Remove/install engine

AR01.10-W-2400D

Remove/install engine

02.08.2017

Engine

904.9 in model 375, 673, 674, 676, 958, 970, 972, 975, 976

Engine

906.9 in model 958, 970, 972, 974, 975, 976

Modification notes

02.08.2017

Reference links to bleed steering, updated.

Operation step 45

Shown on engine 904.9

1

Cap (only for engine 904.9)

7

Shift rod (for code GS1 ("mechanical" transmission) only)

13

Fuel feed line

2

Clutch compressed air line (only for engine 904.9)

8

Wiring harness

14

Return fuel line

3

Compressed air line plug (only for engine 904.9)

9

Electrical connector

15

Filler pipe

4

Load tilter

10

Engine mount

16

Refrigerant compressor (only for vehicles with code H03 (Air conditioning system in front-end assembly))

5

Chain hoist

11

Steering suction line

6

Compressed-air line

12

Steering pressure line

Shown on engine 904.9

22

Exhaust pipe

26

Compressed-air line

G2

Alternator

23

Clip

27

Electrical wiring harness

M1

Starter

24

Air intake hose

28

Terminal 30 cable

25

Electrical wiring harness

29

Ground cable

Shown on engine 906.9

30

Gearshift lever with gearshift linkage (for code GS1 ("mechanical" transmission) only)

31

Bracket

32

Carrier

 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 or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.

Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 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 with the safety strut.

AS60.80-Z-0001-01A

 Danger

Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-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

Disconnect ground line from battery

Model 375, 958, 970, 972, 975, 976

AR54.10-W-0003A

 No repair instructions have been compiled for models 673, 674, and 676.

2.1

Tilt cab using tilting hydraulics

Vehicles with code F30 (tilting hydraulics for cab)

2.2

Tilt cab into repair position

Vehicles without code F30 (Tilting hydraulics for cab)

Model 673, 674, 676

AR60.80-W-0010A

Model 375, 958, 970, 972, 974, 975, 976

AR60.80-W-0010B

3

Remove soundproofing on the left and right on the frame and soundproofing below

4

Remove trim panel above transmission

5

Remove the hydraulic pump or propeller shaft from the engine PTO

For 906.9 engine with codes N52 (PTO at rear, 600 Nm output torque), NJ7 (PTO at rear for hydraulic pump, max. 120 Nm), NJ9 (PTO for hydraulic pump, max. 200 Nm) only

6

Remove charge air pipe of charge air cooler from charge air distributor

Model 375, 958, 970, 972, 974, 975, 976

AR09.41-W-1311D

 No repair instructions have been compiled for models 673, 674, and 676.

7

Remove charge air pipe from ATL to charge air cooler

Model 375, 958, 970, 972, 974, 975, 976.

AR09.41-W-1311C

 No repair instructions have been compiled for models 673, 674, and 676.

8

Remove fan shroud

AR20.40-W-6800A

9

Remove the filler pipe (15) at the oil pan and tie it to one side

 Seal opening at the oil pan.

10

Remove the exhaust pipe (22) at the engine brake flap fitting and transmission, tie the exhaust pipe (22) to the frame

 Installation: Clean sealing surfaces.

11

Check the clamp (23) for wear and replace if necessary

12

Remove the compressed air line (26) from the engine brake cylinder

13

Remove the air intake hose (24) including the hose for crankcase ventilation

14

Remove the electrical wiring harness (27) from the bracket

15

Remove the terminal 30 cable (28) at the starter motor (M1)

 Nut, terminal 30 to starter

*BA15.30-N-1002-01B

16

Remove the electrical wiring harness (25) from the bracket

17

Remove the electrical wiring harness (25) from the alternator (G2)

 Installation: Pay attention to color coding.

