Remove/install charge air housing

AR09.41-W-8682H

Remove/install charge air housing

15.10.2018

Engine

471.9, 473.9 in model 963, 964

Modification notes

09.10.2018

Notes regarding safety-relevant components, added.

AH00.00-Z-0019-01A

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 housing

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

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

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

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Tilt cab.

2

Drain coolant at engine and radiator.

AR20.00-W-1142H

3

Remove left charge air pipe (1).

AR09.41-W-1327H

4

Remove oil/coolant module (2).

Only for engine 471.9.

AR18.20-W-4000H

5

Remove fuel filter module (3).

Engine 471.9 up to engine end number 032690

AR47.20-W-5511H

Engine 471.9 from engine end number 032691, engine 473.9

AR47.20-W-5511HB

6

Remove high-pressure lines (4) to rail.

Engine 471.9 up to engine end number 032690

AR07.16-W-1004H

Engine 471.9 from engine end number 032691, engine 473.9

AR07.16-W-1004HA

7

Remove fuel return lines (10) from threaded fitting (11) on 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 471.9, 473.9Threaded fitting, fuel line to cylinder head

*BA07.16-N-1018-03A

 ENGINE 471.9, 473.9Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

*BA07.16-N-1019-03A

 ENGINE 471.9, 473.9Union 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

8

Remove the lower threaded fitting (11) on cylinder head.

Only for engine 473.9

 Threaded fitting, fuel line to cylinder head

*BA07.16-N-1018-03A

9

Remove guide pin (12) for compressor resonator on charge air distributor (6).

10

Remove high-pressure lines (13) to the injectors on cylinder 4, 5 and 6.

Only for engine 473.9

AR07.16-W-1003H

11

Disconnect electrical connection (5) from charge air temperature sensor in charge air housing (B617).

12

Remove charge air temperature sensor in charge air housing (B617).

 Installation: Replace sealing ring.

 Charge air temperature sensor in charge air housing

*BA09.41-N-1002-04A

13

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

14

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 473.9

BA07.16-N-1018-03A

Threaded fitting, fuel line to cylinder head

M18x1.5

Nm

55

 Common rail diesel injection system

Number

Designation

Engine 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 473.9

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 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

 Common rail diesel injection system

Number

Designation

Engine 473.9

BA07.16-N-1021-03A

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

M16x1.5

Nm

25

 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 471.9

Engine 473.9

BA09.41-N-1003-01P

Bolt, charge air housing to cylinder head

Nm

25

25