Remove/install intake manifold

AR09.20-D-1310G

Remove/install intake manifold

15.11.2019

Engine

111.984

For liquefied petroleum gas system

Modification notes

24.08.2016

Safety notice replaced

Note block before the work description

24.08.2016

Special tool 000 589 10 99 00 Tool kit added

Operation steps 4, 5, 7, 17

1

Air intake hose

2

Mounting clip

3

Injection valve connector

4

Air pump switchover valve

5

Purge control valve

6

Vacuum line

7

Fuel line

8

Air pump

9

Intake manifold

10

Idle speed control actuator

11

Intake manifold gasket

12

Cylinder head cover trim panel

13

Vacuum line

14

Cable tie

15

Electrical connector

16

Hoses

17

Gas distributor

18

Screw

19

Pressure sensors

20

Gas hose

 Danger

Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.

Remove any sources of ignition.
Protective clothing, safety gloves and safety glasses must always be worn.
Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.

AS00.00-Z-0018-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 

Remove/install

1

Empty lines after solenoid valve liquid phase

Engine 111.984 in model 902, 903, 904
with code MY9 (Liquefied Gas Technology (LGT))

AR47.25-D-0019A

2

Detach vacuum line (13) on the intake manifold (9)

 Installation: Replace hose clamps.

3

Disconnect electrical connectors (15)

4

Remove hose (16) for entry pressure to gas distributor (17)

 Hose, entry pressure to gas distributor

*BA47.25-N-1018-01K

 Tool kit

*000589109900

5

Remove hoses (16) for exit pressure on gas distributor (17)

 Hose, exit pressure to gas distributor

*BA47.25-N-1017-01K

 Tool kit

*000589109900

6

Remove screw/bolt (18) and take off pressure sensors (19)

 Screw/bolt, pressure sensor to firewall

*BA47.10-N-1014-02B

7

Remove gas hose (20) at gas distributor (17).

 Gas hose at gas distributor elbow fitting

*BA47.25-N-1011-01K

 Tool kit

*000589109900

8

Disconnect electrical connections to gas distributor (17)

9

Disconnect battery ground line

10

Remove air intake hose (1)

AR09.10-D-8030F

11

Remove idle speed control actuator (10)

AR30.22-D-1152B

12

Remove air pump switchover valve (4)

AR14.30-D-7255A

13

Remove purging switchover valve (5)

AR47.30-D-8220A

14

Release retaining clip (2) at cylinder head cover and unplug injection valve connectors (3) of the injection valves at the intake manifold (9)

15

Remove trim panel for cylinder head cover (12)

AR01.20-D-5014-02C

 Bolt, trim panel of cylinder head cover to cylinder head cover

*BA01.20-N-1002-01A

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

16

Unplug the connector from the primary side of ignition coils, and run the lines out of the housing of the cylinder head cover

 The lines are included with the other lines in a subharness and passed downwards through the intake manifold (9).

17

Detach vacuum lines (6) from intake manifold (9)

AR09.20-D-1310-06B

 Vacuum line at intake manifold vacuum fitting

*BA09.20-N-1004-02A

 Tool kit

*000589109900

18

Remove air pump (8) from the bracket

 Do not disconnect lines of the air pump (8).

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

19

Detach fuel lines (7) at engine

AR47.25-D-1000-01D

20

Remove intake manifold (9) from cylinder head

AR09.20-D-1310-07E

 Installation: First insert outer screw/bolt on cylinder 4 and then fasten the hose on injection fitting.

 Intake manifold to cylinder head

*BA09.20-N-1001-02A

21

Install in the reverse order



Check

22

Check gas distributor (17) with hoses (16), pressure sensors (19) and the injection fitting for leaktightness

AR07.54-D-0002A

23

Document the work in an inspection logbook

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 111.948/978/979/984

BA01.20-N-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

9

 Intake manifold, intake manifold preheating

Number

Designation

Engine 111.979/984

BA09.20-N-1001-02A

Intake manifold to cylinder head

M8

Nm

21

 Intake manifold, intake manifold preheating

Number

Designation

Engine 111.979/984

BA09.20-N-1004-02A

Vacuum line at intake manifold vacuum fitting

Nm

30

 Compressed-gas tank, gas shutoff valve

Number

Designation

Engine 111.984

BA47.10-N-1014-02B

Screw/bolt, pressure sensor to firewall

Nm

10

 Fuel lines/hoses

Number

Designation

Engine 111.984

BA47.25-N-1011-01K

Gas hose at gas distributor elbow fitting

Nm

20

 Fuel lines/hoses

Number

Designation

Engine 111.984

BA47.25-N-1017-01K

Hose, exit pressure to gas distributor

Nm

5,5

 Fuel lines/hoses

Number

Designation

Engine 111.984

BA47.25-N-1018-01K

Hose, entry pressure to gas distributor

Nm

5,5