B01.10-0003-09
Representation in the engine 906.9 with Exhaust Gas Recirculation system |
1 | Charge air tubes | 14 | Fuel tubes | |
2 | Turbocharge air hose | 15 | Fuel tubes | |
3 | Cooling water hose | 16 | Cushion (right side) | |
4 | Cooling water hose | 17 | Hydraulic pump | |
5 | Turbocharger outlet line | 18 | Engine fastening bolt | |
6 | Compressor cooling pipe | 19 | Clutch slave cylinder | |
7 | Compressor air suction line | 20 | Transmission safety screw | |
8 | Compressor cooling pipe | 21 | Exhaust pipe | |
9 | Compressed air piping | M1 | Starting motor | |
10 | Oil filling piping | 22 | Starter motor electrical cables | |
11 | Electronic control module connector | G1 | Alternator | |
12 | Air intake piping | 23 | Alternator electrical cables | |
13 | Belts |
| Remove/install | ||
1 | Disconnect the negative battery cable or turn off the main switch | ||
2 | Remove the rear bumper and the bumper's supporting cross member | Depending on body model, it will also be necessary to remove the taillights. | |
3 | Remove the chassis rear crossmember and the crossmember right side support |
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The removal of the cross member support helps in the engine removal. | |||
4 | Remove engine lower panelling | Remove/install lower engine compartment lining | |
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. | |
5 | Drain the engine cooling system | Drain/pour in coolant | |
6 | Remove the hoses (3) and (4) inlet and outlet of water pump | Installation: Check the clamps, replace it if necessary. | |
7 | Remove the space heating system hoses | Vehicles fitted with space heating system. | |
8 | Remove the retarder cooling system piping | Vehicles equipped with retarder. | |
9 | Remove the engine filler line (10) | ||
10 | Remove the fan drive belts (13) and the air conditioning compressor drive belts | Remove, install V-belt | |
11 | Remove belt breakage indication sensor | ||
12 | Remove charge air inlet line | Remove/install charge air pipe | |
Remove/install charge air pipeEngine 904, 906, 924, 926 in Type 368 without Exhaust Gas Recirculation system. | |||
For engines equipped with an exhaust gas recirculation system, remove the complete assembly (1). Loosen the hose clamps (2) and the union of the assembly (1) to the intake manifold. | |||
13 | Remove the charge air piping (5), between the turbocharger outlet and the charge air after-cooler inlet | Installation: Check the attachment clamps, replace if necessary. | |
14 | Remove the air intake piping (12), between the air filter and the exhaust gas turbocharger | Installation: Check the attachment clamps, replace if necessary. | |
15 | Remove the air intake piping (7), compressed air outlet (9) from the air compressor | Remove/install compressor | |
16 | Release and put the power steering pump (17) away from the air compressor | It is not necessary to remove the hydraulic oil inlet and outlet hoses from the steering pump. | |
Steering box 766Hydraulic steering pump to the compressor | |||
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. | |
17 | Disconnect the fuel lines (14,15) | .Flow and return tubes nut to the fuel filter | |
18 | Disconnect the outlet (11) from the engine electronic module | Separate, connect plug connection of vehicle wiring harness at MR/PLD control module | |
19 | Disconnect the electric lines (22) from the starter (M1 ) | Identify the electrical cables in order to prevent error in the installation. | |
20 | Unplug the electric lines (23) of the alternator (G1) | Identify the electrical cables in order to prevent error in the installation. | |
21 | Disconnect the pneumatic piping from the engine-brake cylinder | ||
22 | Disconnect the compressed-air line from the constant throttles | Engines equipped with (top brake) constant throttles. | |
23 | Release the electric wiring harnesses attached to the engine | If necessary remove the exhaust gas turbocharger baffle plate and | |
24 | Disconnect the exhaust pipe (21) | Installation: Clean the sealing surfaces. Check the attachment clamps, replace them if necessary. | |
25 | Release and place the clutch drive slave cylinder (19) away | Except for vehicles with automatic transmission. | |
It is not necessary to release the hydraulic oil piping. | |||
26 | Remove the screws fastening the engine (18) to the front mounts | .Engine support bolt in the crankcase | |
27 | Support the gearbox with a shim and /or hydraulic device | Use a proper shim and support it correctly in order to prevent damages to the gearbox. | |
28 | Support the engine by the suspension straps on the front and rear part of the engine | Remove/install engine with removal fixture | |
29 | Remove the mount (16) from the right side of the chassis | Installation: Check the condition, if necessary replace the mounts. | |
.Engine support bolt in the bearing | |||
30 | Remove the junction screws (20) from the transmission to the engine | Automatic transmission 723.367Support to the housing, 11 fastenning points | |
Transmissions 712.63Engine gearbox | |||
31 | Remove the engine from the vehicle | Make sure that the are no more components of the vehicle connected to the engine. Be careful, do not damage components, by mechanical shock, during engine removal. After having removed it, put it in a safe and proper location. | |
Lift the engine until it is free, detach it from the transmission with the aid of a plastic hammer, carefully remove it from the chassis. | |||
32 | Install in reverse order | ||
33 | Bleed the fuel system | ||
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34 | Starting the engine | Do not crank the engine continuously for more than 30 seconds. If the engine does not fire within this interval, wait approximately 1 minute to crank it again. | |
35 | Check the engine oil pressure with the engine idling | Do not accelerate the engine until oil pressure is shown on the indicator. The oil pressure will have to be reestablished in approximately 10 seconds. | |
.Engine oil pressure, minimum permissible | |||
36 | Stop the engine and check for eventual leaks | ||
| Engine 904.973/981, 906.998, 924.9 in Type 368.1 | ||
37 | Check the coolant level and replenish, if necessary | ||
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