Remove/Install Charge Air Manifold - AR09.41-P-1310OGR

ENGINE 642 in MODEL 166, 292 

	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 detach coolant hose (21) on coolant thermostat (20)		AR09.41-P-1311-01AL
5	Detach coolant hose (19) on charge air distributor (16)	Check clamp for damage and replace if necessary.
6	Remove left rail		AR07.03-P-1010OGR
7	Disconnect Electrical connections at left intake port shutoff Hall sensor (B96/1) and on right intake port shutoff Hall sensor (B96/2)	Mark electrical connections for identification.
8	Detach leak oil line (18) from fuel lines (17)	Check safety clamp for damage and 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)	Bolt, coolant thermostat housing to charge air manifold	*BA20.10-P-1002-01S
13	Remove screw/bolts on charge air distributor (16) in the area under the clamp (23)
14	Remove remaining screw/bolts on charge air distributor (16)		AR09.41-P-1310-01PI
		Mount charge air distributor (16) according to bolt plan. Bolt, charge air distributor to cylinder head	*BA09.41-P-1009-01J
15	Remove charge air distributor (16) upwards	Tighten clamp (23) with screw/bolt (25) and with screw/bolts (24) on charge air distributor (16). The clamp (23) serves to fix the charge air distributor (16) in place. Replace seals (27) and hook in on charge air distributor (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 distributor (16) and remove connection piece (26)	Replace connection piece (26).
17	Detach exhaust gas recirculation cooler	When replacing the charge air distributor (16)	AR14.20-P-7665OGR
18	Detach coolant thermostat (20)	When replacing the charge air distributor (16)	AR20.10-P-2460OGR
19	Detach coolant temperature sensor (B11/4)	When replacing the charge air distributor (16)	AR15.60-P-2711OGR
20	Detach left intake port shutoff Hall sensor (B96/1) and right intake port shutoff Hall sensor (B96/2)	When replacing the charge air distributor (16)
	Clean
21	Clean sealing surfaces on the left cylinder head and right cylinder head		AR01.00-P-0050-01A
		Do not use any sharp-edged tools or abrasive paper. The sealing surfaces can be damaged otherwise. Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Loctite 7200	*BR00.45-Z-1038-04A
22	Clean sealing surfaces on charge air distributor (16)	When reusing the charge air distributor (16)
23	Install in the reverse order
24	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. Perform engine test run and check engine around charge air distributor (16) for leaktightness	Secure vehicle to prevent it from starting off by itself. Wear buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A

COMMON RAIL DIESEL INJECTION SYSTEM (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	-

CHARGE AIR PIPE/CHARGE AIR COOLING

Number	Designation		Engine 642
BA09.41-P-1009-01J	Bolt, charge air distributor to cylinder head	Nm	18

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation		Engine 642
BA20.10-P-1002-01S	Bolt, coolant thermostat housing to charge air manifold	Nm	9

FUEL FILTER

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

FUEL FILTER

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

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1038-04A	Loctite 7200	Henkel AG & Co.
BR00.45-Z-1046-04A	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10