Remove/install charge air manifold

AR09.41-D-1310SG

Remove/install charge air manifold

23.04.2019

Engine

642.896/898 in model 906

1

Rail

10

Mixing chamber

19

Coolant hose

2

Bracket

11

Engine wiring harness

20

Coolant thermostat

3

Bracket

12

Coolant hose

21

Seal

4

Cable duct

13

Bracket

22

Screw

5

Connecting line

14

Leak oil line

24

Screw

6

Lifting lug (left)

15

Vacuum pump

31

Clip

7

Vacuum line

16

Bracket

B6/24

Camshaft sensor

8

Fuel filter

17

Bracket

B11/19

Coolant temperature sensor

9

Charge air manifold

18

Coolant hose

N14/3

Glow output stage

Shown on engine 642.896

9

Charge air manifold

24

Screw

28

Sealing ring

11

Engine wiring harness

25

Screw

29

Right cylinder head

20

Coolant thermostat

26

Connection piece

30

Left cylinder head

23

Clamp

27

Seal

B11/19

Coolant temperature sensor

Only for engine 642.898

32

Electrical connector

33

Electrical line

34

Electrical line

35

Clamp

36

Intake port shutoff linkage

B90/2

Left EKAS end position measurement sensor

B90/3

Right EKAS end position measurement sensor

M72

Intake port shutoff actuator

X156/1

EKAS end position switch connector /left

X156/2

EKAS end position switch connector /right

 

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 bracket (16) with glow output stage (N14/3) and place to one side

 Unclip coolant hose (12) from bracket (16). Do not disconnect electrical connections at glow output stage (N14/3).

 Bolt, bracket to charge-air distributor

*BA09.41-N-1002-01O

5

Remove bracket (13) from right cylinder head (29)

6

Open Henn coupling and remove coolant hose (18) from the coolant thermostat (20)

AR09.41-D-1311-01WE

7

Remove bracket (17) and place to one side with the attached coolant hose (18)

 Bolt, bracket to charge-air distributor

*BA09.41-N-1002-01O

8

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

9

Remove coolant hoses (12, 19) from charge air manifold (9)

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

10

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.

11

Remove fuel filter (8)

AR47.20-D-1070SF

12

Remove right rail (1)

AR07.03-D-1010SF

13

Disconnect electrical connector (32) from the intake port shutoff actuator (M72)

Engine 642.898

14

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

Engine 642.898

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

15

Remove screws (24) from the charge air manifold (9), twist clamps (31) to expose the connecting line (5), and then tighten screws (24) again with the clamp (23)

 For engine 642.898, expose electric lines (33, 34) of the left intake port shutoff end position measurement sensor (B90/2) and right sensor intake port shutoff end position measurement (B90/3).

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

*BA47.20-N-1003-02M

16

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

17

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

18

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

19

Disconnect engine wiring harness (11) from the camshaft sensor (B6/24) and expose

20

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

 Pliers

*611589003700

21

Disconnect engine wiring harness (11) from the coolant temperature sensor (B11/19)

22

Remove engine wiring harness (11) and cable duct (4) from the charge air manifold (9) and from the lifting lug (6)

23

Fasten engine wiring harness (11) and cable duct (4) to the windshield wiper linkage

24

Remove bracket (2) from right cylinder head (29)

25

Remove bracket (3) from the charge air manifold (9)

 Bolt, bracket to charge-air distributor

*BA09.41-N-1002-01O

26

Remove screws (24) of the clamp (23) and remove clamp (23)

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

*BA47.20-N-1003-02M

27

Remove screws from charge air manifold (9) in the area under the clamp (23)

 Set of flexible head wrenches

*001589810900

28

Tighten screw (25) of the clamp (23)

 Bolt, hose clamp cage to fuel filter

*BA47.20-N-1002-02M

29

Install clamp (23) and tighten with the screws (24) at the charge air manifold (9)

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

*BA47.20-N-1003-02M

30

Remove screws (22) from the mixer housing (10) and from the charge air manifold (9)

 Installation: Install new seal (21).

 Screw/bolt, mixing chamber to charge air distributor

*BA09.41-N-1012-01O

 Set of flexible head wrenches

*001589810900

31

Remove remaining screws from the charge air manifold (9) and remove lifting lug (6)

AR09.41-D-1310-01SG

 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

32

Lift out charge air manifold (9) upward

 Installation: Install new seals (27) and hook into charge air manifold (9).
Install new sealing ring (28) on the charge air manifold (9). Attach charge air manifold (9) free of tension to the mixer housing (10).

33

Disconnect charge air manifold (9) and remove connection piece (26)

 To install new connection piece (26), pull charge air manifold (9) apart.
For engine 642.898, to install new left and right charge air manifold (9), remove clip (35) and disconnect intake port shutoff linkage (36).

 Installation: Install new connection piece (26). For engine 642.898, the clip (35) must be replaced if it is removed.

34

Remove coolant thermostat (20) and coolant temperature sensor (B11/19)

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

 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

35

Remove coolant temperature sensor (B11/19)

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

 Installation: Replace sealing ring at coolant temperature sensor (B11/19).

36

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

 For engine 642.898, if a new charge air manifold (9) is installed.



Clean

37

Clean sealing surfaces on the right cylinder head (29), left cylinder head (30), and on the mixer housing (10)

38

Clean sealing surfaces on charge air manifold (9)

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

39

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

40

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-1002-01O

Bolt, bracket to charge-air distributor

Nm

9

 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-1012-01O

Screw/bolt, mixing chamber to charge air distributor

M6

Nm

9

 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