Remove/install intake manifold · ar0920s1310d · Mercedes-Benz WIS

AR09.20-S-1310D

Remove/install intake manifold

16.12.08

ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)

ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

S09.20-2508-09

2 Exhaust gas recirculation cooling module

3 Cylinder head

4 Rail

6 Dipstick guide tube

10 Air intake collector seal

11 Oil filler neck

16 Gasket

7 Bracket

8 Intake manifold

9 Mixing chamber with exhaust gas recirculation

 	Remove/install
1	Remove mixing chamber with exhaust gas recirculation (9) at intake manifold (8)		AR09.20-S-1330A
Danger!	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
2	Drain coolant		AR20.00-S-1142A
3	Remove front end cross member		AR88.00-S-2302A
4	Remove front grille		AR88.00-S-2115A
5	Remove intake air guide duct on air filter lower section
Danger!	Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
6	Unscrew bolt from fuel lines holder to exhaust gas recirculation cooling module (2)		*BA47.25-N-1001-01E
			*001589760900
7	Unscrew bolts on exhaust gas recirculation cooling module (2) to cylinder head (3)	 The coolant line remains attached to the exhaust gas recirculation cooling module (2). Expose exhaust gas recirculation cooling module (2).  Installation: Replace seal (16).
			*BA14.20-N-1002-01C
			*001589760900
8	Unscrew banjo bolt for return line at rail (4)	 Replace gaskets. Catch escaping fuel. Ensure scrupulous cleanliness.
			*BA07.16-P-1006-01A
9	Unscrew bolt, oil dipstick guide tube (6) to holder (7)		*001589760900
10	Unscrew bolt, oil filler neck (11) to holder (7)		*BA01.45-N-1009-01H
			*001589760900
11	Unscrew bolt, holder (7) to intake manifold (8)		*BA09.20-P-1004-01A
			*001589760900
12	Unscrew upper part and lower part of the holder (7)	 Remove upper part of the holder (7).
			*BA09.20-P-1006-01A
13	Unscrew bolts, holder (7) to cylinder crankcase		*BA09.20-P-1005-01A
			*001589760900

14	Unclip and expose all fuel lines on intake manifold (8)
15	Unscrew bolts (3) from intake manifold (8) to cylinder head		*BA09.20-P-1001-01A
			*001589760900
16	Remove intake manifold (8)	Cover intake ports after removal. Clean sealing surface and replace gasket (10).
17	Install in the reverse order
	Checking
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. Always wear appropriate work clothing when working on the vehicle.	AS00.00-Z-0005-01A
18	Check for leaks with engine running

 Oil pan

Number	Designation		Engine 611.980


BA01.45-N-1009-01H	Bolt, mounting clamp for oil filler neck to intake manifold bracket	Nm	8

 Intake manifold

Number	Designation			Engine 611.980


BA09.20-P-1001-01A	Bolt, intake manifold to cylinder head	M5	Nm	-
		M7	Nm	14
BA09.20-P-1004-01A	Bolt, upper part of intake manifold holder to intake manifold		Nm	8
BA09.20-P-1005-01A	Bolt, lower part of holder to cylinder crankcase		Nm	18
BA09.20-P-1006-01A	Bolt, upper part of intake manifold holder to lower part of holder for cylinder crankcase		Nm	8

 Common rail diesel injection (CDI)

Number	Designation		Engine 611.980


BA07.16-P-1006-01A	Banjo bolt, leak oil line to rail	Nm	20

 Exhaust gas recirculation

Number	Designation		Engine 611.980


BA14.20-N-1002-01C	Bolt, AGR cooling module to cylinder head	Nm	16

 Fuel pipes/hoses

Number	Designation		Engine 611.980


BA47.25-N-1001-01E	Bolt, fuel lines to AGR cooling module	Nm	14

External Torx set

001 589 76 09 00

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