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

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ENGINE 642 in MODEL 207, 212, 218, 221 

Fig 1: Charge Air Manifold Remove/Install Components (1 Of 2)
G09974910Courtesy of MERCEDES-BENZ USA
Fig 2: Charge Air Manifold Remove/Install Components (2 Of 2)
G09974911Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER 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
1 Drain coolant MODEL 207 with ENGINE 642 AR20.00-P-1142CW
MODEL 212, 218 with ENGINE 642 AR20.00-P-1142OGE
MODEL 221 with ENGINE 642 AR20.00-P-1142SXI
2 Remove coolant line from thermostat housing    
3 Remove mixing chamber MODEL 207, 212, 218 with ENGINE 642 AR09.20-P-1320OGE
MODEL 221 with ENGINE 642 AR09.20-P-1320SXI
4 Remove exhaust gas recirculation actuator (Y27/9) MODEL 207, 212, 218 with ENGINE 642 without CODE 927 (Emission control system with Euro 6 technology) AR14.20-P-1020GZB
ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology) AR14.20-P-1020CD
MODEL 221 with ENGINE 642 AR14.20-P-1020SXI
5 Remove turbocharger MODEL 207, 212, 218 with ENGINE 642 AR09.40-P-6020OGE
MODEL 221 with ENGINE 642 AR09.40-P-6020SXI
6 Remove oil supply connection fittings for turbocharger   AR09.40-P-6023SXI
7 Remove left rail   AR07.03-P-1010SXI
8 Unscrew union nuts for vacuum line (19/2) IMPORTANT Close off connections for connecting line (19/2) immediately after removal as a protection against contamination. Do not crush or deform vacuum line (19/2).  
TORQUE SPECIFICATION Connecting line between left and right rail *BA07.16-P-1024-01C 
SPECIAL TOOL Record plug Fig 3
9 Remove leak oil line (2) from fuel lines (1)    
10 Detach fuel lines (3) IMPORTANT To do this open clamps. Check clamps for damage; replace if necessary.  
11 Pull out fuel supply line (6) for high-pressure pump IMPORTANT To do this open clamps. Check clamps for damage; replace if necessary.  
12 Remove screw/bolts for fuel pipe (5)    
13 Remove fuel pipe (5) and fuel filter with cage IMPORTANT To do this, remove screw/bolts on fuel filter cage at charge air distributor.  
TORQUE SPECIFICATION Bolt, fuel filter cage to charge air manifold *BA47.20-P-1001-02D 
14 Unscrew distributor leak oil line (7) TORQUE SPECIFICATION Leak oil line to charge air distribution line *BA07.16-P-1023-01C 
15 Disconnect engine wiring harness (12) at CDI control unit MODEL 221 with ENGINE 642  
16 Disconnect electrical connection at the glow plugs At left cylinder head only  
17 Disconnect electrical connection at the injectors At left cylinder head only  
18 Remove intake port shutoff MODEL 207, 212, 218 with ENGINE 642 AR09.20-P-1314CO
MODEL 221 with ENGINE 642 AR09.20-P-1314SXI
19 Disconnect electrical connection (10) from exhaust pressure sensor ENGINE 642 in MODEL 207, 212, 218, 221 with CODE 474 (Particulate trap)  
20 Remove electrical plug connection from coolant temperature sensor    
21 Place engine wiring harness (12) to one side    
22 Separate hose on expansion reservoir from charge air distributor (13) MODEL 207, 212, 218 with ENGINE 642  
23 Loosen water hose from partition wall MODEL 207, 212, 218 with ENGINE 642  
24 Remove screw/bolt (11) from thermostat housing TORQUE SPECIFICATION Bolt, coolant thermostat housing to charge air manifold *BA20.10-P-1002-01S 
25 Remove screw/bolts on charge air distributor (13) Bolt plan for charge air manifold AR09.41-P-1310-01SXI 
TORQUE SPECIFICATION Screw/bolt, charge air distribution line to cylinder head *BA09.41-P-1009-01J 
26 Remove charge air distributor (13) INSTALLATION NOTES
Replace seal.
Leakage can occur otherwise.		  
    INSTALLATION IMPORTANT For model 221: Install cage for fuel filter to fix the charge air distributor (13).  
27 Install in the reverse order    
28 Check for oil leaks with engine running    
29 Check fuel system for leaks with engine running    
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1023-01C Leak oil line to charge air distribution line M6 X23 Nm 12
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1024-01C Connecting line between left and right rail M15 Nm 27
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 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
Fig 3: Identifying Record Plug (129 589 00 91 00)
G09974912Courtesy of MERCEDES-BENZ USA
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