Remove/install charge air distribution pipe

AR09.41-D-1310A

Remove/install charge air distribution pipe

18.6.99

 

Remove/install

Danger!

Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.

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

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

Danger!

Risk of injury to skin and eyes from scalding with hot coolant which splashes out. 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 bottles.

Wear protective gloves, protective clothing and eye protection.

AS20.00-Z-0001-01A

1

Drain coolant, pour in

At radiator

AR20.00-P-1142HB

2

Disconnect engine wiring harness at vehicle side

AR15.18-D-1000-02A

3

Detach charge air hose (15) at mixing chamber with exhaust gas recirculation

 Pull spring (arrow) up

Installation:Inspect seal, replace if necessary.

4

Remove connector (14) at mixing housing with exhaust gas recirculation

5

Unscrew bolt (3).

6

Detach coolant hose (8) at intermediate piece (6)

7

Detach fuel line (10) at fuel full-flow filter

Installation: Replace collar clamp

8

Detach fuel line (9) at fuel full-flow filter

 Pay attention to operation of locking arm

AR47.25-P-1000-01A

 Collect fuel which flows out.

Replace seal

9

Remove support (7)

 Support to charge air distribution pipe

*BA09.41-N-1002-01F

 Support to crankcase

*BA09.41-N-1003-01F

10

Unscrew bolts (18) and remove bracket (16)

11

Detach vacuum line (12) at vacuum control unit (13)

12

Detach coolant hose (2) at charge air distribution pipe (1)

 Accessible from below

13

Unscrew bolts (11) next to coolant hose (2)

 Accessible from below

14

Take off charge air distribution pipe (1) at cylinder head



*BA09.41-N-1001-01F

15

Lift charge air distribution pipe (1) up and out; guide engine wiring harness (5) and fuel lines (9, 10) through the openings in the charge air distribution pipe (1) during this step

 Cover over intake passages.

Clean sealing surface and replace gasket (17).

Installation: Use stud bolt (thread M7) for fixing gasket (17) and charge air distribution pipe (1) in place. Refer to bolt diagram of charge air distribution pipe (figure).

16.1

Fit on existing mixing chamber with exhaust gas recirculation

Only if charge air distribution pipe is replaced.

AR09.20-D-1320B

17

Install in the reverse order

Danger!

Risk of accident from vehicle starting off by itself when engine running. Risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running

Secure vehicle to prevent it moving off.
Wear closed and close-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

18

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks

19

Encode radio, set clock

Number

Designation

Engine 612.981

BA09.41-N-1001-01F

Bolt of charge air distribution pipe to cylinder head

Nm

16

BA09.41-N-1002-01F

Bolt of support to charge air distribution pipe

Nm

14

BA09.41-N-1003-01F

Bolt of support of charge air distribution pipe to crankcase

Nm

20