Remove/install engine

AR01.10-W-2400C

Remove/install engine

14.2.12

15.12.09

Value changed: nut, electrical line to circuit B2+ ALT

*BA15.40-N-1015-01B

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1.1

Open end cover at fuel tank

Vehicles without code (MS8) Natural gas engine

 Danger!

Risk of explosion caused by escaping natural gas or by overheated compressed-gas tanks when working on natural gas powered vehicles. Risk of frostbite to parts of the body caused by escaping natural gas and by touching components near the valves when emptying compressed-gas tanks. Risk of poisoning or risk of suffocation caused by inhaling natural gas.

Remove any sources of ignition.

Ensure that the work area is adequately ventilated.

Wear heat protective gloves.

AS00.00-Z-0018-01A

1.2

Close gas shutoff valves at compressed-gas tanks

Vehicles with code (MS8) Natural gas engine

AR47.10-W-0005H



Notes on work safety regulations for vehicles with natural gas-powered engines

AH00.10-N-1000-04A

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

2

Start engine and run on idle until the engine goes off by itself

 Only on vehicles with code (MS8) Natural gas engine.

In this way the residual gas from the lines and components is consumed.

3

Switch off ignition

 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.

AS54.10-Z-0001-01A

4

Disconnect ground lead from battery



Notes on battery

AH54.10-P-0001-01A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

5

Drain coolant

Engine 902.9 without code (MS8) Natural gas engine, engine 926.9

AR20.00-W-1142J

Engine 902.9 with code (MS8) Natural gas engine, engine
906.9

AR20.00-W-1142C

6

Remove RH and LH soundproofing on top frame and underride guard soundproofing on lower frame

7

Drain hydraulic fluid from fan drive

 Installation: Only attach leak oil hose (3) to the hydraulic engine after installing the engine.



Hydrostatic fan drive - oil and filter change

AP20.40-W-2001A

8

Remove the hydraulic pump or propeller shaft from the rear engine power take-off and paneling over the transmission

 Only on vehicles with code (N52) rear engine power take-off, output torque 600 Nm, or code (NJ9) rear power take-off for hydraulic pump, 200 Nm max.

9

Remove air intake pipe (20)

Engine 902.9, 906.9 with code (MS8) Natural gas engine

AR09.10-W-8131H

Engine 902.9 without code (MS8) Natural gas engine
Engine 926.9

AR09.10-W-8131JB

Engine 906.9 without code (MS8) Natural gas engine

AR09.10-W-8131B

10

Remove charge air hose (9) and charge air pipe (11) from charge air cooler to charge air manifold

Engine 902.9, 906 with code (MS8) Natural gas engine

AR09.41-W-1311H

Engine 906.9 without code (MS8) Natural gas engine

AR09.41-W-1311D

Engine 902.9 without code (MS8) Natural gas engine
Engine 926.9

AR09.41-W-1311JD

11

Remove charge air pipe (4)

12

Remove charge air hose (8) and charge air pipe (10) from exhaust gas turbocharger to charge air cooler

Engine 902.9 with code (MS8) Natural gas engine
Engine 906.9

AR09.41-W-1311C

Engine 902.9 without code (MS8) Natural gas engine
Engine 926

AR09.41-W-1311JB

13

Disconnect coolant hose (1) from the heater

 Collect coolant that flows out

14

Detach coolant hose (12), remove coolant pipe (6) from oil pan bracket

 Collect coolant that flows out

15

Remove coolant hose (5)

 Collect coolant that flows out

16

Disconnect hydraulic hoses (14, 15) from the steering

 Catch escaping hydraulic fluid.

17

Disconnect hydraulic hose (2)

 Catch escaping hydraulic fluid. Tie leak oil hose (3) to the engine.

18

Disconnect hydraulic hose (16) from hydraulic line (13)

 Catch escaping hydraulic fluid.

19

Swivel tensioning device tensioner pulley upward and remove poly-V belt (21) from the belt pulley of refrigerant compressor (23)

 Only on vehicles with code (H03) Air conditioning in front end.

 Installation: Inspect condition of poly-V belt (21), replace if necessary.

Observe poly-V belt (21) routing diagram.

AR13.22-W-3902-02D



Damage profiles for a poly-V belt

AP13.22-D-1351-01A

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

20

Disconnect fuel lines (36, 37) from main fuel filter

 Only on vehicles without code (MS8) Natural gas engine.

