Remove/install charge air distribution pipe

AR09.41-D-1310NA

Remove/install charge air distribution pipe

15.2.12

 

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

1

Drain coolant

At radiator.

AR20.00-D-1142NA

2

Remove trim panel of cylinder head cover

AR01.20-D-5015NA

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

3

Disconnect engine wiring harness at vehicle side

AR15.18-D-1000-02NA



Notes on battery

AH54.10-P-0001-01A

4

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

Pull spring (arrow) upwards.

 Installation: Check sealing ring, replace if necessary

5

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

6

Unscrew bolt (3)

7

Detach coolant hose (8) at connector (6)

8

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

 Installation: Replace clamp.

9

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

Observe handling of release arm.

Collect fuel which flows out.

Replace seal.

AR47.25-P-1000-01A

10

Remove support (7)



*BA09.41-N-1002-01F



*BA09.41-N-1003-01F

11

Unscrew bolts (18)

12

Unscrew bolt (16) and remove bracket

13

Unplug connector (13) at fuel pressure sensor (12)

14

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

Accessibility from underneath.

15

Unscrew bolts (11) next to the connecting pipe of the coolant hose (2)

Accessibility from underneath.



*BA09.41-N-1001-01F

16

Unscrew remaining bolts (11) and remove charge air distribution tube (1)



*BA09.41-N-1001-01F

17

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 tube (arrows).

18.1

Fit on existing mixing chamber with exhaust gas recirculation

Only if replacing the charge air distribution pipe (1)

AR09.20-D-1320B

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 when working in engine during starting procedure

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

AS00.00-Z-0005-01A

20

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks.

21

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