Remove/install charge air manifold

AR09.41-D-1310SD

Remove/install charge air manifold

25.2.11

10.3.10

Observe bolt plan for the upper section of the charge air manifold

Step 15

 

Remove/install

1

Disconnect battery ground line

AR54.10-D-0003SD

2

Remove washer fluid reservoir

AR82.35-D-6000SD

3

Drain coolant

AR20.00-D-1140SD

4

Remove charge air pipe

AR09.41-D-1311SD

5

Remove trim panel for cylinder head cover (1)

AR01.20-D-5015SD

6

Detach bracket (6)

7

Disconnect electrical connectors (2, 4)

8

Remove electrical line (9) at the support brace (10) and remove support brace (10)

 Installation: Ensure correct seating of electrical line (9) at support brace (10).



*BA09.41-N-1002-01M



*BA09.41-N-1003-01M

9

Disconnect electrical connector (12)

With code (KL5) Fuel filter whit water separator

10

Detach bracket (5) and detach clip of fuel line (arrow) at upper section of the charge air manifold (8)

11

Place bracket (5) with connected lines to one side

12

Remove support brace (11) and place to one side with fuel filter



*BA09.41-N-1002-01M



*BA09.41-N-1003-01M

13

Remove coolant hose (3) on exhaust gas recirculation positioner (Y27/11), unclip coolant hose (3) on clip and place to one side

 Installation: Check clamp, replace if necessary.

14

Remove bracket (7)

15

Detach charge air manifold upper section (8) at cylinder head

 Observe bolt plan for charge air manifold upper section (8).

AR09.41-D-1310-01SD



*BA09.41-N-1001-01M

 Magnetic pin

*210589004000

16

Remove charge air manifold lower section (8)

 For removal of the charge air manifold upper section (8), the electrical line (9) and the fuel lines is not damaged.

 Installation: Clean sealing surfaces and install new gasket.
Ensure correct routing of electrical line (9) and fuel lines in the area of the charge air manifold upper section (8).

17

Detach exhaust gas recirculation positioner (Y27/11) at the charge air manifold upper section (8)

 Only when replacing charge air manifold upper section (8).

 Installation: Clean sealing surfaces and install new gasket.



*BA14.20-N-1001-01G

18

Unscrew exhaust back pressure sensor (B60)

 Only when replacing charge air manifold upper section (8).

 Installation: Install new seal ring and coat thread with paste.



*BA07.04-N-1009-01B

Paste

*BR00.45-Z-1005-06A

19

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

20

Carry out engine test run and check engine for leaks around the charge air manifold upper section (8)

Number

Designation

Engine
646
in model
906

Engine
646.986

BA07.04-N-1009-01B

Pressure sensor on charge air manifold

Nm

25

25

Number

Designation

Engine
646
in model
906

BA09.41-N-1001-01M

Bolt, charge air manifold to cylinder head

M7

Nm

14

BA09.41-N-1002-01M

Bolt, support to charge air manifold

Nm

20

BA09.41-N-1003-01M

Bolt, support to engine bracket

Nm

20

Number

Designation

Engine 646

BA14.20-N-1001-01G

Bolt connecting exhaust gas recirculation valve to charge air manifold

Nm

8

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51