Remove/Install Charge Air Manifold - AR09.41-P-1310CD

ENGINE 651 in MODEL 166, 172, 204, 207, 212, 218, 221 

	Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
	Remove/install
1	Remove cylinder head cover trim
2	Detach cover for upper belt drive to the front and remove upwards	Except MODEL 204
3	Drain coolant at radiator	MODEL 166	AR20.00-P-1142GQ
		MODEL 172, 204, 207	AR20.00-P-1142CW
		MODEL 212 (except 212.098/298), 218, 221	AR20.00-P-1142OMA
		MODEL 212.098/298 Do not pressure-test engine cooling system until engine has reached operating temperature. Leaks can occur on the cylinder head gasket otherwise.	AR20.00-P-1142EH
4	Remove fuel filter
		MODEL 204	AP47.20-P-0780CWD
		MODEL 166, 172, 207, 212, 218	AP47.20-P-0780EWD
		MODEL 221 MODEL 166 Lay fuel filter with attached lines to one side.	AP47.20-P-0780SXI
5	Remove exhaust gas recirculation valve	MODEL 166, 172	AR14.20-P-7662GQ
		MODEL 204, 207, 212, 218, 221	AR14.20-P-7662CD
6	Remove screw/bolt (12) and place fuel lines (13) to one side
7	Unfasten engine wiring harness and lift upwards	MODEL 166	AR07.03-P-1010CD
8	Remove coolant thermostat	Except MODEL 204 Model 166, 172, 207, 212 (except 212.098/298), 218, 221	AR20.10-P-2460CD
		MODEL 212.098/298 Lay coolant thermostat down to side with coolant hoses connected.	AR20.10-P-2460EH
9.1	Remove coolant hose (7) a water outlet (8)	MODEL 204
9.2	Disconnect coolant hose (7) on water outlet (8)	MODEL 166, 172, 207, 212, 218, 221
10	Unhook fuel hose (9), remove screw/bolts (10, 11) and remove fuel filter housing (16) upwards	Replace seal. Bolt, water outlet to cylinder head	*BA20.10-P-1005-01X
		Screw/bolt, water outlet to charge air distributor	*BA20.10-P-1006-01X
11	Remove screw/bolts (2, 3) on high-pressure line (1) bracket
12	Remove high-pressure line (1) from high-pressure pump (4) and rail (5)	After removal of the high-pressure line (1) from the high-pressure pump (4), counterhold the high-pressure fitting (6).	AR07.16-P-1080CD
13	Remove screw/bolts (14) and take out charge air distributor (17)	Install new seal (15). Bolt, charge air distribution line to cylinder head	*BA09.41-P-1001-01N
14	Install in the reverse order
	Check
	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
15	Check fuel system for leaks with engine running