AR09.41-D-1310A | Remove/install charge air distribution pipe | 18.6.99 |
ENGINE 612.981 in MODEL 902.6, 903.6, 904.6, 905.6
D09.41-1103-06
1 Charge air distribution pipe
2 Coolant hose
3 Screw
4 Cable duct of engine wiring harness
5 Engine wiring harness
6 Connector
7 Support
8 Coolant hose
9 Fuel pipe
10 Fuel pipe
11 Screw
12 Vacuum line
13 Vacuum reservoir
14 Connector
15 Charge air hose
16 Bracket
17 Gasket
18 Bolts
D09.20-0014-10
Bolt diagram of charge air distribution pipe
Arrows: Installation position of stud bolts (assembly aid)
| 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. Wear protective clothing when handling fuel. | |
Danger! | Risk of injury to skin and eyes from scalding with hot coolant which splashes out. 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 bottles. Wear protective gloves, protective clothing and eye protection. | |
1 | Drain coolant, pour in | At radiator | |
2 | Disconnect engine wiring harness at vehicle side | ||
3 | Detach charge air hose (15) at mixing chamber with exhaust gas recirculation | Pull spring (arrow) up | |
Installation:Inspect seal, replace if necessary. | |||
4 | Remove connector (14) at mixing housing with exhaust gas recirculation | ||
5 | Unscrew bolt (3). | ||
6 | Detach coolant hose (8) at intermediate piece (6) | ||
7 | Detach fuel line (10) at fuel full-flow filter | Installation: Replace collar clamp | |
8 | Detach fuel line (9) at fuel full-flow filter | Pay attention to operation of locking arm | |
Collect fuel which flows out. Replace seal | |||
9 | Remove support (7) | Support to charge air distribution pipe | |
Support to crankcase | |||
10 | Unscrew bolts (18) and remove bracket (16) | ||
11 | Detach vacuum line (12) at vacuum control unit (13) | ||
12 | Detach coolant hose (2) at charge air distribution pipe (1) | Accessible from below | |
13 | Unscrew bolts (11) next to coolant hose (2) | Accessible from below | |
14 | Take off charge air distribution pipe (1) at cylinder head | | |
15 | 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 pipe (figure). | |||
16.1 | Fit on existing mixing chamber with exhaust gas recirculation | Only if charge air distribution pipe is replaced. | |
17 | Install in the reverse order | ||
Danger! | Risk of accident from vehicle starting off by itself when engine running. Risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running | Secure vehicle to prevent it moving off. | |
18 | Inspect fuel system for leaks | Run engine, switch off and inspect for leaks | |
19 | Encode radio, set clock |
Charge air pipe/charge air cooling
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