Mercedes Om904 Et om906LA PDF

I
Engines OM 904 LA, OM 906 LA

(Mod. des. 904.9,906.9)
Order No. 6517 5031 02

Printed in Germany
0998 0,12 ff
From the library of Barrington Diesel Club

Contents P a rti
Title Validity________________________________________________________ Page

Technical data engine complete ENGINE 904.905 /906 /907 /908 /909 /911 /921 /922 /923, 3
906.910 /911 /920 /921 /922 /923
D isc o n n e ctin g , co n n e c tin g e n g in e w irin g harness E N G IN E 906.920/921 /922 /923 12
Removing, installing engine ENGINE 904.909/910/911 /922,906.910/911 17

Removing, installing engine ENGINE 906.920 /921 /922 /923 24
Removing, installing engine with transmission ENGINE 904.905/906/907/921 32
Removing, installing engine with transmission ENGINE 904.909/910/911 /922,906.910/911 37
Inspecting engine for dust damage ENGINE 904/, 906,541, 542 43
Inspecting cylinders with light probe ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 45
/911 /920 /921 /922 /923/940/941
Testing compression pressure ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 48
/911 /920 /921 /922 /923 /940 /941
Removing, installing cylinder head cover ENGINE 904.905/906/907 /908/909/910/911 /921 19221923, 51
906.910/911 /920 /921 /922 /923 /940 /941
Removing, installing oil separator ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 53

/911 /920 /921 19221923
ENGINE 904.9081923 in MODEL 668, 670
ENGINE 906.940/941 in MODEL957
Removing, installing protective sleeve ENGINE 904.905/906/907/908/909/910/911 /921 /922, 54
906.910/911 /920 /921 1922 1923 /940 /941
Removing and installing cylinder head ENGINE 904.905/906/907 /909/910/911 /921 /922, 906.910 58
/911 /920 /921 19221923 /940/941
Removing, installing decompression brake valve ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 66
/911 /920 /921 /922 /923 /940 /941
ENGINE 904.908 /923 with CODE (MB1) Engine brake with
decompression brake valve
Inspecting, facing cylinder head contact surface ENGINE 904.905 /906 /907 /908 /909 /910 /911 /921 /9221923, 69
906.910/911 /920 /921 /922 /923 /940/941
Measuring cylinder bores ENGINE 904.905 /906 /907 /908 /909 /910 /911 /921 19221923, 75
906.910 /911 /920 /921 /922 /923 /940 /941
Flex-honing cylinder wall ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 77
/911 /920 /921 19221923
ENGINE 904.908 /923 in MODEL 668,670
ENGINE 906.940/941 in MODEL 957
Widening cylinder bore in crankcase ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 79
/911 /920/921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
ENGINE 906.940/941 in M O D EL957
Removing cylinder liner ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 82
/911 /920 /921 19221923
ENGINE 904.908 /923 in MODEL 668, 670
Installing cylinder liner ENGINE 904.905 /906 /907 /909 /910 /911 /921 1922,906.910 84
/911 /920 /921 /922 /923
ENGINE 904.908 /923 in MODEL 668, 670
Removing and installing oil sump ENGINE 904.905/906/907/921 89
R e m o v in g a n d in sta llin g o il p an ENGINE 904.909/910/911 /922.906.910 /911 /920/921 /922 91
/923
Removing, installing timing case ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 93
/911 /920 /921 19221923
ENGINE 904.908 /923 in MODEL 668, 670
ENGINE 906.940 /941 in MODEL 957
Removing, installing timing case ENGINE 906.920/921 /922 /923 95
Timing case SAE 1 or 2, prepared for engine output or installed
engine output
Engines OM904 LA, 906 LA (m od. des. 904.9,906.9), F4 1

2
Contents Part 2
Title Validity Page

Removing, installing pistons ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 3
/911 /920/921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
Removing, installing piston rings ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 11
ENGINE 904.908/923 in MODEL 668,670

Inspecting, repairing conrod ENGINE 904.905 /906 /907 /908 /909 /910 /911 /921 /922 /923, 13
906.910/911 /920 /921 /922 /923 /940 /941
Replacing front crankshaft radial seal ENGINE 904.905 /906/907/909/910/911 /921 /922,906.910 20
/911 /920 /921 /922 /923
ENGINE 904.908 /923 in MODEL 668,670
Replacing rear crankshaft radial seal ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 22
/911 /920 /921 /922 /923
ENGINE 904.908 /923 in MODEL 668, 670
Removing, installing crankshaft ENGINE 904.905/906/907 /908/909/910/911 /921 /922/923, 24
906.910 /911 /920 /921 /922 1923 /940 /941
Measuring and mounting crankshaft ENGINE 904.905/906/907 /908/909/910/911 /921 19221923, 30
906.910/911 /9Z0 /921 /922 /923 /940/941
Removing, installing crankshaft sprocket ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 40

/911 /920 /921 /922 1923
ENGINE 904.908 /923 in MODEL 668, 670
Removing, installing drive gear for oil pump on crankshaft ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 41
/911 /920/921 1922 1923
ENGINE 904.908 /923 in MODEL 668, 670
Removing, installing belt pulley/vibration damper ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 42
1911 /920 /921 1922 1923 /940 /941
Removing, installing flywheel ENGINE 904.905 /906 /907 /909 /910 /911 7921 /922,906.910 45
/911 7920 /921 1922 1923
E N G IN E 904.908 /923 in M O D E L 668, 670
Inspecting, machining flywheel ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 48
1911 /920 /921 /9221923
ENGINE 904.908 /923 in MODEL 668, 670
Replacing ring gear of flywheel ENGINE 904.905/906/907 /909/910/911 /921 /922, 906.910 51
7911
ENGINE 904.908 /923 in MODEL 668, 670
Removing, installing guide bearing in flywheel ENGINE 904.905 /906 1907 1909 /910 /911 /921 /922,906.910 53
/911 /920 /921 1922 1923 /940 /941
ENGINE 904.908 /923 in MODEL 668, 670
Checking valve lift ENGINE 904.905/906/907 /909/910/911 /921 /922, 906.910 56
7911 /920/921 1922 1923
ENGINE 904.908 7923 in MODEL 668.670
ENGINE 906.940 7941 in MODEL 957
Removing, installing rocker arm assembly ENGINE 904.905 /906 /907 /908 7921 # # up to 39739 58
Removing, installing rocker arm assembly ENGINE 904.909/910/911 /922,906.910/911 /920/921 1922 61
1923 /940 /941
Disassembling, assembling rocker arm assembly ENGINE 904.905 /906 /907 /908 /909 7910 /911 7921 7922 /923, 63
906.910 /911 /920 /921 7922 /923 /940 /941
Removing, installing valves ENGINE 904.905/906/907 /909/910/911 /921 1922/923, 65
906.910 /911 /920 /921 1922 1923
ENGINE 904.908 in MODEL 668,670
Inspecting, removing, installing valve guides ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 73
/911 /920/921 /922/923
E N G IN E 904.908/923 in M O D E L 668, 670
Replacing valve stem seals ENGINE 904.905/906/907 /908/909/910/911 /921 /922, 78
906.910 7911 /920 7921 922 1923 1940 /941
Replacing valve seat rings ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 80
/911 /920 /921 /922/923
ENGINE 904.908 /923 in MODEL 668, 670
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 1

2
Contents Part 3
Title Validity Page

Machining valve seat rings ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922 /923, 3
906.910 /911 /920 /921 /922 /923
E N G IN E 906.940/941 in M O D E L 957
Grinding valves ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922 /923, 15
906.910 /911 /920 /921 /922 /923
Removing, installing camshaft ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 18
/911 /920/921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
Removing, installing MR/PLD control unit ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 24
/911/920 /921 /922 /923
Removing and installing MR/PLD Injection lines ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 27
/911 /920 /921 /922 /923
ENGINE 906.940 /941 in MODEL957
Removing and installing nozzle holder combination ENGINE 904.905/906/907/921 ##upto40487 31
ENGINE 904.908 # # up to 40487 in MODEL 668, 670
Removing and installing nozzle holder combination ENGINE 904.905 /906 /907 /921 # # as of 40488 34
ENGINE 904.908 # # as of 40488,
904.923
in MODEL 668, 670
ENGINE 904.909/910/911 /922,906.910/911 /920/921 /922
/923 /940 /941
Removing and installing MR/PLD unit pump ENGINE 904.905/906/907 /908/909/910/911 /921 1922, 37
906.910 /911 /920 /921 1922 /923 /940 /941
Removing, adjusting and installing crankshaft angle position ENGINE 904.905 /906 /907 /909/910/911 /921 /922,906.910 41
sensor bracket /911 /920/921 1922 /923/940/941
Testing low pressure fuel circuit ENGINE 904.905 /906 /907 /921 # # up to 040487 43
Testing low pressure fuel circuit ENGINE 904.905 /906 /907 /921 # # as of 040488 58
ENGINE 904.909/910/911 /922,906.910/911 /920/921 /922
/923 /940 /941
Inspecting turbocharger ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 67
/911 /920 /921 /922 /923 /940/941
Removing and installing turbocharger ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 70
/911 /920 /921 1922 /923 /940/941
Removing, installing boost air pipe ENGINE 904.905/906/907/921 75
Removing, installing boost air pipe ENGINE 904.909 /910 /911 /922,906.910/911 /920 /921 /922 76
/923/940/941
Removing, installing boost air pipe F N G IN F 904.909/910/911 /977. 906 910 /911 /970/971 /977 77
/923
From intercooler to boost air manifold
Removing and installing boost air manifold ENGINE 904.905/906/907/921 79
Removing, installing boost air manifold E N G IN F 904.909/910/911 /922, 9 06 .9 1 0 /911 /920/921 /922 81
/923 /940 /941
Removing, installing boost pressure, boost air temperature ENGINE 904.909/910/922/911,906.910/911 /920/921 /922 83
sensor /923
Testing intercooler and boost air hoses for leaks ENGINE 904.909 /910/911 /922,906.910/911 /920/921 /922 84
/923
Removing, installing poly V-belt ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 86
/911 /920 /921 /922/923
Removing, installing poly V-helt tensioning device F N G IN F 904 905 /906 /907 /909 /910 /911 /921 /922. 906.910 88
/911 /920 /921 1922 /923
ENGINE 904.908 /923 in MODEL 668,670
Removing, installing compressor ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922, 906.910 89
/911 /920 /921 /922 /923
@ *3 ^ Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 1

Contents Part 4
Title validity Page

Removing, installing exhaust manifold ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 3
/911 /920 /921 /922 /923 /940/941
Removing, installing engine brake flap connection ENGINE 904.905/906/907/909/910/911 /921/922 10
Removing, installing engine brake flap connection ENGINE 906.910 /911 /920 /921 /922 /923 /940 /941 12
Repairing engine brake flap connection ENGINE 904.905 /906 /907 /908 /909 /910 /911 /921 /922 /923 14
Repairing engine brake flap connection ENGINE 906.910 /911 /920 /921 /922 /923 /940 /941 17
Removing, installing starter ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 20
/911 /920 /921 /922 /923 /940 /941
Removing and installing generator ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 22
/911 /920 /921 /922 /923 /940 /941
Removing and installing the generator poly V-belt pulley ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 24
/911 /920 /921 /922/923
Removing, installing oil pump ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 26
/911 /920 /921 /922 /923
ENGINE 904.908 /923 in MODEL668.670
Removing, installing oil-water heat exchanger ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 29
/911 /920 /921 /922 /923 /940 /941
Removing, installing oil filter housing ENGINE 904.905/906/907 /909/910/911 /921 /922.906.910 35
/911 /920 /921 /922 /923 /940 /941
Removing, installing oil filter bypass valve ENGINE 904.905/906/907/921 # # up to 16109 39
Removing, installing oil pressure, oil temperature sensor ENGINE 904.909/910/922/911,906.910/911/920/921 /922 42
/923 /940 /941
Removing and installing oil level sensor ENGINE 904.909/910/911 /922,906.910/911 /920/921 /922 45
/923 /940 /941
Removing, installing oil spray nozzles (piston cooling) ENGINE 904.905 /906/907 /909/910/911 /921 /922,906.910 47
/911 /920 /921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
Filling engine oil circuit ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 49
/911 /920 /921 /972/973
ENGINE 904.908 /923 in MODEL 668, 670
Removing and installing coolant pump ENGINE 904.905 /906 /907 /909 /910 /911 /921 1922,906.910 52
7911 /920 /921 /922 /923 /940/941
Disassembling and assembling coolant pump ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922, 906.910 55
/911/920 /921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
Removing and installing engine coolant thermostat ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 58
/911 /920/921 /922 /923
ENGINE 904.908 /923 in MODEL 668,670
Testing coolant thermostat ENGINE 904.905 /906 /907 /908 /909 /910 /911 /921 /922, 60
906.910/911 /920 /921 /922 /923
ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920
/921 /922 /923/925/926
ENGINE 906.940/941
Removing and installing fan shroud ENGINE 904.909/910/911 /922,906.910/911 62
Removing and installing fan ENGINE 904.909/910/911 /922,906.910/911 /920/921 /922 64
/923 /940/941
Removing, installing radiator ENGINE 904.905 /906 /907 /921 66
Removing and installing radiator ENGINE 904.909/910/911 /922 68
Removing and installing radiator ENGINE 906.920/921 /922 /923 70
Removing grease and scale in cooling system ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 73
/911 /920/921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
Checking cooling system for leaks ENGINE 904.909/910/911 /922,906.910/911 /940/941 76
Removing and installing coolant level sensor ENGINE 904.909 /910 /922 /911,906.910 /911 78
Removing and installing power steering pump STEERING 765.820 /821 /830 /840 /844 with ENGINE 904.905 79
/906 /907 /909 /910 /911 /921 /922,906.910 /911 /920 /921
1922 /923

Title Validity Page
Removing, installing fuel full-flow filter ENGINE 904.905 /906 /907 /921 # # up to 33991 81
Removing, installing fuel full-flow filter ENGINE 904.909/910/911 /922,906.910/911 /920/921 /922 83
/3Z3 /940 m i
Removing, installing fuel heat exchanger ENGINE 904.905 /906 /907 /921 # # up to 33991 85
ENGINE 904.908 # # up to 33991 in MODEL 668,670
Removing and installing fuel pumps ENGINE 904.905/906/907/909/910/911,906.910/911 /920 87
/921 /922 /923
ENGINE 904.908 /923 in MODEL 668, 670
2
GF01.00-W-2000A Technical data engine complete 17.4.96
ENGINE 904.905/906/907/908/909/911/921 Z922/923,906.910/911/920/921 Z922/923
Technical data engine OM904LA (engine 904.905) Page 3

OM 904LA (engine 904.906/908) Page 4
OM 904LA (engine 904.907) Page 5
O M 904LA ( M o to r 904.909) Page 6
OM 904LA (Motor 904.911) Page 7
OM 904LA (Motor 904.921 /922/923) Page 8
OM 906LA (Motor 906.910/920/922) Page 9
OM 906LA (Motor 906.911 /921/923) Page 10
G F01.00-W-1000-01A Technical data engine Engine 904.905 r- ^ G F
P Engine output
M Engine torque
n Rated speed
b Specific fuel consumption
Additional Information
Engines O M904 LA, 906 LA (m od. des. 904.9, 906.9), F4 3

Engine model designation 904.905
Engine type OM 904LA 1/1
Engine power (P) kW/HP 90(122)
rpm 2300
Engine torque (M) max. Nm 470
rpm 1200-1500
Rated speed rpm 2300

Bore mm 102
Stroke mm 130
Total displacement cm3 4250
Compression ratio e 17,4
Firing order 1-3-4-2
Number and arrangement of cylinders 4 inline
Valves Inlet 2
Exhaust 1
Working method 4-stroke diesel with direct injection
Combustion method Exhaust turbocharger and intercooler
Injection method Single unit pump with pump-line-nozzle system (PLD)
Tim ing E le c tro n ic e n g in e m a n a g e m e n t with so le n o id v a lve -co n tro lled fu e l
injection
Specific fuel consumption (b) g/kWh (see diagram)
O
Li.
GF01.00-W-1000-01B Technical data engine Engine 904.906/908
P Engine output
M Engine torque
n Rated speed
4
Engine model designation 904.906/908
Engine type OM 904LA 11/1
rpm 2300
rpm 1200-1500
Bore mm 102
Stro ke mm 130
Valves Inlet 2
Exhaust 1
Timing Electronic engine management with solenoid valve-controlled fuel
injection
GF01.00-W-1000-01C Technical data engine Engine 904.907
P Engine o u tp u t
M Engine torque
n Rated speed
W01.00-0004-12
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 5

Engine type OM 904LA ill/3
rpm 2300
rpm 1200-1500

Bore mm 102
Stroke mm 130
Valves Inlet 2
Exhaust 1

T im ing E le c tro n ic e n g in e m a n a g e m e n t w ith so leno id v a lve -co n tro lled fu el
injection
GF01.00-W-1000-01K Technical data - engine Engine 904.909 C -GF
P Engine output
M Engine torque
n Rated speed
Engine type OM 904 LA 11/2
Engine power (P) kW/HP 90/122
rpm 2300
rpm 1200-1500
Rated speed rpm 2300/2500
Bore mm 102
Stroke mm 130
Valves Inlet 2
Exhaust 1
Timing Electronic engine manaqement with solenoid valve-controlled fuel
injection
G F01,00-W-1000-01L Technical data -engine Engine 904.911 PS^G F
P Engine output
M Engine torque
n Rated speed

Engine type OM 904 LA lt/4
rpm 2300
rpm 1200-1500
Bore mm 102
Stroke mm 130
Valves Inlet 2
Exhaust 1
Injection method Single unit pump with pump-llne-nozzle system (PLD)
T im in g Ele ctro n ic e n g in e m a n a g e m e n t w ith s o le n o id va lve -co n tro lled fu e l
Injection
GF01.00-W-1000-01M Technical data - engine Engine 904.921/922/923 r-s-'GF
P Engine output
M Engine torque
n Rated speed
Engine model designation 904.921/922/923
Engine type OM 904 LA II/8
rpm 2300
rpm 1200-1300
Bore mm 102
Stroke mm 130
Valves Inlet 2
Exhaust 1
W o r k in g m eth o d 4-stroke diesel w ith d ire c t Injectio n

Tim ing F lectrn n ic e n g in e m a n a g e m e n t w ith so le n o id valve-con trolled fu e l
injection
GF01.00-W-1000-01N Technical data -engine Engine 906.910/920/922 p^ g f
P Engine output
M Engine torque
n Rated speed

Engine type OM 906 LA 11/1

rpm 2300
rpm 1200-1500
Bore mm 102
Stro ke mm 130

Firing order 1-4-2-5-3-6
Valves Inlet 2
Exhaust 1
Timing Electronic engine management with solenoid valve-controlled fuel
injection
GF01.00-W-1000-010 Technical data -engine Engine 906.911/921/923 M s-G F
P Engine output
M Engine torque
n Rated speed
Engine type OM 906 LA II/3
rpm 2300
rpm 1260-1500
Bore mm 102
Stroke mm 130
Compression ratio e 18.0
Firing order 1-4-2-5-3-6
Valves Inlet 2
Exhaust 1
W o r k in g m eth o d 4-stroke d iesel w ith direct in jectio n

T im ing E le ctro n ic e n g in e m a n a g e m e n t w ith so le n o id valve-con trolled fu e l
injection
SB* Engines OM904 LA, 906 LA {mod. des. 904.9, 906.9), F4 11

AR01.00-W-241 OF Disconnecting, connecting engine wiring harness 12.6.98
ENGINE 906.920/921 Z922/923
7 Cab -chassis connector

2 Cover
3 Cable (red)
4 Engine wiring harness
X2.1 Connector
X2.2 Connector
X2.3 Connector
W01.00-1001-06
m m Removing, installing
/\ Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 13
poisoning and burns from swallowing Wearacid-resistantgloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
Notes on battery All models Page 15

2 Open maintenance flap
3 Remove front grille S3 000 589 01 1000
4 Take off cover (2) at cab -chassis connector IH Installation: cover of cab - chassis
(1) connector must be closed tight
HI 000 589 01 10 00
5 Separate cable (red) (3) and the connectors

(X2.1 to X2.3) at cab -chassis connection
point (1)
6 Unclip engine wiring harness (4) and place Do not damage engine wiring harness
down
Danger Risk of injury from bruises and jamming No person should be in the tilting area of Page 15
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
7 Tilt cab
Notes on tilting cab Model 950,952,953,954 Page 16
12
8 Take engine wiring harness (4) out at the @ Do not damage engine wiring harness
fixture at the right-hand frame
lo n g itu d in a l m em b er a n d tie u p a t e n g in e
9 Install in the reverse order
/2223-T
8g 0
0 0 0 @ @
2224-T
n n n n n n n n
Bflu ufl flfl 0 0

V_______ 000 589 01 10 00
Torxbitset
AS54.10-Z-0001-01A Explosion hazard from explosive gas. Flames, sparks, open light and Danger!
Danger of poisoning and acid burns when smoking prohibited, w ear acid
battery acid is swallowed. Danger of acid resistant gloves, clothing and goggles.
burns to skin and eyes from battery acid or Store battery acid only in suitable,
when handling damaged lead-acid appropriately marked containers.
batteries.
Possible dangers
Injury hazard
Explosion Hazard Battery acid contains sulfuric acid, which can cause severe burns
A highly explosive gas mixture is generated when lead-acid to skin and eyes. W hen handling damaged lead-acid batteries
batteries are charged (removing from accident vehicle) increased care is necessary due
to the sharp edges on the broken housing and direct contact with
Poisoning hazard the lead plates.
When battery acid is taken orally toxic symptoms can occur such
as headache, dizziness, stomach pain, paralysis of the respiratory Rules of behavior/protective measures
system, unconsciousness, vomiting, acid burns and cramps. - Charge lead-acid batteries only in well ventilated rooms.
Battery acid vapor can burn eyes. Inhalation can result in burns to Fire, sparks, open light and smoking prohibited.
mucous membranes and respiratory paths. - Do not lay tools or other conductive items on lead-acid
Lead in the body can damage blood, nerves and kidneys; batteries (danger of short circuiting).
moreover, lead compounds pose a hazard for the reproduction - Disconnect and remove lead-acid batteries for charging.
organs. - Always disconnect negative pole first; always connect positive
pole first.
- Switch on charger only after connecting to poles; switch off
before disconnecting.

