S09.41-A004-78
1 | Coolant hose | 6 | Bracket | 11 | Bolts | ||
2 | Coolant thermostat housing | 7 | Fuel hose | 12 | Left engine suspension lug | ||
3 | Left rail | 8 | Return fuel line | 13 | Vent hose | ||
4 | Right rail | 9 | Fuel feed line | 29 | Screw | ||
5 | Leak oil line | 10 | Screw |
S09.41-A005-79
2 | Coolant thermostat housing | 14 | Exhaust manifold on the left | 18 | Right engine suspension lug | ||
8 | Return fuel line | 15 | Retaining clips | 19.1 | Left charge air distributor | ||
9 | Fuel feed line | 16 | Screw | 19.2 | Right charge air distributor | ||
10 | Screw | 17 | Bolts | 20 | Exhaust gas recirculation cooler |
S09.41-A007-79
25 | Nut | 27 | Bracket | |
26 | Bolts | 28 | Heat shield |
19.1 | Left charge air distributor |
19.2 | Right charge air distributor |
20 | Exhaust gas recirculation cooler |
21 | Intake port shutoff actuator motor |
22 | Fuel filter bracket |
23 | Connection piece |
24 | Coolant temperature sensor |
S09.41-A006-81
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. | |
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. | |
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
| Remove/install | ||
1 | Remove mixer housing. | ||
Installation: Only install upper engine cover after the leak test. | |||
2 | Remove exhaust gas recirculation positioner. | ||
Installation: Install front and center engine compartment lining only after the leak test. | |||
3 | Remove inlet port shutoff actuator motor (21). | ||
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. | |
4 | Remove coolant hose (1) from the coolant thermostat housing (2). | ||
Plug openings. | |||
Set of protective caps | |||
5 | Remove left rail (3). | ||
6 | Remove right rail (4). | ||
Remove high-pressure line between the left rail (3) and right rail (4). | |||
7 | Remove the leak oil line (5) from the fuel injectors. | ||
8 | Remove screw (29). | ||
9 | Remove bracket (6). | Screw, control unit holder to charge-air distributor | |
Screw, control unit holder to engine lifting lug | |||
10 | Remove air filter housing. | ||
11 | Remove nut (25). | ||
12 | Remove screw/bolts (26). | ||
13 | Remove heat shield (28) of the left exhaust manifold (14). | To do this, pull the bracket (27) to one side. | |
14 | Detach retaining clamps (15) from the left cylinder head. | Installation: Check retaining clamps (15) for damage. | |
If damage exists, | |||
| |||
Replace affected retaining clamps (15). | |||
15 | Remove fuel hose (7) from the return flow fuel line (8). | Capture escaping fuel with a suitable rag. Plug openings. | |
Record plug | |||
Pliers for click clamps | |||
16 | Remove screws (10, 16). | Screw, fuel line holder to charge-air distributor/cylinder head cover | |
Screw, fuel lines holder to cylinder head | |||
Screw, fuel lines holder to crankcase | |||
17 | Remove screws (11). | Screw/bolt, engine suspension lug to cylinder head | |
18 | Remove left engine lifting lug (12). | Place fuel line return flow (8) to one side together with the feed line fuel line (9). | |
19 | Disconnect electrical connections at the glow plugs | ||
20 | Disconnect electrical connector from the coolant temperature sensor (24). | ||
21 | Remove vent hose (13) from the coolant thermostat housing (2). | Capture escaping coolant with a suitable rag. Plug openings. | |
Installation: Check clamp for damage. | |||
Record plug | |||
Hose clamp pliers | |||
If damage exists, | |||
| |||
Replace clamp. | |||
22 | Remove right engine lifting lug (18). | To do this, remove screws (17). | |
Screw/bolt, engine suspension lug to cylinder head | |||
23 | Install the fuel filter bracket (22). | This secures both charge air distributors (19.1, 19.2) to each other and thus makes removal and installation easier. | |
24 | Remove screws from the charge-air distributors (19.1, 19.2) in reverse numerical sequence of the tightening procedure. | ||
Remember that the shafts vary in length. | |||
Installation: Observe tightening procedure. | |||
Screw, left/right charge-air distributor to left/right cylinder head | |||
25 | Remove charge-air distributors (19.1, 19.2) upward. | Aid of helper required. | |
Installation: Replace the seals and hook them onto the charge air distributors (19.1, 19.2). | |||
26 | Cover the openings an the cylinder heads with clean rags. | ||
27 | Remove the fuel filter bracket (22). | Screw, fuel filter holder to charge-air distributor | |
28 | Detach charge-air distributors (19.1, 19.2) from the connection piece (23). | Installation: Install new connection piece (23). | |
29 | Remove exhaust gas recirculation cooler (20). | If the charge air distributor (19.1) is being replaced. | |
30 | Remove the coolant thermostat housing (2). | If the charge air distributor (19.2) is being replaced. | |
31 | Remove coolant temperature sensor (24). | If the charge air distributor (19.1) is being replaced. | |
| Clean | ||
32 | Clean sealing surfaces on the left and right cylinder head with a lint-free cloth. | ||
33 | Clean sealing surfaces on the charge-air distributors (19.1, 19.2). | If the charge air distributors (19.1, 19.2) are re-used. | |
Assembly cleaner | |||
34 | Install in the reverse order. | ||
| Check | ||
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. | |
35 | Perform engine test run and check engine in the area of the charge air distributors (19.1, 19.2) for leak tightness. | Visual inspection only. |
454 589 00 37 00
Hose clamp pliers
129 589 00 91 00
Record plug
171 589 00 37 00
Pliers for click clamps
001 589 02 91 00
Set of protective caps
Referenced documents
- ah0000p500001a Notes on avoiding damage through contamination and foreign objects
- ah5400p000101a Information on preventing damage to electronic components due to electrostatic discharge
- ar0703s1011ps Remove/install left rail
- ar0703s1012ps Remove/install right rail
- ar0703s9110ps Remove/install leak oil line to fuel injectors
- ar0910s1150ps Remove/install air filter housing
- ar0920s1313ps Remove/install intake port shutoff actuator motor
- ar0920s1320ps Remove/install mixing chamber
- ar0941s868301ps Tightening procedure for charge air distributor
- ar1420s1020ps Remove/install exhaust gas recirculation positioner
- ar1420s7665ps Remove/install exhaust gas recirculation cooler
- ar1520s4111ps Remove/install glow plugs
- ar1560s2712ps Remove/install coolant temperature sensor
- ar2010s2461ps Remove/install coolant thermostat
- ar2020s386515s Disconnect/connect coolant hose on coolant thermostat housing
- as0000z000501a 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.
- as0000z001701a Risk of injury caused by scraping or cutting body parts on sharp vehicle parts
- as2000z000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.
- as4700z000101a 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.