Remove/install charge air housing

AR09.41-G-8682NA

Remove/install charge air housing

09.10.2018

Engine

470.9 in model 800.110/112

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 distributor

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

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Drain off coolant.

AR20.00-G-1142N

2

Remove oil/coolant module (2).

AR18.20-G-4000N

3

Remove left charge air pipe (1).

AR09.41-G-1327N

4

Remove fuel filter module (3).

AR47.20-G-5511NA

5

Remove fuel high-pressure pump (12).

AR07.16-G-1005NA

6

Remove fuel return lines (10) from 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

Seal openings on the rail with protective covers.

Only if during continued work no leak test of the high-pressure fuel circuit with the diagnostic device takes place.


Do not reuse  protective covers.
If they are reused, contamination can damage the system.

 Set of protective covers

*470589279100

8

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

9

Expose electrical wiring harness (11) of the bracket on the charge-air distributor (6).

10

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.

 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).

 Bolt, charge air housing to cylinder head

*BA09.41-N-1003-01P

11

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

Only when installing new charge air distributor (6).

 Installation: Replace sealing ring.

 Charge air temperature sensor in charge air housing

*BA09.41-N-1002-04A

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

 Boost pressure sensor

Number

Designation

Engine 470.9, 471.9, 473.9

BA09.41-N-1002-04A

Charge air temperature sensor in charge air housing

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