the holder and place to one side
GRA-PIX-GRRB-12-014-29
Unlock and pull off all connectors (2) on the DME control unit for the cylinders 1 to 4.
Release DME control unit for the cylinders 1 to 4 (1) from the holder and place to one side.
6 – Release DME control unit for the cylinders 5 to 8 from the holder and place to one side
GRA-PIX-GRRB-12-014-31
Unlock and pull off all connectors (2) on the DME control unit for the cylinders 5 to 8.
Release DME control unit for the cylinders 5 to 8 (1) from the holder and place to one side.
7 – Removing the ignition coil
Prerequisite
Ignition is switched off.
GRA-SYM-GRCI0000-10-NOTICE
RISK OF DAMAGE
Damage to the ignition coil.
The silicone hose of the ignition coil must not be contaminated by fuel as this can lead to failure of the ignition coil.
Cover ignition coils using suitable covers when working on the fuel system, if necessary remove them.
Do not oil or grease the silicone tube of the spark plug connector. The silicone tube is coated with talc to reduce the pulling forces.
GRA-SYM-GRCI0000-10-NOTICE
NOTICE
The description is for one component only. The procedure is identical for all further components.
GRA-PIX-GRRB-12-002-07
Unlock the connector fastener (1) of the ignition coil and disconnect the connector (2).
Ensure that cables are not crushed or damaged.
Repair damaged cables.
Slowly pull the ignition coil up and take out without jerking it.
Pulling out the ignition coil with jerks may cause silicone hose to tear.
GRA-PIX-GRRB-12-012-94
After removing the ignition coils: Blow off the silicone hose (1) of the ignition coils with an air gun (2).
The ignition coils must be free of oil and fuel residue.
Main Work
8 – Remove spark plugs
GRA-SYM-GRCI0000-10-WARNING
WARNING
Hot surfaces.
Risk of burning!
Perform all work only on components that have cooled down.
GRA-SYM-GRCI0000-10-CAUTION
CAUTION
Swirling dirt particles caused by compressed air.
Danger of injury!
Collect dirt particles, e.g. when blowing out, use cloth to do so.
GRA-SYM-GRCI0000-10-AUGE
Wear safety goggles.
GRA-SYM-GRCI0000-10-INFO
TECHNICAL INFORMATION
Clean spark plug slot with compressed air.
The spark plug shaft must be cleaned using compressed air after having removed the ignition coils and before removing the spark plugs. After having removed the spark plugs, once again check the sealing surface for contamination and (if necessary) clean using a moist cloth or clean using compressed air.
Deposits that are not removed according to instructions may enter the combustion chamber and lead to uncontrolled combustion. Remaining deposits on the spark plug sealing surfaces may lead to leaks and the spark plugs may come loose during engine operation.
Spark plug threads must not be greased or oiled. Insufficiently tightened spark plugs may cause leaks and the sparks plugs may come loose during engine operation.
GRA-PIX-GRRB-12-001-06
Before removing spark plugs: Clean spark plug slot with compressed air.
GRA-SYM-GRCI0000-10-INFO
TECHNICAL INFORMATION
Exclusively swivelling extensions may be used for the reversible ratchet. Rigid mounting tool and variable plug connections with rigid option may not be used; there is a risk that the insulator breaks.
Unscrew spark plugs with special tool 0 495 560 (12 1 220) and an extension with joint.
9 – Install spark plugs
GRA-PIX-GRRA1127-84
Insert the spark plugs (1) into the special tool 0 496 065 (12 1 230).
GRA-PIX-GRRA1127-85
GRA-SYM-GRCI0000-10-INFO
TECHNICAL INFORMATION
Do not drop spark plug into spark plug shaft! This can lead to a reduction of the electrode gap and can thus impair smooth running of the engine, especially in idle position.
Check the sealing surfaces for contamination. If applicable, remove any contamination using a moist cloth or compressed air.
Initially loosely screw in the spark plugs using special tool0 496 065 (12 1 230)
GRA-PIX-GRRB-12-001-06
GRA-SYM-GRCI0000-10-INFO
TECHNICAL INFORMATION
Exclusively swivelling extensions may be used for the reversible ratchet. Rigid mounting tool and variable plug connections with rigid option may not be used; there is a risk that the insulator breaks.
Tighten the spark plugs using a torque wrench, special tool 0 495 560 (12 1 220) and an articulated extension.
Spark plugs
M12x1.25
Tightening torque
23Nm
Postprocesses
10 – Install ignition coil.
GRA-SYM-GRCI0000-10-NOTICE
RISK OF DAMAGE
Damage to the ignition coil.
The silicone hose of the ignition coil must not be contaminated by fuel as this can lead to failure of the ignition coil.
