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
|
Danger !
| Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid
| Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.
| AS42.50-Z-0001-01A
|
| Brake fluid notes
|
| AH42.50-P-0001-01A
|
| Information on preventing damage to electronic components due to electrostatic discharge
|
| AH54.00-P-0001-01A
|
| Remove/install
|
|
|
1
| Remove air filter housing
|
| AR09.10-D-1150SF
|
2
| Remove engine hood
|
| AR88.40-D-3000SD
|
3
| Remove front module
|
| AR88.30-D-1064SE
|
4
| Remove holder (13) for air filter housing on firewall
|
| AR09.10-D-1150-03SF
|
5
| Remove trim panel on right cylinder head cover
|
| AR01.20-D-5015SG
|
6
| Remove trim panel on left cylinder head cover
|
| AR01.20-D-5015SG
|
7
| Place gearshift into neutral
|
|
|
8
| Disconnect ground line, terminal for positive line to the battery and unfasten battery
|
| AR54.10-D-0005SD
|
|
|
| Do not remove bleed line, do not remove battery, only push battery to side. Disconnect positive line from terminal and expose.
|
|
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
|
9
| Disconnect ground line from additional battery
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code E28 (Additional battery for retrofitted consumers)
Engine 642.896/898 in model 906 with transmission 722.9
with code E28 (Additional battery for retrofitted consumers)
Engine 642.898 in model 906 with transmission 722.683
with code E28 (Additional battery for retrofitted consumers)
Engine 642.992 in model 906 with transmission 711.660, 722.683
with code E28 (Additional battery for retrofitted consumers)
Engine 642.993 in model 906 with transmission 722.683
with code E28 (Additional battery for retrofitted consumers)
Engine 642.993 in model 906 with transmission 722.9
with code E28 (Additional battery for retrofitted consumers)
|
|
| Notes on battery
|
| AH54.10-P-0001-01A
|
10
| Lift/jack up vehicle and secure against falling down
|
| AR00.60-D-1000H
|
11
| Disconnect hose and line connections
|
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ8 (ECO start/stop function)
| AR01.10-D-2400-02SE
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
| AR01.10-D-2400-02SG
|
|
|
| Engine 642.898 in model 906 with transmission 722.683
Engine 642.898/993 in model 906 with transmission 722.9
Engine 642.993 in model 906 with transmission 722.683
| AR01.10-D-2400-02S
|
|
|
| Engine 642.992 in model 906 with transmission 711.660, 722.683
| AR01.10-D-2400-02SF
|
|
|
| Engine 642.898 in model 906 with transmission 722.683
with code H08 (Roof-mounted air conditioning system, reinforced)
except code N63 (PTO at front with bracket for extra refrigerant compressor)
Engine 642.898 in model 906 with transmission 722.9
with code H08 (Roof-mounted air conditioning system, reinforced)
except code N63 (PTO at front with bracket for extra refrigerant compressor)
Engine 642.993 in model 906 with transmission 722.683
with code H08 (Roof-mounted air conditioning system, reinforced)
except code N63 (PTO at front with bracket for extra refrigerant compressor)
Engine 642.993 in model 906 with transmission 722.9
with code H08 (Roof-mounted air conditioning system, reinforced)
except code N63 (PTO at front with bracket for extra refrigerant compressor)Bolt, refrigerant lines to refrigerant compressor
| *BA83.55-N-1004-01L
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code H08 (Roof-mounted air conditioning system, reinforced)
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
except code N63 (PTO at front with bracket for extra refrigerant compressor)
Engine 642.896 in model 906 with transmission 722.9
with code H08 (Roof-mounted air conditioning system, reinforced)
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
except code N63 (PTO at front with bracket for extra refrigerant compressor)
Engine 642.992 in model 906 with transmission 711.660, 722.683
with code H08 (Roof-mounted air conditioning system, reinforced)
except code N63 (PTO at front with bracket for extra refrigerant compressor)Bolt, refrigerant lines to refrigerant compressor
| *BA83.55-N-1004-01L
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
Engine 642.898 in model 906 with transmission 722.683
Engine 642.898 in model 906 with transmission 722.9
Engine 642.992 in model 906 with transmission 711.660, 722.683
Engine 642.993 in model 906 with transmission 722.683
Engine 642.993 in model 906 with transmission 722.9Bolt, vehicle speed sensor to transmission housing
| *BA54.00-N-1003-01A
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)High pressure expansion hose to power steering pump
| *BA46.30-N-1003-01A
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)Nut, pressure differential sensor to bracket
| *BA07.04-N-1006-01G
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)Bolt, pressure differential sensor to bracket
| *BA07.04-N-1005-01G
|
|
|
| Paste, hot lubrication 1 kg, DBL 6879.20
| *BR00.45-Z-1005-06A
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code HH9 (Air conditioner, automatic heater control)
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code HH9 (Air conditioner, automatic heater control)
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code HH9 (Air conditioner, automatic heater control)
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code HH9 (Air conditioner, automatic heater control)
