Remove/install charge air manifold

AR09.41-S-1310SE

Remove/install charge air manifold

13.8.10

 

Remove/install

 Danger!

Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.

Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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 and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove oil supply connection fittings for turbocharger

AR09.40-S-6023SE

2

Drain coolant

AR20.00-S-1140S

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

3

Lower and lift engine with front axle carrier

 Attach engine with front axle carrier on the vehicle frame using old collar bolts for continued repair work. Do not tighten the collar bolt with a torque to do this.

AR01.00-S-3000-03SE



*BA31.35-N-1008-01A



*BA46.20-N-1004-01A

Transmission jack 2.0-7.0 t

gotis://H_00.10_01.0

Assembly deviceV00

gotis://A25/35/49_03.0

4

Remove coolant pipe (9) on coolant thermostat

 Place coolant pipe (9) with attached hose to one side.

AR20.10-S-2460SE

5

Remove coolant hoses to connections (14, 15)

 Installation: Check clamps, replace if necessary.

6

Remove exhaust gas recirculation positioner

AR14.20-S-1020SE

7

Partially remove mixing chamber

 Only remove mixing chamber on charge air manifold (13) and on cylinder crankcase holder; remove charge air hose.

AR09.20-S-1320SE

8

Remove hose (16)

9

Remove left rail

AR07.03-S-1010SE

10

Unscrew connecting line union nut (8) on right rail

 Close off connections of connecting line (8) immediately after removal as a protection against contamination. Do not damage the connecting line (8).



*BA07.16-N-1007-01B

 Set of stop plugs

*129589009100

11

Remove turbocharger noise damper holder to cylinder head cover



*BA01.20-N-1004-01O

12

Remove high-pressure line to high-pressure pump



*BA07.16-N-1008-01B

13

Remove leak oil line (2) from fuel lines (1)

14

Detach fuel lines (1) on fuel filter

 Set of stop plugs

*129589009100

15

Disconnect electrical connector on fuel filter water level sensor

Only with code (KL5) Fuel filter with water separator

16

Remove drain pipe on fuel filter

Only with code (KL5) Fuel filter with water separator

17

Disconnect fuel hose (6) at high-pressure pump

 Set of stop plugs

*129589009100

18

Remove fuel pipe (5) and place to one side

 To do this remove bolts for mounting the fuel pipe (5). Do not remove fuel pipe (5) from fuel lines (3).



*BA01.20-N-1004-01O

19

Remove fuel filter with cage



*BA47.20-N-1001-02M

20

Remove leak oil line (7) distributor



*BA07.16-N-1006-01B

21

Detach engine cable harness to detachable part for charge air manifold (13) and place to one side

 Remove engine cable harness to front and rear left cylinder head cover and disconnect electrical connector for injectors for cylinders 4 and 6.

22

Remove right air filter housing holder on firewall

 Push away the insulation slightly if necessary.

23

Remove engine suspension lugs at front on left and rear cylinder head on right cylinder head

 The engine suspension lugs are each located above the charge air manifold (13).



*BA01.20-N-1003-01O

24

Remove bolts (13) at charge air manifold

 Loosen bolts on charge air manifold (13) to cylinder head in reverse order to the tightening procedure on a cooled engine and remove. No distortion of the charge air manifold (13) should occur, see:



Bolt plan for charge air manifold

AR09.41-S-1310-01SE



*BA09.41-N-1010-01O

25

Remove charge air manifold (13)

 Installation: Use aid of helper. Ensure correct seating of the connection piece (17); replace seals.

26

Install in the reverse order

Number

Designation

Engine
642

BA01.20-N-1003-01O

Bolt, bracket to cylinder head

M612

Nm

9

BA01.20-N-1004-01O

Bolt, bracket to cylinder head cover

M612

Nm

9

Number

Designation

Engine
642.890/990

BA07.16-N-1006-01B

Leak oil line on charge air distribution line

M623

Nm

12

BA07.16-N-1007-01B

Connecting line between left and right rail

M151

Stage 1

Nm

27

Stage 2

°

-

BA07.16-N-1008-01B

Pressure line to high-pressure pump

M141.5

Stage 1

Nm

33

Stage 2

°

-

Number

Designation

Engine
642

BA09.41-N-1010-01O

Bolt, charge air distribution line to cylinder head

Nm

16

Number

Designation

Model
639
without code ZG2
up to VIN
176133

Model
639
without code ZG2
as of VIN
176134

BA31.35-N-1008-01A

Bolt, subframe to longitudinal frame member

Nm

150

172

Number

Designation

Model
636, 639

BA46.20-N-1004-01A

Bolt on universal joint

Nm

28

Number

Designation

Engine
642

BA47.20-N-1001-02M

Bolt connecting fuel filter cage to charge air manifold

Nm

12