Remove/install engine with transmission

AR01.10-W-2401G

Remove/install engine with transmission

14.2.12

28.11.07

Value changed: Air intake pipe hose clamp

Engine 541.9 with code MJ1

Engine 542.9 except code MJ1

Engine 542.9 with code MJ1

*BA09.20-N-1002-02C

 

Remove/install

 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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

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

2

Disconnect ground lead from battery



Notes on battery

AH54.10-P-0001-01A

3

Detach the trim panel (3) on the cab rear wall

 Only in vehicles with code (F15) MEGASPACE cab.

4

Open maintenance flap

5

Remove cover of cab chassis connector plate (2).

 Installation: Check seal on cover and replace cover if necessary. The cover should be closed tightly.

6

Disconnect electrical connectors for electrical engine wiring harness (1) at cab-chassis connector plate (2)

7

Unclip electrical engine wiring harness (1) and place downward

 Danger!

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.

AS60.80-Z-0001-01A

8.1

Tilt cab

Vehicles without code (GS3) "Hydraulic" gearshift.



Notes on tilting the cab

AH60.80-N-0003-01A

 Danger!

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.

AS60.80-Z-0001-01A

8.2

Remove sensor unit with hydraulic lines on cab

Vehicles with code (GS3) "Hydraulic" gearshift

AR26.60-W-0012-01G



*BA26.60-N-1025-01D



*BA26.60-N-1026-01D



*BA26.60-N-1030-01D



Notes on tilting the cab

AH60.80-N-0003-01A

9

Detach soundproofing at frame at top left and right

10

Detach electrical engine wiring harness (1) at fixture and frame and tie up at engine

11

Clamp off coolant line (31) using clamping device (32)

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



*000589543700

12

Clamp off coolant line (35) using clamping device (32)

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



*000589543700

13

Drain coolant

AR20.00-W-1142A

14

Remove oil dipstick guide tube (12) on radiator and tie to engine

15

Disconnect oil filler pipe (10) between engine and radiator at connecting point

16

Detach charge air hoses (13, 14) at charge air cooler

 Installation: Check charge air hoses (13, 14); replace if necessary. The charge air hoses (13, 14) must not get mixed up, only the charge air hose (red) (13) is temperature-resistant.



*BA09.41-N-1006-01C

17

Remove air intake hose with air intake pipe (4)



*BA09.20-N-1001-02C



*BA09.20-N-1002-02C

18

Detach compressed air line (19) at compressor and at connecting point on frame

 Installation: Check compressed-air line (19) for signs of carbonization.

In the event of carbonization, check compressed-air line (19) up to four circuit protection valve and replace coked parts if necessary.

19

Remove step plate over transmission

20

Remove compressed air and supply lines to cab mount

21

Detach cab support from frame

 Cut cable ties and move cab support to one side with the lines connected.



*BA60.80-N-1016-01B

22

Detach brackets for compressed-air line (19) at engine and at transmission

23

Disconnect constant throttle compressed air line (22) on holder

24

Disconnect engine brake compressed air line (23) on holder

25.1

Disconnect compressor control line (20) on holder for timing case on the left

Vehicles with code (MZ7) Engageable 1-cylinder compressor or with code (MZ8) Engageable dual compressor, without code (MS4) BlueTec 4 or code (MS5) BlueTec 5

25.2

Disconnect compressor control line (37) on holder for timing case on the right

Vehicles with code (MZ7) Engageable 1-cylinder compressor or with code (MZ8) Engageable dual compressor, in combination code (MS4) BlueTec 4 or code (MS5) BlueTec 5

26

Separate compressed air line for AdBlue metering device (21) at bracket on left of timing case

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

27

Disconnect compressed air line (5) to transmission

28

Detach exhaust pipe at engine brake flap fitting (16).

 Installation: Clean sealing surfaces and check clamp; replace clamp if necessary.



*BA49.10-N-1001-01J

29

Pull retainer (arrow) and disconnect connection piece (30) on SCR tank heater solenoid valve (Y107)

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

Collect coolant which flows out.

 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

30

Disconnect AdBlue hose (33) with clamping device (32) and disconnect at AdBlue line (34)

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

 Catch escaping AdBlue and dispose of it. Do not reuse caught AdBlue since contaminated AdBlue can lead to damage in exhaust aftertreatment system.



*000589543700

 Installation: Before assembly of AdBlue hose (33) check for foreign objects, contamination and damage.

If the AdBlue hose (33) is reused, in the area in which the hose clamp was seated it must be shortened by approx. 2 cm. If as a result the AdBlue hose (33) should be too short, it must be replaced.

