Disconnect/connect hose and line connections

AR01.10-D-2400-02SE

Disconnect/connect hose and line connections

Engine

642.896 in model 906

with code MJ7 (ECO start/stop function)

Engine

642.896 in model 906

with code MJ8 (ECO start/stop function)

Modification notes

29.10.2014

High pressure expansion hose to power steering pump

MODEL 906 with ENGINE 642

BA46.30-N-1003-01A

 Sensors, transmitters

Number

Designation

Engine 642

BA07.04-N-1002-01G

Temperature sensor to diesel particulate filter

Nm

45

 Sensors, transmitters

Number

Designation

Engine 642

BA07.04-N-1014-01G

NOx sensor downstream of diesel particulate filter

Nm

60

 Diesel particulate filter

Number

Designation

Engine 642.896 in model 906

BA14.40-N-1002-01B

Screw/bolt, clamping plates of pressure lines

Nm

10

 Diesel particulate filter

Number

Designation

Engine 642.896 in model 906

BA14.40-N-1010-01B

Union nut, pressure line to catalytic converter with diesel particulate filter

Nm

45

 Power steering pump

Number

Designation

Model 906 with engine 642

BA46.30-N-1003-01A

High pressure expansion hose to power steering pump

–

Nm

38

VDA pump

Nm

–

VT pump

Nm

–

 Pulse generator

Number

Designation

Model 906 with engine 642

BA54.00-N-1003-01A

Bolt, vehicle speed sensor to transmission housing

Nm

10

 Battery

Number

Designation

Model 906 with code MJ7 (ECO start/stop function)

Model 906 with code MJ8 (ECO start/stop function)

BA54.10-N-1001-01G

Nut, circuit 30 to connection for battery box

M8

Nm

16

16

 Battery

Number

Designation

Model 906 with code MJ7 (ECO start/stop function)

Model 906 with code MJ8 (ECO start/stop function)

BA54.10-N-1002-01G

Nut, circuit 30 to connection for connecting point

M8

Nm

16

16

 Air conditioning

Number

Designation

Model 906, 909 with code HH9

BA83.30-N-1010-01F

Bolt, refrigerant line to refrigerant compressor

Nm

22

Repair materials

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DBL 6879.20

A 000 989 76 51

1

Remove cap (32).

2

Engine 642.896 in model 906
with code LG1 (Bi-xenon headlamps with cornering function)
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906
with code LG1 (Bi-xenon headlamps with cornering function)
with code MJ8 (ECO start/stop function)
Detach electrical connection (2) and electrical line from electrical line (3).

3

Unscrew nut (1) and place electrical line (3) to one side  .

4

Detach cover (4).

5

Remove nut (5) and remove electrical lines,  .

6

Mark fuel hoses (10, 11) relative to the fuel lines (12, 13), disconnect and close off using suitable  stop plugs.

 Collect escaping fuel in a suitable container.

7

Engine 642.896 in model 906 with transmission 711
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711
with code MJ8 (ECO start/stop function)
Pull out securing clamp (7).

8

Engine 642.896 in model 906 with transmission 711
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711
with code MJ8 (ECO start/stop function)
Pull clutch line (9) out of central clutch release bearing (8) and close off using suitable  stop plugs.

Shown on transmission 711

9

Engine 642.896 in model 906 with transmission 711
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711
with code MJ8 (ECO start/stop function)
Disconnect neutral electrical connection (56).

Shown on transmission 711

10

Remove temperature sensor (51),  .

 Installation: Coat thread of temperature sensor (51) with hot lubrication paste.

11

Detach pressure lines (52) from diesel particulate filter (50)  .

12

Remove NOx sensor (53)  .

13

Detach retaining clamp (54) from pressure lines (52),  .

14

Detach retaining clamp (55) from pressure lines (52),  .

15

Engine 642.896 in model 906 with transmission 722
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722
with code MJ8 (ECO start/stop function)
Detach heat shield (17).

16

Engine 642.896 in model 906 with transmission 722
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722
with code MJ8 (ECO start/stop function)
Disconnect electrical connection (18).

17

Engine 642.896 in model 906 with transmission 722
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722
with code MJ8 (ECO start/stop function)
Disconnect electrical connection (16) from electrical auxiliary oil pump and expose electrical line (19) and detach electrical line from transmission (14).

Shown on transmission 722

18

Engine 642.896 in model 906
with code J19 (Tachograph 1 day/2 drivers automatic (CM))
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906
with code J19 (Tachograph 1 day/2 drivers automatic (CM))
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906
with code JD1 (Digital tachograph)
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906
with code JD1 (Digital tachograph)
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906
with code JD2 (Tachograph digital EC with rpm + aux-recorder)
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906
with code JD2 (Tachograph digital EC with rpm + aux-recorder)
with code MJ8 (ECO start/stop function)
Remove lead seal (15).

 Installation: Fit a new lead seal (15).

19

Remove speed sensor (40) from transmission (14) and lay down to side with electrical wiring harness connected,  .

Shown on transmission 722

20

Engine 642.896 in model 906
with code MJ7 (ECO start/stop function)
with code ZG1 (Engageable all-wheel drive)
Engine 642.896 in model 906
with code MJ7 (ECO start/stop function)
with code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.896 in model 906
with code MJ8 (ECO start/stop function)
with code ZG1 (Engageable all-wheel drive)
Engine 642.896 in model 906
with code MJ8 (ECO start/stop function)
with code ZG3 (Engageable all-wheel drive with gear reduction)
Disconnect electrical connections (61, 62) on transfer case (60).

Shown on transmission 711

21

Remove cable tie (64).

22

Disconnect electrical connection on oxygen sensor (B85/3x1) and expose electrical line (65) to oxygen sensor.

23

Remove vacuum hose (22) from aneroid capsule (21).

24

Remove vacuum line (29) at vacuum pump (30).

Shown on model 906.111

25

Engine 642.896 in model 906 with transmission 722.9
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ8 (ECO start/stop function)
Open brackets (35), unclip automatic oil lines (36) and fasten to engine with cable tie.

Shown on model 906.111

26

Remove ground line (23) on longitudinal member (24).

 Installation: The connection for ground line (23) on the longitudinal member (24) must be free of paint, dirt or corrosion.

27

Open cable tie and expose engine wiring harness (25) in engine compartment.

28

Disconnect electrical connections (26, 27).

29

Unlock electrical connection (28) and detach from CDI control unit (N330).

30

Fasten engine wiring harness (25) to engine with cable tie.

Shown on model 906.111

31

Remove high-pressure line (37) at power steering pump (38)  .

 Installation: Replace sealing ring.

 Collect hydraulic oil running out in suitable container. Seal openings with suitable  stop plug.

32

Engine 642.896 in model 906
with code HH9 (Air conditioner, automatic heater control)
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906
with code HH9 (Air conditioner, automatic heater control)
with code MJ8 (ECO start/stop function)
Remove screw/bolts (41, 42), remove refrigerant lines (39, 40) from A/C compressor (A9) and plug openings with suitable  stop plugs  .

 Installation: Install new sealing rings.

33

Connect in reverse order.