ar4920w100102a

Modify pressure line with connection on exhaust aftertreatment unit

Type ar · topic 49.20 · version 0200 · 2017-07-25

Applies to: Engine 934.9, 936.9 in model 967 Engine 936.9 in model 956, 963, 964

Where it sits

Function group 1 Engine › 49 Exhaust system, exhaust gas cleaning › 49.20 Exhaust gas aftertreatment — Series 934 (models 9**) · Series 936 (models 9**) · Series 956 · Series 963 · Series 964 · Series 967

EinPAS 15 Engine › 15.40 Exhaust system/exhaust aftertreatment › 15.40.13 Line/hose/valve — Series 934 (models 9**) · Series 936 (models 9**) · Series 956 · Series 963 · Series 964 · Series 967

AR49.20-W-1001-02A

Modify pressure line with connection on exhaust aftertreatment unit

Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

General information and guidelines for welding on the exhaust aftertreatment unit

AH49.20-N-0001-01A

Engine

934.9, 936.9 in model 967

Engine

936.9 in model 956, 963, 964

Repair materials

Number

Designation

Order number

BR00.45-Z-1017-06A

MB multipurpose grease, 400 g

A 001 989 34 51 11

BR00.45-Z-1103-06A

Paste, hot lubrication 100 g DBL 6879.20

A 000 989 76 51 11

Modify pressure line with connection on exhaust aftertreatment unit

1

Saw off pressure line (1) near to the union nut (4).



2

Loosen union nut (2) and press away pressure line (1) to the side.


W49.20-1165-11

Modify pressure line with connection on exhaust aftertreatment unit

3

Drill pressure line connection (3) straight in so deep that the union nut (4) is completely removed and the repair adapter (5) can later be inserted up to its collar.


Ensure that neither grease nor chips can find its way into the EATU.
This would lead to malfunctions.


Coat the drill bit with grease so that the chips stick to it and cannot find their way into the EATU. Use various drill bit with ever larger diameters one after the other. Beginning with Ø 10 mm to about Ø 14.5 mm. Start with 1 mm steps - later with 0.5 mm steps.


W49.20-1166-11

Modify pressure line with connection on exhaust aftertreatment unit

4

Clean pressure line connection (3).



5

Place the repair adapter (5) as shown in the pressure line connection (3).


The repair adapter (5) must lie with its collar on the pressure line connection (3).


W49.20-1167-11

Modify pressure line with connection on exhaust aftertreatment unit

6

Weld the repair adapter (5) into the pressure line connection (3) gas-tight.


W49.20-1188-11

Modify pressure line with connection on exhaust aftertreatment unit

7

Coat the union nut (7) thinly with high-temperature grease.



8

Introduce the new pressure line (6) with a cutting ring (8) and union nut (7) into the repair adapter (5).



9

Tighten the union nut (7) slightly.


The new pressure line (6) must still remain rotatable.



10

Align the remaining pressure line (1) and the new pressure line (6) together.



11

Cut to length the new pressure line (1) and the remaining pressure line (6).


There are different variants according to the EATU. For this reason the pressure lines (6) and (1) must be cut to a length as required. For the following operation step there should be as little bridging as possible with the hose piece (9). If necessary the pressure lines (6) and (1) must be bent back somewhat.


W49.20-1169-11

Modify pressure line with connection on exhaust aftertreatment unit

12

Connect both pressure lines (1, 6) with the hose piece (9) and the hose clamps (10).


One must ensure that the hose piece (9) is not kinked.
Otherwise malfunctions can occur.


The hose piece (9) should be shortened in such a way that the pressure lines (1, 6) jut out on either side by about 3 cm in the hose piece (9).


W49.20-1170-11