Remove/install charge air distributor

AR09.41-S-8683PD

Remove/install charge air distributor

27.11.2019

Model

470, 471 with engine 699.300/301/302/303

Modification notes

21.11.2019

Basic data reference added.

Operation step 1

AR09.41-S-8683-01PD

26.11.2019

Method extended

Operation step 13

1

Charge air distributor

5

Electrical connector

7

Hose

2

Electrical wiring harness

6

Hose

9

Vacuum valve

3

Electrical connector

8

Bolts

10

Nuts

11

Stud bolt

12

Screw

 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

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

 

Remove/install

1

Remove coolant pipe.

Model 470, 471 with engine 699.301/303

AR20.20-S-7450PD

2

Remove the throttle valve actuator.

AR09.41-S-1330PD

3

Remove the alternator

AR15.40-S-5032PD

4

Disconnect electrical connector (3).

5

Disconnect electrical connector (5).

6

Remove hose (7) from the vacuum valve (9).

7

Remove hose (6) from the vacuum valve (9).

8

Remove hose (6) from the charge-air distributor (1).

9

Disconnect glow plug connectors from the glow plugs of cylinders 1 and 2.

AR15.20-S-4111PD

Firing order

AH01.00-N-0100-02P

 Removal: Mark assignment of glow plug connector to respective cylinder.

 Installation: Observe marks of glow plug connectors.

10

Remove electrical wiring harness (2) from charge-air distributor (1).

 Installation:
Ensure that the electrical wiring harness (2) is correctly routed.
To prevent damage to electrical wiring harness (2).

11

Remove screw (12).

 M6

*BA00.10-N-1002-01A

12

Remove screws (8).

AR09.41-S-8683-01PD

 Installation: Tighten screws (8) and nuts (10) as per the tightening procedure.

 Bolt, charge air distributor to cylinder head

*BA09.41-N-1005-01PD

 Nut, charge air distributor to cylinder head

*BA09.41-N-1007-01PD

13

Remove nuts (10).

 Installation: Do not tighten nuts (10) yet.

14

Remove stud bolt (11).

 Stud bolt, charge-air distributor to cylinder head

*BA09.41-N-1008-01PD

15

Remove charge-air distributor (1) upwards.

 Installation: Replace seal.

16

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.

AS00.00-Z-0005-01A

17

Check for leaktightness when engine is running.

 Visual inspection only.

 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, charge air hose, throttle valve actuator, charge air distributor, boost pressure sensor

Number

Designation

Model 470, 471 with engine 699

BA09.41-N-1005-01PD

Bolt, charge air distributor to cylinder head

Nm

25

 Charge air pipe, charge air hose, throttle valve actuator, charge air distributor, boost pressure sensor

Number

Designation

Model 470, 471 with engine 699

BA09.41-N-1007-01PD

Nut, charge air distributor to cylinder head

Nm

25

 Charge air pipe, charge air hose, throttle valve actuator, charge air distributor, boost pressure sensor

Number

Designation

Model 470, 471 with engine 699

BA09.41-N-1008-01PD

Stud bolt, charge-air distributor to cylinder head

Nm

15