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

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ENGINE 276.8 in MODEL 207, 212, 218 

Shown on model 212 

Fig 1: Charge Air Manifold Remove/Install Components - Shown On Model 212 (1 Of 3)
G09974907Courtesy of MERCEDES-BENZ USA
Fig 2: Charge Air Manifold Remove/Install Components - Shown On Model 212 (2 Of 3)
G09974908Courtesy of MERCEDES-BENZ USA
Fig 3: Charge Air Manifold Remove/Install Components - Shown On Model 212 (3 Of 3)
G09974909Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
1 Detach ground line from battery   AR54.10-P-0003EW
2 Remove upper engine cover INSTALLATION IMPORTANT Ensure correct seating of the upper engine cover.  
3 Remove right and left air filter housing (1, 2)   AR09.10-P-1150ELS
4 Detach control unit (N3/10) MODEL 207, 212, 218  
MODEL 207, 212 AR07.08-P-7008ELS
5 Disconnect CN from pressure sensor downstream of throttle valve (B28/7)    
6 Detach check valve partial load ventilation (4) on the charge air manifold (3) INSTALLATION IMPORTANT Replace seal.  
7 Detach engine wiring harness for removal of cylinder head cover   AR01.00-P-2410-02ELS
8 Loosen screw clamp (5) on throttle valve actuator (M16/6)    
9 Detach throttle valve actuator electrical connection (M16/6x1) from electrical connection (M16/6)    
10 Remove screw/bolts (7) and detach charge air manifold (3) with throttle valve actuator (M16/6) INSTALLATION IMPORTANT Replace seals (8).
Tighten screw/bolts (7) cross-wise from inside to outside.		  
TORQUE SPECIFICATION Screw/bolt, charge air distributor to intermediate flange *BA09.41-P-1001-01R 
11 Detach throttle valve actuator (M16/6) from charge air manifold (3) If necessary AR07.51-P-1401ELS
12 Remove right intermediate flange (10) or left intermediate flange (11) If necessary
INSTALLATION IMPORTANT Replace seals between cylinder head and the respective intermediate flange (10, 11).
Tighten screw/bolts (9) from the inside to the outside.		  
TORQUE SPECIFICATION Screw/bolt, intermediate flange to cylinder head *BA09.41-P-1004-01R 
13 Remove sealant residue on both sides on the intermediate flange on the right (10), intermediate flange on the left (11) and on cylinder head If necessary
NOTES The sealing surfaces on intermediate flanges (10, 11) and on cylinder head must not have any foreign objects, scratches or grooves. Non-observance leads to leaks between the intermediate flanges (10, 11) and cylinder head, or charge air manifold (3).		  
14 Install in the reverse order    
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 Carry out an engine test run, checking the engine for proper operation and leaktightness    
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 276.8
BA09.41-P-1001-01R Screw/bolt, charge air distributor to intermediate flange Nm 9
CHARGE AIR PIPE/CHARGE AIR COOLING

Number Designation ENGINE 276.8
BA09.41-P-1004-01R Screw/bolt, intermediate flange to cylinder head Nm 9
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