Remove/install charge air distributor

AR09.41-S-8683SE

Remove/install charge air distributor

23.11.2017

Model

639 with engine 642.8

1

Coolant hose

4

High-pressure line

7

Fuel hose

2

Electrical connection

5

Screw/bolt

8

Fuel filter

3

Union nut

6

Screw/bolt

9

Electrical connection

11

Screw/bolt

13

Lifting eye

10

Electrical connection

12

Screw/bolt

14

Bracket

19

Fuel hose

24

Charge air distributor

15

Bracket

20

Screw/bolt

25

Lifting eye

16

High-pressure line

21

Fuel line

26

Connection piece

17

Screw/bolt

22

Coolant hose

18

Leak oil line

23

Coolant hose

 Danger

Risk of explosion caused by 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 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

 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

 

Remove/install

1

Drain off coolant

AR20.00-S-1140S

2

Remove fan

AR20.40-S-5614SE

3

Remove exhaust gas ATL

AR09.40-S-6020SE

4

Remove oil supply connection fittings for ATL

AR09.40-S-6023SE

5

Remove coolant hose on coolant thermostat housing

AR20.20-S-3865-15S

6

Remove changeover flap housing

AR14.20-S-7671S

7

Partially remove mixing chamber

AR09.20-S-1320SEA

 Only remove mixing chamber on charge air distributor (24) and on crankcase holder.

8

Remove rail on left cylinder bank

AR07.03-S-1010SE

9

Remove coolant hose (1)

10

Disconnect electrical connection (2)

11

Unscrew union nut (3)

 Connecting line between left and right rail

*BA07.16-N-1007-01B

12

Remove screw/bolts (5)

 M6

*BA00.10-N-1002-01A

13

Remove high-pressure line (4)

 Close off connection on rail. Grommets are available as an replacement part of the fuel injection system; see EPC Group 07.

14

Remove screw/bolt (6)

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

*BA47.20-N-1001-02M

15

Remove fuel hoses (7)

 Seal connections. Grommets are available as an replacement part of the fuel injection system; see EPC Group 07.

16

Disconnect electrical connection of fill level sensor

Model 639 with engine 642.8
with code KL5 (Fuel filter with water separator)

17

Remove drain hose on fuel filter (8)

18

Raise fuel filter (8) with a cage and lay outside the working area

19

Disconnect electrical connections (9, 10)

20

Disconnect electrical connections for glow plugs

21

Remove screw/bolt (11)

 M6

*BA00.10-N-1002-01A

22

Remove screw/bolt (12)

23

Remove electrical wiring harness on left cylinder head cover

 Installation: Check clamps, inspect and, if necessary, replace.

24

Remove lifting eye (13)

 M6

*BA00.10-N-1002-01A

25

Remove bracket (14)

 Screw/bolt, bracket to cylinder head

*BA01.20-N-1003-01O

26

Remove bracket (15)

 Screw/bolt, bracket to cylinder head cover

*BA01.20-N-1004-01O

27

Remove screw/bolt (17)

28

Remove high-pressure line (16)

 To do this undo union nut. Close off connection on high-pressure pump. Grommets are available as an replacement part of the fuel injection system; see EPC Group 07.

 Pressure line to high-pressure pump

*BA07.16-N-1008-01B

29

Remove leak oil line (18)

30

Remove fuel hose (19)

31

Unscrew screws/bolts (20)

 M6

*BA00.10-N-1002-01A

32

Remove fuel lines (21) and swivel to the side

33

Remove coolant hose (22)

34

Remove coolant hose (23)

35

Remove glow plugs

AR15.20-S-4111SE



000 588 00 84 00 Heat gun

WS54.00-P-0049B

 Heat up areas on the cylinder head to about 90°C.

36

Remove screw/bolts on charge air distributor (24)

AR09.41-S-1310-01SE


Remove screw/bolts of the charge air distributor (24) for a cooled off engine in the reverse order of the bolt plan.
Distortion of the charge air distributor (24) can occur otherwise.

 To do this remove lifting eye (25).

 Screw/bolt, charge air distributor to cylinder head

*BA09.41-N-1010-01O

37

Remove charge air distributor (24)

 Installation: Use aid of helper. Replace connection piece (26), seals and sealing rings.



Clean

38

Clean sealing surfaces on the cylinder heads

39

Clean sealing surfaces on charge air distributor (24)

40

Install in the reverse order

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 642 in model 639
Engine 642 in model 906

BA01.20-N-1003-01O

Screw/bolt, bracket to cylinder head

M612

Nm

9

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 642 in model 639
Engine 642 in model 906

BA01.20-N-1004-01O

Screw/bolt, bracket to cylinder head cover

M612

Nm

9

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.890/990 in model 639

BA07.16-N-1007-01B

Connecting line between left and right rail

M151

Stage 1

Nm

27

Stage 2

°

–

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.890/990 in model 639

BA07.16-N-1008-01B

Pressure line to high-pressure pump

M141.5

Stage 1

Nm

33

Stage 2

°

–

 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

 Fuel filter

Number

Designation

Engine 642 in model 639

BA47.20-N-1001-02M

Bolt, cage for fuel filter to charge-air distributor

Nm

12