Cover ignition coils using suitable covers when working on the fuel system, if necessary remove them.
Do not oil or grease the silicone tube of the spark plug connector. The silicone tube is coated with talc to reduce the pulling forces.
GRA-SYM-GRCI0000-10-NOTICE
NOTICE
The description is for one component only. The procedure is identical for all further components.
GRA-PIX-GRRB-12-012-95
Before installing the ignition coils: Blow the spark plug shafts (2) out with an air gun (1).
GRA-PIX-GRRB-12-002-08
Position the ignition coil and gently push it to the limit position, if necessary by twisting it back and forth slightly.
Check anti-twist lock.
The rubber seal (3) of the ignition coil must completely enclose the opening for the spark plug on the cylinder head cover.
Push connector (1) onto the ignition coil with the connector fastener (2) open.
Carefully close the connector fastener (2) in the direction of the arrow.
When closing the locking lever, the connector (1) must rest against the counter-piece nearly gap-free. In the process, the crank webs of the locking lever are positioned inside of the counter piece.
Ensure that cables are not crushed or damaged.
The connector fastener must snap into place without great effort.
Repair damaged cables.
11 – Mount DME control unit for the cylinders 5 to 8 on the holder
GRA-PIX-GRRB-12-014-31
Mount DME control unit for the cylinders 5 to 8 (1) on the holder.
Connect all connectors (2) to the DME control unit for the cylinders 5 to 8 and lock them audibly.
12 – Mount DME control unit for the cylinders 1 to 4 on the holder
GRA-PIX-GRRB-12-014-29
Mount DME control unit for the cylinders 1 to 4 (1) on the holder.
Connect all connectors (2) to the DME control unit for the cylinders 1 to 4 and lock them audibly.
13 – Mount oil reservoir for the hydraulic steering
GRA-PIX-GRRB-12-014-30
Mount the oil reservoir (2) for the hydraulic steering on the holder.
Tighten the screws (1).
Oil reservoir to holder
M6
5,3Nm
14 – Mount expansion tank for the charge air cooler
GRA-PIX-GRRB-12-014-28
Mount the expansion tank (2) for the charge air cooler on the bracket.
Tighten down screw (1).
Expansion tank for charge air cooler to holder
4Nm
15 – Install upper section of intake filter housing, left and right
GRA-SYM-GRCI0000-10-NOTICE
NOTICE
Description is for left component only. Procedure on the right side is identical.
▶ Install the upper section of the intake filter housing
Prerequisite
Ignition is switched off.
GRA-PIX-GRRB-13-002-56
Install the upper section of the intake filter housing (5).
Tighten the bolts along the line (3).
Intake filter housing upper section to intake filter housing lower section
3,3Nm
Connect connector (1) to the hot film air mass meter and lock audibly.
Mount clean air pipe (4) onto the intake filter housing.
Tighten clamp (2).
Intake filter housing to clean-air pipe
Hose clamp
3Nm
16 – Install acoustic cover
GRA-SYM-GRCI0000-10-NOTICE
RISK OF DAMAGE
Damage to the acoustic cover.
Jerky movements during disassembly and excessive application of force during installation may result in breakage of the acoustic cover.
Disassemble or mount the acoustic cover carefully.
Disassemble or mount snap-lock couplings of the ball pivots one after the other.
Disassemble or mount acoustic cover only at temperatures >20 °C.
Use only distilled water as an auxiliary material during installation, no lubricants.
GRA-PIX-GRRB-12-014-32
Install acoustic cover (1) and attach it to the rubber mounts.

Additional Information

Overview of Tightening Torques

Used in step9
Spark plugs
M12x1.25
Tightening torque
23Nm
Used in step13
Oil reservoir to holder
M6
5,3Nm
Used in step14
Expansion tank for charge air cooler to holder
4Nm
Used in step15
Intake filter housing upper section to intake filter housing lower section
3,3Nm
Used in step15
Intake filter housing to clean-air pipe
Hose clamp
3Nm

Overview of Special Tools

Socket
Used in step89
EGR-EGR-GRSW1212-20
Common
Usage For removing and installing the spark plugs (WAF 14 bihexal).
Included in the tool or work
Storage location C18
Replaced by
In connection with
SI-Number 01 20 06 (299)
Fitting aid
Used in step9
EGR-EGR-GRSW1212-30
Common
Usage Fitting aid for spark plug installation. Original BERU ZMH 001 rubber hose 0 890 00 001.
Included in the tool or work
Storage location individual
Replaced by
In connection with
SI-Number 01 04 07 (352)
Sponsored links