Engine OM 904 LA, OM 906 LA (Mod. des. 904.9, 906.9) Order no. 6517 5124 02 Printed in Germany 0700 0,1 ffPart Title ‘Technical data of complete engine Disconnecting, connecting engine witing harness Removing, installing engine Removing, installing engine Removing, instaling engine with transmission Removing, stalling engine with transmission inspecting engine for dust damage inspecting cylinders with light probe "esting compression pressure ‘Removing, installing elinder head cover iRemaving, installing il separator Removing, installing ll separator Removing, insaling protective sleeve ‘Removing, installing cylinder head Removing, installing decompression brake valve ‘Checking, facing inde head contact surdace leaning main oi galiery iWeasuring ojinder bores Flexchening einder wail ‘Widening cinder bore in crankcase Removing eyinder liner installing Glinder liner Valiity ENGINE 904.9, 906.9) ENGINE” 906-920 7824 1993 1903 1908 7526 1937 ToD Todd 79a ENGINES 904 S09 /910 /911 1918 /916 /917 7922, 906.910 /911 sis /3i6 ENGINES S06 S20 7924 1972 1903 7928 fSn6 027 on 9A 9a NiGiNES 904 908 1908 i907 i924 ENGINES 804 S08 /910 1911 1915 1916 1817 1922, S08 910 181% 1918916 ENGINE Sai, 542, 964, S08 ENGINE 904-905 1906 1907 7808 1908 /8i0 917 1918 916 917 1821 1922 /933, 906 910/911 /915 /916 919 920 /921 1922 1823 1825 /926 /927 1928 939 /940 (941 (942 943/951 /952 ENGINE 904-805 /908 907/908 /909 /910 911/921 1922 1923, 506.910 /911 1920 921 1922 923 940/941 /942 1943 /981 1952 ENGIN 90d. 808 1808 1907 /808 /909 /St0 1911 fats 916 917 7321 1922 (933, 906910811 /915 916 919/920 /921 /922 1823 /925 /926 927 (928 939 /940 /941 942 943 /951 /952 ENGINE 904 908 /906 (907/910 7921 ENGINE 904908 /923 in MODEL 668, 570 ENGINE 904.909 /911 /922 ## up to.040652 ENGINE 906.910 /911 /919/920 /921 /922 923 #1 upto ‘87608 ENGINE 906.940 /941 ## up to 047608 in MODEL 957 ENGINE 904909 /917 7922 04 as of O40683 ENGINE 908,910 /911 /920/921 1922 /923 /940 /941 ## as of (047609 ENGINE 904.915 1916 /917, 906.915 /916 /919 925 926 927 1928 939 /982 /943 ENGINE 964 965 1906 1907 /968 i908 (910 i911 1915 1946 1917 182% 1922 1933, 806.910 911/915 /916 /919,920,/921 1922. 1823 /825 1926 /927 1928 39 /940 (941 1942 943/951 /952 ENGINE 904.905 1906 1907 1909 i910 1917 1915 916 1917 i921 1822, 906.910 '911 /915/916 /919 /920 /921 922/923 1925, 1826 /927 1928 (939 1940 (281 /942 (983 951/952 ENGINE 904-805 1806 f907 1808 (910 1917 1918 916 917/804 7922, 906,910,911 1915 /9°6 /919 920/921 /922 /923 /925 1826 /927 1928 (939 940 (s81 /942 /943 9511952 ENGINE 908,908 923 wthCODE (MB) Engine bake with constant throttle ENGINE 90d 908 1908 907/808 /909 /9i0 7917 ois 916/917 1921 1922 /923, 906.910 '9°1 1915 1916 /919 /920,/921 922. 1923 1925 1926 /927 1928 939/940 /981 /942 943 /951 1952 ENGINE ‘804308 906 967/908 /309 910 917/918 /916 1917 1921 1822 1923, 806.910 /9'1 915 /916 /919 920/921 1922 1823 1825 /926 /927 1928 39 /940 /941 (942 943 /951 1952 ENGINE 804.808 1806 7907 908/808 /910 fat W915 916 917 1921 1922 1933, 806.910/911 /915 /916 /919,920,/921 1922, 1823 /825 /926 /927 1928 939 /940 (941 (942 (943 /951 /952 ENGINE 904-808 7606 (907/909 j9 10 1911 915 916 917/924 17322, 906:910 1911 /915,/916 /919 /920 921 7922 /923 /925 1926 /927 1928 1939 /942 343 ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 906.940 /941 /951/952 in MODEL957 ENGINE 904-908 1906 f307 1909 [810 f917 918 916 919/504 322,906 910 911 /915 916 /919 920 921 1922 /923 /925 1926 /927 1928 939 942 /9t3 ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 906'940 /941 /951 952 in MODEL9S7 ENGINE 908.981 in MOUEL 84 ENGINE 904 905 1906 967/909 [910 f917 18 916/917 1594 1823, 906.910 /911/915 /916 /919 /920 921 922/923 925 1826 /927 /928 '939 /942 943 ENGINE 904.908 /923 in MODEL 668, 670, ENGINE 908,340 /941 /9517952 In MODEL 957, ENGINE 904-808 1908 1907 7809 /910 1917 1918 916 947 193% 7922, 906.910 /911 1915 916/919 /920 921 1922 /923 /925 1826 /927 1928 (939 /942 1943 ENGINE 904.908 /923 in MODEL 668, 70 iE 908,940 /941 /951/952 in MODEL957 Page fw 36 ‘a ‘a 3 38 38 ef oH a 6 Cy 6 8 cy ca 6 93 GER Engine OM 808 4,00 061A Mod. des. 904.9, 8065), partTitle Validity Page, Removing and installing oll pan ENGINE 904.905 /906 907 921 97 Removing and installing oll pan ‘ENGiNE ‘904 909 f910 1917 918 946 917 1922, 906,910/911 98 1915 /916 919 920 921 1922 /923 /925 926 (827 /928 /939 1382 (943 Removing, insaling timing case ENGINE 904908 1908 907 08 910 817 1918 916/917 921° 01 7922, 906.910 /911 915/916 /920 /921 1922 1923 /925 /926 1927 /928 1939 942/943, ENGINE 904.908 /223 in MODEL 668,570 ENGINE 806'940 /941 /951 952in MODEL957 Femeving, installing timing case ENGINE 906 920 1991 7932 /923 /928 1926 7027 7928 08) ‘timing case SAE 1 or 2, readied for engine output or installed engine output[contents part? Title Removing and installing pistons Removing and installing piston Testing, repaiting connecting rod Repiacing front crankshaft radial seal Replacing rear crankshaft radial seai Removing and installing crankshaft ‘Measuring and mounting crankshaft Removing and installing crankshaft gear Removing, instaling drive gear for ol pump on erankshatt Removing ard installing belt puliey/vibration damper ‘Removing, installing fiywheel “Checking and re-machining fies! Replacing ving gear of fiywheel Removing, installing guide bearing in fywheei Removing, installing guide bearing in fiywheei ‘Checking waive lift ‘Removing installing rocker arm assembly Validity ENGINE 904.905 /906 /907 909 /910 1911 1915 1916 917 /92% 7322, 906:910 1911 915 816 /919 920 921 /922 /923 1925 1926 /927 1928 939 942 943 ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 906.940 /841 /951 952in MODEL9S7 ENGINE 904 908 1908 1907 i909 /st0 914 1915 948/919 1994 1922, 906.910 /911 /915 /916 /919 /920 /921 1922923 /925 1826 /927 /928 /939 1942 7343, ENGINE 304.908 /323 in MODEL 668, 670 ENGINE 806.840 /941 /951 952in MODEL 957, ENGINE 964-808 (806 1307 /908 1909 /910 1917 7918 916/917 1924 1822 1933, 806 910/911 /915 916 919/920 /921 /922 1823 /825 /926 /927 1928 939 /940 /941 942/943 /951 (952 ENGINE 904.905 (906 (907/908 7910 fat 918 96/917 1994 7922, 906,910 911 1915 916 /919 920 921 1922 /923 925 1826 /927 /928 /939 /942 743 ENGINE 904.908 /923 in MODEL 668, 670, ENGINE 806.840 /841 /95"7952in MODEL 957 ENGINE 964-808 1806 i307 908 /9 10 1917 915 916 917/924 7922, 906.910 /911 1915,916 /919 920 921 1922 /923 1925 1826 /927 1928 1939 (942 943, ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 906.540 /941 /951 /952 in MODEL957 ENGINE 904 905 /906 907/908 /909 910 917 1918 /916/947 1821 1822 1323, 906.910 /911 1915 1916 /919 /920,921 1922. 1823 1825 1826 /927 1928 939/940 /981 (942 943 /951 1952 ENGiNe 604-808 1806 7807 68 908 /910 1917 1915 f9i6 917 1921 1922 /923, 806.910 911/915 /916 /919 920/921 /922 1823 1825 /826 /927 1928 939 /940 (941 1942 943/951 /952 ENGIN 904-808 (608 i307 1908 f9i0 1917 1915 96 [917/924 7922, 906.910 1911 1915916 /919 920/921 1922 /923 1925 1926 /927 1928 1939 942 943 ENGINE 904.908 /923 in MODEL 668,670 ENGINE 806.840 /841 /951/952 in MODEL9S7 ENGINE 904.305 /906 '907/309 /910 fa11 1918 7946 917/924 1822, 906.910 /911 7915 916/919 /920 /921 922/923 925, 1826 1927 1928 /939 /942 1943, ENGINE 904-908 /923 in MODEL 668, 670, ENGINE 806°840 /841 /951/952 in MODEL 957, ENGINE 904.905 1906 (907 /908 /910 (911 1945 1916 1917 1921 7922, 906'910 1911 915/916 /919 920 921 1922 /923 1925 1826 /927 1928 /939 940 (881 /942 1983 951 1952 ENGINE 804 805 /906 /907 i909 /3i0 fati 918 1916 917/924 1922, 906.910 /911 /915 /9°6 /919 /920 /921 1922 923 925, 1926 1927 /928 1939 /942 /s43 ENGINE 902.908 /923 in MODEL 668, 670 ENGINE 806.840 /941 /951/952 in MODEL 957 ENGINE 804.808 1906 1307 /909 /9i0 1917 1918 1916 917 1994 1822, 906.910 /911 19151946 /919 920 921/922 /923 1925 1926 /927 1928 1939 (942 343 ENGINE 904.908 /923 in MODEL 668, 670 ENigiNe 904.805 j906 (907/809 /9i0 i917 1818 916/917 /90% 17822, 906 310 911 915 916 /919 920 921 1922 /923 925 1826 /827 /928 /939 /942 /943 ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 904 96 905 907/909 910/911 19311234 Up to 408313 ENGINE 906.910 /911/920/921 /922 /923 ## up to 106161 ENGINE 804-908 /923 in MODEL 668, 670 ENG 804.808 1808 1607 7808 1910 7911 1931 1032 1836 1933 ‘#2 as of 106314 Enicine 906-910 /911 /920/921 /922 /923 /929 932 933 #4 «> of 106162, ENGINE 904.915 /916 /917,906.915 /916 925 926/927 /928 1939 /942 /983 ENGiNE 804-808 7806 1907 808/910 191 1913 1916 917/931 1822, 906.910 /911 /915 916/919 /920 921 1922 1923 /925 1826 /927 1928 (939 (942 1983 ENGINE 904.908 /923 in MODEL 668, 670, ENGINE 906.940 /941 /951 952in MODEL957, ENE 904 308 1908 1907 1908 1924 #8 up to 38739 B 38 8 38 36 ‘ a6 ‘8 52 9 Cy @ ea GER Engine Oo S044, OM 9061 (Mod. de. 904, 906.9, part2Title Removing, installing rocker arm assembly Disassembiing, assembling rocker arm assembiy Removing and installing vaives Replace valve guide Replacing valve stem seais Replacing valve seat rings Validity ENGINE 904.905 /906 907 1908 /921 ## as of 039740 ENGINE 304.909 /910 911 915/916 {917 922/923, 906,910, 914/915 1916 1919 920 921 /922 (923 925 /926 1927 1928 939 /900 /941 1942 943 /951 /952 ENGINE 904 905 /908 907/908 /909 910 91 1918 /916 /917 921 1922 1933, 86.910 911/915 /916 919 /920 /921 /922 1923 /925 1926 927 1928 /939 /9d0 /941 1942 /943 (951 952 ENGINE 908 905 /908 1907 909 /910 911 018 916/917 1924 7922, 906.910 911 915/916 /919 /920 921 /922 /923 /925 1926 /977 1928 938 942/943, ENGINE 904.908 /923 In MODEL 668, 670 ENGINE 906.940 /941 /951 95zin MCDEL9S7 ENGINE 904.905 1906 907/908 /910 911 918 016/917 1904 7922, 906.910 911 915/916 /919 /920 921 /922 /923 /925 (926 /977 1928 938 942/943, ENGINE 904.908 /923 in MODEL 668,670 ENGINE 906'940 /941 /951 952in MCDEL9S7 ENGINE 904908 /906 907 908 /909 ‘910 911 1915 /916 /917 921/922 1933, 906.910/91/915 /916 919 /920 /921 922 1823 /925 1926 927 1928 /939 /940 /941 1942 /943 (951/952 ENGINE 904 905 1906 907/909 /910 911/918 946 /917 1924 7922, 906 910 911 915/916 /919 /920 921 /922 /923 /925 1926 /927 1928 938 942/943, ENGINE 904.908 /923 in MODEL 668,670 ENGINE 906.940 /941 951 952in MCDEL9S7 o 6 Hi a cy[Contents part Title ‘Machining valve seat ings Grinding valves “Removing and installing camshait Removing, installing MiRIPLO control unit Removing, iastaling MRIPiO injection lines Removing and installing nozzie holder combination ‘Removing and installing nozzle holder combination Removing, installing MR/PLD unit pump iiemoving, adjusting and insaling crankahaft angie postion Semsorbracket * eer ‘esting iow pressure fuel credit “esting low pressure fuel dreult inspecting turbocharger Removing ad installing exhaust gas turbocharger Removing, installing boost air pipe Removing and installing charge ar pipe Removing and installing charge air pipe Removing and installing boost air manifold Removing, installing boost air manitoid Removing, installing boost pressure, Boost air temperature “Testing charge air cooler and charge alrhasesYorleaks Validity ENGINE 904.905 /906 /907 /909 /910 1911 915 1916 917/921 1822, 906.910 /911 /915/816 /919 /920 921 1922 /923 /925 1326 /927 /928 (939 /942 943 ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 906,940 /941 /951 952 in MODEL957 ENGINE 904-808 1908 9071909 /9i0 1917 918 948/917 190% 7322, 906:910 911 915 1916 /919 920 921 1922 /923 /925 1326 /927 1928 939 (942 943 ENGINE 904.908 /923 in NODEL 668, 670 ENGINE 906'940 /941 /951 952 in MODEL9S7 ENGINE 904908 1906 19671909 /9i0 911 918 704/919 1934 7922, 906.910 /911/915 (916/919 /920 /921 922/923 /925 1826 /927 /928 /939 /942 343, ENGINE 904.908 /923 in MODEL 668, 670, ENGINE 908,940 /941 /951 /952in MODEL 957 ENGINE 904-908 1908 1907 1809 /9i0 fat 1918 946/917 1984 7922, 906.910 /911 1915 916 /919 920 921 1922 /923 /925 1826 /927 1928 939 942/383 ERiGine” 904-968 1908 19071969 /9i0 i917 818 946 /917 /924 7922, 906,910 911 1915 916 /919 920 921 1922 /923 /925 1926 /927 1928 939 (942 /343 ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 906:940 /941 98" /952in MODEL9S7 ENGINE 904 908 1908 1907 1924 #4 up to aoaa ENGINE 904.908 ## up tc 40487 in MODEL 668, 670 ENGINE 904 808 1906 1907 7921 di as of odode ENGINE 904.908 #4 as of040488 in MODEL 668, 670 ENGINE 904-923 in MODEL 668, 670, ENGINE 904-909 /910 /911 7915 /916 /917 (922, 906,910 911 7915 1916 /930 921 1922 823 /925 1926 927 828 /939 /340 1983 1943 (943 1951 (952 ENGINE” 904-908 1908 1907 1808 /909 /9i0 1317918 916 917 7924 1922 /933, 906.910 911/915 /916 919/920 /921 /s22 1923 (925 /926 927 (928 (939 /940 1941 942 943 /951 (952 ENGINE 904 908 1908 1907 1908 /909 /910 1917 921 1923 1923 9 up to 083285, ENGINE 306,910 911 /91$ /920 /921 /922 923 940/981 ## up to.082652, ENGINE 804.805 1906 1907/8244 up to 040487 ENGINE 904 908 7808 1907 7821 di as of 40a ENGINE 304'909 /910 /911/915 /916/917 1922, 906,910 /911 7318 /916 /919 /920 921/822 /923 925 926 927 /928 /939 3d9 /98% (942 1943 (951/952 ENGINE 904,905 1906 (907 /909 1910 /911 1915 1916 1917 1921 7922, 906,910/911 915/916 /919 920 921 1922 /923 1925 1826 /927 1928 (939 940/981 /942 1943 /951 1952 ENGINE 904905 /908 [967/909 /910 917 98 916 /917 1994 922,906 910 911 915 /916 /919 920 /921 1922 /923 1925 1826 /927 /928 /939 /940 /941/942 (943 1951 952 ENN 864'308 308 967/804 ENGINE 904-808 1916 181179185 /916 1817 1832, 306.510 7017 1915 1916 1919 /920 /9217£22 /923 /925 926 (927 1928 /939 940 /9an /942 /943 (951/252. From turbocharger to charge air cooler ENGINE 904-809 /si0 fat 1/918 /9i6 7917 1992, 906.910 017 7915 1916 /919 /920 921 /£22 /923 1925 926 /927 /928 /939 aaa /943 From charge ar cooler to charge air manifold ENGINE 904905 j906 907/921 RGN B04 508 fat 911/918 fae fat7 998, 906.940 1547 1918 19161949 /920 /921 1922 /923 /925 926 927/928 /939 1940 /941 /942 /943 /951 (952, ENGINE '$04.808 7806 7807 /831 7808 ## as of dca 904909 /910 (911 915 915 (917 1922 923,906.910/911 1915 1916 7919 /920 1921 1922 S23 /925 (926 927 928 /939 /942 3 ENGINE 904-868 (516 16111918 foie fot7 1692, 306.910 /9it 1348 946 919/820 921 122/923 925 926/927 928/939 Page 6 is 3a # Fa 3a # ‘io ‘a 66 i i 8 iW 8 cy is BER Engine OM S0414, 0M S061 (Mod. des. 904, 5069), part 3Title Removing and installing poly-V-belt Removing and installing paly V-belt tensioning device Removing, installing compressor Validity ENGINE 904.905 906 1907 909 /9101911 1915 916/917 /921 7922, 806,910 911 915/916 /919 920/921 /922 /923 /925 926/927 1928 939 942/943, ENGINE 904.905 /906 907/909 /910)917 7918 1946 /917 1924 922,806,910 911 915 /916 /919 920/921 /922 /923 1925 1926 /977 1928 939/942 /943, ENGINE 904.908 923 in MODEL 668,570 ENGINES 964.908 /906 1307 1908 /909/910 911 948 1916/9177 921/922 923, 96.910 /911 /915 /916/919 /920 1921 1922 1923 /925 1926 927 1928 /939 1942 (963 ‘with single-cylinder compressor Page 87 9 6(contents Title Removing and installing exhaust manifold Removing, instaling engine brake lap connection Removing, instaling engine brake flap connection Repairing engine brake flap connection iepaiting engine brake fap connection Removing and installing starter Removing and installing generator Removing and installing the generator paly-Vpuley Removing and instliing oil pump Removing and installing the oliwater heat exchanger Removing and installing ol fiter housing Temoving, insaling ol fiter bypass valve Removing, installing ol pressure, ol temperature sensor Removing and installing oilievel sensor Removing and installing oil spray nozzles (pistons) Removing and installing ol spray nozzles (pistons) Filing engine oil ircuit Removing and installing engine codiant pump Disassembling, assembling coolant pump Removing and installing engine coolant thermostat ‘esting coolant thermostat Parte Validity ENGINE 904.905 /906 1907 909 /910 1911 1915 1916 917 /921 7922, 906 910 /911 1915 /916 /919 920 921 922 /923 /925 1826 /927 1928 (939 940 (981 /942 (943 951 1952 ENGINE 904.95 906907909 910/911 915 91678177821 ENGINE 906.910 1971 1915 1916 1919 1920 1921 1922 1923 1925 19261927 1928 /939 /940 /941 /942 /943 951 952 ENGINE 96d 908 1908 907/908 /909 /a10 94/918 /916 1917 19211922 1923 ENGINE 806 910 fat [918/916 /919 fan0 a3 V903 1823 1595 1926 /927 /928 /939 /940 941/942 /943 [ENGINE 964 905 1906 /907 i909 /910 1911 1915 /916 /917 /921 1922, 906.910 /911 1915 916/919 /920 /921 922/923 1925 1826 /927 1928 /939 /940 941 7942 (943 951/952 ENGINE 904.908 /906 /907 909 j910 /911 /915 916 917 1921 17322, 906.910 /911 /915,/916 /919 /920 921 1922 1923 /925 1826 /927 1928 /939 942 43, ENGINE 904.908 /906 /907 i909 jai /91 1913 i916 [917 1904 7322, 906.910 1911 /915/916 /919 920 921 1922 /923 1925 (926 /927 1928 (939 942 543, inigiNe 904.905 /906 (907 1909 /9i0 191 1913 916 1917 1984 7922, 906.910 /911 915/946 /919 /920 921/922 /923 1925 1826 /927 1928 939 (92 (£43 951/952 ENGINE 904.808 /823 in MODEL 668, 670, ENGINE 906.940 /981 in MODEL 957 ENGINE 904 905 /906 /907/909 /9i0 /a1 1 1915 916 917/924 7922, 806 910 1911 915 /9°6 /919 920/921 1922 /923 /925 (826 /977 1928 /939 940 (S41 /342 /943 9511952, ENGINE 904 905 1906 907/909 /910 i911 1915 916/917 1924 1822, 906.910 /911 /915 /9°6 /919 /920 1921 /922 923 925, 1926 /927 1928 /939 /940 /941/942 /943 /951 1982 ENGINE 964 908 /906 19071921 #4 up to 16109 ENGINE 804.308 ## up to 16109 in MODEL 668, 670, ENGINE 904.908 /906 1907 i908 /92% #4 as of 040d ENGINE 904.915 1916 /917 909/910 /91 1/922 923, 906.910 1911 1915 /946 /919 /920 921/922 /923 /925 926 927 /928 1939 /9a0 /9a% (942 /943 /951 /952 ENGINE 804.808 1516 18111918 (916 1917 1823, 906.510 (917 1918 /916 /949 /920 921/922 /923 /925 926 927 /928 /933 1940 /94% /951 (952 (942 943 ENGINE 804-968 1823 in MODEL 668, 670 ENGINE 904.95 906/907 909/910 911921 922 #4 upto 192 ENGINE 906.910 /911 (920/921 /922 /923 ## up 10067198 ENGINE 806.840 /841 ## up to. 067198 in MODEL957 ENGINE 904969 j9t0 911 1922 #9 as of 066193 ENGINE 906.910 /911 (920/921 /922 /923 940 941 ## asof ‘og7199 ENGINE 904.915 /916 /917, 906.915 /916 /925 926 /927 /928 939/942 943/951 1952, ENGINE 964 908 /906 19671809 90 iat 1918 946/917 1994 1822, 906-910 /911 /915 /916 /919 /920 /921 1922923 925, 1926 /927 1928 /939 /942 /343 ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 908,840 /941 /951/952in MODEL 957 ENGINE 904.805 /906 73077909 /910 191/915 /916 917 921 1923, 906.910 /911/915 916/919 /920 /921 1922923 /925, 1926 /927 1924 /939 /940 91 1942 (943 (991 (952 Engine ‘964.905 i906 /907 1909 /9i0 /91% 1915 916 917/934 7993, 906.910 1911 915/916 /919 1920 92 1922 /929 1925 926 /927 1928 /939 (942 943 ENGINE 904.908 /923 in MODEL 668, 670 ENGINE 806.940 /941 /951/9527 in MODEL 957 ENGINE 904.905 /906 (907/909 /9i0 /911 1915 1946 1917 1984 7322, 906.910 911 915/916 /919 920 921 1922 /923 /925 (926 /927 1928 1939 942/983 ENGINE 904.508 /923 in MODEL 668,670 ENGINE 906.940 /941 /951/952 in MODEL9S7 ENGINE 904'3; 906.9, ENGINE 541.8, 542.9 Page 3 is 8 2 Fr aa 8 ‘6 a ‘é 50 82 58 7 ER Engine OM SO4LA OM SO6LA (Nod. des. 9089, S06), partTite Removing and installing fan shroud Removing and installing fan Removing, installing radiator Removing and installing radiator Removing and installing radiator Removing and installing expansion tank Removing grease and scale in cooling system ‘Checking cooling System forieaks Removing and installing coolant ievel sensor Removing and installing power steering pump Removing, instaliing fuel fui-fiow fer Removing and installing fuel fulltiow filter ‘Removing, installing fuel heat exchanger ‘Removing and installing fuel pumps Vatiaity ENGINE 904,909 1910 1911 1915 /916 /917 922, 906.910 /911 1918 /916 939 942/943, ENGINE 904.909 fat0 1911 1915 /9%6 /917 1922, 906.910 /917 (315 916/919 920 921/922 923/925 926 927 528 939 ENGiie 904 308 7308 967 831 ENGiNe 904.909 i910 1911 915 1916 1917 922 ENGiNie” 906.920 1924 1992 1923 7928 /906 927/928 /9a2 Joa ENGiNie 908.909 f910 1911 7918 7916 /917 1922, 906.910 /911 1918 /916 with BODY 972.899 ‘ENGiNE 904-905 1906 f9G7 908 /9i0 /911 918 946 /917 182% 1822, 906.910 /911 915/916 /919 /920 921 1922 /923 /925 1826 /927 1928 1939 942 943, ENGINE 904.908 /923 in MODEL 668, 70 ENGINE 906 940 /941 /951 /952 in MGDEL 957 ‘ENGINES 904-809 1910 1917 1918 916/917 922, 806.910 /9it 1918 /916 (940 941 942/943 /951 /952 ‘ENGiNE” 90d.909 fat0 911 915/916 /917 922, 06.910 (911 1918916 939 942/943, ‘STEERING 765.602 1604 1608 (420 /a2' [630 (640 4 fat ass /889 with ENGINE 904.305 /906 907 /909 /910 911 915, 1916 /917 (921 1922, 06.910 /911 /915 /916 /919/920 /921 (B22 93 9251926 927 926/939 940 941 1942943951 ENGINE 804 905 1906 807 1901 #4 upto 33981 ENGINE 904 908 ## up to 33991 in MODEL 668, 670 ENGINE 80d 905 1906 907 /908 /821 ## as of 033902 ENGINE 904,909 910/911 /915 /916 1917 1922 /923, 906, 910 1911 1918 /916 /919 920 921 1922 /923 925 1926 1927 /928 1939 /940 /941 1942 943/951 /952 ENGINE 904905 1906 /907 1921 #4 up 1033991 ENGINE 804 308 ## up to 33991 in MODEL 668, 670 ENGINE 904.903 7906 807 1809 /310 911 1918 /916 /917 1321 1922, 906.910 /911 915 916/919 /920 921 922/923 /925 (926 927 1928 939 /942 /943 ENGINE 904908 923 in MODEL 668, 670 ENGINE 906'940 /941 951 /952in MCDEL 957 59 ef 6 és @ 6 8 8 w 76 6 # a aePart 1[sF0%-00-w-2000a [Technica data of complete engine 28.11.96 ENGINE 904.9, 906.9 echnical data engine [OM 904LA (engine 904.805) Page3 }OM 90414 (engine 9045061908) Page 4 (OM 9081A (engine 904307) Pages (OM 041A (engine 904.308) Pages (OM 9081A (engine 904915) Page? JOMS041A (engine 904.911) Pages JOM 90418 (engine 904521/822/923) Page 9 JOMS04LA (engine 904.916) Page 10 Jo S06LA (engine 906.910/920/922) Page 11 Jon 20618 (engine 306.940) Page 12, Jon 9061A (engine 906 915,925/927/95%) Page 13, Jom 9061A (engine 906 911/921/923) Page 14 Jon 9061A (engine 906.941) age 15 JOM 9061A (engine 906.916/926/928/952) Page 17 (OM 9061A (engine 906.939) Page 18 (OM 9061A (engine 9065201922) Page 19) [sroraow-ieoa1A [Fecal dts rane gine 908905 or P Engine output M Engine torque Rated speed b Speci fuel consumption " BE engine om 041A, OM 506A od, de 9049, 5069), prt 3echnical data engine Engine model designation [904.905 Engine type OM SOTA TT Engine power) wine [a0(r22) tom 7300 Engine torque (M) max Ne 70 pm 72001500 Ratedspeed pm 2300 Bore oa 702 Stroke mam 130 FFotaldaplacement ms aa50 [Compression ratio @ 7 Firing order 1342 [Number and arrangement of finders fainting valves Talet 2 Exhaust 1 [Working method “stroke diesel with drectinjection [Combustion method Exhaust turbocharger and intercooler Injection method Single unit pump with pump-linesnozzle system (PLD) Timing Electronic engine management with solenoid valve-controlled fuel Injection SpediicTuel consumption (B) gikWh Gee diagram) | GFO1.00-W-1000-018 [Engine 904,906/908 IGF Engine output M Engine torque Rated speed b Specific fuel consumption 2 ee 8 trae[Engine model designation [904,906/908 Engine type (OMSoaLA TT Engine power) win "100 (136) ‘pm 2300 Engine torque (M) max. Ne 520 ‘pm 12001500 Rated speed ‘pm 2300 Bore mam 102, Stroke mm 130 Frotal displacement ms aso [Compression ratio. e Ta 1342 inline inlet 2 Bihaust 7 Working method “stroke diesel with directinjection [Combustion method Exhaust turbocharger and intercooler Injection method Single unit pump with pump-line-nozzle system PLD) Timing Electronic engine management with solenoid valve-contrlied fuel Injection Specific fuel consumption () ‘gkWh_Geediagram) | GFO1.00-W-1000-01C Technical data engine Engine 904.907 GF P Engine output M- Engine torque n Rated speed 6 Specific fuel consumption ELE ER Engine oo S044, OM S061 (Med. des. 904.9, 5069), part[Engine model designation 08.907 Engine type [OM S0atA I” Engine power (>) ar 125 (170) em 2300 Engine torque (max. Ne 630 em 772001500 Rated speed Tem 2300 Bore mom 702 Stroke oo 730 Total displacement em 250 [Compression ratio e Firing order [Number and arrangement of finders Valves inlet Exhaust 7 [Working method “asroke devel with directinjection [Combustion method Exhaust turbocharger and intercooler Injection method Single unit pump with pump-ine-nozzle system (PLD) Timing Electronic engine management with solenoid valve-controied fuel Injection [Specific fuel consumption) ‘gikWh (ee diagram) [eror00-w-1000.01K [echnical data-engine Engine 904908 For PEnginecutput = M Engine torque 2 0 Rated speed Specie uel consumptionEngine model designation [904.909 Engine type [OM S04 A 2 Engine output) kWihp porta mint 2300 Engine torque (M) max Ne oo ‘min=T 1200-1500 Rated speed/upper load speed mint [2300/2500 Bore mm 102, Stroke mam 130) Total displacement ems 4250 [Compression ratio e 7a Fring order 342 [Numberfarrangement of ejinders aiming Valves inlet 2 Exhaust o [Working method “stroke diesel with drectinjection [Combustion method Exhaust gas turbocharging and charge air cooling Injection method Single unit pump with pump-line-nozzie system PLD) Timing Electronic engine management with solenoid valve-controlied uel injection Spee: fuel consumption) gikWh (Gee chart) |GFO1.00-W-1000-01KA __| Technical data - engine Engine 904.915 GF Engine output ; ‘M Engine torque F Rated speed " b Specific uel consumption i PeCER TE BER Engine OM 304 4.0m SOSA od des. 904.9, 906), partEngine model designation aoa Engine ype [OM 904 ATT Engine output ®) iain 90/122 om 7200 Engine torque (max Nm 470 rm 1200-1600 Rated speed/upper load speed ‘om 720072500 Bore mm 02 stoke mm 30 Total displacement oe 2250 [Compresion ratio = 780 Firing order 1342 Numberlarrangement of qlinders aintine valves inlet rz Exhaust 7 Working method -stroke devel with drectnjection [Combustion method Exhaust turbocharging and charge ar cooling Injection method ‘Single unit pump with pump-line-nozzle system (PLD) Engine management Elecronic engine management with slencidvalve-contoled ful injection Speci fuel consumption 1kWh_Gee chart [ero1 0051000011 [Technical data engine Engine 904.971 Gr Engine output = M Engine torque 5 n Ratedspeed v Specific fuel consumption ohEngine model designation oat Engine type [OM S04TA I Engine output (P) kwihp 125/170 min? 2300 Engine torque (M) max, Nm 60 min=t 1200-1500, Rated speed/upper load speed mint 230072500 Bore oo 702 stroke om 130 Total displacement em 350 [Compression ratio @ 7a Firing order 1342 Numberlarrangement of linders fainting Valves inet 2 Exhaust 7 [Working method “stroke diesel with direct injection [combustion method Exhaust gas turbocharging and charge air cooling Injection method “Single unit pump with pump-line-nozzle system (PLD) Timing Electronic engine management with solenoid vave-coniroled Yul Spec fuel consumption &) ‘o/kWh (ee chart) [cF01.00-W-1000-01M __ [Technical data engine Engine 904.921/922/923 CF Engine output a M- Engine torque os n Rated speed 0 1b Specific fuel consumption ‘ BE Engine OM 904,01 906 LA Mod des. 9049, 9065), partgine model designation pease Engine pe low soatAr8 Engine outpaT wie Tas? n=? 00 Traine Tore max 520 TFS Tae peedTipperTondipeed n= 007500 Bore i 702 stroke i 30 Total dace om 250 compresionato t 7a nore 134 rb ara TGemeTe ToT nine aver Tae 2 haa i Working netted stroke eee wih rec eon Combustor method Tahu gu turbocharging ard charge a oolog injection method Single uit purp with pumpine-norae stern ID) Ting Ean eine management wih ori vaveenaTTa Spec Tl orsamTan Gee ard [rox ao w-s00001Ma [Tecnica data egine Eine 98976 or PErgine output = Engine orque 3 mn hatedspeed & 8 Spec tul consumption a = orca 10[Engine model designation [904.916 Engine type fom 90a A> Engine output) iWikp 110/150 rpm EO Engine torque (M) max New 560 tem 1200-1600 Rated speediupper load speed pm 7220072500 Bore ra 102 stroke mm 130 Total displacement om 250 (Compression ratio e 180 Firing order 342 Numberlarrangement of jinders inline Valves inlet B Exhaust 7 [Working method “stroke diesel with direct injection [combustion method Exhaust turbocharging and charge air cooling Injection method Single unit pump with pump-ine-nozzle system (PLD) Engine management Electronic engine management with solenoid vave-contaled Tul Specific fuel consumption () ‘gkWh (ee chart) |GFO1.00-W-1000-01N Technical data - engine Engine 906.910/920/922 GF P Engine output 7 M- Engine torque = nated speed 0 'b Specific fuel consumption na BER Engine om S044, 0M 90614 (Mod. des. 904.9, 8065), part "‘model designation [906.91079207922 Engine wpe [OM 06 LAIN Engine output) wine Worst min? 2300 Engine torque (w) max. ew 10 mint 7200-1500 Rated speed/upper load speed mint 230072500, Bore rm 102, Stroke mm 130) Total displacement on (6370 [Compression ratio e a Firing order Numberlarrangement of finders inline Valves inlet 2 Bhaur 7 Working method “stroke desel with direct injection [Combustion method Exhaust gas turbocharging and charge ai cooling Injection method Single unit pump with pump line-nozzle system (PLD) Friming Elecyanc engine management wit solenld valve convo fok Spec. fuel consumption (@) ‘wkWh (ee chart [GFo1.00-W-1000-01 [Technical data- engine Engine 906.940 GF P Engine output M Engine torque . Memetnn ones n Rated speed 4 b Specific fuel consumption g Co 2Frechnical data- engine [Engine model designation [906.940 Engine type [OM S06LA Engine output?) kwihp Worst min= 2300 Engine torque (w) max Nm 10 min=t 1300 Rated speed/upper oadspeed min=¥ 2300 Bore mm 102, Stroke 7am 730) Total displacement om (6370 [compression ratio e 7a Firing order T5624 INumberfarrangement of jinder inline Valves inlet 2 Exhaust 7 | Working method “stroke diesel with direct injection [Combustion method Exhaust gas turbocharging and charge air cooling Injection method Single unit pump with pump-line nozzle system PLD) Timing Electronic engine management with solenoid vave-controlied fuel Injection Spec: fuel consumption ®) kWh (Gee char) [cFot-00-W-1000-01NA Engine 906,915/925/927/951 GF Engine output -M Engine torque nated speed b Specific fuel consumption wor 00101712 GER Engine OM SD4LA, OM 9061 (Nod. der. 904.9, 906), part 13model designation (906 STS792579277951 Engine wpe [OM 906 LA 2 Engine output) kWihp Tons rem 2200 Engine torque (M) max Ne 10 Tem 7200-1600 Rated speed/upper load speed Tem [220072500 Bore mam 102 Stroke rin 730) Total displacement om (es70 [Compression ratio e 780 Firing order Numberlarrangement of eyinders inline Valves iniet 2 Bihar 7 [Working method “atroke diesel with drectinjection [Combustion method Exhaust turbocharging and charge air cooling Injection method Single unit pump with pump line-nozzle system (PLD) Engine management Electronic engine management with solenoid valve-controliad fuel Injection Specific fuel consumption @) ‘gkWh (ee chart [GFo1.00-W-1000-010 [Technical data- engine Engine 906.911/921/923 GF P Engine output ‘M Engine torque n Rated speed b Specific fuel consumption 14ree deinaton poe Ena PE