Convert vehicle (installation of low-quality fuel package)

SM00.10-W-0071A

Convert vehicle (installation of low-quality fuel package)

22.06.2020

Model

964 with engine 470.9

German Armed Forces vehicles with code JMAB (Preparation for low-quality fuel package)

Preliminary information

All the vehicle parts removed for replacement during the following operation steps must be stored as specified so that the vehicle can be returned to its original as-built configuration at a later stage if necessary. See associated SI00.10-W-0039A.

1

Exhaust aftertreatment unit

4

Rear fender section

A67

AdBlue® metering device

2

Connector

5

Muffler

A

Removed exhaust gas aftertreatment unit

3

Flexible exhaust pipe (new)

A60

Exhaust aftertreatment (ACM) control unit

B

Vehicle after conversion

6

Exhaust gas recirculation line

7

Charge air pipe

 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 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 it with the safety strut.

AS60.80-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Topical note

Assembly notes for flexible exhaust pipes

AH49.10-N-0302-01H

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Remove/modify parts of exhaust system

1

Switch off ignition.

2

Tilt cab.

3

Drain coolant at radiator.



AR20.00-W-1142H

4

Remove rear fender section (4).

5

Remove flexible exhaust pipe and exhaust gas aftertreatment unit (1).



Vehicles with code M5C (Euro VI, D engine version)

AR49.20-W-3000HB

 The exhaust gas aftertreatment unit (1) and the flexible exhaust pipe are replaced. Disconnect AdBlue®  lines from AdBlue® metering device because the latter remains on the exhaust gas aftertreatment unit (1).
Seal connections of AdBlue®  lines on AdBlue®  metering device using stop plugs provided for this. Seal electrical connections on exhaust gas aftertreatment unit (1) with blind caps provided for this purpose. Seal inlet and outlet pipe against ingress of dirt, objects etc. using suitable measures.

6

Convert parts of exhaust system or exhaust gas aftertreatment system.

SM00.10-W-0071-01A

 The heat shields on the muffler and on the tailpipe must be painted in the following color before installation: Code 6431, designation: bronze green, dull mate.

 Holder, muffler to frame mounting support

*BA49.10-N-1037-02A

 Carrier to muffler

*BA49.10-N-1038-02A

 Tailpipe to muffler

*BA49.10-N-1039-02A

 Muffler mounting support to frame

*BA49.10-N-1041-02A

7

Install rear fender section (4).

Convert AdBlue®  components

8

Convert AdBlue®  components.

SM00.10-W-0071-02A

 Before conversion, remove AdBlue®  deposits from AdBlue® line system by flushing with water.

 Pump module on bracket

*BA14.40-N-1015-02I

Convert engine components

9

Remove fuel filter module.



AR47.20-W-5511HA

 The fuel filter module is only removed in order to route a condensation line in a later operation step. It is then reinstalled.

10

Replace charge air pipe (7) and exhaust gas recirculation line (6).



AR09.41-W-1327H

 The charge air pipe (7) to be installed has a condensation outlet.

11

Convert engine components.

SM00.10-W-0071-03A

 Clamp, condensation line to crankcase

*BA01.40-N-1010-02A

 Condensation line holder to crankcase

*BA01.40-N-1011-02A

 Clamp, condensation line to holder

*BA01.40-N-1012-02A

 Clamp, condensation line to timing case

*BA01.60-N-1011-01N

 Threaded fitting for condensation line to charge air pipe

*BA09.41-N-1018-01P

 Condensation line to charge air pipe threaded fitting

*BA09.41-N-1019-01P

 Threaded fitting for condensation line to exhaust pipe

*BA49.10-N-1034-02A

 Condensation line to exhaust pipe threaded fitting

*BA49.10-N-1035-02A

 Cap to exhaust pipe

*BA49.10-N-1036-02A

12

Install fuel filter module.



AR47.20-W-5511HA

13

Fill in coolant.



AR20.00-W-1142H

14

Tilt back cab.

Software revision

15

Perform software change in various control units.

SM00.10-W-0077A

 The installation of the low-quality fuel package consists of a software change in various control units in addition to the mechanical modifications. The changes are completely menu-assisted.

VeDoc documentation

16

Document conversion in VeDoc.

SM00.10-W-0007-02G

Marking

17

Change engine type plate and vehicle identification plate.

SM00.10-W-0034B

Certification

18

Print out and sign manufacturer certificate.

 The signed manufacturer certificate must be enclosed with the vehicle.

