Remove/install engine

AR01.10-B-2400TD

Remove/install engine

10.03.2020

Engine

904.9 in model 958

Engine

906.9 in model 958

1

Cover (only engine 904.9)

7

Shifting rod (only in code (GS1), "manual" transmission shifting)

12

Steering gear pressure manifold

2

Compressed air pipe coupling (only engine 904.9)

8

Electric wiring harness

13

Fuel manifold, flow

3

Compressed air pipe connector (only engine 904.9)

9

Electric connection

14

Fuel manifold, return

4

Device for removing and installing the engine

10

Engine mounting block

15

Oil filler tube

5

Suspension chain

11

Steering gear suction manifold

16

Refrigerant compressor (only in the code (H03), air-conditioning system in the front side)

6

Compressed air piping

22

Exhaust pipe

26

Compressed air piping

29

Ground wire

23

Clamp

27

Electric wiring harness

G2

Alternator

24

Air suction hose

28

Terminal 30 electric wire

M1

Starting motor

25

Electric wiring harness

Represented in vehicle 906.9

30

Gearshift lever with articulated shifting rods (only in the code (GS1), manual transmission control

31

Holder

32

Platter

 

Remove/install

 Danger

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 poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.

No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect battery ground cable

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

 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 the cabin using the hydraulic tilting system

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

3

Tilt the cab to the repair position

Manual tilting cab.

AR60.80-B-0010TB

4

Remove the acoustic encapsulation on the chassis right and left aide and in the lower part

5

Remove the hydraulic pump or the transmission axle at the engine output and the lining on the transmission

Only for 906 engine with:



Code (N52) rear engine outlet, 600 Nm torque outlet.

Code (NJ7) rear engine drive for hydraulic pump, max. 120 Nm.

Code (NJ9) rear engine drive for hydraulic pump, max. 200 Nm.

6

Disassemble the turbocharger outlet pipe to the charge air after-cooler

7

Remove the fan's frame

8

Remove the oil filler neck (15) on the oil pan and secure it aside

 Shut the oil pan opening

9

Remove the exhaust tube (22) at the engine brake throttle tube and at the transmission, fasten the exhaust tube (22) to the chassis

 Installation: Clean the sealing surfaces. Check the clamp's wear (23), eventually, replace it.

10

Disassemble the compressed air tubes (26) from the engine brake cylinder

11

Remove the air intake hose (24) with engine ventilation hose

12

Remove the terminal electric cable 30 (28) at the starter (M1) and wiring harness (27) from the support

 Terminal 30 nut on starter

*BA15.30-B-1002-01C

13

Remove the installation harness (25) from the alternator (G2) and the support

 Installation: Observe the colored identifications.

 .Electrical cable nut in the alternator terminal B+

*BA15.40-B-1010-01B

 .Electrical cable nut in the alternator terminal W

*BA15.40-B-1011-01B

 .Electrical cable nut in the alternator terminal B

*BA15.40-B-1012-01B

 .Mass cable bolt in the generator

*BA15.40-B-1009-01B

 .Electric cable nut in the alternator's B2+ terminal

*BA15.40-B-1015-01B

14

Remove the ground cable (29) and wiring harness (27) from the timing case

15

Remove the wiring harness bracket (8) on the transmission

16

Detach the compressed air pipe (6) on the air compressor and check for eventual carbonization

 In the case of carbonization, it is necessary to additionally check the compressed air pipe (6) between the air compressor and the compressed air desiccator and the four circuit protection valve, eventually replace carbonized parts.

17.1

Remove the shift rod (7) on the selection lever

Engine 904.9 and code (GS1), transmission's manual control

17.2

Disassemble the selection lever with the shifting rods (30) and bracket (31) on the cross member (32)

Engine 906.9 and code (GS1), "manual" transmission shifting

17.3

Remove the bracket for the hydraulic pipes of the transmission shifting of the engine and of the transmission and secure to a side

Engine 906.9 and code (GS3), transmission's hydraulic control

 Do not detach the hydraulic lines.

 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

18

Open the closing cap on the fuel reservoir and separate the flow (13) and return (14) fuel pipes on the fuel filter

 Collect the drained fuel. Identify the flow (13) and return (14) fuel pipes.

 Flow and return tubes nut to the fuel filter

*BA47.25-B-1008-01B

19

Release the stretcher and disassemble the toothed belt

Only in the code (H03), air-conditioning system in the front side.

.

AR13.22-B-1202TJ

20

Separate the electric connector and remove the coolant compressor (16) with bracket, securing them aside

Only in the code (H03), air-conditioning system in the front side.

