Remove/install intake manifold - AR09.20-P-1310QK

ENGINE 271.940 in MODEL 203.042 /242 /742, 209.342 /442 

ENGINE 271.941 in MODEL 211.242 

ENGINE 271.946 in MODEL 203.046 /246 /746 

ENGINE 271.948 in MODEL 203.040 /240 /740 

ENGINE 271.941 in MODELS 211.042 except CODE (924) Bivalent natural gas drive 

ENGINE 271.921 in MODEL 203.730 

ENGINE 271.955 in MODEL 209.341 /441 

ENGINE 271.956 in MODEL 211.241 

ENGINE 271.956 in MODELS 211.041 except CODE (924) Bivalent natural gas drive 

Fig 1: Identifying Intake Manifold Remove/Install Components - Engine 271.948 In Model 203.040 /240 /740 (1 Of 2)

Fig 2: Identifying Intake Manifold Remove/Install Components - Engine 271.948 In Model 203.040 /240 /740 (2 Of 2)

	Remove/install
1	Open engine hood	Model 203	AR88.40-P-1000P
		Model 209	AR88.40-P-1000Q
		Model 211	AR88.40-P-1000T
2	Remove engine cover (1)	Hold the engine cover (1) with both hands and pry it off.
3	Remove air filter housing		AR09.10-P-1150Q
4.1	Remove charge air line	Model 203, 209 For this step slacken upper and lower hose clamp and remove charge air manifold toward compressor.
4.2	Detach the charge air line from the throttle valve actuator (M16/6) and set aside	Model 211
5	Remove the throttle valve actuator (M16/6)	Model 203, 209	AR07.61-P-1401QK
6	Unplug connector of charge air temperature sensor (B17/8)	Detach the clamp (7) on the wiring harness for the charge air temperature sensor (B17/8) from the intake manifold (10).
7	Detach hose (6) of crankcase ventilation
8	Detach hose (5) of tank ventilation system from intake manifold (10).
9	Release fuel distributor rail (11) with injectors	Unscrew only two bolts (8) and pry off fuel distributor rail (11) (leave enough space to remove the intake manifold (10)).
		Model 203, 209	AR07.03-P-1450Q
		Model 211	AR07.03-P-1450TK
			*BA07.52-P-1001-01B
10	Slacken wiring harness (3)	For this step unscrew bolt (2) and place wiring harness (3) to the side.
11	Unplug connector for pressure sensor (B28)
12	Unscrew bolts (9) on intake manifold (10)		*BA09.20-P-1001-01I
			Fig 3
13	Remove intake manifold (10)	For this step press wiring harness (3) slightly to the side. Installation:  Clean sealing surfaces. Replace seals on intake manifold (10). Check that the guide sleeves of the intake manifold (10) are correctly seated in the cylinder head, in order to prevent leaks.
14	Remove the throttle valve actuator (M16/6)	Model 211 When replacing the intake manifold (10)
15	Remove pressure sensor (B28)	When replacing the intake manifold (10)
16	Remove charge air temperature sensor (B17/8)	When replacing the intake manifold (10)
17	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
18	Check for leaks with engine running
19	Read out and erase fault memory using STAR DIAGNOSIS	Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

FUEL DISTRIBUTOR

INTAKE MANIFOLD

Fig 3: Identifying Flexible Head Wrench Set (001 589 81 09 00)