Remove/install 2-cylinder compressor

AR13.30-G-0002US

Remove/install 2-cylinder compressor

14.02.2020

Engine

936.97 in model 405

Modification notes

13.02.2020

Check gearwheel (11) for damage and wear, added.

Operation step 19

13.02.2020

Check counter gear of the gearwheel (11) in the timing case for damage, added.

Operation step 20

1

Resonator

2

Air intake line

3

Coolant lines

4

Compressor

5

Hydraulic line

6

Compressed-air line

7

Bracket

4

Compressor

11

Gear

12

O-ring

13

O-ring

15

Fitting

16

Fitting

 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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Drain off coolant.



AP20.00-G-2080U

2

Tilt cab to repair position.

AR60.80-G-0005B

 Installation: Only tilt back cab after the leak test.

3

Remove ground line of battery.

AR54.10-G-0003UG

4

Remove the resonator box (1).

AR13.10-G-5840US

5

Remove the air intake line (2).

 Installation: Check sealing rings on the air intake duct (2) for damage.

If problems exist,



Replace sealing rings on the air intake duct (2).

6

Seal connection fitting of the air intake line (2) on the compressor (4) with a suitable stop plug.

 Plug

*963589019100

7

Remove power steering pump.

AR46.30-G-0500US

 Installation: Only purge steering equipment after pouring in the coolant.

8

Completely remove hydraulic line (5) of the clutch operation and capture escaping brake fluid.

 Installation: Check sealing rings on the hydraulic line (5) for damage.

If problems exist,



Replace sealing rings on the hydraulic line (5).

9

Seal connection fittings of the hydraulic line (5) with suitable stop plugs.

 Record plug

*129589009100

10

Remove compressed-air line (6) between the compressor (4) and the first separating point.

 Installation: Check compressed-air line (6) for carbonization.

If problems exist,



replace the compressed air line (6) and all carbonized parts.

 Union nut, compressed air line to compressor fitting

*BA13.30-N-1008-01P

11

Seal connection fitting of the compressed-air line (6) on the compressor (4) with a suitable stop plug.

 Plug

*963589019100

12

Release coolant lines (3) from the compressor (4), remove, and capture escaping coolant.

13

Remove the bracket (7).

 Bolt, compressor bracket to crankcase

*BA13.30-N-1010-01P

 Bolt, bracket to compressor

*BA13.30-N-1011-01P

14

Remove screws of the compressor (4) from the timing case.

 The compressor (4) is fastened with four screws on the timing case.
First remove the rear upper screw/bolt.

 Bolt, compressor to timing case

*BA13.30-N-1001-01P

15

Remove compressor (4) and collect escaping engine oil.

 Installation: First insert the rear upper screw/bolt in the bore on the compressor (4), then place the compressor (4) on the timing case.
If necessary, turn the gear (11) of the compressor (4).

16

Remove O-rings (12, 13) from the compressor (4).

 Installation: Install new O-rings (12, 13).

17

Remove the fitting of the compressed-air line (6) from the compressor (4).

Only if compressor (4) was replaced or fitting of air line (6) is leaky.

 Fitting to compressor

*BA13.30-N-1007-01P

18

Remove fittings (15, 16) from the compressor (4).

Only if the compressor (4) is replaced or the fittings (15, 16) are leaky.

 Fitting, coolant line to compressor

*BA13.30-N-1006-01P



Check

19

Check gearwheel (11) for damage and wear.

If problems exist,



Replace gearwheel (11).

AR13.30-G-7044U

20

Check counter gear of the gearwheel (11) in the timing case for damage.

If problems exist,



replace counter gear.

AR05.10-G-4660U

21

Install in the reverse order.

22

Bleed clutch operating system.



Vehicles without code G48 (Electronic Automated Gearshift (EAS))

AP25.20-G-2981U



Vehicles with code G48 (Electronic Automated Gearshift (EAS))

AP25.20-G-2981UG



Check

23

Check engine oil level on the instrument cluster.



AP18.00-G-0101-07U

If problems exist,



Correct engine oil level .

 Engine oil

*BF18.00-N-1001-01T

24

Start engine and perform an engine test run.

25

Check all connectors and lines on the compressor (4) for leaktightness.

 Visual inspection.

26

Switch off engine.

27

Check/correct coolant level.



AP20.00-G-2010U

 Compressor (compressed air system)

Number

Designation

Engine 936.9

BA13.30-N-1001-01P

Bolt, compressor to timing case

Stage 1

Nm

10

Stage 2

Nm

50

 Compressor (compressed air system)

Number

Designation

Engine 936.9

BA13.30-N-1006-01P

Fitting, coolant line to compressor

M18x1.5

Nm

45

 Compressor (compressed air system)

Number

Designation

Engine 936.9

BA13.30-N-1007-01P

Fitting to compressor

M10x1

Nm

-

M14x1.5

Nm

40

M26x1.5

Nm

75

M36x1.5

Nm

15

 Compressor (compressed air system)

Number

Designation

Engine 936.9

BA13.30-N-1008-01P

Union nut, compressed air line to compressor fitting

Nm

75

 Compressor (compressed air system)

Number

Designation

Engine 936.9

BA13.30-N-1010-01P

Bolt, compressor bracket to crankcase

Nm

30

 Compressor (compressed air system)

Number

Designation

Engine 936.9

BA13.30-N-1011-01P

Bolt, bracket to compressor

Nm

50

 Filling capacities for engine lubrication system

Number

Designation

Engine 936.97

BF18.00-N-1001-01T

Engine oil

Filling capacity with oil filter

Liter

25

Sheet

BB00.40-P-0228-51A