Remove/install engine with transmission

AR01.10-D-2401RU

Remove/install engine with transmission

09.01.2020

Engine

646 in model 909

Modification notes

08.01.2020

Bolt, speed sensor for tachograph to transmission

Transmission 711.680/683/685

BA26.19-N-1001-01I

Shown on vehicle with code MS9(Engine version EURO 4) without code H08 (Roof A/C intensified)

12

Ventilation box

15

Coolant hose

13

Coolant hose

16

Vacuum line

14

Coolant line

Shown on vehicle with code MP5(Engine version EURO 5) without code H08 (Roof A/C intensified)

6

Cooling pipe

10

Coolant hose

8

Coolant line

11

Heat shield

9

Coolant hose

Radiator package for vehicles with code MS9 (Engine version Euro 4)

2

Radiator

3

Condenser

4

Additional fan

6

Cooling pipe

7

Coolant expansion reservoir

Shown on model 909.633 with code MS9 (Engine version Euro 4)

17

Transmission

21

Hydraulic line

18

Propeller shaft

22

Fuel hoses

19

Rear engine crossmember

G3

Tachograph travel distance and speed sensor

20

Hydraulic hose

S19

Backup lamp switch

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. 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 containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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

 Caution

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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on coolant level

AH20.00-P-1142-01CW

 

Remove/install

1

Remove hood.

AR88.40-D-3000F

 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

2

Disconnect ground line from battery.

Topical note

Notes on battery

AH54.10-P-0001-01A

3

Remove ventilation box (12).

AR83.10-D-0010-03F

4

Remove front bumper.

AR88.20-D-2000F

5

Secure vehicle on vehicle lift.

AR00.60-D-0100F

 Installation: Only lower vehicle fully after the leak test.

6

Drain coolant from radiator (2).

AR20.00-D-1140R

7

Remove lock crossmember.

AR88.00-D-2302F

8

Remove coolant hoses from cooler (2).

AR20.20-D-3865-09R

 Engine 646 in model 909
with code MP5 (Engine version Euro 5)
Hose clamp pliers

*454589003700

9

Unclip coolant line (8) from fan shroud.

10

Remove refrigerant reservoir.

Engine 646 in model 909
with code HH9 (Air conditioner, automatic heater control)

AR83.30-D-6520F

 Installation: Replace the fluid reservoir.

11

Remove refrigerant lines from condenser (3) and seal exposed connections with suitable stop plugs.

Engine 646 in model 909
with code HH9 (Air conditioner, automatic heater control)

AR83.30-D-6540F

 Record plug

*129589009100

12

Remove low-pressure line from refrigerant compressor and seal exposed connections with suitable stop plugs.

Engine 646 in model 909
with code HH9 (Air conditioner, automatic heater control)

 Bolt, refrigerant line to refrigerant compressor

*BA83.30-N-1010-01F

 Record plug

*129589009100

13

Remove 2nd refrigerant compressor from attached assembly carrier, place to one side with connected lines, and secure against falling down.

Engine 646 in model 909.8
with code H08 (Roof-mounted air conditioning system, reinforced)

AR83.55-D-5310RU

14

Remove additional fan (4).

Engine 646 in model 909
with code HH9 (Air conditioner, automatic heater control)

AR83.30-D-5610R

15

Remove charge air hoses.

 Clamp, charge air hose to turbocharger

*BA09.41-N-1009-01M

 Clamp, charge air hose to charge air cooler/throttle valve actuator

*BA09.41-N-1010-01M

16

Suction off oil from expansion reservoir of the power steering system.


Thoroughly clean area around the separating point upstream of the opening of the hydraulic system.
Otherwise, even the smallest dirt particles that get into the hydraulic system lead to malfunctions or a total failure of the hydraulic system.

 Hand pump

*210589007100

17

Remove hydraulic hoses of the power steering system from the cooling pipe (6) and seal exposed connections with suitable stop plugs.

 Collect escaping oil in a suitable container.

 Hose clamp pliers

*454589003700

 Record plug

*129589009100

18

Remove high-pressure line from power-steering pump and seal exposed connections with suitable stop plugs.

 Installation: Replace sealing ring.

 Collect escaping oil in a suitable container.

 High pressure expansion hose to power steering pump

*BA46.30-N-1003-01A

 Record plug

*129589009100

19

Release and disconnect electrical connector from coolant expansion reservoir (7).

Engine 646 in model 909
with code MS9 (Engine version Euro 4)

20

Unclip coolant hose (9) from fan shroud.

Engine 646 in model 909
with code MP5 (Engine version Euro 5)

21

Remove coolant hose (10) from coolant thermostat.

Engine 646 in model 909
with code MP5 (Engine version Euro 5)

 Hose clamp pliers

*454589003700

22

Remove radiator package.

 Installation:
Do not bend or kink lines or hoses .
Otherwise leaks can occur on the individual hydraulic circuits.

23

Remove coolant hose (13) from coolant line (14).

 Hose clamp pliers

*454589003700

24

Remove coolant hose (15) from exhaust gas recirculation positioner.

25

Remove vacuum line (16) from vacuum pump and place to one side.

26

Remove air intake hose between the exhaust gas turbocharger and the air filter housing.

27

Disconnect engine wiring harness.

AR15.18-D-1000-05R

28

Remove diesel particulate filter differential pressure sensor (B28/8) and place to one side with connected hoses.

Engine 646 in model 909
with code MP5 (Engine version Euro 5)

AR07.04-D-0006R

29

Remove heat shield (11).

