Remove/install charge air manifold · ar0941d1310we · Mercedes-Benz WIS

AR09.41-D-1310WE

Remove/install charge air manifold

07.08.2015

Engine	651 in model 900
Engine	651.955/956/957 in model 906

Modification notes

31.07.2015	Clean thread of the screw/bolts (11 to 18) on the cylinder head, added	Operation step 11
31.07.2015	Clean screw/bolts (11 to 18) on the charge air distributor (1), added	Operation step 12
31.07.2015	Tightening sequence of the screw/bolts (11 to 18), added	Operation step 14
31.07.2015	Screw/bolt, charge air distributor to cylinder head	ENGINE 651 in MODEL 900	BA09.41-N-1011-01M
31.07.2015	Screw/bolt, charge air distributor to cylinder head	ENGINE 651 in MODEL 906	BA09.41-N-1011-01M

D09.41-1197-09

Shown on model 906 without CODE MP5 (Model version Euro 5)

1	Charge air distributor	8	Coolant hose	15	Screw/bolt
3	Thermostat housing	9	Engine wiring harness	16	Screw/bolt
4	Coolant hose	11	Screw/bolt	17	Screw/bolt
5	Clamp	12	Screw/bolt	18	Screw/bolt
6	High-pressure line	13	Screw/bolt
7	Heat exchanger	14	Screw/bolt

Shown on model 906 without CODE MP5 (Model version Euro 5)

1	Charge air distributor
10	Seal
11	Screw/bolt
12	Screw/bolt
13	Screw/bolt
14	Screw/bolt
15	Screw/bolt
16	Screw/bolt
17	Screw/bolt
18	Screw/bolt

D09.20-1045-05

	Remove
1	Remove high-pressure line (6)		AR07.03-D-7000WE
2	Remove connection fitting for coolant hoses		AR20.20-D-7470WE
3	Remove exhaust gas recirculation valve	Engine 651 in model 900 Engine 651.955/956/957 in model 906 except code MS3 (Engine version EURO 3)	AR14.20-D-7662WE
4	Remove coolant hose (8) on heat exchanger (7)	 Hose clamp pliers	*003589033700
5	Detach coolant hose (4) on thermostat housing (3)	 Press engine wiring harness (9) to the side.
		 Hose clamp pliers	*003589033700
6	Disconnect electrical connection from intake port shutoff actuator motor	Engine 651.955/957 in model 906 with code MP5 (Engine version Euro 5)	AR09.20-D-1313WE
7	Remove screws/bolts (11 to 18)	 The screw/bolts (11 to 18) remain on the charge air distributor (1).
		 Set of flexible head wrenches	*001589810900
8	Remove the charge air distributor (1)
	Install
9	Clean sealing surfaces on charge air distributor (1)
10	Replace seal (10)
11	Clean thread of the screw/bolts (11 to 18) on the cylinder head	 The thread of the screw/bolts (11 to 18) on the cylinder head must be cleaned. Leaks can occur on the charge air distributor (1) otherwise.
12	Clean the screw/bolts (11 to 18) on the charge air distributor (1)	When reusing the charge air distributor (1).
		 The screw/bolts (11 to 18) on the charge air distributor (1) must be cleaned. Leaks can occur on the charge air distributor (1) otherwise.
13	Insert the charge air distributor (1)
14	Screw in screw/bolts (11 to 18)	 Observe tightening sequence. Tighten screw/bolts (11 to 18) in the numerical sequence.
		 Bolt, charge air distributor to cylinder head	*BA09.41-N-1011-01M
		 Set of flexible head wrenches	*001589810900
15	Connect electrical connection to intake port shutoff actuator motor	Engine 651.955/957 in model 906 with code MP5 (Engine version Euro 5)	AR09.20-D-1313WE
16	Check clamp (5) and coolant hose (4)	For damage
		
		Replace clamp (5) or coolant hose (4)
17	Mount coolant hose (4) on thermostat housing (3)	 The marking on the coolant hose (4) and on the thermostat housing (3) (arrows) must coincide. Position clamp (5) between markings on the coolant hose (4).
		 Hose clamp pliers	*003589033700
18	Check clamp on coolant hose (8) and coolant hose (8)	For damage
		
		Replace clamp on coolant hose (8) or coolant hose (8)
19	Mount coolant hose (8) on heat exchanger (7)	 Position clamp between the markings on the coolant hose (8).
		 Hose clamp pliers	*003589033700
20	Install exhaust gas recirculation valve	Engine 651 in model 900 Engine 651.955/956/957 in model 906 except code MS3 (Engine version EURO 3)	AR14.20-D-7662WE
21	Install connection fitting for coolant hoses		AR20.20-D-7470WE
22	Install high-pressure line (6)		AR07.03-D-7000WE
	Check
 Danger !	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
23	Perform engine test run and check engine or fuel system around the charge air distributor (1) for leaktightness

 Charge air pipe/charge air cooling

Number	Designation			Engine 651 in model 900	Engine 651 in model 906
BA09.41-N-1011-01M	Bolt, charge air distributor to cylinder head	Stage 1	Nm	15	15
		Stage 2	°	60	60

001 589 81 09 00

Set of flexible head wrenches

003 589 03 37 00

Hose clamp pliers

Referenced documents

ar0703d7000we Remove/install pressure line from high-pressure pump/fuel distributor
ar0920d1313we Remove/install intake port shutoff actuator motor
ar1420d7662we Remove/install exhaust gas recirculation valve
ar2020d7470we Remove/install connection fittings for coolant hoses
as0000z000501a 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.