Remove/install charge air manifold

AR09.41-D-8681WE

Remove/install charge air manifold

22.02.2018

Engine

651 in model 900

Engine

651.955/956/957 in model 906

Modification notes

17.01.2017

Screw/bolt, charge air pipe with throttle valve actuator/intermediate flange to charge air line

ENGINE 651 in MODEL 900

BA09.41-N-1016-01M

17.01.2017

Schraube Ladeluftrohr mit Drosselklappensteller/Zwischenflansch an Ladeluftleitung

Motor 651 im Typ 900

BA09.41-N-1016-01M

17.01.2017

Screw/bolt, charge air pipe with throttle valve actuator/intermediate flange to charge air line

ENGINE 651 in MODEL 906

BA09.41-N-1016-01M

17.01.2017

Schraube Ladeluftrohr mit Drosselklappensteller/Zwischenflansch an Ladeluftleitung

Motor 651 im Typ 906

BA09.41-N-1016-01M

15.02.2017

Method extended

Operation step 7

Shown on vehicle except CODE MS3(Engine version EURO 3)

1

Charge air pipe

2

Screw/bolts

3

Screw/bolts

4

Exhaust pipe

5

Electrical wiring harness

6

Screw/bolts

7

Screw/bolts

8

Screw/bolts

9

Clamp

10

Bracket

11

Charge air pipe

B5/6

Boost pressure sensor

M16/45

Throttle valve actuator (except code MS3 (Engine version EURO 3)

 

Remove/install

1

Remove exhaust gas recirculation cooler

AR14.20-D-7665WE

2

Remove screw/bolts (2, 3) and exhaust pipe (4)

 Installation: Clean sealing surfaces. Replace seal and sealing ring for exhaust pipe (4).

 Bolt, exhaust gas recirculation line to charge air line

*BA14.20-N-1033-01H

 Bolt, exhaust gas recirculation line to bypass flap

*BA14.20-N-1034-01H

3

Disconnect Electrical connection for boost pressure sensor (B5/6)

4

Unclip clamp (9) for electrical wiring harness (5) on charge air manifold (1)

5

Remove screw/bolts (6)

 Screw/bolt, charge air pipe to mounting plate

*BA09.41-N-1015-01M

6

Unclip vacuum supply line at bracket (10)

7

Unscrew screw/bolts (7) and remove bracket (10)

AR09.41-S-1330-01E

 Installation: Observe tightening procedure of screw/bolts (7).

 Screw/bolt, charge air pipe with throttle valve actuator/intermediate flange to charge air line

*BA09.41-N-1016-01M

8

Remove screws/bolts (8)

 Screw/bolt, charge air pipe to charge air distributor

*BA09.41-N-1014-01M

9

Remove charge air pipe (1)

 Installation: Clean sealing surfaces and replace sealing rings.

10

Disconnect electrical connection (M16/45) at throttle valve actuator

Engine 651 in model 900
Engine 651.955/956/957 in model 906
except code MS3 (Engine version EURO 3)

11.1

Remove throttle valve actuator (M16/45) from charge air pipe (11)

Engine 651 in model 900
Engine 651.955/956/957 in model 906
except code MS3 (Engine version EURO 3)

 Installation: Clean sealing surfaces and replace sealing ring on charge air pipe (11).

11.2

Remove connecting flange from charge air pipe (11)

Engine 651.955/956/957 in model 906
with code MS3 (Engine version EURO 3)

 Installation: Clean sealing surfaces and replace sealing ring on charge air pipe (11).

12

Remove boost pressure sensor (B5/6) from charge air pipe (1)

When replacing the charge air pipe (1).

 Bolt, boost pressure sensor on charge air manifold

*BA07.04-N-1012-01B

13

Install in the reverse order



Check

 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

15

Perform an engine test run and check charge air system in the area of the charge air pipe (1) for leaktightness

 Visual inspection only.

 Sensors, transmitters

Number

Designation

Engine 651 in model 900
Engine 651 in model 906

BA07.04-N-1012-01B

Bolt, boost pressure sensor on charge air manifold

Nm

5

 Charge air pipe/charge air cooling

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.41-N-1014-01M

Screw/bolt, charge air pipe to charge air distributor

Nm

9

9

 Charge air pipe/charge air cooling

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.41-N-1015-01M

Screw/bolt, charge air pipe to mounting plate

Nm

9

9

 Charge air pipe/charge air cooling

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA09.41-N-1016-01M

Screw/bolt, charge air pipe with throttle valve actuator/intermediate flange to charge air line

Nm

10

10

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA14.20-N-1033-01H

Bolt, exhaust gas recirculation line to charge air line

Nm

9

9

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA14.20-N-1034-01H

Bolt, exhaust gas recirculation line to bypass flap

Nm

10

10