Remove/install charge air housing · ar0941g8682ci · Mercedes-Benz WIS

AR09.41-G-8682CI

Remove/install charge air housing

13.11.2018

Engine

541.9, 542.9, 941.9, 942.9 in model 000.001

Shown on engine 541.9 up to engine end number 311843

1	Charge air distributor
2	Electrical connector
3	Seal
4	Nut
5	Compensating element
6	Flame starting system (only for flame starting system)
7	Seal (only for flame starting system)
8	Adapter
8.1	Sealing ring
9	Threaded pins
10	Threaded pins
11	Charge air hose, black
12	Charge air hose, red
13	Charge air pressure and temperature sensor

G09.41-3194-06

 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
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
 	Remove/install
1	Switch off ignition.
2	Remove black charge air hose (11) from charge-air distributor (1).	 Installation: The black charge air hose (11) and red charge air hose (12) may not be swapped. Check black charge air hose (11) and clamps for damage.
		 Clamp, charge air hose to charge-air distributor or charge air pipe or charge air cooler	*BA09.41-N-1001-01L
		If damage is identifiable
		
		replace black charge air hose (11) and clamps.
3	Remove red charge air hose (12) from charge-air distributor (1).	Only for engine 541.9, 941.9.
		 Installation: The red charge air hose (12) and black charge air hose (11) may not be swapped. Check red charge air hose (12) and clamps for damage.
		 Clamp, charge air hose to charge-air distributor or charge air pipe or charge air cooler	*BA09.41-N-1001-01L
		If damage is identifiable
		
		replace red charge air hose (12) and clamps.
4	Remove flame starting system (6).	Only for engine with flame starting system (6).
		 Do not remove fuel lines and do not disconnect electrical connector from the engine wiring harness.
		 Installation: Replace seal (7).
		 Bolt, bracket of flame starting system to charge air pipe	*BA09.30-N-1001-01C
5	Disconnect electrical connector (2) from charge air pressure and temperature sensor (13).
6	Remove front left bracket for steering hydraulic line from the lifting eye.
7	Remove charge air pipe from the charge-air distributor (1).	Only for engine 542.9, 942.9.
		 Installation: Center adapter (8) relative to the charge-air distributor (1) and the exhaust gas turbocharger.
		 Screw/bolt, charge air pipe to charge air distributor	*BA09.41-N-1009-01L
8	Unclip leak fuel lines from the two rear threaded pins (9) or screws.
9	Remove both rear threaded pins (9).	Only for engine 542.9, 942.9 up to engine end number 311843.
		 Threaded pin or bolt on crankcase	*BA09.41-N-1006-01L
10	Remove charge-air distributor (1) from the engine.
	Mounting of charge air housing on engine - altered	Engine 541.9, 941.9 as of engine end number 311844 or engine 542.9, 942.9 as of engine end number 313193.	BT09.41-G-0003-01CI
		 Nut, charge-air distributor to threaded pin	*BA09.41-N-1005-01L
		 Threaded pin or bolt on crankcase	*BA09.41-N-1006-01L
		 Threaded bolt on oil filter housing bracket	*BA09.41-N-1007-01L
		 Threaded pin or bolt on oil filter housing	*BA09.41-N-1011-01L
11	Remove seals (3) and check for damage and wear.	 Installation: Observe installation position of the seals (3).
		If damage is identifiable
		
		Install new seals(3).
12	Check compensating elements (5) and nuts (4) or screws for wear.
	Mounting of charge air housing on engine - altered	Engine 541.9, 941.9 as of engine end number 311844 or engine 542.9, 942.9 as of engine end number 313193.	BT09.41-G-0003-01CI
		 Installation: Observe installation location of the screws.
		If damage is identifiable
		
		replace compensating elements (5) and nuts (4) or screws.
13	Remove adapter (8) or charge air hose.
	Intermediate piece from charge air housing to turbocharger altered	Engine 541.9, 941.9 as of engine end number 024778 or engine 542.9, 942.9 as of engine end number 026083.	BT09.41-W-0002-01A
		 Depending on the model and version, a charge air hose can be installed for engine 941.9, 942.9 instead of the adapter (8).
		 Installation: Install new sealing rings (8.1) on the adapter (8). Check charge air hose for wear and damage.
		 Clamp, charge air hose to charge-air distributor or charge air pipe or charge air cooler	*BA09.41-N-1001-01L
		If damage is identifiable
		
		replace charge air hose.
14	Remove charge air pressure and temperature sensor (13).	Only when replacing the charge air distributor (1).
			AR09.41-G-2003CH
15	Install in the reverse order
16	Perform engine test run.
17	Check engine in the area of the charge-air distributor (1) for leak tightness.	 Visual inspection.

 Intake air preheater

Number	Designation		ENGINE 541.9, 542.9, 941.9, 942.9
BA09.30-N-1001-01C	Bolt, bracket of flame starting system to charge air pipe	Nm	20