with code MJ8 (ECO start/stop function)Bolt, refrigerant line to refrigerant compressor
| *BA83.30-N-1010-01F
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ8 (ECO start/stop function)Bolt, vehicle speed sensor to transmission housing
| *BA54.00-N-1003-01A
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ8 (ECO start/stop function)High pressure expansion hose to power steering pump
| *BA46.30-N-1003-01A
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ8 (ECO start/stop function)Union nut, pressure line to catalytic converter with diesel particulate filter
| *BA14.40-N-1010-01B
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ8 (ECO start/stop function)Screw/bolt, clamping plates of pressure lines
| *BA14.40-N-1002-01B
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ8 (ECO start/stop function)NOx sensor downstream of diesel particulate filter
| *BA07.04-N-1014-01G
|
|
|
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code MJ8 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ7 (ECO start/stop function)
Engine 642.896 in model 906 with transmission 722.9
with code MJ8 (ECO start/stop function)Temperature sensor to diesel particulate filter
| *BA07.04-N-1002-01G
|
|
|
| Record plug
| *129589009100
|
12
| Remove 2nd A/C compressor
|
Engine 642.896 in model 906.6/7 with transmission 711.685, 722.683
with code H08 (Roof-mounted air conditioning system, reinforced)
Engine 642.896 in model 906.6/7 with transmission 722.9
with code H08 (Roof-mounted air conditioning system, reinforced)
Engine 642.898 in model 906.6/7 with transmission 722.683
with code H08 (Roof-mounted air conditioning system, reinforced)
Engine 642.898 in model 906.6/7 with transmission 722.9
with code H08 (Roof-mounted air conditioning system, reinforced)
Engine 642.992 in model 906.6/7 with transmission 711.660, 722.683
with code H08 (Roof-mounted air conditioning system, reinforced)
Engine 642.993 in model 906.6/7 with transmission 722.683
with code H08 (Roof-mounted air conditioning system, reinforced)
Engine 642.993 in model 906.6/7 with transmission 722.9
with code H08 (Roof-mounted air conditioning system, reinforced)
| AR83.55-D-5300WE
|
|
|
| Hang 2nd A/C compressor to side and fasten. Do not separate refrigerant lines.
|
|
13.1
| Remove shift cables (1) from transmission (4)
| Engine 642.896 in model 906 with transmission 711.685
Engine 642.992 in model 906 with transmission 711.660
|
|
|
|
|
| AR26.60-D-6626-01A
|
|
|
| Long-life grease
| *BR00.45-Z-1001-06A
|
13.2
| Unhook Bowden cable selector lever from transmission (4)
| Engine 642.896 in model 906 with transmission 722.683
Engine 642.896/898 in model 906 with transmission 722.9
Engine 642.898 in model 906 with transmission 722.683
Engine 642.992 in model 906 with transmission 722.683
Engine 642.993 in model 906 with transmission 722.683
Engine 642.993 in model 906 with transmission 722.9
|
|
|
|
|
| AR27.60-D-0100-02C
|
|
|
| Long-life grease
| *BR00.45-Z-1001-06A
|
14
| Remove clamp (8) and disconnect front exhaust system (7) and rear exhaust system (9)
| Engine 642.896 in model 906 with transmission 711.685, 722.683
Engine 642.896 in model 906 with transmission 722.9Clamp, catalytic converter with diesel particulate filter to muffler
| *BA14.40-N-1012-01B
|
|
|
| Engine 642.898 in model 906 with transmission 722.683
Engine 642.898 in model 906 with transmission 722.9
Engine 642.992 in model 906 with transmission 711.660, 722.683Clamp connecting diesel particulate filter to catalytic converter
| *BA14.40-N-1003-01B
|
|
|
| Engine 642.993 in model 906 with transmission 722.683
Engine 642.993 in model 906 with transmission 722.9Bolt, catalytic converter clamp to diesel particulate filter
| *BA14.40-N-1018-01B
|
15
| Remove propeller shaft center support bearing (10) on frame floor assembly (11)
| Screw/bolt, propeller shaft center support bearing to frame floor assembly
| *BA41.40-N-1001-01A
|
16
| Remove propeller shaft from power take-off output flange
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.896 in model 906 with transmission 722.9
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.896 in model 906 with transmission 722.9
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.898 in model 906 with transmission 722.683
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.898 in model 906 with transmission 722.683
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.898 in model 906 with transmission 722.9
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.898 in model 906 with transmission 722.9
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.992 in model 906 with transmission 711.660, 722.683
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.992 in model 906 with transmission 711.660, 722.683
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.993 in model 906 with transmission 722.683
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.993 in model 906 with transmission 722.683
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.993 in model 906 with transmission 722.9
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.993 in model 906 with transmission 722.9
with code N07 (Power take-off countershaft (2b) with flange)
|
|
17
| Remove electrical and hydraulic connections from power take-off