omsos tana Ensine out Wi sano iat 2300 Eine ora max ca Ti00 nal 12607505 aed speaTappeandpeed mint T7500 Bore a 02 Soke om 130 Total dplocent aT 70 [conpresion ato fl 7a ing oder 153604 Numberarangement oF Onde Tiine aves Tae H Shai i Working mato atroke dee wih dea econ combustion method Tahaus gas turbocharging and charge a oihg jection meted Single uit pup with pump ine-naze stem CLD) Timing Eleni engine management with lend vale-conv aed Toa nen be Tel corsompton rk Gee ard froncow-1000010 [fecal data engine Eine 96381 or P Engine output M- Engin torque mmoveesotenis in fated peed Spec tuctconsumetion EW Engine M804 LA,0M 906.A od des. 904.9, 9065), part 15[Engine model designation 906.967 [Engine ype [OM S05TA Engine output) twine 2057280 rnin? 2300 Engine torque (w)max. Nm 1100 mint 1300 Rated speed/upper load speed mint 2300 Bore ‘mm 102 stroke mm 130) Total displacement ent ea70 (Compression ratio e 7 Firing order 153628 Numberfarrangement of ejinder inline Valves inet 2 Bihaust 7 [Working method “stroke diesel with directinjection [Combustion method Exhaust gas turbocharging and charge air cooling Injection method “ingle unit pump with pumpline-nozzle system (PLD) Timing Electronic engine management with solencid valve-controlled fuel Injection [Spec fuel consumption ®) ‘gkWh_(ee chart) Engine 906 longitudinal sectiont 16Engine 906 transverse section wor 10002612 [Grov.00-w-1000-010A _ [Technical data- engine Engine 906,916/926°928/952 GF Engine output M Engine torque # fn Rated speed ad b Specific fuel consumption we oh wor.00161952 GER Engine OM 90614, 0M 906 LA Mol des 9049, 9069), part 7model designation 906 91679267928/952 Engine ype [OM S06 LA II8 Engine output’) wine [2057280 Tem [2200 Engine torque (M) max Nm 1100 em 7200-1600 Rated speed/upper load speed pm [220072500 Bore mm 702 Stroke om 130) Total displacement emt (ea70 (Compression ratio. e 780) Firing order Tsa624 [Numberlarrangement of ejinders inline Valves inlet 2 Exhaust 7 (Working method “stroke diesel with divectinjection [Combustion method Exhaust turbocharging and charge air cooling Injection method “ingle unit pump with pumpine-nozzle system (PLD) Engine management Electronic engine management with solenoid valve-contrlled fuel Injection [Specific fuel consumption @) ‘g/kWh (ee chart) [cF07.00-W-1000-015A | Technical data- engine Engine 906.939 = GF Engine output M Engine torque fn Rated speed b Specific fuel consumption 18[Engine model designation 906.939 [Engine ype (OM 906 TA Engine output) kWikp T0245 ‘pm 2200 Engine torque (w) max. New 1100 pm 7260-7500 Rated speed/upper load speed pm 220072500, Bore ram 02 stroke ram 130) Total displacement one e370 [Compression ratio. e 180) Fring order 133624 [Numberfarrangement of inders inline Valves inlet 2 Exhaust 7 [Working method “stroke diesel with directinjection [Combustion method Exhaust turbocharging and charge air cooling Injection method Single unit pump with pump-ine-nazzle system PLD) Engine management Electronic engine management with solenoid vave-conroied fuel injection Specie fuel consumption (B) gikwh (see chart) [GF0r.00-W-1000-01R __ [Technical data- engine Engine 906.9207 922, GF Engine output MM Engine torque 1 Rated speed b Specific uel consumption ceri (GHP Ensine OM 90414, OM 906 LA Mod des 904.9, 906.9), prt 19Engine model designation (906.920/822 Engine type [OM S05LA Engine output ®) wip Tors em 2300 Engine torque (MW) max Nm 10 Tem 1300 Rated speed/upperloadspeed em [2300 Bore mm 102, Stroke me 130 Total displacement en (ea70 [compression ratio e 7a Firing order 153624 Number/arrangement of ejinders (inline Valves, number play (inspection | inlet [270a0mm (4207-10 mm) acces Exhaust 170.60 ram (+ 20/-10 mm) Working method “stroke diesel with direct injection [Combustion method Exhaust turbocharging and charge air cooling Injection method “Single unit pump with pumpiline-nozzle system (PLD) Engine management Electronic engine management with solencid valve-contrlled fuel Injection Specific fuel consumption @) ‘wkWh_(ee char) Cir filling capacity El ar 20[ARO1.00-W-2410F Disconnecting, connecting engine wiring hamess 12.6.98 ENGINE 906.920 /921 /922 /923 /925 /926 /927 /928 /942 /943 X21 Plug connector X22 Plug connector X23 Plug connector Cab-chassisplug connection cover Red cable Engine wiring harness ° = ° iO x22 Oxd Xe x22 Ox23 5 3 4 (e) ‘Wor 00-1007-06 EE Removal, installation DS danger! Risk of explosion from explosive gas. Risk | No fire, sparks, naked flames or smoking, Page 22 ‘of poisoning and caustic burns from Wear aci-protective gloves, clothing and swallowing battery electrolyte. Risk of | eye protection. Pour battery electrolyte injury from caustic burns to eyesand skin _| only into suitable and appropriately from battery electrolyte or from handling | marked containers. Jdamaged lead acid batteries, 1 Disconnect battery ® Notes on battery All models Page 24 2 (Open service flap 3 Remove front grille [000 58901 1000 4 Take off cover (2) at cab-chassis plug, Li) installation: Cover of cab-chassis plug connection (1) connection must be closed leaktight. @ (000 58901 1000 5 Separate red cable (3) and plug connector [(x2.1 toX2.3) at eab-chassis connection point (1) 6 Unclip engine wiring harness (4) and place |® Do not damage engine wiring harness, down AS Danger! Risk of injury from hand beingjammed —_|No person must be within the tilting range Page 24, and bruised when tilting eab lof the cab when the cab sited. Always tit Jab as far asthe end position and secure with safety prop. N Titteab ® Notes ontilting cab Model 375, 950, 952,953, 954 Page 25 eRP Engine OM 90414, OM 906 LA (Mod. des. 904, 9069), part 2fe Detach engine wiring harness (@) at the ixture ofthe right frame longitudinal member and tie up at engine ‘® do not damage engine wiring harness. 3 Install in the reverse order 10 Set time at tachograph 58907 1000 [ASS@.10-7-0007-01A | Explosion hazard from explosive gas. anger of poisoning and acid burns when battery acid is swallowed. Danger of acid burns to skin and eyes from battery acd or when handling damaged lead-acid batteries. Flames, sparks, open light and ‘A danger! smoking prohibited. Wear acid resistant gloves, clothing and goggles. store battery acid only in suitable, appropriately marked containers. Possible dangers Explosion hazard Ahighly explosive gas mixture is generated when lead-acid batteries are charged Poisoning hazard ‘When battery acid is taken orally toxic symptoms can occur such asheadache, dizziness, stomach pain, paralysis of the respiratory system, unconsciousness, vomiting, acid burns and cramps. Battery aid vapor can burn eyes Inhalation can resultin burns to ‘mucous membranes and respiratory paths. Lead in the body can damage blood, nerves and kidneys; ‘moreover, lead compounds pose a hazard forthe reproduction organs. Injury hazard Battery acid contains sulfuric acid, which can cause severe burns to skin and eyes, When handling damaged lead-acid batteries (removing from accident vehicle) increased care s necessary due to the sharp edges on the bracen housing and direct contact with the lead plates Rules of behavior/protective measures = Charge lead-acid batteries only in well ventilated rooms. Fire, sparks, open light and smoking prohibited. onot lay tools or other conductive items on lead-acid batteries (danger of short circuiting) Disconnect and remove lead-acid batteries for charging Always disconnect negative pole first; always connect positive pole first. = Switch on charger only after connecting to poles; switch off 2~ Keep lead-acid batteries and battery acid away from Unauthorized persons. Store battery acid only in suitable, appropriately marked = Store lead-acid batteries only in upright position, Engure that gassing line is properly connected. + Check gassing line for kinks and proper passage. + Observe instructions for applicable lead-acid battery and vehicle operating instructions = Wear acid protective dothing and protective goggles with side guard. Firstaid measures Eye contact ‘¢- Rinse eyes immediately with large quantities of water. ‘Skin contact 4¢ Remove affected clothing ‘© Neutralize acc on skin or clothing immediately with acid neutralizer or ap solution and rinse with large quantities of water. Inhalation of battery acid vapor © Move affected person to fresh air Swallowing battery acid ‘¢ Have person diink large quantities of water containing activated charcoal Generally medicalservices ora physician should be contacted after administering first aid, Fire protection measures Suitable extinguishing agents = COzand dry extinguishing agents 2 4 5 7 Poa T0-a708 Warning notes on lead acid batteries 1 Fire, sparks, open light and smoking «Observe operating instructions 6 Keepaway from children prohibited 4 Danger of acid burns 7 Firstaid 2 Explosion hazard 5 Weareye protection GER Engine OM 805 4,00 906: (od des. 9049, 9055), part 23[av154.10-P-0007-01A Notes on battery [All models [® ® ‘+ Donot store lead-acid batteries for extended periods of time Ina place where they ae exposed todirectsunlight. ‘+ Alwaysstore lead-acid batteries horizontally to prevent acid from escaping; do not tit them when they are being transported. ‘Discharged or faulty lead-acid batteries can freeze up: ‘therefore, ensure that they are stored at temperatures above feezing level + Donot place any tools or other electrically conductive objects ‘on a lead-acid battery (isk of short-circuit) ‘+ Avoid mixing up positive and negative poles and avoid short- circuits. ‘+ Before removing or installing a lead-acid battery, switch off all electrical consumers where possible, and switch off the engine, s0.a5to minimize the possibilty of creating sparks 1+ Alwaysdisconnect the negative pole firs; always connect the. positive poefirst. ‘+ Donot switch on battery chargers until they have been ‘connected to the battery roles; switch them off before disconnecting ‘© Only charge lead-acid batteries with direct current For the charging current we recommend 10% of capacity fornormal ‘charging and 50% of capacity for rapid charging. ‘+ During rapid charging it must be Insured thatthe casing ofthe lead-acid battery does notwarm up excessively (< 55°O) © Lead-acid batteries should be kept lean and dry as