AR09.41-D-1310SG Remove/install charge air manifold 23.04.

2019

Engine 642.896/898 in model 906

D09.41-1161-09

1 Rail 10 Mixing chamber 19 Coolant hose

2 Bracket 11 Engine wiring harness 20 Coolant thermostat
3 Bracket 12 Coolant hose 21 Seal
4 Cable duct 13 Bracket 22 Screw
5 Connecting line 14 Leak oil line 24 Screw
6 Lifting lug (left) 15 Vacuum pump 31 Clip
7 Vacuum line 16 Bracket B6/24 Camshaft sensor
8 Fuel filter 17 Bracket B11/19 Coolant temperature sensor
9 Charge air manifold 18 Coolant hose N14/3 Glow output stage

D09.41-1162-09

Shown on engine 642.896

© Daimler AG, 7/6/22, L/10/20, ar09.41-d-1310sg, Remove/install charge air manifold Page 1 of 5
Engine 642.896/898 in model 906
9 Charge air manifold 24 Screw 28 Sealing ring
11 Engine wiring harness 25 Screw 29 Right cylinder head
20 Coolant thermostat 26 Connection piece 30 Left cylinder head
23 Clamp 27 Seal B11/19 Coolant temperature sensor

Only for engine 642.898

32 Electrical connector
33 Electrical line
34 Electrical line
35 Clamp
36 Intake port shutoff linkage
B90/2 Left EKAS end position
measurement sensor
B90/3 Right EKAS end position
measurement sensor
M72 Intake port shutoff actuator
X156/1 EKAS end position switch
connector /left
X156/2 EKAS end position switch
connector /right

D09.41-1168-06

ed Remove/install
a Warning Risk of injury to skin and eyes suffering Do not open cooling system unless coolant AS20.00-Z-0001-01A
scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly
Risk of poisoning from swallowing coolant. and release the pressure. Do not pour coolant
into beverage containers.
Wear protective gloves, protective clothing
and safety glasses.
a Danger Risk of explosion caused by fuel igniting, risk No fires, sparks, open flames or smoking. AS47.00-Z-0001-01A
of poisoning caused by inhaling and Pour fuels into suitable and appropriately
swallowing fuel as well as risk of injury to eyes marked containers only.
and skin caused by contactwith fuel. Wear protective clothing when handling fuel.
Notes about Common-Rail components AH07.16-P-0002-01TX
1 Drain off coolant AR20.00-D-1140SD
2 Remove trim panel on right cylinder head AR01.20-D-5015SF
cover
3 Remove oil supply connection fittings for ATL AR09.40-S-6023SE
4 Remove bracket (16) with glow output stage i Unclip coolant hose (12) from bracket (16).
(N14/3) and place to one side Do not disconnect electrical connections at
glow output stage (N14/3).
n Bolt, bracket to charge-air distributor *BA09.41-N-1002-01O
5 Remove bracket (13) from right cylinder head
(29)
6 Open Henn coupling and remove coolant hose AR09.41-D-1311-01WE
(18) from the coolant thermostat (20)
7 Remove bracket (17) and place to one side n Bolt, bracket to charge-air distributor *BA09.41-N-1002-01O
with the attached coolant hose (18)
8 Remove vacuum line (7) from the vacuum
pump (15) and unclip from the cover of the left
cylinder head cover
9 Remove coolant hoses (12, 19) from charge i Installation: Inspect condition of collar
air manifold (9) clamps, replace if necessary.
10 Pull vacuum line (7) out of the brake booster i Installation: Check sealing ring on the
and place vacuum line (7) to one side brake booster; replace if necessary.
11 Remove fuel filter (8) AR47.20-D-1070SF
12 Remove right rail (1) AR07.03-D-1010SF
13 Disconnect electrical connector (32) from the Engine 642.898
intake port shutoff actuator (M72)
14 Disconnect left EKAS end position switch Engine 642.898
connector (X156/1) and right EKAS end
position switch connector (X156/2)
© Daimler AG, 7/6/22, L/10/20, ar09.41-d-1310sg, Remove/install charge air manifold Page 2 of 5
Engine 642.896/898 in model 906

