Remove/install charge air manifold

AR09.41-D-1310S

Remove/install charge air manifold

23.04.2019

Engine

642.993 in model 906

1

Right rail

11

Engine wiring harness

21

Nut

2

Bracket

12

Coolant hose

22

Electrical connector

3

Clip

13

Bracket

23

Bolts

4

Screw

14

Leak oil line

B6/20

Camshaft sensor

5

Connecting line

15

Vacuum pump

B11

Coolant temperature sensor

6

Lifting lug (left)

16

Coolant pipe

N14/3

Glow output stage

7

Vacuum line

17

Bracket

M72

Intake port shutoff actuator

8

Fuel filter

18

Coolant hose

X156/1

EKAS end position switch connector /left

9

Charge air manifold

19

Coolant hose

X156/2

EKAS end position switch connector /right

10

Mixing chamber

20

Coolant thermostat

9

Charge air manifold

29

Sealing ring

34

Left cylinder head

24

Clamp

30

Seal

B11

Coolant temperature sensor

25

Bolts

31

Clamp

B90/2

Left EKAS end position measurement sensor

26

Screw

32

Intake port shutoff linkage

B90/3

Right EKAS end position measurement sensor

27

Connection piece

33

Right cylinder head

M72

Intake port shutoff actuator

28

Seal

 

Remove/install

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

1

Drain off coolant

AR20.00-D-1140SD

2

Remove trim panel on right cylinder head cover

AR01.20-D-5015SF

3

Remove oil supply connection fittings for ATL

AR09.40-S-6023SE

4

Remove glow output stage (N14/3) from mixer housing (10) and place to one side

 Do not disconnect electrical connections at glow output stage (N14/3).

 Bolt, glow output stage to mixing chamber

*BA15.20-N-1004-01C

5

Remove bracket (13) from right cylinder head (33)

6

Remove coolant hose (19) from coolant thermostat (20)

 Installation: Check clamp, replace if necessary.

7

Remove coolant hose (18) from coolant pipe (16)

 Installation: Check clamp, replace if necessary.

8

Remove bracket (17)

9

Remove screws (23) and remove coolant thermostat (20) and coolant pipe (16)

 Installation: Check sealing ring on coolant thermostat (20); replace coolant thermostat (20) if necessary.

 Bolt, coolant thermostat housing to charge air distributor

*BA20.10-N-1005-01Q

10

Remove vacuum line (7) from the vacuum pump (15) and unclip from the cover of the left cylinder head cover

11

Pull vacuum line (7) out of the brake booster and place vacuum line (7) to one side

 Installation: Check sealing ring on the brake booster; replace if necessary.

12

Remove coolant hose (19) from charge air manifold (9)

 Installation: Inspect condition of collar clamps, replace if necessary.

13

Remove fuel filter (8)

AR47.20-D-1070SF

14

Remove right rail (1)

AR07.03-D-1010SF

15

Disconnect electrical connector (22) from the intake port shutoff actuator (M72)

16

Disconnect left EKAS end position switch connector (X156/1) and right EKAS end position switch connector (X156/2)

 Mark left EKAS end position switch connector (X156/1) and right EKAS end position switch connector (X156/2).

17

Remove union nut of the connecting line (5) from the left rail

 Installation: Check sealing cone of the connecting line (5) for damage; replace connecting line (5) if necessary.

 Connecting line between left and right rail

*BA07.16-N-1007-01B

 Open wrench insert, (18 mm)

*000589300100

18

Remove screws (4) at the two clamps (3) of the connecting line (5) from the charge air manifold (9)

19

Disconnect leak oil line (14) at the charge air manifold (9) from the injectors (arrows A) of the right cylinder bank and place leak oil line (14) to one side

AR07.03-D-9105SF

20

Disconnect engine wiring harness (11) from the injectors (arrows A) of the right cylinder bank and expose

21

Disconnect engine wiring harness (11) from the camshaft sensor (B6/20) and expose

22

Disconnect engine wiring harness (11) from the glow plugs (arrows B) and expose

 Pliers

*611589003700

23

Disconnect engine wiring harness (11) from coolant temperature sensor (B11)

24

Expose engine wiring harness (11) at charge air manifold (9) and lifting lug (6) and place to one side

25

Remove bracket (2) from right cylinder head (33)

26

Tighten screw (26) of the clamp (24)

 Bolt, hose clamp cage to fuel filter

*BA47.20-N-1002-02M

27

Remove nuts (21) from the mixer housing (10) and charge air manifold (9)

 Nut, mixer housing to charge-air distributor

*BA09.41-N-1014-01O

 Set of flexible head wrenches

*001589810900

28

Remove screws from charge air manifold (9)

AR09.41-D-1310-01S

 Remove lifting lug (6) from charge air manifold (9).

 Installation: Tighten charge air manifold (9) according to the bolt plan.

 Screw/bolt, charge air distributor to cylinder head

*BA09.41-N-1010-01O

 Set of flexible head wrenches

*001589810900

29

Pull charge air manifold (9) toward the rear out of the mixer housing (10) and lift out upward

 Twist charge air manifold (9) when lifting out.

 Installation: Install new seals (30) and hook into charge air manifold (9).
Install new sealing ring (29) and sealing ring (28) on charge air manifold (9). Attach charge air manifold (9) free of tension to the mixer housing (10).

30

Disconnect charge air manifold (9) and remove connection piece (27)

 Remove screw (25) from the right and left charge air manifold (9).
To install new connection piece (27), pull the charge air manifold (9) apart. To install new left and right charge air manifold, (9) remove clip (31) and disconnect intake port shutoff linkage (32).

 Installation: Install new connection piece (27). Replace clip (31) only if it has been removed.

 Bolt, clamp for fuel filter to charge-air distributor

*BA47.20-N-1003-02M

31

Remove left intake port shutoff end position measurement sensor (B90/2) and right intake port shutoff end position measurement sensor (B90/3)

 Only if a new charge air manifold (9) is installed.

32

Remove coolant temperature sensor (B11)

 Only if installing a new charge air manifold (9).

 Installation: Install new sealing ring on the coolant temperature sensor (B11).



Clean

33

Clean sealing surfaces on the right cylinder head (33), left cylinder head (34), and on the mixer housing (10)

34

Clean sealing surfaces on charge air manifold (9)

 Only if a new charge air manifold (9) is not installed.

35

Install in the reverse order

 Warning

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

36

Perform an engine test run and check engine for leak tightness in the area of the charge air manifold (9)

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1007-01B

Connecting line between left and right rail

M151

Stage 1

Nm

20

Stage 2

°

60

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1010-01O

Screw/bolt, charge air distributor to cylinder head

Nm

16

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1014-01O

Nut, mixer housing to charge-air distributor

M6

Nm

9

 Preglow system

Number

Designation

Engine 642

BA15.20-N-1004-01C

Bolt, glow output stage to mixing chamber

Nm

8

 Coolant pump, coolant thermostat

Number

Designation

Engine 642 in model 639
Engine 642 in model 906

BA20.10-N-1005-01Q

Bolt, coolant thermostat housing to charge air distributor

Nm

9

 Fuel filter

Number

Designation

Engine 642 in model 906

BA47.20-N-1002-02M

Bolt, hose clamp cage to fuel filter

Nm

5

 Fuel filter

Number

Designation

Engine 642 in model 906

BA47.20-N-1003-02M

Bolt, clamp for fuel filter to charge-air distributor

Nm

12