Remove/install charge air housing

AR09.41-W-8682HA

Remove/install charge air housing

15.10.2018

Engine

470.9 in model 963, 964

Modification notes

09.10.2018

Notes regarding safety-relevant component parts added.

AH00.00-Z-0019-01A

09.10.2018

Seal openings on the rail using protective covers, added.

Operation step 8

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 high-pressure pump

B617

Charge air temperature sensor in charge air housing

6

Charge air distributor

8

Screw

7

Decoupling disc

9

Sealing rings

 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 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).

AR18.20-W-4000H

5

Remove fuel filter module (3).

AR47.20-W-5511HA

6

Remove fuel high-pressure pump (12).

AR07.16-W-1005HA

7

Remove fuel return lines (10) on 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

8

Seal openings on the rail using protective covers.

Only if no leak test is carried out on the high-pressure fuel circuit using the diagnostic device during continued work.


Do not reuse the  protective covers.
In the event of reuse, soiling may damage the diesel injection system.

 Set of protective covers

*470589279100

9

Disconnect electrical connector (5) from charge air temperature sensor in the charge air housing (B617)

10

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

11

Remove charge-air distributor (6) from the cylinder head.

 Check disengage discs (7) on the 12 screws/bolts (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

12

Remove charge air temperature sensor in charge air housing (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

13

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