Remove/install charge air manifold

AR09.41-D-1310R

Remove/install charge air manifold

06.03.2020

Engine

646 in model 909

Modification notes

12.12.2016

Tightening torque inserted.

Operation step 5

12.12.2016

Remove charge air pipe, added.

Operation step 12

13.12.2016

Remove exhaust gas recirculation positioner, for replacing the charge air distributor upper part, added.

Operation step 15

13.12.2016

Remove exhaust back pressure sensor, for replacing the charge air distributor upper part, added.

Operation step 16

1

Charge air distributor upper part

2

Fuel lines

2a

Bracket

2b

Bracket

3

Fuel filter

3a

Bracket

4

Bracket

1a

Charge air distributor lower section

1d

Seal

1r

Sealing ring

1s

Bolts

 

Remove/install

1

Remove engine

AR01.10-D-2401RU

2

Release and disconnect electrical connection on exhaust gas recirculation positioner

AR14.20-D-7662R

3

Release and disconnect electrical connection on exhaust back pressure sensor

AR07.04-D-0009R

4

UnClamp engine wiring harness on charge air distributor upper part (1)

5

Remove holder (2a) on charge air distributor upper part (1) and on cylinder head

 M71

*BA00.10-N-1003-04A

 M81

*BA00.10-N-1004-04A

6

Remove bracket (2b)

 Installation: Pay attention to different lengths of screws.

7

Remove holder (4) with fuel lines (2) on charge air distributor upper part (1)

8

Remove fuel lines (2) on charge air distributor upper part (1)

9

Remove fuel lines (2) on the holder (2a) and place the holder (2a) with engine wiring harness to one side

10

Remove fuel filter (3)

AR47.20-D-1070R

11

Remove holder (3a)

 Screw/bolt, support to engine bracket

*BA09.41-N-1003-01M

 Screw/bolt, support to charge air distributor

*BA09.41-N-1002-01M

12

Remove charge air pipe

AR09.41-D-1311R

13

Remove screw/bolts for charge air distributor upper part (1)

AR09.41-D-1310-01R

 Installation: Note bolt plan of charge air distributor upper part (1).

 Screw/bolt, charge air distributor to cylinder head

*BA09.41-N-1001-01M

14

Remove charge air distributor upper part (1)

 Installation: Replace seal (1d) and sealing ring (1r).

15

Remove exhaust gas recirculation positioner

When replacing of charge air distributor upper part (1).

AR14.20-D-7662R

16

Remove exhaust back pressure sensor

When replacing of charge air distributor upper part (1).

AR07.04-D-0009R

17

Clean sealing surfaces on charge air distributor­upper part (1)

Assembly cleaner

*BR00.45-Z-1028-04A

18

Remove screw/bolts (1s)

 Screw/bolt, charge air distributor to cylinder head

*BA09.41-N-1001-01M

19

Remove charge air distributor­lower part (1a)

 Installation: Replace seal.

20

Clean sealing surfaces on charge air distributor (1) and on cylinder head

Assembly cleaner

*BR00.45-Z-1028-04A

21

Install in the reverse order

 Metric bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-N-1003-04A

M71

Nm

15

22

 Metric bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-N-1004-04A

M81

Nm

23

33

 Charge air pipe/charge air cooling

Number

Designation

Engine 646.7 in model 909

BA09.41-N-1001-01M

Screw/bolt, charge air distributor to cylinder head

M7

Nm

14

 Charge air pipe/charge air cooling

Number

Designation

Engine 646.7 in model 909

BA09.41-N-1002-01M

Screw/bolt, support to charge air distributor

Nm

20

 Charge air pipe/charge air cooling

Number

Designation

Engine 646.7 in model 909

BA09.41-N-1003-01M

Screw/bolt, support to engine bracket

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01