MR Air Intake Connection

Air Intake Connection Page 1 of 14
010-080 Air Intake Connection
Preparatory Steps
Without EGR
WARNING
Batteries can emit explosive
gases. To reduce the
possibility of personal injury,
always ventilate the
compartment before
servicing the batteries. To
reduce the possibility of
arcing, remove the negative
(-) battery cable first and
attach the negative (-)
battery cable last.
l Disconnect the batteries.

Refer to OEM service
manual.
l Disconnect the cold
starting aid (if equipped).
Refer to Procedure 010-
029 in Section 10.
l Remove the charge-air
piping. Refer to
Procedure 010-019 in
Section 10.
l Remove the air intake
connection adapter (if
applicable). Refer to
Section 10.
With EGR
mk:@MSITStore:C:\Users\jorispc\Downloads\Quick%20Serve%20DVD\MR_D.CHM::/e... 15-Mar-19
WARNING
compartment before
battery cable last.
l Disconnect the batteries.

Refer to The OEM service
manual.
l Disconnect the cold
starting aid (if equipped).
029 in Section 10.
l Remove the charge-air
piping. Refer to
Section 10.
l Remove the air intake
Section 10.
l Use the following
procedure in the ISB,
ISBe2, ISBe3, ISBe4,
QSB4.5, QSB5.9,
QSB6.7, ISC, QSC8.3,
ISL, ISLe3, ISLe4, and
QSL9 CM850 Electronic
Control System
Troubleshooting and
Repair Manual, Bulletin
4021416, to remove the
EGR temperature sensor.
378 in Section 19.
l Use the following
QSB4.5, QSB5.9,

Control System
Troubleshooting and
4021416, to remove the
EGR differential pressure
sensor. Refer to
Section 19.
l Remove the EGR
connection tube. Refer to
Section 11.
l Remove the EGR mixer.
021 in Section 11.
Remove
Automotive and Industrial
Remove the mounting

capscrews, air intake
connection, top gasket, cold
starting aid, and bottom
gasket.
NOTE: Some air intake

connections may not have
an EGR connection as
shown.
NOTE: Be sure not to tape

over all manifold edges so
the mounting surfaces can be
properly cleaned.
Tape off the intake manifold
cover opening or place a clean

rag in the intake to prevent
debris from entering the intake
system.
Marine Applications
Remove the four mounting

capscrews at the intake
manifold.
Loosen the hose clamps.
Remove the front portion of

the connection.
Remove the four mounting

capscrews at the aftercooler
assembly.
Remove the rear portion of

the connection.
Clean and Inspect for Reuse

NOTE: Keep the gasket

material and any other
debris out of the air intake.
Remove old gasket material

from the air intake
connection, cold starting aid
(if equipped), and intake
manifold cover sealing
surface.
Remove the pipe plugs from

the cross-drillings.
NOTE: On engines
equipped with EGR:
l The inside of the air

intake connection may
have a protective
coating. When cleaning
the intake connection,
do not damage this
coating. It protects the
air intake connection
from corrosion.
l A nylon brush is
advised when cleaning
the cross drillings and
the EGR orifice. Avoid
using hard wire
brushes, as the EGR
orifice is a very
sensitive measurement
device.
WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.
WARNING
When using solvents, acids,
or alkaline materials for
cleaning, follow the
manufacturer's
recommendations for use.
Wear goggles and protective
clothing to reduce the
possibility of personal injury.
Saturate the inside of the air

intake connection, the EGR
differential pressure sensor
flow ports, and cross drillings
with safety solvent.
NOTE: Cleaning solvent

needs to be safe for cleaning
aluminum. Mineral based
solvents can be used if
expected results with the
safety solvent are not
acceptable.
Clean out the debris in the

air intake connector with a
non-abrasive brush.
Clean the EGR differential

pressure sensor flow ports
and cross drillings with a
pipe cleaner or similar
device. Be sure to clean the
ports completely prior to
installing the air intake
connection.
Dry the air intake
connection, EGR differential

pressure sensor flow port,
and cross drillings with
compressed air.
Install the pipe plugs in cross

drillings. Use thread sealant
to prevent any leaks.
NOTE: On engines
equipped with EGR, it is
not uncommon to have a
layer of soot and carbon
buildup on the intake
connection inner surfaces.
Remove the tape or rag from

the intake manifold. Inspect
the intake manifold cover,
cold starting aid, and air
intake connection sealing
surfaces for cracks or other
damage.

