Check charge air system for leaks

AR09.41-D-1000NA

Check charge air system for leaks

21.03.2016

Engine

647.981 in model 903.6, 904.6

with code ZU7 (National version for Canada)

Engine

647.981 in model 903.6, 904.6

with code ZU8 (National version for USA)

Engine

647.981 in model 903.6, 904.6

with code ZU9 (National version for Mexico)

1

Air intake hose

5

Compressed air hose

6.4

Oil dipstick guide tube grommet

2

Engine ventilation hose

6

Leak tester

6.5

Engine ventilation stop plug

2.1

Heating element of engine ventilation

6.1

Shutoff valve

6.6

Tester cap

3

Oil dipstick

6.2

Pressure regulator

6.7

Hose

4

ATL

6.3

Pressure gauge

6.8

Retaining clamp

 Danger !

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



Remove

1

Remove air intake hose (1)

 Check air intake hose (1) for damage; replace as per findings.

2

Remove the oil dipstick (3)

3

Remove engine ventilation hose (2) with engine ventilation heating element (2.1) from engine

 The engine ventilation hose (2) remains with the engine ventilation heating element (2.1) on the cylinder head cover.



Check

4

Insert oil dipstick guide tube grommet (6.4)

 Leaktightness tester

*611589022100

5

Place tester cap (6.6) onto inlet connection of ATL (4) and fix with retaining clamp (6.8) at ATL (4)

 Leaktightness tester

*611589022100

6

Connect hose (6.7) to tester cap (6.6)

 Leaktightness tester

*611589022100

7

Close off engine ventilation heating element (2.1) with engine ventilation grommet (6.5)

 Leaktightness tester

*611589022100

8

Close shutoff valve (6.1)

 Leaktightness tester

*611589022100

9

Relieve pressure regulator (6.2)

 To do this remove pressure regulator (6.2) up to the stop.

 Leaktightness tester

*611589022100

10

Open shutoff valve (6.1)

 Leaktightness tester

*611589022100

11

Screw in pressure regulator (6.2)

 For this purpose screw in pressure regulator (6.2) until the test pressure of about 0.3 bar is shown on the pressure gauge (6.3)

 Leaktightness tester

*611589022100

If a test pressure of approx. 0.3  bar is not reached



Subject to a separate repair order, check the pressure loss in the charge air system and repair the charge air system.

12

Check charge air system for leaktightness

 For this purpose wet the respective area with a suitable foam forming agent.

In case of leakage on the charge air system



Subject to a separate repair order, repair charge air system in the respective area.

13

Close shutoff valve (6.1)

 Leaktightness tester

*611589022100

14

Remove leaktightness tester (6), test connection (6.6), oil dipstick guide tube grommet (6.4) and engine ventilation grommet (6.5)

 The charge air system must not be under pressure.

 Leaktightness tester

*611589022100



Install

15

Install engine ventilation hose (2.1) with engine ventilation heating element (2)

16

Install oil dipstick (3)

17

Install air intake hose (1)

 Check clamps; replace as per findings.