Remove/install connection fitting downstream of charge air cooler

AR09.41-S-8630PS

Remove/install connection fitting downstream of charge air cooler

06.03.2020

Engine

642 in model 470, 471

Modification notes

10.07.2018

Operation steps added.

Operation steps 1, 2, 6,

1

Connection fitting

4

Electrical wiring harness

7

Screw

2

Charge air temperature sensor upstream of throttle valve

5

Bolts

8

Throttle valve actuator

3

Retaining clamp

6

Bolts

1

Connection fitting

9

Screw

10

Bracket

11

Electrical wiring harness

12

Bracket

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Disconnect ground line from battery.

AR54.10-S-0003P

2

Remove air duct segment together with air ducts.

 WIS Service Media
wsm://04_ 201800_05

3

Remove right air intake hose.

AR09.10-S-8030PS

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

4

Remove charge air hose downstream of charge air cooler from connection fitting (1) and place to one side.

AR09.41-D-1311-01WE

 Assembly tool

*000589936300

5

Seal opening on charge air hose downstream of charge air cooler with suitable protective cover.

 Set of protective caps

*001589029100

6

Remove screw (9) and place bracket (10) with electrical wiring harness (11) to one side.

 Screw/bolt, alternator to crankcase

*BA15.40-N-1002-01PS

7

Unclip charge air temperature sensor upstream of throttle valve (2) from connection fitting (1) and place to one side.

AR09.41-S-2009PS

8

Remove retaining clip (3) and place electrical wiring harness (4) to one side.

9

Remove screws (5).

 Bolt, throttle valve actuator holder to cylinder head

*BA09.41-N-1008-01O

10

Remove screw/bolts (6).

 Bolt, fitting to throttle valve actuator

*BA09.41-N-1007-01O

11

Unscrew bolt (7).

 Bolt, throttle valve actuator to mixer housing

*BA09.41-N-1009-01O

12

Push bracket (12) to the side and remove connection fitting (1).

 Installation: Replace sealing ring.

 Assembly tool

*000589936300

13

Clean sealing surfaces on throttle valve actuator (8) and connection fitting (1).

Assembly cleaner

*BR00.45-Z-1028-04A

14

Seal opening on throttle valve actuator (8) with suitable protective cover.

 Set of protective caps

*001589029100

15

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

16

Perform engine test run and while doing so, check engine in area of connection fitting (1) in terms of leak tightness.

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1007-01O

Bolt, fitting to throttle valve actuator

Nm

9

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1008-01O

Bolt, throttle valve actuator holder to cylinder head

Nm

9

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1009-01O

Bolt, throttle valve actuator to mixer housing

Nm

5

 Alternator

Number

Designation

Engine 642 in model 470, 471

BA15.40-N-1002-01PS

Screw/bolt, alternator to crankcase

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01