Remove/install charge air housing

AR09.41-G-8682N

Remove/install charge air housing

09.10.2018

Engine

471.9 in model 800.110/112

Modification notes

08.10.2018

Work procedure completely revised.

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

B617

Charge air temperature sensor in charge air distributor

6

Charge air distributor

8

Screw

7

Decoupling disc

9

Sealing rings

6

Charge air distributor

11

Threaded fitting

12

Guide pins

13

High pressure pipe

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

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Drain off coolant.

AR20.00-G-1142N

2

Remove left charge air pipe (1).

AR09.41-G-1327N

3

Remove oil/coolant module (2).

AR18.20-G-4000N

4

Remove fuel filter module (3).

Engine 471.9 up to engine end number 032690

AR47.20-G-5511N

Engine 471.9 as of engine end number 032691

AR47.20-G-5511NC

5

Remove high-pressure lines (4) to rail.

Engine 471.9 up to engine end number 032690

AR07.16-G-1004N

Engine 471.9 as of engine end number 032691

AR07.16-G-1004NA

6

Remove fuel return lines (10) from the threaded fittings 11) of the cylinder head.


When detaching the fuel return lines (10), counterhold the threaded fitting (11) on cylinder head using the  counterholder.
Otherwise the fuel return lines (10) can be damaged.

 Engine 471.9Threaded fitting, fuel line to cylinder head

*BA07.16-N-1018-03A

 Engine 471.9Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

*BA07.16-N-1019-03A

 Engine 471.9Union nut, fuel line (pressure intensifier return) to cylinder head threaded fitting

*BA07.16-N-1021-03A

 Counterholder

*470589000100

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

7

Remove guide pins (12) of compressor the resonator box on the charge-air distributor (6).

8

Disconnect electrical connector (5) from charge air temperature sensor in the charge-air distributor (B617).

9

Remove charge air temperature sensor in the charge-air distributor (B617).

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

AR09.41-G-2010N

 Installation: Replace sealing ring.

10

Remove charge-air distributor (6) from cylinder head.

 Installation: Clean sealing surfaces on cylinder head and on charge air distributor (6).
Clip in new seals (9) using the guide pin on charge-air distributor (6).
Replace damaged decoupling discs (7) on the screw/bolts (8).

 Bolt, charge air housing to cylinder head

*BA09.41-N-1003-01P

11

Install in the reverse order.

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

Engine 471.9## ## as of 032691

BA07.16-N-1018-03A

Threaded fitting, fuel line to cylinder head

M18x1.5

Nm

55

55

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

Engine 471.9## ## as of 032691

BA07.16-N-1019-03A

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

M16x1.5

Nm

25

25

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

Engine 471.9## ## as of 032691

BA07.16-N-1021-03A

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

M16x1.5

Nm

25

25

 Charge air pipe/charge air cooling

Number

Designation

Engine 471.9

BA09.41-N-1003-01P

Bolt, charge air housing to cylinder head

Nm

25