far as, possible. © Itisadvisable to grease the poles lightly with battery pole grease. + Lead-acid batteries should not be stored for extended periods without being recharged. ‘+ fallead.acid batteryisto remain ina vehicle which isnotin use for an extended period, the negative terminal clamp should be disconnected. Tascoaoz-o00 ata |injuyharard irom pinching and crushing when ing ese thatnoores [A Danger wen cabistited present inthe titing are ofthe cab always titab to end postion and secure with sey brace. Injury hazard ‘Addamaged tilting mechanism or improper handling of the tting ‘mechanism can lead to severe injuries when tilting the cab. Rules of behavior/protective measures Before titing cab: + Shutoff engine. = Apply parking brake. ~ Secure vehicle against roling = Onvehicles with manual transmission, move shift lever to reutral position. = Onvehicles with automatic transmission, move selection lever to position “N ‘When tilting the cab: = Protect iting area and particularly iting device against ‘unauthorized acces, e.g y blocking off or with human guard. = Attach safety cable before iting when so specified inthe vehicle operating instructions. Never work under cab when partially tilted ‘Always tilt cab to end position and secure with safety brace. ry[AH60.80-N-0003-018 | Notes on tilting cab Model 375, 673, 674, 675, 676,677, [@ 678,679, 684, 950,952, 953, 954, 957, 970,971,972, 973,374, 975,976 Prior to tilting cab: ‘¢ Switch off engine ‘© Apply parking brake 1¢ Secure vehicle to prevent it moving off © Removeall loose objects (e.g. cans, bottles, tools, bags etc) from the cab '# Models fitted with manual transmission: move shift lever into Neutral ‘¢ Model 957: unlock steering column and open front flap. ‘The front coupling pin must be correctly inserted. @ ‘© Always tit cab as far asthe end position. © After tilting cab, support witha prop. '# _Ifnoresistance can be felt when operating the cab tiking pump, check whether sufficient oils presentin the tilting pump. (¢ faim resistance can be felt when operating the cab tilting pump, check whether the valve lever at the tilting pump isin the desired tilting direction. Models fitted wit refrigeration compartment ‘©The refrigeration compartment mustbe switched off before tilting the eb. ‘© The refrigeration compartment mustnot be switched on ain until Y0 minutes after tilting back the cab. Refer also to operating instructions of refrigeration compartment manufacturer and red information sticker on ‘the refrigeration compartment. ER Engine OM 906A, 0% 906 A od des. 9049, 9069), part 5[ARo1.10-w-24000 [Removing, installing engine 5.8.97 ENGINES 904,909 /910 /911 /915 /916/917 /922, 906.910 /911 /915/916 1 Cap(onengines 904.809. 911/915-917/922) 2 Coupling, compressed airline (on engines 904,909. 911/915-917/922) 3 Plug, compressed airline (on engines 904.909. 911/915-917/922) 8 Cable harness, cable andbracket 9 Connector (control module) 10° Engine mount 11 Steering line return flow) 12 Steering line (oressure) worieanreoe 4 Blengine hoist 13° Fuellin teed) 5 Blchaintacke 14 Feline (return flow) & —Compresedir line compresor) 15. Oifilerpipe 7 Shifted (on engines 904909-911/915.917/22) 16. Refrigerant compresior a cy O =- = gS b iG fe a r/) lana J foe = 00 es a ° ——| J BIS 20° 26 ®: warroaoTE@22° exhaustpipe 23° Clamp 24 Alrintake house 25. Electric cable (generator) 26 Compressed airline engine brake cylinder) 27 Cable harness On engines 906.910/911/915/916 30 Gearshift lever with gearshift linkage 31 Bracket 32. Support 28 startercable 29° Groundcable G1 Generator Mt Starter wo.toann741 10.1199 [Settime attachograph step 31 added ae Removing, installing D installation Replace alset-ocking nus and bots BS danger Rsk of explosion from explosive gas. Rsk No ire, parks, naked fares or smoking. Page 22 of poisoning and caustic burns from [Wear acd-protecive gloves, clothing and swallowing batery electrolyte. Rskat [eye protection. Pour battery electrolyte injury from caustic burns to eyesand skin [ony into suitable and appropriately from batter electrolyte or from handling [marked containers. damaged ead acd batteries. 1 Disconnect battery ® Notes on battery All models Page 24 B dangert Rsk of injury from hand beingjemmed __|Noperson must be within the tilting range Page 24 and bruised when siting cab ofthe cab when the casted Always tit cabs far athe end psition and secure ith safety prop. 2 Tit cabinto repair poston ® Notes ontiting cab Models 375,970.976 Page 25 B Rerwe noise encapsulation panels a Remove charge api from charge ar ranoa.a-w-13110 lero charge airmanifold 5 Remove charge ir pipe from turbocharger fanoa a-w-t3i1¢ to charge acooter é Remove fan shroud 2040-68008, 7 Detach olfilerline (5) toll pan and tie upattrame fe Detach exhaust pipe (2) atengine brake |[H] Secure exhaust pipe on frame. fap connection and attransmision [LL installation: Clean sealing surtacas ER Engine OM 9084, OM 051A (Nod det. 904.9, 806), part 27526/627 Fe3 Transmissions 715,050/060/320 3 Detach compressed alin (2) atengine brake ofinder 10 Detach arnt hove (air ener howsing rn Diconnect electrical able at fame glow | plug and at solenoid valve 2 Diconnecteleciccabe (0) attarcer sty and wiring hares (27 at bracket 3 Diconnetelecticcable 25) at generator | [I] Pay attention color coding (Gt and at bracket, i Diconnet ground able (3) and wiring harness attiming case ro Unbolt compressed ar ine () 38 i ierbon depose are presen he compresor and inspector carnon depots |comprested-airtine between ompresor and compressed dir and the ourciruit protection valve must sonal be ispected Replace pars with carbon depos El testatiion: spect compress ai ine freaks. 163 Detach shit inkage )atshiflever [Only with engines 9089089117 sis-t7/902 62 Detach shit levertogeter wth htt [Onywith motors 906 10391/915/916 linkage 2) and bracket (31 at care 02) Booanger Fisk of explosion romignion.rak of [Note sparks, naked ames or smoking Page 30 peisoning trom inhaling and swallowing [Pour telson into sultabe and elas wellasrisk of injury from skin and | appropriately marked containers. eve contact with ue Wear protective clothing when handling uel ” separatefutine(12, 0 attueltter —_|(E cote vel which fows ou. Mark ue ines. 8 slacken poly V-beleand ake of [Hl ony onmodets fied with ai aniaz2 W202 condoning, 9 Detach retigerantcomprenor(16) | [A] bonotueparateretrigerantines. together with bracket atengine 0 separate compressedairlines(2,)of | [Al onengines oasoo-at1a1s-s17922 constant throttle with constant throttle only, ulloff cap (1, pres clamp aparcusng ples andl connector outot socket. B danger ik of jury to skin or eyes rom hydraulic | Render the hydraulics presureles Page 3t uidspraying out under presre Risk of | before commencing workon sytem Wear poltoning from swallowing hydraulic ld |protecvecothing and eye protesion. a Separatebothhosesatthestering | [EJ calecthydrauicoltwhich flows out | AP4s.00.W-4611 lines, 12) Installation: Topuphydreltui and ifnecesey | eed steering asas.2s- ss fe lens and separate connecor of cable hares (9) on MRVPLD contol unit, ps Attach rensmison or support fa Unscrew bots a tension Fe Wansmisions710.21/s22/e037 —_[aaae.ton-108-018 BA26.10-N-1001-01C 2BLH inspect engine mounts for wear, as Remove bolts at both engine mounts (10) replace if necessary. 2s Remove engine with removal fixture Page 31 |WH58.30-2-1001-07 'BROO.45-2-1002-068 27 Install in the reverse order 28 Reprogram transponder key [U1] only fa reconditioned engine ora | ARBO.57-W-0010A (also spare key) new MR/PLD control unitis installed 29 [check engine-oll level va electrical See operating instructions part 3 dicator and if necessary correct 30 [Check coolant level and if necessary adjust [AP20.00-W-2010A, to correct level & danger! Risk of accident from vehicle starting off by | Secure vehicle to prevent it moving off by Page 33 tse when engine running. Risk of injury itself. from bruises and burnsif you hold your | Wear closed and cosesiting work clothes. hand into engine whenitisstarted or _| Do not grasp hot or rotating parts ‘when itis running. 31 Start engine ® donot revup engine as ong asno oil | BE18.00-N-1001-01¢ pressure is indicated [i] The oil pressure gage must indicate oil pressure after about 10 seconds 32 Switch off engine 3 Inspect engine, cooling system and steering | [i] visual check. hydraulics for leaks 34 Set time at tachograph 35 [Enter engine number in FDOK 1] only if reconditioned engine is ‘Screen 1111" installed. Test data of engine ol pressure Number Designation Engines 04.9, 906.9 per.00-w-001-016 Engine oil Idle speed bar =05 [eed Maximum speed bar 225 el Manual transmission complete Number Designation Transmissions osz1622/ 623/626/627/68 ax26 101-006-018 Transmission to flywhee! housing nen] a5 £3 Manual transmission complete Number Designation trans. |rans- [Trane mission | mission |missions ‘715.050 |715.060 |715.320/ 715.321 pazeroncoraic | Transmission to flywheel housing nen 45 as a5 GER Engine OM S08, 06 SDELA (Hod, de. 9043, 9069), par 3 29Commercially available tools (see Workshop Equipment Manual) Fuels toxic when inhaled or swallowed. contact with fuel can cause kin and eye injury. Number Designation Make(e.3) lorderno. fwuse20z1001-078 | Engine holst (self-locking) Backer 3188) HerdersraBe -42853Remscheld Repair products Number Designation lorder no. bRo0<5.2- 1002068 [MB long-term grease [ooo saa 6351 [AS47.00-2-0007-01A Fuel vapors present an explosion hazard. [No fire, sparks, naked flames or A Danger! smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective lothing when handling fuel Possible hazards Risk of explosion, poisoning and injury Fuels are easily flammable and polsonous when swallowed. Fuel can cause skin damage. For example, contact with gasoline fuel removes the natural ol ofthe skin. Fuel vapors are explosive, invisible and disperse on the ground. They are poisonous it inhaled and have a narcotic effectif they are present in high concentrations. Protective measures/rules of conduct ‘Observe the safety precautions and regulations applicable in the specific country. No ire, sparks, naked flames or smoking, Ensure that the work place is adequately ventilated "Never drain or pour in fuels above assembly