Replace 1-ear clamping device by using a clamp pliers with side cutting pliers.



Notes on use, material properties and handling of AdBlue®

AH14.40-N-0001-01A

31

Detach coolant line (35) on the coolant manifold (36)

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

Collect coolant which flows out.

 Installation: Install new sealing rings.

32

Detach all coolant hoses from engine to radiator

 Only disconnect coolant hoses at radiator.

 Installation: Check coolant hoses and clamps; replace if necessary.

 Danger!

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; shield off hazard area if necessary.
Inspect special tools for damage and proper operation (visual inspection).
Wear protective gloves.

AS00.00-Z-0001-01A

33

Release tension on alternator poly-V belt and remove it from belt pulley for refrigerant compressor

 Only for vehicles with code (H03) Air conditioning in front end or with code (H07) AAC.

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

Routing diagram of poly-V belt

AR13.22-W-3902-02A



Damage profiles for a poly-V belt

AP13.22-D-1351-01A

34

Unplug electrical connector at refrigerant compressor and detach refrigerant compressor at bracket

 Only for vehicles with code (H03) Air conditioning in front end or with code (H07) AAC.

Do not detach refrigerant lines and attach refrigerant compressor to the frame.



*BA83.55-N-1002-01C

35

Separate transmission oil lines (11) at connecting points to oil cooler and close off with an appropriate plug.

 Only on vehicles with code (N55) Transmission oil cooling.

Collect escaping transmission oil.

 Only disconnect transmission oil lines (11) at connecting points to transmission oil hoses. If transmission oil hoses are removed at the oil cooler, the oil cooler can be damaged.

36

Remove bolts to the right and left radiator mounting and press radiator forwards

37

Remove propeller shaft on engine power take-off at the rear and bind to one side

 Only for vehicles with code (N52) Rear engine power take-off, output torque 600 Nm.

38

Remove hydraulic pump on engine power take-off at the rear and bind to one side

 Only for vehicles with code (N53) Rear engine power take-off, for hydraulic pump.

Do not separate hydraulic lines.

 Installation: Install new gasket

39

Remove the propeller shaft on transmission output flange and strap down to one side



*BA41.10-N-1002-01F

40

Disconnect adapter or connections on PTO

41

Remove electrical line for circuit 30 on starter (M1), on timing case and on transmission



*BA15.18-N-1003-01A



*BA15.30-N-1002-01C

42

Detach ground line at timing case and at transmission

43

Remove compressed-air line on clutch servo unit (25)

 Only on vehicles without code (GE2) Electronic drive control II or without code (GE3) Mercedes PowerShift.

Do not separate hydraulic line.



*BA25.20-N-1003-01J



*BA25.20-N-1010-01J

44.1

Remove clutch booster (25) on transmission and attach to frame

Vehicles without code (GE2) Electronic drive control II or without code (GE3) Mercedes PowerShift.

 Do not disconnect hydraulic line and compressed air line.



*BA25.20-N-1001-01J

 Danger!

Risk of injury caused by body parts being trapped or crushed when working on the pressurized clutch actuator

Always remove ignition key and open bleed screw before removing clutch actuator.

AS25.00-Z-0001-01A

44.2

Remove clutch actuator (24) on transmission and attach to frame.

Vehicles with code (GE2) Electronic drive control II or code (GE3) Mercedes PowerShift

AR25.20-W-3000A

45

Pull plunger out of the clutch release lever

 Installation: Clean tappet and check for damage; replace if necessary.

Lubricate tappet head, tappet cup with long-life grease.

*BR00.45-Z-1001-06A

 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

46

Disconnect fuel feed line (6) and fuel return line (7) at connecting points in right longitudinal frame member and close

 Collect escaping fuel.

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

AS00.00-Z-0013-01A

47

Disconnect steering oil return line (8) and steering oil pressure line (9) to power steering pump

 Catch escaping hydraulic fluid.

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

AS00.00-Z-0013-01A

48

Disconnect steering oil return line and steering oil pressure line for primary power steering pump

 Only on vehicles with dual circuit steering system 765.887.

Collect escaping hydraulic oil.

49

Detach compressed air line at proportioning valve of retarder (18)

 Only vehicles with code (BA1) Performance-optimized Voith retarder or with code (BA9) Voith secondary retarder R 115.

