AR09.41-W-8682A | Remove/install charge air housing | 3.11.10 |
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W09.41-1046-09
Shown on engine 542.9 with code (MS5) BlueTec 5
1 Charge air pipe (only for engine 542.9)
2 Charge air hose, red
3 Charge air housing
4 Bolt
5 Bolt
6 Gasket
13 Charge air hose, black
Y1 Pneumatic constant throttle solenoid valve (only for vehicles with code (GE7) Mercedes
PowerShift 2)
7 Tensioning element
8 Clip
9 Leak fuel line
10 Intermediate piece
11 Sealing ring
12 Bracket for the steering oil line
W09.41-1047-06
Shown on engine 542.9 with code (MS5) BlueTec 5
1 Charge air pipe (only for engine 542.9)
2 Charge air hose, red
3 Charge air housing
13 Charge air hose, black
14 Electrical connector*
15 Fuel line*
16 Flame starting system*
17 Electrical lines*
18 Electrical connector
19 Screw
B111 Charge air temperature and boost pressure combination sensor
* Only on vehicles with code (M89) Flame starting system (FLA)
Modification notes
15.9.10 | Remove pneumatic constant throttle solenoid valve (Y1) on charge air housing (3) added. | Step 12 |
| 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 tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut. | |
2 | Tilt cab | Installation: Only tilt cab back after leak test has been conducted. | |
| Notes on tilting the cab | ||
3 | Remove charge air hose black (13) on charge air housing (3) | Installation: Charge air hose black (13) and charge air hose red (2) must not get mixed up with each other. | |
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4 | Remove charge air hose red (2) on charge air housing (3) | Only on engine 541.9. | |
Installation: Charge air hose black (13) and charge air hose red (2) must not get mixed up with each other. | |||
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5 | Separate electrical connector (14) and electrical lines (17) on the flame starting system (16) | Only for vehicles with code (M89) Flame starting system (FLA) | |
6 | Detach fuel line (15) and flame starting system (16) from charge air housing (3) | Only for vehicles with code (M89) Flame starting system (FLA) | |
Do not disconnect fuel line (15). | |||
Installation: Install new seal | |||
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7 | Detach mounting plate with hydraulic lines and clamps of hydraulic lines on engine and tie up to one side | Only on vehicles with code (GS3) "Hydraulic" gearshift. Do not separate hydraulic lines. | |
8 | Disconnect electrical connector (18) on charge air temperature and boost pressure combination sensor (B111) | ||
9 | Remove bracket for the left front steering oil line (12) at the lifting eye | ||
10 | Detach charge air pipe (1) at charge air housing (3) | Only on engine 542.9. | |
Installation: On engine with code (MS4) BlueTec 4 or with code (MS5) BlueTec 5 center the distances between the adapter (10) to the charge air pipe (1) and to the turbocharger. | |||
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11 | Unclip leak fuel lines (9) at the two rear threaded pins or bolts (5) | ||
12 | Remove pneumatic constant throttle solenoid valve (Y1) on charge air housing (3) | Only on vehicles with code (GE7) Mercedes PowerShift 2. | |
13 | Detach charge air housing (3) from the engine and remove seals (6) | For engine 541.9 up to engine end no. 311843 remove both rear threaded bolts. | |
Installation: Check all threaded pins are correctly tightened and tighten if necessary. Pay attention to installation position of seals (6). Check tensioning elements (7) for wear, replace bolts (4, 5, 19) if necessary. Observe installation location of bolts (4, 5, 19). | |||
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| Mounting of charge air housing on engine - altered | Engine 541.9 as of engine end no. 311844 Engine 542.9 as of engine end no. 313193 | |
14 | Remove intermediate piece (10) | Only on engine 541.9. | |
Installation: Check seal rings (11) and replace if necessary. | |||
15 | Remove charge air temperature and boost pressure combination sensor (B111) | Only when replacing the charge air housing (3). | |
Installation: Check sealing ring; replace charge air temperature and boost pressure combination sensor (B111) if necessary. | |||
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16 | Install in the reverse order | ||
Danger! | Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running | Secure vehicle to prevent it from moving by itself. | |
17 | Start engine and afterwards allow the engine to run at alternating rpm. Check charge air housing (3), black charge air hose (13) and red charge air hose (2) for leaktightness, then switch off engine | Visual inspection. |
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, charge air housing to threaded bolt | Nm | 40 | 40 | |
BA09.41-N-1002-01C | Threaded bolt/bolt on cylinder crankcase | Nm | 50 | 50 | |
BA09.41-N-1003-01C | Threaded bolt on 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 bolt/bolt on 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 | |