Remove/install engine · ar0110w2400c · Mercedes-Benz WIS

AR01.10-W-2400C

Remove/install engine

14.2.12

ENGINES 902.9, 906.9, 926.9 in MODEL 957

W01.10-1056-09

Illustrated on vehicle with code (H03) AC system in front end

1 Coolant hose

2 Hydraulic hose (fan drive)

3 Leak oil hose (fan drive)

4 Charge air pipe (cold air)

5 Coolant hose

6 Coolant pipe

11 Charge air pipe

12 Coolant hose

13 Hydraulic line (fan drive)

14 Hydraulic hose (steering)

15 Hydraulic hose (steering)

16 Hydraulic hose (fan drive)

7 Refrigerant lines (only for vehicles with code (H03) Air conditioning in front end)

8 Charge air hose (red)

9 Charge air hose (black)

10 Charge air pipe

W01.10-1057-09

Illustrated on vehicle with code (H03) AC system in front end

6 Coolant pipe

7 Refrigerant lines 1)

9 Charge air hose (black)

11 Charge air pipe

17 Starter line (circuit 30)

18 Ground cable

19 Wiring harness mount

20 Air intake pipe

G2 ALT

M1 Starter

1) Only on vehicles with code (H03) air conditioning in front end.

21 Poly-V belt

22 Electrical connector 1)

23 Refrigerant compressor 1)

24 Wiring harness electrical connector

25 Electrical line (circuit B2+)

26 Ground cable

W01.10-1058-09

Shown on vehicle with code (H03) air conditioning system at front end and with code (AN8) hydraulically steered leading axle

7 Refrigerant lines 1)

23 Refrigerant compressor 1)

28 Vent line (coolant)

29 Coolant pipe

30 Coolant pipe

31 Hydraulic hoses (fan drive)

32 Coolant line

33 Compressed-air line (compressor)

34 Hydraulic line 2)

35 Hydraulic line 2)

36 Fuel line 3)

37 Fuel line 3)

38 Screw

39 Oil level sensor electrical connector

1) Only on vehicles with code (H03) air conditioning in front end.

2) Only on vehicles with code (AN8) hydraulically steered leading axle or with code (AN9) hydraulically steered trailing axle

3) Only on vehicles without code (MS8) natural gas engine

40 Engine wiring harness electrical connector

41 Electrical connector of vehicle wiring harness

42 Engine wiring harness electrical connector

43 Coolant hose

44 Coolant hose

A6 Engine control (MR) control unit 3)

A85 Gaseous fuel engine (MR) control unit (only on vehicles with code (MS8) natural gas engine)

W01.10-1059-09

31 Hydraulic hoses (fan drive)

33 Compressed-air line (compressor)

34 Hydraulic line 1)

35 Hydraulic line 1)

45 Expansion reservoir (fan drive)

46 Electrical line

47 Heat shield

48 Strut

49 Exhaust pipe

50 Expansion reservoir (coolant)

1) Only on vehicles with code (AN8) hydraulically steered leading axle or with code (AN9) hydraulically steered trailing axle