15 Remove screws (24) from the charge air
manifold (9), twist clamps (31) to expose the
connecting line (5), and then tighten screws
(24) again with the clamp (23)
16 Remove union nut of the connecting line (5)
from the left rail
17 Disconnect leak oil line (14) at the charge air
manifold (9) from the injectors (arrows A) of
the right cylinder bank and place leak oil line
(14) to one side
18 Disconnect engine wiring harness (11) from
the injectors (arrows A) of the right cylinder
bank and expose
19 Disconnect engine wiring harness (11) from
the camshaft sensor (B6/24) and expose
20 Disconnect engine wiring harness (11) from
the glow plugs (arrows B) and expose
21 Disconnect engine wiring harness (11) from
the coolant temperature sensor (B11/19)
22 Remove engine wiring harness (11) and cable
duct (4) from the charge air manifold (9) and
from the lifting lug (6)
23 Fasten engine wiring harness (11) and cable
duct (4) to the windshield wiper linkage
24 Remove bracket (2) from right cylinder head
(29)
25 Remove bracket (3) from the charge air
manifold (9)
26 Remove screws (24) of the clamp (23) and
remove clamp (23)
27 Remove screws from charge air manifold (9) inl Set of flexible head wrenches
the area under the clamp (23)
28 Tighten screw (25) of the clamp (23)
29 Install clamp (23) and tighten with the screws n Bolt, clamp for fuel filter to charge-air
(24) at the charge air manifold (9)
30 Remove screws (22) from the mixer housing i Installation: Install new seal (21).
(10) and from the charge air manifold (9)
31 Remove remaining screws from the charge air
manifold (9) and remove lifting lug (6)
32 Lift out charge air manifold (9) upward
33 Disconnect charge air manifold (9) and
remove connection piece (26)
34 Remove coolant thermostat (20) and coolant
temperature sensor (B11/19)
© Daimler AG, 7/6/22, L/10/20, ar09.41-d-1310sg, Remove/install charge air manifold
Engine 642.896/898 in model 906
i Mark left EKAS end position switch
connector (X156/1) and right EKAS end
position switch connector (X156/2).
i For engine 642.898, expose electric lines
(33, 34) of the left intake port shutoff end
position measurement sensor (B90/2) and
right sensor intake port shutoff end position
measurement (B90/3).
n Bolt, clamp for fuel filter to charge-air *BA47.20-N-1003-02M
distributor
i Installation: Check sealing cone of the
connecting line (5) for damage; replace
connecting line (5) if necessary.
n Connecting line between left and right rail *BA07.16-N-1007-01B
l Open wrench insert, (18 mm) *000589300100
AR07.03-D-9105SF
l Pliers *611589003700
n Bolt, bracket to charge-air distributor *BA09.41-N-1002-01O
n Bolt, clamp for fuel filter to charge-air *BA47.20-N-1003-02M
distributor
*001589810900
n Bolt, hose clamp cage to fuel filter *BA47.20-N-1002-02M
*BA47.20-N-1003-02M
distributor
n Screw/bolt, mixing chamber to charge air *BA09.41-N-1012-01O
distributor
l Set of flexible head wrenches *001589810900
AR09.41-D-1310-01SG
i Installation: Tighten charge air manifold
(9) according to the bolt plan.
n Screw/bolt, charge air distributor to *BA09.41-N-1010-01O
cylinder head
l Set of flexible head wrenches *001589810900
i Installation: Install new seals (27) and
hook into charge air manifold (9).
Install new sealing ring (28) on the charge air
manifold (9). Attach charge air manifold (9)
free of tension to the mixer housing (10).
i To install new connection piece (26), pull
charge air manifold (9) apart.
For engine 642.898, to install new left and
right charge air manifold (9), remove clip (35)
and disconnect intake port shutoff linkage (36).
i Installation: Install new connection piece
(26). For engine 642.898, the clip (35) must be
replaced if it is removed.
i Only if installing a new charge air manifold
(9).
i Installation: Check sealing ring on coolant
thermostat (20); replace coolant thermostat
(20) if necessary.
Page 3 of 5
 n Bolt, coolant thermostat housing to charge *BA20.10-N-1005-01Q
air distributor
35 Remove coolant temperature sensor (B11/19) i Only if installing a new charge air manifold
(9).
i Installation: Replace sealing ring at
coolant temperature sensor (B11/19).
36 Remove left intake port shutoff end position i For engine 642.898, if a new charge air
measurement sensor (B90/2) and right intake manifold (9) is installed.
port shutoff end position measurement sensor
(B90/3)
m Clean
37 Clean sealing surfaces on the right cylinder
head (29), left cylinder head (30), and on the
mixer housing (10)
38 Clean sealing surfaces on charge air manifold i Only if a new charge air manifold (9) is not
(9) installed.
39 Install in the reverse order
a Warning Risk of accident from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A
itself when engine running. Risk of injury itself. Wear closed and snug-fitting work
(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts.
the engine while it is being started or when it is
running.
40 Perform an engine test run and check engine
for leak tightness in the area of the charge air
manifold (9)

n Common rail diesel injection (CDI)

Number Designation Engine

642.896/898/992/99
3 in model 906
BA07.16-N-1007-01B Connecting line between M15 1 Stage 1 Nm 20
left and right rail
Stage 2 ° 60

n Charge air pipe, charge air cooling, mixer housing

Number Designation Engine 642

BA09.41-N-1002-01O Bolt, bracket to charge-air distributor Nm 9

n Charge air pipe, charge air cooling, mixer housing

Number Designation Engine 642

BA09.41-N-1010-01O Screw/bolt, charge air distributor to cylinder head Nm 16

n Charge air pipe, charge air cooling, mixer housing

Number Designation Engine 642

BA09.41-N-1012-01O Screw/bolt, mixing chamber to charge air M6 Nm 9
distributor

n Coolant pump, coolant thermostat

Number Designation Engine 642 in

model 639
Engine 642 in
model 906
BA20.10-N-1005-01Q Bolt, coolant thermostat housing to charge air distributor Nm 9

n Fuel filter

Number Designation Engine 642 in

model 906

© Daimler AG, 7/6/22, L/10/20, ar09.41-d-1310sg, Remove/install charge air manifold Page 4 of 5
Engine 642.896/898 in model 906
BA47.20-N-1002-02M Bolt, hose clamp cage to fuel filter Nm 5

n Fuel filter

Number Designation Engine 642 in

model 906
BA47.20-N-1003-02M Bolt, clamp for fuel filter to charge-air distributor Nm 12

611 589 00 37 00 001 589 81 09 00 000 589 30 01 00

Pliers Set of flexible head wrenches Open wrench insert, (18 mm)

© Daimler AG, 7/6/22, L/10/20, ar09.41-d-1310sg, Remove/install charge air manifold Page 5 of 5
Engine 642.896/898 in model 906