We want to inform you that we are currently working on implementing the remanufacturing of the intake manifold for the Mercedes OM654 and OM656 engines. These are the direct successors to the OM651 and OM642 manifolds, which we also offer in our range.
The intake manifold for the Mercedes OM654, OM656 engines is an example of a well thought-out design. Failures of the manifold do not result from design errors, but from the conditions in which it operates. The main issue is carbon deposits, which block the movement of the swirl flaps.
Construction of the OM654 OM656 manifold
Below we describe how this manifold is built and how we implement its remanufacturing at PT-PRO.
The swirl flap mechanism has a similar design to the one used in the OM651 manifold. The flaps are mounted on a common shaft and are housed in two cassettes. Each flap is mounted on a single bushing made of sintered material. The element transmitting motion from the actuator to the flap shaft is a system of two levers: one made of polymer and one metal, mounted in a sliding bushing. The position of the flaps is controlled by an actuator driven by a PWM signal, which smoothly sets the opening angle of the flaps.
Construction of the OM654 OM656 manifold
How we implement intake manifolds at PT-PRO
We implement every manifold according to an established process, in which the solution is first designed, then tested on a prototype, and only at the end made from the proper materials. This way, we know it works before it reaches the customer.
We implement the manifold in several steps:
1. 3D scan and measurements of the original components
We 3D-scan the manifold’s components and measure them in order to precisely reproduce the geometry.
2. CAD design and implementation of our solutions
Based on the scans, a CAD design is created. In this step we introduce our engineering solutions.
3. 3D printing of prototypes
We print the designed elements on 3D printers. A prototype is cheap and quick to produce, so it lets us check the geometry before we order parts made from the final materials. If something doesn’t fit, we correct the design instead of bearing the cost of machining.
4. Assembly of the manifold on prototype parts and verification of design assumptions
We assemble the manifold using the prototype parts and check our assumptions in practice: whether the flaps move freely, whether the levers have a shape that allows the actuator to reach its full range of motion. This is the stage at which we catch design errors.
5. Production documentation and ordering of prototypes made from the proper materials, machined on CNC
Once the design passes verification, we prepare the production documentation and order prototypes made from the final materials, machined on CNC machines.
In our remanufacturing process, all worn components are replaced, as well as those that may wear over time, which is why the manifold after remanufacturing is comparable to a brandnew one.
The manifolds are used in:
OM654 (OE: A6540902100, A6540901201): W205, W206, W213, C257, X253, X254, V167, W447, W177, W247, C118, X118, H247, X247
OM656 (OE: A6560902300): W213, W222, W223, C257, V167, X167, W463