2) Only on vehicles without code (MS8) natural gas engine

51 Coolant hose

52 Coolant hose

53 Heat shield

54 Gas pressure line (only on vehicles with code (MS8) natural gas engine)

55 Engine brake cylinder 2)

56 Engine brake compressed air line 2)

S122 Hydrostatic cooling system oil level switch

Modification notes

15.12.09

Value changed: nut, electrical line to circuit B2+ ALT

*BA15.40-N-1015-01B

 	Remove/install
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Danger!	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with 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
1.1	Open end cover at fuel tank	Vehicles without code (MS8) Natural gas engine
 Danger!	Risk of explosion caused by escaping natural gas or by overheated compressed-gas tanks when working on natural gas powered vehicles. Risk of frostbite to parts of the body caused by escaping natural gas and by touching components near the valves when emptying compressed-gas tanks. Risk of poisoning or risk of suffocation caused by inhaling natural gas.	Remove any sources of ignition. Ensure that the work area is adequately ventilated. Wear heat protective gloves.	AS00.00-Z-0018-01A
1.2	Close gas shutoff valves at compressed-gas tanks	Vehicles with code (MS8) Natural gas engine	AR47.10-W-0005H
	Notes on work safety regulations for vehicles with natural gas-powered engines		AH00.10-N-1000-04A
 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
2	Start engine and run on idle until the engine goes off by itself	 Only on vehicles with code (MS8) Natural gas engine.
		In this way the residual gas from the lines and components is consumed.
3	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
4	Disconnect ground lead from battery
	Notes on battery		AH54.10-P-0001-01A
 Danger!	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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
5	Drain coolant	Engine 902.9 without code (MS8) Natural gas engine, engine 926.9	AR20.00-W-1142J
		Engine 902.9 with code (MS8) Natural gas engine, engine 906.9	AR20.00-W-1142C
6	Remove RH and LH soundproofing on top frame and underride guard soundproofing on lower frame
7	Drain hydraulic fluid from fan drive	 Installation: Only attach leak oil hose (3) to the hydraulic engine after installing the engine.
	Hydrostatic fan drive - oil and filter change		AP20.40-W-2001A
8	Remove the hydraulic pump or propeller shaft from the rear engine power take-off and paneling over the transmission	 Only on vehicles with code (N52) rear engine power take-off, output torque 600 Nm, or code (NJ9) rear power take-off for hydraulic pump, 200 Nm max.
9	Remove air intake pipe (20)	Engine 902.9, 906.9 with code (MS8) Natural gas engine	AR09.10-W-8131H
		Engine 902.9 without code (MS8) Natural gas engine Engine 926.9	AR09.10-W-8131JB
		Engine 906.9 without code (MS8) Natural gas engine	AR09.10-W-8131B
10	Remove charge air hose (9) and charge air pipe (11) from charge air cooler to charge air manifold	Engine 902.9, 906 with code (MS8) Natural gas engine	AR09.41-W-1311H
		Engine 906.9 without code (MS8) Natural gas engine	AR09.41-W-1311D
		Engine 902.9 without code (MS8) Natural gas engine Engine 926.9	AR09.41-W-1311JD
11	Remove charge air pipe (4)
12	Remove charge air hose (8) and charge air pipe (10) from exhaust gas turbocharger to charge air cooler	Engine 902.9 with code (MS8) Natural gas engine Engine 906.9	AR09.41-W-1311C
		Engine 902.9 without code (MS8) Natural gas engine Engine 926	AR09.41-W-1311JB
13	Disconnect coolant hose (1) from the heater	 Collect coolant that flows out
14	Detach coolant hose (12), remove coolant pipe (6) from oil pan bracket	 Collect coolant that flows out
15	Remove coolant hose (5)	 Collect coolant that flows out
16	Disconnect hydraulic hoses (14, 15) from the steering	 Catch escaping hydraulic fluid.
17	Disconnect hydraulic hose (2)	 Catch escaping hydraulic fluid. Tie leak oil hose (3) to the engine.
18	Disconnect hydraulic hose (16) from hydraulic line (13)	 Catch escaping hydraulic fluid.
19	Swivel tensioning device tensioner pulley upward and remove poly-V belt (21) from the belt pulley of refrigerant compressor (23)	 Only on vehicles with code (H03) Air conditioning in front end.
		 Installation: Inspect condition of poly-V belt (21), replace if necessary.
		Observe poly-V belt (21) routing diagram.	AR13.22-W-3902-02D
	Damage profiles for a poly-V belt		AP13.22-D-1351-01A
Danger!	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with 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
20	Disconnect fuel lines (36, 37) from main fuel filter	 Only on vehicles without code (MS8) Natural gas engine.
		Mark installation position of fuel line (36). Collect escaping fuel and close off the holes.
		 Installation: Note the marking on fuel line (36).
			*BA47.25-N-1008-01J
21	Expose the electrical wiring harness and disconnect electrical connector (22) from refrigerant compressor (23)	 Only on vehicles with code (H03) Air conditioning in front end.
22	Detach refrigerant compressor (23) from the carrier, move forward and tie to the frame	 Only on vehicles with code (H03) Air conditioning in front end. Do not disconnect refrigerant lines (7).
			*BA83.55-N-1001-01C
23	Disconnect engine wiring harness electrical connector (40) and vehicle wiring harness electrical connector (41) from engine control (MR) control unit (A6) or gaseous fuel engine (MR) control unit (A85)	 Push vehicle electrical wiring harness to one side.
