Remove/install pump module of exhaust gas aftertreatment system

AR49.20-G-2010CH

Remove/install pump module of exhaust gas aftertreatment system

10.08.2018

Engine

457.9, 458.9, 541.9, 542.9, 941.9, 942.9 in model 000.001

with BlueTec

1

Line fitting for AdBlue® (suction)

4

Compressed-air connector

7

Electrical connector

2

Line fitting for AdBlue® (feed line)

5

Line fitting for coolant (outlet)

8

Pump module

3

Line fitting for AdBlue® (return line)

6

Line fitting for coolant (inlet)

9

Pressure reservoir housing

 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 burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue

Pour AdBlue into suitable containers only. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.

AS14.40-Z-0001-01A

 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

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Notes on use, material properties and handling of AdBlue®

AH14.40-N-0001-01A

 

Remove/install

1

Switch off ignition.

2

Release pressure in coolant circuit.

 See information from body manufacturer.

3

Open insulating hose near the AdBlue® line fitting (1) along a length of approx. 10 cm and push back.

 Roller tongs

*950589013700

4

Use a clamping device to clamp off the AdBlue® line, remove it from the AdBlue® line fitting (1), and close off the opening using a suitable stop plug.


Electric lines must not come into contact with AdBlue®.
If they do, damage may occur in the electrical wiring harness and the exhaust gas aftertreatment unit control unit.

 Clamp

*000589543700

5

Open insulating hose near the AdBlue® line fittings (2, 3) along a length of approx. 20 cm and push back.

 Roller tongs

*950589013700

6

Clamp off AdBlue® lines at the AdBlue® line fittings (2, 3) using clamping devices.

 Clamp

*000589543700

7

Mark the AdBlue® lines in relation to the AdBlue® line fittings (2, 3).

8

Remove the AdBlue® lines from the AdBlue® line fittings (2, 3) and plug the opening with a suitable stop plug.


Electric lines must not come into contact with AdBlue®.
If they do, damage may occur in the electrical wiring harness and the exhaust gas aftertreatment unit control unit.

 Installation: Install new sealing rings.
Observe the markings on the AdBlue® lines in relation to the AdBlue® line fittings (2, 3).

9

Remove the compressed-air connector (4) on the pressure reservoir housing (9).



Pump module altered

BT14.40-W-0001-01A

 Compressed air connection system SCHÄFER "SDF" in metallic material

*BA00.18-N-1003-01C

10

Clamp off coolant lines at the coolant line fittings (5, 6) using clamping devices.

 Clamp

*000589543700

11

Mark the coolant lines in relation to the coolant line fittings (5, 6).

12

Remove the coolant lines from the coolant line fittings (5, 6) and plug the opening with a suitable stop plug.

 Collect escaping coolant using suitable vessel.

 Installation: Replace O-rings.
Observe the marking of the coolant lines in relation to the coolant line fittings (5, 6).

13

Disconnect electrical connector (7) from pump module (8).


The plug and the connector socket of the electrical connector (7) must not come into contact with AdBlue®.
If they do, damage may occur in the electrical wiring harness and the exhaust gas aftertreatment unit control unit.

14

Check the electrical wiring harness of the pump module (8).

AR49.20-G-0013CH

15

Remove the pump module (8).



Pump module altered

BT14.40-W-0001-01A

 Pump module on bracket

*BA14.40-N-1010-02H

16

Install in the reverse order.

17

Fill the pressure reservoir.

Only when replacing the pump module (8).

AR49.20-G-2051CH

18

Start engine.

19

Check engine cooling system for leak tightness and switch off engine.

 Visual inspection.

20

Check coolant level and correct.

 See information from body manufacturer.

 Compressed air lines

Number

Designation

Model 000.001

BA00.18-N-1003-01C

Compressed air connection system SCHÄFER "SDF" in metallic material

M101

Nm

5

 Exhaust aftertreatment, Blue Tec

Number

Designation

Engine 457.9, 458.9

engine 541.9, 941.9

BA14.40-N-1010-02H

Pump module on bracket

Nm

60

60

 Exhaust aftertreatment, Blue Tec

Number

Designation

Engine 542.9, 942.9

BA14.40-N-1010-02H

Pump module on bracket

Nm

60