Remove/install timing case

AR01.60-W-8200B

21.10.11

ENGINES 541.9 in MODEL 950, 952, 953, 954

ENGINES 542.9 in MODEL 950, 952, 954

W01.60-1019-09

1 Exhaust manifold pipe (engine 541.9)

2 Resonance tank (engine 542.9)

3 Sealing ring (engine 542.9)

4 Threaded bolt (engine 542.9)

5 Resonance tank (engine 541.9)

6 Hose (engine 541.9)

7 Hose (engine 541.9)

8 Bracket (engine 541.9)

9 Engine wiring harness

10 Bracket

11 Engine wiring harness

23 Timing case

24 Bracket with electrical lines

25 Bracket with fuel lines

26 Bracket with transmission oil lines (for code (N55) Transmission oil cooling)

27 Seals

28 Constant throttle compressed air line

B15 Crankshaft angle position sensor

B16 Cylinder 1 (camshaft) top dead center sensor

M1 Starter

12 O-ring

13 Locking bush

14 Oil return line on turbocharger

15 Fitting

16 Suspension eye (engine 542.9)

17 Bracket (engine 542.9)

18 Radial sealing ring

19 Elbow fitting (engine 542.9)

20 Compressed air line for engine brake

21 Constant throttle compressed air line

22 Bracket with distributor piece

Modification notes

28.11.07

Value changed: Air intake pipe hose clamp

*BA09.20-N-1002-02C

 	Remove/install
	Notes on self-locking nuts and Screw/bolts		AH00.00-N-0001-01A
1	Remove engine		AR01.10-W-2400B
2	Attach engine to engine repair stand	Engine assembly stand for commercial vehicles gotis://A_01_15.1
3	Remove starter (M1) on timing case (23)	 Installation: Check starter drive pinion in starter (M1) for wear; replace starter (M1) if necessary.
			*BA15.30-N-1001-01C
4	Remove flywheel		AR03.30-W-8002B
5	Take off oil pan		AR01.45-W-7500B
6	Remove exhaust manifold pipe (1) on the left and right	 Engine 541.9 only
		 Installation: Clean sealing surfaces. The stamped in arrow on the exhaust manifold pipe (1) must point in the direction of the exhaust collector. Install exhaust manifold pipe (1) free of tension.
			*BA14.10-N-1003-01C
			*BA14.10-N-1005-01C
7	Remove fuel pump and power steering pump unit		AR47.20-W-5712A
8.1	Take off resonance tank (5) together with bracket (8) and hoses (6, 7) at compressor	Engine 541.9
			*BA13.30-N-1010-01B
8.2	Remove resonance tank (2) at compressor	Engine 542.9
		 Counterhold threaded bolt (4).
9.1	Remove exhaust manifold together with turbocharger and engine brake valve fitting	Engine 541.9	AR14.10-W-3920-01G
		 Screw/bolt, intake manifold to compressor cylinder head	*BA09.20-N-1003-02C
		 Hose clamp intermediate piece to intake manifold and turbocharger	*BA09.20-N-1004-02C
		 Oil pressure line on exhaust gas turbocharger	*BA09.40-N-1009-01C
		 Exhaust gas turbocharger oil return line to fitting on timing case	*BA09.40-N-1010-01C
		 Screw/bolt, oil pressure line to exhaust gas turbocharger bracket	*BA09.40-N-1012-01C
		 Screw/bolt, exhaust manifold to timing case	*BA14.10-N-1004-01C
		 Bolt for support/exhaust plenum chamber on timing case	*BA14.10-N-1009-01C
9.2	Remove transverse exhaust pipe together with right turbocharger and intake manifold	Engine 542.9	AR14.10-W-3925-01G
		 Banjo bolt, oil pressure line for turbocharger to timing case	*BA01.60-N-1010-01B
		 Screw/bolt, air intake pipe to bracket	*BA09.20-N-1001-02C
		 Air intake pipe hose clamp	*BA09.20-N-1002-02C
		 Screw/bolt, oil return flow line to exhaust gas turbocharger	*BA09.40-N-1003-01C
		 Nut, turbocharger to exhaust manifold	*BA09.40-N-1005-01C
		 Oil pressure line on exhaust gas turbocharger	*BA09.40-N-1009-01C
		 Nut, transverse exhaust pipe to flanged manifold and valve fitting	*BA14.10-N-1007-01C
10	Remove lifting eye (16) and bracket (17) at rear at timing case (23)	 only on engine 542.9
			*BA22.10-N-1003-01D
11	Take off timing case cover		AR01.40-W-8000A
12	Remove oil return lines for turbocharger (14) at timing case (23)	 Only on engine 542.9
			*BA01.60-N-1008-01B
13	Disconnect compressed air line for constant throttle (28) at bracket with distributor piece (22)		*BA01.50-N-1003-01A
14	Remove bracket with distributor piece (22) with engine brake (20) compressed air line and constant throttle (21) compressed air line
15	Remove bracket together with electric cables (24) at timing case (23)		*BA15.18-N-1003-01A
16	Remove bracket with fuel lines (25) at timing case (23)		*BA47.25-N-1008-01B
17	Remove fixture together with transmission oil lines (26) at timing case (23)	 Only with code (N55) Transmission oil cooling.
18	Disconnect engine wiring harness (9) at crankshaft position sensor (B15) and pull out crankshaft position sensor (B15) at timing case (23)	 Installation: Replace O-ring (12) and inspect locking bush (13); replace if necessary. Press in locking bush (13) and crankshaft angle position sensor (B15) fully.
19	Pull out cylinder 1 (camshaft) TDC sensor (B16) at timing case (23)	 Installation: Replace O-ring (12) and inspect locking bush (13); replace if necessary. Press in locking bush (13) and cylinder 1 (camshaft) TDC sensor (B16) all the way.
20	Take off fixture (10) together with engine wiring harness (9), lines and attached parts at timing case (23)		*BA15.18-N-1003-01A
21	Remove timing case (23)	 Check timing case (23) for damage; replace if necessary.
		 Installation: Place timing case (23) over dowel pins.
		Replace radial sealing ring (18) in timing case (23). Check whether a race is mounted on the flywheel; install appropriate radial sealing ring (18) in the timing case (23) if necessary.	AR03.20-W-3063B
			*BA01.60-N-1002-01B
22	Take off attached parts at timing case (23)	 Only when replacing timing case (23).
		 Screw/bolt, TDC inspection hole cap to timing case	*BA01.60-N-1001-01B
		 Screw/bolt, compressor opening end cover on side to timing case	*BA01.60-N-1003-01B
		 Nut for turbocharger oil return on the left to timing case	*BA01.60-N-1004-01B
		 Screw of screw cap (engine power take-off) to timing case	*BA01.60-N-1005-01B
		 Screw plug for turbocharger oil return flow in timing case	*BA01.60-N-1006-01B
		 Turbocharger oil return flow fitting to timing case	*BA01.60-N-1007-01B
23	Take off gaskets (27)	 Clean sealing surfaces
		 Installation: Replace seals (27).
	Seals between crankcase and timing case altered	As of engine end no. 349692	BT01.60-W-0001-01A
24	Install in the reverse order