Keep lead-acid batteries and battery acid away from First-aid measures
unauthorized persons. Eye contact
Store battery acid only in suitable, appropriately marked Rinse eyes immediately with large quantities of water.
containers. Skin contact
Store lead-acid batteries only in upright position. Remove affected clothing.
Ensure that gassing line is properly connected. Neutralize acid on skin or clothing immediately with acid
Check gassing line fo r kinks a n d p ro p e r passage. neutralizer or soap solution and rinse with large quantities
Observe instructions for applicable lead-acid battery and of water.
vehicle operating instructions. Inhalation of battery acid vapor
Wear acid protective clothing and protective goggles with side Move affected person to fresh air
guard. S w a llo w in g b a tte ry acid
Have person drink large quantities of water containing
activated charcoal.
G e n e r a lly m edical services o r a p h ysicia n sh o u ld b e co ntacted

after administering first aid.
Fire protection measures

Suitable extinguishing agents
- CO2 and dry extinguishing agents.
P S 4.1 0 *0 2 7 0 -0 8
Warning notes on lead add batteries
1 Fire, sparks, open light and smoking 3 Observe operating instructions 6 Keep away from children
prohibited 4 Danger o f acid burns 7 First aid
2 Explosion hazard 5 W ear eye protection
14
AH 54.10-P-0001 -01A Notes on battery All models
Do not store lead-acid batteries for extended periods of time Do not switch on battery chargers until they have been
in a place where they are exposed to direct sunlight. connected to the battery poles; switch them off before
Always store lead-acid batteries horizontally to prevent acid disconnecting.
from escaping; do not tilt them when they are being Only charge lead-acid batteries with direct current. For the
transported. charging current we recommend 10% of capacity for normal
Discharged or faulty lead-acid batteries can freeze up; charging and 50% of capacity for rapid charging.
t h e re fo re , en su re t h a t th e y a rc sto red a t te m p e ra tu re s a b o v e D u rin g rapid charging it must be Insured that the casing Of the
feezing level. lead-acid battery does not warm up excessively (< 55 C).
Do not place any tools or other electrically conductive objects Lead-acid batteries should be kept clean and dry as far as
on a lead-acid battery (risk of short-circuit!). possible.
Avoid mixing up positive and negative poles and avoid short- it is advisable to grease the poles lightly with battery pole
circuits. grease.
Before removing or installing a lead-acid battery, switch off all Lead-acid batteries should not be stored for extended periods
electrical consumers where possible, and switch off the engine, without being recharged.
so as to minimize the possibility of creating sparks. If a lead-acid battery is to remain in a vehicle which is not in
Always disconnect the negative pole first; always connect the use for an extended period, the negative terminal clamp
positive pole first. should be disconnected.
Bearbeitungsvermerk
Datum ; Ersteiier j Vermerk i Se/te
AS60.80-Z-0001-01A Injury hazard from pinching and crushing When tilting ensure that no one is Danger!
when cab is tilted present in the tilting area of the cab.
Always tilt cab to end position and
secure with safety brace.
Injury hazard
A damaged tilting mechanism or improper handling of the tilting
mechanism can lead to severe injuries when tilting the cab. When tilting cab:
- Protect tilting area and particularly tilting device against
Rules o f b e h a v io r/ p ro te c tiv o m ea su res u n a u th o riz e d access, e.g. by b lo ckin g o ff o r w it h h u m a n
Before tilting cab: guard.
- Shut off engine. - Attach safety cable before tilting when so specified in the
- Apply parking brake. vehicle operating instructions.
Se cu re v e h ic le a g a in s t ro lling . - Never work under cab when partially tilted.
- On vehicles with manual transmission move shift lever to - Always tilt cab to end position and secure with safety brace.
neutral position.
- On vehicles with automatic transmission move selection lever
to position " n ".
AH60.80-N-0003-01A Notes on tilting the cab Models 673,674,675,676,677,678,
679, 950,952,953,954, 957, 970,971,
972, 973, 974, 975, 976
Before tilting the cab On vehicles with a refrigerator box

Switch off engine e The refrigerator box must be switched off before the cab is
Apply parking brake tilted.
Secure vehicle to stop it rolling away The refrigerator box may only be switched on 10 minutes
Remove all loose objects (e.g. cans, bottles, tools, bags etc.) after tilting the cab back again.
from the cab E l Also refer to the refrigerator box manufacturers
On vehicles with manual transmission move shift lever to Operating Instructions and the red information plate on the
neutral position refrigerator box.
e Model 957: release steering column and open front flap
The coupling pin must be inserted correctly.
E3Always tilt cab up to its final position.
16
AR01.10-W-2400D Removing, installing engine 5,8.97
ENGINE 904.909/910/911/922, 906.910/911
W 01.10-0014-09
1 Cap (engine 904.909- 911/922) 9 Connector (control unit)
2 Clutch compressed air line (engine 904.909-911/922) 10 Engine mounting
4 compressed air line connector (engine 904.903- 97 I/9ZZ) l ; steering line (return flow)
4 19Engine hoist 12 Steering line (pressure)
5 19 Chain block 13 Fuel line (feed)
6 Compressed air line (compressor) 14 Fuel line (return flow)
7 Shift rod (engine 904.909- 911/922) 15 Oil filler pipe
8 Wiring harness, line and bracket 16 AC compressor
W 01.10-0012-09
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), E4 17

22 Exhaust pipe 28 Starter cable
23 Clamp 29 Ground cable
24 A ir intake hose
25 Electric cable (generator) Gl Generator
26 Compressed air line (engine brake cylinder) Ml Starter
27 W iring harness
30 Sh ift lever with shift rod (engine 906.910/911)

31 Bracket (engine 906.910/911)
32 Support (engine 906.910/911)
W01.10-0017-11
Modification notes
6.7.98 Enter engine number in FDOK after replacing engine Step 31 added Page 17
nnu Removing, installing
Installation Replace all self-locking nuts and bolts
Danger Risk o f ex p lo sio n fro m gas. Risk o f N o fire, sparks, n a k e d fla m es o r sm oking. P a g e 13
poisoning and burns from swallowing Wear acid-resistant gloves, clothing and
No tes on b a tte ry A ll m od els P a g e 15
with a safety prop.
2 Tilt cab into repair position
Notes on tilting cab Model 970- 976 Page 16

3 Remove noise encapsulation CD At side, at bottom rear, and over
transmission
A R em o ve ch arg e a ir p ip e fro m in te rco o lcr to AR09.41 W 1311D
charge air manifold
5 Remove charge air pipe from turbocharger AR09.41-W-1311C

to intercooler
6 Remove fan shroud AR20.40-W-6800A

7 Detach oil filler line (15) at oil pan and tie
up at frame
18
8 Detach exhaust pipe (22) at engine brake Tie up exhaust pipe at frame
flap connection and transmission CDInstallation: clean sealing surfaces
9 Detach compressed air line (26) at engine II On engine with engine brake
brake cylinder
10 Detach air intake hose (24) at air cleaner

housing
11 Detach electric cables at flame glow plug II On engine with flame starting system
and at solenoid valve
12 Detach electric cable (28) at starter (M 1)

and wiring harness (27) at fixture
13 Detach electric cable (25) at generator (G1) [I Pay attention to color coding
and fixture
14 Detach ground cable (29) and wiring

harness at timing case
15 Unbolt compressed air line (6) at [ I If coking present, it is then also

compressor and inspect for coking necessary to additionally inspect
compressed air line between compressor
and compressed air drier with integrated
pressure regulator and the four-circuit
protection valve.
Replace coked parts.
II Installation: inspect compressed air line

for leaks
16.1 Detach shift linkage (7) at shift lever On engine 904.909-911/922
16.2 Detach shift lever with shift linkage (30) O n e n g in e 906 91(1/911
and bracket(31)atsupport(32)
A Danger Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 21
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
17 Separate fuel lines (13,14) at fuel filter [I Collect fuel which flows out. Mark fuel
lines.
18.1 Slacken poly V-belt and take off [I On vehicle with air conditioning AR13.22-W-1202A
18.2 Detach AC compressor (16) with bracket at II On vehicle with air conditioning.
engine Do not separate refrigerant lines.
19 Separate compressed air lines (2, 3) of tl On engine 904.909-911 /922 with

constant throttle constant throttle, pull off cab (1). Use pliers
to press clamp apart and unplug connector
from socket
. Danger Risk of injury to skin or eyes as a result of Render system pressureless before Page 22
hydraulic fluid spraying out under high commencing work on hydraulic system.
pressure. Risk of poisoning from W ear protective clothes and eye
swallowing hydraulic fluid. protection.
20 Separate both hoses at the steering lines Collect hydraulicfluid which flows out AP46.00-W-4611A
(11.12) II Installation: top up hydraulicfluid and
bleed steering
21 Release and separate connector of wiring

harness (9) at PLD control unit
22 Attach transmission or support
23 Unscrew bolts at transmission With transmission BA26.10-N-1006-01B

710.621/622/623/626/627
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4

Additional Information 19
0 W ith transmission 715.050/060/320 BA26.10-N-1001-01C
24 Take off bracket at enqine mounts (10) DO Inspedt enaine mounts for wear,
replace if necessary
25 Remove engine with removal fixture, Page 22

install
I S Engine hoist WH58.30-Z-1001-07A
MB longlife grease BR00.45-Z-1002-06A
26 Install in th e reve rse o rd e r
27 Relearn transponder keys H I W hen installing a replacement engine AR80.57-W-0010A

ora new MR (PLD) control unit
28 Check engine oil level at electric gage See operating instruction part 3
29 Start engine and observe oil pressure gage Start engine with starter for not more BE18.00-N-1001-01C
when engine idling than 90 seconds. Wait about 2 minutes
before repeating attempt at starting. Do
not rev up engine so long as no oil pressure
vindicated.
S The oil pressure gage should indicate
oil pressure afterabout 10seconds.
30 Switch off engine and inspect for leaks
31 Enter engine number in FDOK "Screen H Only if a replacement engine is fitted

1111
Test data of engine oil pressure
Number Designation Engine 904.905/

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idle speed bar 0.5
maximum speed bar >2.5
s Manual transmission, complete
Number Designation Transmission

710.621/622/
623/626/627
B A26.10-N-1006-01B Transmission to flywheel housing Nm 45
0 Manual transmission, complete
Number Designation Trans Trans Trans

mission mission mission
715.050 715.060 715.320
BA26.10-N-1001-01C Transmission to flywheel housing Nm 45 45 45
Commercially available tools (see Workshop Equipment Manual)
Number Designation Make (e.g.) Order number
WH58.30-2-1001-07A Engine hoist (self-locking) Bcker 3188

Herderstrae
D-42853 Remscheid
20
Repair products
Number Designation Order number
S R00.45-Z-1002-06A M B lo n g life g rease 000 989 63 51
A947 00-7-0001-01A Risk o f ex p lo sio n fro m ig n itio n o f fu e l, risk Fire, th e c re a tio n o f sparks, naked A D a n g er!
of poisoning if fuel is inhaled or swallowed lights and smoking prohibited.
and risk of injury if skin or eyes come into Only pour fuels into containers which
contact with fuel are suitable and are correspondingly
m arked.
Wear protective clothing when
handling fuels.
P o te n tia l d ang ers
Risk of explosion, poisoning and injury

Fuels are highly flammable and are poisonous if swallowed. Fuel - Always put drained fuel into containers which are suitable and
can cause damage to the skin. Contact with gasoline fuel, for can be properly closed off.
example, removes the skins natural oils. Fuel vapors are explosive - Immediately remove any fuel which has been spilt,
and invisible, and spread out along the floor. They are poisonous
if inhaled and can cause unconsciousness in high concentrations. Working on the vehicle using a naked flame
(e.g. when welding etc.).
Protective measures/rules for handling fuels - Before carrying out such work, remove the relevant parts of
- Observe local national safety regulations. the fuel system and seal off open fuel lines with plugs.
- Fire, the creation of sparks, naked lights and smoking
forbidden. First aid measures
- Make sure that the work area is sufficiently well ventilated. Wash any fuel from skin using soap and water.
- Never drain or add fuels over workshop pits. Change out of clothing on which fuel has been spilt as soon as
possible.
e If fuel is splashed into the eyes, rinse out the eyes immediately
with water; consult a doctor if appropriate.
E ngines O M 9 0 A I A. 906 L A (m o d . doc. 904.0, 00 6 .0 ), FA 21
AS00.00-Z-0013-01A Risk of injury to skin or eyes from Before starting work on the hydraulic ^ Danger!
pressurized hydraulicfluid spraying out. system, depressurize the system. Wear
Risk of poisoning from swallowing protective clothing and safety glasses.
hydraulicfluid
Potential danger
Risk of injury - Ensure only authorized persons have access to hydraulic fluid.
Serious injuries can be caused to the skin or eyes when loosening - Seal disconnected lines and hoses and connections on the
hydraulic lines without depressurizing the system beforehand, subassemblies immediately with blind plugs.
due to the very high pressures (above 200 bar). Damage to the - Wear safety gloves, protective clothing and safety glasses.
skin may be caused if unprotected skin comes into contact with If it is not possible to wear safety gloves, the following points are
hydraulic fluid, particularly central hydraulic fluid (this is to be observed:
especially harmful to health). - Only allow hydraulic fluid to come into contact with the skin
for as short a time as possible, wash fluid off skin with soap
Risk of poisoning and water.
Anyone who swallows hydraulic fluid can expect to suffer - Change wet clothing as quickly as possible
sym ptom s o f p o iso n in g in clu d in g he ad ach es, dizziness, sto m ach
ache, vomiting, diarrhoea, cramps and unconsciousness First aid
Have the casualty drink plenty of water with activated charcoal
Safety measures/operating instructions additive.
B e fo re s ta rtin g w o r k o n h y d ra u lic system s th e y sh o u ld be A fte r s w a llo w in g la rg e r q u a n titie s .c o n s u lta d o cto r.
depressurized and the system must be emptied if necessary. If hydraulicfluid gets into the eyes, rinse out the eyes
- Do not pour hydraulic fluid into drinking containers. immediately with plenty of clean water/using a eye rinsing
- Ensure adequate ventilation, particularly in the case of central glass.
h y d ra u lic flu id . In th e e v e n t o f injuries to skin o r eyes fro m a je t o f hyd rau lic
fluid, consult a doctor Immediately.
AR01.10-W-2400-01B Removing and installing engine with

removal fixture
WH58.30-Z-1001-07A Engine hoist (self-locking) Bcker 3188

Herderstrae
D-42853 Remscheid
R e p a ir products
Number Designation Ordernumber
BR00.45-Z-1001-06A MB longlife grease 000 989 63 51
22
1 Attach engine hoist (1) to the lifting
eye (2) of the coolant pump at the
front or to the connector and at the
rear left to the lifting eye (3).
2 Attach chain block (4) at the rear right

to the lifting eye (3) and tension
ch ains a t th e e n g in e h o ist (1) a n d a t
the chain block. Secure engine to
prevent it toppling.
3 Push engine sufficiently far away from

the transmission until the transmission
shaft is pulled out of the clutch plate.
4 Lift out engine.

