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

AR09.41-G-1331DE

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

18.09.2019

Engine

902.90 in model 000.001

Engine

906.90 in model 000.001

Modification notes

23.08.2019

Operation steps 9, 11, 12 added.

1

Charge air pipe

2

Charge air pipe

2.1

Sealing ring

3

Engine wiring harness

3.1

Electrical connector

4

Clip

5

Bracket

6

Coolant line

7

Charge air hose (black)

8

Throttle valve actuator

 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

 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

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

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

AH00.10-N-1000-04A

 

Remove/install

1

Switch off ignition.

2

Loosen engine wiring harness (3) from bracket (5).

3

Disconnect electrical connection (3.1) from throttle valve actuator (8).

4

Loosen coolant line (6) from bracket (5).

 Do not disconnect coolant line (6).

5

Remove bracket (5) from charge air pipe (2) and the coolant pump.

 Bracket to coolant pump

*BA20.10-N-1005-01L

6

Loosen clamp (4) and pull charge air pipe (2) out of the charge air distributor.

 Installation: Clean sealing surfaces.

 Clamp at charge air distributor/charge air pipe

*BA09.41-N-1011-01I

7

Remove (black) charge air hose (7) from charge air pipe (1).

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

*BA09.41-N-1010-01I

8

Remove charge air pipes (1, 2) together with throttle valve actuator (8).

 Installation: Replace sealing ring (2.1).
First tighten bolt on clamp (4) and bolts on bracket (5) slightly by hand and then tighten one after the other to avoid tensions on charge air pipes (1, 2).

9

Close off opening on charge air distributor.

10

Install in the reverse order



Check

11

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

 See information from body manufacturer.
Visual inspection.

12

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

 Coolant pump, coolant thermostat

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9 in model 000.001

BA20.10-N-1005-01L

Bracket to coolant pump

Nm

50