Remove/install charge air manifold

AR09.41-D-1310NG

Remove/install charge air manifold

3.9.08

 

Remove/install

1

Close the gas cylinder, drain the gas lines of the natural gas system

AR47.10-D-0028NG

2

Disconnect battery ground line

AR54.10-D-0003SD

3

Removing fuel rail with injection valves

AR07.03-D-1450NG

4

Unscrew bolt (20) on the gas hose bracket (21)

5

Mark union nut (22) and open it

 Open union nut (22) carefully, as there may be gas remaining in gas hose (21).

Use suitable plugs to seal the openings.

 Installation: Tighten union nut (22).

See 

Tighten threaded pipe connections for gas lines

AR47.25-D-0030NG

6

Unclip electrical connectors (23, 24) from bracket

7

Detach electrical connector (23) and release the electrical wiring harness

8

Unscrew bolts (3) and remove air intake pipe (2)

9

Disconnect electrical connector (4) at boost pressure sensor (B5/7)

10

Disconnect electrical connector (5) on charge air temperature sensor

11

Detach electrical connector (6) from throttle valve positioner (M16/47) and unclip electrical wiring harness (7) from retaining clips (8, 9)

12

Loosen clamp and pull off crankcase ventilation hose (10) from charge air manifold (1)

13

Pull off vacuum hose (11) from charge air manifold (1)

14

Pull off purge line (12) from charge air manifold (1)

15

Loosen hose clamps (13, 14)

16

Unscrew bolts (16) and pull off charge air pipe (15) from compressor (18)

 Fasten charge air pipe (15) to the underfloor. Close off the openings with a rag.

17

Remove bolts (19)

18

Remove poly-V belt from supercharger (18) belt pulley

 Do not remove poly-V belt.

AR13.22-D-1202NG

19

Pull off charge air pipe (17) from throttle valve positioner (M16/47)

 Close off the openings with a rag.

 Installation: Check the seal on throttle valve positioner (M16/47), and replace if necessary.

20

Unscrew bolt (25) from oil dipstick guide tube (26)



*BA18.40-N-1003-01L

21

Unscrew bolt (27) from intake muffler (28)



*BA09.50-N-1004-01A

22

Unscrew bolts (29, 30) and carefully push compressor (18) to one side



*BA09.50-N-1001-01A



*BA09.50-N-1002-01A

23

Unscrew bolts (31) and remove charge air manifold (1)

 Close off the openings with a rag.

 Installation: Install new sealing rings.

24

Remove throttle valve actuator (M16/47), boost pressure sensor (B5/7) and charge air temperature sensor on charge air manifold (1)

 If replacing the charge air manifold (1).

25

Remove gas distributor rail with injection valves from charge air manifold (1)

 If replacing the charge air manifold (1).

26

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

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

AS00.00-Z-0005-01A

27

Test run engine and check engine for leaks around charge air manifold (1)

28

Carry out leak test of natural gas system

AR07.54-D-0001NG

Number

Designation

Engine
271
in model 906

BA09.50-N-1001-01A

Bolt, compressor to timing case cover

M8

Nm

20

BA09.50-N-1002-01A

Bolt, supercharger to engine support

M8

Nm

20

BA09.50-N-1004-01A

Bolt, intake muffler to oil filter housing

M6

Nm

11

Number

Designation

Engine
271 in model 906

BA18.40-N-1003-01L

Bolt for oil dipstick guide tube

Nm

20