AR01.10-I-2400A | Removing and installing engine | 14.2.12 |
ENGINE 384.907 in MODEL 397
ENGINE 384.906 /907 in MODEL 684
N01.10-2048-09
1, 2, 3 Coolant line
4 Radiator
5 Starter wiring harness
6 Generator harness
7, 8 Power steering pump hydraulic lines
9, 10, 11 Fuel lines
12 Vacuum line
13 Compressor major assembly
14 Intake hose
15 Oil vent hose
16 Clutch slave cylinder
17 Exhaust pipe
N01.10-2049-09
18 Vacuum line
19 Front engine mount nuts
20 Rear engine mount nuts
21 Cab locking bracket
| Remove/install | ||
Danger! | Risk of injury caused by being caught or pinched 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. | |
1 | Tilt cab | See owner's manual. | |
Danger! | Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices | No fire, sparks, open flames or smoking. Wear acid-resistant gloves and clothing and safety glasses with side guards. Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground. Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers. | |
2 | Disconnect ground cable | ||
3 | Remove transmission | ||
Danger! | Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. 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 bottles. Wear protective gloves, protective clothing and eye protection. | |
4 | Drain coolant at radiator, collect | ||
5 | Drain and collect engine oil | Installation: Replace gasket for drain plug. | |
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6 | Remove coolant hoses (1, 2, 3) | ||
7 | Remove radiator (4) | ||
8 | Connect wiring harness (5) to starter | ||
9 | Connect wiring harness (6) to generator | ||
10 | Lock all electrical lines to engine | ||
Danger! | Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning caused by swallowing hydraulic fluid. | Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses. | |
11 | Detach hydraulic hoses (7, 8) at power steering pump, collect hydraulic oil | Installation: Top up and bleed the power steering system | |
Danger! | Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel. | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
12 | Detach fuel lines (9, 10, 11) at injection pump, fuel filter and fuel return line at cylinder 4 | Installation: Replace gaskets. | |
13 | Detach vacuum line (12) at upper section of compressor major assembly (13) | Vacuum line must not be bent. | |
Installation: Replace gaskets. | |||
14 | Remove throttle link | Installation: Coat socket pad with Oiliest Moly 2 | |
Adjust throttle link. | |||
15 | Detach intake hose (14) and oil bleed hose (15) | ||
Danger! | Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes. | Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. | |
16 | Remove clutch slave cylinder (16) | Removal: Pay attention to the position of the clutch slave cylinder and its spacer sleeve before removing. | |
Installation: Coat socket pad with Oiliest Moly 2 Bleed clutch system. | |||
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17 | Detach vacuum line (18) at engine brake cylinder and engine shutoff cylinder. | ||
Danger! | Risk of injury to skin and eyes from handling hot or glowing objects. | Wear safety gloves, protective clothing and safety glasses, if necessary. | |
18 | Detach exhaust (17) at flange connector. | Installation: Replace hexagon nuts. | |
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19 | Unscrew nut (19) from front engine mount on left and right | ||
20 | Unscrew nuts (20) from rear engine mount on left and right | ||
21 | Undo bolts and nuts (arrows) from cab locking bracket (21) | Remove cab locking bracket together with expansion reservoir. | |
22 | Carefully lift out engine and place on supporting device. | ||
23 | Install in the reverse order | ||
24 | Inspect cooling system for leaks | ||
| Cooling and heating system - checking condition of radiator, lines and hoses | Model 684 with engine 384 | |
Danger! | Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns when working in engine during starting procedure | Secure vehicle to prevent it from moving. | |
25 | Run engine and inspect for leaks |
Oil pan
Exhaust system
Number | Designation | Engine 384.906/ | |
BA49.10-N-1001-01E | Front exhaust pipe to exhaust manifold of turbocharger | Nm | 45 |
Clutch mechanism
Engine lubrication
Referenced documents
- ap2000i2050k Cooling and heating system - checking condition of radiator, lines and hoses
- ar2020i3865a Remove/install radiator
- as0000z000201a Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
- as0000z000501a 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.
- as0000z001301a Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.
- as2000z000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.
- as4250z000101a Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid
- as4700z000101a 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.
- as5410z000101a Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of
- as6080z000101a Risk of injury caused by body parts being pinched or crushed as cab is tilted