Remove/install charge air manifold

AR09.41-P-1310MT

Remove/install charge air manifold

05.02.2019

Engine

270 in model 117, 156, 176, 242, 246.2

Shown on model 246.2

2

Wide open throttle bleed line

3

Partial load bleed line

4

Engine oil filler neck

5

Vent valve

6

Purge line

7a

Vacuum hose

7b

Vacuum hose

8

Charge air distributor

9

Electrical connector

10

Cover

B17/9

Charge air temperature sensor downstream of throttle valve

B28/7

Pressure sensor downstream of throttle valve

Y58/2

Partial load operation crankcase ventilation valve

Y77/1

Boost pressure control pressure transducer

Y133

Coolant pump switchover valve

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove the throttle valve actuator.

AR07.61-P-1401MT

 Installation: Only install upper engine cover after the leak test.

2

Depressurize gas system.

Engine 270 in model 242
with code 924 (Bivalent natural gas drive)

AR47.10-P-0028NKB

3

Remove gas distribution rail.

Engine 270 in model 242
with code 924 (Bivalent natural gas drive)

AR07.03-P-0001NKB

4

Remove the oil separator.

Engine 270 in model 117, 156
with code 494 (US version)

AR01.20-P-9750MTU

5

Remove full-load bleed line (2) from air intake pipe.

Engine 270 in model 117, 156
except code 494 (US version)
Engine 270 in model 176, 242, 246.2

6

Remove partial-load bleed line (3) from air intake pipe.

Engine 270 in model 117, 156
except code 494 (US version)
Engine 270 in model 176, 242, 246.2

7

Unclip spacer at partial-load bleed line (3) and full-load bleed line (2).

Engine 270 in model 117, 156
except code 494 (US version)
Engine 270 in model 176, 242, 246.2

8

Unclip partial-load bleed line (3) at engine oil filler neck (4).

Engine 270 in model 117, 156
except code 494 (US version)
Engine 270 in model 176, 242, 246.2

9

Unclip vacuum line at engine oil filler neck (4).

Engine 270 in model 117, 156
except code 494 (US version)
Engine 270 in model 176, 242, 246.2

10

Unclip coolant pump switchover valve (Y133) at bracket.

11

Remove boost pressure control pressure transducer (Y77/1).

AR07.17-P-7002MT

12

Disconnect electrical connection at pressure sensor downstream of throttle valve (B28/7).

13

Disconnect electrical connection at charge air temperature sensor downstream of throttle valve (B17/9).

14

Place all supply lines and vacuum lines to one side.

15

Unclip partial-load bleed line (3) at charge-air distributor (8).

Engine 270 in model 117, 156
except code 494 (US version)
Engine 270 in model 176, 242, 246.2

16

Unclip full-load bleed line (2) at charge-air distributor (8).

Engine 270 in model 117, 156
except code 494 (US version)
Engine 270 in model 176, 242, 246.2

17

Remove bleed valve (5) from charge-air distributor (8).

 Installation: Replace sealing ring.

18

Unclip purge line (6) at charge-air distributor (8).

19

Remove vacuum hoses (7a, 7b) from vacuum reservoir at charge-air distributor (8).

20

Release screws of charge-air distributor (8) in reverse order to tightening procedure and remove.

AR09.41-P-1312-01MT

 Installation: Replace seals. Observe tightening procedure.

 Screw/bolt, charge air distributor to cylinder head

*BA09.20-P-1001-01U

21

Detach partial-load operation crankcase ventilation valve (Y58/2) at bracket of charge-air distributor (8).

22

Unclip electrical connector (9) of knock sensor at charge-air distributor (8).

23

Remove charge-air distributor (8).

24

Remove cap (10) at blind flange.

When replacing the charge-air distributor (8).

 Installation: Replace seal.

25

Install in the reverse order.

26

Read out, clear fault memory with vehicle diagnosis system.



AD00.00-P-2000-04A

27

Check leak tightness of natural gas system with the engine running.

Engine 270 in model 242
with code 924 (Bivalent natural gas drive)

AR07.54-P-0001NKB

 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

28

Perform engine test run and check engine and fuel system for leak tightness.

29

Install upper engine cover.

 Intake manifold

Number

Designation

Engine 270

BA09.20-P-1001-01U

Screw/bolt, charge air distributor to cylinder head

Nm

14