Max. 30 inclination of engine when
lifting out or inserting.
W01.10-0011-06
5 Before installing the engine, lightly grease the transmission

shaft.
6 Lift engine into the frame and align to the transmission.
7 Push engine and transmission together.
m
If it is not possible to push the engine and the transmission
together, rotate starter ring gear sufficiently so that the
internal splines of the clutch plate are aligned with the
splines of the transmission shaft.
AR01.10-W-2400F Removing, installing engine 12.6.98
ENGINE 906.920 /921 /922 /923
W 01.10-1002-09
7 Bracket in frame 7 Connector (w iring harness)
2 Engine mount 8 Connector (engine wiring harness)
3 W iring harness 9 Fuel line
4 Exhaust pipe 70 Hydraulic fluid line (steering system)
5 Compressed air line (compressor) 11 AC compressor (air conditioning)
6 Clutch servo unit 12 O il filler line
W01.10-1003-01 W01.10-1004-01 W26.19-1001-01
13 Engine ventilation hose 16 Starter cable 18 Connector (transmission wiring

14 A ir intake hose with air intake line 17 Transmission o il line harness)
15 Compressed air line (engine brake)
m i HU Removing, installing
@ Installation Replace all self-locking nuts and bolts
1 Separate engine wiring harness at the cab - Page 12

chassis connector
2 Remove radiator AR20.20-W-3865F
3 Remove noise encapsulation at top, rear,

on left and right
24
4 Detach hydraulic pump or propshaft With engine output at rear
5 Remove trim panel over transmission
6 Detach hydraulic lines from engine, With HPS transmission Page 28

transmission and also hydraulic gear and E Do not separate hydraulic lines; place
gate shift cylinder at transmission gear and gate shift cylinders to the side
with hydraulic lines connected
0 Gear hydraulic cylinder to shift shaft BA26.60-N-1009-01D
@ Bearing bracket to transmission BA26.60-N-1010-01D

housing
Gate hydraulic cylinder to transmission BA26.60-N-1011-01D

housing
Gate hydraulic cylinder to shift shaft BA26.60-N-1012-01D
@ Gear hydraulic cylinder to transmission BA26.60-N-1024-01D

housing
7 Remove air intake hose (14) between air

intake line and turbocharger
8 Detach engine ventilation hose (13) at

engine ventilation line
9 Remove exhaust pipe (4) at engine brake CD Installation: clean sealing surfaces and
flap connection and at rear lifting eye inspect clip for wear; replace clip if
necessary
10 Detach wiring harness (3) at bracket (1) in ED Installation: attach wiring harness with
right frame longitudinal member cable straps
11 Detach compressed air line (15) of engine

brake
12 Separate connector (18) at transmission

and detach bracket
13 Separate starter cables (16) at starter
14 Slacken poly V-belt and take off On vehicle with air conditioning AR13.25-W-3200B
15 Detach AC compressor (11) with bracket at On vehicle with air conditioning

engine ED Do not separate refrigerant lines
H AC compressor support to crankcase BA01.40-N-1005-01C
Danger Risk of explosion from ignition. Risk of No fire, naked flame or smoking.
poisoning from inhaling and swallowing Pour fuels only into suitable and Page 21
fuel.
16 Open cap at fuel tank
17 Separate fuel lines (9) at fuel filter ED Collect fuel which flows out. Mark fuel
lines an d tie up.
18 Remove oil filler line (12) ID Seal opening at oil filler hose
A Danger Risk of injury to skin or eyes as a result of Render system pressureless before Page 22
h y d ra u lic flu id sp ra y in g o u t u n d e r h ig h co m m e n cin g w o r k on h y d ra u lic system .
19 Separate both hoses at the hydraulic fluid Collect hydraulic fluid which flows out
lines (10) of the steering system f f i Installation: top up hydraulic fluid
20 Release and separate connector (7) of Tie up connector at frame so that it is not
wiring harness at MR (PLD) control unit damaged when lifting out the engine
D installation: secure connector

21 Release and separate connector (8) of Do not damage connector when lifting out
engine wiring harness at MR (PLD) control engine
unit [ U Installation: secure connector
22 Detach compressed air line (5) at IT] Counterhold connection at compressor

compressor and at fixtures at transmission If coking present, it is then necessary to
and inspect for coking additionally inspect the compressed air line
between compressor and compressed air
drier with integrated pressure regulator as
well as the four-circuit protection valve
23 Detach transmission oil line (17) at engine [ I ] Collect transmission oil which flows out
24 Remove clutch servo unit (6) at With transmission 715.5

transmission and tie up at frame Do not separate hydraulic line. Separate
electric ca b le a n d com pressed a ir line.
Grease plunger head with Olista Longtime BR00.45-Z-1031-06A

3E P
25 U n s c re w bo lts a t b o th e n g in e m o u n ts (2)
26 Attach engine to removal device Page 29

E l Engine hoist WH58.30-Z-1001-07A
27 Attach transmission or support
28 Unscrew bolts at transmission housing 0 With transmission 715.060/320,715.5 BA26.10-N-1001-01C
29 Remove engine with removal device Page 29

I S Engine hoist WH58.30-Z-1001-07A
Olista Longtime 3 E P B R00.45-Z-1031-06A
30 Inspect engine mounts (2) for wear I S If wear present |
replace engine mounts
32 Relearn transponder keys S If a replacement engine or a new MR AR80.57-W-0010A

(PLD) control unit is installed
33 Inspect engine oil level at electric gage See operating instructions part 3
34 Inspect coolant level and adjust to correct AP20.00-W-2010A

level
A Danger Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 31
starting off when engine running. Risk of Wear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
35 Start engine Do not rev up engine so long as no oil BE18.00-N-1001-01C

pressure is indicated
S The oil pressure gage should indicate

oil pressure after about 10 seconds
36 Bleed steering AR46.25-W-3300C
37 Set time at tachograph
38 Switch off engine
39 Inspect engine, cooling system and steering

hydraulics for leaks
40 Enter engine number in FDOK "Screen 0 Only if replacement engine is fitted

1111"
26

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idle speed bar 2 0 .5
maximum speed bar 2:2.5
0 Crankcase, timing case cover, end cover

906/907/909/910
/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
B A01.40-N-1005-01C Bolt of AC compressor support to Nm 55

crankcase

715.060 715.320 715.500/
510/520/
540
B A26.10-N-1001-01C Transmission to flywheel housing Nm 45 45 50
0 Shift mechanism
Number Designation Transmission Transmission Transmission

715.060 with 715.320 with 715.500/510/520/
code GS3 code GS3 540 with code
GS3
BA26.60-N-1009-01D Gear hydraulic cylinder to shift shaft Nm 57 70 50
B A 2 G .6 0 -N -1 0 1 0 -0 1 D B e a rin g b ra ck e t to transm ission housing Nm - - 80
BA26.60-N-1011-010 Gate hydraulic cylinder to transmission Nm 25 25 50

housing
B A 2 6 .6 0 -N -1 0 1 2 -0 1 D G a te h yd ra u lic cy lin d e r to shift s h a ft Nm - - 50
BA26.60-N-1024-01D Gear hydraulic cylinder to transmission Nm 140 80 -

housing
Commercially available tools (see Workship Equipment Manual)

Herderstrae
D-42853 Remscheid
Repair products
B R00.45-Z-1031-06A Olista Longtime 3 E P 001 989 36 51 10
Eng ines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4

AR26.60-W-7000-01A Detaching and attaching shift cylinder with Transmissions 715.060/320/ 5
hydraulic line
0 Gear shift
Number Designation Transmission Transmission Transmissions

715.060 with 715.320 with 715.500/510/520/
code GS3 code GS3 540 with code
GS3
BA26.60-N-1009-01D Gear hydraulic cylinder to shift shaft Nm 57 70 50
BA26.60-N-1010-01D Bearing bracket to transmission housing Nm - - 80
BA26.60-N-1011-01D Gate hydraulic cylinder to transmission Nm 25 25 50

housing
B A26.60-N-1012-01D Gate hydraulic cylinder to shift shaft Nm - - 50
BA26.60-N-1024-01D Gear hydraulic cylinder to transmission Nm 140 80 -

housing
0 Gear shift
Number Designation Transmission

715.320
B A26.60-N-1005-01F Compressed-air line to control valve/gear M10 Nm 20

shift cylinder
M12 Nm 30
1 Detach both fixing clamps (2) from hydraulic lines (1)
2 Unscrew bolts (3) to detach mounting plate (4) for hydraulic

lines (1) from engine.
W26.60-1005-11
28
W26.60-1006-08
Hydraulic lines on transmission

Transmission 715.060 Transmission 715.320 Transmission 715.5
3 Detach line fixing (7) with hydraulic lines (1)from 5 D e ta ch g e a r h y d ra u lic s h ift c y lin d e r (5) fro m transm ission
transmission. with hydraulic lines (1) connected.
0 Do not open fixing clamp. 0 On transmission 715.320, also detach compressed-air line
and electrical connector from shift cylinder.
4 Detach gate hydraulic shift cylinder (6) from transmission On transmission 715.510, detach shift cylinder with bearing
with hydraulic lines (1) connected. bracket.
0 On transmission 715.320, press the shift cylinder
forwards and lift out backwards. 6 Install in reverse order.
Replace self-locking nuts.
AR01.10-W-2400-01F Removing and installing engine with

removal fixture
Number Designation Make (e.g.) Ordernumber
WH 58.30-2-1001-07A Engine hoist (self-locking) Bcker 3188

Flerderstrae
D-42853 Remscheid
Repair products
B R00.45-Z-1031-06A Olista Longtime 3 E P 001 989 36 51 10
Engines OM904 LA, 906 LA (mod. des. 904.9. 906 9). F4 29
1 Attach engine hoist (2) at the front at
the connection piece (1) and at the
rear left at the lifting eye (4).
2 Attach chain tackle (3) at the rear right

at lifting eye (4) and tension chains at
engine hoist (2) and chain tackle.
Secure engine to prevent it tipping.
3 Push engine sufficiently far away from

transmission until the transmission
sh a ft is pu lled o u t o f th e clu tch p la te .
4 Lift out engine.

Max. incline position of engine when
lifting out or inserting is 30.
IXI Steps 5, 6and7 only for transmission 715.5.

5 Before installing the engine, apply a thin film of Olista Longtime 3 E P grease to the
transmission shaft and a sliding sleeve in the release bearing (5).
6 Turn release bearing (5) until the tensioning pin (5.1) is in horizontal position.
7 Position release lever in correct installation position to release bearing.
8 Lift engine into the frame and align to transmission.
m
Do not damage cables, connectors and attached parts.
9 Push engine and transmission together.
m
If it is not possible to push the engine and the transmission together, rotate starter ring
gear sufficiently so that the internal splines of the clutch plate are aligned with the
splines of the transmission shaft.
W01.10-1005-03
30
AS00.00-Z-0005-01 A Risk of accident as a result of vehicle Secure vehicle to prevent it from Danger!
starting off when engine is running. Risk of moving off.
injury as a result of bruises and burns if you wear closed and close-fitting work
insert your hands into engine when it is clothes.
being started or when it is running. Do not grasp hot or rotating parts.
Possible dangers Rules of conduct / Protective measures

- As a general rule, carry out work on the running engine only if
Risk of accident this is absolutely essential.
from vehicle starting off during starting operation (e.g. when - Before starting the engine, apply parking brake.
testing compression pressure) as a result of gear engaged or when - On models with manual transmission, move gearshift lever
engine running and vehicles with automatic transmission as a into Neutral position.
result of selector lever position "P " or N not engaged - On models with automatic transmission, move selector lever
(exception: some vehicles do not have a selector lever position into position P or N" (exception: some vehicles do not have
p.,)
a selector lever position P").
- On models which do not have selector lever position "P ,
Risk of injury secure selector lever to prevent it from being operated
S e v e r e Injuries m a y b e caused h y fre e ly r o ta tin g p arts in th e a rea u n in te n tio n a lly .
of the running engine. The heat produced by the engine when it - Wear closed and close-fitting work clothes.
is operating can result in severe burns if contact Is made with - Take off any jewelry, such as chains, rings etc.
individual, unshielded parts. - If you have long hair, wear a suitable head cover.
B e fo re co m m e n cin g w o r k o n th e ru n n in g e n g in e , ch eck to
obtain a general picture of the positioning of parts which may
be hot.
- When carrying out work when starting the engine or when
e n g in e is ru n n in g , d o n o t to u ch a n y h o t a n d ro ta tin g parts.
First aid measures in the event of burns

Do not rub the skin areas affected; flush with plenty of cold
water and cover skin with sterile bandages.
Immediately consult a physician.
AR01.10-W-24Q1A Removing, installing engine w ith transmission 15.9.97
ENGINE 904.905/906/907/921
2 Compressed air line (compressor) 12 Shiftlinkage

3 Connector (transmission) 13 Bolt
4 Connector (transmission) 14 Engine m ounting
5 Propeller shaft 15 Frame crossmember
6 Clutch slave cylinder 16 Dipstick guide tube
7 Connector (speedodrive) 17 Engine w iring harness (solenoid valve)
8 Connector (PLD control unit) 18 Engine w iring harness (flam e glow plug)
9 Fuel line (fuel priming pump)
10 Fuel line (fuel filter) A6 PLD control unit
11 Compressed a ir line (constant throttle)
W01.10-0016-09
13 Bolt 27 A ir intake hose (compressor)
14 Engine mounting 28 Wiring harness (generator)
20 Exhaust pipe 29 Ground cable
21 Clam p 30 Compressed air line (engine brake cylinder)
22 Rear lifting eyes 31 Starter cable
23 I S Engine hoist 32 Electric control cable (starter)
23.1 I S Shackle
24 I S Chain block M1 Starter
25 Front lifting eye (coolant pump) G1 Generator
26 A ir intake hose (turbocharger)
5 P ro p e lle r shaft
7 Connector (speedodrive)
33 Bolt
34 Nut
35 R ear transm ission m o u n tin g
Modification notes
nans Removing, installing
A Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 13

ZEs Danger Risk of injury from bruises and jamming No person should be in the tilting area of Page 15
with a safety prop.
2 Tilt cab
Notes on tilting cab Model 673- 679 Page 16

3 Tilt cab into repair position AR60.80-W-0010A
4 Remove rear cab mounting
5 R em ove noise en ca p su la tio n EH! At side and bottom
6 Remove radiator and intercooler AR20.20-W-3865A
7 Tie up dipstick guide tube (16) at engine
8 Detach exhaust pipe (20) at engine brake ED installation: clean sealing surfaces
flap connection
9 Detach compressed air line (30) at engine EE On engines with engine brake
brake cylinder
10 Detach air intake hoses (26, 27) for

turbocharger and compressor at air filter
11 Se p a ra te electric cables (17, 18) a t fla m e E l O n e n g in es w ith fla m e s ta rtin g system
glow plug and at solenoid valve

12 Separate starter cable (31) and control
cable (32) at starter (M1)
13 Separate electric wiring harness (28) at 12 Pay attention to color coding

generator (G1)
14 Separate ground cable (29) at timing case
15 Detach shift linkage (12) at transmission

shift mechanis
16 Remove clutch slave cylinder (6) 2 Installation: grease thrust bolt
17 Unbolt compressed air line (2) at S If coking present, it is then necessary to

compressor and inspect for coking additionally inspect the compressed air line
between compressor and compressor and
co m pressed a ir d rie r w ith in te g ra te d
pressure regulator and the four-circuit
protection valve.
2 Installation: inspect compressed air line

for leaks
^ Danger Risk of explosion from ignition. Risk of No fire, naked flame or smoking, Page 21
poisoning from inhaling and swallowing pour tuels only into suitable and
coming into contact with skin and eyes. W ear protective clothing when handling
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 2 On engines with constant throttle

throttle
20 Release and separate connector (8) at PLD

control unit (A6)
Danger Risk of injury to skin or eyes as a result of Render system pressureless before Page 22
21 Separate both hoses at the steering lines 2 Collect hydraulic fluid which flows out
2 Installation: top up hydraulic fluid and WH4611

bleed steering
22 Remove frame crossmember (15) 2 Below radiator and engine
23 Attach engine hoist (23) at front at the 12 Engine hoist WH58.30-Z-1001-07A

liftin g eye (25) o f th e c o o la n t p u m p a n d
guide up
24 Attache engine hoist (23) at rear left at Insert shackles (23.1) as intermediate
lifting eye (22) pieces so that the engine hoist does not run
over the cylinder head cover
13 Shackle WH58.30-Z-1002-07A
25 Attach chain block (24) at rear right at @ Insert shackles (23.1) as intermediate
lifting eye (22) and tension chains at pieces so that the engine hoist does not run
engine hoist and chain block over the charge air manifold.
Secure engine to prevent it tipping.
2 Shackle WH58.30-Z-1002-07A
26 Separate connectors (3,4,7) at 2 Installation: replace anti-tamper seal

transmission (arrow) at connector (7)
27 Detach propshaft (5) at transmission and BA41.10-N-1001-01F

attach to frame
34
28 Unscrew bolt (33) at rear transmission ELI Installation: replace nut (34)
mounting (35)
29 Unscrew bolts (13) on both sides at engine E Inspect engine mounts for wear,
mounts (14) replace if necessary
30 Lift out engine with transmission H J Max. tilt of engine with transmission
w h e n liftin g o u t o r insertin g 30
31 Detach transmission from engine 0 With transmission 710.620 BA26.10-N-1003-01B
0 With transmission 715.050 BA26.10-N-1006-01C
33 Check engine oil level with dipstick WH0101.40
34 Start enqine and observe oil pressure qaqe @ Start engine with the starter for not BE18.00-N-1001-01C
when engine idling more than 90 seconds. Wait about 2
minutes before repeating attempt at
starting. Do not rev up engine so long as no
oil pressure is indicated.
GO The oil pressure gage should indicate
oil pressure after about 10 seconds
36 Enter engine number in FDOK "Screen E Only if replacement engine is fitted

1111"
T est d a ta o f e n g in e oil pressure

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE1S.CO-N-10OI-O1C E n g in e oil pressure a t id le s peed bar ==0.5
Number Designation Trans

mission
710.820
B A26.10-N-1003-01B Transmission to engine Nm 51
Number Designation Trans

mission
715.050
BA26.10-N-1006-01C Transmission to engine Nm 51
0 Propeller shaft
Number Designation Model 673,674,

675,676,677,
679
BA41.10-N-1001-01F Propeller shaft to transmission M10X1.5 Nm 59
M 12X1.5 Nm 92
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4

WH58.30-Z-1001-07A E n g in e h o ist (self-locking ) Bck er 3188

Herderstrae
D-42853 Remscheid
WH58.30-Z-1002-07A Shackle C1 DIN 82101
36
AR01.10-W-2401B Removing, installing engine w ith transmission 15.9.97
ENGINE 904.909/910/911 /922, 906.910/911
1 Cap (on engines 904.909- 911/922) 12 Clutch line

2 Compressed-air line coupling (on engines 904.909- 911/922) 13 Electric wiring harness, cable and bracket
3 Compressed-air line plug (on engines 904.909- 911/922) 14 Attachment plug (control module)
A 13 Engine hoist 15 Engine suspension
5 3 Chain pulley block 16 Steering line (return)
6 Compressed-air line (compressor) 17 Steering line (pressure)
/ nropenor shaft 78 fuel line (supply)
8 Transmission suspension 19 Fuel line (return)
9 Attachm ent plug (speedometer drive) 20 O ilfiller pipe
10 Seal 21 A/C compressor
11 Attachment plug (transmission)

22 Exhaust pipe 28 Starter cable
23 Clamp 29 Ground cable
24 A ir intake hose
25 Electric cable (generator) G1 Generator
26 Compressed-air line (engine brake cylinder) M1 Starter
27 Electric wiring harness
Modification notes
HDIS! Removing, installing
Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 13
poisoning and burns from swallowing W ear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes ey e p ro te c tio n . P o u r b a tte r y e le c tro ly te

/ts Danger Risk of Injury from bruises and jamming No person should be in the tilting area of Page 15
with a safety prop.
Notes on tilting cab Model 970-976 Page 16

3 Remove noise encapsulation CEI At side, bottom rear and over
transmission
4 Remove charge air pipe from intercooler to AR09.41-W-1311D

charge air manifold
5 Remove charge air pipe from turbocharger AR09.41-W-1311C

to intercooler
38
6 Remove fan shroud AR20.40-W-68Q0A
7 Detach oil filler line (20) at oil pan and tie

up at frame
8 Detach exhaust pipe (22) at engine brake Tie up exhaust pipe at frame
flap connection and transmission E Installation: clean sealing surfaces
9 Detach compressed air line (26) at engine E On engine with service brake
brake cylinder
10 Detach air intake hose (24) at air filter

housing
11 Detach cable at flame glow plug and at E On engines with flame starting system
solenoid valve
12 Detach electric cable (28) at starter (M1)

and wiring harness (27) at fixture
13 Detach electric cable (25) at generator (G1) E Pay attention to color coding
and fixture
14 Detach ground cable (29) and wiring B At side and bottom

harness at timing case
13 U n b o lt com pressed a ir lin e (G) a t H If coking p resen t, it is th e n necessary to

compressor and inspect for coking additionally Inspect the compressed air line
drier with integrated pressure regulator
a n d th e fo ur-clrcu lt p ro te c tio n valve.
E Installation: inspect compressed air line

for leaks
Danger Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 21
fuel.
16 Separate fuel lines (18,19) at fuel filter E Mark fuel lines and collect fuel which
flo w s o u t
17.1 Slacken poly V-belt and take off B On vehicle with air conditioning AR13.25-W-3200B
17.2 Detach AC compressor (21) at engine E On vehicle with air conditioning.