 Engines 904.9, 906.9 as of end no. 190708Bolt, ground line to alternator

*BA15.40-N-1009-01B

 Engines 904.9, 906.9 as of end no. 190708Nut, electrical line to alternator terminal B2+

*BA15.40-N-1015-01B

 Engine 904.9, 906.9 up to end no. 190707Nut, electrical line to alternator terminal B+

*BA15.40-N-1010-01B

 Engine 904.9, 906.9 up to end no. 190707Nut, electrical line to alternator terminal W

*BA15.40-N-1011-01B

 Engine 904.9, 906.9 up to end no. 190707Nut, electrical line to circuit B alternator

*BA15.40-N-1012-01B

18

Remove ground line at timing case (29)

19

Remove the electrical wiring harness (27) from the timing case

20

Detach bracket from wiring harness (8) at transmission

21

Unscrew the compressed air line (6) at the compressor and check for carbon deposits

If the compressed-air line (6) is carbonized.



Replace compressed-air line (6). In addition, check compressed-air lines between compressor, compressed-air dryer and four-circuit protection valve.

If compressed-air lines between compressor, compressed-air dryer and four-circuit protection valve are carbonized.



Replace respective compressed-air line.

22

Remove shift rod (7) on gearshift lever

For 906.9 engine with code GS1 ("mechanical" transmission) only

23

Remove the shift lever including shift linkage (30) and bracket (31) from the carrier (32)

For 906.9 engine with code GS1 ("mechanical" transmission) only

24

Remove the hydraulic line brackets for gear shifts from the engine and transmission and tie them to one side

For 906.9 engine with code GS3 ("hydraulic" transmission) only

 Do not separate hydraulic lines.

25

Open cap on fuel tank

26

Disconnect the fuel feed line (13) on the fuel filter

 Collect escaping fuel. Highlight the fuel feed line (13).

 Nut, feed line and return line to fuel filter

*BA47.25-N-1008-01J

27

Disconnect the fuel return line (14) on the fuel filter

 Collect escaping fuel. Highlight the fuel return line (14).

 Nut, feed line and return line to fuel filter

*BA47.25-N-1008-01J

28

Slacken poly-V-belt and remove

For vehicles with code H03 (air conditioning in front-end assembly) only

AR13.22-W-1202A

29

Disconnect the electrical connection for the refrigerant compressor (16)

For vehicles with code H03 (air conditioning in front-end assembly) only

30

Remove the refrigerant compressor (16) including bracket from the engine and tie it to one side

For vehicles with code H03 (air conditioning in front-end assembly) only

 Do not separate refrigerant lines.

 Bolt, refrigerant compressor carrier to crankcase

*BA01.40-N-1005-01C

31

Detach cap (1)

Only for engine 904.9

32

Disconnect the compressed air connector (3) from the compressed air line coupling (2) of the constant throttle

Only for engine 904.9

 Press apart with pliers to disconnect the bracket (arrows).

33

Detach power steering pump and secure to one side with steering pressure line (12) and steering intake line (11) to one side

Exclusively if replacement engine not installed.

 Do not disconnect the steering pressure line (12) and steering intake line (11).
The power steering pump is also supplied when a reconditioned engine is installed.

 Model 375, 958, 970, 972, 974, 975, 976Bolt, power steering pump to compressor

*BA46.30-N-1001-01R

 765.60 steering in model 673, 674, 676Bolt, power steering pump to compressor

*BA46.30-N-1001-01B

34

Disconnect both hoses at steering pressure line (12) and steering intake line (11)

If replacement engine is installed only.

 Collect escaping hydraulic fluid.

 Engine 904.9, 906.9Union nut, oil pressure hose/line to fitting for power steering pump

*BA46.30-N-1002-01R

35

Unlock and disconnect the electrical connectors (9) on the engine control unit (MR)

36

Tie the electrical connectors (9) to one side

37

Support transmission

38

Unscrew the transmission screws on the engine

 Transmission 710Transmission to engine

*BA26.10-N-1003-01B

 712.611 transmissionTransmission to engine

*BA26.10-N-1018-01D

 712.62/63, 715 transmissionTransmission to engine

*BA26.10-N-1006-01C

39

Unscrew bolts at both engine mounts (10)

Check the engine mount (10) for wear.



Replace engine mounts (10) if they are worn.

40

Remove engine with removal fixture

Model 375, 673, 674, 676, 970, 972, 974, 975, 976

AR01.10-W-2400-01B

 No work instructions have been produced for model 958.