 Do not detach the refrigeration pipes

 Bolt that fastens the compressor support of the coolant to the engine block

*BA01.40-B-1005-01B

21

Remove the cover (1), and disconnect the connection (3) of the Top Brake air compressed piping (2).

Only for engine 904.9.

 To disconnect the compressed air piping (3), compress the clips (arrows) using a pliers.

22.1

Remove the hydraulic steering pump and secure to a side with the steering pressure pipe (12) and the steering return oil pipe (11) connected

Not in the case of installing a change engine.

 Do not detach pressure pipe (12) and the return pipe (11) from the steering

 Hydraulic steering pump to the compressor

*BA46.30-B-1001-01B

 Warning

Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.

Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

22.2

Separate both hoses in the steering pressure line (12) and return line (11)

In the assembling of a change engine.

 Catch the run off hydraulic oil, the hydraulic steering pump is supplied together in the case of installing a replacement engine

23

Unlock and separate the electric connector (9) on the control module of the engine control (MR)

 Secure the electric connector (9) to a side.

24

Support or hang the transmission

25

Loosen the transmission bolts on the engine

 .Engine gearbox

*BA26.10-B-1001-01B

26

Remove the bolts of the two engine mounts (10)

 Installation: Check the engine mounts (10) for wear, eventually replace.

27

Remove the engine using the device for removing and installing the engine (4)

Only remove the device for removing and installing the engine (4) and the lifting chain (5), when the transmission is bolted.

AR01.10-B-2400-01TB

 Load regulator for the device for removing and installing the engine (4), see GOTIS

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

*BR00.45-Z-1062-06A

When the clutch disc hub or the transmission shaft is not nickel plated:



Lightly grease the transmission shaft.

28

Install in reverse order

Check

29

Check the engine oil level with the dipstick or by the display, correct it if necessary

 Pay attention to the quality of the engine oil supplied to the maintenance system, i.e., in the instructions concerning fuel.

 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

30

Start the engine and, at idle, note the oil pressure indicator

 Actuate the starter for no more than 90 seconds.
Only repeat the starting procedure after a pause of at least 2 minutes elapses.

 Do not accelerate the engine, while no oil pressure reading is indicated.
After approximately 10 seconds, the pressure gauge must indicate the oil pressure.

Engine oil pressure, minimum permissible

*BE18.00-B-1001-01A

31

Bleed the steering

Only when mounting a spare engine.

AR46.25-B-3300TC

32

Stop the engine

33

Check tightness of the engine, cooling system, fuel system and steering system

 Visual inspection

34

Set the time and synchronize it with the tachograph

35

Insert the engine number in the FDOK "mask 1111"

Only when mounting a spare engine.

Oil pressure

Number

Designation

Engine 904.9, 906.9

BE18.00-B-1001-01A

Engine oil pressure, minimum permissible

idle rotation

bar

0,5

maximum rotation

bar

2,5

 Engine block, fuel rail housing cover, cover

Number

Designation

Engine 904.9, 906.9

BA01.40-B-1005-01B

Bolt that fastens the compressor support of the coolant to the engine block

Nm

55

 Starter

Number

Designation

Engine 904.9, 906.9

BA15.30-B-1002-01C

Terminal 30 nut on starter

Nm

30

 Alternator

Number

Designation

Engine 904.9, 906.9

BA15.40-B-1009-01B

Mass cable bolt in the generator

Nm

12

 Alternator

Number

Designation

Engine 904.9, 906.9

BA15.40-B-1010-01B

Electrical cable nut in the alternator terminal B+

Nm

-

 Alternator

Number

Designation

Engine 904.9, 906.9

BA15.40-B-1011-01B

Electrical cable nut in the alternator terminal W

Nm

-

 Alternator

Number

Designation

Engine 904.9, 906.9

BA15.40-B-1012-01B

Electrical cable nut in the alternator terminal B

Nm

-

 Alternator

Number

Designation

Engine 904.9, 906.9

BA15.40-B-1015-01B

Electric cable nut in the alternator's B2+ terminal

Nm

15

 Complete manual transmission

Number

Designation

Transmissions 712.62/63

BA26.10-B-1001-01B

Engine gearbox

Nm

45

 Hydraulic steering pump

Number

Designation

Steering gear 765, 766, 767 with engine 906.9 and 904.9

BA46.30-B-1001-01B

Hydraulic steering pump to the compressor

Nm

40...45

 Fuel line/hose

Number

Designation

Engine 904 , 906, 924, 926

BA47.25-B-1008-01B

Flow and return tubes nut to the fuel filter

Nm

45

Repair materials

Number

Designation

Order number

BR00.45-Z-1062-06A

Olista Longtime lubricating grease, DB supply specification 6804.60, 100 g

A 001 989 36 51 10