Remove/Install Charge Air Distributor - Ar09.41-D-8683TSV

Engine 642 in model 907 

Shown except code MH8 (SULEV low-emission engine) 

Shown except code MH8 (SULEV low- emission engine) 

	Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.	No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	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 overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	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
	Risk of injury  to skin and eyes due to handling of engine oil. Risk of poisoning  caused by swallowing engine oil	Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers.	AS18.00-Z-0001-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Notes about Common-Rail components		AH07.16-P-0002-01TX
	Remove
1	Drain off coolant.		AR20.00-D-1142TSR
2	Remove oil supply connection fitting (1) of exhaust gas turbocharger.		AR09.40-D-6023TSV
3	Remove fuel filter (2).		AR47.20-D-5510TSV
4	Remove the bracket (3).	To do this, remove screw (4).
5	Remove screw (5).
6	Remove coolant hose (6) from coolant thermostat housing.	Plug openings.	AR20.20-S-3865-15S
		Set of protective caps	Fig 6
7	Remove coolant hose (7).	Plug openings. Record plug	Fig 5
		Hose clamp pliers	Fig 2
8	Remove vacuum line (8).	To do so, disassemble and remove vacuum line (8) on vacuum pump and on brake booster. Plug openings.
		Record plug	Fig 5
9	Remove rail (9) on right cylinder head.		AR07.03-D-1012TSV
10	Remove high-pressure line (10).	For this purpose, remove screws (11) and nut (12). Close off connection on rail.
		Open wrench insert, (18 mm)	Fig 4
		Record plug	Fig 5
11	Remove leak oil line (13) at fuel injectors.		AR07.03-D-9110TSV
12	Remove leak oil line (13) from coolant thermostat housing and place outside working area.
13	Disconnect electrical connectors (14) for fuel injectors.
14	Disconnect electrical connector (15) on camshaft position sensor.
15	Disconnect electrical connectors (16) of glow plugs.	Pliers	Fig 1
16	Disconnect electrical connector (17) of coolant temperature sensor.
17	Remove electrical wiring harness (18).	Proceed by first removing the screws (19).
18	Place electrical wiring harness (18) outside the working area.
19	Remove engine lifting lug (20).	To do this, unscrew screws.
20	Remove intake port shutoff actuator motor.	Engine 642 in model 907 with code MH8 (Motor schadstoffarm SULEV)	AR09.20-D-1313TSV
21	Remove bracket (21) from charge-air distributor (25).	To do this, unscrew screws.
22	Remove bracket (22) for fuel filter (2).	Remove screw (23) to do this.
23	Remove sensor end position detection of intake port shutoff.	Engine 642 in model 907 with code MH8 (Motor schadstoffarm SULEV)
24	Remove two screws from charge-air distributor (25) in the area below the bracket (22).	Set of flexible head wrenches	Fig 3
25	Tighten the loosened screw in bracket (22).	Bolt, hose clamp cage to fuel filter	*BA47.20-N-1002-02M
26	Reinstall bracket (22) for fuel filter (2).	To do this, screw in the screws (11, 23).
		Screw, high-pressure line retaining clamp to cylinder head cover/charge-air distributor	*BA07.16-N-1013-03TSV
		Bolt, clamp for fuel filter to charge-air distributor	*BA47.20-N-1003-02M
27	Remove screws (24).
28	Remove remaining screws on charge-air distributor (25).	In the process, remove engine lifting lug (26). Note down the assignment of the screws due to the differing shank lengths. Set of flexible head wrenches	Fig 3
29	Remove charge-air distributor (25).
30	Remove sealing ring (27).	Dispose of sealing ring (27).
31	Remove seal (28).	Dispose of seal (28).
32	Remove seals (29).	Dispose of seals (29).
33	Remove bracket (22) for fuel filter (2).	To do so, remove the screws (11, 23).
34	Remove connection piece (30).	To this end, disassemble sections of the charge-air distributor (25) from one another. Dispose of connection piece (30).
	Clean
35	Clean sealing surfaces on cylinder heads and on mixer housing with a lint-free cloth.
36	Clean sealing surfaces on charge-air distributor (25).	When reusing the charge-air distributor (25). Assembly cleaner	*BR00.45-Z-1028-04A
	Install
37	Transfer the coolant thermostat housing.	When replacing charge-air distributor (25).	AR20.10-D-2461TSV
38	Transfer coolant temperature sensor.	When replacing charge-air distributor (25).	AR15.60-D-2712TSV
