Remove/install engine

AR01.10-W-2400J

Remove/install engine

04.12.2019

Engine

902.9 in model 375, 950, 952, 953, 954

Engine

926.9 in model 950, 952, 953, 954, 958

Modification notes

07.05.2008

Work procedure completely revised.

01.01.1970

Lift out engine with the engine hoist, changed.

Operation step 39

AR01.10-W-2400-01J

Shown on engine 926.9

1

Engine mount

7

Compressed-air line

12

Fuel line (return flow)

2

Engine wiring harness

8

Suction line (steering)

13

Oil filling line

3

Clip

9

Pressure line (steering)

14

Electrical wiring harness (only for vehicles with code H03 (air conditioning in the front-end assembly))

4

Exhaust pipe

10

Power steering pump

15

A/C compressor (only for vehicles with code H03 (air conditioning in the front-end assembly))

5

Manual transmission

11

Fuel line (feed)

16

Coolant pipe

6

Clutch booster (only for attached clutch booster on the manual transmission)

Shown on vehicle with manual transmission

17

Electrical connection1)

22

Ground cable

M1

Starter

18

Air intake pipe

23

Electrical line, terminal 30

X29

Transmission connector

19

Air intake hose

24

Bracket

XM.31

Motor ground point

20

Compressed-air line

B132

SCR air temperature and air humidity combination sensor1)

1)

Only on vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5)

21

Engine brake cylinder

Vehicles with code MS4 (BlueTec 4) or with code MS5 (BlueTec 5)

25

Coolant line

26

AdBlue feed line

27

Compressed-air line

28

Metering device

29

Coolant line

Y107

SCR tank heater solenoid valve

 

Remove/install

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Disconnect electrical engine wiring harness (2) from the cab-chassis connector

Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 926.9 in model 950, 952, 953, 954

AR01.00-W-2410J

 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

2

Tilt cab

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

3

Remove noise encapsulation from the top left and right frame

4

Expose electrical engine wiring harness (2) and connect to the engine

5

Open cap on fuel tank

6

Remove hydraulic-pneumatic power shift (HPS) lines from the engine and tie to one side

AR26.60-W-7260-01J

 Only for vehicles with code GS3 (Gearshift, "hydraulic").
Do not separate hydraulic lines.

7

Remove radiator

Engine 902 except code BA1 (Voith retarder, performance optimized)

AR20.20-W-3865JD

Engine 902 with code BA1 (Voith retarder, performance optimized), engine 926

AR20.20-W-3865J

8

Remove coolant pipes from engine to retarder

AR20.20-W-7450J

 Only for vehicles with code BA1 (performance optimized Voith retarder) or with code BA9 (Voith secondary retarder R 115).

9

Remove coolant pipes from engine to automatic transmission

 Only on vehicles with automatic transmissions.

10

Remove coolant hose from the coolant pump and remove with the coolant pipe (16)

 Installation: Check clamps; replace if necessary.

11

Slacken poly-V-belt and remove

AR13.22-W-1202J

 Only on vehicles with code H03 (Air conditioning in front end).

12

Expose electrical wiring harness (14) and disconnect electrical connector from the A/C compressor (15)

 Only on vehicles with code H03 (Air conditioning in front end).

13

Remove A/C compressor (15) from the engine and fasten to the frame

 Only on vehicles with code H03 (Air conditioning in front end).
Do not separate refrigerant lines.

 Screw/bolt, A/C compressor to carrier

*BA83.55-N-1001-01C

14.1

Remove power-steering pump (10) from the compressor and fasten to the frame

If the engine continues to be used.

 Do not disconnect the suction line (8) and pressure line (9).

 Installation: Align drive of the power-steering pump (10) to the cross plate of the compressor.

 Bolt, power steering pump to compressor

*BA46.30-N-1001-01R

14.2

Disconnect suction line (8) and pressure line (9) of the steering

When installing a new engine.

 Capture hydraulic oil.

 Oil pressure line to power steering pump

*BA46.30-N-1008-01R

 Oil suction line to power steering pump

*BA46.30-N-1009-01R

 Connection fitting to power steering pump

*BA46.30-N-1010-01R

15

Remove cross plate from the power steering pump (10) or from the compressor

Only if the engine continues to be used.

 Installation: Secure cross plate against sliding with long-life grease.

Long-life grease

*BR00.45-Z-1001-06A

16

Remove oil filling line (13) from the oil pan and tie to one side

 Plug openings.

 Installation: Check sealing ring and clamp of the oil filling line (13); replace if necessary.

 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

17

Disconnect fuel lines (11, 12) from the main fuel filter

 Mark installation position of the fuel lines (11, 12). Collect escaping fuel and close off bores.

