Remove/install charge air manifold - AR09.41-P-1310TA
ENGINE 648.961 in MODEL 211.023 /026 /223 /226
| Remove/install | |||
|---|---|---|---|
| Risk of death caused by vehicle slipping or toppling off the lifting platform. | Align vehicle between columns of lifting platform and position four support plates at lifting platform support points specified by vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with 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 | |
| Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure. | Keep all ignition sources out of hazard area. Do not carry out any work on the system when it is pressurized. |
AS07.16-Z-0001-01A | |
| Risk of explosion
caused by oxyhydrogen gas. Risk of poisoning and caustic burns
caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries |
No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. |
AS54.10-Z-0001-01A | |
| 1 | Disconnect ground line from battery | ||
| Model 211.0 | AR54.10-P-0003T | ||
| Model 211.2 | AR54.10-P-0003TA | ||
| Notes on battery | AH54.10-P-0001-01A | ||
| Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof. | Keep body parts and limbs well clear of moving parts. | AS00.00-Z-0011-01A | |
| 2 | Open engine hood | AR88.40-P-1000T | |
| 3 | Remove cylinder head cover trim | AR01.20-P-5014-02C | |
| *BA01.20-P-1002-01G | |||
| *BA01.20-P-1003-01G | |||
| 4 | Remove bottom section of soundproofing | AR94.30-P-5300T | |
| 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 | |
| 5 | Drain coolant from radiator | AR20.00-P-1142HB | |
| 6 | Remove fuel filter (1) with bracket | *BA47.20-P-1001-02A | |
| 7 | Detach fuel hoses (2) from fuel pipe (3) | ||
| 8 | Detach the top fuel pipe (3) from charge air manifold (4) | *BA47.25-P-1001-01C | |
| 9 | Remove exhaust gas recirculation valve | AR14.20-P-7662T | |
| 10 | Remove exhaust gas recirculation cooler (5) | AR14.20-P-7665TA | |
| 11 | Disconnect electrical connector (6) at TDC sensor | ||
| 12 | Remove cable tie (7) and disconnect electrical connector (8) at glow output stage | ||
| Remove/install glow output stage | AR15.20-P-4500TU | ||
| 13 | Detach electrical connector (9) at charge air temperature sensor | ||
| 14 | Unscrew bolts of mixing chamber (15) from charge air manifold (4) | ||
| *BA09.41-P-1011-01A | |||
| 15 | Remove dipstick guide tube | AR01.45-P-9600T | |
| 16 | Mark bottom fuel hoses (10) to fuel pipe (3) and detach | ||
| 17 | Detach bottom fuel pipe (3) from charge air manifold (4) | ||
| *BA47.25-P-1001-01C | |||
| 18 | Remove cable tie (12) and disconnect electrical connector (11) at oil sensor to oil pan | ||
| 19 | Detach electrical line terminal 50 (13) from starter | *BA15.30-N-1003-01G | |
| 20 | Place wiring harness upwards to the side | ||
| 21 | Unscrew bolts (14) of charge air manifold (4) from cylinder head | *BA09.41-P-1001-01A | |
| 22 | Take out charge air manifold (4) | ||
| 23.1 | Detach intake port shutoff motor from charge air manifold (4) | When replacing charge air manifold | |
| *BA09.41-P-1007-01A | |||
| 24.1 | Detach glow output stage with bracket from charge air manifold (4) | When replacing charge air distribution pipe to vehicles with USA version, code 494a | |
| *BA15.20-P-1007-01A | |||
| 25 | Install in the reverse order | ||
| 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 | |
| 26 | Check fuel system for leaks with engine running | ||
| 27 | Inspect cooling system for leaks | AR20.00-P-1010HA | |
| 28 | Read out fault memory and erase if necessary | STAR DIAGNOSIS diagnosis system | |
| Connect STAR DIAGNOSIS and read out fault memory | D00.00-P-2000-04A |
| Number | Designation | Engine 648 | |
|---|---|---|---|
| BA01.20-P-1002-01G | Bolt, cylinder head cover trim to cylinder head | Nm | 9 |
| BA01.20-P-1003-01G | Bolt, cover to charge air manifold. | Nm | 9 |
| Number | Designation | Engine 646 except 646.98, Engine 647, 648 | |
|---|---|---|---|
| BA47.20-P-1001-02A | Bolt, fuel filter to charge air manifold | Nm | 9 |
| Number | Designation | Engine 648 | |
|---|---|---|---|
| BA47.25-P-1001-01C | Bolts of fuel line to charge air manifold | Nm | 9 |
| Number | Designation | Engine 648.960/ 961 | ||
|---|---|---|---|---|
| BA09.41-P-1001-01A | Bolt to charge air manifold | M5 | Nm | - |
| M7 | Nm | 16 | ||
| BA09.41-P-1011-01A | Bolt, mixing chamber to charge air distribution line | M6 | Nm | 9 |
| Number | Designation | Engine 648.961 | |
|---|---|---|---|
| BA09.41-P-1007-01A | Bolt, intake port shutoff actuator motor to charge air manifold | Nm | 9 |
| Number | Designation | Engine 646.951/ 961/962/ 963/966, Engine 647, 648 | |
|---|---|---|---|
| BA15.30-N-1003-01G | Nut for connection for circuit 50 | Nm | 6 |
| Number | Designation | Engine 647, 648 | |
|---|---|---|---|
| BA15.20-P-1007-01A | Nut, glow output stage to bracket | Nm | 5 |