Do not separate refrigerant lines.
18 Separate compressed air lines (2, 3) of E On engine 904.909-911/922 with

constant throttle constant throttle, pull off cap (1). Use pliers
to press clamp apart and pull connector out
of socket.
19 Release and separate connector of wiring

harness (14) at PLD control unit
Danger Risk of injury to skin or eyes as a result of Render system pressureless before Page 22
pressure. Risk of poisoning from Wear protective clothes and eye
20 Separate both hoses at the steering lines Collect brake fluid which flows out AP46.00-W-4611A
(16,17) E Installation: top up brake fluid and
bleed steering
21 Remove lock and pull out clutch line (12) at Collect brake fluid which flows out
transmission E Installation: replace seal at clutch line
Bleed clutch mechanism AR25.20-W-0070C
Notes on brake fluid All models Page 41

22 Separate connectors (9,11) at transmission ED Installation: replace anti-tamper seal
(10) at connector (9)
23 Detach propshaft (7) at transmission and H BA41.10-N-1001-01F

tie up at frame
24 Detach transmission bracket at S Inspect transmission mounting for

transmission mounting (8) wear, replace if necessary
25 Detach bracket at engine mounts (15) HHI Inspect engine mounts for wear,
replace if necessary
26 Remove engine with removal device, install page 41

IS Engine hoist WH58.30-Z-1001-07A
27 Detach transmission from engine 0 On transmission BA26.10-N-1006-01B

710.621/622/623/626/627
0 On transmission 715.050/060/320 BA26.10-N-1001-01C
28 Install in the reverse order [HIIf a replacement engine or a new PLD

control unit is fitted, the transponder keys
have to be relearned J
Learning transponder keys AR80.57-W-0010A
29 Inspect engine oil level at electric gage See operating instructions part 3
30 Start engine and observe oil pressure gage Start engine with starter for not more BE18.00-N-1001-01C
with engine idling than 90 seconds. W ait about 2 minutes
before repeating attempt at starting. Do
not reve up engine so long as no oil
pressure is indicated.
LLl The oil pressure gage should indicate
oil pressure after about 10 seconds.
32 Enter engine number in FDOK "Screen Q] Only if replacement engine fitted

1111"
Test values for engine oil pressure

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idle speed bar >0.5
max. engine speed bar >2.5
0 Complete mechanical transmission
Number Designation Transmissions

710.621/622/
623/626/627
BA26.10-N-1006-01B Transmission to flywheel housing Nm 45
40
S Complete mechanical transmission

715.050 715.060 715.320
B A26.10-N-1001-01C Transmission to flywheel housing Nm 45 45 45
0 Propellor shaft
Number Designation Models 970,972,

974,975,976
BA41.10-N-1001-01F Propellor shaft to transmission M10X1.5 Nm 59
M12X1.5 Nm 92
Commercially available tools (refer to Workshop equipment manual)
Number Designation Company (e.g.) Ordernumber
WH58.30-Z-1001-07A Engine hoist (self-locking) Backer 3188

Herderstrae
D-42853 Remscheid
AH42.50-P-0001-01 A Notes on brake fluid All models @
Do not allow the brake fluid to come into contact with the Brake fluid is colorless to yellow in color and therefore may
paintwork of the vehicle as it contains elements which act as be easily confused with mineral oil products. For this reason,
a solvent on the paint. Should brake fluid come into contact always pour brake fluids out of the original cans and store it
w ith t h e p a in tw o rk d esp ite all p re ca u tio n s h aving b e en sep ara te ly fro m m in e ra l oils a n d o th e r fluids.
taken, the moistened area should be rinsed immediately
with plenty of water (do not attempt to rub off brake fluid). Disposal instructions for workshops located in Federal
Republic of Germany see:
B ra k e flu id is g re a tly h ygroscopic, in o th e r w o rd s it absorbs " U m w eltschutz H andbuch f r K fz -R c p a ra tu rb c tric b c "
moisture from the air, as a result of which the boiling point is Publisher: Verband der Automobilindustrie e.V. (VDA)
lowered. For this reason, brake fluid must only be stored in D-60625 Frankfurt am Main, Westendstrae 61
closed and properly sealed containers (original cans).
Used brake fluid must not be re-used.
AR01.10-W-2400-01A Removing and installing engine with

removal fixture

H erd e rstra e
D-42853 Remscheid
1 Attach engine hoist (1) to the lifting
eye (2) of the coolant pump at the
front or to the connection piece and
to t h e liftin g e ye (3) a t th e
transmission.
2 Attach chain block (4) at the rear right

to the exhaust manifold and tension
chains at the engine hoist (1) and at
the chain block. Secure engine to
prevent it toppling.
3 Lift out engine with transmission.
Max. 30 inclination of engine with

transmission when lifting out or
lowering in.
4 When installing, align engine with

transmission to the engine and
transmission mounts.
W01.10-0010-06
42
A R 01.00-W -0001A inspecting engine for dust dam age 30.11.95
ENGINE 904/, 906, 541, 542
Removing
m If the oil consumption is high or if the

engine fails, it is often not clear whether
dust damage or normal wear and tear
exists
1 Remove pistons Engine 904,906 AR03.10-W-7021A
Engine 541, 542 AR03.10-W-7021B
a Inspecting
2 Inspect intake tract between air cleaner CO Severe dust deposits In the elbows of
and engine for dust deposits the intake pipes and hoses are a reliable
indication of dust damage.
A very fine film is permissible on engines
with oil bath air cleaner.
3 Inspect pistons and cylinder wall for wear GO The wear patterns of the stems of the
(dust d a m a g e ) pistons a n d th e h o ning p a tte rn s o f th e
cylinders make it possible to recognize
damage caused by severe dust deposits.
If wear exists j
Install new cylinder liner

Engine 904,906 Page 84
Replace cylinder liner AR01.40-W-9324A
En g in e 541, 542
Replace piston, engine 904,906 AR03.10-W-7021A
Replace piston, engine 541, 542 AR03.10-W-7021B
ffl Notes for assessing wear of cylinder walls in Engine 541,542,904,906

the case of dust damage Page 43
m Notes for assessing wear of pistons in the Engine 541, 542, 904,906
case of dust damage Page 44
AH01.40-N-0001 -01A Notes for assessing wear of cylinder wall if Engines 904, 906, 541,542 m
dust damage present
Cylinder walls and cylinder liners without dust damage

The honing Is more or less clearly visible on the entire contact surface. The honing may be
partially worn at the reversal point of the first piston ring.
Cylinder walls and cylinder liners with dust damage
The traces of machining from honing are only very faintly visible or not at all. If the wear is
well advanced, a wear step can be felt at the reversal point of the first piston ring.
m
Dust damage is caused by poor sealing, splits, chafing damage of the intake lines, seals and
hoses.
When carrying out repair and service work, make a careful inspection of intake lines, seals
and hoses, also at points not easily accessible.
A H 0 3 .10-N-0001-01A N o tes fo r assessing w e a r to pistons in th e E n g in e 541, 542, 904, 906 m

case of dust damage
Pistons without dust damage

The contact surface of the piston stem is visible over a large area and the machining grooves
can still be recognized within this area.
ffl
The machining grooves at the circumference are intentional recesses which are filled with oil
and contribute to better lubrication.
W 0 3 .10-0012-01
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. In the advanced stage of wear, slight
traces of seizure are already present on the stem and the piston rings are sharp-edged.
44
AR01.00-W-0200A Inspecting cylinders w ith light probe 3.7.97
ENGINE 904.905/906/907/909/910/911/921/922, 906.910/911/920/921 /922/923/940/941

1 I S Inspection probe
2 I S Cylinder inspection equipment
W 0 1.00-0018-06
In sp e ctin g
1 Attach cranking device to timing case Page 46

If] 904 589 04 63 00
@ Bolt of end cover to timing case BA01.60-N-1002-01A
2 Remove nozzle holder combination Engine 904.905-907/921 AR07.03-W-6831A
F n g in e 904.909- 911/922 and AR07.03-W-6831C

906.910/911/920- 923/940/941
3 Rotate crankshaft with the cranking device Position piston of cylinders to be inspected
toBDC
4 Connect cylinder inspection equipment (2) E9 Cylinder inspection equipment WH58.30-Z-1028-05A

and insert inspection probe (1) through the Q ] Connection of cylinder inspection
protective sleeve hole into the cylinder equipment, see operating instructions of
e q u ip m e n t m a n u fa c tu re r
5 Inspect cylinder wall and piston crown ( 3 Cylinder walls must not reveal any Page 43
scorch streaks and rubbing streaks.
Individual slight drawing scores are not
critical.
Inspect condition of piston crown, if

necessary J,
remove cylinder head Page 58

6 Inspect remaining cylinders in the same
way
Engines O M904 LA, 906 LA (mod des. 904.9,906.9), F4 45
S Timing case

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.60-N-1002-01A Cover of inspection hole to timing Nm 25

case
WH58.30-2-1028-05A Cylinder inspection equipment Karl Storz GmbH

M o to sk o p T W (d ich ru ic) w ith lens pro bes 103 26 C W (570 m m ) and D-78532 T u ttlin g e n
103 26 CT (210 mm)
AR03.30-W-1600-03A Attaching, detaching cranking/blocking

device for engine
@ Timing case
Number Dsignation Engine 904.905/ Engine

906/907/909/ 904.904/908/923
910/911/921/322,
906.910/911/919/
920/921/922/923
/940/941
BA01.60-N-1002-01A End cover of inspection hole to to Nm 25 25

timing case
46
1 Remove noise encapsulation below the flywheel housing.
2 Remove cover (1) at flywheel housing (except engine 906.920-923/940/941).
3 Attach E l cranking and blocking device (2) tight to flywheel housing with bolts (4).
HI Cranking and blocking device (2)can be blocked by inserting the pin (3).
@ Cranking and blocking device (2) must be removed before starting the engine.
W 03.30-0001-02
AR01.00-W-1200A Testing compression pressure 3.7.97
ENGINE 904.905/906/907/909/910/91119211922,906.910/911/920/921 /922 /923 /940 /941
W 01.00-0019-09
1 Nozzle holder combination 7.1 S I Compression recorder
2 Bolt 7.2 S I Diagram sheet
3 Spherical washer 7.3 S I Adapter
4 Tensioning arm 8 Seal
5 S I Connector
6 End cover fo r c o n sta nt th ro ttle S10 S ta rt sw itch
S JI Stop switch
Revisions
7.7.98 Tightening torque for bolt of tensioning arm at cylinder Step 5 Page 48
head modified
Compression pressure modified and permissible Step 10

d iffe re n c e b e tw e e n in d iv id u a l cylin ders a d d ed
121 R em oval
A Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 15
with a safety prop.
1 Tilt cab
Notes on tilting cab Page 16

2 Adjust valve clearance [L I Carry out setting only when engine
cold or thoroughly warmed through. Wait
at least 30 minutes after switching off
engine.
Engine 904.905-907/921 Wartung LKW Band 1,

0560.30
Engine 904.909-9117922 and AP05.30-W-0560B

906.910/911 /920- 923/940/941
48
3 Warm engine up to operating temperature (XI Coolant temperature approx. 70 to
95 C
4 Remove nozzle holder combinations (1) Engine 904.905-907/921 AR07.03-W-6831A
Engine 904.909- 911/922 and AR07.03-W-6831C

906.910/911/920- 923/940/941
5 Install connector (5) DD Smooth surface on seal (8) should be

pointing toward the connector. Turn
tensioning arm (4) and spherical washer (3)
a t th e c y lin d e r h ead u n til th e in te rfe re n c e
fit ball (arrow) in the tensioning arm (4) Is
aligned with the locating element In the
end cover (6) of the constant throttle.
E n g in e 904.909- 9 07/92V. te n s io n in g arm
with part number 906 017 07 39 should be
used.
0 Bolt of tensioning arm to cylinder head BA07.15-N-1003-01A
m 904 589 01 21 00
6 Attach compression recorder (7.1) to the I S See operating instructions for 001 589 78 2100
c o n n e cto r (5) connection of compression recorder
m 904 589 01 21 00
7 Insert diagram sheet (7.2) into the m 001 589 78 21 00

com pression reco rd e r (7.1)
Testing
Danger! Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 31
8 Crank engine with the starter by CD At least 8 engine revolutions

simultaneously pressing start switch (S10)
and stop switch (S11)
9 Test rem ain in g cy lin ders in th e sam e w a y
10 Compare measurements on diagram sheet Compression pressure at starter speed BE01.00-N-1001-01E

(7.2) with the specified values
Permissible difference between individual BE01.00-N-1002-01E

cylinders
If the pressure measured is below the

minimum compression pressure, determine
and rectify cause j.
Detach cylinder head Page 58
SI Installation
11 Detach compression recorder (7.1) and

connector (5) together with seal (8)
12 Install nozzle holder combinations (1) Engines 904.905-907/921 AR07.03-W-6831A
Engines 904.909- 911/922 and AR07.03-W-6831C

906.910/911/920- 923/940/941
Test data of compression pressure
Number Designation Engines 904.905/

906/907/908/909
/910/911/921/
922/923
906.910/911/920/
921/922/923/940
/941
BE01.00-N-1001-01E Compression pressure at starter speed bar > 2 8
DE01.00-N-1002 01E Permissible difference between individual bar a 4

cylinders
@ D iesel in je ctio n sy stem w ith in-line pum ps (P L D )

906/907/909/
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BA07.15-N-1003-01A Bolt for nozzle holder assembly clamp on Allen bolt Nm 30

cylinder head
Bolt with twelve 35
point head with
spherical collar
a r
904 589 01 21 00
Connector
50
AR01.20-W-5014A Removing, installing cylinder head cover 17.7.95
ENGINE 904.905/906/907/908/909/910/911/921/922/923, 906.910/911/920/921/922/923/940/941

1 Hexagon socket bolt
2 Sealing washer
3 Gasket
4 tngine ventilation nose
5 Cylinder head cover
6 Gasket
7 Engine trim panel
W 01.20-0001-06
Engine 906.920-923 w ith "hydraulic" transmission shift code GS3
30 Hydraulic lines
31 Securing clips
32 Mounting plate
33 Bolt
HU EU Removing, installing
Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 15
with a safety prop.
1.1 Tilt cab
Notes on tilting cab Model 673-679, 950-954, 957, 970-976 Page 16

1.2 Remove maintenance cover Model 668,670
2 Remove engine trim panel (7)
3 Detach hydraulic lines (30) with the On engine 906.920-923 with "hydraulic"
mounting plate (32) and the securing clips transmission shift code GS3
(31) at the engine and place to the side E Do not separate hydraulic lines
4 Detach engine ventilation hose (4) at

cylinder head cover (5)
5 Take off cylinder head cover (5) E Installation: replace sealing washers (2)
and gasket (6) of cylinder head cover.
Inspect gasket (3) between cylinder head
cover and boost air manifold, if necessary
1
replace gasket (3)
0 Bolt of cylinder head cover to cylinder BA01.20-N-1001 -01B

head
6 Clean sealing surfaces of cylinder head

cover (5) and cylinder head
@ Cylinder head cover
Number Designation Engine 904.905/ Engine

906/907/909/910 904.904/908/923
/911/921/922,
906 910/911/919/
920/921/922/923
/940/941
BA01.20-N-1001-01B Bolt, cylinder head coverto cylinder Nm 30 30

head
52
AR01.20-W-9750A Removing, installing oil separator 28.8.95
ENGINE 904.905/906/907/909/910/911 /921 /922. 906.910/911 /920/921Z922/923

ENGINE 904.908 /923 in MODEL 668,670
1 Hexagon socket screw
2 O il separator
2.1 Cover
2.2 Diaphragm
4 Gasket
W 0 1 .20-0005-06
1 Remove cylinder head cover (3) Page 51

2 Remove oil separator (2) at cylinder head QD Pull off cover (2.1) at oil separator and
(3) remove diaphragm (2.2), inspect and
replace if necessary.
L U In s ta lla tio n : in sert stud ( a n u w ) a t uil
separator into the guide of the cylinder
head cover.
3 Replace gasket (4) at oil separator (2) H I Clean sealing surfaces
4 Install In the reverse order
En g in es O M 9 0 4 LA, 906 L A (m o d . des. 904.9, 90G.9), F4 53
AR01.30-W-5461A Removing, installing protective sleeve 17.7.95
ENGINE 904.905/906/907/908/909 /910 /911 /921 /922, 906.910 /911 /920/921 /922 /923 /940/941
1 Nozzle holder combination
2 Protective sleeve
3 O-ring
4 E l Slotted nut wrench
Modification notes
7.7.98 Tightening torque and thread diameter for protectice Step 3 Page 54
sleeve at cylinder head added
3E] Removing, installing
Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 56
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
o ut. Risk o f p o iso n in g fro m s w a llo w in g ca p s lo w ly a n d a llo w th e pressure to
coolant release. Do not pour coolant into
containers for drinks.
W ear protective gloves, protective clothes,
a n d e y e p ro te c tio n .
1 Drain coolant and collect Engine 904.905- 907/921 WH2080
Engine 904.908 AP20.00-D-2080A
Engine 904.909- 911/922 and AP20.00-W-2080A

906.910/911/920- 923/940/941
Notes on coolant Page 56

2 Remove nozzle holder combination (1) Engine 904.905- 908/921 AR07.03-W-6831A
Engine 904.909- 911 /922 and AR07.03-W-6831C

906.910/911/920- 923/940/941
3 Use slotted nut wrench (4) to remove IE 904 589 0007 00

protective sleeve (2) from the cylinder head
[ S Installation: clean sealing surfaces of

protective sleeves (2) and of cylinder head
0 Protective sleeve to cylinder head BA01.30-N-1001-01C
4 Remove O-rlng (3) from the cylinder head Q ] Installation: replace O-ring (3) and coat B R00.45-Z-1018-06A
with acid-free grease
54
6 Inspect coolant level Engine 904.905-907/921 WH2080
Engine 904.908 AP20.00-D-2080A
Engine 904.909- 911/922 and AP20.00-W-2080A

906.910/911/920- 923/940/941
S Cylinder head

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BA01.30-N-1001-01C Protect ive sleeve to cylinder head M 12x1 Nm 40 40
M 14x1 Nm 45 45
S
V 904 589 00 07 00 J
Slotted nut wrench
Repair products
B K U U .4b-Z-101B -U bA ATE grease -
AS20.00-Z-0001-01A Risk of injury to skin and eyes from Do not open the cooling system unless A Danger!
scalding from hot coolant which splashes the coolant temperature is below 90
o ut..R isk o f p o iso n in g fro m sw a llo w in g C. O p e n cop s lo w ly a n d a llo w th e
coolant. pressure to release.
Do not pour coolant into containers
for drinks.
Wear protective gloves, protective
clothes, and eye protection.
Possible dangers Protective measures/rules of conduct