39	Assemble sections of charge-air distributor (25).	Install new connection piece (30).
40	Install bracket (22) for fuel filter (2).	To do this, screw in the screws (11, 23).
		Screw, high-pressure line retaining clamp to cylinder head cover/charge-air distributor	*BA07.16-N-1013-03TSV
		Bolt, clamp for fuel filter to charge-air distributor	*BA47.20-N-1003-02M
41	Mount new seals (29).	Clip seals (29) onto charge-air distributor (25).
42	Install new seal (28).
43	Install new sealing ring (27).
44	Install and align charge-air distributor (25).
45	Screw in screws of charge-air distributor (25) according to the tightening procedure.		AR09.41-D-8683-01TSV
		Clip: Tightening procedure for charge-air distributor	GB09.41-D-0000-03A
		In the process, engine lifting lug (26) is installed and bracket (22) is removed. Remember that the shafts vary in length. Screw/bolt, charge air distributor to cylinder head	*BA09.41-N-1010-01O
		Set of flexible head wrenches	Fig 3
46	Screw in screws (24).	Screw/bolt, mixing chamber to charge air distributor	*BA09.41-N-1012-01O
47	Install sensor end position detection of intake port shutoff.	Engine 642 in model 907 with code MH8 (Motor schadstoffarm SULEV)
48	Install bracket (22) for fuel filter (2) and fasten using screw (23).	Tighten screw (23) slightly by hand.
49	Install bracket (21) on charge-air distributor (25).	For this purpose, screw in screws. Bolt, bracket to charge-air distributor	*BA09.41-N-1002-01O
50	Install intake port shutoff actuator motor.	Engine 642 in model 907 with code MH8 (Motor schadstoffarm SULEV)	AR09.20-D-1313TSV
51	Install engine lifting lug (20).	For this purpose, screw in screws.
52	Position electrical wiring harness (18) in the working area.
53	Connect electrical connector (17) of coolant temperature sensor.
54	Connect electrical connectors (16) of glow plugs.
55	Connect electrical connector (15) of camshaft position sensor.
56	Connect electrical connectors (14) of fuel injectors.
57	Fasten electrical wiring harness (18) in the working area.	To do so, screw in screws (19).
58	Position leak oil line (13) in the working area.
59	Attach leak oil line (13) to fuel injectors.		AR07.03-D-9110TSV
60	Attach leak oil line (13) to coolant thermostat housing.
61	Install high-pressure line (10).
	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths	Initially attach nut (12) of high-pressure line (10) to rail lightly by hand. Then tighten to torque and tightening angle. Tension can otherwise arise at high-pressure line (10).	AH00.00-P-0015-01CW
		Union nut, rail high-pressure line to rail	*BA07.16-N-1004-03TSV
		Open wrench insert, (18 mm)	Fig 4
		Record plug	Fig 5
62	Screw in screws (11).	Screw, high-pressure line retaining clamp to cylinder head cover/charge-air distributor	*BA07.16-N-1013-03TSV
63	Tighten screw (23).	Bolt, clamp for fuel filter to charge-air distributor	*BA47.20-N-1003-02M
64	Install rail (9) on right cylinder head.		AR07.03-D-1012TSV
65	Install vacuum line (8).	To do so, attach vacuum line (8) to vacuum pump and brake booster. Check seal on brake booster for damage.
		Record plug If the seal is damaged. Replace seal.	Fig 5
66	Attach coolant hose (7).	Record plug	Fig 5
		Hose clamp pliers	Fig 2
67	Attach coolant hose (6) to coolant thermostat housing.		AR20.20-S-3865-15S
		Set of protective caps	Fig 6
68	Screw in screw (5).
69	Install bracket (3).	Screw in screw (4) to do this.
70	Install fuel filter (2).		AR47.20-D-5510TSV
71	Install oil supply connection fitting (1) of exhaust gas turbocharger.		AR09.40-D-6023TSV
72	Fill in coolant.		AR20.00-D-1142TSR
	Check
	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
73	Check for leaktightness when engine is running.	Visual inspection only.

COMMON RAIL DIESEL INJECTION SYSTEM

COMMON RAIL DIESEL INJECTION SYSTEM

CHARGE AIR PIPE, CHARGE AIR COOLING, MIXER HOUSING

CHARGE AIR PIPE, CHARGE AIR COOLING, MIXER HOUSING

CHARGE AIR PIPE, CHARGE AIR COOLING, MIXER HOUSING

FUEL FILTER

FUEL FILTER

Fig 1: Pliers (611 589 00 37 00)

Fig 2: Hose Clamp Pliers (454 589 00 37 00)

Fig 3: Set Of Flexible Head Wrenches (001 589 81 09 00)

Fig 4: Open Wrench Insert, 18 Mm) (000 589 30 01 00)

Fig 5: Record Plug (129 589 00 91 00)

Fig 6: Set Of Protective Caps (001 589 02 91 00)