Remove/install charge air manifold - AR09.41-P-1310OGR

ENGINE 642 in MODEL 166 

Fig 1: Identifying Charge Air Manifold Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
1	Remove mixing chamber		AR09.20-P-1320OGR
2	Remove intake port shutoff actuator motor		AR09.20-P-1314OGR
3	Disconnect electrical connection for the coolant pump switchover valve on bracket (22) and remove bracket (22)
4	Open Henn coupling and remove coolant hose (21) on coolant thermostat (20)		AR09.41-P-1311-01AL
5	Detach coolant hose (19) at charge air manifold (16)	Check clamp and replace if necessary.
6	Remove right rail		AR07.03-P-1010OGR
7	Disconnect Electrical connections at left intake camshaft Hall sensor (B96/1) and on right intake port shutoff Hall sensor (B96/2)	Mark electrical connections for identification.
8	Detach fuel return line (18) from leak oil lines (17)	Check safety clamp; replace if necessary.
9	Remove fuel lines (17)	Replace clamps if necessary.
		Fuel line to cylinder head cover/lifting eye/charge air manifold	*BA07.16-P-1022-01C
10	Detach leak oil line (18) at fuel injectors for the right cylinder head and place leak oil line (18) to one side		AR07.03-P-9105OGR
11	Remove screw/bolts (24) and take off clamp (23)
12	Remove lower screw/bolt for the coolant thermostat (20)	Screw/bolt, coolant thermostat housing to charge air manifold	*BA20.10-P-1002-01S
13	Remove screw/bolts on charge air manifold (16) in the area under the clamp (23)
14	Remove remaining screw/bolts on charge air manifold (16)		AR09.41-P-1310-01PI
		Mount charge air manifold (16) according to the bolt plan.
		Screw/bolt, charge air distribution line to cylinder head	*BA09.41-P-1009-01J
15	Lift out charge air manifold (16) upwards	Tighten clamp (23) with screw/bolt (25) and with screw/bolts (24) on charge air manifold (16). The clamp (23) serves to fix the charge air manifold (16) in place. Replace seals (27) and hook in on charge air manifold (16).
		Bolt, hose clamp cage to fuel filter	*BA47.20-P-1002-02D
		Bolt, fuel filter cage to charge air manifold	*BA47.20-P-1001-02D
16	Disconnect charge air distribution pipe (16) and replace connection piece (26)	Replace connection piece (26).
17	Detach exhaust gas recirculation cooler	When replacing the charge air manifold (16)
			AR14.20-P-7665OGR
18	Detach coolant thermostat (20)	When replacing the charge air manifold (16)
			AR20.10-P-2460OGR
19	Detach coolant temperature sensor (B11/4)	When replacing the charge air manifold (16)
			AR15.60-P-2711OGR
20	Detach left intake port shutoff Hall sensor (B96/1) and right intake port shutoff Hall (B96/2)	When replacing the charge air manifold (16)
	Clean
21	Clean sealing surfaces on the left cylinder head and right cylinder head
22	Clean sealing surfaces on charge air manifold (16)	When charge air manifold (16) is reused
23	Install in the reverse order
	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
24	Perform and engine test run and check engine for leaktightness around charge air manifold (16)

FUEL FILTER

Number	Designation		ENGINE 642
BA47.20-P-1002-02D	Bolt, hose clamp cage to fuel filter	Nm	5

FUEL FILTER

Number	Designation		ENGINE 642
BA47.20-P-1001-02D	Bolt, fuel filter cage to charge air manifold	Nm	12

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		ENGINE 642
BA09.41-P-1009-01J	Screw/bolt, charge air distribution line to cylinder head	Nm	18

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation		ENGINE 642
BA20.10-P-1002-01S	Screw/bolt, coolant thermostat housing to charge air manifold	Nm	9

COMMON RAIL DIESEL INJECTION (CDI)

Number	Designation			ENGINE 642
BA07.16-P-1022-01C	Fuel line to cylinder head cover/lifting eye/charge air manifold	M6x12	Nm	9
		M6x15	Nm	14
		M6x19	Nm	-