50

Hook in engine hoist (15) to the front and rear engine mount then insert at rear lifting eyes at transmission and secure engine and transmission against tilting using a chain hoist

51

Remove left and right bolts (17) on transmission carrier

 Transmission 715.500/507/510/513/520/
540

*BA26.10-N-1003-01C

 Transmission 715.350/370/380/515/525

*BA26.10-N-1003-01KL

52

Remove bolts on left and right engine support (26)



*BA22.10-N-1004-01D

53

Lift out engine together with transmission

 Do not damage lines, connectors and detachable parts.

54

Place engine on engine supports (26) and transmission carriers (17) at right and left on jack stands

 Secure engine and transmission against falling down and tilting.

55

Check engine mount and transmission bearing in frame for wear

 If necessary: replace engine mount or transmission bearing.



*BA22.10-N-1006-01D

56

Install in the reverse order

57

Re-teach in transponder keys (also replacement keys)

 Only after installing a new motor.

AR80.57-W-0010C

58

Check engine oil level using oil dipstick or on display, correct if necessary

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



Notes on engine oil

AH18.00-N-0101-01B

59

Check transmission oil level, correct if necessary

AR26.00-W-0100A

 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 moving off.

Wear closed and close-fitting work clothes.

Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

60

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

 The fuel system is bled automatically. If engine fails to start or only runs for a brief period:



*BE18.00-N-1001-01D



Purge fuel system by hand.

AP47.00-W-1720-01A

61

Switch off engine and check for leaks

 Visual inspection.

62

Bleed steering system

Steering system 765.82

AR46.25-W-3300C

Steering 765.887

AR46.25-W-3300B

63

Synchronize time between tachograph disk and display

64

Enter engine number in FDOK screen 1111

 Only after installing a new motor.

Number

Designation

Engine 541.9, 542.9

BE18.00-N-1001-01D

Engine oil pressure at

Idling speed

bar

0.5

maximum speed

bar

2.5

Number

Designation

Engine
541.9
except code MJ1

Engine
541.9
with code MJ1

BA09.20-N-1001-02C

Bolt, air intake pipe at bracket

Nm

50

60

BA09.20-N-1002-02C

Air intake pipe hose clamp

Nm

6.0

6.0

Number

Designation

Engine
542.9
except code MJ1

Engine
542.9
with code MJ1

BA09.20-N-1001-02C

Bolt, air intake pipe at bracket

Nm

50

60

BA09.20-N-1002-02C

Air intake pipe hose clamp

Nm

6.0

6.0

Number

Designation

Engine
541.9

Engine
542.9

BA09.41-N-1006-01C

Clamp, charge air hose to charge air housing/charge air pipe and charge air cooler

Nm

7.5

7.5

Number

Designation

Engine 541.9, 542.9

BA15.18-N-1003-01A

Bolt, wiring loom to timing case

Nm

25

Number

Designation

Engine
541.9, 542.9

BA15.30-N-1002-01C

Nut connecting circuit 30 line to starter/solenoid switch

Nm

30

Number

Designation

Engine
541.9

Engine
542.9

BA22.10-N-1004-01D

Bolt, engine carrier to engine mount

Front

Nm

330

330

at the rear

Nm

330

330

BA22.10-N-1006-01D

Engine mount to frame

Front

Nm

150

150

at the rear

Nm

150

150

Number

Designation

Model
930, 932,
933, 934

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-1003-01C

Supporting arm to frame

Nm

330

Number

Designation

Transmission
715.350

Transmissions
715.370/380

Transmission 715.515/525

BA26.10-N-1003-01KL

Supporting arm to frame

Nm

330

330

330

Number

Designation

Transmission 715.500/507/510/513/520/540
with code GS3 without code IY2

Transmission 715.500/507/510/513/520/540/561 with code GS3 and code IY2

BA26.60-N-1025-01D

Nut and bolt, shift control unit to center tunnel

Nm

30

30

BA26.60-N-1026-01D

Bolt, HPS line bracket to center tunnel

Nm

20

20

BA26.60-N-1030-01D

Clamp bolt for gearshift lever

Nm

20

20

Number

Designation

Model
930, 932, 933, 934

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

Engine
541.9, 542.9

BA49.10-N-1001-01J

Clamp bolt, exhaust pipe to engine brake valve fitting

Nm

50

Number

Designation

Body 943.899
in model 930, 932, 933, 934, with code FL2 or FL4

BA60.80-N-1016-01B

Bolt behind cab carrier
on vehicle frame

Nm

225

Number

Designation

Model
930, 932, 933, 934, 950.0, 950.1, 950.2, 950.3, 952.0, 952.1, 952.2, 952.3, 953.1, 953.3, 954.0, 954.1, 954.2

BA83.55-N-1002-01C

Support on fixture for refrigerant compressor/frigoblock and alternator support

Nm

50

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11