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

*BR00.45-Z-1062-06A

41

Install in the reverse order

42

Initialize all transponder keys

Only if a remanufactured engine is installed.

Model 375, 970, 972, 974, 975, 976

AR80.57-W-0010C

 No repair instructions have been compiled for models 958, 676, 674, and 673.

43

Check engine oil level with oil dipstick or on display, add oil if necessary

 Observe engine oil grade set in maintenance system or Specifications for Operating Fluids.

44

Start engine and observe oil pressure indicator with the engine running at idle speed

 Start the engine for a maximum of  90 s using the starter motor. Wait at least for about 2 minutes before repeating attempt at starting. Do not rev up engine before oil pressure is indicated. The oil pressure gage must show an oil pressure after approximately 10 s.

45

Bleed steering system

Only if a remanufactured engine is installed.

ZF 8097 steering

AR46.25-W-3001G

765.6 steering

AR46.25-W-3300D

765.83/84 steering

AR46.25-W-3300C

765.861 steering

AR46.25-W-3300A

46

Turn off engine

47

Check the engine cooling system, fuel system, and steering for leaks

 Visual inspection

48

Set the time and synchronize the tachograph

49

Enter engine number in FDOK "Screen 1111"

Only if a remanufactured engine is installed.

 Cylinder crankcase, timing case cover, end cover

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BA01.40-N-1005-01C

Bolt, refrigerant compressor carrier to crankcase

Nm

55

 Starter

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

BA15.30-N-1002-01B

Nut, terminal 30 to starter

Nm

30

 Alternator

Number

Designation

ENGINE 900.9, 902.9, ENGINE 904.9## ## as of 190708, 906.9## ## as of 190708

BA15.40-N-1009-01B

Bolt, ground line to alternator

Nm

12

 Alternator

Number

Designation

ENGINE 904.9## ## up to 190707, 906.9## ## up to 190707

BA15.40-N-1010-01B

Nut, electrical line to alternator terminal B+

Nm

8

 Alternator

Number

Designation

ENGINE 904.9## ## up to 190707, 906.9## ## up to 190707

BA15.40-N-1011-01B

Nut, electrical line to alternator terminal W

Nm

4

 Alternator

Number

Designation

ENGINE 904.9## ## up to 190707, 906.9## ## up to 190707

BA15.40-N-1012-01B

Nut, electrical line to circuit B alternator

Nm

7

 Alternator

Number

Designation

ENGINE 900.9, 902.9, ENGINE 904.9## ## as of 190708, 906.9## ## as of 190708

BA15.40-N-1015-01B

Nut, electrical line to alternator terminal B2+

Nm

30

 Manual transmission complete

Number

Designation

Transmission 710.60

BA26.10-N-1003-01B

Transmission to engine

Nm

50

 Manual transmission complete

Number

Designation

Transmission 712.62, 715.050

Transmission 715.320

BA26.10-N-1006-01C

Transmission to engine

Nm

50

50

 Manual transmission complete

Number

Designation

Transmission 715.570/576

BA26.10-N-1006-01C

Transmission to engine

Nm

50

 Manual transmission complete

Number

Designation

Transmission 712.611

BA26.10-N-1018-01D

Transmission to engine

Nm

50

 Power steering pump

Number

Designation

Steering gear 765.60 in model 673, 674, 676 with engine 904

BA46.30-N-1001-01B

Bolt, power steering pump to compressor

Nm

40

 Power steering pump

Number

Designation

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

BA46.30-N-1001-01R

Bolt, power steering pump to compressor

Nm

40

 Power steering pump

Number

Designation

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

BA46.30-N-1002-01R

Union nut, oil pressure hose/line to fitting for power steering pump

Nm

60

 Fuel lines/hoses

Number

Designation

Engine 900.9
Engine 902.9
Engine 904.9
Engine 906.9
Engine 924.9
Engine 925.9
Engine 926.9

BA47.25-N-1008-01J

Nut, feed line and return line to fuel filter

Nm

45

Repair materials

Number

Designation

Order number

BR00.45-Z-1062-06A

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

A 001 989 36 51 10