Remove/install engine with transmission

AR01.10-W-2401B

Remove/install engine with transmission

14.2.12

15.12.09

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

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

*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 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

 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

2.1

Tilt cab using tilting hydraulics

With code (F30) Tilting hydraulics for cab.



Notes on tilting the cab

AH60.80-N-0003-01A

2.2

Tilt cab into repair position

Without code (F30) Tilting hydraulics for cab.

AR60.80-W-0010B

3

Remove soundproofing on the left and right on the frame and soundproofing below

4

Remove charge air pipe from charge air cooler to charge air manifold

AR09.41-W-1311D

5

Remove charge air pipe from turbocharger to charge air cooler

AR09.41-W-1311C

6

Remove fan shroud

AR20.40-W-6800A

7

Detach oil filler pipe (20) at oil pan and secure to frame

 Seal opening at the oil pan.

8

Remove exhaust pipe (22) on engine brake flap fitting and remove at transmission; bind exhaust pipe (22) to frame

 Installation: Clean sealing surfaces. Check clamp (23) for wear, replace if necessary.

9

Detach compressed air line (26) from engine brake cylinder

10

Remove air intake hose (24)

11

Detach line for terminal 30 (28) at starter (M1) and detach electrical wiring harness (27) at bracket



*BA15.30-N-1002-01B

12

Disconnect electric wiring harness (25) at alternator (G2) and at bracket

 Mark lines.

 Installation: note markings.

Up to engine end no. 190707



*BA15.40-N-1010-01B



*BA15.40-N-1011-01B



*BA15.40-N-1012-01B

As of engine end no. 190708



*BA15.40-N-1009-01B



*BA15.40-N-1015-01B

13

Detach ground line (29) and electrical wiring harness (27) at the timing case

14

Unbolt compressed air line (6) at compressor and inspect for carbon deposits

 If carbon deposits are present, it is also necessary to inspect the compressed air line (6) between compressor and compressed-air drier and the four-circuit protection valve.

Replace parts showing carbon deposits.

 Installation: Check compressed-air line (6) for leaks.

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

15

Open fuel tank cap and disconnect fuel feed line (18) and fuel return line (19) at the fuel filter

 Collect escaping fuel. Mark fuel feed line (18) and fuel return line (19).



*BA47.25-N-1008-01J

16

Slacken poly-V belt and remove

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

AR13.22-W-1202A

17

Disconnect electrical connector for refrigerant compressor (21) and detach the refrigerant compressor (21) with bracket at the engine and secure to one side

 Only with code (H03) Air conditioning in front end.
Do not separate refrigerant lines.



*BA01.40-N-1005-01C

18

Pull off cap (1) and disconnect connector for compressed air line (3) from clutch compressed air line (2) for the constant throttle

 Only for engine 904.9.
Press apart with pliers to disconnect bracket (arrows).

19.1

Detach power steering pump and secure to one side with steering pressure line (17) and steering intake line (16) to one side

Not if a reconditioned engine is installed.
 Do not disconnect the steering pressure line (17) and steering intake line (16).



*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

19.2

Disconnect both hoses at steering pressure line (17) and steering intake line (16)

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

20

Release and disconnect electrical connector (14) at engine control (MR) control unit

21.1

Detach clutch slave cylinder at the transmission and secure to the frame with hydraulic line connected

Transmission with clutch slave cylinder.

 Installation: Grease the thrust pins.

*BR00.45-Z-1062-06A

Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

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

21.2

Remove locking element and pull out clutch line (12) at transmission

Transmission with central clutch release bearing.
 Collect escaping brake fluid.

 Installation: Bleed clutch operation.



Brake fluid notes

AH42.50-P-0001-01A

22

Disconnect electrical connector (9, 11) at transmission

 Installation: Install new lead seal (10) at electrical connector (9).

23

Remove propeller shaft (7) at transmission and at frame



*BA41.10-N-1002-01F

24

Unscrew screw/bolt for transmission bracket at transmission bearing (8)

 Installation: Check transmission bearing (8) for wear; replace if necessary.

25

Unscrew screw/bolts at both engine mounts (15)

 Installation: Check engine mount (15) for wear, replace if necessary.

26

Remove engine with removal fixture

AR01.10-W-2400-01A

Load regulator

gotis://H_00.12_04.0

27

Detach transmission from engine

 Installation: If hub on clutch plate or transmission shaft is not nickel-plated:



Lightly grease transmission shaft.

*BR00.45-Z-1062-06A

 Transmission 710

*BA26.10-N-1003-01B

 Transmission 712.611

*BA26.10-N-1018-01D

 Transmission 712.62/63, 715

*BA26.10-N-1006-01C

28

Install in the reverse order

29

Initialize all transponder keys

AR80.57-W-0010C

30

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.

 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

31

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

32

Bleed steering system

 Only if a reconditioned engine is installed.

Steering 765.83/84

AR46.25-W-3300C

Steering 765.861

AR46.25-W-3300A

33

Turn off engine

34

Check engine, cooling system and steering hydraulics for leaks

 Visual inspection.

35

Set time and synchronize tachograph

36

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

BA01.40-N-1005-01C

Screw/bolt, refrigerant compressor carrier to crankcase

Nm

55

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

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

BA15.40-N-1009-01B

Screw/bolt, ground line to alternator

Nm

-

12

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

-

BA15.40-N-1015-01B

Nut, electrical line to alternator terminal B2+

Nm

-

30

Number

Designation

Transmission 710.59/60/69

Transmission 710.62/68/82

BA26.10-N-1003-01B

Transmission to engine

Nm

50

50

Number

Designation

Trans-mission 712.62,
715.050

Trans-mission 712.63,
715.060/
068

Trans-mission 715.320/
321

Trans-mission 715.570/
576

BA26.10-N-1006-01C

Transmission on engine

Nm

50

50

50

50

Number

Designation

Transmission
712.611

BA26.10-N-1018-01D

Transmission on engine

Nm

50

Number

Designation

Model 374

Model 375.1, 958.0,
970, 972, 974, 975, 976

BA41.10-N-1002-01F

Bolt/nut, propeller shaft to flange connection

M10

Nm

60

60

M12

Nm

100

100

M14

Nm

160

160

M16

Nm

200

200

Number

Designation

Steering
765.8, 766.4
with engine
900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9

BA46.30-N-1001-01B

Screw/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