Replace charge air pipe upstream and downstream of charge air cooler

SM09.41-G-0010B

Replace charge air pipe upstream and downstream of charge air cooler

29.4.11

Category

Op. no.

Operation text

Time

Acc. no.

Code

U

027277

Replace charge air pipe (both) on charge air cooler

10 WU/0.8 h

50001 ZZ



1

Tilt cab

AR60.80-G-0005B

2

Disconnect battery ground line

with CODE (M89) Intake air preheater

AR54.10-G-0003B

3

Remove cable ties on bracket (1)

with CODE (M89) Intake air preheater

4

Detach clamps (2)

with CODE (M89) Intake air preheater

5

Remove intake air preheating control unit (grid heater) with integrated heater flange (A31)

with CODE (M89) Intake air preheater

 The positive line (3) and connection line (4) remain connected.

6

Remove cold charge air pipe (5) and hot charge air pipe (6)

 Seal opening on charge air manifold and turbocharger.

7

Remove black charge air hose (7) and red charge air hose (8)

8

Install new hot charge air pipe (9) and red charge air hose (8)

 Clean sealing surface.

The red charge air hose (8) is temperature-resistant and it has to be fitted between the hot charge air pipe (9) and the inlet on the charge air cooler.

9

Install new cold charge air pipe (10) and black charge air hose (7)

 Clean sealing surface.

10

Replace blade connector (11) of ground line (12)

with CODE (M89) Intake air preheater

 Use heat-shrinkable tube.

11.1

Install intake air preheating control unit (grid heater) with integrated heater flange (A31) into new cold charge air pipe (10)

with CODE (M89) Intake air preheater

11.2

Fit new cap with new seal to new cold charge air pipe (10)

except CODE (M89) Intake air preheating

12

Install cable tie firmly to lower hole (arrow) on new cold charge air pipe (10)

with CODE (M89) Intake air preheater

13

Fit positive line (3) and ground line (12) using clamps (2) to upper threaded hole on new cold charge air pipe (10)

with CODE (M89) Intake air preheater

 Rotate clamps (2) through 180°.

14

Attach connection line (4) firmly to cable tie

with CODE (M89) Intake air preheater

15

Fasten positive line (3), connection line (4) and ground line (12) loosely using cable tie to holder (1)

with CODE (M89) Intake air preheater

 Rotate holder (1) through 180°.

16

Connect ground cable to battery

with CODE (M89) Intake air preheater

AR54.10-G-0003B

17

Lower cab

AR60.80-G-0005B

Part no.

Designation

Quantity

A 460 098 03 80

Gasket (only vehicles except code (M89) Intake air preheating)

1

A 904 998 00 90 05

Cap (only vehicles except code (M89) Intake air preheating)

1

A 906 090 05 42 05

Hot charge air pipe

1

A 906 090 06 42 05

Cold charge air pipe

1

A007 997 56 90

Fixed cable tie (only vehicles with code (M89) Intake air preheating)

1

N 046234 008000

Blade connector A 8-16 (only vehicles with code (M89) Intake air preheating)

1

N 910105 008005

Bolt M825

4

Loose cable tie (as required) (only vehicles with code (M89) Intake air preheating)