- Allow cooling system to cool down to a coolant temperature
Risk of injury of less than 90 C.
The cooling system is pressurized when the engine is warm. Risk - Open coolant system cap slowly; open a conventional type of
of scalding from hot coolant which splashes out if the cooling coolant system cap to the first detent and open a screw-type
system is opened suddenly. coolant system cap about 1/2 turn, and allow the pressure to
release.
Risk of poisoning - Wear protective gloves, protective clothes, and eye protection.
If coolant is swallowed, the person affected is likely to show signs - Do not pour coolant into containers for drinks.
of poisoning such as headaches, giddiness and stomach aches,
paralysis of the respiratory system, unconsciousness, nausea, and First aid measures
convulsions. Pour large quantities of cold water over the affected area of
skin and cover over with sterile bandages.
Have person affected drink plenty of water to which medicinal
carbon has been added.
Consult a doctor if the person affected has severe burns or has
swallowed considerable quantities.
AH20.00-N-2080-01 A Instructions re coolant
Coolant composition
Passenger car and commercial vehicle engine (normal case): A concentration of anticorrosion/antifreeze agent higher than
50 % by volume water and 55 % by volume should not be used as the maximum antifreeze
50 % by volume anticorrosion/antifreeze agent. protection is thus reached. An even higher concentration again
See M B Specifications for Service Products for differing coolant reduces the antifreeze protection and impairs heat dissipation.
composition for commercial vehicle engines.
Water
Purposes of anticorrosion/antifreeze agent Use water which is clean and not too hard. Drinking water
Corrosion and cavitation protection for all components in the frequently, but not always, satisfies the requirements. The
cooling system contents of dissolved substances in the water can be of
Antifreeze protection importance for the occurrence of corrosion. In cases of doubt,
Increasing boiling point so that the coolant does not evaporate analyze the water. See MB Specifications for Service Products for
so rapidly. Ejection of coolant is avoided at high coolant fresh water regulations.
temperatures.
Operation of monitoring of coolant
Antifreeze protection Inspect coolant for resistance to low temperatures before the start
50 % by volume of anticorrosion/antifreeze concentration offers of the cold season of the year.
antifreeze protection down to approx. -37 C. In countries with high ambient temperatures, inspect the
A higher concentration is only practical at even lower ambient anticorrosion/antifreeze concentration once a year.
temperatures. The corrosion protection in the coolant is reduced during
55 % by volume of anticorrosion/antifreeze concentration offers operation. Such coolants have a severely corrosive effect.
antifreeze protection down to approx. -45 C. The maximum permissible period of use of the coolant is for
passenger car and commercial vehicle engines (normal case)
3 years.
See MB Specifications for Service Products for the period of use
for differing coolant composition for commercial vehicle engines.
56
Disposing of coolants
Before pouring fresh coolant into the system, flush the used Observe legal regulations and local wastewater regulations.
coolant out of the cooling system. Clean cooling system if severe For workshops located in the Federal Republic of Germany see:
soiling or oil contamination exist. "Umweltschutz-Handbuch fr Kfz-Reparaturbetriebe "
(Environm ental protection m anual for vehicle repair
workshops)
Publisher: Verband der Automobilindustrie e.V. (VDA)
D-60625 Frankfurt am Main, Westendstrae 61
)*- 'U ' Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 57
AR01.30-W-5800A Removing and installing cylinder head 17.7.95
ENGINE 904.905/906/907/909/910/911 /921 /922,906.910/911/920/921 /922/923/940/941

1 Noise encapsulation
2 Boost air manifold
3 Injection pipe
4 R ocker arm assem bly
5 Valve bridge
6 Tappet rod
7 Gasket
8 C o n nector
9 Bolt
10 Connection fitting
2 coolant pipes
B8 Coolant temperature sensor
13 Exhaust manifold with turbocharger

14 Constantly open throttle valve lines
15 Coolant pipe for compressor
16 Leak fuel pipe
17 Cylinder head bolt
18 Cylinder head
19 Cylinder head gasket
20 Centering sleeves
W 0 1 .30-0017-06
58
W O l.30-0018-09
77 Cylinder head bolt shank length (L) 21 I S Lifting device

18 Cylinder head 22 I S Knife-edge straightedge
19 Cylinder head gasket 23 Shift lever with bracket
20 Centering sleeves
MM Removing, installing
Danger Risk of injury to skin and eyes from Do not open the cooling system unless the Page 56
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into
Wear protective gloves, protective clothes,
and eye protection.
1 Drain coolant and collect On engine 904.905-907/921 WH2080
On engine 904.909- 911/922 AP20.00-W-2080A

On engine 906.910/911/920- 923/940/941

2 Remove noise encapsulation (1) HI O n rig h t an d le ft
3 Detach shift lever with bracket (23) at On engine 904.909- 9111922 and
cylinder head (18) 906,910/911/920-923/940/941
4 R em o ve boost a ir m a n ifo ld (2) O n e n g in e 904.905- 907/921 AR09.41-W-8681A
On engine 904.909-911/922 and AR09.41-W-8681C

906.910/911/920-923/940/941
5 Detach exhaust manifold (13) and cylinder AR14.10-W-3915A

head (18)
6 Detach bracket of hydraulic lines at On engine 906.920-923 with "hydraulic"

cylinder head (18) shift code GS3
7 Remove injection lines (3) AR07.15-W-9235A
8 Detach constant throttle lines (14) at On engine 904.905- 909- 911/9211922

cylinder head (18) HI Installation: replace seals

On engine 906.910/911/920- 923/940/941
mCollect engine oil which flows out.
Installation: replace seals
9 Detach leak-fuel line (16) at cylinder head [ 2 installation: replace seals

(18)
10 Detach coolant line (15) to compressor at [UC o lle ct co o la n t w h ich flo w s o u t

cylinder head (18)
11 Separate engine wiring harness (11) at

both coolant temperature sensors (B8)
12 Remove connection piece (8) at cylinder EEInstallation: replace connection fitting Page 63
head (18) and at coolant pump (10) and gasket (7)
0 Bolt of connection fitting of coolant BA20.10-N-1003-01C

pump to cylinder head
13 Remove rocker arm assembly (4) On engine 904.905- 907/921 AR05.00-W-5521A
On engine 904.909- 911 /922 and AR05.00-W-5521C

906.910/911/920- 923/940/941
14 Remove tappet rods (6) n Installation: oil tappet rods with

engine oil and ensure correctly located in
tappets
15 Unscrew cylinder head bolts (17) HIInstallation: pay attention to Page 64

tightening instructions of cylinder head
bolts
0 Cylinder head bolts to crankcase BA01.30-N-1002-01C
IS 422 589 02 09 00
16 Attach lifting device (21) at cylinder head @ Do not damage installed nozzle holder
(18) and take off cylinder head combinations
HIInstallation: fit on cylinder head over
centering sleeves (20)
IS 904 589 01 63 00
17 Take off cylinder head gasket (19) Hi Seal oil and coolant holes at crankcase.
Clean and inspect crankcase contact
surface.
HIInstallation: fit new cylinder head

gasket over the centering sleeves (20) onto
th e p la n e fa c e o f th e crankcase. P a y
attention to installation position.
18 Clean threaded, oil and coolant holes in

crankcase
Inspecting
19 Measure length of shank of cylinder head If the maximum shank length (L) is BE01.30-N-1001-01B
bolts (17) exceeded (
replace cylinder head bolts
20 Inspect cylinder head (18) for cracks and HI If problem exist, replace cylinder head
damage
21 Inspect flatness of cylinder head (18) and Flatness of cylinder head contact surface BE01.30-N-1002-02B
crankcase contact surface with knife-edge
straightedge
Flatness of crankcase contact surface BE01.40-N-1013-02B
IBKnife-edge straightedge WH58.30-Z-1002-12A
HI If u n e v e n |
60 Additional Information
face contact surface of cylinder head Page 69
face contact surface of crankcase
22 Install in reverse order
23.1 Check engine oil level with dipstick On engine 904.905- 907/921 WH0101.40
23.2 Check engine oil level at electric gage On engine 904.909- 911/922 and
906.910/911 /920- 923/940/941
See ATEGO operating instructions part 3
24 Check coolant level On engine 904.905- 907/921 WH2080
On engine 904.909- 911/922 and AP20.00-W-2080A

906.910/911 /920- 923/940/941
* D anger Risk o f accident as a resu lt o f vehicle Secure vehicle to prevent it starting off. Page 31
bein g started o r w h e n it is run ning.
25 Start engine and observe oil pressure gage @ Crank engine with starter for not more BE18.00-N-1001-01C
when engine idling than 90 seconds. Wait about 2 minutes
before repeating attempt at starting.
Do not rev up engine so long as no oil
CD The oil pressure gage should indicate
Test data of cylinder head bolts

906/907/909/
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE01.30-N-1001-01B Cylinder head bolts Thread diameter M 16X2
Shank length when new mm 149.0
Max, shank length mm 151.0
Test data of cylinder head
Number Designation Engines 904.905/ Engines

906/907/909/910 906.910/911/920/
/911/921/922 921/922/923/940
/941
BE01.30-N-1002-02B Permissible difference in flatness over entire length mm 0.05 0.07

of bottom contact surface in
over a length of mm 0.02 0.02
longitudinal direction
150 mm
Test data of crankcase

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE01.40-N-1013-02B Flatness of contact surface of over entire length mm 0.030

crankcase
over a length of 150 mm mm 0.015
in longitudinal and
transverse direction

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idling speed bar a 0.5
@ Cylinder head

906/907/909/
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
B A01.30-N-1002-01C Cylinder head bolts to crankcase 1st stage Nm 20
2nd stage Nm 70
3rd stage Nm 170
4th stage Nm 280
5th stage 90
6 th stage X 90
@ Coolant pump, coolant thermostat
Number Designation Engines 904.905/ Engines 904.909/

906/907/921 910/911/922
906.910/911/920/
921/922/923/940
/941
BA20.10-N-1003-01C Bolt, coolant pump connecting piece to cylinder head Nm 25 25
62
422 589 02 09 00 J \ 904 5890163 00 J
Wrench socket lifting device
Number Designation Company (e.g.) Order number
WH58.30-Z-1002-12A Knife-edge straightedge Hahn and Kolb 37 550050

Borsigstr. 50
D-70469 Stuttgart
AR20.10-W-1290-02A Removing and installing connector coolant

@ Coolant pump, thermostat
Num ber D e sig n a tio n En g in es 904.905/ E n g in e E n g in es 904.909/

906/907/921 904.908/ 910/911/922
923 906.910/911/920/
921/922/923/940
/941
BA20.10-N-1003-01C Bolt for connector coolant pump to cylinder head Nm 25 25 25
1 Remove coolant lines (1,2) from connector (3).
2 Unscrew screws (4) and remove crankcase vent line (5).
3 Remove connector (3) upward out of connection fitting (6).
4 Replace gasket (7) and connection fitting (6).
W 20.10-0014-11
Engines OM904 LA, 906 LA (mod, des. 904.9, 906.9), F4 63
AR01.30-W-5800-07A Tightening specification of cylinder head
bolts
0 Cylinder head

906/907/909/ 904908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
B A01.30-N-1002-01C Cylinder head bolts to crankcase 1st stage Nm 20 20
2nd stage Nm 70 70
3rd stage Nm 170 170
4th stage Nm 280 280
5th stage 90 90
6th stage 90 90
Oil cylinder head bolts with engine oil and tighten with I S socket a
wrench bit. If the tightening torque has been exceeded at a cylinder head
bolt, unscrew cylinder head bolts, inspect shank length (replace
cylinder head bolt if necessary) and tighten, beginning with stage
It is important to observe all the tightening torque stages and to 1.
tighten the bolts in the correct sequence in order to achieve
uniform contact pressure of the cylinder head gasket; see Cylinder head bolts are not retightened.
tightening diagram.
Shown on engine 904

fo o o o
.D o D o D o D o .
64
Shown on engine 906
W 0 1 .3 0 -0 0 2 0 -0 4
AR01.50-W-1000A Removing, installing decompression brake valve 1.9.95
66
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 /922/923/940/941
ENGINE 904.908/923 w ith CODE (MB1) Engine brake with decompression brake valve
1 End cover
2 O-ring
3 Seal
4 Piston
5 Locking wedge
6 Top spring plate
7 Spring
8 Bottom spring plate
9 Valve
11 Spacer
4 Piston
5 Locking wedge
6 Top spring plate
7 Soring
12 Pliers
13 W ] Spring retainer depresser
15 W1 M agnetic pin
W 0 1 .50-0010-06
nu mi Removing and installing
1 Remove cylinder head Engine 904.905- 907/909- 911/921/922, Page 58

906.910/911 /920-923/940 /941
Engine 904.908/923 AR01.30-D-5800D
Remove oorzAe hoWer comfcAnaViora. op\o end no.

040487
Engines OM904 LA, 906 LA {mod. des. 904.9. 906.9). F4 67
Engines 904.909-911/922, AR07.03-W-6831C
906.910/911/920-923/940/941 and engine
904.905-908/921 as of end no. 040488
3 Remove end cover (1) at cylinder head (10) IT!Installation: replace O-ring (2)
4 Insert a suitable spacer (11) between valve [Li Height of spacer approx. 5.3 mm
disk and base
5 Remove piston (4) with pliers (12) m 442 589 00 37 00

[I] Installation: Lubricate piston and
sealing ring (3) and do not damage.
6 Inspect seal (3) at piston (4) B If wear and damage present \

replace piston with seal.
7 Remove locking wedges (5) Compress spring with spring retainer

depresser (13) and remove locking wedges
with magnetic pin (15).
in Installation :The locking wedges must
lock in position.
m 210 589 0040 00
D 442 589 05 63 00
8 Relieve the load on the spring, remove top Q ] Do not transpose top spring plate and
spring plate (6), spring and bottom spring Sring guide.
plate (8) lU Installation: Mount spring guide,
spring and spring retainer on the valve
stem of the decompression brake valve.
9 Turn cylinder head (10) and pull out valve Mark valve.
(9) B Installation: oil valve stem, push in
valve and place spacer (11) (height approx.
5.3 mm) below valve disk.
68
AR01.30-W-7162A Inspecting, facing cylinder head contact surface 21.11.95
ENGINE 904.90S/906/907/908/909/910/911 /921 /922 /923.906.910/911/920/921 /922/923 /940/941

1 Inlet valve
2 Exhaust valve
3 Constant throttle valve
A IS D ia l gage
5 S I Dial gage holder
6 Guide bolt
a Projection o f guide bolt (engine

904.905- 908/921)
B Piston setback
C Difference between both inlet valve
stem ends (engine 904.909-911/922
and 906.910/911/920- 923/940/941)
H Height o f cylinder head
W 0 1.30-0019-06
E3 R e m o v in g
1 Remove cylinder head On engine 904.905- 907 /909- 911 /921 /922 Page 58
and 906.910/911/920- 923/940/941
O n e n g in e 904.008 AR01.30-D-S800D
2 Remove nozzle holder combinations On engine 904.905- 908/921 AR07.03-W-6831A
On engine 904.909- 911/922 and AR07.03-W-6831C

906.910/911 /920- 923/940/941
3 Remove valves (1,2) AR05.30-W-3511A
4 Remove constant throttle (3) On engine 904.905- 907/909- 911/921/922 Page 66

an d 906.910/911/920- 923/940/941
On engine 904.908 with constant throttle
code MB1
Inspecting
5 Measure cylinder head overall height (H) [ I ] If measurement is less than permissible 8E01.30-N-1001-02B
and variation of parallelism from top to minimum height J,
bottom contact surface
replace cylinder head
6 Inspect flatness of cylinder head contact Permissible difference of flatness of BE01.30-N-1002-02B

surface (combustion chamber side) bottom contact surface in longitudinal
direction
Machining
7 Face cylinder head contact surface @ Surface quality (peak-to-valley height BE01.30-N-1003-02B
(combustion chamber side) R3z / waviness W t ) of cylinder head contact
surface must be maintained
Engines O M 904 LA. 906 LA (mod. des. 904.9.906.91. F4

IX! Only face cylinder head contact surface BE01.30-N-1002-02B
if impermissible variation of flatness is
measured in longitudinal direction or if
porous or damaged points are present. The
stock removal at the cylinder head must be
calculated so as to maintain the permissible
minimum height (H).
8 Clean cylinder head
El Measuring
9 Once again measure cylinder head overall Height of cylinder head BE01.30-N-1001-02B
height and variation of parallelism of top
to bottom contact surface
10 Insert valves (1, 2) into the cylinder head IHPay attention to marking of valves
11.1 Measure valve setback (B) to cylinder head On engine 904.905-908/921 Page 72
Measure valve setback at both inlet valves BE05.30-N-1001-01B
and at exhaust valve and note
HI 001 589 53 21 00
HI 343 589 00 40 00
CDIf the measurement obtained is not

within the permissible tolerance j,
machine valve seat rings AR05.30-W-4511A
11.2 Measure valve setback (B) to cylinder head, On engine 904.909- 911/922 and Page 73
and permissible difference (C) between 906.910/911/920-923/940/941
both inlet valve stems
Measure valve setback at both inlet valves BE05.30-N-1001-01B

and at exhaust valve and note
Difference between both inlet valve stem BE05.30-N-1014-01B

ends must not be exceeded
HI 001 589 53 21 00
HI 363 589 02 21 00
HI 343 589 004000
CDIf the measurement obtained is not

within the permissible tolerance J,
machine valve seat rings AR05.30-W-4511A
12 Measure projection of guide bolt (6) from On engine 904.905- 908/921 BE05.30-N-1003-04B
cylinder head and correct
m Installing
13 Install constant throttle (3) On engine 904.905- 907/909- 911 /921/922 Page 66
and906.910/911/920- 923/940/941
On engine 904.908 with constant throttle
Code MB1
14 Install valves (1, 2) AR05.30-W-3511A
15 Install nozzle holder combinations On engine 904.905- 908/921 AR07.03-W-6831A

906,910/911 /920- 923/940/941
16 Install cylinder head On engine 904.905- 907/909- 911/921/922 Page 58

and 906.910/911/920- 923/940/941
On engine 904.908 AR01.30-D-5800D
70
Number Designation Engine 904.905/ Engine 904.908/

906/907/909/910 923
/911/921/922
BE01.30-N-1001-02B Height of cylinder head when new mm 107.9-108.1 107.9-108.1
after stock removal mm 106.9 106.9
BE01.30-N-1002-02B Permissible difference in flatness over entire length mm 0.05 0.05

over a length of mm 0.02 0.02
150 mm
BE01.30-N-1003-02B Peak-to-valley height (Rz) of cylinder pm 8-16 8-16

head contact surface
Number Designation Engine

906.910/911/920/
921/922/923/940
/941
BE01.30-N-1001-02B Height of cylinder head when new mm 107.9-108.1
after stock removal mm 106.9
BE01.30-N-1002-02B Permissible difference in flatness over entire length mm 0.07

over a length of mm 0.02
150 mm
BE01.30-N-1003-02B Peak-to-valley height (Rz) of cylinder pm 8-16

Test data of valves
N u m ber D e sig n a tio n E n g in e 904.905/ E n g in e E n g in e 904.909/

906/907/921 904.904/908/923 910/911/922,
906.910/911/919/
920/921/922/923
/940/941
BE05.30-N-1001-01B Valve setback relative to cylinder mm 1.1-1.5 1.1-1.5 1.1-1.5

