Remove/install charge air manifold - AR09.41-P-1310TI
ENGINES 642 in MODEL 211
| Remove/install | |||
| Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running | Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. |
AS00.00-Z-0005-01A | |
| Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure. | Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized. | AS07.16-Z-0001-01A | |
| Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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 | |
| Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| 1 | Drain coolant | AR20.00-P-1142TI | |
| 2 | Remove coolant line from thermostat housing | ||
| 3 | Remove mixing chamber | AR09.20-P-1320TI | |
| 4 | Remove turbocharger | AR09.40-P-6020TI | |
| 5 | Remove oil supply connection fittings for turbocharger | AR09.40-P-6023TI | |
| 6 | Remove left rail | ↓ |
|
| Remove/install rail | AR07.03-P-1010TI | ||
| 7 | Unscrew union nuts on connecting line (19/2) | ||
| *BA07.16-P-1024-01C | |||
| Figure | |||
| 8 | Remove leak oil line (2) from fuel lines (1) | ||
| 9 | Detach fuel lines (1) from fuel filter | ||
| 10 | Detach fuel lines (3) | ||
| 11 | Pull out fuel supply line (6) for high-pressure pump | ||
| 12 | Remove bolts of fuel pipe (5) | ||
| 13 | Remove fuel pipe (5) | ||
| 14 | Remove fuel filter with cage | *BA47.20-P-1001-02D | |
| 15 | Unscrew distributor leak oil line (7) | *BA07.16-P-1023-01C | |
| 16 | Disconnect engine wiring harness (12) at control unit | ||
| 17.1 | Detach glow plugs plug | ||
| 18.1 | Detach injectors plug | ||
| 19 | Detach plug (8) from intake port shutoff motor (M55) | ||
| 20.1 | Detach plug (10) from exhaust back pressure sensor (B60) | ||
| 21 | Remove left exhaust gas recirculation positioner (Y27/9) | AR14.20-P-1020TI | |
| 22 | Remove bottom bolt (11) at thermostat housing | *BA20.10-P-1002-01S | |
| 23 | Place engine wiring harness (12) to one side | ||
| 24 | Remove bolts (13) at charge air manifold | ↓ |
|
| Bolt plan for charge air manifold | AR09.41-P-1310-01TI | ||
| *BA09.41-P-1009-01J | |||
| 25 | Remove charge air manifold (13) | ||
| 26 | Install in the reverse order | ||
| 27 | Check for oil leaks with engine running | ||
| 28 | Check fuel system for leaks with engine running |
FUEL FILTER
| Number | Designation | Engine 642 | |
|---|---|---|---|
| BA47.20-P-1001-02D | Bolt connecting fuel filter cage to charge air manifold | Nm | 12 |
COMMON RAIL DIESEL INJECTION (CDI)
| Number | Designation | Engine 642 | ||
|---|---|---|---|---|
| BA07.16-P-1023-01C | Leak oil line on charge air distribution line | M6x23 | Nm | 12 |
| BA07.16-P-1024-01C | Connecting line between left and right rail | M15 | Nm | 27 |
COOLANT PUMP, COOLANT THERMOSTAT
| Number | Designation | Engine 642 | |
|---|---|---|---|
| BA20.10-P-1002-01S | Bolt, coolant thermostat housing to charge air manifold | Nm | 9 |
CHARGE AIR PIPE/CHARGE AIR COOLING
| Number | Designation | Engine 642 | |
|---|---|---|---|
| BA09.41-P-1009-01J | Bolt, charge air distribution line to cylinder head | Nm | 16 |