Disassemble/assemble compressor · ar1330w5511a · Mercedes-Benz WIS

AR13.30-W-5511A

Disassemble/assemble compressor

8.6.10

ENGINES 541.9 in MODEL 950, 952, 953, 954 except CODE (M32) Dual compressor

ENGINES 542.9 in MODEL 950, 952, 954 except CODE (M32) Dual compressor

W13.30-1016-09

1 Suction pipe

2 Intake manifold (only for engine 541.9 as of engine end no. 128268)

3 Hose (oil separator)

4.1 Resonator with hoses (only for engine 541.9 up to engine end no. 128267)

4.2 Resonator with detachable part (only for engine 541 as of engine end no. 128268)

4.3 Resonance tank (only for engine 542.9)

5.1 Resonator holder (only for engine 541.9 up to engine end no. 128267)

5.2 Resonator holder (only for engine 541.9 as of engine end no. 128268)

19 Cylinder liner

20 Coolant line

21 Coolant line

22 Cylinder head with valve intermediate plate

22.1 Intake valve disk

23 Compressed-air line

24 Bracket (only on engine 541.9)

26 Plain bearing (only to engine end no. 067518)

27 Bearing flange

28 O-ring

29 Bearing flange (in timing case)

30 Drive gear

31 Screw

6 Threaded stud (only for engine 542.9)

7 Bracket (only on engine 542.9)

8 Cover

9 Gasket

10 Crankshaft

11 Connecting rods

12 Piston

13 Fuse

14 Piston pin

15 Piston ring (groove III double beveled slotted oil control ring with coil spring)

16 Piston ring (groove II taper faced hook scraper ring)

17 Piston ring (groove I taper faced hook scraper ring)

18 Gasket

W13.30-1089-09

12 Piston

13 Fuse

14 Piston pin

19 Cylinder liner

33  Blocking device

34  Box wrench

35  Cranking device

29 Bearing flange (in timing case)

30 Drive gear

32  Piston ring compressor pliers

Modification notes

21.2.06

Document revised completely.