BE05.30-N-1014-01B Permissible difference of Inlet valves 0.2 0.2 0.2

measured between cylinder head
and end of valve stem
Test data of valve timing

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
B E05.30-N-1003-04B Valve bridge - guide pin projection mm 25.1-25.5 25.1-25.5

from cylinder head (A)
Fig. see - -
\ f \
343 589 004000
Dial gage Dial gage holder Dial gage holder
AR05.30-W-4100-01A Measuring amount by which valve stands

back to cylinder head
Test data of valves

906/907/921 904.904/908/923
BE05.30-N-1001-01B Amount by which valve stands back mm 1.1-1.5 1.1-1.5

relative to cylinder head contact
surface
a r
Dial gage holder
m
Valve disk (3) should be making contact with valve seat.
1 Attach [sZl dial gage (1) to I S dial gage holder (2).
2 Mount [ S dial gage (1) with a preload onto the plane face of the cylinder head.
3 Set scale of dial gage to "0".
4 Move H3 dial gage (1) sufficiently until the tracer pin is touching the valve disk (3).
m W05.30-0060-01
If the reading obtained (A) is not within the permissible tolerance, inspect valve seat
ring or the valve disk.
72
AR05.30-W-4100-01C Measuring amount by which valve stands
Test data of valves
Number Designation Engine 904.909/ Engine 904.905/ Engine

910/911/922, 906/907/921 904.904/908/923
906.910/911/919/
920/921/922/923
/940/941
BE05.30-N-1001-01B Amount by which valve stands back mm 1.1-1.5 1,1-1,5 1,1-1,5

surface
B E 0 5 .3 0 -N -1 0 1 4 -0 1 B Permissible difference of inlet valves 0.2 0,2 0.2

and valve stem ends
Dial gage holder Dial gage holder
E
V a lv e disk (3) s h o uld be m a k in g c o n ta c t w ith v a lv e seat.
1 Attach E dial gage (1) to E dial gage holder (2).
2 M ount d ial g a g e (1) w ith a p re lo a d o n to th e p la n e fa c e o f th e c y lin d e r head .
4 Move dial gage (1) sufficiently until the tracer pin istouching the valve disk (3).
m W05.30-0060*01
E n g in e * O M 9 (M LA, 906 L A (m o d . des. 904.9, 90G.9), F4 73
5 A tta c h 1311d ial g a g e ( i ) t o I S j th e dial
g a g e h o ld e r (4) a n d m o u n t on t h e to p
c o n ta ct su rface o f t h e cy lin d e r h e ad .
6 Position IS]dial gage (1) with a

preload on one of two inlet valve stem
ends (5).
8 Pull back tracer pin on IS ! dial gage

(1). Position dial gage (1) on the other
inlet valve stem end (5) and read off
indication on gage.
ffl
Permissible difference (C) between
both inlet valve stem ends (5) must not
be exceeded.
If the readout obtained (C) is not

within the permissible tolerance,
inspect the valve seat ring or the valve.
74
AR01.40-W-9202A Measuring cylinder bores 17.11.95
ENGINE 904.905/906/907/908/909/910/911/921/922/923,906.910/911/920/921/922/923/940/941
1 Crankcase
2 S I Dial gage
3 [ 0 Quick calipers for internal
m easurem ents
A ,B Directions o f measurement in
crankcase
I M easut iu y jo in ts a t to y reve rsa l p o in t
of first piston ring
n Measuring points in middle o f cylinder
wall
W 01.40-0034-06
MM Removing and installing
1 Remove cylinder head Engine 904.905- 907/909- 911 /921 /922 and Page 58
906.910/911/920- 923/940/941
Engine 904.908/923 AR01.30-D-5800D
2 Clean cylinder walls
0 Inspecting
3 In sp e ct cy lin d e r w a lls or cylin d er lin ers S3 C ylin d er w a ll or cylin der lin ers m ust n o t
reveal any scorch streaks. Individual slight
drawing streaks are not critical.
E Notes for assessing wear of cylinder wall Page 43

with dust damage
El Measuring
4 Set dial gage (2) and quick calipers (3) with E l Preload 5 mm BE01.40-N-1001-02B
the micrometer to the inner 0 of the
cylinder liner
E 001 589 53 21 00
H I Quick calipers WH58.30-Z-1009-12A
IS Micrometer WH58.30-Z-1027-12A
5 Measure cylinder wall or cylinder liner E Measure in the unworn area (top land BE01.40-N-1001-02B
inner 0 and set dial gage (2) to 0" zone) above the top reversal point of the
first piston ring. Directions of
measurement in direction of travel (A) and
in transverse d irectio n (B).
Difference in cylinder shape BE01.40-N-1002-02B
6 Measure difference in diameter of cylinder [0 Measure wear of cylinder wall or BE01.40-N-1003-02B
liner cylinder liner at measuring points (1, II) in
direction of travel (A) and in transverse
direction (B).
The specifications should be

maintained. Installed cylinder liner must
not be remachined, if necessary j,
H I If deviations from tolerance J,
widen cylinder bore in crankcase j Page 79

install cylinder liners or J Page 84
replace cylinder liners Page 82
7 Install in th e reverse order
Number Designation Engines 904.905/ Engine 904.908/

906/907/909/910 923
/911/921/922,
906.910/911/920/
971/922/923/940
/941
BEI.40-N-1001-02B Cylinder wall or cylinder liner code letter A mm 101.985-101.991 101.985-101.991

inner 0
co d e le tte r B mm 101.992-102.008 101.992-102.008
code letter C mm 102.009-102.015 102.009-102.015
BE01.40-N-1002-02B Difference in shape of cylinder mm 0.012 0.012

wall
BE01.40-N-1003-02B Wear to cylinder wall or upper reversal point mm 0.1 0.1

cylinder liner measured in of first piston ring,
direction of travel and max.
in middle of cylinder mm 0.05 0.05
wall, max.
Num ber D e sig n a tio n M a k e (e.g.) O rd er num ber
WH58.30-Z-1009-12A Quick calipers for internal measurements, 0 100-120 mm
WH58.30-Z-1027-12A Micrometer 100-125 mm Hahn and Kolb 313346 100

Borsigstr. 50
D-70469 Stuttgart
76
AR01.40-W-9211A Flex-honing cylinder wall 4.12.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 in MODEL 668, 670
1 Crankcase
2 IS Honing brush
3 IS Hand drill
W 0 1 .40-0001-06
Machining
1 Remove piston AR03.10-W-7021A
2 Measure cylinder bore P a g e 75
3 Mask over openings and bores at crankcase

contact surface (1)
4 Insert pieces of foam through the cylinder H I Cleaning rags do not adequately ab
walls over the crankshaft and the bearings sorb grinding residues and lubricant.
(protection against grinding residues)
5 clamp honing brush (2 ) into hand drill (3) 00 use honing oil, viscous engine oil,
and immerse in lubricant petroleum or diesel fuel.
Fit guard or guard box onto crankcase
contact surface (1) in order to prevent
soiling of surrounding area and of clothes.
19 Honing brush WH58.30-Z-1001-04A
6 Insert hand drill (3) with honing brush (2) @ Do not operate drill at a speed of more
into the cylinder bore to be machined than about 200 rpm (risk of honing brush
snapping off).
7 Move honing brush (2) evenly up and down 3 ] Change direction as soon as about 1/4
of honing brush projects at top or bottom.
Machining time about 1 to 2 minutes.
8 Take out honing brush (2) and inspect H I Aim for a grinding pattern of approx.
surface structure 45 and a mat appearance.
If the surface is glossy I
repeat honing
9 Take out pieces of foam and remove HI Use a clean rag.

grinding residues

10 Remove masking at the crankcase contact
surface (1)
11 C lea n c y lin d e r w a lls w ith w h ite spirit
12 Install pistons AR03.10-W-7021A
WH58.30-Z-1001-04A Honing brush (roughness 120) Walter Krupp

Gddertzgarten
53340 Meckenheim-
Merl
78
AR01.40-W-9271A Widening cylinder bore in crankcase 3.11.95
ENGINE 904.905/906/907/909/910/911/921 /922.906.910/911/920/921 Z922/923

ENGINE 904.908/923 in MODEL 668, 670
ENGINE 906.940/941 in M ODEL 957
1 Crankcase
A Reference height o f crankcase

B Bore 0 o f cylinder liner
C Bore 0 o f cylinder liner collar
D Distance between seat o f cylinder li
ner collar and contact surface o f
crankshaft bearing cap
Fillet radius o f cylinder liner collar to
cylinder liner collar seat
Chamfer at cylinder liner collar seat
W 01.40-0002-06
Machining
1 Clamp crankcase (1) to the boring machine
2 Align cylinder wall relative to boring E Using centering device above reversal
machine point of 1st piston ring.
3 Clamp boring tool and widen cylinder bore B If several cylinder liners are installed,
in several operations pay attention to sequence of work in order
to avoid excessive thermal stresses.
Engine 904; cylinder bore 2-4-1-3
Engine 906; cylinder bore 1-3-5-2-4-6
Widen to leave approx. 0.05 mm of the
desired final dimension (cylinder liner bore
0).
E Settings for honing machine.
Working pressure (p): 2.5 to 3.0 bar
Speed (n): 60to100rpm
Honing angle (a): 40 to 60
No. of strokes; 30 to 40
Height of crankcase (A) B E01.40-N-1006-02B
4 Machine cylinder bore to final dimension E Set boring tool to the respective
(precision boring) diameter using the measuring device.
Bore 0 (B) BE01.40-N-1007-02B
Max. peak-to-valley height BE01.40-N-1012-02B
5 Bore seat of liner collar E Use drilling tool with 90 cutting angle
Bore diameter (C) BE01.40-N-1008-02B
E n g in e s O M 9 0 4 LA . Qflfi L A (m o d des 9 4.S, 90 6 .9 ), F4 79
Distance between cylinder liner collar seat BE01.40-N-1009-02B
and contact surface of crankshaft bearing
cap (D).
Contact surface of cylinder liner collar. BE01.40-N-1014-02B
Concentricity and peak-to-valley height of BE01-40-N-1015-02B

cylin d er lin e r co llar b o re.
Overlap of cylinder liner to crankcase. BE01.40-N-1017-02B
Fillet radius (E) BE01.40-N-1018-02B
Chamfer (F) BE01.40-N-1019-02B
6 Deburr crankcase at the chamfer with a

burnishing stone
80

906/907/909/910 923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE01.40-N-1006-02B Crankcase height (A), Standard mm 298.35-298.50 298.35-298,50

measured from main bearing
Undersize-0.3 mm 298.05-298.20 298.05-298.20
shell seat to contact surface
o f c y lin d e r h e ad Undersi2e-0.fi mm 297 75-297 90 297.75-297.90
Undersize-0.9 mm 297.45-297.60 297.45-297.60
BE01.40-N-1007-02B Bore 0 for cylinder liner in crankcase mm 106.000-106.035 106.000-106.035

(B)
B EOI .40-N-1008-02B Bore 0 for cylinder liner collar in mm 109.572-109.626 109.572-109.626

crankcase (C)
Fig. see - -
BE01.40-N-1009-02B Distance between cylinder liner mm 338.900-339.100 338.900-339.100

collar seat and contact surface of
Fig. see - -
crankshaft bearing cap (D) in all
installation sizes
BE01.40-N-1012-02B Peak-to-valley height (Rz) of bored pm 25 25

(honed) cylinder bore for installing
cylinder liners
BE01.40-N-1014-02B Contact surface of cylinder liner Concentricity mm 0.030 0.030

collar in crankcase
Flatness mm 0.010 0.010
Peak-to-valley height pm 16 16
(Rz)
BE01.40-N-1015-02B Bore for cylinder liner collar In Concentricity mm 0.060 0.060
crankcase
Peak-to-valley height pm 25 25
(Rz)
BE01.40-N-1017-02B Overlap of cylinder liner to max. mm 0.040 0.040
machined crankcase
BE01.40-N-1018-02B Fillet radius of cylinder liner mm 0.2 0.2

collar 0 to cylinder liner collar
Fig. see - -
seat in crankcase (E)
BEO l .4 0 -N -1 0 1 9 -0 2 0 C h a m fe r a t cy lin d e r lin er collar m m 0.3-0.4 0.3-0.4

seat to cylinder bore (F)
45 45
Fig. see - -
AR01.40-W-9272A Removing cylinder liner 20.11.95
ENGINE 904.905/906/907/909 /910 /911 /921 /922,906.910 /911 /920 /921 /922 /923
ENGINE 904.908/923 In M ODEL 668. 670
W 01.40-0004-06
12 Removing
1 Remove crankshaft AR03.20-W-4351A
2 Clamp crankcase (1) to boring machine (3)
3 Align cylinder wall to boring machine (3) E Using centering device above reversal
point of 1st piston ring.
4 Clamp boring tool and widen cylinder liner E If several cylinder liners are removed,
(2) in several operations to half of the wall pay attention to sequence of work in order
thickness to avoid excessive thermal stresses.
Engine 904 cylinder bore 2-4-1-3
Engine 906 cylinder bore 1-3-5-2-4-6
Cylinder liner outer diameter. BE01.40-N-1001-03B
Cylinder liner inner diameter. BE01.40-N-1001-02B
5 Cylinder liner (2) as far as about 0.2 mm DOThe liner collar detaches with this
below the outer diameter setting of the boring tool.
Cylinder liner outer diameter. BE01.40-N-1001-03B
6 Draw a triangular file over the entire @ Do not damage crankcase.

surface of the cylinder liner (2) so that the
cylinder liner breaks apart
82

906/907/909/910 923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE01.40-N-1001-02B Cylinder wall or cylinder liner inner Code letter A mm 101.985-101.991 101.985-101.991
0
Code letter B mm 101.992-102.008 101.992-102.008
Code letter C mm 107.009-102.015 102.009-102.015
Test data of cylinder liner

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE01.40-N-1001-03B Cylinder liner outer 0 mm 106.075-106.095 106.075-106.095
AR01.40-W-9273A Installing cylinder liner 20.11.95
ENGINE 904.905/906/907/909/910/911/921/922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 in M ODEL 668, 670
W01.40-0035-09
1 Crankcase A Crankcase height
2 Cylinder liner B Bore diam eter o f cylinder liner
3 M arking surfaces on crankcase C Bore diam eter o f cylinder liner collar
m Installing
1 Widen cylinder bore in crankcase (1) E Only if no cylinder liner (2) is fitted. Page 79
2 Remove cylinder liner (2) CDOnly if no cylinder liner (2) is fitted. Page 82
3 Measure bore and collar seat in crankcase Bore 0 (B) of cylinder liner BE01.40-NA 007-02B
(1)
Bore 0 (C) of cylinder liner collar BE01.40-N-1008-02B
4 Coat bore in crankcase (1) with acid-free B R00.45-Z-1018-06A

grease
5 Measure cylinder liner (2) Overlap BE01.40-N-1017-02B
Cylinder liner outer 0 B E01.40-N-1001-03B
C y lin d er lin er co llar o u le r 0 BE01.40-N-1002-03B
6 Place crankcase (1) on the press and align ES Workshop press WE58.40-Z-1001-12A
7 Position cylinder liner (2) at right angles to

the bore
8 Press in cylinder liner (2) until it projects CDUse a suitable plate for pressing in.
approx. 20 mm Inspect collar seat for abrasion (arrow) and
clean with compressed air if necessary.
9 Press in cylinder liner (2) fully CD 3

Press in with approx. 1 until contact,
then briefly release pressure and press in
fully with approx. 7 1for a period of
approx. 5 s.
84
10 Face contact surface of crankcase (1) Pay attention to undersize stages of BE01.40-N-1006-02B
crankcase height, height (A) measured
fro m m ain b e a rin g shell seat to co n ta ct
surface of cylinder head
Peak-to-valley height (Rz) of crankcase BE01.40-N-1011-02B

contact surface
Flatness of crankcase contact surface BE01.40-N-1013-02B
Parallelism of crankcase contact surface, BE01.40-N-1016-02B

measured to main bearing shell seat
11 Clamp crankcase (1) on the drill
12 Align cylinder liner to drill E W ith centering device above reversal

point of 1st piston ring.
13 Clamp in boring tool and widen cylinder S If several cylinder liners are fitted, pay
liner (2) in several operations attention to sequence of work in order to
avoid excessive thermal stresses.
Engine 904 cylinder bore 2-4-1-3
Engine 906 cylinder bore 1-3-5-2-4-6
Widen leaving approx. 0.05 mm of the
desired final dimension (bore 0 of cylinder
liner).
Widen leaving approx. 0.05 mm of the BE01.40-N-1001-02B

desired final dimension (cylinder wall or
cylinder liner Inner 0 ).
E Settings for precision boring machine

Speed (n): 250to280rpm
Infeed (f): 0.04 to 0.06 mm/rev.
14 Hone cylinder liner to final dimension Cylinder liner inner 0 BE01.40-N-1001-02B
Difference of cylinder shape BE01.40-N-1002-02B
Peak-to-valley height (Rz) of cylinder liner BE01.40-N-1004-02B
Difference of cylinder wall or cylinder liner BE01.40-N-1005-02B
E Settings of honing machine

Working pressure (p): 2.5 to 3.0 bar
Speed (n): 60 to 100 rpm
Honing angle (a): 40to60
No. of strokes: 30 to 40
15 Gage adjacent walls and re-hone, if @ Pressing in can result in changes in the BE01.40-N-1001-02B
necessary structure which result In a slight change in
the inner 0 of the cylinder wall (cylinder
shap e) o f th e a d ja c e n t cylinders.
Difference of cylinder shape BE01.40-N-1002-02B
16 Clean crankcase (1)
17 Re-mark marking surfaces (3) on crankcase E Markings of classification Page 87

after machining

906/907/909/910 923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
0
Code letter B mm 101.992-102.008 101.992-102.008
Code letter C mm 102.009-102.015 102.009-102.015
BEOV40-N-1002-02B Cylinder wall -difference in shape of mm 0.012 0.012

cylinder
BE01.40-N-1004-02B Peak-to-valley height (Rz) of cylinder ym 2.5-4.S 2.5-4.5

wall or cylinder liner
BE01.40-N-1005-02B Difference of cylinder wall or max. mm 0.050 0.050

cylinder liner, measured vertically to
crankshaft axis and to main bearing
shell seat
BE01.40-N-1006-02B Crankcase height (A), measured Standard mm 298.35-298.50 298.35-298.50

from main bearing shell seat to
undersize -0.3 mm 298.05-298.20 298.05-298.20
contact surface of cylinder head
Undersize-0.6 mm 297.75-297.90 297.75-297.90
Undersize-0.9 mm 297.45-297.60 297.45-297.60
BE01.40-N-1007-02B Bore 0 for cylinder liner in crankcase mm 106.000-106.035 106.000-106.035

(B)
B E01.40-N-1008-02B Bore 0 for cylinder liner collar in mm 109.572-109.626 109.572-109.626

crankcase (C)
Fig. see - -
BE01.40-N-1011-02B Peak-to-valley height (Rz) of pm 8-16 8-16

crankcase contact surface
BE01.40-N-1013-02B Crankcase -flatness of contact Over entire length mm 0.030 0.030

surface
Over a length of 150 mm mm 0.015 0.015
in longitudinal and
BE01.40-N-1016-02B Crankcase contact surface mm 0.05 0.05

parallelism, measured to main
b e a rin g shell sea t
BE01.40-N-1017-02B Overlap of cylinder liner to max. mm 0.040 0.040

machined crankcase
Test data of cylinder liner

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE01.40-N-1001-03B Cylinder liner outer 0 mm 106.075-106.095 106.075-106.095
BE01.40-N-1002-03B Cylinder liner collar outer 0 mm 109.374-109.428 109.374-109.428
86
Repair products
BROO 4 5 -7 -1 0 1 8 -0 6 A A T E g rease -
Workshop equipment/MB testers (see Workshop Equipment Manual)
WE58.40-Z-1001-12A Fixed installation workshop press 651, e.g. make Matra-Werke GmbH, D-60314 Frankfurt/Main
AR01.40-W-9273-01A Marking crankcase after machining