 Crankcase, end cover

Number

Designation

Engine 470.9

BA01.40-N-1010-02A

Clamp, condensation line to crankcase

Nm

30

 Crankcase, end cover

Number

Designation

Engine 470.9

BA01.40-N-1011-02A

Condensation line holder to crankcase

Nm

30

 Crankcase, end cover

Number

Designation

Engine 470.9

BA01.40-N-1012-02A

Clamp, condensation line to holder

Nm

30

 Timing case

Number

Designation

Engine 470.9, 471.9

BA01.60-N-1011-01N

Clamp, condensation line to timing case

Nm

30

 Charge air pipe/charge air cooling

Number

Designation

Engine 470.9

BA09.41-N-1018-01P

Threaded fitting for condensation line to charge air pipe

Nm

22

 Charge air pipe/charge air cooling

Number

Designation

Engine 470.9

BA09.41-N-1019-01P

Condensation line to charge air pipe threaded fitting

Nm

17

 Exhaust aftertreatment, BlueTec®

Number

Designation

Engine 470.9, 471.9, 473.9

BA14.40-N-1015-02I

Pump module on bracket

Nm

60

 Exhaust system

Number

Designation

Engine 470.9, 471.9

BA49.10-N-1034-02A

Threaded fitting for condensation line to exhaust pipe

Nm

22

 Exhaust system

Number

Designation

Engine 470.9, 471.9

BA49.10-N-1035-02A

Condensation line to exhaust pipe threaded fitting

Nm

17

 Exhaust system

Number

Designation

Engine 470.9, 471.9

BA49.10-N-1036-02A

Cap to exhaust pipe

Nm

30

 Exhaust system

Number

Designation

Engine 470.9, 471.9

BA49.10-N-1037-02A

Holder, muffler to frame mounting support

Nm

150

 Exhaust system

Number

Designation

Engine 470.9, 471.9

BA49.10-N-1038-02A

Carrier to muffler

Nm

150

 Exhaust system

Number

Designation

Engine 470.9, 471.9

BA49.10-N-1039-02A

Tailpipe to muffler

Nm

50

 Exhaust system

Number

Designation

Engine 470.9, 471.9

BA49.10-N-1041-02A

Muffler mounting support to frame

Nm

225

Parts ordering note

Part no.

Designation

Quantity

Software and VeDoc change

A 000 827 98 59

DVD (must be ordered to make code entry in VeDoc)

1

A 058 448 66 35

MCM data record (service data record)

1

Parts scopes for exhaust system

A 960 490 76 20

Front exhaust gas line ZB

1

A 960 491 32 15

Mounting support

1

N 000 000 005 514

Hexagon head bolt MBN 10105 M14x1.5x40-10.9 DB supply specification 9440.89

1

N 000 000 005 514

Hexagon head bolt MBN 10105 M14x1.5x40-10.9 DB supply specification 9440.89

1

N 000 000 005 536

Hexagon head bolt MBN 10105 M16x1.5x60-10.9 DB supply specification 9440.89

2

N 000 000 005 542

Hexagon head bolt MBN 10105 M16x1.5x60-10.9 DB supply specification 9440.89

1

A 005 990 78 50

Nut with flange M16

3

A 002 990 75 50

Nut with collar

1

A 002 990 75 50

Nut with collar

1

A 960 491 09 42

EATU holder

1

A 960 491 23 18

Shim plate

1

N 910 105 014 013

Hexagon head bolt MBN 10105 M14x1.5x35-10.9 DB supply specification 9440.40

1

N 910 105 014 013

Hexagon head bolt MBN 10105 M14x1.5x35-10.9 DB supply specification 9440.40

1

A 960 491 24 41

Front bracket

1

N 000 000 005 514

Hexagon head bolt MBN 10105 M14x1.5x40-10.9 DB supply specification 9440.89

4

A 961 490 09 35

Tailpipe (ADR version)

