Remove/install charge air manifold

AR09.41-D-1310NH

Remove/install charge air manifold

26.10.10

15.9.10

"Unscrew charge air manifold bolts on cylinder head with flexible head wrench, screw in and tighten to specified torque" added.

Step 18

*BA09.20-N-1001-01D

 

Remove/install

1

Remove engine trim panel

AR01.10-D-2405NG

2

Remove gas distributor rail with injection valves

On vehicles with code (MY9) Liquefied Gas Technology (LGT)

AR07.03-D-0001LG

3

Remove air filter housing

AR09.10-D-1150NG

4

Removing fuel rail with injection valves

AR07.03-D-1450NG

5

Unscrew bolts (3) or pull out clips and remove air intake pipe (2)

6

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

7

Disconnect electrical connector (5) on charge air temperature sensor

8

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

9

Remove clamp on crankcase ventilation hose (10) and pull crankcase ventilation hose (10) off of charge air manifold (1)

 Installation: Check clamp, replace if necessary.

10

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

11

Remove purge line (12) from charge air manifold (1)

12

Loosen clamp (13) on charge air pipe (14)

 Installation: Inspect clamp (13), install new one if necessary.

13

Lift/jack up vehicle

AR00.60-D-1000H

14

Remove bolts (15)

15

Lower vehicle

16

Pull off charge air pipe (14) from throttle valve positioner (M16/47)

Close off openings with a rag.

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

17

Detach electrical connector (16), release the electrical wiring harness and place to one side

18

Unscrew bolts (17) and remove charge air manifold (1)

Close off openings with a rag.

 Installation: Install new sealing rings (18).



*BA09.20-N-1001-01D

 Flexible head wrench set

*001589810900

19

Remove throttle valve positioner (M16/47) from charge air manifold (1)

If replacing the charge air manifold (1).

20

Remove boost pressure sensor (B5/7) from charge air manifold (1)

If replacing the charge air manifold (1).

21

Remove charge air temperature sensor from charge air manifold (1)

If replacing the charge air manifold (1).

22

Slide protective sleeves back on gas hoses (19, 20) until gas injection fittings (21) are accessible

On vehicles with code (MY9) Liquefied Gas Technology (LGT)

If replacing the charge air manifold (1).

23

Unscrew gas injection fittings (21) for gas hoses (19, 20) from charge air manifold (1)

On vehicles with code (MY9) Liquefied Gas Technology (LGT)

 If replacing the charge air manifold (1).

 Installation: Coat threads on gas injection fittings (21) with Loctite 243 and screw gas injection fittings (21) into charger manifold (1) down to stop.
When tightening gas injection fittings (21) observe reference values for tightening torque.

Failure to observe this procedure can result in leakage at the gas injection fittings (21) or charge air manifold (1) or damage to the thread in the charge air manifold (1).

 Installation: Observe different lengths of gas hoses (19, 20). The gas hose (19) to the connection on cylinders 1 and 2 is 270 mm long. The gas hose (20) to the connection on cylinders 3 and 4 is 310 mm long.



*BA07.54-N-1001-01D

 Double open-ended wrench

*271589020100

Loctite 243

*BR00.45-Z-1066-01A



Clean

24

Clean threads on gas injection fittings (21)

On vehicles with code (MY9) Liquefied Gas Technology (LGT)

 When gas hoses (19, 20) are reused.

25

Clean threads for gas injection fittings (21) in charge air manifold (1)

On vehicles with code (MY9) Liquefied Gas Technology (LGT).

 When charge air manifold (1) is reused.

26

Clean sealing surfaces on charge air manifold (1)

 When charge air manifold (1) is reused.

27

Clean sealing surfaces on cylinder head

28

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

29

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

30

Check gas system for leakage in area of gas hoses (19, 20) on charge air manifold (1)

On vehicles with code (MY9) Liquefied Gas Technology (LGT)

AP47.00-D-4752LG

Number

Designation

Engine
271.951
with code MY9

BA07.54-N-1001-01D

Gas hose with gas injection fitting on charge air manifold

Nm

1

Number

Designation

Engine
271

BA09.20-N-1001-01D

Bolt, charge air manifold or fuel distributor to cylinder head

Nm

14

Number

Designation

Order number

BR00.45-Z-1066-01A

Loctite 243

A 613 989 09 71