Remove/install cold air intake

AR09.00-Y-0002A

Remove/install cold air intake

28.06.2020

Engine

400.925/926/927/928 in model 831.001/002/005

(RHD)

Air intake system removal and installation

1

Battery negative terminals

2

Air inlet duct

3

Air compressor air inlet pipe

4

Air inlet pipe

7

Secondary air filter element

9

Air filter mounting bracket

5

Air filter end cover

8

Air filter case

10

Turbocharger air inlet hose

6

Primary air filter element

11

Turbocharger outlet hose

14

Intercooler inlet pipe

16

Intercooler outlet pipe

12

Worm-drive clamps

15

Intercooler air outlet hose

17

Intercooler outlet hose

13

Intercooler inlet hose

18

Inlet air temperature sensor

19

Radiator stay rod

20

Intercooler mounting bolts

 

Remove/install

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

1

Switch off ignition.


Allow the engine to cool down to atmospheric temperature, before starting any service procedure on the vehicle.
Cause burn injuries.

 Engage parking brake.
Choke the wheels to avoid the vehicle from rolling.

2

Disconnect the battery negative terminals (1).

 Installation: Prior to fitment, ensure ignition key is in switched off condition before connecting the battery terminals.

3

Remove air inlet duct (2) by loosening worm-drive clamp from the air filter case.

 Air inlet duct to chassis bracket

*BA09.00-Y-1011-01A

4

Remove air compressor inlet pipe (3) line from the air inlet pipe by loosening the worm-drive clamp.

5

Remove air inlet pipe (4) between air filter case and turbocharger by loosening the worm-drive clamps.

 Air inlet pipe worm-drive clamps

*BA09.00-Y-1010-01A

6

Remove air filter end cover (5) from the air filter case by releasing the locking clips.

 Installation: Ensure that filter cover pinch must match with the slot in the filter unit and the arrow mark must face the air inlet side.

7

Remove the primary air filter element (6) from the air filter case.

 Installation:
Ensure air filter element is prevented from being punctured or damaged.
The result in ineffective filtration.

8

Remove secondary air filter element (7) from the air filter case.

 Installation:
Ensure air filter element is prevented from being punctured or damaged.
The result in ineffective filtration.

9

Remove air filter case (8) from the mounting bracket.

 If required, remove air filter mounting bracket (9) from the chassis frame.

 Air filter case to the mounting bracket

*BA09.00-Y-1009-01A

 Air filter case mounting bracket to chassis frame

*BA09.00-Y-1008-01A

10

Remove air inlet hose (10) from turbocharger by loosening the worm-drive.

 Turbocharger air inlet hose worm-drive clamps

*BA09.00-Y-1007-01A

11

Remove turbocharger outlet hose (11) from turbocharger and intercooler inlet pipe by loosening the worm-drive clamps at both ends.

 Turbocharger outlet hose worm-drive clamps

*BA09.00-Y-1006-01A

12

Remove intercooler inlet hose (13) by loosening the worm-drive clamps (12).

 Intercooler inlet hose worm-drive clamps

*BA09.00-Y-1004-01A

13

Remove intercooler inlet pipe (14) from the chassis frame.

 Intercooler inlet pipe support bracket to chassis frame

*BA09.00-Y-1005-01A

14

Remove intercooler outlet hose (17).

 Loosen the worm-drive clamps from the intercooler outlet pipe and intake manifold to remove intercooler outlet hose.

 Intercooler outlet hose worm-drive clamps

*BA09.00-Y-1003-01A

15

Loosen the worm-drive clamps of intercooler air outlet hose (15) on both sides.

16

Remove intercooler outlet pipe (16) from chassis frame and remove intercooler air outlet hose.

 Intercooler air outlet pipe bracket to chassis frame

*BA09.00-Y-1002-01A

17

Disconnect the electrical connector of inlet air temperature sensor (18).

18

Remove radiator stay rod (19) by removing the circlip and lock pin.

 Tilt the stay rods forward.

19

Remove intercooler unit from radiator by removing the mounting bolts (20).

 Intercooler unit to radiator

*BA09.00-Y-1001-01A

20

Install in the reverse order.

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1001-01A

Intercooler unit to radiator

Nm

202

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1002-01A

Intercooler air outlet pipe bracket to chassis frame

Nm

17.63.5

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1003-01A

Intercooler outlet hose worm-drive clamps

Nm

5.50.5

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1004-01A

Intercooler inlet hose worm-drive clamps

Nm

5.50.5

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1005-01A

Intercooler inlet pipe support bracket to chassis frame

Nm

17.63.5

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1006-01A

Turbocharger outlet hose worm-drive clamps

Nm

5.50.5

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1007-01A

Turbocharger air inlet hose worm-drive clamps

Nm

5.50.5

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1008-01A

Air filter case mounting bracket to chassis frame

Nm

584.5

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1009-01A

Air filter case to the mounting bracket

Nm

201.6

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1010-01A

Air inlet pipe worm-drive clamps

Nm

4.5

 Air intake system removal and refitment procedure

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA09.00-Y-1011-01A

Air inlet duct to chassis bracket

Nm

101.6