 Installation: Check O-rings and replace if necessary. Observe marking of fuel lines (11, 12).

 Nut, feed line and return line to fuel filter

*BA47.25-N-1008-01J

18

Remove compressed-air line (7) from the compressor and manual transmission (5) or automatic transmission and check for carbonization

 In the event of carbonization, the compressed-air line (7) must also be checked between the compressor, the compressed-air drier, and the 4-circuit protection valve; replace carbonized parts if necessary.

19

Relieve supply pressure from the compressed-air system and then remove the clutch booster (6) from the manual transmission (5)

Only for vehicles with clutch booster (6) on the manual transmission (5).

 Do not disconnect hydraulic line from the clutch booster (6).

 Installation: Check tappet for damage; replace if necessary.

Long-life grease

*BR00.45-Z-1001-06A

20

Disconnect electrical connector (17) from the SCR air temperature and air humidity combination sensor (B132)

 Only in vehicles with code MS4 (BlueTec 4) or code MS5 (BlueTec 5).

21

Remove air intake pipe (18) with air intake hose (19)

22

Remove compressed-air line (20) from the engine brake cylinder (21) and fasten to the frame

 Do not kink compressed-air line (20).

23

Remove terminal 30 electric line (23) from starter (M1)

 Nut, terminal 30 to starter

*BA15.30-N-1002-01B

24

Remove ground line (22) from the engine ground point (XM.31)

25

Remove terminal 30 electric line (23) and ground line (22) from the engine

26

Disconnect transmission connector (X29) from bracket (24)

 Depending on the various transmission models, the number of transmission connectors (X29) may vary and deviate from the representation.

27

Remove transmission oil lines from the engine

 Only on vehicles with code N55 (Transmission cooling).

28

Remove compressed-air line (27) from the metering device (28)

 Only in vehicles with code MS4 (BlueTec 4) or code MS5 (BlueTec 5).
Seal connections.

 Banjo bolt, compressed air line to metering device

*BA14.40-N-1033-02C

 Warning

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

Pour AdBlue into suitable containers only. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.

AS14.40-Z-0001-01A

29

Remove AdBlue feed line (26) from the metering device (28)

Notes on use, material properties and handling of AdBlue®

AH14.40-N-0001-01A

 Only in vehicles with code MS4 (BlueTec 4) or code MS5 (BlueTec 5).
Seal connections.

 Installation: Before assembling, check the AdBlue feed line (26) and the connection to the metering device (28) for foreign objects, contamination, and damage.

30

Remove coolant line (25) from the SCR tank heater solenoid valve (Y107)

 Only in vehicles with code MS4 (BlueTec 4) or code MS5 (BlueTec 5).
Collect coolant which flows out.

31

Remove coolant line (29) from the coolant line to the coolant pump and tie AdBlue wiring harness to one side

 Only in vehicles with code MS4 (BlueTec 4) or code MS5 (BlueTec 5).
Collect coolant which flows out.

32

Remove exhaust pipe (4)

Engine 902.9, 926.9 in model 950, 952, 953, 954

AR49.10-W-5530E

 Model 375, 958
No removal/installation instructions have yet been created for these models.

 Installation: Pay attention to the installation position of the clamp (3) relative to the engine brake valve fitting.

33

Remove propeller shaft from the rear engine power take-off

 Only for vehicles with code N52 (rear engine power take-off, output torque 600 Nm).

34

Remove rear engine drive hydraulic pump from the timing case

 Only for vehicles with code NJ7 (rear engine drive for hydraulic pump, max. 120 Nm) or
with code NJ9 (rear engine drive for hydraulic pump, max. 200 Nm).

35

Remove bottom cap from the timing case and remove torque converter from the drive plate

 Only on vehicles with automatic transmissions.

 Engine 902.9 in model 950, 952 with transmission 723.6
Engine 926.9 in model 950, 952 with transmission 723.6Screw/bolt, torque converter to drive plate

*BA27.10-N-1005-04D

36

Attach manual transmission (5) or automatic transmission or support from the bottom

37

Remove screws for the manual transmission (5) or automatic transmission from the engine

 Manual transmission, model designation 712, 715Transmission to engine

*BA26.10-N-1006-01C

 Automatic transmission, model designation 723.6Screw/bolt, automatic transmission to cylinder crankcase

*BA27.10-N-1003-04D

38

Remove engine carrier screws from the left and right engine mount (1)

 Bolt, engine carrier to engine mount

*BA22.10-N-1002-01B

39

Lift out engine with the engine hoist

Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 926.9 in model 950, 952, 953, 954

AR01.10-W-2400-01J

 Installation:
The nickel plated hub surface of the clutch plate may not be greased.
This is to prevent the clutch plate from jamming.