 Constant throttle

Number	Designation		Engine 541.9, 542.9


BA01.50-N-1003-01A	Compressed-air line, constant throttle to distributor piece	Nm	30

 Timing case

Number	Designation			Engine 541.9. 542.9


BA01.60-N-1001-01B	Screw/bolt, cap of TDC inspection hole to timing case		Nm	25
BA01.60-N-1002-01B	Screw/bolt, timing case to crankcase	M1257	Nm	100
		M12105	Nm	100
		M12167	Nm	100
BA01.60-N-1003-01B	Screw/bolt, side compressor hole cover to timing case		Nm	50
BA01.60-N-1004-01B	Nut, turbocharger oil return flow fitting on the left to timing case	M261.5	Nm	50
BA01.60-N-1005-01B	Screw/bolt, screw cap (engine power take-off) to timing case		Nm	25
BA01.60-N-1006-01B	Screw plug, for turbocharger oil return flow in the timing case		Nm	80
BA01.60-N-1007-01B	Turbocharger oil return flow fitting to timing case		Nm	120
BA01.60-N-1008-01B	Exhaust gas turbocharger oil return line on timing case fitting		Nm	50
BA01.60-N-1010-01B	Banjo bolt, oil pressure line for turbocharger to timing case	M141.5	Nm	35

 Intake manifold, intake manifold preheater

Number	Designation		Engine 541.9 except code MJ1	Engine 541.9 with code MJ1


BA09.20-N-1003-02C	Screw/bolt, intake manifold to compressor cylinder head	Nm	50	50
BA09.20-N-1004-02C	Hose clamp intermediate piece on intake manifold and turbocharger	Nm	6.0	6.0

 Intake manifold, intake manifold preheater

Number	Designation		Engine 542.9 except code MJ1	Engine 542.9 with code MJ1


BA09.20-N-1001-02C	Screw/bolt, air intake pipe at bracket	Nm	50	60
BA09.20-N-1002-02C	Air intake pipe hose clamp	Nm	6.0	6.0

 Turbocharger

Number	Designation			Engine 541.9	Engine 542.9


BA09.40-N-1003-01C	Screw/bolt, oil return flow line to turbocharger		Nm	25	25
BA09.40-N-1005-01C	Nut, turbocharger to exhaust manifold		Nm	-	50
BA09.40-N-1009-01C	Oil pressure line on turbocharger	M141.5	Nm	35	35
BA09.40-N-1010-01C	Exhaust gas turbocharger oil return line on timing case fitting	M261.5	Nm	50	50
BA09.40-N-1012-01C	Screw/bolt, oil pressure line to exhaust gas turbocharger bracket		Nm	25	25

 Compressor (compressed air system)

Number	Designation		Engine 541.9, 542.9


BA13.30-N-1010-01B	Screw/bolt, resonator to bracket	Nm	25

Exhaust manifold

Number	Designation			Engine 541.9	Engine 542.9


BA14.10-N-1003-01C	Nut, exhaust pipe to exhaust manifold		Nm	50	-
BA14.10-N-1004-01C	Screw/bolt, exhaust manifold to timing case	M16	Nm	150	150
		M12	Nm	100	100
		M10	Nm	50	50
BA14.10-N-1005-01C	Nut, pipe to exhaust manifold		Nm	50	50
BA14.10-N-1007-01C	Transverse exhaust pipe nut to flanged manifold and engine brake valve fitting		Nm	-	50
BA14.10-N-1009-01C	Screw/bolt, support/exhaust manifold to timing case		Nm	40	-

Engine wiring harness

Number	Designation		Engine 541.9, 542.9


BA15.18-N-1003-01A	Screw/bolt, wiring loom to timing case	Nm	25

Starter

Number	Designation		Engine 541.9, 542.9


BA15.30-N-1001-01C	Nut, starter to timing case	Nm	80

Engine mounts, engine supports

Number	Designation		Engine 542.9


BA22.10-N-1003-01D	Screw/bolt, rear engine lifting eyes to timing case	Nm	150

Fuel pipes/hoses

Number	Designation		Engine 541.9. 542.9


BA47.25-N-1008-01B	Screw/bolt, fixture of fuel line to timing case cover and timing case	Nm	25

เอกสารที่อ้างถึง