Remove/install charge air manifold - AR09.41-P-1310MT

ENGINE 270 in MODEL 117, 156, 176, 242, 246.2 

Shown: engine model 246.2 

Fig 1: Charge Air Manifold Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Risk of Injury  . Skin or eye injuries may result when handling hot or glowing objects	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and nondeburred vehicle parts.	AS00.00-Z-0017-01A
		Deburr repair panels.
	Risk of injury  to skin and eyes due to handling of engine oil. Risk of poisoning  caused by swallowing engine oil	Wear protective gloves, protective clothing and safety glasses.	AS18.00-Z-0001-01A
		Do not fill engine oil into beverage containers.
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove/install
1	Remove throttle valve actuator		AR07.61-P-1401MT
		Only install upper engine cover after the leak test.
2	Depressurize gas system	Engine 270 in model 242 with code 924 (Bivalent natural gas drive)	AR47.10-P-0028NKB
3	Remove gas distribution rail	Engine 270 in model 242 with code 924 (Bivalent natural gas drive)	AR07.03-P-0001NKB
4	Remove the oil separator.	Engine 270 in model 117, 156 with code 494 (US version)	AR01.20-P-9750MTU
5	Remove full-load bleed line (2) from air intake pipe.	Engine 270 in model 117, 156 except code 494 (US version) Engine 270 in model 176, 242, 246.2
6	Remove partial-load bleed line (3) from air intake pipe.	Engine 270 in model 117, 156 except code 494 (US version) Engine 270 in model 176, 242, 246.2
7	Unclip spacer at partial-load bleed line (3) and full-load bleed line (2).	Engine 270 in model 117, 156 except code 494 (US version) Engine 270 in model 176, 242, 246.2
8	Unclip partial-load bleed line (3) at engine oil filler neck (4).	Engine 270 in model 117, 156 except code 494 (US version) Engine 270 in model 176, 242, 246.2
9	Unclip vacuum line at engine oil filler neck (4).	Engine 270 in model 117, 156 except code 494 (US version) Engine 270 in model 176, 242, 246.2
10	Unclip coolant pump switchover valve (Y133) at bracket.
11	Remove boost pressure control pressure transducer (Y77/1).		AR07.17-P-7002MT
12	Disconnect electrical connection at pressure sensor downstream of throttle valve (B28/7).
13	Disconnect electrical connection at charge air temperature sensor downstream of throttle valve (B17/9).
14	Place all supply lines and vacuum lines to one side.
15	Unclip partial-load bleed line (3) at charge-air distributor (8).	Engine 270 in model 117, 156 except code 494 (US version) Engine 270 in model 176, 242, 246.2
16	Unclip full-load bleed line (2) at charge-air distributor (8).	Engine 270 in model 117, 156 except code 494 (US version) Engine 270 in model 176, 242, 246.2
17	Remove bleed valve (5) from charge-air distributor (8).	Replace sealing ring.
18	Unclip purge line (6) at charge-air distributor (8).
19	Remove vacuum hoses (7a, 7b) from vacuum reservoir at charge-air distributor (8).
20	Release screws of charge-air distributor (8) in reverse order to tightening procedure and remove.		AR09.41-P-1312-01MT
		Replace seals. Observe tightening procedure.
		Bolt, charge air distributor to cylinder head	*BA09.20-P-1001-01U
21	Detach partial-load operation crankcase ventilation valve (Y58/2) at bracket of charge-air distributor (8).
22	Unclip electrical connection (9) for knock sensor at charge air distributor (8)
23	Remove charge air distributor (8)
24	Remove cap (10) at blind flange.	When installing a new charge air manifold (8). Replace seal.
25	Install in the reverse order
26	Read out and clear fault memory using the diagnostic system
			AD00.00-P-2000-04A
27	Check leak tightness of natural gas system with the engine running.	Engine 270 in model 242 with code 924 (Bivalent natural gas drive)	AR07.54-P-0001NKB
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
28	Perform engine test run and check engine and fuel system for leak tightness.
29	Install upper engine cover.