Remove/install charge air manifold

AR09.41-G-8681DE

Remove/install charge air manifold

18.09.2019

Engine

902.90 in model 000.001

Engine

906.90 in model 000.001

Modification notes

20.08.2019

Work procedure completely revised.

Shown on engine 906.90

1

Engine wiring harness

10.1

Gas injection valve cylinder 1

2

Charge air pipe

10.2

Cylinder 2 gas injection valve

2.1

Sealing ring

10.3

Cylinder 3 gas injection valve

3

Clip

10.4

Gas injector cylinder 4

4

Cover

10.5

Gas injection valve cylinder 5

5

Charge-air distributor

10.6

Gas injection valve, cylinder 6

6

Gas pressure line

11

Charge air pressure and temperature sensor

7

Cover

12

Gas pressure sensor

8

Seal

13

Gas temperature sensor

9

Holder

 Danger

Risk of death when working on component parts and systems with U >= 25 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

 Danger

Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.

Remove any sources of ignition.
Protective clothing, safety gloves and safety glasses must always be worn.
Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.

AS00.00-Z-0018-01A

 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

Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Notes on work safety regulations for vehicles with natural gas-powered engines

AH00.10-N-1000-04A

Note on threaded connections of gas lines

AH47.25-N-0001-01A

 

Remove/install

1

Close gas shutoff valves at gas cylinders.

2

Start the engine and allow to run in idle until the engine stops by itself.

 See information from body manufacturer.
In this way the residual gas from the lines and assembly parts is consumed.

3

Switch off ignition.

4

Remove cylinder head cover.

AR01.20-G-5014DE

5

Remove holder (9) from charge air pipe (2) and loosen at coolant pump.

 Bracket to coolant pump

*BA20.10-N-1005-01L

6

Loosen clamp (3) and pull out charge air pipe (2) at charge-air distributor (5).

 Installation: Clean sealing surfaces. Replace sealing ring (2.1).

 Clamp at charge air distributor/charge air pipe

*BA09.41-N-1011-01I

7

Remove covers (4, 7) from charge-air distributor (5).

8

Disconnect electrical connector of engine wiring harness (1) from gas temperature sensor (13).

9

Disconnect electrical connector of engine wiring harness (1) from gas pressure sensor (12).

10

Disconnect electrical connector of engine wiring harness (1) from charge air pressure and temperature sensor (11).

11

Expose engine wiring harness (1) at charge-air distributor (5) and disconnect electrical connector of lambda sensor from engine wiring harness (1).

12

Loosen gas pressure line (6) at the holder and unscrew from fitting of charge-air distributor (5).

 Counterhold the fitting of charge-air distributor (5).

 Fitting, gas line to cylinder head

*BA07.54-N-1005-01C

13

Disconnect the electrical connector of engine wiring harness (1) at the gas injection valves of cylinders 1 to 6 (10.1 to 10.6).

14

Remove charge-air distributor (5) from the cylinder head.

 Seal openings of the intake ports.

 Installation: Clean sealing surfaces. Replace seals (8), observe installation position.

 Bolt, charge air distributor to cylinder head

*BA09.41-N-1001-01I

15

Install in the reverse order

16

Check gas line connection at the fitting of charge-air distributor (5) for leaktightness.

 Apply a foam-forming product, such as soapy water or leak detection spray, all around the gas line connection. Start engine and check gas line connection for bubble formation at idle speed.
See information from body manufacturer.

If a leak is detected:



Seal or replace component part in question.

17

Switch off engine.

 Gas injection and ignition system

Number

Designation

Engine 902.90, 906.90 in model 000.001

BA07.54-N-1005-01C

Fitting, gas line to cylinder head

Nm

45

 Charge air pipe/charge air cooling

Number

Designation

ENGINE 900.9, 902.9, 904.9, 924.9

Engine 906.9, 925.9, 926.9 in model 000.001

BA09.41-N-1001-01I

Bolt, charge air distributor to cylinder head

Nm

25

25

 Charge air pipe/charge air cooling

Number

Designation

ENGINE 900.9, 902.9, 904.9, 924.9

Engine 906.9, 925.9, 926.9 in model 000.001

BA09.41-N-1011-01I

Clamp at charge air distributor/charge air pipe

Nm

10

10

 Coolant pump, coolant thermostat

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9 in model 000.001

BA20.10-N-1005-01L

Bracket to coolant pump

Nm

50