Remove/install 2-cylinder compressor

AR13.30-G-0002H

Remove/install 2-cylinder compressor

08.08.2018

Engine

471.9 in model 800.310/320

Compressor, two-stage, provides for optimum fuel consumption

1

Fuel filter module

3

Fuel line (feed)

5

Compressor

2

Fuel line (return flow)

4

Air intake duct (compressor)

6

Air line (compressor)

1

Fuel filter module

5

Compressor

7

Coolant line

8

Coolant line

9

Bracket

10

Electrical line

11

Bolts

12

Screw

13

Crankcase

14

Drive gear

15

Sealing ring

16

Sealing ring

17

Fitting

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

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 coolant at engine radiator

AR20.00-G-1142H

2

Remove air intake line (4)

3

Unscrew fuel lines (2, 3) on fuel filter module (1)

 Use an open double-hexagon-box wrench size 32.
Allow escaping fuel to drain into a suitable container.

 Installation: Observe installation position of the fuel lines (2, 3); see cast-on arrows on fuel filter module (1).

 Union nut, fuel line (fuel tank) to fuel filter module

*BA47.25-N-1005-01N

4

Remove the fuel lines' holder (2, 3) on fuel filter module (1) and bind fuel lines (2, 3) to the side

 Fuel line bracket screw/bolt

*BA47.25-N-1003-01N

5

Remove compressed air line (6) at compressor (5) and check for carbonization

 Installation: In the event of carbonization, replace compressed-air line (6) and carbonized parts.

 Union nut, compressed air line to compressor fitting

*BA13.30-N-1010-01M

6

Unlock and disconnect coolant lines (7, 8)

 Collect coolant which flows out.

7

Expose electrical line (10) on bracket (9)

8

Remove bracket (9) on compressor (5) and on the crankcase (13)

 Screw/bolt, compressor bracket to crankcase

*BA13.30-N-1006-01M

 Screw/bolt, bracket to compressor

*BA13.30-N-1007-01M

9

Remove screw/bolts (11, 12) and remove compressor (5) from crankcase (13)

 Collect escaping engine oil.

 Installation: Before placing the compressor (5) on the crankcase (13), insert the rear top screw (12).
Turn the drive wheel (14) if necessary while placing the compressor (5).

 Screw/bolt, compressor to crankcase

*BA13.30-N-1001-01M

10

Check drive gear (14) for damage

If damaged



Replace the drive gear (14) and also check the counter-gearwheel for the gearwheel drive involved for damage.

AR13.30-G-7044H

11

Remove sealing rings (15, 16) at compressor (5)

 Installation: Replace sealing rings (15, 16).

12

Remove fitting (17) for air line (6), the air intake duct (4) and the coolant lines (7, 8) on compressor (5)

The air intake duct (4) and the coolant lines (7, 8) are leaky only if the compressor (5) is replaced or the fitting (17) for the air line (6).

 Installation: Install new sealing rings if necessary.

 Fitting to compressor

*BA13.30-N-1008-01M

 Fitting, coolant line to compressor

*BA13.30-N-1004-01M

13

Install in the reverse order

14

Check/correct engine oil level

 Engine oil

*BF18.00-N-1001-01V

15

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

If engine fails to start or only runs for a brief period.



Fill fuel low-pressure circuit.

AR07.16-G-1007H

16

Check all connectors on the compressor (5) for leaktightness and stop engine

 Visual inspection.

 Compressor (compressed air system)

Number

Designation

Engine 471.9

BA13.30-N-1001-01M

Screw/bolt, compressor to crankcase

Nm

60

 Compressor (compressed air system)

Number

Designation

Engine 471.9

BA13.30-N-1004-01M

Fitting, coolant line to compressor

M16x1.5

Nm

50

M18x1.5

Nm

45

 Compressor (compressed air system)

Number

Designation

Engine 471.9

BA13.30-N-1006-01M

Screw/bolt, compressor bracket to crankcase

Nm

30

 Compressor (compressed air system)

Number

Designation

Engine 471.9

BA13.30-N-1007-01M

Screw/bolt, bracket to compressor

Nm

50

 Compressor (compressed air system)

Number

Designation

Engine 471.9

BA13.30-N-1008-01M

Fitting to compressor

M14x1.5

Nm

40

M26x1.5

Nm

100

 Compressor (compressed air system)

Number

Designation

Engine 471.9

BA13.30-N-1010-01M

Union nut, compressed air line to compressor fitting

Nm

75

 Fuel lines/hoses

Number

Designation

Engine 471.9

BA47.25-N-1003-01N

Fuel line bracket screw/bolt

M6

10.9

Nm

15

M8

10.9

Nm

30

M10

10.9

Nm

60

 Fuel lines/hoses

Number

Designation

Engine 471.9

BA47.25-N-1005-01N

Union nut, fuel line (fuel tank) to fuel filter module

Nm

60

 Engine lubrication

Number

Designation

Engine 471.9 with oil pan width of 330 mm and firewall height of 225 mm

Engine 471.9 with oil pan width of 460 mm and firewall height of 120 mm

BF18.00-N-1001-01V

Engine oil

Filling capacity of oil pan

Liter

39

34

Filling capacity of oil filter

Liter

3

3

Filling capacity after repair on engine in the case of emptied oil ducts

Liter

6

6

Sheet

BB00.40-P-0228-31A

BB00.40-P-0228-31A

Sheet

BB00.40-P-0228-51A

BB00.40-P-0228-51A

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A

 Engine lubrication

Number

Designation

Engine 471.9 with oil pan width of 470 mm and firewall height of 335 mm

Engine 471.9 with oil pan width of 530 mm and firewall height of 155 mm

BF18.00-N-1001-01V

Engine oil

Filling capacity of oil pan

Liter

36

36

Filling capacity of oil filter

Liter

3

3

Filling capacity after repair on engine in the case of emptied oil ducts

Liter

6

6

Sheet

BB00.40-P-0228-31A

BB00.40-P-0228-31A

Sheet

BB00.40-P-0228-51A

BB00.40-P-0228-51A

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A