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.896 in model 906 with transmission 722.9
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.896 in model 906 with transmission 722.9
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.898 in model 906 with transmission 722.683
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.898 in model 906 with transmission 722.683
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.898 in model 906 with transmission 722.9
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.898 in model 906 with transmission 722.9
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.992 in model 906 with transmission 711.660, 722.683
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.992 in model 906 with transmission 711.660, 722.683
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.993 in model 906 with transmission 722.683
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.993 in model 906 with transmission 722.683
with code N07 (Power take-off countershaft (2b) with flange)
Engine 642.993 in model 906 with transmission 722.9
with code N05 (Power take-off countershaft (2c) without flange)
Engine 642.993 in model 906 with transmission 722.9
with code N07 (Power take-off countershaft (2b) with flange)
|
|
18.1
| Remove screw/bolts (2), remove propeller shaft (3) on transmission (4) and hang to the side outside the working area
| Engine 642.896 in model 906 with transmission 711.685, 722.683
except code ZG1 (Engageable all-wheel drive)
except code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.896/898 in model 906 with transmission 722.9
except code ZG1 (Engageable all-wheel drive)
except code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.898 in model 906 with transmission 722.683
except code ZG1 (Engageable all-wheel drive)
except code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.992 in model 906 with transmission 711.660, 722.683
except code ZG1 (Engageable all-wheel drive)
except code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.993 in model 906 with transmission 722.683
except code ZG1 (Engageable all-wheel drive)
except code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.993 in model 906 with transmission 722.9
except code ZG1 (Engageable all-wheel drive)
except code ZG3 (Engageable all-wheel drive with gear reduction)
|
|
|
|
| Propeller shaft to transmission
| *BA41.10-N-1001-01B
|
18.2
| Remove transfer case
| Engine 642.896 in model 906 with transmission 711.685, 722.683
with code ZG1 (Engageable all-wheel drive)
Engine 642.896 in model 906 with transmission 711.685, 722.683
with code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.896/898 in model 906 with transmission 722.9
with code ZG1 (Engageable all-wheel drive)
Engine 642.896/898 in model 906 with transmission 722.9
with code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.898 in model 906 with transmission 722.683
with code ZG1 (Engageable all-wheel drive)
Engine 642.898 in model 906 with transmission 722.683
with code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.992 in model 906 with transmission 711.660, 722.683
with code ZG1 (Engageable all-wheel drive)
Engine 642.992 in model 906 with transmission 711.660, 722.683
with code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.993 in model 906 with transmission 722.683
with code ZG1 (Engageable all-wheel drive)
Engine 642.993 in model 906 with transmission 722.683
with code ZG3 (Engageable all-wheel drive with gear reduction)
Engine 642.993 in model 906 with transmission 722.9
with code ZG1 (Engageable all-wheel drive)
Engine 642.993 in model 906 with transmission 722.9
with code ZG3 (Engageable all-wheel drive with gear reduction)
|
|
|
|
|
| AR28.10-D-0100H
|
19
| Insert suitable wooden block between transmission (4) and crossmember (12) (arrow)
| The transmission (4) must not lie on crossmember (12) after loosening the rear engine mount (6).
|
|
20
| Remove screw/bolts (5) and detach rear engine mount (6) on transmission (4)
| Screw/bolt, rear engine mount to transmission
| *BA22.10-N-1006-01S
|
21
| Attach engine removal fixture with engine crane (18) to engine (17)
|
| AR01.10-D-2400-09SF
|
|
|
| Support plate
| *906589016200
|
22
| Remove screw/bolts (14) on right and left engine mount at the front (15)
| Screw/bolt, engine mount to front engine support
| *BA22.10-N-1004-01S
|
23
| Lift engine (17) with transmission (4) and move out to the front
|
Lift out engine (17) with transmission (4) carefully.
Otherwise the surrounding assembly parts will be damaged.
|
|
|
|
| Helper required.
|
|
|
|
| Installation: Ensure correct seating of right and left engine mount at the front (15) on front axle carrier (16).
|
|
|
|
| When replacing the engine (17)
|
|
|
|
|
|
|
|
|
| Modify appropriate detachable parts for the engine (17).
|
|
24
| Modify appropriate detachable parts for the engine (17)
| When replacing the engine (17).
|
|
25
| Install in the reverse order
|
|
|
26
| Attach diagnostic system, read out fault memory, delete if necessary and perform initialization in menu item "Control unit adaptation"
| When replacing the flywheel or the drive plate.
|
|
|
|
| AD00.00-D-2000-04SD
|
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
|
27
| Conduct engine test run and inspect engine (17) for leaktightness
|
|
|
