Remove/Install Charge Air Manifold - Ar09.41-D-1310SG
ENGINES 642.896 /898 in MODEL 906
REMOVE/INSTALL CHARGE AIR MANIFOLD - ENGINES 642.896 /898 IN MODEL 906
| Remove/install | |||
| 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 | |
| Notes about Common-Rail components | AH07.16-P-0002-01SM | ||
| 1 | Drain coolant | AR20.00-D-1140SD | |
| 2 | Remove trim panel on right cylinder head cover | AR01.20-D-5015SF | |
| 3 | Remove oil supply connection fittings for turbocharger | AR09.40-S-6023SE | |
| 4 | Remove bracket (16) with glow output stage (N14/3) and lay down to side | ||
| 5 | Remove bracket (13) from right cylinder head (29) | ||
| 6 | Open Henn coupling and remove coolant hose (18) on coolant thermostat (20) | AR09.41-P-1311-01AL | |
| 7 | Remove bracket (17) and lay down to side with attached coolant hose (18) | ||
| 8 | Remove vacuum line (7) from vacuum pump (15) and unclip cover from left cylinder head cover | ||
| 9 | Remove coolant hoses (12, 19) from charge air manifold (9) | ||
| 10 | Pull vacuum line (7) out of brake booster and lay vacuum line (7) down to side | ||
| 11 | Remove fuel filter (8) | AR47.20-D-1070SF | |
| 12 | Remove right rail (1) | AR07.03-D-1010SF | |
| 13 | Disconnect electrical connector (32) from intake port shutoff actuator (M72) | Engine 642.898 | |
| 14 | Disconnect left EKAS end position switch connector (X156/1) and right EKAS end position switch connector (X156/2) | Engine 642.898 |
|
| 15 | Unscrew bolts (24) on charge air manifold (9), turn clamps (31) for exposing connection line (5) and then tighten bolts (24) with clamp (23) | ||
| 16 | Unscrew union nut on connecting line (5) from right rail | ||
| Figure | |||
| 17 | Disconnect leak oil line (14) on charge air manifold (9) on injectors (arrows) on right cylinder bank and lay leak oil line (14) down to side. | AR07.03-D-9105SF | |
| 18 | Disconnect engine wiring harness (11) on injectors (arrows A) from right cylinder bank and expose | ||
| 19 | Disconnect engine wiring harness (11) from camshaft sensor (B6/24) and expose | ||
| 20 | Disconnect engine wiring harness (11) from glow plugs (arrows B) and expose | Figure | |
| 21 | Disconnect engine wiring harness (11) from coolant temperature sensor (B11/19) | ||
| 22 | Remove engine wiring harness (11) and cable duct (4) from charge air manifold (9) and lifting eye (6) | ||
| 23 | Fasten engine wiring harness (11) and cable duct (4) t windshield wiper linkage | ||
| 24 | Remove bracket (2) from right cylinder head (29) | ||
| 25 | Remove bracket (3) from charge air manifold (9) | ||
| 26 | Unscrew bolts (24) from clamp (23) and remove clamp (23) | ||
| 27 | Unscrew bolts am charge air manifold (9) in area below clamp (23) | Figure | |
| 28 | Unscrew bolt (25) from clamp (23) | ||
| 29 | Install clamp (23) and unscrew bolts (24) from charge air manifold (9) | ||
| 30 | Unscrew bolts (22) from mixing chamber (10) and charge air manifold (9) | ||
| Figure | |||
| 31 | Unscrew remaining bolts am charge air manifold (9) and remove lifting eye (6) | AR09.41-D-1310-01SG | |
| Figure | |||
| 32 | Lift out charge air distribution tube (9) upwards | ||
| 33 | Separate charge air manifold (9) and remove connection piece (26) | On engine 642.898 to replace left and right charge air manifold (9), remove clip (35) and disconnect intake port shutoff linkage (36). On engine 642.898 replace clip (35) if removed. |
|
| 34 | Remove coolant thermostat (20) from coolant temperature sensor (B11/19) | ||
| 35 | Remove coolant temperature sensor (B11/19) | ||
| 36 | Remove left EKAS end position sensor (B90/2) and right EKAS end position sensor (B90/3) | ||
| Clean | |||
| 37 | Clean sealing surfaces on right cylinder head (29), left cylinder head (30) and mixing chamber (10) | ||
| 38 | Clean sealing surfaces on charge air manifold (9) | ||
| 39 | Install in the reverse order | ||
| 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 | |
| 40 | Test run engine and check engine for leaks around charge air manifold (9) |
CONNECTING LINE BETWEEN LEFT & RIGHT RAIL TORQUE SPECIFICATIONS - ENGINE 642.896/898/992/993
| Number | Designation | Engine 642.896/898/992/993 | |||
|---|---|---|---|---|---|
| BA07.16-N-1007-01B | Connecting line between left and right rail | M15x1 | Stage 1 | Nm | 20 |
| Stage 2 | Degrees | 60 | |||
CHARGE AIR COOLER TORQUE SPECIFICATIONS - ENGINE 642
| Number | Designation | Engine 642 | ||
|---|---|---|---|---|
| BA09.41-N-1002-01O | Bolt, holder to charge air distribution line | Nm | 9 | |
| BA09.41-N-1010-01O | Bolt, charge air distribution line to cylinder head | Nm | 16 | |
| BA09.41-N-1012-01O | Bolt of mixing chamber to charge air manifold | M6 | Nm | 9 |
COOLANT THERMOSTAT HOUSING TO CHARGE AIR MANIFOLD BOLT TORQUE SPECIFICATIONS - ENGINE 642
| Number | Designation | Engine 642 | |
|---|---|---|---|
| BA20.10-N-1005-01Q | Bolt, coolant thermostat housing to charge air manifold | Nm | 9 |
FUEL FILTER TORQUE SPECIFICATIONS - ENGINE 642
| Number | Designation | Engine 642 | |
|---|---|---|---|
| BA47.20-N-1002-02M | Screw, hose clamp cage to fuel filter | Nm | 5 |
| BA47.20-N-1003-02M | Bolt, fuel filter clamp to charge air manifold | Nm | 12 |