Remove/Install Charge Air Distributor - AR09.41-P-8683MND
Engine 276.8 In Model 213, 238
| Remove | |||
| 1 | Remove upper Engine cover | ||
| 2 | Remove right air filter housing (1) | AR09.10-P-1152MND | |
| 3 | Remove left air filter housing (2) | AR09.10-P-1151MND | |
| 4 | Remove Engine management control unit (24) | AR07.08-P-7013MND | |
| 5 | Release and disconnect electrical connection at pressure sensor downstream of throttle valve (23) | ||
| 6 | Detach check valve (4) at charge air distributor (3) | ||
| 7 | Remove screw/bolts of EGR line at charge air distributor (3) | Engine 276.853 in model 213 | AR14.20-P-0001MND |
| 8 | Remove screw/bolts of cable duct (6) | ||
| 9 | Release and disconnect electrical connections of Engine wiring harness and place cable duct (6) to one side | AR15.18-P-1000-04MND | |
| 10 | Unfasten screw clamp on throttle valve actuator (26) | AR07.70-P-0005MND | |
| 11 | Release and disconnect electrical connection at throttle valve actuator (26) | AR07.70-P-0005MND | |
| 12 | Remove screw/bolts (7) crosswise from inside outwards and detach charge air distributor (3) with throttle valve actuator (26) | ||
| 13 | Close off the opening in the charge air cooler with protective cover | Fig 1 | |
| 14 | Detach throttle valve actuator (26) from charge air distributor (3) | When replacing charge-air distributor (3). | AR07.70-P-0005MND |
| 15 | Protect intake ports of the left and right cylinder head with clean rags against soiling and foreign objects | ||
| 16 | Remove sealant residue on charge air distributor (3) and on left and right connecting flange | The sealing surfaces on the charge air distributor (3) and on the left connecting flange must not have any foreign objects, scratches or grooves. Non-observance leads to leakage between the charge air distributor (3) and the left connecting flange. Do not use any sharp-edged tools or abrasive paper. The sealing surfaces can get damaged otherwise. Loctite 7200 |
*BR00.45-Z-1038-04A |
| 17 | Check connecting flange of charge air distributor (3) on left cylinder head for damage | Left connecting flange damaged ↓ Replace left connecting flange. |
AR09.41-P-0009MND |
| 18 | Check connecting flange for charge air distributor (3) on right cylinder head for damage | Right connecting flange damaged ↓ Replace right connecting flange. |
AR09.41-P-0010MND |
| Install | |||
| 19 | Check seal between the throttle valve actuator (26) and the charge air distributor (3) | When replacing charge-air distributor (3). | |
| 20 | Mount throttle valve actuator (26) on the charge air distributor (3) | When replacing charge-air distributor (3). | AR07.70-P-0005MND |
| 21 | Replace seals (8) | ||
| 22 | Remove the rags from the intake ports of the left and right cylinder head | ||
| 23 | Remove protective cover at opening of the charge air cooler | Fig 1 | |
| 24 | Insert the charge air distributor (3) | ||
| 25 | Screw in screw/bolts (7) cross-wise from inside to outside | *BA09.41-P-1001-01R | |
| 26 | Screw screw/bolts of EGR line onto charge air distributor (3) | Engine 276.853 in model 213 | AR14.20-P-0001MND |
| 27 | Assemble and lock electrical connection on throttle valve actuator (26) | ||
| 28 | Tighten screw clamp on throttle valve actuator (26) | ||
| 29 | Screw in screw/bolts of cable duct (6) | *BA00.10-P-1002-01A | |
| 30 | Put together and lock electrical connections of Engine wiring harness | AR15.18-P-1000-04MND | |
| 31 | Mount check valve (4) on charge air distributor (3) | ||
| 32 | Put together and lock electrical connection on pressure sensor downstream of throttle valve (23) | ||
| 33 | Install Engine management control unit (24) | AR07.08-P-7013MND | |
| 34 | Install left air filter housing (2) | AR09.10-P-1151MND | |
| 35 | Install right air filter housing (1) | AR09.10-P-1152MND | |
| Risk of burn injuries,
suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. |
Wear protective clothing and safety glasses. Use the extraction system. Move people out of the danger zone. |
AS49.00-Z-0001-01A | |
| 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 | |
| 36 | Carry out an Engine test run, checking the Engine for proper operation and leaktightness | ||
| 37 | Install upper Engine cover |
HEADLESS SCREWS: BOLTS AND NUTS, COARSE-PITCH THREAD
| Number | Designation | Model all (4xWD, CAR, smart) | |||
|---|---|---|---|---|---|
| BA00.10-P-1002-01A | M6 | 8.8 | Galvanized | Nm | 9 |
| Phosphated | Nm | 9 | |||
| 10.9 | Galvanized | Nm | 13 | ||
| Phosphated | Nm | 12 | |||
| 12.9 | Galvanized | Nm | 16 | ||
| Phosphated | Nm | 14 | |||
CHARGE AIR PIPE/CHARGE AIR COOLING
| Number | Designation | Engine 276.8 | |
|---|---|---|---|
| BA09.41-P-1001-01R | Screw/bolt, charge air distributor to intermediate flange | Nm | 9 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1038-04A | Loctite 7200 | A 010 989 90 71 |