pits = Store drained fuel in suitable and sealed containers. = Immediately eliminate fuel which has poured out. Carrying out work on a vehicle with a naked flame (eg. welding, etc) = Before commencing such work, remove the relevant parts of the fuel system and seal ary open fuel lines with plugs. Firstaid measures ‘© Cleanmoistened skin withsoap and water. {© Change moistened clothing as rapidly as possible © If fuel gets into the eyes, immediately rinse out the eyes with water; contact adoctor,ifnecessary 30[As00.00-2-0013-01A | Risk of injury toskin or eyes from pressurized hydraulic fluid spraying out. Risk of poisoning from swallowing hydraulic fluid Before starting work on the hydrautic | ZS Danger! system, depressurize the system. Wear protective clothingand safety glasses. Potential danger Risk of injury Serious injures can be caused to the skin or eyes when loosening hydraulic lines without depressurzing the system beforehand, ‘due tothe very high pressures (above 200 ba). Damage tothe skin may be caused if unprotected skin comes into contact with hydraulic fluid, particularly central hydraulic fluid (this is ‘especially harmful to health) Risk of poisoning ‘Anyone who swallows hydraulic fluid can expect to suffer symptoms of poisoning including headaches, dizziness, stomach ache, vomiting, diarthoea, cramps and unconsciousness Safety measures/operating instructions Before starting work on hydraulicsystems they should be pressurized and the system must be emptied ifnecessary. = Donot pour hydraulic fluid into drinking containers. + Ensure adequate ventilation, particularly inthe case of central hydraulic fis. ~ Ensure only aushorized persons have acess to hydrauli fluid. = Seal disconnected lines and hoses and connections on the subassemblies mmediately with blind plugs. = Wear safety gloves, protective clothing and safety glasses. IHitis not possibleto wear safety gloves, the following points are to be observed: = Only allow hydraulic fluid to come into contact with the skin foras short a tine as possible, wash fluid off skin with soap and water. Change wet clothing as quickly as possible First ald ‘¢ Have the casualty drink plenty of water with activated charcoal additive ‘¢Afterswallowing larger quantities consult a doctor. ‘© If hydraulic fluid gets into the eyes, rinse out the eyes. immediately wit plenty of clean water/using a eye rinsing glass. f¢ Inthe event of injuries to skin or eyes from a et of hydraulic fluid, consult adoctor immediately. [aRo%.10--2400-018 [Removing and installing engine with removal fixture [Engine without transmission Commercially available tools (ee Workshop Equipment Manual) Number Designation Make (e.9.) [order no. fwnsssoziorara [Engine hoist (selt-locking) Backer 3188) Herderstrade 10-42853 Remscheid Repair products Number Designation lorderno. 0.a5.2-1001-050 MB long-term grease 000 989.63 51 o Engine OM 908 LA, OM SD6LA (Mod des. 906.9, 906 9), part 31. Attach engine holst(1) to the lifting ‘eyes (2and3), 2 Attach chain block () atthe rear right of the iting eye (3) and tension chains at engine hoist (1) and at chain block. Secure engine to prevent it tikng. 3 Push engine sufficiently far away from ‘transmission until the transmission shaftis pulled out ofthe clutch plate. 4 Uiftoutengine WOri6007706 5 Before installing engine, lightly grease transmission shaft. 6 _Uftengine into the frame and align relative to transmission, 7. Attach engine to the transmission, [HD Ensure that the internal spline of the clutch plate is matched ‘up withthe spline ofthe transmission shaft, rotate starter ring sear, if necessary. 32[AS00.00-2-0005-01 | Risk of accident asa result of vehicle starting off when engine isrunning. Risk of injury asa result of bruises and burns ifyou insert your hands into engine when itis. being started or when itisrunning. ‘Secure vehicle to prevent it from (AS Dangert moving off. Wear closed and cese-itting work clothes Donot grasp hot orrotating parts Postible dangers Risk of accident ‘rom vehicle starting off during starting operation (e.g. when testing compression pressure) as a result of gear engaged or when tengine running and vehicles with automatic transmission asa result of selector lever position "P* or "N" not engaged jome vehicles do not have a selector lever position Risk of injury Severe injuries may be caused by freely rotating parts inthe area of the running engine. The heat produced by the engine when it isoperating can result insevere burns if contactis ade with Individual, unshielded parts. First ald measures in the event of burns '* Donot rub the skin areas affected; flush with plenty of cold water and cover skin with sterile bandages. ‘¢ Immediately consult a physician. Rules of conduct /Protective measures = Asa general rue, carry out work on the running engine only if this is absolutely essential. = Before starting the engine, apply parking brake. ~ On models with manual transmission, move gearshift lever Into Neutral pastion ~ On models with automatic transmission, move selector lever into position “P* oF “N* (exception: some vehicles do nothave ‘selector lever postion *P"), ‘On models whith do not have selector lever potition “P", secure selectorlever to prevent it from being operated unintentionally. ‘Wear closed and close-itting work clothes. = Take off any jewelry, such as chains rings ete. = Ifyouhave long hair, wear asuitable head cover. = Before commencing work on the running engine, check to ‘obtain a general picture ofthe positioning of parts which may be hot, ~ When carrying aut work when stating the engine or when engine isrunning, do not touch any hot and rotating parts. GER Engine OM 908 LA, OM 905. (od des. 9049, 9055), part 3[ARO1.10-W-2400F [Removing, installing engine 12.6.98 ENGINES 906.920 /921 /922 /923 /925 /926 /927 /928 /942 /943 Were 1 bracket in frame 7 Pug connector (able hanes) 2° Enginemount {8 Plug connector engin cable harness) 3 cablehomess 9 Fulline 4 Exhaustpipe 10. Hydraulic olline(teerig system) 5 Compressed airine comoresor) 11 Refrigerant compressor airconditioning) 6 Chtchservounit 12. olfiterine D 19 Crankatevetiation hose 16. Startercable 18 Fug connector 14 Arintakehotevithairintake ine 17. Tranamison oiling (transmission cable harness) 15. Compresiedairtine (engine bake) Modifiation notes 114400 | Volue changed fom 57 Nn to 6m VelvechengedinBA26.60.N-100501 on ]BA26.60.N-1009.01D eansmision 1560 win code GS ay Removal instalation [@ instalation Replace aleetlocking nuts and boltstogether with bracket at engine DB danger Rk of explosion rom eplosve gas Rak [Nore part, naked fares orsoKing Page 22 cf poisoningand causticburnsfrom | Wear ad-protecve loves, clothing and Swallowing battery elecroyte. Rik of eye protection. Pourbattry electrolyte ojry trom cautcburrstoeyesandskin | ony nt sutable ard appropriately trom battery electrolyte or fremhandling marked containers. damaged ead ac batteries 1 Disconnect battery © Noteronbatery Al models Page 24 2 Separate engine wiringharnes at plug Page 21 connection o cab [Gear hydraulic cylinder to shift shaft Nm] 60 70 50 faazesonrorocr> [Bearing bracket to transmission housing im] ‘30 feazecon-sorrar> | Gate hydrauliccylinder to wansmission umn ]25 Fs 50 housing ea2econsorzar> [Gate hydrauliccyinderto shift shaft umn |35 50 A2econ-te2earo [Gear hydrauliccylindertotwarsmission —_M10_Nm|- as peal Mi2_Nm|- 80 Mia Nm] 140 7 Bel shift mechar Number Designation Transmissions 715,320/321 pazeson-1005.01F Compressed-airline to control M10 _Nm|20) valve/gearshift cylinder m2 nml30 ‘Commercially available tools (ee Workshop Equipment Manual) Number Designation Make (e.g) [order no. jwrsesozro0r07a | Engine hoist (self-locking) Backer 3188 HerdersraBe 42853 Remscheid Repair products Number Designation lorderno, 2R00.5-2 103-068 Olista Longtime 3 EP 001 989.3651 10 [aR26.60:W.7000-01A Detaching, attaching shift cylinder with hydraulic tine Transmission 715.060/320/5 Modification notes 10.400 | Figure modified from 57 Nm to 60Nm Figure in BA26.60-N-1009-010 for transmission 715.060 with code G33 [BAZ6.60.N-1009-010 modified Fl shift mechanism Number Designation ‘Transmission [Transmission | Transmission H715.060with —|715.320with | 715.5001510/520/, code G53 code G53 540 with code joss [8x2660."-1008010 ___| Gear hydraulic ylindertoshiftshaft Nm] 60 70 50 18A2660.01010010 __ [Bearing bracket to transmission housing Nm] ‘30 faxzeeoni0r1oi0 | Gate hydraulic qylindertotransmission| umn ]25 2s 50 housing Jaxzeeoni0r2010 __| Gate hydrauliceylindertoshiftshaft mn] 35 50 38fel shift mechanism Number Designation Transmission [Transmission [Transmission miso6owith —|715.320with | 715.500/5101520/ code G53 code Gs3 540 with code loss faazecon-to2e010 [Gear hydrauliceylindertotransmission _M10_Nm|- 45 housing ane Fj M4 _Nm| 140 fel shift mechanism Number Designation Transmission 715.320/921 aa26 60.0005. Compressed airline to controlvalve/gear_M10_Nm|20 shift cylinder ES 1. Detach both securing clamps (2) atthe hydrauliclines (1). 2 Detach mounting plate (4) fr the hydraulic lines (1) at engine; unscrew bolts (3) for this stp. wae 600051 5 7 ct [es ai < a | Ede ol | ' Z al 5 @ 6 was t00608 Hydroulietines to ransmision Transmision 715.060 Transmision 715.220 Transmision 7155 GER Engine Oo SOHLA, OM 906A (Mod, ds. 9049, 9069), par3 Detachline attachment (7) together with hydraulic lines (1) at transmission, [i Do not open the securing clamp. 4. Detach hydraulic gate shift ylinder (6) with connected hydraulic tines (1) at transmission. ‘Transmission 715.320: push shift cylinder forward and lft outto the rear. Detach hydraulic gate shift cylinder (5) with connected rauliclines 1) at trarsmission Transmission 715,320: a irline and electrical plug connection a shite yl ransmission 715.510: detach shitt cylinder together with bearing bracket nally detach compressed Reinstall in opposite order. D Replace self-locking nuts. [aR0%.10.W-2400-01F | Removing and installing engine with removal fixture ‘Commercially available tools (see Workshop Equipment Manual) Number Designation Make (e.3) ‘woisezoztonra7a [Engine hoist (self-locking) Backer 18 HerdersraBe -42853Remscheid Repair products Number Designation [order no. ko0as.2-1031-068 Olista Longtime 3 P [001 989.3651 70 1. Attach engine hoist (2)to the lifting ‘eyes (1 and), 2 Attach chain tackle (3) atthe lifting ‘eye (4) and tension chains at the ‘engine hoist (2)and atthe chain tackle. Secure engine to preventit siting. 