Remove/install 2-cylinder compressor

AR13.30-W-0002MD

Remove/install 2-cylinder compressor

02.05.2013

ENGINE

936.9 in MODEL 963, 964

1

Resonator

5

Control line

9

Bracket

2

Air intake duct

6

Coolant line

10

Timing case

3

Compressed-air line

7

Coolant line

14

Fitting

4

Compressor

8

Power steering pump

A4

Engine management control unit (MCM)

4

Compressor

11

Drive gear

12

Sealing ring

13

Sealing ring

15

Fitting

16

Fitting

 Danger !

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

 Danger !

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 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

 Danger !

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.

AS00.00-Z-0001-01A



Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Notes on coolant

AH20.00-N-2080-01A



Notes on tilting the cab

AH60.80-N-0003-01A



Notes on engine oil

AH18.00-N-0101-01HA

 

Remove/install

1

Tilt cab

 Installation: Only tilt back cab after the leak test.

2

Drain coolant at engine radiator

AR20.00-W-1142M

3

Remove soundproofing

4

Remove resonator (1)

AR13.10-W-5840MD

5

Remove engine management (MCM) control unit (A4)

AR07.08-W-7013MD

6

Remove air intake duct (2)

 Installation: Check sealing ring for damage; replace if necessary.

7

Remove compressed air line (3) from compressor (4)

 Installation: Check compressed-air line (3) for carbonization. In event of any carbonization the air line (3) and the carbonized parts must be replaced.

 Union nut, air line to fitting for compressor

*BA13.30-N-1008-01N

8

Remove control line (5) from compressor (4)

Only on vehicles with code M6L(Air compressor, 2 cylinder)

 Installation: Check sealing ring for damage; replace if necessary.

 Union nut, control line to compressor

*BA13.30-N-1003-01N

9

Release and remove coolant lines (6, 7) on compressor (4)

 Collect flowing out coolant in a suitable container.

10

Remove power steering pump (8) on compressor (4) and place to the side with connected hydraulic lines

AR46.30-W-0500-02MD

 Bolt, power steering pump to compressor

*BA13.30-N-1009-01N

11

Remove bracket (9)

 Bolt, bracket for compressor to crankcase

*BA13.30-N-1010-01N

 Bolt, bracket to compressor

*BA13.30-N-1011-01N

12

Release vehicle wiring harness on frame

13

Remove compressor (4) from timing case (10)

 Collect escaping engine oil in a suitable container.

 Installation: First insert the rear upper screw/bolt, then place compressor (4) on the timing case (10). Turn the drive gear (11) of the compressor (4).

 Bolt, compressor to timing case

*BA13.30-N-1001-01N

14

Remove drive gear (11)

Only if the drive gear (11) is damaged.

AR13.30-W-7044MD

 Installation: Attach new drive gear (11) and also check the counter-gearwheel for the gearwheel drive involved for damage; replace if necessary.

15

Remove sealing rings (12, 13) on compressor (4)

 Installation: Replace sealing rings (12, 13).

16

Remove fitting (14) on compressor (4)

Only if compressor (4) was replaced or fitting (14) is leaky.

 Fitting to compressor

*BA13.30-N-1007-01N

17

Remove fitting (15, 16) for the coolant lines (6, 7) on the compressor (4)

Only if compressor (4) was replaced or fitting (15, 16) is leaky.

 Fitting, coolant line to compressor

*BA13.30-N-1006-01N

18

Install in the reverse order

19

Check engine oil level at display; correct if necessary

 Observe set engine oil specification in the maintenance system.

20

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

21

Turn off engine

 Compressor (compressed air system)

Number

Designation

ENGINE 936.9

BA13.30-N-1001-01N

Bolt, compressor to timing case

Stage 1

Nm

10

Stage 2

Nm

50

 Compressor (compressed air system)

Number

Designation

ENGINE 936.9

BA13.30-N-1007-01N

Fitting to compressor

M141.5

Nm

40

M261.5

Nm

75

 Compressor (compressed air system)

Number

Designation

ENGINE 936.9

BA13.30-N-1009-01N

Bolt, power steering pump to compressor

M10

Nm

50

 Compressor (compressed air system)

Number

Designation

ENGINE 936.9

BA13.30-N-1003-01N

Union nut, control line to compressor

Nm

5

 Compressor (compressed air system)

Number

Designation

ENGINE 936.9

BA13.30-N-1006-01N

Fitting, coolant line to compressor

M161.5

Nm

50

M181.5

Nm

45

 Compressor (compressed air system)

Number

Designation

ENGINE 936.9

BA13.30-N-1011-01N

Bolt, bracket to compressor

Nm

50

 Compressor (compressed air system)

Number

Designation

ENGINE 936.9

BA13.30-N-1008-01N

Union nut, air line to fitting for compressor

Nm

75

 Compressor (compressed air system)

Number

Designation

ENGINE 936.9

BA13.30-N-1010-01N

Bolt, bracket for compressor to crankcase

Nm

30