Mark installation position of fuel line (36). Collect escaping fuel and close off the holes.

 Installation: Note the marking on fuel line (36).



*BA47.25-N-1008-01J

21

Expose the electrical wiring harness and disconnect electrical connector (22) from refrigerant compressor (23)

 Only on vehicles with code (H03) Air conditioning in front end.

22

Detach refrigerant compressor (23) from the carrier, move forward and tie to the frame

 Only on vehicles with code (H03) Air conditioning in front end.

Do not disconnect refrigerant lines (7).



*BA83.55-N-1001-01C

23

Disconnect engine wiring harness electrical connector (40) and vehicle wiring harness electrical connector (41) from engine control (MR) control unit (A6) or gaseous fuel engine (MR) control unit (A85)

 Push vehicle electrical wiring harness to one side.

24

Disconnect engine wiring harness electrical connector (42)

25

Disconnect oil level sensor electrical connector (39)

26

Expose electrical line (46) and disconnect from hydrostatic cooling system oil level switch (S122)

27

Disconnect hydraulic hoses (31) and tie to the top of expansion reservoir (45)

 Catch escaping hydraulic fluid.

28

Remove coolant line (32)

 Collect coolant that flows out

29

Disconnect compressed air line (33) from the compressor, from the transmission and from the connecting point, and check it for carbonization

 If carbon deposits are present, it is also necessary to inspect the compressed-air line between the compressor and compressed-air drier and the four-circuit protection valve.

Replace parts showing carbon deposits.

30

Detach coolant hoses (43, 44) from the bottom of coolant pipes (29, 30) and push back

 Collect coolant that flows out

31

Expose vent line (28) at coolant pipe (30)

32

Detach coolant pipes (29, 30) from the top coolant hoses and from the brackets, and remove

 Collect coolant that flows out

33

Disconnect coolant hoses (51, 52) from expansion reservoir (50)

 Collect coolant that flows out

34

Remove gas pressure line (54) from the bracket and detach from the charge air manifold fitting

 Only on vehicles with code (MS8) Natural gas engine.

Counterhold charge air manifold fitting when detaching gas pressure line (54).

 Installation: Use a check gauge when tightening the gas pressure line (54).



Note on threaded pipe connections of gas pressure lines

AH47.25-N-0001-01A

35

Detach engine brake compressed air line (56) from engine brake cylinder (55)

 Only on vehicles without code (MS8) Natural gas engine.

Danger!

Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue

Only pour AdBlue into suitable containers. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.

AS14.40-Z-0001-01A

36

Remove hose and line connections from the exhaust aftertreatment system

 Only for vehicles with code (MS4) BlueTec 4 or with code (MS5) BlueTec 5.

AR14.40-W-2010-01A



*BA00.18-N-1003-01A



Notes on use, material properties and handling of AdBlue®

AH14.40-N-0001-01A

37

Remove strut (48) with heat shield (47)

38

Remove heat shield (53) from engine brake valve fitting or from exhaust fitting and exhaust pipe (49)

39

Remove exhaust pipe (49)

AR49.10-W-5530E

40

Detach hydraulic lines (34, 35) from the transmission and disconnect them

 Only on vehicles with code (AN8) Hydraulically steered leading axle or with code (AN9) hydraulically steered trailing axle.

Collect escaping hydraulic oil.

41

Detach electrical line (circuit B2+) (25) and ground line (26) from alternator (G2)



*BA15.40-N-1009-01B



*BA15.40-N-1015-01B

42

Remove cable tie and detach wiring harness electrical connector (24) from alternator (G2)

 Installation: Secure retaining clip on wiring harness electrical connector (24) with a cable tie.

43

Detach starter line (circuit 30) (17) from starter (M1)



*BA15.30-N-1002-01B

44

Disconnect ground cables (18) at timing case

45

Detach starter line (circuit 30) (17), ground lines (18) and electrical wiring harness from wiring harness bracket (19)

46

Remove bolt (38) on the left and right engine mount



*BA22.10-N-1002-01B

47

Drain transmission oil

Only on vehicles with automatic transmission 723.



