Remove/install charge-air distributor with integrated charge air cooler

AR09.41-S-0020EH

Remove/install charge-air distributor with integrated charge air cooler

19.08.2020

Engine

622.8 in model 447

1

Charge air distributor with integrated charge air cooler

5

Mounting clip

2

Bolts

6

Bolts

3

Bracket

7

Air duct housing

4

Electrical connectors

12

Bracket

1

Charge air distributor with integrated charge air cooler

10

Coolant pipe

8

Coolant hoses

11

Bolts

9

Coolant hose

Tightening sequence

15

Nut

21

Nut

16

Nut

22

Nut

17

Nut

23

Nut

18

Nut

24

Nut

19

Nut

25

Nut

20

Nut

 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.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

 

Remove/install

1

Remove radiator unit.

AR20.20-S-3871EH

2

Remove high pressure exhaust gas recirculation actuator (Y27/20).

AR14.20-S-7676EH

3

Remove the throttle valve actuator.

AR09.41-S-1330EH

4

Remove screws (6) and remove air duct housing (7).

 Installation: Replace seal.

 Screws (6) have different lengths.

 M6

*BA00.10-N-1002-01A

5

Remove oil dipstick tube.

AR18.40-S-3520EH

6

Remove screws (2) and place bracket (3) to one side.


Do not crush or kink or subject electric lines to tension.
This will result in damage to the electric lines and can impair their function.

7

Release and disconnect the electrical connections (4).

8

Unclip retaining clip (5) and place the electrical wiring harness to one side.


Do not crush or kink or subject electric lines to tension.
This will result in damage to the electric lines and can impair their function.

 Dismantling tool

*000589956300

9

Remove high-pressure charge air distributor temperature sensor (B16/10) from charge air distributor with integrated charge air cooler (1).

AR49.20-S-0015EH

10

Remove coolant hoses (8) from charge air distributor with integrated charge air cooler (1) and seal exposed openings with suitable protective covers.

 Set of protective covers

*001589019100

11

Remove coolant hoses (9) from coolant pipe (10) and seal exposed openings with suitable protective covers.

 Set of protective covers

*001589019100

12

Unscrew screws (11) and remove coolant pipe (10).

 Installation: Replace seal.

 M6

*BA00.10-N-1002-01A

 Assembly tool

*000589936300

13

Remove nuts (15 to 25) and remove charge air distributor with integrated charge air cooler (1).

 Installation: Observe tightening sequence.

 Nut, charge air distributor to cylinder head

*BA09.41-N-1005-01U

If the stud bolts have worked loose,



replace the stud bolts.

 Stud bolt, charge-air distributor to cylinder head

*BA09.41-N-1006-01U

14

Seal exposed openings with suitable means.

15

Remove seal from the stud bolts of charge air distributor with integrated charge air cooler (1).

16

Remove temperature sensor downstream of charge air cooler (B17/8).

If charge air distributor with integrated charge air cooler (1) is being replaced.

AR09.41-S-0019EH

17

Remove charge air temperature sensor downstream of throttle valve (B17/16).

If charge air distributor with integrated charge air cooler (1) is being replaced.

AR09.41-S-0018EH

18

Remove charge air pressure and temperature sensor (B5/14).

If charge air distributor with integrated charge air cooler (1) is being replaced.

AR09.41-S-2007EF

19

Remove bracket (12).

If charge air distributor with integrated charge air cooler (1) is being replaced.

20

Install in the reverse order.



Check

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 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.

AS00.00-Z-0005-01A

21

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 Charge air pipe

Number

Designation

Model 447 with engine 622.8

BA09.41-N-1005-01U

Nut, charge air distributor to cylinder head

Nm

25

 Charge air pipe

Number

Designation

Model 447 with engine 622.8

BA09.41-N-1006-01U

Stud bolt, charge-air distributor to cylinder head

Nm

8