Remove/install engine

AR01.10-D-2400D

Remove/install engine

14.2.12

Tightening torques for transmission on engine - added

Operation step 30

2.4.07

Fitting, compressed air line to compressor

*BA13.30-N-1007-01A

 

Remove/install

 Installation

Replace all self-locking nuts and bolts

1

Switch off ignition

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

2

Disconnect the battery



Notes on battery

All models

AH54.10-P-0001-01A

3

Remove service cover

4.1

Remove forked crossmember

Does not apply to AWD vehicles

AR31.00-D-1100D

4.2

Remove front engine support

AWD vehicles

AR22.10-L-4320A

4.3

Remove engine crossmember at rear

AWD vehicles

AR22.10-L-1170A

5

Remove soundproofing panels on oil pan and transmission

 Engine 904.904/908 up to 049131

Installation: Quick-release fittings must latch.

6

Remove radiator

AR20.20-D-3865D

7

Remove air intake hose (5) and charge air pipe (2)

AR09.10-D-8030D

8

Remove charge air pipe (6)

AR09.41-D-1311D

9

Remove coupling jaw crossmember

AR31.00-D-1000D

10

Detach coolant hose (38) at coolant pump

AR20.20-D-7440-03D

11

Detach coolant hose (37) at connection piece of coolant pump

AR20.20-D-7440-02D

12

Disconnect ground cables (13) at timing case

13

Detach compressed air line (14) from engine brake cylinder

 Engines fitted with engine brake.

14

Remove starter (M1)

AR15.30-D-7100D

15

Disconnect wiring harness (10) at alternator (G2) with connection

AR15.40-D-5032-01D

16

Disconnect plug connection for vehicle wiring harness (30) at PLD control unit (A6)

AR07.15-D-1628-01D

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

17

Disconnect fuel line (31) at fuel priming pump and fuel line (32) at the fuel filter

 Collect escaping fuel.

18

Disconnect pressure line for constant throttle

 Engines fitted with constant throttle.

19.1

Detach vacuum line (33) at vacuum pump

 Engines fitted with vacuum pump



*BA43.05-N-1002-01B

19.2

Disconnect lines from compressor

 Engines fitted with compressor

 Connection, compressed air line to compressor.

*BA13.30-N-1007-01A

 Connection, inlet line to compressor.

*BA13.30-N-1008-01A

20

Detach power steering pump (34) at vacuum pump or compressor

 Do not separate hydraulic oil lines. Tie up power steering pump to the side if necessary.

AR46.30-D-0500-02D



*BA46.30-N-1002-01B

21

Disconnect plug connection (23) at reversing lamp switch

AR26.19-D-0001-01D

22

Disconnect plug connection (22) at neutral position switch

AR26.19-D-0001-03D

23

Take off tachometer sensor connection (24) at transmission

 Installation: Replace sealing.

AR26.19-D-0001-04D

24

Detach clutch slave cylinder (28) at transmission

AR25.20-D-0150-01D



*BA25.20-N-1002-01E

25

Take off propeller shaft (25) at transmission

AR41.10-D-0050-14D



*BA41.10-N-1001-01D

26

Remove exhaust pipe (17)

AR49.10-D-7140-01D

27

Take off shift lever (18)

AR26.60-D-0610-11D

28

Detach transmission bearing bracket at transmission; unscrew bolts (15) for this step

AR26.10-D-0020-01D



*BA26.10-N-1001-01B

29

Remove engine (1) together with engine supporting arm (39)

AR01.10-D-2400-01D

Shackle, DIN 82101

Engine supporting arm

30

Disconnect engine (1) from transmission

 Place down engine and transmission securely after lifting out.

 With transmission 710.640

*BA26.10-N-1003-01B

 With transmission 715.051

*BA26.10-N-1006-01C

31

Install in the reverse order

32

Re-teach in transponder keys (also replacement keys)

 Only if a reconditioned engine or a new MR/PLD control unit is fitted.

AR80.57-L-0010A

33

Inspect engine oil level and adjust to correct level if necessary

See owner's manual

34

Check coolant level and adjust to correct level, if necessary

AP20.00-D-2080A

 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.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

35

Start engine

 Do not rev up engine as long as no oil pressure is indicated.

*BE18.00-N-1001-01C

 The oil pressure gage must indicate oil pressure after about 10 seconds.

36

Turn off engine

37

Check engine, cooling system and steering hydraulics for leaks

 Visual inspection.

38

Set time on tachograph

39

Enter engine number in FDOK "Screen 1111"

 Only if a reconditioned engine is installed.

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BE18.00-N-1001-01C

Engine oil pressure at

Idling speed

bar

0.5

maximum speed

bar

2.5

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BA13.30-N-1007-01A

Fitting, compressed air line to compressor

Nm

90

BA13.30-N-1008-01A

Fitting, suction line to compressor

Nm

100

Number

Designation

Engine
904.908
with transmission
710.64

Engine
904.9
with transmission
715.051

BA25.20-N-1002-01E

Clutch slave cylinder on transmission

Nm

25

25

Number

Designation

Trans-mission 710.640

BA26.10-N-1001-01B

Transmission bearing bracket on transmission

Nm

96

BA26.10-N-1003-01B

Transmission to engine

Nm

50

Number

Designation

Trans-mission 715.051

BA26.10-N-1006-01C

Transmission to engine

Nm

50

Number

Designation

Model
667

Model
668.3, 670

BA41.10-N-1001-01D

Propeller shaft on transmission

M101

Nm

62

62

M121.5

Nm

-

100

Number

Designation

Model
668, 670
with engine 904.908/
923

BA43.05-N-1002-01B

Vacuum line on vacuum pump

Nm

30 X

Number

Designation

Steering
765.8, 766.4
with engine
900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9

BA46.30-N-1002-01B

Screw/bolt, power steering pump to vacuum pump

Nm

40