AR09.41-W-8681B | Removing/installing charge air manifold | 27.2.07 |
ENGINE 541.9 in MODEL 950, 952, 953, 954
ENGINE 542.9 in MODEL 950, 952, 954
W09.41-1025-06
Shown on engine 541.9
1 Charge air manifold/charge air housing
2 Electrical connector
3 Seal
4 Nut
5 Tensioning element
6 Flame starting system (only for code (M89) Flame starting system (FLA))
7 Seal (only for code (M89) Flame starting system (FLA))
8 Intermediate piece
8.1 Sealing ring
9 Threaded stud
10 Threaded stud
11 Charge air hose, black
12 Charge air hose, red
B111 Charge air temperature and boost pressure combination sensor
Modification notes
| Remove/install | ||
1 | Switch off ignition | ||
Danger! | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut. | |
2 | Tilt cab | ||
| Notes on tilting the cab | ||
3 | Remove air filter housing | Only on vehicles with code (M97) Front air intake. | |
4 | Remove flame starting system (6) | Only for vehicles with code (M89) flame starting system (FSS) | |
Do not separate fuel lines and engine wiring harness. | |||
Installation: Install new seals (7). | |||
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5 | Disconnect electrical connector (2) at charge air combination sensor (temperature, pressure) (B111) | ||
6 | Loosen charge air hose, black (11) on charge air manifold/charge air housing (1) or charge air pipe | Installation: Charge air hose black (11) and charge air hose red (12) must not get mixed up with each other. | |
Perform visual inspection on charge air hose, black (11) and the clamp. In case of damage: | |||
Replace charge air hose, black (11) or clamp. | |||
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7 | Loosen charge air hose, red (12) on charge air manifold/charge air housing (1) | Only on engine 541.9. Perform visual inspection on charge air hose, red (12) and the clamp. In case of damage: | |
Replace charge air hose, red (12) or clamp. | |||
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8 | Remove charge air pipe on charge air manifold/charge air housing (1) | Only on engine 542.9. | |
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9 | Remove nuts (4) and pull tensioning elements (5) out of the charge air manifold/charge air housing (1). | Counterhold threaded bolts (9, 10). Installation: Fully tighten threaded bolts (9, 10) and check tensioning elements (5) for wear; if necessary. Replace tensioning element (5). | |
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10 | Lift charge air manifold/charge air housing (1) at the front and remove both rear threaded bolts (9) | Only on engine 541.9. | |
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11 | Remove charge air manifold/charge air housing (1) | Installation: Replace gaskets (3) and pay attention to installation position. | |
12 | Remove intermediate piece (8) | Only on engine 541.9. | |
Installation: Install new sealing rings (8.1). | |||
| Intermediate piece charge air housing to turbocharger altered | As of engine end no. 024778 | |
13 | Modify charge air temperature and boost pressure combination sensor (B111) | Only if charge air manifold/charge air housing (1) is replaced. | |
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14 | Install in the reverse order |
Intake manifold preheater
Number | Designation | Engine | |
BA09.30-N-1001-01A | Bolt, bracket of flame starting system to charge air pipe | Nm | 20 |
Charge air pipe/charge air cooling
Number | Designation | Engine | Engine | ||
BA09.41-N-1001-01C | Nut of charge air housing to threaded bolt | Nm | 40 | 40 | |
BA09.41-N-1002-01C | Threaded stud/bolt to cylinder crankcase | Nm | 50 | 50 | |
BA09.41-N-1003-01C | Threaded bolt to oil filter housing bracket | Nm | 50 | 50 | |
BA09.41-N-1005-01C | Bolt, charge air pipe to charge air housing | Nm | - | 25 | |
BA09.41-N-1006-01C | Clamp, charge air hose to charge air housing/charge air pipe and charge air cooler | Nm | 7.5 | 7.5 | |
BA09.41-N-1008-01C | Threaded stud/bolt to oil filter housing | Nm | 50 | 50 | |
BA09.41-N-1009-01C | Bolt, charge air temperature and charge pressure combination sensor to air housing | Nm | 10 | 10 | |