 	Disassemble/assemble
 Danger!	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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
 Danger!	Risk of injury caused by body parts being pinched or crushed as cab is tilted	Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.	AS60.80-Z-0001-01A
1	Tilt cab
	Notes on tilting the cab		AH60.80-N-0003-01A
2	Remove intake line (1)
3.1	Remove resonance tank with hoses (4.1)	Engine 541.9 up to engine end no. 128267
			*BA01.60-N-1003-01B
			*BA13.30-N-1010-01B
3.2	Remove resonance tank with detachable parts (4.2)	Engine 541.9 as of engine end no. 128268
			*BA13.30-N-1010-01B
3.3	Remove resonance tank (4.3)	Engine 542.9
		 Counterhold threaded bolt (6).
4	Remove intake manifold (2) at intermediate piece or turbocharger	 Only for engine 541.9 as of engine end no. 128268.
			*BA09.20-N-1001-02C
5	Drain coolant partially	 Installation: Fill with coolant before the engine test run.	AR20.00-W-1142A
6	Remove coolant lines (20, 21) at cylinder head with valve intermediate plate (22)		*BA13.30-N-1001-01B
7	Remove compressed air line (23) on cylinder head with valve intermediate plate (22)
8	Inspect compressed-air line (23) for carbon deposits	 In the event of coking, also check compressed air line (23) between compressor, compressed air drier and four circuit protection valve and replace coked parts if required.
9.1	Remove cylinder head with valve intermediate plate (22) using resonance tank bracket (5.2) and bracket (24)	Engine 541.9
		 Installation: Replace intake valve disk (22.1) and seal (18). Ensure that the roll pins in the valve intermediate plate are correctly positioned.
			*BA13.30-N-1005-01B
9.2	Remove cylinder head with valve intermediate plate (22) and bracket (7)	Engine 542.9
		 Installation: Replace intake valve disk (22.1) and seal (18). Ensure that roll pins in the valve intermediate plate are correctly positioned.
			*BA13.30-N-1005-01B
10	Disassemble/assemble cylinder head with valve intermediate plate (22)		AR13.30-W-5511-04A
			*BA13.30-N-1003-01B
			*BA13.30-N-1004-01B
			*BA13.30-N-1006-01B
			*BA13.30-N-1007-01B
			*BA13.30-N-1008-01B
			*BA13.30-N-1011-01B
11	Remove soundproofing on frame below
12	Remove cover of TDC inspection hole on timing case		*BA01.60-N-1001-01B
13	Install cranking device (35) at timing case		*407589006300
			*BA01.60-N-1009-01B
14	Remove cylinder liner (19)	 Installation: Observe attached note marking if used cylinder liner (19) is reinstalled and install cylinder liner (19) turned through 90°.	AR13.30-W-7041-02A
			*BE13.30-N-1002-01B
			*BE13.30-N-1003-01B
			*BE13.30-N-1010-01B
			*541589003700
			*407589006300
15	Remove gasket (18)	 Installation: Replace seal (18).
16	Cover opening on crankcase
17	Turn engine with turning device (35) until piston pin (14) is accessible		*407589006300
18	Remove securing device (13) with piston ring compressor pliers (32) and pull out piston pin (14)		*541589003700
19	Remove piston (12)	 Installation: From engine end no. 075703 modified pistons (12) with bores in piston ring groove III have been fitted. If piston (12) is replaced, only install this version. Install piston ring gaps in correct order and offset 120° at piston (12). Lubricate piston (12) and piston ring (15 to 17).
20	Remove piston rings (15 to 17)	 Check end gap of piston ring (15 to 17). Replace piston rings (15 to 17) if value not reached.	AR13.30-W-5511-01A
			*BE13.30-N-1004-01B
			*000589373700
		Feeler gauge
21	Remove timing case cover	 These and all other following operation step are only required if the crankshaft (10), connecting rod (11) or bearing flange (27) are removed / installed.	AR01.40-W-8000A
22	Remove fuel/power steering pump unit		AR47.20-W-5712A
23	Remove cover (8) at side of timing case	 Installation: Replace seal (9).
			*BA01.60-N-1003-01B
24	Remove crankshaft (10)		AR13.30-W-5511-02GA
			*BA13.30-N-1013-01B
			*442589000300
			*442589096300
			*407589006300
		 Installation: Install crankshaft (10).	AR13.30-W-5511-03GA
			*BE13.30-N-1007-01B
			*BA13.30-N-1002-01B
			*BA13.30-N-1012-01B
			*BA13.30-N-1013-01B
			*442589000300
			*001589532100
			*363589022100
			*366589002105
			*442589096300
	Retaining device for installation of dial indicator holder at compressor		WF58.50-W-1330-02G
25	Check stroke and connecting rod journal diameter to crankshaft (10)	 Replace crankshaft (10) if necessary.	*BE13.30-N-1001-01B
			*BE13.30-N-1006-01B
26.1	Check inside diameter of bearing bushing (26) in outer bearing flange (27)	Engine 541.9, 542.9 up to engine end no. 067518	*BE13.30-N-1008-01B
		 If worn: 
		Replace bearing bushing (26) or install new bearing flange (27).	AR13.30-W-5511-05A
			*730589031500
26.2	Check inner diameter of bearing bore in outer bearing flange (27)	Engine 541.9, 542.9 as of engine end no. 067519	*BE13.30-N-1008-01B
		 In case of wear, replace bearing flange (27).
27	Check inner diameter of bearing bore in bearing flange (29)	 If worn: 	*BE13.30-N-1013-01B
		Replace bearing flange (29).	AR13.30-W-5511-07A
			*730589031500
			*000589293300
			*000589343300
28	Assemble in the reverse order
 Danger!	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
29	Start engine and perform an engine test run	 Continue running engine at idlingspeed until operating temperature is reached and then switch off engine.
30	Check compressor and all lines for leaks	 Visual inspection.

