Remove/install charge air manifold

AR09.41-D-1310SF

Remove/install charge air manifold

23.04.2019

Engine

642.992 in model 906

1

Charge air manifold

7

Vacuum line

13

High pressure pipe

2

Coolant thermostat

8

Leak oil line

14

Bolts

3

Coolant pipe

9

Connecting line

15

Bracket

4

Coolant hose

10

Fuel filter

16

Fuel line

5

Mixing chamber

11

Coolant hose

17

Fuel hose

6

Vacuum pump

12

Rail

M41

Common rail high pressure pump

1

Charge air manifold

20

Cylinder head

24

Shell

2

Coolant thermostat

21

Engine wiring harness

25

Connection piece

18

Bracket

22

Exhaust gas recirculation cooler

B11

Coolant temperature sensor

19

Cylinder head

23

Sealing rings

B60

Exhaust back pressure sensor

 

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

Remove housing for exhaust gas recirculation valve

AR14.20-D-7666SF

2

Release mixer housing (5) from charge air manifold (1) and cylinder head (20)

AR09.20-D-1320SF

 Do not disconnect electric lines and charge air hoses.
Pull out mixer housing (5) until the charge air manifold (1) can be removed upward.

3

Remove trim panel on right cylinder head cover

AR01.20-D-5015SF

4

Remove trim panel on left cylinder head cover

AR01.20-D-5015SG

5

Remove coolant hose (11) from charge air manifold (1)

6

Remove coolant pipe (3) from coolant thermostat (2) and place to one side

7

Remove coolant hose (4) from coolant thermostat (2)

8

Remove vacuum line (7) from vacuum pump (6) and place to one side

9

Remove oil supply connection fittings for ATL

AR09.40-S-6023SE

10

Remove fuel filter (10)

AR47.20-D-1070SF

11

Remove left rail (12)

AR07.03-D-1010SF

12

Remove connecting line (9) from charge air manifold (1)

 Installation: Check sealing cone of the connecting line (9) for damage; replace connecting line (9) if necessary.

 Connecting line between left and right rail

*BA07.16-N-1007-01B

13

Remove leak oil line (8) from the fuel line (16) and from the charge air manifold (1)

 Leak oil line to charge air distribution line

*BA07.16-N-1006-01B

14

Remove fuel hose (17) from the high-pressure pump (M41) and seal connections with suitable stop plugs

 Installation: Check clamp and fuel hose (17) for damage; replace if necessary.

 Record plug

*129589009100

15

Remove screws (14) and remove bracket (15)

16

Remove high-pressure line (13) from the high-pressure pump (M41) and seal connections with suitable stop plugs

 Pressure line to high-pressure pump

*BA07.16-N-1008-01B

 Record plug

*129589009100

17

Remove fuel line (16) and place to one side

18

Disconnect engine wiring harness (21) from the glow plugs (arrows) and expose

19

Remove right bracket (18) for the air filter housing from the firewall

AR09.10-D-1150-03SF

20

Remove charge air manifold (1) from the cylinder heads (19, 20)

AR09.41-S-1310-01SE

 Installation: Tighten charge air manifold (1) according to the bolt plan.

 Screw/bolt, charge air distributor to cylinder head

*BA09.41-N-1010-01O

21

Lift out charge air manifold (1) upward

 Installation: The seals (23) are hooked into the charge air manifold (1).

22

Remove shell (24) from the charge air manifold (1)

 Only if the charge air manifold (1) is split or in the event of leakage of the connection piece (25).

23

Disconnect charge air manifold (1) and install new connection piece (25)

24

Remove coolant thermostat (2), exhaust gas back pressure sensor (B60), coolant temperature sensor (B11), and exhaust gas recirculation cooler (22)

 Only if replacing the charge air manifold (1).

 Bolt, exhaust gas recirculation cooler to charge air distributor

*BA14.20-N-1001-01H

 Bolt, coolant thermostat housing to charge air distributor

*BA20.10-N-1005-01Q

25

Install in the reverse order



Check

 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

26

Perform an engine test run and check engine for leaktightness around charge air manifold (1)

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1006-01B

Leak oil line to charge air distribution line

M623

Nm

12

 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

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1008-01B

Pressure line to high-pressure pump

M141.5

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

 Exhaust gas recirculation

Number

Designation

Engine 642.992 in model 906

BA14.20-N-1001-01H

Bolt, exhaust gas recirculation cooler to charge air distributor

M6x15

Nm

12

M6x20

Nm

-

 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