shown.
Marine Applications
WARNING
When using solvents, acids,
or alkaline materials for
cleaning, follow the
manufacturer's
recommendations for use.
Wear goggles and protective
clothing to reduce the
possibility of personal injury.
WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.
NOTE: Use a rag inside the

intake manifold and the
aftercooler assembly to
prevent gasket material from
entering the engine while
scraping off the gasket
material.
Clean the gasket surfaces of

the aftercooler and intake
manifold.
Clean the connections with

solvent. Dry with compressed
air. Inspect the two air inlet
connections for nicks, burrs, or
other damage.
Inspect the hose connection for

damage or cuts. Replace if
necessary.
Install
INITIAL CHECK: If replacing

the air intake connection on
engines equipped with EGR,
check to make sure the EGR
measurement venturi (1) is
properly installed.
NOTE: The EGR

measurement venturi (1) is
a non-serviceable part.
The air intake connection
must be purchased with
the EGR measurement
venturi pre-installed.
Position the cold starting aid

(if equipped) using new
gaskets. Refer to Procedure
010-029 in Section 10.
Install the air intake

connection and four
mounting screws.
If the engine is equipped

with EGR, leave the four
capscrews loose at this
point. This will help minimize
assembly stress on the
attaching EGR connection
tube to be installed next.
If the engine is not equipped

with EGR, go to the step
referencing tightening the
four capscrews.
If the engine is equipped

with EGR, position the air
intake connection so that the
Marmon™ flange meets the
tube flare connection
correctly.
Install the EGR connection

tube. Refer to Procedure
011-025 in Section 11.
Tighten the V-band clamps.
Torque
Value: 11 n.m [97 in-lb]
Tighten the four capscrews

on the air intake connection.
Torque

shown.
Marine Applications
Install the rear connection on

the aftercooler assembly
with a new gasket and the
four mounting capscrews.
Tighten the capscrews.
Torque
Install the front portion of the

air intake connection and the
four capscrews.
Tighten the capscrews.
Torque
Tighten the hose clamps.
Torque
Finishing Steps
With EGR
WARNING

compartment before
battery cable last.
l Install the EGR mixer.

021 in Section 11.
l Install the EGR
connection tube. Refer to
Section 11.
l Use the following
QSB4.5, QSB5.9,
Control System
Troubleshooting and
4021416, to install the
EGR differential pressure
sensor. Refer to
Section 19.
l Use the following
QSB4.5, QSB5.9,
Control System
Troubleshooting and
4021416, to install the
EGR temperature sensor.
378 in Section 19.
l Install the air intake
Section 10.
l Install the charge-air

piping. Refer to
Section 10.
l Connect the cold starting
aid (if equipped). Refer to
Section 10.
l Connect the batteries.
Refer to the OEM service
manual
l Operate the engine and
check for leaks.
Without EGR
WARNING
compartment before
battery cable last.
l Install the air intake

Section 10.
l Install the charge-air
piping. Refer to
Section 10.
l Connect the cold starting
aid (if equipped). Refer to
Section 10.
l Connect the batteries.
Refer to the OEM service
manual.
l Operate the engine and
check for leaks.
Last Modified: 11-Mar-2013
Copyright © 2000-2010 Cummins Inc. All rights reserved.

MR Air Intake Connection

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Air Intake Connection Page 1 of 14

010-080 Air Intake Connection

l Disconnect the batteries.

l Disconnect the batteries.

QSL9 CM850 Electronic

Remove the mounting

NOTE: Some air intake

NOTE: Be sure not to tape

Tape off the intake manifold

cover opening or place a clean

Remove the four mounting

Loosen the hose clamps.

Remove the front portion of

Remove the four mounting

Remove the rear portion of

Clean and Inspect for Reuse

NOTE: Keep the gasket

Remove old gasket material

Remove the pipe plugs from

l The inside of the air

Saturate the inside of the air

NOTE: Cleaning solvent

Clean out the debris in the

Clean the EGR differential

Dry the air intake

connection, EGR differential

Install the pipe plugs in cross

Remove the tape or rag from

NOTE: Some air intake

NOTE: Use a rag inside the

Clean the gasket surfaces of

Clean the connections with

Inspect the hose connection for

INITIAL CHECK: If replacing

NOTE: The EGR

Position the cold starting aid

Install the air intake

If the engine is equipped

If the engine is not equipped

If the engine is equipped

Install the EGR connection

Tighten the V-band clamps.

Tighten the four capscrews

NOTE: Some air intake

Install the rear connection on

Tighten the capscrews.

Install the front portion of the

Tighten the capscrews.

Tighten the hose clamps.

possibility of personal injury,

l Install the EGR mixer.

l Install the charge-air

l Install the air intake

Last Modified: 11-Mar-2013

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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