Remove/install compressor

AR13.30-W-5510CA

Remove/install compressor

04.12.2019

Engine

457.9 in model 374, 375, 940, 942, 943, 944, 958

with code MZ8 (Air compressor, 2-cylinder, regulated)

except code MZ7 (Air compressor, 1-cylinder, regulated)

Shown on model 944

1

Power steering pump

5

Suction pipe

9

Coolant line (feed)

2

Compressed-air line

6

Oil separator

10

Sealing ring

3

Screw

7

Control line

11

Coolant line (return flow)

4

Resonator

8

Compressor

12

Cross plate

Only vehicle with code BA1 (Performance-optimized Voith retarder) or with code BA9 (Voith secondary retarder R 115)

13

Retarder coolant hoses

15

Clip

17

Bracket

14

Retarder coolant pipes

16

Bracket

8

Compressor

18

Drive gear

19

Sealing rings

20

Sealing ring

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Notes on engine oil

AH18.00-N-0101-01HA

 

Remove/install

1

Remove oil separator (6)

Only for model 374, 940, 942, 943, 958; Model 375, 944 with engine 457.9 as of engine end number 036948

Model 374, 940, 942, 943; Model 375, 944 with engine 457.9 as of engine end number 036948

AR01.20-W-9750CA

 Model 958
Work instructions have not been created for these vehicles.

2

Partially drain coolant at radiator

AR20.00-W-1142B

 Collect escaping coolant in a clean vessel.

3

Disconnect suction line (5) on resonator (4)

 Installation: Check sealing ring of suction line (5) for damage.

If sealing ring is damaged.



Replace suction line (5).

4

Remove screw/bolt (3) and resonator box (4)

 Installation: Replace sealing ring (10).

5

Remove coolant line (11) on compressor (8) and on crankcase

 Counterhold fitting on compressor (8) and catch escaping coolant in a clean vessel.

 Union nut, coolant line to compressor fitting

*BA13.30-N-1010-01L

6

Remove coolant line (9) on compressor (8)

 Counterhold fitting on compressor (8) and catch escaping coolant in a clean vessel.

 Union nut, coolant line to compressor fitting

*BA13.30-N-1010-01L

7

Disconnect compressed air line (2) at connecting point for frame

8

Remove clamp for compressed air line (2) on timing case bracket

9

Remove compressed-air line (2) on compressor (8) and check for carbonization

 Counterhold fitting on compressor (8).

If the compressed-air line (2) is carbonized.



Replace compressed-air line (2). In addition, check compressed-air lines between compressor (8), compressed-air drier and four-circuit protection valve.

If the compressed-air lines between the compressor (8), the compressed-air drier or the four-circuit protection valve are carbonized.



Replace respective compressed-air line.

10

Remove control line (7) on compressor (8)

 Installation: Install new sealing rings.

 Banjo bolt, control line to compressor

*BA13.30-N-1006-01L

11

Completely drain coolant at retarder

Only for vehicles with code BA1 (Performance-optimized Voith retarder) or code BA9 (Voith secondary retarder R 115)

AR20.00-W-1142B

 Collect escaping coolant in a clean vessel.

12

Remove clamp (15) on bracket (17) and both brackets below on the transmission

Only for vehicles with code BA1 (Performance-optimized Voith retarder) or code BA9 (Voith secondary retarder R 115)

13

Detach both coolant hoses below on retarder

Only for vehicles with code BA1 (Performance-optimized Voith retarder) or code BA9 (Voith secondary retarder R 115)

 Collect escaping coolant in a clean vessel.

14

Loosen clamps (15) and remove bracket (16)

Only for vehicles with code BA1 (Performance-optimized Voith retarder) or code BA9 (Voith secondary retarder R 115)

15

Detach retarder (13) coolant hose and push back onto retarder (14) coolant pipe

Only for vehicles with code BA1 (Performance-optimized Voith retarder) or code BA9 (Voith secondary retarder R 115)

 Collect escaping coolant in a clean vessel.

16

Pull retarder coolant pipes (14) to the front and bind to side of frame

Only for vehicles with code BA1 (Performance-optimized Voith retarder) or code BA9 (Voith secondary retarder R 115)

17

Remove power-steering pump (1) on compressor (8)

 Do not disconnect steering gear oil lines.

 Installation: Replace sealing ring on power-steering pump (1).

 Bolt, power steering pump to compressor

*BA46.30-N-1001-01R

18

Remove cross plate (12) on power steering pump (1) or on compressor (8)

 Installation: Insert cross plate (12) into compressor (8) and secure against slipping with high-temperature grease.

High-temperature grease

*BR00.45-Z-1051-06A

19

Remove compressor (8) from timing case

 Remove a bolt through the opening of the oil separator (6) on the timing case at the rear. Remove remaining screws/bolts from front on compressor (8).
Collect escaping engine oil.

 Installation: Before the compressor (8) is placed on the timing case, insert the long screw/bolts.
When placing the compressor (8), turn the drive gear (18) if necessary.

 Bolt, compressor to crankcase

*BA13.30-N-1001-01L

20

Check drive wheel (18) and drive wheel on camshaft for damage

 Visual inspection.

If the drive wheel (18) on the compressor (8) is damaged.



Replace drive gear (18).

AR13.30-W-7043C

If the drive gear on the camshaft is damaged.



Replace drive wheel or camshaft.

Remove/install camshaft

AR05.20-W-6292C

21

Remove sealing rings (19, 20) at compressor (8)

 Installation: Install new sealing rings (19, 20).

22

Unscrew fitting of compressed-air line (2) and the fitting to which the resonator box (4) is mounted

Only if compressor (8) was replaced or fitting is leaky.

 Installation: Install new sealing rings.

 Fitting, compressed air line to compressor

*BA13.30-N-1004-01L

 Fitting, suction line to compressor

*BA13.30-N-1005-01L

23

Remove fittings of coolant lines (9, 11) on compressor (8)

Only if compressor (8) was replaced or fitting is leaky.

 Installation: Install new sealing rings.

 Fitting, coolant line to compressor

*BA13.30-N-1008-01L

24

Install in the reverse order

25

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

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

26

Fill in coolant

AR20.00-W-1142B

27

Start engine and perform an engine test run

28

Check compressed air line (2) for leaks

 Visual inspection.

29

Turn off engine and check near compressor (8) for leak tightness

 Visual inspection.

30

Check retarder coolant hoses (13) and retarder coolant hoses at retarder bottom for leaks by means of a visual check

Only for vehicles with code BA1 (Performance-optimized Voith retarder) or code BA9 (Voith secondary retarder R 115)

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1001-01L

Bolt, compressor to crankcase

Nm

60

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1004-01L

Fitting, compressed air line to compressor

Nm

80

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1005-01L

Fitting, suction line to compressor

Nm

80

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1006-01L

Banjo bolt, control line to compressor

Nm

15

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1008-01L

Fitting, coolant line to compressor

Nm

30

 Compressor (compressed air system)

Number

Designation

ENGINE 457.9 with CODE MZ8

BA13.30-N-1010-01L

Union nut, coolant line to compressor fitting

Nm

40

 Power steering pump

Number

Designation

Engine 457.9, 460.9

BA46.30-N-1001-01R

Bolt, power steering pump to compressor

Nm

40

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-06A

High-temperature grease

A 000 989 81 51