24	Disconnect engine wiring harness electrical connector (42)
25	Disconnect oil level sensor electrical connector (39)
26	Expose electrical line (46) and disconnect from hydrostatic cooling system oil level switch (S122)
27	Disconnect hydraulic hoses (31) and tie to the top of expansion reservoir (45)	 Catch escaping hydraulic fluid.
28	Remove coolant line (32)	 Collect coolant that flows out
29	Disconnect compressed air line (33) from the compressor, from the transmission and from the connecting point, and check it for carbonization	 If carbon deposits are present, it is also necessary to inspect the compressed-air line between the compressor and compressed-air drier and the four-circuit protection valve. Replace parts showing carbon deposits.
30	Detach coolant hoses (43, 44) from the bottom of coolant pipes (29, 30) and push back	 Collect coolant that flows out
31	Expose vent line (28) at coolant pipe (30)
32	Detach coolant pipes (29, 30) from the top coolant hoses and from the brackets, and remove	 Collect coolant that flows out
33	Disconnect coolant hoses (51, 52) from expansion reservoir (50)	 Collect coolant that flows out
34	Remove gas pressure line (54) from the bracket and detach from the charge air manifold fitting	 Only on vehicles with code (MS8) Natural gas engine.
		Counterhold charge air manifold fitting when detaching gas pressure line (54).
		 Installation: Use a check gauge when tightening the gas pressure line (54).
	Note on threaded pipe connections of gas pressure lines		AH47.25-N-0001-01A
35	Detach engine brake compressed air line (56) from engine brake cylinder (55)	 Only on vehicles without code (MS8) Natural gas engine.
Danger!	Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue	Only pour AdBlue into suitable containers. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.	AS14.40-Z-0001-01A
36	Remove hose and line connections from the exhaust aftertreatment system	 Only for vehicles with code (MS4) BlueTec 4 or with code (MS5) BlueTec 5.	AR14.40-W-2010-01A
			*BA00.18-N-1003-01A
	Notes on use, material properties and handling of AdBlue®		AH14.40-N-0001-01A
37	Remove strut (48) with heat shield (47)
38	Remove heat shield (53) from engine brake valve fitting or from exhaust fitting and exhaust pipe (49)
39	Remove exhaust pipe (49)		AR49.10-W-5530E
40	Detach hydraulic lines (34, 35) from the transmission and disconnect them	 Only on vehicles with code (AN8) Hydraulically steered leading axle or with code (AN9) hydraulically steered trailing axle. Collect escaping hydraulic oil.
41	Detach electrical line (circuit B2+) (25) and ground line (26) from alternator (G2)		*BA15.40-N-1009-01B
			*BA15.40-N-1015-01B
42	Remove cable tie and detach wiring harness electrical connector (24) from alternator (G2)	 Installation: Secure retaining clip on wiring harness electrical connector (24) with a cable tie.
43	Detach starter line (circuit 30) (17) from starter (M1)		*BA15.30-N-1002-01B
44	Disconnect ground cables (18) at timing case
45	Detach starter line (circuit 30) (17), ground lines (18) and electrical wiring harness from wiring harness bracket (19)
46	Remove bolt (38) on the left and right engine mount		*BA22.10-N-1002-01B
47	Drain transmission oil	Only on vehicles with automatic transmission 723.
	Automatic transmission - oil and filter change		AP27.00-W-2702A
48.1	Separate engine from the automatic transmission and lift out	Vehicles with automatic transmission	AR01.10-W-2400-01D
			*BA01.60-N-1002-01A
			*BA01.60-N-1003-01A
			*BA22.10-N-1005-01B
			*BA27.10-N-1003-04D
			*BA27.10-N-1004-04D
			*BA27.10-N-1005-04D
			*904589046300
48.2	Disconnect engine from manual transmission and lift out	Vehicles with manual transmission	AR01.10-W-2400-01DA
			*BA01.60-N-1002-01A
			*BA01.60-N-1003-01A
			*BA22.10-N-1005-01B
			*BA25.20-N-1001-01J
			*BA25.20-N-1003-01J
			*BA25.20-N-1010-01J
			*BA26.10-N-1001-01C
			*904589046300
		Long-life grease	*BR00.45-Z-1001-06A
49	Check both engine mounts for wear	 Installation: If necessary, replace engine mount.
			*BA22.10-N-1005-01B
50	Install in the reverse order
51	Re-teach in transponder keys (also replacement keys)	 Only if a reconditioned engine is installed.	AR80.57-W-0010C
52	Check the engine oil level on the display or using the oil dipstick, and adjust if necessary	 Observe engine oil grade set in maintenance system or Specifications for Operating Fluids.
	Notes on engine oil		AH18.00-N-0101-01B
 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
53	Start engine and allow to run in idle for 10 s until the oil pressure has built up, then run the engine at varying speeds	Crank engine with the starter for not more than 90 seconds. The fuel system is ventilated automatically. If the engine stops or does not start, repeat starting procedure after a break of 2 minutes.
54	Bleed steering system	Steering system 765.82	AR46.25-W-3300C
		Steering 765.88/89	AR46.25-W-3300A
55	Switch off engine and check for leaks	 Visual inspection.
56	Synchronize the time of the tachograph disk record	 Only on vehicles with MTCO tachograph.
57	Enter engine number in VeDoc screen 1111	 Only if a reconditioned engine is installed.
58	Check the gas system for leaktightness in accordance with the national regulations	 Only on vehicles with code (MS8) Natural gas engine.
		In Germany the GAP should be performed according to §41a of the German vehicle licensing regulations.