 Pay attention to lines and detachable parts.

 Inspection hole cap to timing case

*BA01.60-N-1002-01A

 Bolt, turning device to timing case

*BA01.60-N-1003-01A

 Pliers

*715589003700

 Turning device

*904589046300

40

Position engine on engine mounts on jack stand and support it under timing case with a suitable component lifter

 Secure engine against falling down and tilting.

41

Check both engine mounts (1) for wear

 Installation: Install new engine mount (1) if necessary.

42

Install in the reverse order

43

Teach in all transponder keys (also replacement keys) again

Engine 902.9 in model 375, 950, 952, 953, 954
Engine 926.9 in model 950, 952, 953, 954

AR80.57-W-0010C

 Only when installing a new engine.

44

Check engine oil level at display; correct if necessary

Notes on engine oil

AH18.00-N-0101-01HA

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

 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

45

Start engine and allow to run in idle for approx. 10 s until the oil pressure has built up; then, allow the engine to run at varying rotational speeds; switch off engine

46

Bleed steering system

Engine 902.9 in model 375, 950, 952, 953, 954 with steering gear 765.82
Engine 926.9 in model 950, 952, 953, 954, 958 with steering gear 765.82

AR46.25-W-3300C

 Only when installing a new engine.

47

Check transmission oil level; correct if necessary

 Only on vehicles with code N55 (Transmission cooling).

 Installation: Observe oil quality set in maintenance system or Specifications for Operating Fluids.

48

Check engine, cooling system, fuel system, and steering system for leak tightness

 Visual inspection.

49

Synchronize the time of the tachograph disk record

 Only for vehicles with modular tachograph.

50

Enter engine number in FDOK "Screen 1111"

 Only when installing a new engine.

 Timing case

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

ENGINE 924.9, 925.9, 926.9

BA01.60-N-1002-01A

Inspection hole cap to timing case

Nm

25

25

 Timing case

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

ENGINE 924.9, 925.9, 926.9

BA01.60-N-1003-01A

Bolt, turning device to timing case

Nm

25

25

 Exhaust aftertreatment

Number

Designation

Engine 900.9, 902.9, 924.9, 925.9, 926.9 with code MS4 or code MS5

BA14.40-N-1033-02C

Banjo bolt, compressed air line to metering device

Nm

15

 Starter

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9

ENGINE 924.9, 925.9, 926.9

BA15.30-N-1002-01B

Nut, terminal 30 to starter

Nm

30

30

 Engine mounts, engine supports

Number

Designation

ENGINE 900.9, 902.9, 904.9 906.9, 924.9, 925.9, 926.9 in MODEL 374, 375, 673, 674, 676, 950, 952, 953, 954, 958, 970, 972, 974, 975, 976

BA22.10-N-1002-01B

Bolt, engine carrier to engine mount

Nm

225

 Manual transmission complete

Number

Designation

Transmission 712.63, 715.060/068

Transmission 715.320

BA26.10-N-1006-01C

Transmission to engine

Nm

50

50

 Manual transmission complete

Number

Designation

Transmission 715.500/507/510/513/517/520/527/540/561/567/568

Transmission 715.570/576

BA26.10-N-1006-01C

Transmission to engine

Nm

50

50

 Complete automatic transmission

Number

Designation

Transmission 723.6 in model 949, 950, 952, 957
Transmission 723.6 in model 970, 975, 976

BA27.10-N-1003-04D

Screw/bolt, automatic transmission to cylinder crankcase

Nm

40

 Complete automatic transmission

Number

Designation

Transmission 723.6 in model 949, 950, 952, 957
Transmission 723.6 in model 970, 975, 976

BA27.10-N-1005-04D

Screw/bolt, torque converter to drive plate

Nm

65

 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-1008-01R

Oil pressure line to power steering pump

Nm

90

 Power steering pump

Number

Designation

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

BA46.30-N-1009-01R

Oil suction line to power steering pump

Nm

90

 Power steering pump

Number

Designation

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

BA46.30-N-1010-01R

Connection fitting to power steering pump

Nm

75

 Fuel lines/hoses

Number

Designation

Engine 900.9, 904.9, 924.9, 925.9, 926.9, engine 902.9, 906.9 except natural gas engine

BA47.25-N-1008-01J

Nut, feed line and return line to fuel filter

Nm

45

 Refrigerant compressor

Number

Designation

Model 374.5, 375.1/3, 949, 950.5/6, 952.5/6, 953.6, 954.5, 957, 958.0/2, 970, 972, 974, 975, 976

BA83.55-N-1001-01C

Screw/bolt, A/C compressor to carrier

Nm

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11