Check values for compressor

Number	Designation			Engine 541.9, 542.9 without code M32, MZ7, MZ8


BE13.30-N-1001-01B	Piston stroke		mm	48
BE13.30-N-1002-01B	Cylinder liner inner dia.	Marking B	mm	100.000 to 100.010
		Marking C	mm	100.010 to 100.020
		Marking D	mm	100.020 to 100.030
BE13.30-N-1003-01B	Piston outer dia.	Marking B	mm	99.925 to 99.935
		Marking C	mm	99.935 to 99.945
		Marking D	mm	99.945...99.955
BE13.30-N-1004-01B	Piston ring gap clearance	Grooves I, II, III	mm	0.20 to 0.40
BE13.30-N-1006-01B	Crankshaft connecting rod bearing journal dia.		mm	43.959 to 43.975
BE13.30-N-1007-01B	Crankshaft bearing clearance	Axial	mm	0.150 to 0.250
BE13.30-N-1008-01B	Bearing bush/bearing flange	Inside dia.	mm	38.000 to 38.039
BE13.30-N-1010-01B	Cylinder liner height from timing case		mm	88.8 to 89.0
BE13.30-N-1013-01B	Bearing bushes in timing case	Inside dia.	mm	37.99 to 38.05

 Timing case

Number	Designation		Engine 541.9. 542.9


BA01.60-N-1001-01B	Bolt, end cover of TDC inspection hole to timing case	Nm	25
BA01.60-N-1003-01B	Bolt, side compressor hole cover to timing case	Nm	50
BA01.60-N-1009-01B	Bolt, engine cranking device to timing case	Nm	25

 Intake manifold, intake manifold preheater

Number	Designation		Engine 541.9 except code MJ1	Engine 541.9 with code MJ1


BA09.20-N-1001-02C	Bolt, air intake pipe at bracket	Nm	50	60

 Intake manifold, intake manifold preheater

Number	Designation		Engine 542.9 except code MJ1	Engine 542.9 with code MJ1


BA09.20-N-1001-02C	Bolt, air intake pipe at bracket	Nm	50	60

 Compressor (compressed air system)

Number	Designation			Engine 541.9, 542.9


BA13.30-N-1001-01B	Coolant line to compressor		Nm	35
BA13.30-N-1002-01B	Bolt, drive gear at compressor, with special tool	(direct)	Nm	360
		(indirect)	Nm	270
BA13.30-N-1003-01B	Screw plug on compressor cylinder head	M261.5	Nm	80
BA13.30-N-1004-01B	Fitting, coolant line on compressor cylinder head	M141.5	Nm	35
BA13.30-N-1005-01B	Bolt, cylinder head and cylinder liner at timing case	Stage 1	Nm	20
		Stage 2	Nm	40
BA13.30-N-1006-01B	Fitting, compressed air line to compressor cylinder head	M261.5	Nm	80
BA13.30-N-1007-01B	Bolt, valve intermediate plate to compressor cylinder head		Nm	12
BA13.30-N-1008-01B	Bolt of pressure disk valve to valve intermediate plate		Nm	12
BA13.30-N-1009-01B	Bearing flange on timing case		Nm	30
BA13.30-N-1010-01B	Bolt, resonance tank to bracket		Nm	25
BA13.30-N-1011-01B	Fittings for intake air line on compressor cylinder head	M361.5	Nm	80
BA13.30-N-1012-01B	Bolt, bearing flange to timing case		Nm	60
BA13.30-N-1013-01B	Bolt, blocking device to timing case		Nm	40

730 589 03 15 00

Dial indicator

Drift

Ring wrench

Dial indicator holder

442 589 00 03 00

001 589 53 21 00

363 589 02 21 00

000 589 29 33 00

Counter stay

Internal puller

Extension

Pliers

366 589 00 21 05

000 589 34 33 00

000 589 37 37 00

407 589 00 63 00

Blocking device

Cranking device

Piston ring compressor pliers

541 589 00 37 00

442 589 09 63 00

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