Engine 646 in model 909
with code MP5 (Engine version Euro 5)

30.1

Release clamp of the diesel particulate filter from the main muffler and lay down in the direction of the main muffler.

Engine 646 in model 909
with code MP5 (Engine version Euro 5)

 Pipe clamp, diesel particulate filter to main muffler

*BA14.40-N-1005-02D

30.2

Remove catalytic converter clamp from the diesel particulate filter and lay down in the direction of the diesel particulate filter.

Engine 646 in model 909
with code MS9 (Engine version Euro 4)

 Pipe clamp, catalytic converter to diesel particulate filter

*BA14.40-N-1002-02D

31

Remove shift cable from transmission (17).

AR26.60-D-6626-01R

Long-life grease

*BR00.45-Z-1001-06A

32

Release and disconnect electrical connector from backup light switch (S19).

33

Remove tachograph travel and speed sensor (G3) from transmission (17) and attach to the side of on the substructure.

Engine 646 in model 909
with code IT6 (4.6-tonner)
with code JV6 (Tachograph pre-installation kit)

 Engine 646 in model 909 with transmission 711.683
with code IT6 (4.6-tonner)
with code JV6 (Tachograph pre-installation kit)Bolt, speed sensor for tachograph to transmission

*BA26.19-N-1001-01I

34

Secure propeller shaft (18) in the area of the transmission (17) and the propeller shaft intermediate bearings against falling down.

35

Remove propeller shaft (18) from transmission (17).

AR41.10-D-0050R

36.1

Remove propeller shaft intermediate bearings from the frame floor assembly.

Engine 646 in model 909
with code IR5 (Wheelbase 4025 mm)
With 3-piece propeller shaft (18).

 Screw/bolt, propeller shaft center support bearing to frame floor assembly

BA41.40-N-1001-01A

36.2

Remove propeller shaft intermediate bearing from the frame floor assembly.

Engine 646 in model 909
with code IR3 (Wheelbase 3550 mm)
For 2-piece propeller shaft (18).

 Screw/bolt, propeller shaft center support bearing to frame floor assembly

BA41.40-N-1001-01A

37

Remove rear engine mount.

AR22.10-D-1160R

38

Lower transmission (17) onto the rear engine crossmember (19).

39

Pull out safety clip at separating point (arrow) of the clutch operation.

40

Remove hydraulic hose (20) from hydraulic line (21) and seal exposed connections with suitable stop plugs.

 Installation: Replace sealing ring.

 Collect brake fluid which runs out in a suitable container.

 Record plug

*129589009100

41

Remove fuel hoses (22) from fuel lines, place to one side, and seal exposed connections with suitable stop plugs.

 Collect escaping fuel in a suitable container.

 Record plug

*129589009100

42

Remove cylinder head cover trim.

AR01.20-D-5014-02R

 Installation: Only install cylinder head cover trim panel after the leak test.

 Screw/bolt, cover to cylinder head cover

*BA01.20-N-1003-01M

43

Remove engine with removal fixture.

AR01.10-D-2400-01R

 Aid of helper required.

 Commercially available devices/tools
Engine crane

 Screw/bolt, engine mount to front engine support

*BA22.10-N-1004-01S

 C clamp

*639589016200

 Adapter plate

*646589006200

44

Install in the reverse order.



Check

45

Bleed clutch operating system.

AR25.20-D-0070R

46

Charge power-steering pump and bleed.

AR46.30-D-0010F

47

Check gearshift system and shift cable for ease of movement.

If it is not possible to shift through the gears of the transmission (17) easily,



Adjust shift cables.

AR26.60-D-6633R

48

Connect vehicle diagnosis system, read out fault memory, and delete.



AD00.00-D-2000-04F

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 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

49

Perform engine test run, check engine and transmission (17) for proper operation and leak tightness.

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 646 in model 909

BA01.20-N-1003-01M

Screw/bolt, cover to cylinder head cover

Nm

10

 Charge air pipe/charge air cooling

Number

Designation

Engine 646.7 in model 909

BA09.41-N-1009-01M

Clamp, charge air hose to turbocharger

Tightening torque

Nm

4

Control torque (after waiting time of approx. one hour)

Nm

4

 Charge air pipe/charge air cooling

Number

Designation

Engine 646.7 in model 909

BA09.41-N-1010-01M

Clamp, charge air hose to charge air cooler/throttle valve actuator

Nm

5,5

 Exhaust aftertreatment

Number

Designation

Engine 646 in model 906, 909

BA14.40-N-1002-02D

Pipe clamp, catalytic converter to diesel particulate filter

Nm

35

 Exhaust aftertreatment

Number

Designation

Engine 646 in model 906, 909

BA14.40-N-1005-02D

Pipe clamp, diesel particulate filter to main muffler

Nm

47

 Engine mounts, engine supports

Number

Designation

Engine 646 in model 909

BA22.10-N-1004-01S

Screw/bolt, engine mount to front engine support

Nm

72

 Sensors

Number

Designation

Transmission 711.680/683/685

BA26.19-N-1001-01I

Bolt, speed sensor for tachograph to transmission

Nm

4

 Power steering pump

Number

Designation

Model 690.6, 901.6, 902.6, 903.6, 904.6, 905.6, 909

BA46.30-N-1003-01A

High pressure expansion hose to power steering pump

–

Nm

–

VDA pump

Nm

38

VT pump

Nm

–

 Air conditioning

Number

Designation

Model 906, 909 with code HH9

BA83.30-N-1010-01F

Bolt, refrigerant line to refrigerant compressor

Nm

22

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11