 Compressed air lines

Number	Designation			Model 930, 932, 933, 934, 950, 952, 953, 954, 957, 958


BA00.18-N-1003-01A	Compressed air connection system SCHÄFER "SDF" in metallic material	M101	Nm	5

 Timing case

Number	Designation		Engines 900.9, 902.9, 904.9, 906.9	Engine 924.9, 925.9, 926.9


BA01.60-N-1002-01A	Inspection hole closure cover on timing case	Nm	25	25
BA01.60-N-1003-01A	Bolt, turning device to timing case	Nm	25	25

 Starter

Number	Designation		Engines 900.9, 902.9, 904.9, 906.9	Engine 924.9, 925.9, 926.9


BA15.30-N-1002-01B	Nut, circuit 30 to starter	Nm	30	30

 Alternator

Number	Designation		Engines 904.9, 906.9 as of end no. 190708, Engine 900.9, 902.9	Engine 924.9, 925.9, 926.9


BA15.40-N-1009-01B	Bolt, ground line to alternator	Nm	12	12
BA15.40-N-1015-01B	Nut, electrical line to alternator circuit B2+	Nm	30	30

 Engine mounts, engine supports

Number	Designation		Engine 902.9, 906.9, 926.9 in model 957


BA22.10-N-1002-01B	Bolt, engine carrier to engine mount	Nm	260
BA22.10-N-1005-01B	Bolt, engine mount to frame	Nm	175

 Clutch booster

Number	Designation		Model 950, 952, 953, 954, 957


BA25.20-N-1001-01J	Bolt, clutch booster to transmission housing	Nm	50
BA25.20-N-1003-01J	Banjo bolt (compressed-air line) on clutch booster	Nm	40
BA25.20-N-1010-01J	Union nut (compressed-air line) on clutch booster	Nm	40

 Complete manual transmission

Number	Designation		Trans-mission 715.500/ 507/510/ 513/517/ 520/527/ 540/561/ 567/568


BA26.10-N-1001-01C	Transmission on flywheel housing	Nm	50

 Automatic transmission complete

Number	Designation		Transmission 723.6


BA27.10-N-1003-04D	Bolt, automatic transmission to crankcase	Nm	40
BA27.10-N-1004-04D	Bolt, cover plate for PTO to transmission	Nm	55
BA27.10-N-1005-04D	Bolt, torque converter to driven plate	Nm	65

 Fuel pipes/hoses

Number	Designation		Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9


BA47.25-N-1008-01J	Nut, feed and return line to fuel filter	Nm	45

 Refrigerant compressor

Number	Designation		Model 374.5, 375.1, 375.3, 949, 950.5, 950.6, 952.5, 952.6, 953.6, 954.5, 957, 958.0, 958.2, 970, 972, 974, 975, 976


BA83.55-N-1001-01C	Bolt, refrigerant compressor/bracket	Nm	25

Cranking device

904 589 04 63 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51 11

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