906/907/909/910 923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
0
Code letter B mm 101.992-102.008 101.992-102.008
Code letter C mm 102.009-102.015 102.009-102.015
B E01.40-N-1006-02B Crankcase height (A), measured Standard mm 298.35-298.50 298.35-298.50

from main bearing shell seat to
Undersize -0.3 mm 298 05-298.20 298.05-298.20
cylinder head contact surface
Undersize -0.6 mm 297.75-297.90 297.75-297.90
Undersize-0.9 mm 297.45-297.60 297.45-297.60
The markings (classification) of the cylinder bore 0 and of the

crankcase height (dimension "A ") are indicated on the marking
surfaces (I, 11) at the crankcase in the area of the unit pump
bores.
Engine 904 with 3 marking surfaces ( I ) at cylinders 1 to 3 and
1 marking surface ( 11) at cylinder 4.
Engine 906 with 5 marking surfaces ( I ) at cylinders 1 to 5 and
1 marking surface ( 11) at cylinder 6.
@ Each time the crankcase is machined, the markings on the
marking surfaces ( I , II) of boxes "1, 2, 6" have to be revised.
Box 1": classification of cylinder bore 0 with abbreviated symbol

"A "/"B"/"C ".
If the cylinder bore 0 differs, box 1 should be marked at all
cylin ders w ith th e a p p ro p ria te co d e letters.
If the cylinder bore 0 is uniform, box "1 at the last cylinder is
blank.
Box 2" . at the last cylinder, classification of uniform cylinder bore

0 with abbreviated symbols " A ' T B ' V C (marking inbox 1" at
last cylinder not required).
Box ", 4,5": no significance for repairs (machining codes for

engine production). W01.40-0036-12
Box "6 ": at last cylinder
No marking means standard crankcase without cylinder
liners".
If the box is marked with the marking "-.3'7',-.6 /-.9",thisis
a crankcase with a reduced crankcase height (undersize).
If the box is additionally marked with the marking Z",
cylinder liners are installed in the crankcase.
Example: Marking "-.3" to indicate reduced crankcase height.
Marking "-.3 Z" to indicate reduced crankcase height
and cylinder liners fitted.
88
AR01.45-W-7500A Removing and installing oil sump 17.7.95
EN GIN E 904.905/906/907/921
OH filler pipe
Gasket
O il sump
Bolt
Seal
O il drain plug
Noise encapsulation
W 01.45-0001.06
Modification notes
7.7.98 Pay attention to installation position of shortened bolt Step 4 Page 89

at oil pan (as of engine end no. 004 313 up to engine
end no. 004449)
Tightening torque of oil drain plug modified Step 4
M M Removal, installation
1 Remove noise encapsulation (7) at the oil CDInstallation: quick-locks must engage
sump properly.
2 Extract or drain engine oil WH0101.40
3 Disconnect oil filler pipe (1)at oil sump
4 Remove oil sump (3) EDInstallation: Clean oil sump and contact
surface at crankcase.
Replace gasket (2); pay attention to instal
lation position.
As of engine end no. 004 313 up to

engine end no. 004 449 one bolt (2) was
shortened; pay attention to installation
position at rear left of oil pan (compressor
side)
3 Screw oil sump to cylinder crankcase BA01.45-N-1001-01B
CDInstallation: Replace gaskets (5).

0 Oil drain plug (M 26x1.5) BA01.45-N-1002-01B
0 Oil drain plug (M 20x1.5) BA01.45-N-1003-01B
5 Reinstall in opposite order
e Check engine oil level with oil dipstick WH0101.40

A Dangerl Accident hazard resulting from vehicle Secure vehicle against starting to move Page 31
starting to move by itself with engine unintentionally.
r u n n in g D a n g e r o f in ju ry resu ltin g fro m W e a r closed a n d t ig h t fittin g w o rk
pinching and burning when reaching in clothing.
during the starting operation or with the Do not touch hot or rotating parts.
engine running.
7 Start engine and check oil pressure gauge Do not crank engine for more than BE18.00-N-1001-01C
at Idle speed 90 seconds with starter. Repeat starting
operation after waiting for approx.
2 minutes.
Do not rev up engine before oil pressure is
indicated.
[ 3 The oil pressure gauge should indicate
oil pressure a fte r a p p ro x . 10 seconds.
8 Switch off engine and check for leaks

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idling bar a 0.5
maximum speed bar S2.5
@ Oil sump

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.45-N-1001-01B Screw for oil sump on crankcase Nm 25
B A01.45-N-1002-016 Oil drain plug to oil sump M 26x1.5 Nm 85
BA01.45-N-1003-01B Oil drain plug to oil sump M 20x1.5 Nm 65
90
AR01.45-W-7500C Removing and installing oil pan 3.7.97
ENGINE 904.909 /910 /911 /922, 906.910 /911 /920 /921 /922 /923
7 Oil pan
2 Gasket
3 Bolts
4 OH filler line
5 Seal
6 Oil drain plug
B14 Engine oil level sensor
W01.45-0005-06
Modification notes
7.7.98 Tightening torque of oil drain plug modified Step 4 Page 91
num i Removing and installing
1 Extract or drain engine oil AP18.00-W-0101B
2 Detach oil filler line (4) at the oil pan
3 Separate electric cable of engine oil level

sensor (B14) at engine wiring harness (7)
4 Detach ATF lines at the fixtures and tie up On transmission 715.5

DO Do not separate ATF lines
5 Detach oil pan (1) Clean oil pan and contact surface of
crankcase.
CD Installation*, replace gasket (2), pay
a tte n tio n to in s ta lla tio n p o sitio n
S Bolt of oil pan to crankcase BA01.45-N-1001-01B
H Installation: replace seal (5)
S o i l drain plug (M 26x1.5) BA01.45-N-1002-01B
S Oil drain plug (M 20x1.5) BA01.45-N-1003-01B
7 Inspect engine oil level at electric See ATEGO operating Instructions

indication
Danger Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 31
starting off when engine running. Risk of W ear closed and close-fitting work clothes.

8 Start engine and check oil pressure gage @ Crank engine with the starter for not BE18.00-N-1001-01C
with engine idling more than 90 seconds. W ait approx.
2 m in u te s b e fo re m a k in g a re p e a t a tte m p t
at starting.
L U T h e oil pressure gcige s h o uld in d ica te
oil pressure after approx. 10 seconds.

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idle speed bar 0.5
0 Oil pan

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.45-N-1001-01B Bolt of oil pan to crankcase Nm 25
B A01.45-N-1002-01B Oil drain plug to oil pan M 26x1.5 Nm 85
BA01.45-N-1003-01B Oil drain plug to oil pan M 20x1.5 Nm 65
92
AR01.60-W-8200A Removing, installing timing case 17.7.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 in MODEL 668,670
W01.60-0006-06
M o d ific a tio n n o tes
24.6.98 Pay attention to installation position of shortened bolt Step 5

at oil pan (as of engine end no. 004 313 up to engine
end no. 004 449)
3HH Removing, installing
1 Remove starter (M 1) Engine 904.905- 907/909- 911 /921/922 and AR15.30-W-7100A

906.910/911 /920- 923/940/941
Engine 904.908/923 AR15.30-D-7100D
2 Remove flywheel (10) AR03.30-W-8002A
3 Take off attached parts at timing case (2)
4 Pull o u t c ra n k sh a ft a n g le p o sitio n [XI In s ta lla tio n : press in c ra n k s h a ft a n g le

sensor (B 15) position sensor as far as the stop.
5 Unscrew bolts (7) at oil pan (8) in the As of engine end no. 004 313 up to
area of the timing case (2) engine end no. 004 449 one bolt (2) was
shortened; pay attention to installation
position at rear left of oil pan (compressor
side)
E li Bolt of oil pan to crankcase BA01.45-N-1001-01B
6 Slacken remaining bolts (7) at oil pan (8) @ Do not damage oil pan gasket,
and lower oil pan (8) if necessary J
Remove oil pan and replace oil pan gasket
Engine 904.905-907/921 Page 89

Engine 904.908/923 AR01.45-D-7500D
Engine 904.909- 911/922 and Page 91
906.910/911 /920- 923/940/941
7 Detach timing case (2) E l Cover over opening at oil pan.

Inspect timing case for signs of damage,
if necessary j,
Replace timing case and fit all existing

attached parts.
Remove bracket of crankshaft angle AR07.15-W-1640B

position sensor, install, adjust.
0 Bolt of timing case to crankcase BA01.60-N-1001-01A
@ Bolt of end cover of TDC inspection BA01.60-N-1002-01A

hole to timing case
8 Clean contact surfaces at timing case (2) IXI Installation: coat contact surfaces at BR00.45-Z-1010-01A
and at crankcase timing case with sealant.
9 Replace radial seal (9) DU Replace radial seal only if timing case AR03.20-W-3063A
(2) installed as installation dimension is
related to crankshaft.
@ Timing case
Number Designation Engines 904.905/ Engine

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.60-N-1001-01A Timing case to crankcase Nm 50 50
BA01.60-N-1002-01A End cover of inspection hole to Nm 25 25

timing case
@ Oil pan
Number Designation Engine Engine 904.905/

904.904/ 906/907/909/
908/923 910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.45-N-1001-01B Bolt of oil pan to crankcase Nm 25 25
Repair products
BR00.45-Z-1010-01A Loctite 574 sealant 001 989 89 20
94
AR01.60-W-8200F Removing, installing timing case 25.6.98
ENGINE 906.920 /921/922 /923

T im in g case SAE 1 o r 2, p re p a re d fo r e n g in e o u tp u t o r in s ta lle d e n g in e o u tp u t
1 Cover plate 12 Transmission oil line

2 Gasket 13 Bracket
3 Cover plate 14 W iring harness (transmission and retarder)
4 Gasket 15 Ground cable
5 Clamping bush 16 W iring harness
6 Bracket 17 Radial seal
7 Timing case 18 Flywheel
8 Oil line (rear engine output)
9 Dowel pin B15 Crankshaft angle position sensor
10 Gasket M l Starter
11 O il pan
H UIS] Removing, installing
1 Remove starter (M1) AR15.30-W-7100A
2 Remove flywheel (18) AR03.30-W-8002A
3 Take off cover plate (3) together with

gasket (4) at timing case (7)
4.1 Take off cover plate (1) together with Except with rear engine output
gasket (2) at timing case (7)
4.2 Remove engine output at timing case (7) With rear engine output
5 Remove oil line (8) With rear engine output

Q ] Collect engine oil which flows out
6 Take off bracket (13) with wiring harness

(14) a t tim in g case (7)
7 Detach transmission oil lines (12) at timing E E Collect transmission oil which flows out
case (7) and crankcase
8 D etach y io u n d cab le (15), w irin g harness

( 16) and attached parts at timing case (7)
Eng ines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4

9 Pull out crankshaft angle position sensor CDInstallation: press in clamping bush (5)
(B15) and detach lines at timing case (7) and crankshaft angle position sensor as far
as a stop
10 Unscrew bolts at oil pan (11) in area of 0 Bolt of oil pan to crankcase BA01.45-N-1001-01B
timing case (7)
n Slacken remaining bolts at oil pan (11) and Do not damage oil pan gasket (10), If
lower oil pan necessary J
remove oil pan and replace oil pan gasket Page 91

12 Take oft timing case (7) E E Pay attention to bolts in the two
openings at timing case.
Cover over opening at oil pan.
Inspect timing case for damage, if
necessary I
replace timing case and fit on all existing

attached parts
Remove bracket (6) of crankshaft position AR07.15-W-1640B

sensor, install, adjust
0 Bolt of timing case to crankcase BA01.60-N-1001 -01A
0 Bolt of cover plate of inspection hole to B A01.60-N-1002-01A

timing case
13 Clean contact surfaces at timing case (7) CDInstallation: coat contact surfaces at B R00.45-Z-1010-01A
and crankcase timing case with sealant
14 Replace radial seal (17) CD Replace radial seal only if timing case AR03.20-W-3063A
(7) installed
0 Oil pan
N um ber D e sig n a tio n E n g in e E n g in e 904.905/

904.904/ 906/907/909/
908/923 910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.45-N-1001-01B Bolt of oil pan to crankcase Nm 25 25
0 Timing case

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.60-N-1001-01A Bolt of timing case to crankcase Nm 50
B A01.60-N-1002-01A Cover plate of inspection hole to Nm 25

timing case
Repair products
BR00.45-2-1010-01A Loctite 574 sealant 001 989 89 20
96
AR03.10-W-7021A Removing, installing pistons 21.11.95
ENGINE 904.905/906 /907/909 /910/911 /921 /922, 906.910 /911 /920 /921 /922 /923
ENGINE 904.908 /923 in MODEL 668, 670
1 Piston
2 Piston pin
3 Circlip
4 Conrod
5 Conrod bearing cap
6 Conrod bolt
7 Conrod bearing shells
W 03.10-0005-06
1 Piston
2 Piston pin
4 Conrod
ft Dii spray nn?7/p
W 03.10-0006-06
@ 5 ^ Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 3
1 Piston
6 Conrod bolt shank length (L)
9 Tensioning strap
A Piston projection
W 0 3 .10-0007-06
EH Removing
1 Remove cylinder head Engine 904.905- 907/909- 911 /921/922 and AR01.30-W-5800A
906.910/911 /920- 923/940/941
Engine 904.908/923 AR01.30-D-5800D
2 Remove oil pan Engine 904.905- 90?/921 AR01.45-W-7500A
Engine 904.908/923 AR01.45-D-7500D
Engine 904.909- 911/922 and AR01.45-W-7500C

906.910/911/920- 923/940/941
3 Use a scraper to carefully remove HITo avoid damaging the piston rings
combustion residues above the top land when removing the pistons.
zone in the cylinder wall
4 Remove conrod bearing caps (5) CDMark conrod bearing caps and conrod
to each other.
@ D o n o t d a m a g e cracked c o n ta ct
surface. If damaged |
replace conrod.
5 T ak e piston (1) w ith co n ro d (4) o u t o f th e @ Use a w o o d e n o r plastic h a n d le .

crankcase If cracked contact surface is damaged,
replace conrod.
CDIf the direction arrow on the piston is
no lo n g e r visible, m ak e d ire c tio n a r r o w
(facing forward in opposite direction of
force).
@ Do not damage oil spray nozzle (8) |
Replace damaged oil spray nozzle. AR18.00-W-4000A
6 Mark conrod bearing shells (7) to conrod [DEngines have different conrod bearing
bearing cap (5) and conrod (4) and remove shells in the conrod bearing cap and
conrod.
7 Remove piston pin (2) and take out conrod HIClamp conrod with piston; use soft
(4) protective jaws.
4
8 Measure conrod bolts (6) S If the maximum shank length (L) is BE03.10-N-1014-01B
exceeded J,
replace conrod bolt.
a Inspecting
9 Inspect piston stem and cylinder walls for

signs of wear
E Notes for assessing wear of cylinder wall Page 8

with dust damage
e Notes for assessing wear of pistons with Page 8

dust damage
10 Inspect piston rings for spalling of the E Replace damaged piston rings. Page 11
coating
11 Inspect piston crown for signs of damage E Replace damaged pistons.
12 Assign piston to cylinder bore E Markings are stamped on the piston Page 9
crown.
E If the crankcase has been faced J
install new pistons with a reduced

compression height
Piston 0 group marking BE03.10-N-1001-02B
Piston compression height BE03.10-N-1002-02B
13 Inspect conrods (4, 5) and conrod bearing Page 13

shells (7), measure
m Installing
14 Assemble oiston (1) and conrod (4) E Oil piston pin and press in by hand
15 Oil piston (1) and position piston ring gaps

(arrows) each offset by 120
16 Guide tensioning strap (9) loosely over the w\ 000 589 38 31 00

piston rings and pull together to the outer B It should still just be possible to move
diameter of the piston (1) the collar of the tensioning strap
17 Insert conrod bearing shell (7) in conrod (4) E Pay attention to marking. Lug on BE03.10-N-1001-01B
and oil contact surface conrod bearing shell should be located in
the slot of the conrod.
B Engines have different conrod bearing

s h e ll, in th e c o n ro d b e a rin g cap a nd
conrod. Pay attention to abbreviated part
number on the rear of the conrod bearing
shell halves.
18 Insert piston (1) into the crankcase until the E Direction arrow on piston crown should
tensioning strap (9) is touching the face forward (opposite direction of force)
crankcase and the cracked contact surface at the
conrod (4) points toward the camshaft or
unit pump.
Turn piston slightly when inserting so

that the conrod does not damage the oil
spray nozzle (8) when installing J.
Replace damaged oil spray nozzle AR18.00-W-4000A
19 Press piston (1) into the crankcase E Until conrod bearing shell (7) makes
contact with conrod journal of crankshaft.
20 Attach conrod (4) and conrod bearing cap 0 Bolt of conrod bearing cap to conrod BA03.10-N-1001-01B
(5) to the crankshaft
Engines OM904 LA, 906 LA {mod. des. 904.9,906.9), F4

21 Rotate crankshaft and ensure it rotates Conrod bearing play BE03.10-N-1003-01B
freely
22 Measure piston projection at all pistons Page 9

Piston projection at TDC relative to top BE03.10-N-1003-02B
edge of crankcase
13 001 589 53 2100
HI 541 589 012100
H I If the dimensions for piston projection

are not correct |
inspect conrod and piston
23 Install oil pan Engine 904.905- 907/921 AR01.45-W-7500A
Engine 904.908/923 AR01.45-D-7500D
Engine 904.909- 911/922 and AR01.45-W-7500C

906.910/911/920- 923/940/941
24 Install cylinder head Engine 904.905- 907/909- 911/921/922 and AR01.30-W-5800A

906.910/911/920- 923/940/941
E n g in e 904.908/923 A R 0 1 .3 0 D 5800D
Test data of conrod

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE03.10-N-1001-01B Conrod bearing inner 0 with Standard mm 70.054-70.093 70.054-70.093

conrod bearing shells installed
Undersize 0-25 mm 69.804-69.843 69.804-69.843
Undersize 0.5 mm 69.554-69.593 69.554-69.593
Undersize 0.75 mm 69.304-69.343 69.304-69.343
Undersize 1.0 mm 69.054-69.093 69.054-69.093
B E03.10-N-1003-01B Conrod bearing play radial mm 0.039-0.098 0.039-0.098
axial mm 0.170-0.470 0.170-0.470
BE03.10-N-1014-01B Conrod bolt Thread 0 M 12X1.25 12X1.25
Shank length (L) mm 56.0 56.0

when new
Max. shank length (L) mm 57.0 57.0
Fig. see - -
6
Test data of piston

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE03.10-N-1001-02B Piston 0 Group BA mm 101.781-101.790 101.781-101.790

identification
BC mm 101.790-101.799 101.790-101.799
BE03.10-N-1002-02B Piston compression Standard 102 BA mm 64.36-64.40 64.36-64.40

height
102 BC mm 64.35-64.40 64.36-64.40
Undersize I 102 BA-0.3 mm 64.06-64.10 64.06-64.10
102 BC-0.3 mm 64.06-64.10 64.06-64.10
Undersize II 102 BA-0.6 mm 63.76-63.80 63.76-63.80
102 BC-0.6 mm 63.76-63.80 63.76-63.80
Undersize III 102 BA-0.9 mm 63.46-63.50 63.46-63.50
102 BC-0.9 mm 63.46-63.50 63.46-63.50
BE03.10-N-1003-02B Piston projection at TDC mm 0.28-0.50 0.28-0.50

relative to top edge of
crankcase
0 Conrod

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
0A03.10 N 1001-010 B o lt o f co n ro d b e a rin g cop to 1st sta g e Nm 10 10

co n rod
2nd stage Nm 45 45
3rd stage 90 90
541 589 01 21 00
y v y 000 589 38 31 00
Measuring bridge Tensioning strap
Engines OM904 LA, 906 LA {mod. des. 904.9,906.9), F4 7
AH01.40-N-0001-01 A Notes for assessing wear of cylinder wall if Engines 904,906,541,542 ffl
dust damage present
Cylinder walls and cylinder liners without dust damage

