Remove/install charge air pipe from turbocharger to charge air cooler

AR09.41-G-1332DD

Remove/install charge air pipe from turbocharger to charge air cooler

18.09.2019

Engine

900.91/92 in model 000.001

Engine

902.90/91/93 in model 000.001

Engine

904.94/95/96/97 in model 000.001

Engine

906.90/93/94/95/96/98/99 in model 000.001

Engine

924.91/93/94 in model 000.001

Engine

925.9 in model 000.001

Engine

926.91/92/93/95/97/98 in model 000.001

Shown on engine 924.9 with BlueTEC 4 (Euro IV Standard)

1

Charge air pipe

4

Charge air hose

7

O-ring

2

Charge air pipe

5

Turbocharger

8

Screw (only for engine 900.91/92, 924.91/93/94)

3

Clip

6

Clip

Shown on engine 926.9 with BlueTEC 4 (Euro IV Standard)

1

Charge air pipe

2

Charge air pipe

3

Clip

4

Charge air hose

5

Turbocharger

6

Clip

7

O-ring

 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 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

 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

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

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

AH00.10-N-1000-04A

 

Remove/install

1

Remove charge air pipe (1).

with natural gas engine

AR09.41-G-1331DE

except natural gas engine

AR09.41-G-1331DD

2

Remove charge air hose (4) from charge air pipe (2).

 Clamp, charge air hose to charge air distributor/charge air pipe/charge air cooler

*BA09.41-N-1010-01I

3

Remove screw (8).

Only for engine 900.91/92, 924.91/93/94.

4

Remove screw for clamp (6).

 Clamp at charge air distributor/charge air pipe

*BA09.41-N-1011-01I

5

Remove charge air pipe (2).

 Installation: Clean sealing surfaces and replace O-ring (7).
First tighten screw on clamp (6) and screw (8) slightly by hand and then tighten one after the other in order to avoid tensions on charge air pipe (2).

6

Seal opening on turbocharger (5).

7

Install in the reverse order



Check

8

Start engine and check charge air pipes (1, 2) for leaktightness with engine running.

 See information from body manufacturer.
Visual inspection.

9

Switch off engine.

 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-1010-01I

Clamp, charge air hose to charge air distributor/charge air pipe/charge air cooler

Nm

8

8

 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