Remove/install charge air distributor

AR09.41-P-8683MRT

Remove/install charge air distributor

06.03.2020

Engine

256.9 in model 222

1

Charge air distributor

7

Cable rails of 48 V wiring harness

2

Coolant lines

8

Screw

4a

Purge line

9

Engine wiring harness

4b

Purge line

11

Bolts

5

Partial load bleed line

B28/27

Pressure and temperature sensor downstream of throttle valve

6

Bolts

23

Screw

18

Charge air line

20

Bracket

22

Charge air line

24

Screw

B28/26

Pressure and temperature sensor upstream of throttle valve

M16/6

Throttle valve actuator

 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 

Remove/install

1

Remove air filter housing.

AR09.10-P-1150MRT

 Installation: Only install upper engine cover after the leak test.

2

Release and disconnect pressure and temperature sensor electrical connector downstream of throttle valve (B28/27) and place electric line to one side.

3

Remove screws (6) and remove 48 V wiring harness  cable rails (7).

 M61

*BA00.10-P-1002-04A

4

Remove screw (24).

 Screw/bolt, charge air line to chain case cover

*BA09.41-P-1002-01MRT

5

Drain coolant of low-temperature circuit.

AR09.41-P-6834MRT

 Installation: Only install lower engine compartment paneling after leak test.

6

Release and disconnect electrical connector of pressure and temperature sensor upstream of throttle valve (B28/26) and place electric line to one side.

7

Remove charge air line (22) from charge air line (18).

8

Remove bracket (20) and remove charge air line (18) from throttle valve actuator (M16/6).

 Installation: Replace sealing ring.

 Screw, charge air line bracket to throttle valve actuator

*BA09.41-P-1005-01MRT

9

Release and disconnect electrical connector at throttle valve actuator (M16/6).

10

Remove screw (23).

 M81

*BA00.10-P-1004-04A

11

Remove screw (8).

 Screw, coolant return line to charge air distributor

*BA09.41-P-1013-01MRT

12

Remove coolant lines (2) from charge-air distributor (1) and seal openings with suitable stop plugs.

AR20.20-P-7441-01RQ

 Record plug

*129589009100

13

Remove purge control valve (Y58/1).

AR47.30-P-8252MRT

14

Remove purge lines (4b) from charge-air distributor (1), seal openings with suitable stop plugs and place to one side.

 Record plug

*129589009100

15

Remove partial load bleed line (5) from charge-air distributor (1) and seal openings with suitable stop plugs and place to one side.

 Record plug

*129589009100

16

Remove engine wiring harness (9) from charge-air distributor.

17

Remove screws (11) in reverse order to tightening procedure.

Tightening procedure for charge air distributor

AR09.41-P-8683-01MSA

 Screw/bolt, charge air distributor to cylinder head

*BA09.41-P-1001-01MRT

18

Remove charge-air distributor (1) and seal openings with clean rags.

 Installation: Replace seals.

19

Remove throttle valve actuator (M16/6).

When replacing charge-air distributor (1).

AR07.51-P-1401MRT

20

Remove pressure and temperature sensor downstream of throttle valve (B28/27).

When replacing charge-air distributor (1).

AR09.41-P-2012MRT

21

Remove purge line (4a).

When replacing charge-air distributor (1).



Clean

22

Clean sealing surfaces of cylinder head and charge-air distributor (1).

Assembly cleaner

*BR00.45-Z-1028-04A

23

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

24

Carry out engine test run and check engine for proper operation and leak tightness.

25

Install lower engine compartment lining.

AR61.20-P-1105LF

26

Install upper engine cover.

AR01.10-P-2405MRT

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1004-04A

M81

Nm

23

33

 Charge air pipe/charge air cooling

Number

Designation

Engine 256.9

BA09.41-P-1001-01MRT

Screw/bolt, charge air distributor to cylinder head

Nm

8

 Charge air pipe/charge air cooling

Number

Designation

Engine 256.9

BA09.41-P-1002-01MRT

Screw/bolt, charge air line to chain case cover

Nm

8

 Charge air pipe/charge air cooling

Number

Designation

Engine 256.9

BA09.41-P-1005-01MRT

Screw, charge air line bracket to throttle valve actuator

Nm

8

 Charge air pipe/charge air cooling

Number

Designation

Engine 256.9

BA09.41-P-1013-01MRT

Screw, coolant return line to charge air distributor

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01