Remove/install engine with transmission

AR01.10-W-2401A

Remove/install engine with transmission

14.2.12

30.3.05

Tightening torque for terminal 30 at starter - added

Step 11

Tightening torque for electrical wiring harness at alternator - added

Step 12

 

Remove/install

 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

1

Disconnect ground lead from battery



Notes on battery

AH54.10-P-0001-01A

2

Tilt cab into repair position

AR60.80-W-0010A

3

Remove rear cab mount

4

Remove soundproofing on the left and right at frame and below

5

Remove radiator with charge air cooler

AR20.20-W-3865A

6

Bind oil dipstick guide tube (16) to engine (1)

7

Detach exhaust pipe (20) from engine brake valve connection

 Installation: Clean sealing surfaces. Check the clamp (21) for wear, replace if necessary.

8

Detach compressed air line (30) from engine brake cylinder

9

Remove air intake hose (26) for turbocharger and air intake hose (27) for compressor

10

Disconnect electrical engine wiring harness (17, 18) at flame glow plug and solenoid valve

 Only for code (M89) Flame starting system (FLA).

11

Disconnect lines for circuit 30 (31) and circuit 50 (32) from starter (M1)



*BA15.30-N-1002-01B

12

Disconnect wiring harness (28) from generator (G1)

 Mark lines.

 Installation: Note markings.



*BA15.40-N-1010-01B



*BA15.40-N-1011-01B



*BA15.40-N-1012-01B

13

Remove ground line at timing case (29)

14

Detach shift linkage (12) from transmission shift mechanism

15

Remove clutch slave cylinder (6) at transmission and bind to frame with hydraulic line connected

 Installation: Grease the thrust pins.

*BR00.45-Z-1062-06A

16

Unbolt compressed air line (2) at compressor and inspect for carbon deposits

 If carbon deposits are present, it is also necessary to inspect compressed air line (2) between compressor and compressed air drier and four-circuit protection valve.

Replace parts showing carbon deposits.

 Installation: Check compressed-air line (2) for leaks.

 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.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

17

Disconnect fuel feed line (9) at fuel pump and fuel return line (10) at fuel filter and bind to the side

 Mark fuel feed line (9) und fuel return line (10).

Collect escaping fuel.



*BA47.25-N-1008-01J

18

Disconnect pressure line (11) for constant throttle

19

Release and disconnect connector (8) on MR/PLD control unit (A6)

20.1

Remove power steering pump and bind to one side with attached steering pressure line and steering suction line

Not if a reconditioned engine is installed.
 Do not disconnect steering pressure line and steering suction line.



*BA46.30-N-1001-01B

 Danger!

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

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

AS00.00-Z-0013-01A

20.2

Disconnect both hoses at steering pressure line and steering suction line

Only if a reconditioned engine is installed.
 Catch escaping hydraulic fluid. The power steering pump is also supplied when a reconditioned engine is installed.

21

Remove frame cross member (15)

 Under radiator and engine (1).

22

Attach engine hoist (23) at the front to lifting eye (25) of coolant pump and guide upwards

Load regulator

gotis://H_00.12_04.0

23

Attach engine hoist (23) at rear left to lifting eye (22)

 Insert shackles (23.1) as an intermediate pieces so that engine hoist (23) does not damage cylinder head cover.

Shackle, DIN 82101

Load regulator

gotis://H_00.12_04.0

24

Attach chain tackle (24) at right rear to lifting eye (22) and tension chains on the engine hoist (23) and chain tackle (24)

 Insert shackles (23.1) as an intermediate pieces so that chain hoist (24) does not damage charge air manifold.

Secure engine to prevent it from tilting.

Shackle, DIN 82101

Load regulator

gotis://H_00.12_04.0

25

Disconnect electrical connector (3, 4, 7) at transmission

 Installation: Replace lead seal (arrow) at electrical connector (7).

26

Remove propeller shaft (5) at transmission and at frame



*BA41.10-N-1002-01F

27

Unscrew bolt (33) from rear transmission mount (35)

 Support transmission.
 Installation: Replace nut (34).

28

Remove bolts (13) at left and right engine mounts (14)

 Check engine mounts (14) for wear; replace engine mounts (14) if necessary.

29

Remove engine (1) with removal fixture

 Max. 30° tilt of engine (1) together with transmission when lifting out or inserting.

AR01.10-W-2400-01A

Load regulator

gotis://H_00.12_04.0

30

Remove transmission from engine (1)

 For transmission 710

*BA26.10-N-1003-01B

 With transmission 715

*BA26.10-N-1006-01C

31

Install in the reverse order

32

Check engine oil level using oil dipstick

 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

33

Start engine and observe oil pressure gauge with the engine idling

 Crank engine with the starter for not more than 90 seconds. Repeat starting procedure after a break of approx. 2 minutes at the earliest.
Do not rev up the engine before oil pressure is indicated. The oil pressure gauge must indicate oil pressure after about 10 seconds.

*BE18.00-N-1001-01C

34

Bleed steering system

 Only if a reconditioned engine is installed.

AR46.25-W-3300D

35

Switch off engine and check for leaks

 Visual inspection.

36

Set time on tachograph

37

Enter engine number in FDOK
"Screen 1111"

 Only if a reconditioned engine is installed.

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BE18.00-N-1001-01C

Engine oil pressure at

Idling speed

bar

0.5

maximum speed

bar

2.5

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BA15.30-N-1002-01B

Nut, terminal 30 at starter

Nm

30

Number

Designation

Engines
904.9, 906.9
up to end no..
190707

BA15.40-N-1010-01B

Nut, electrical line to alternator terminal B+

Nm

8

BA15.40-N-1011-01B

Nut, electrical line to alternator terminal W

Nm

4

BA15.40-N-1012-01B

Nut, electrical line to alternator terminal B

Nm

7

Number

Designation

Transmission 710.62/68/82

BA26.10-N-1003-01B

Transmission to engine

Nm

50

Number

Designation

Trans-mission 712.62,
715.050

BA26.10-N-1006-01C

Transmission to engine

Nm

50

Number

Designation

Model 673, 674, 675, 676, 677, 679

BA41.10-N-1002-01F

Bolt/nut, propeller shaft to flange connection

M10

Nm

60

M12

Nm

100

M14

Nm

160

M16

Nm

200

Number

Designation

Steering
765.60
with engine
904

BA46.30-N-1001-01B

Bolt, power steering pump to compressor

Nm

40

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

Order number

BR00.45-Z-1062-06A

Lubricating grease, Olista Longtime, DB supply specification 6804.60

A 001 989 36 51 10