Automatic transmission - oil and filter change

AP27.00-W-2702A

48.1

Separate engine from the automatic transmission and lift out

Vehicles with automatic transmission

AR01.10-W-2400-01D



*BA01.60-N-1002-01A



*BA01.60-N-1003-01A



*BA22.10-N-1005-01B



*BA27.10-N-1003-04D



*BA27.10-N-1004-04D



*BA27.10-N-1005-04D



*904589046300

48.2

Disconnect engine from manual transmission and lift out

Vehicles with manual transmission

AR01.10-W-2400-01DA



*BA01.60-N-1002-01A



*BA01.60-N-1003-01A



*BA22.10-N-1005-01B



*BA25.20-N-1001-01J



*BA25.20-N-1003-01J



*BA25.20-N-1010-01J



*BA26.10-N-1001-01C



*904589046300

Long-life grease

*BR00.45-Z-1001-06A

49

Check both engine mounts for wear

 Installation: If necessary, replace engine mount.



*BA22.10-N-1005-01B

50

Install in the reverse order

51

Re-teach in transponder keys (also replacement keys)

 Only if a reconditioned engine is installed.

AR80.57-W-0010C

52

Check the engine oil level on the display or using the oil dipstick, and adjust if necessary

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



Notes on engine oil

AH18.00-N-0101-01B

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

53

Start engine and allow to run in idle for 10 s until the oil pressure has built up, then run the engine at varying speeds

Crank engine with the starter for not more than 90 seconds. The fuel system is ventilated automatically. If the engine stops or does not start, repeat starting procedure after a break of 2 minutes.

54

Bleed steering system

Steering system 765.82

AR46.25-W-3300C

Steering 765.88/89

AR46.25-W-3300A

55

Switch off engine and check for leaks

 Visual inspection.

56

Synchronize the time of the tachograph disk record

 Only on vehicles with MTCO tachograph.

57

Enter engine number in VeDoc screen 1111

 Only if a reconditioned engine is installed.

58

Check the gas system for leaktightness in accordance with the national regulations

 Only on vehicles with code (MS8) Natural gas engine.

In Germany the GAP should be performed according to §41a of the German vehicle licensing regulations.

Number

Designation

Model
930, 932, 933, 934, 950, 952, 953, 954, 957, 958

BA00.18-N-1003-01A

Compressed air connection system
SCHÄFER "SDF" in metallic material

M101

Nm

5

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

Engine
924.9, 925.9, 926.9

BA01.60-N-1002-01A

Inspection hole closure cover on timing case

Nm

25

25

BA01.60-N-1003-01A

Bolt, turning device to timing case

Nm

25

25

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

Engine
924.9, 925.9, 926.9

BA15.30-N-1002-01B

Nut, circuit 30 to starter

Nm

30

30

Number

Designation

Engines
904.9, 906.9
as of end no. 190708,
Engine
900.9, 902.9

Engine
924.9, 925.9, 926.9

BA15.40-N-1009-01B

Bolt, ground line to alternator

Nm

12

12

BA15.40-N-1015-01B

Nut, electrical line to alternator circuit B2+

Nm

30

30

Number

Designation

Engine
902.9, 906.9, 926.9
in model
957

BA22.10-N-1002-01B

Bolt, engine carrier to engine mount

Nm

260

BA22.10-N-1005-01B

Bolt, engine mount to frame

Nm

175

Number

Designation

Model
950, 952,
953, 954,
957

BA25.20-N-1001-01J

Bolt, clutch booster to transmission housing

Nm

50

BA25.20-N-1003-01J

Banjo bolt (compressed-air line) on clutch booster

Nm

40

BA25.20-N-1010-01J

Union nut (compressed-air line) on clutch booster

Nm

40

Number

Designation

Trans-mission 715.500/
507/510/
513/517/
520/527/
540/561/
567/568

BA26.10-N-1001-01C

Transmission on flywheel housing

Nm

50

Number

Designation

Transmission
723.6

BA27.10-N-1003-04D

Bolt, automatic transmission to crankcase

Nm

40

BA27.10-N-1004-04D

Bolt, cover plate for PTO to transmission

Nm

55

BA27.10-N-1005-04D

Bolt, torque converter to driven plate

Nm

65

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9

BA47.25-N-1008-01J

Nut, feed and return line to fuel filter

Nm

45

Number

Designation

Model
374.5, 375.1, 375.3, 949, 950.5, 950.6, 952.5, 952.6, 953.6, 954.5, 957, 958.0, 958.2, 970, 972, 974, 975, 976

BA83.55-N-1001-01C

Bolt, refrigerant compressor/bracket

Nm

25

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11