Remove/install charge air housing

AR09.41-G-8682HA

Remove/install charge air housing

08.08.2018

Engine

470.9 in model 800.310/320

1

Charge air pipe

2

Oil/coolant module

3

Fuel filter module

4

High-pressure lines

5

Electrical connector

6

Charge air distributor

10

Fuel return lines

11

Electrical wiring harness

12

Fuel system high pressure pump

B617

Charge air temperature sensor in charge air housing

6

Charge air distributor

8

Screw

7

Decoupling disc

9

Sealing rings

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Drain off coolant

AR20.00-G-1142H

2

Remove left charge air pipe (1)

AR09.41-G-1327H

3

Remove oil/coolant module (2)

AR18.20-G-4000H

4

Remove fuel filter module (3)

AR47.20-G-5511HA

5

Remove fuel high-pressure pump (12)

AR07.16-G-1005HA

6

Remove fuel return lines (10) on cylinder head and rail


When detaching the fuel return lines (10) counterhold the threaded fitting on cylinder head using the  counterholder.
The fuel return lines (10) can be damaged otherwise.

 Threaded fitting, fuel line to cylinder head

*BA07.16-N-1018-03A

 Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

*BA07.16-N-1019-03A

 Union nut, fuel line (pressure intensifier return) to cylinder head threaded fitting

*BA07.16-N-1021-03A

 Banjo bolt, fuel line to rail (pressure limiting valve return)

*BA07.16-N-1024-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

 Counterholder

*470589000100

7

Disconnect electrical connection (5) from charge air temperature sensor in charge air housing (B617)

8

Loosen electrical wiring harness (11) on bracket on charge air distributor (6)

9

Remove charge-air distributor (6) from cylinder head

 Check disengage discs (7) on the 12 screws (8) of the charge-air distributor (6) for damage; replace if necessary.

 Bolt, charge air housing to cylinder head

*BA09.41-N-1003-01P

10

Clean sealing surfaces on cylinder head and on charge-air distributor (6)

 Installation: Clip in new seals (9) using the guide pin on charge-air distributor (6).

11

Remove charge air temperature sensor in charge air housing (B617)

Only if the charge air distributor (6) is replaced.

AR09.41-G-2010H

12

Install in the reverse order

 Common rail diesel injection system

Number

Designation

Engine 470.9

BA07.16-N-1018-03A

Threaded fitting, fuel line to cylinder head

M18x1.5

Nm

55

 Common rail diesel injection system

Number

Designation

Engine 470.9

BA07.16-N-1019-03A

Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

M16x1.5

Nm

25

 Common rail diesel injection system

Number

Designation

Engine 470.9

BA07.16-N-1021-03A

Union nut, fuel line (pressure intensifier return) to cylinder head threaded fitting

M16x1.5

Nm

25

 Common rail diesel injection system

Number

Designation

Engine 470.9

BA07.16-N-1024-03A

Banjo bolt, fuel line to rail (pressure limiting valve return)

M14x1.5

Nm

30

 Charge air pipe/charge air cooling

Number

Designation

Engine 470.9

BA09.41-N-1003-01P

Bolt, charge air housing to cylinder head

Nm

25