1

A 002 990 75 50

Hexagon nut with collar

1

A 003 995 73 02

Clip

1

N 000 000 005 519

Nut MBN 10105 M14x1.5x35-10.9 DB supply specification 9440.89

1

N 910 105 010 011

Nut MBN 10105 M10x40-10.9 DBL9440.40

1

N 913 023 010 002

Nut N13023 M10-10 DB supply specification 9440.40

1

A 961 492 58 88

Shield

1

A 004 994 19 45

Spring nut

4

N 000 000 006 721

Hexalobular bolt MBN 10228 M8x16-8.8 DB supply specification 9440.47

4

A 961 492 73 88

EURO 3 side shield

1

A 004 994 19 45

Spring nut

4

N 000 000 006 721

Hexalobular bolt MBN 10228 M8x16-8.8 DB supply specification 9440.47

4

A 960 490 57 30

ENDR. GGVS shield ZB Cover

1

N 000 000 006 720

Hexalobular bolt MBN 10228 M8x12-8.8 DB supply specification 9440.47

9

A 003 995 73 02

Clip

1

N 910 105 010 011

Nut MBN 10105 M10x40-10.9 DBL9440.40

1

N 913 023 010 002

Nut N13023 M10-10 DB supply specification 9440.40

1

A 960 490 04 01

EURO 3 muffler

1

A 021 990 01 01

Hexagon bolt with flange

4

A 002 997 58 90

Cable tie

30

A 002 997 24 90

Cable tie

30

A 663 470 63 24

dia16 ADBLUE HOSE ZB

1

A 663 470 62 24

dia10 ADBLUE HOSE ZB

1

A 002 997 95 70

CONNECTION FITTING/CONNECTION SPIGOT 1/4" PA

1

A 000 995 62 35

HOSE CLAMP

2

A 967 997 00 90

PIPE/HOSE CONNECTOR

2

A 005 997 67 89

Plug connection

2

A 967 997 09 89

Plug-in connector

1

A 930 476 00 01

dia16 AdBlue®  MOLDED HOSE

0,2m

A 967 476 05 01

dia10 AdBlue®  MOLDED HOSE

0,2m

A 663 491 66 41

SUPPLY UNIT HOLDER

1

A 000 540 08 92

BLIND CAP (small) LU

1

A 057 545 12 28

21-pin pin housing (plug, large plug of exhaust box)

1

A 000 545 62 80 (TB A 000 545 27 39)

Blind plug for 21-pin socket housing

21

A 000 540 01 92 (TB A 000 540 04 92)

Blind cap (plug, small electrical connection on MCS exhaust box)

1

A 000 998 61 21

Cover cap (plug, large electrical connection on MCS exhaust box)

1

A 663 998 00 50

Stop plug Ø6x20 SWB 00017 (plug, AdBlue®  line on MCS exhaust box)

1

A 663 998 01 50

Stop plug Ø8x20 SWB 00018 (plug, AdBlue® line on MCS exhaust box)

1

Engine scopes

N 916 016 006 202

Clamp N 16016-B RSGU 6/ 20

2

N 910 105 008 011

Screw MBN 10105-M 8X 20- 10.9 DBL9440.40

2

A 470 140 45 08

LU Exhaust Gas Line

1

A 007 997 20 71

Stainless steel threaded fitting

1

A 473 142 00 91

Cover

1

A 472 142 05 80

Metal seal

1

N 000 000 001 067

Seal Ring DIN 7603-A 10 X 16-CU CU/SN12

1

N 910 105 008 005

Screw MBN 10105-M 8X 25- 10.9 DBL9440.40

2

N 000 000 006 235

Union nut (6 mm bore)

2

N 005 401 308 000

Ball D = 8 mm

2

A 470 090 18 37

LU Charge Air Pipe

1

A 470 140 63 08

LU Exhaust Gas Line

1

A 470 140 35 40

Bracket

1

N 916 016 006 202

Clamp N 16016-B RSGU 6/ 20

1

N 910 105 008 008

Screw MBN 10105-M 8X 16-10.9 DBL9440.40

3

A 007 997 20 71

Stainless steel threaded fitting

1

A 473 142 03 80

Seal

1

N 000 000 000 884

Fuel pump screw plug

1

N 000 000 001 067

Fuel pump seal

N 000 000 000 884

Metering device screw plug

2

N 000 000 001 067

Metering device seals

2

A 470 078 10 10

Pressure line (high-pressure pump to rail)

2

A 472 997 19 45

Contoured gasket (high-pressure fuel pump flange)

2

A 017 997 89 45

O-ring (high-pressure fuel pump)

1

A 022 997 25 48

Sealing ring (crankshaft position sensor)

1

A 472 094 00 60

Sealing ring (lines of fuel filter element to high-pressure pump)

8

A 472 094 01 60

Sealing ring (lines of fuel filter element to high-pressure pump)

4

A 936 078 01 80

Sealing ring (lines of fuel filter element to high-pressure pump)

2

A 472 094 00 60

Sealing ring (fuel filter element return lines)

6

A 470 098 01 80

Seal (charge air pipe to manifold)

1

A 472 098 04 80

Seal (charge air pipe to intake connection)

1

A 470 140 53 08

Return line to cooler

1

A 472 098 06 80

Seal (charge air pipe to return line)

1

A 140 832 06 99

O-ring (pressure sensor charge air pipe)

1