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

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

Fig 1: Charge Air Manifold Remove/Install Components (1 Of 3)
G09974904Courtesy of MERCEDES-BENZ USA
Fig 2: Charge Air Manifold Remove/Install Components (2 Of 3)
G09974905Courtesy of MERCEDES-BENZ USA
Fig 3: Charge Air Manifold Remove/Install Components (3 Of 3)
G09974906DANGERREMOVINGINSTALLINGINSTALLATION NOTESREFER TO MAINTENANCEREFER TO MAINTENANCEREFER TO MAINTENANCEIMPORTANTIMPORTANTINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONIMPORTANTINSTALLATION IMPORTANTTORQUE SPECIFICATIONINSPECTDANGERCourtesy of MERCEDES-BENZ USA
DANGER 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
REMOVINGINSTALLING 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
INSTALLATION NOTES
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    
REFER TO MAINTENANCE   MODEL 204 AP47.20-P-0780CWD
REFER TO MAINTENANCE   MODEL 166, 172, 207, 212, 218 AP47.20-P-0780EWD
REFER TO MAINTENANCE   MODEL 221
IMPORTANT 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  
ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 22166 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 AR20.10-P-2460EH
IMPORTANT Lay coolant thermostat down to side with coolant hoses connected.  
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 INSTALLATION IMPORTANT Replace seal.  
TORQUE SPECIFICATION Bolt, water outlet to cylinder head *BA20.10-P-1005-01X 
TORQUE SPECIFICATION Bolt, water outlet to charge air distribution line *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)   AR07.16-P-1080CD
    IMPORTANT After removal of the high-pressure line (1) from the high-pressure pump (4), counterhold the high-pressure fitting (6).  
13 Remove screw/bolts (14) and take out charge air distributor (17) INSTALLATION IMPORTANT Install new seal (15).  
TORQUE SPECIFICATION Bolt, charge air distribution line to cylinder head *BA09.41-P-1001-01N 
14 Install in the reverse order    
INSPECT Check     
DANGER 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    
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 651
BA09.41-P-1001-01N Bolt, charge air distribution line to cylinder head Nm 14
COOLANT PUMP, COOLANT THERMOSTAT

Number Designation ENGINE 651
BA20.10-P-1005-01X Bolt, water outlet to cylinder head Nm 9
COOLANT PUMP, COOLANT THERMOSTAT

Number Designation ENGINE 651
BA20.10-P-1006-01X Bolt, water outlet to charge air distribution line Nm 9
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