3 Pushengine sufficiently far away from transmission until the transmission shaftispulled out ofthe clutch pate. 4 Uftengine up and out 40[HI steps, 6 and 7 only for transmission 715.5 5 Before installing the engine, lightly grease the transmission shaft and the sliding sleeve Inthe release (5) with Oita Longtime 3€. 6 Rotate release (5) until the tensioning pin (5.1) s positioned horizontally 7 Position release lever in the correct installation postion relative to release). 8 Lift engine into the frame and align relative to transmission. Gi) vo not damage cables, plug connectors and attached parts. 9. Attach engine to transmission. i ensure that the internal splines of the clutch plate are aligned with the splines of the transmission shat; rotate starter ring gear, ifnecessary. ER Engine OM GOHLA, OM SOELA (Mod. des. 9048, 905.9), par a[ARO1.10-W-2401A_ Removing, installing engine with transmission 15.9.97 ENGINES 904.905 /906 /907/921 2 Compressed airline (compressor) 12 Shiftlinkage 3. Plug connector (transmission) 13 Bott 4. Plug connector (transmission) 14 Engine mounting 5 Propellershatt 15 Frame crossmember 6 Clutehslave cylinder, 16 Oildipstick guide tube 7 Connector (speedo drive) 17 Engine wiring harness (solenoid valve) 8 Connector (control module) 18 Engine wiring harness (fame glow plug) 9 Fuelline (manual fuel feed pump) 10. Fuel ine (fuel iter) AG PLO-control module 11 Compressed airline (constant throttle) 4213 bolt 14 Engine mount 20° Exhaustpipe 21° Camp 22 Rearliting eyes 23 Bengine hoist 23.1 El shackle 24 Exchain tackie 25 Front ifting eve (coolant pump) 26 Airintake hose (turbocharger) Propeller shaft Plug connection (speedo drive) 5 7 33. Bolt 34 Nut 35 Rear transmission mounting Modification notes 27 Airintake hose (compressor) 28 Wiring harness (generator) 29° Ground-able 30 Compressed airline (exhaust brake tinder) 31 Startercable 32 Electric control cable (starter) MI Starter G1 Generator [67.98 [Enter engine numberin FDOK after replacing engine [Step 36 added ests installing AS Danger! Risk of explosion from explosive gas. Risk | No fire, sparks, naked flames or smoking. Page 22 of poisoning and caustic burns from Wear acid-protective gloves, clothing and swallowing battery electrolyte. Risk of | eye protection. Pour battery electrolyte injury from causticburns to eyes and skin _| only into suitable and appropriately rom battery electrolyte or fromhandling |marked containers. damaged lead acid batteries 1 Disconnect battery 1® Notes on battery All models Page 24, AS dang Risk of injury from hand being jammed —_ | No person must be within the tilting range Page 24 | and bruised when titing cab of the cab when the cabs tilted. Always tit cab as far asthe end position and secure hater oop. p rice ® otesontiing cab odes 673-679 page 25 fi iecabinto repair potion 60 3050-00108| a Remove rea abmountng 5 remove nie eneapiation panes |) Onsdeand at boro a Remove raditor and charge al cooler 8202030 38654 a Tie un irc guide ube (16 at engine a [Detach exhaust pipe (20) at engine brake [1] installation: Clean sealing surfaces: ep connection 3 Detach compreeda ine GO atengine |Elengne fied with engine brake rate tne rr Detach irintake hoes (6 2 for turbocharger and compressor at air cleaner 1 Separate electric cables (17, 18) at flame glow plug and at solenoid valve [i] Engines fitted with flame starting system GER Engine OM G04 A,O€ SDELA (Mod, des. 9048, 9069), par2 ‘Separate starter cable (31) and control cable (32) atstarter(Mt) 1B ‘Separate wiring harness (28) at generator | [i] Pay attention to color coding wn 14 ‘Separate ground cable (28) at timing case 15 Detach shift linkage (12) at transmission shift mechanism 16 [Remove clutch slave cylinder (6) Lid installation: Grease thrust pin. 7 ‘Unbolt compressed airline (2) at HD tf carbon deposits are present, the ‘compressor and inspect fr carbon deposits | compressed airline between compressor and compressed ar drier with integrated Pressure regulator and the four-ccuit Protection valve must additionally be Inspected. Replace parts with carbon deposit. HD instattation: inspect compressed air line for leaks. Q Danger Risk of explosion from ignition, riskof _|No fire, sparks, naked flames or smoking. Page 30 poisoning from inhaling and swallowing | Pour fuels ony into suitable and fuel as well a isk of injury from skin and_ | appropriately marked containers. eye contact with fue. | Wear protective clothing when hendling fuel 18 Separate fuel lines (9, 10) [2 at fuel priming pump and at fuel filter. Collect fuel which flows out. 19 Separate pressure line (11) of constant | iJEngines fitted with constant throttle throttle 20 Release and separate connector (8) at PLD control module (A6) AS Dangert Risk of injury to skin or eyes from hydraulic |Render the hydraulic system pressureless Page 31 uid spraying out under pressure. Risk of | before commencing work on system. Wear Poisoning from swallowing hydraulic fluid. [protective clothing and eye protection. a Separate both hoses at steering lines collect hydraulic oll which flows out installation: Top up hydraulicfluid and | wH4611 bleed steering. 22 Remove frame crossmember (15) [i] Below radiator and engine 3 [Attach engine hoist (23) at the front to /[Eengine hoist | WH58.30-2-1001-07 iting eye (25) of coolant pump and guide up 24 [Attach engine hoist (23) at rearleft to |® insert shackle (23.1) as intermediate lifting eye (22) piece so that engine hoist does not run across the cylinder cover. shackle | WH58.30-7-1002-07A 25 [Attach chain tackle (24) at rearright to | ® insert shackle (23.1) as intermediate iting eye (22) and tension chainsat piece so that engine hoist does not run engine hoist and at chain tackle across the charge air manifold. Secure engine to preventittiting, shackle | WHS8.30-2-1002-07A 26 Separate connectors (3,4, 7) at EL installation: Replace anti-tamper seal transmission (arrow) at connector (7), 27 [Detach propeller shaft(5) at transmission [B85 BAA1.10-N-1002-01F and attach to frame[a1 instalation: Replace nut (34). ant Urscrew bot (3) atear aromisvon mounting 5) ps Uscrew bots (1) on both sdesatengine | wapect engine mounting Torwear mountings (1) replace engine mountings tt neces 30 Lift out engine together with transmission |i) Max, 30° tilt of engine with ranision when ing out or nsetng. Fy Detach vansmision rom engine 5 ransmision 710.820 Baze oN 03-018 5 ranmision 715.080 bx26.10N- 106-016 i stalinhe revere oder 3 check engine oilevel with ipsck comers M4 sar engin and obrereoilpreure gage [© startengine withsarterformax 0 | zet8.o04-t001-01¢ tide speed seconds Waltabout2 minutes before repeating star operaton Motor niet hechrehen solange noch ein Olek angezeigt wis Li) The oit pressure gage must indicate oil presure after abot Tseonds, 5 atcha engine and ape fries 36 Ener engine number infDOK “Screen |] onyifvecondtond engine nsaled Test data of engine oil pressure Number Designation Engines 904.9, 906.9 ae ieoon-00r.016 Engine oll Idle speed bar] =05 Pressureat Maximum speed bar =25 fie] Manual transmission complete Number Designation Trans. 710.620 faxz6.o.1003018 | Transmission to engine nm |51 ie} Manual transmission complete Number Designation Trans- mission 715.050 pa26x0nioo60%c _| Transmission to engine Nm |51 Propeller shaft Number Designation Models 673, 674, 675,676,677, 679 xan sonso02o1F Boltinut of proper shaft to M10 Nm|60 ransmission/rear axle (flange wD uml 100 Jconnection) GER Engine OM 904A, OM 906LA (Mod. des. 904.9, 995.9), part 45,Commercially av ble tools (see Workshop Equipment Manual) Number Designation Make(e.9) [Orderno. jwnsesoztoorara | Engine hoist (self-locking) Backer 188 HerdersraBe D-42853Remscheid jwusea0z100207a [Shackle [cr pINszi01[ARO1.10-W-2401B Removing, installing engine with transmission 159.97 ENGINES 904,909 /910 /911 /915 /916 /917 /922, 906.910 /911 /915 /916 1 Cap (on engines 904.909-911/915-917/922) 2° Coupling, compressed-airline (on engines 904.909. 911/915-917/922) 3 Plug, compressed.airline (on engines 904.909-911/915-917/922) Engine hoist ‘Chain tackle Compressed airline (compressor) Propeller shaft Transmission bearing Connector speedo drive) Lead seal Plug connector (transmission) Clutch ine Cable harness, cable and bracket Connector (control module) Engine mount Steering line (return flow) Steering line (pressure) Fuel ine (Feed) Fuel ine (return flow) Oil filler pipe Refrigerant compressor EW Engine OM S048, OM SOELA (Mod, des. 9048, 2069), par 1 4723° Clamp 22 Exhaust pipe 24 Airintake house 25 Electric cable (generator) 28 Startercable 29 Ground.able G1 Generator ‘Wor T0001208 26 Compressed airline (engine brake cylinder) MI Starter 27. Electriceable harness ‘Modification notes 10.1299 _ |Settime at tachograph Step 34 added es Removing, installing |® installation Replace all self-locking nuts and bolts AS Danger! Risk of explosion from explosive gas. Risk | No fire, sparks, naked flames or smoking. Page 22 of poisoning and caustic burns from Wear acid-protective gloves, clotring and swallowing battery electrolyte. Risk of | eye protection. Pour battery elecroyte injury from caustic burns to eyes and skin | only into suitable and appropriately from battery electrolyte or from handling |marked containers. Jdamaged lead acid batteries. 1 Disconnect battery |® Notes on battery All models Page 24, AS Dangert Risk of injury from hand being jammed —_| No person must be within the tilting range Page 24 and bruised when titing cab of the cab when the cab stilted. Always tt Jab as far as the end postion and secure with safety prop. 2 Tit cab into repair position @ Notes on tilting cab |Models 375, 970-976 Page 25 3 Remove noise encapsulation panels ja Remove charge air pipe from charge air [ano9.41-W-1311D cooler to charge air manifold 5 Remove charge air pipe from turbocharger fanos.at-w-r3tic to charge air cooleré Remove fansroud a0. 4030. 6800 7 Detach alfiler line 2) atl panand | [1] Plug opening on sump. secure on frame a Detach exhaurtpipe 2) atengine brake | Secure exhaust pipe cn ame: ap connection and at transion 3 Detach compressed ar ine (26) at engine brake glinder 10 Detach airintake hose (2) at ar ceaner howsng 0 Detach able at lame glow plug and at leno vale 2 Disconnect elec cable) at tarer (kt) and wing hanes (27) at bracket 8 Detach electric cable (25) at generator (G1) |[L]Pay attention to clor coding and at bracket 4 Disconnect ground cable @s)and wring |[L]Onside and at botom harness at timing case 5 [Unbot compressed ar line at, [Hl carbon deposits are present the compresor and inspect for aon depos | compressed airline between compressor sndcompressd-air der andthe our protetionvalve must sdaonaly be nspeced Replace pars with arson depots. TT instalation: Inspect compressed ait line forteaks. ZS danger Rsk of explosion rom ignition riko |Nofre, parks, naked Tames or smoking Page 30 poisoning from ahalingand swallowing [Pour telson into sutable and tar well arrisk of injury tromskin and [appropriteymerkedcontanes eye contac ith fuel Wear protective clothing when handling et 16 Separate fuelines (18, 19)atfut iter |E] Mak tul ines anc collect ful which lows out 7 slacken poly V-belt andake of TT ony on models tte wth ar fantaa2.W-1a02A conditioning 7 Ostahrefigerantcompresor(@njat [U1] Donotseparateretigerantlnes engine 9 Sepratecompresiedsrines@,3)0f |[ATengines904909.911915-917822 with constant tote onstant thot, pulltt ap (1), ores clamp apartsing ple and pull connector out of socket. 0 Release and separate connector of able ares) at MAVPLD contol uit ZS Danger Rick of injury to skin or eyes rom hydraulic | Render the hydraulicystem presureles Page 31 fuidspreying out under pressure Rsk o | before commencing work on system, Wear poling fom swallowing hydraulic fd. [protective dothing and eye protection. a Separatebothhosesatthestering | [H callectesaping hydra. fines (6,7) a Remove locking element and pullout |) cole evaping bre fd lute ine (12) ransmision (D instatiation:Bledctutch actuation. | aras.205-0o70c e Notesonbrake ud Allmodels Page 51 (GEE Engine OM 90414, OM 906 LA (Mod. des. 904.9, 906.9), part 1 492 Separate connectors (@, Hat wanaminion [ID installation: Replace antitarpe sel 10) atconnector(). 7% Detach propeller shats@) at wanamision |B saat s0n-10020%F and atachto frame 5 Remove bors of transmision racketto | [iipectansmision mounting fer tranamision mounting) swear replace necessary Fs Remove bos atboth engine mount(15) | inspect engine mouns for west, replaceitnecesay 7 Remove engine with emoval ature Page 5st e ws. 202-1001.07% 8 Detach anamision from engine ES rransmisions iosvene2y ——[pA26s0-N-I005018 easicar 3 ranamisons715.050/080/320 | AZ60-Nt001.01¢ By Installin the reverse order 0 Reprogram wransponder Key [HT oniy ira reconditioned engine ora |AROOS7-W-00108 (asospare key) new MR/PLD control units inal Br check engine level via elec! | Se operating instructions part. Indeator andi neesarycorect Es Inspect coolant level and necessary dst A020.00.W-20108 ro correct evel BS anger Fisk of accident from vehicle starting of by [Secure vile to prevent moving oy Page 33 Teel when engine running. isk of injury | elt trom brusesand busi youhold your” | Wear closed and dotetiting work clothes handinto engine whenitistaredor |Do notgresphot or rotating part wen Ris runing. 2 startengine ® oonorrevpengineasiongsenocit_ |se18008-100r-01C pressreisindicated Di tme ot pressure gage mustiniate il pressure afte about 0 seconds ae swith off engine 5 Top up hydraulic ld of ering ane Pas ooW-A6TTA bleed steering 6 Inspect engine cooing stem and steering | Visual heck Pyrat for oaks Ea Set tine atachograph 38 Enter engine number in FDOK Tony ifreconditoned engines *sereen 1111" installed Test data of engine il pressure Number Designation Engines 08.9, soe cinconcovare [Engineoll _tdlespeed tar|z0s Dreseure at Maximum speed bar|=2.5 50Number Designation Transmissions 7106211622" | 623/626/627/68 fsazeiorr006018 | Transmission to flywheel housing Nm 45 ie] Manual transmission complete Number Designation trans [trans | Frans. mission | mission | missions 715.050 |715.060 [715.3207 715.321 2A2610267001-016 __| Transmission to flywhee! housing nm a5 as as E53 Propelier shaft Number Designation Models 970,972, 974,975,976 pads s0n-1002.01F Boit/nut of propeller shaft to M10 ‘nm 60 ransmissionirear axle (flange connection) me Nm} 100 Commercially available tools (see Workshop Equipment Manual) Number Designation Make e.9) order no. jwises0zor-07a [Engine hoist (set-locking) Backer 188 Herderstrabe D-42853 Remscheid [A¥42.50-P-0001-018 [Notes on brake fluid [All models ® ‘* Donetallow brake fluid to come into contact with vehicle paintwork, asit contains ingredients that act as solvents on the paint. If, inspite of taking appropriate cae, brake fluid does come into contact with the paintwork, the affected surface must immediately be rinsed with copious amounts of ‘water (do not rub off brake fluid). © Brake fluids highly hygroscopic, Le. it absorbs humidity Which reducesits boiling point. Brake fluid must therefore only be kept n closed, wellsealed storage containers (original container. (© Used brake fluid must not be re-used, 1# Brake fluid iscoloress to yellow colored ands therefore easily confused with mineral oll products. Brake fluid must therefore always be taken only from original containers and stored separately from mineral oll and other fluids ‘© For disposal information for the Federal Republic of Germany, see: "Umweltschute Handbuch far Kfz-Reparaturbetriebe” Publisher: Verband der Automobilindustrie .V. (VDA) £60625 Frankfurt am Main, WestendstraBe 61 [aR01.10:w-2400-01A | Removing and installing enaine with removal fixture Engine with transmision Commercially available tools (see Workshop Equipment Manual) Number Designation Make (e.9.) [Order no. fwsesozrooro7a [Engine hoist (self-locking) Backer 188 Herderstrate D-42853 Remscheid EW Engine OM 904A, OM 305 1A Mod des 9049, 9065), prt 51‘Attach engine hoist (1) to the lifting ‘eyes (2and3). ‘Attach chain block (4) at the rear right, ‘of the exhaust manifold and tension chains at engine hoist (1) and at chain block, Secure engine to prevent it siting. Lift out engine together with When installing, align engine and ‘transmission the engine and ‘transmission mounts. ‘Wor 16001006 52dust damage present [AROT.00-W-0001A [Inspecting engine for dust damage 3049.95 ENGINE 581,542, 904, 96 Ea Removing w fll consumption high oi engine has fied, tisoften unclear whether dust, amage or normal wen exits 7 remove itor, Engine 904,908 anos. so w7021A Engine 41,542 Ano3.10.-70218 a espectng 2 nspectintake passage between ai dleaner [UL Severe dust deposis inthe elbows of andengine for dust deposts te ake pipes ana noses area cea indlcation of dust damage Om engines ted wthol bath lr eaner, avery ine ns permissible. 3 Inspect pstors and onder walls tor wear | [I] thestem contact patterns ofthe (dust damage pistons and the honing pater ofthe ernders indicate damage caused by increned preence oF ur ifwear presen, | isa new lndertiner Page 92 Engine 204, 206 Replace onder ner anos 4-ws324a Engine 41,542 Replace ions engine 906,905 anos.10.7021A Replace pistons, engin $41,542 os. r0..70218 o Note fr assing wear toner walin [Engine 5%, 52, 904,906 Page 3 the cate of ust damage w Notes for astesing wear of pstonsin the | Engine $41,542, 904,506 Page 54 case of dustdamage Tavoiaoicaoor aia [Notes foranessing wear ofayinder wall Engine 908, 98,51 542 w {Cylinder walls or cylinder liners without dust damage ‘The honing is more of less clearly recognizable over the entire contact surface. The honing ‘may be partially worn off at the reversal point ofthe first piston! 8 GER Engine Oo GOHLA, OM 906A Mod. des. 9048, 9059), par 53{Cylinder walls or eylinder liners with dust damag ‘The trace of machining from honing are only still weakly visible or not at ll. wears at an advanced stage, a wear step can be felt atthe reversal point ofthe first piston ring. ira Dust damage is caused by poor seal, splits or chafing of the inlet lines, seals and hoses. ‘When carrying out maintenance and repair work, inspect all the inet lines, seals and hoses carefully, even at points which are not easly accessible. \ ©) ) [AHO3.10N-0001-01A [Notes for assessing wear topistonsin the | Engine 541, 542,904, 905, case of dust damage Pistons without dust damage ‘The contact surface ofthe piston stem is visible over alarge area and the machining grooves canst be recognized within this area. @ The machining grooves atthe circumference are intentional recesses which are filled with oi and contribute to better lubrication Pistons with dust damage The contact pattern at the stem has a mat (pumiced) appearance and the machining grooves are completely worn away within the contact surface. n the advanced stage of wear, slight traces of seizure are already present on the stem and the piston rings are sharp-edged. | eS: Qa _ A B[ARO1.00-W-0200A [inspecting cylinders with light probe 3.7.97 ENGINE 904.905 /906 /907 /908 /909 /910 /911 /915 /916 /917 /921 /922 /923, 906.910 /911 /915/916 /919 /920 /921 /922 1923 /925 /926 /927 /928 /939 /940 /941 /942 /943 /951 /952 1 Inspection probe 2 Blojiinderinspection equipment esses EE} Removing, salina 1 [Attach cranking device toting case Page 56 gi 904 589.04 63 00 Bleck otendcovertotimingcase _|eaor.son-ro0z01a Fi Remove nozleholdercombination [Engine 908 305 908/921 upto AnOT Os WSERIA endo. 20487 Engine 904905308921 a of anor os. wsa3ic end no. #0888, s04s0s-st1913:9179227925, sos.st0/s11/915/91601992352528) 330/940/941942/949951/952 3 Totatecanishaftwth canking device [Postion piston of order tobe speced fone a ‘Connect cylinder inspection equipment (2) | [2 cyiinder inspection equipment. | WH58.30-7-1028-05A andinsertnspection probe (1) through te |(E] Connection a ner nspection holeattheprotectvesteeeintothe equipment see operating instructions of tinder eaupment manufocrer a inspecting s Inspect cylinder wall and piston crown LH) cylinder wall mustnot have any scorch Page 53 steatsand rubbing teak. navel sigh drawing scores erenot etal Inspect condition often crown, if necessary | Remove cfinderhead (BER Engine 0M 904 LA, OM 906 LA (Mod. des. 804.9, 906.9), part 1 55