The honing is more or less clearly visible on the entire contact surface. The honing may be
partially worn at the reversal point of the first piston ring.
Cylinder walls and cylinder liners with dust damage

The traces of machining from honing are only very faintly visible or not at all. If the wear is
well advanced, a wear step can be felt at the reversal point of the first piston ring.
m
Dust damage is caused by poor sealing, splits, chafing damage of the intake lines, seals and
hoses.
When carrying out repair and service work, make a careful inspection of intake lines, seals
and hoses, also at points not easily accessible.
AH03.10-N-0001-01A Notes for assessing wear to pistons in the Engine 541, 542,904,906 a
case of dust damage
Piston s w ith o u t d u st d a m a g e
The contact surface of the piston stem is visible over a large area and the machining grooves
can still be recognized within this area.
m
The machining grooves at the circumference are intentional recesses which are filled with oil
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. In the advanced stage of wear, slight
traces of seizure are already present on the stem and the piston rings are sharp-edged.
W 0 3 .10-0013-0!
AR03.10-W-7021 -03A Assigning piston to cylinder bore
Test data of pistons

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE03.10-N-1001-02B Piston 0 Group marking BA mm 101.781-101.790 101.781-101.790
BC mm 101.790-101.799 101.790-101.799
BE03.10-N-1002-02B Piston compression Standard 102 BA mm 64.36-64.40 64.36-64.40

height
102 BC mm 64.36-64.40 64 36-64 40
Undersize 1 102 BA-0.3 mm 64.06-64.10 64.06-64.10
102 BC-0.3 mm 64.06-64.10 64.06-64.10
Undersize II 102 BA-0.6 mm 63.76-63.80 63.76-63.80
102 BC-0.6 mm 63.76-63.80 63.76-63.80
Undersize III 102 BA-0.9 mm 63.46-63.50 63.46-63.50
102 BC-0.9 mm 63.46-63.50 63.46-63.50
Tolerance group marking on piston

Assign piston (piston 0 and compression height marking, see arrow) to the corresponding
cylinder bore 0 and crankcase height.
Piston 0 Cylinder bore 0

BA A or B
BC Bo rC
Piston 0 and > C ra n k ca se h e ig h t

compression height
BA or BC -> Standard
BA -0.3 or BC -0.3 - undersize-0.3
B A -0.6 or BC -0.6 undersize-0.6
B A -0.9 or BC -0.9 -> undersize-0.9
AR03.10-W-7041-01A Measuring piston projection
Test data of pistons

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE03.10-N-1003-02B Piston projection in TDC mm 0,28-0,50 0,28-0,50

relative to top edge of
crankcase
m
Measure projection between piston crown and contact surface of crankcase without
cylinder head gasket fitted on.
The measurement has to be carried out in the direction of the piston pin in order to
eliminate the piston rock.
1 Rotate crankshaft until the piston to be measured is positioned approx. 5 mm before

TDC.
2 I S Attach dial gage (1) in the S measuring bridge (2) with a preload.
3 S Mount measuring bridge (2) onto the contact surface of the crankcase (arrows) and W 0 3 .10-0031-01
set scale of dial gage to "0 '.
Move [Sj measuring bridge (2) from the contact surface of the crankcase over the
cylinder bore.
m
Pull back tracer pin on HQ dial gage (1) when moving measuring bridge.
Rotate crankshaft until the piston to be measured is at TDC.
Measuring pin of S dial gage (1) is pushed back by the piston crown; the reading
obtained is the piston projection.
10
AR03.10-W-7311A Removing, installing piston rings 17.7.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 Z922/923

ENGINE 904.9081923 in MODEL 668,670
7 Keystone piston ring (groove 1)

2 Taper face piston ring with internal
angle (groove II)
3 Double cham fered oil control ring
with garter spring (groove III)
3.1 Carter spring
4 Piston
5 S Pliers
6 13Feeler gage
W03.10-0032-06
m um R e m o v in g , in sta llin g
1 Remove piston (4) Page 3

2 Remove piston rings (1,2,3) in the order s 000 589 37 37 00
fro m to p to b o tto m GO installation: marking " i u p ' should
face toward piston crown.
The piston rings have to be inspected
visually for spalling of the coating before
re-installing and after installing; if
necessary j
replace piston rings.
3 Measure piston ring gap clearance of Insert piston rings in the unworn area BE03.10-N-1001-05B
piston rings (1,2) (above reversal point of 1st piston ring) of
the cylinder wall or cylinder liner and
measure gap clearance.
SS Feeler gage WH58.30-Z-1008-12A
4 Measure piston ring gap clearance of the Remove garter spring (3.1) from the piston BE03.10-N-1001-05B
piston ring (3) ring.
Insert piston ring in the unworn area
(above reversal point of 1st piston ring) of
the cylinder wall or cylinder liner and
measure gap clearance.
E Feeler gage WH58.30-Z-1008-12A
E Installation: install garter spring (3.1)

In to th e p isto n ring.
Garter spring joint should be positioned
offset 180 relative to piston ring joint.

Test data of piston rings

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE03.10-N-1001-05B Max. piston ring Groove I when new mm 0.35-0.55 0.35-0.55

gap clearance
Keystone ring wear limit mm 1.0 1.0
Groove II when new mm 0.40-0.60 0.40-0.60
taper face ring wear limit mm 1.0 1.0

with internal
angle
Groove III when new mm 0.25-0.50 0.25-0.50
Double wear limit mm 1.0 1.0

chamfered oil
control ring with
garter spring
WH58.30-Z-1008-12A Feeler gage Stiefelmayer 59

D-73734 Esslingen
12
AR03.10-W-6111A Inspecting, repairing conrod 21.11.95
ENGINE 904.905/906/907/908/909/910/911 /921Z922/923,906.910/911 /920/921 /922/923 /940/941
1 Conrod
4 Conrod bolt
5 Conrod bush
1 Conrod
5 Conrod bush
6 H j Dial gauge
7 I S Dial gauge holder
A Distance from conrod bearing bore to

conrad bush bore
B Permissible difference in axial
parallelism between conrod bearing
bore and conrod bush bore, related to
distance measured
C Distance measured
S3 Removing
1 Remove piston Page 3
0 Inspecting
2 Inspect conrod (1) for blue discoloration, H I Conrod with blue discoloration (caused
cross scores and notches by bearing damage), with cross scores or
notches must not be reused.
3 Inspect inner diameter of conrod bush (5) Wi 001 589 53 21 00

m WH58.30-Z-1004-12A
H ] If value was exceeded j BE03.10-N-1012-01B
replace conrod.
4 Inspect con rod (1) for twisting and m WH58.30-Z-1023-12A

dimensional tolerance
Measure distance (dimension A) from BE03.10-N-1015-01B

conrod bearing seat to conrad bush inner
diameter on both sides; if value was
exceeded J,
replace conrod.
Measure permissible difference BE03.10-N-1004-01B

(dimension B) of axial parallelism between
conrod bearing seat and conrod bush inner
diameter to measured distance
(dimension C); if value was exceeded |
replace conrad.
Conrod must not be straightened.
5 Install conrod bearing shells (3), 00 Engines have different conrod bearing Page 17
gage shells in the conrod bearing cap and
conrod. Pay attention to abbreviated part
number on the rear of the conrod bearing
shell halves.
Conrod bearing inner 0 BE03.10-N-1001-01B
Basic bore 0 BE03.10-N-1002-01B
Lon rod bearing radial play BE03.10-N-1003-01B
Permissible out-of -roundness of B E03.10-N-1006-01B

basic bores
Conrod bolt shank length (L) BE03.10-N-1014-01B
Conrod bearing journal 0 BE03.20-N -1004-02B

@ BA03.10-N-1001-01B
El 001 589 53 21 00
WH5B.30-Z-1006-12A
m WH58.30-Z-1009-12A
6 Calculate axial clearance of conrod bearing Conrod bearing axial play BE03.10-N-1003-01B
Conrod width BE03.10-N-1008-01B
Conrod bearing journal width BE03.20-N-1005-02B
m Installing
7 Install piston Page 3
14
Test data of conrod

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE03.10-N-1001-01B Conrod bearing inner 0 with conrod Standard mm 70.054-70.093 70.054-70.093

bearing shells inserted
Undersize 0.25 mm 69.804-69.843 69.804-69.843
Undersize 0.5 mm 69.554-69.593 69.554-69.593
U ndersize 0.75 mm 69.304 69.343 69.304-69.343
Undersize 1.0 mm 69.054-69.093 69.054-69.093
BE03.10-N-1002-01B Basic bore 0 for conrod bearings mm 75.000-75.019 75.000-75.019
BE03.10-N-1003-01B Conrod bearing play radial mm 0.039-0.098 0.039-0.098
axial mm 0.170-0.470 0.170-0.470
BE03.10-N-1004-01B Permissible difference of axial max. mm 0.025 0.025

parallelism between conrod bearing
and conrod bush bore over a length
of 50 mm
BtU3.10-N-l U06-01B Perm issible o u t-of-roundness o f b a conrod bearing mm 0.008 0.0U8

sic bores
Conrod bush mm 0.006 0.006
BE03.10-N-1008-01B Conrod width mm 33.730-34.830 33.730-34.830
BE03.10-N-1012-01B Conrod bush inner 0 mm 40.03-40.04 40.03-40.04
Shank length (L) when mm 56.0 56.0

new
Shank length (L) max. mm 57.0 57.0
Fig. see - -
BE03.10-N-1015-01B Distance from conrod bearing seat mm 157.510-157.445 157.510-157.445

to conrod bush inner diameter
Test data of crankshaft

906/907/909/910 923
/911/921/922,
BE03.20-N-1004-02B Conrod bearing journal 0 Standard mm 69.995-70.015 69.995-70.015
Undersize-0.25 mm 69.745-69.765 69.745-69.765
Undersize-0.5 mm 69.495-69.515 69.495-69.515
Undersize-0.75 mm 69.245-69.265 69.245-69.265
Undersize-1.0 mm 68.995-69.015 68.995-69.015
BE03.20-N-1005-02B Conrod bearing journal width mm 34.0-34.2 34.0-34.2

906.910/911/920/
921/922/923/940
/941
B E03.20-N-1004-02B Conrod bearing journal 0 Standard mm 69.995-70.015
Undersize-O .Z3 mm 09.743-09.705
Undersize-0.5 mm 69.495-69.515
Undersize-0.75 mm 69.245-69.265
Undersize-1.0 mm 68.995-69.015
BE03.20-N-100S-02B Conrod bearing journal width mm 34.0-34.2
@ Conrod

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BA03.10-NI-1001-01B Conrod bearing cap to conrod 1st stage Nm 10 10
2nd stage Nm 45 45
3rd stage 90 90
WH5B.30-Z-1004-12A Quick calipers for internal measurements, 0 40 - 60 mm
WH58.30-Z-1006-12A Micrometer 50 - 75 mm Hahn und Kolb 31400 005

Borsigstr. 50
D-70469 S tu ttg a rt
WH58.30-Z-1009-12A Quick calipers for internal measurements, 0 100- 120 mm
WH58.30-Z-1023-12A Caliper gage with round scale Hahn und Kolb 31 165
Borsigstr. 30
D-70469 Stuttgart
16
AR03.10-W-6111-06A Installing, gaging conrod bearings
Test data of conrod

906/907/909/ 923
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE03.10-N-1001-01B Conrod bearing inner 0 with Standard mm 70.054-70.093 70.054-70.093

conrod bearing shells Inserted
Undersize 0.25 mm 69.804-69.843 69.804-69.843
Undersize 0.5 mm 69.554-69.593 69.554-69.593
Undersize 0.75 mm 69.304-69.343 69.304-69.343
Undersize 1.0 mm 69.054-69.093 69.054-69.093
BE03.10-N-1002-01B Basic bore 0 for conrod bearings mm 75.000-75.019 75.000-75.019
BE03.10-N-1003-01B Conrod bearing play radial mm 0.039-0.098 0.039-0.098
axial mm 0.170-0.470 0.170-0.470
BE03.10-N-1006-01B Permissible out-of-roundness of ba Conrod bearing mm 0.008 0.008

sic bores
Conrod bush mm 0.006 0.006

when new
Fig. see - -

906/907/909/910 923
/911/921/922
B E 03.20-N -1 0 0 4 -0 2 B C o n ro d b e a rin g jo u rn a l 0 S ta n d ard m m 69.995-70.015 69.995-70.015
Undersize-0.25 mm 69.745-69.765 69.745-69.765
Undersize-0.5 mm 69.495-69,515 69.495-69.515
Undersize-0.75 mm 69.245-69.265 69.245-69.265
Undersize-1.0 mm 68.995-69.015 68.995-69.015

906.910/911/920/
921/922/923/940
/941
BE03.20-N-1004-02B Conrod bearing journal 0 Standard mm 69.995-70.015
Undersize-0.25 mm 69.745-69.765
Undersize-0.5 mm 69.495-69.515
U nd ersiz e -0.75 mm 69.245-69.265
Undersize-1.0 mm 68.995-69.015

0 Conrod
Number Designation Engines 904.905/ Engine

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BA03.10-N-1001-01B Conrod bearing cap 1st stage Nm 10 10

to conrod
2nd stage Nm 45 45
3rd stage 90 90
C o m m e rc ia lly a v a ila b le to o ls (see w o r k s h o p tq u ip m e n t M a n u a l)
WH58.30-Z-1006-12A 50-75 mm micrometer Hahn und Kolb

Borsigstr. 50
D-70469 Stuttgart
WH58.30-Z-1009-12A Quick calipers for internal measurements, 0 100-120mm
1 Measure conrod bearing journal with the micrometer at two points (vertically and at
an angle of about 90) and note measurements. Calculate the average of the conrod
bearing journal diameter from these two measurements.
2 Clean bearing points of the conrod and the conrod bearing cap with a chamois leather.
W 0 3 .10-0033-01
18
3 Insert conrod bearing shells (3) into the conrod and the conrod bearing cap (2).
E Pay attention to marking on conrod bearing shells (3) and code numbers of conrod
relative to conrod bearing cap (2).
Conrod and conrod bearing cap (2) have different conrod bearing shells (3).
Pay attention to abbreviated part number on the rear of the conrod bearing shell
halves.
If the conrod bearings are replaced, install conrod bearing shells (3) of the matching
installation stage; pay attention to measured conrod bearing journal diameter.
Locking lugs (arrows) of the conrod bearing shells should be located in the slots of the
basic bore of the conrod bearing cap (2) and of the conrod.
W 0 3 .10-0002-01
4 Fit conrod bearing cap (2) to fit exactly onto the conrod.
@ Code numbers on conrod and on conrod bearing cap (2) should agree and be
positioned on the one side. The cracked contact surface must not be damaged.
5 0 Lightly oil the thread and contact surface of bolt head of conrod bolt (4) and
tighten with wrench bit.
m Press against conrod bearing cap (2) by hand at the conrod when screwing in the
conrod bolt (4).
Clamp conrod just below the conrod bearing in order to prevent it turning.
6 Set dial gauge and quick calipers with the micrometer to the measurement calculated
beforehand (average) of the conrod bearing journal diameter (preload 5 mm)
7 Measure conrod bearing bore at three points (A, B, C) (vertically and each about 30
away from the separation points, up and down) with dial gauge and quick calipers.
Note measurements.
m If one of the measurements obtained is not to tolerance, replace conrod bearing

shells. Conrod bearing shells are factory-supplied ready for installation. It is not
permitted to carry out any machining.
8 Remove conrod bearing cap (2) again.
@ Never bolt conrod bearing cap (2) tight to conrod without the conrod bearing shells
(3) inserted, only position against conrod.
The shank length of the conrod bolts (4) should be measured before re-installing.
AR03.20-W-3000A Replacing front crankshaft radial seal 6.11.95
ENGINE 904.905/906/907/909/910/911 /921 /922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 in MODEL 668. 670
W 03.20 0032-09
1 V ib ra tio n d a m p e r 5 E l G uide sleeve

2 Radial seal 6 H Drift
3 S23Puller
4 Self-tapping screws A Am ount by which radial seal stands back relative to oil pump
housing
IS) Removing
1 Remove vibration damper (1) Engine 904.905- 907/909- 911 /921 /922 and Page 42
906.910/911/920- 923/940/941
Engine 904.908/923 AR03.30-D-1600D

L Attach puller (3) with three self-tapping m 904 589 00 33 00
screws ( 0 3.2 mm) (4) at radial seal (2) HI Three holes are provided on the radial
seal. These are covered with plastic. The
position of the holes can be recognized
from the three recesses (arrows) of the felt
cover.
3 Pull off radial seal (2) 904 589 00 33 00
m Inspecting
4 Inspect contact surface at crankshaft for tSIf wear is present, a radial seal with race
scores or traces of wear will be available shortly for repairs.
m Installing
5 Fit guide sleeve (5) onto the crankshaft and Q] Sealing lip of radial seal should point
push radial seal (2) over the guide sleeve (5) toward oil pump at the guide sleeve.
904 589 021500
20
6 Press radial seal (2) into the oil pump LlJPress in radial seal dry. parallel to the
axis and evenly around the entire
circumference. Pay attention to installation
po sition a n d setb ack (A ) o f 1-5 m m . Do n o t
damage radial seal when installing.
u 904 589 02 15 00
7 Install v ib ra tio n d a m p e r (1) E n g in e 904.905 907/909 911 /921/922 and P a g e 42

906.910/911 /920- 923/940/941
Engine 904.908/923 AR03.30-D-1600D
904 589 00 33 00
y V
Puller
8 ^ ^ Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 21
AR03.20-W-3063A Replacing rear crankshaft radial seal 6.11.95
ENGINE 9 0 4 .9 0 5 /9 0 6 /9 0 7 /9 0 9 /9 1 0 /9 1 1 /9 2 1 /922, 906.910/911/920/921 Z922/923

EN G IN E 9 0 4 .9 0 0 /9 2 3 in M O D E L 66 0, 6 7 0
1 Flywheel
2 Radial seal
3 I S D rift
W03.20-0033-06
Operation no. of operation texts or standard texts and flat rates
Sector Op. no. Operation text
F, T, S 03-3059 Rear crankshaft seal
m Removing
1 Remove flywheel (1) Page 45
2 Press out radial seal (2) @ Cover over crankshaft with a cleaning
rag as a protection.
kl Inspecting
3 Inspect contact surface on flywheel for 5 ] if wear is present, a radial seal with race
scores or signs of wear will shortly be available for repairs.
II Installing
4 Fit on radial seal (2) at timing case and [D Press in radial seat dry, parallel to axis
press in and evenly around the entire
circumference. Pay attention to installation
position of radial seal. Do not damage
radial seal when installing.
I Drift must be positioned at crankshaft

flange. Inspect sealing lip on radial seal
after installing to ensure it is correctly
positioned.
904 589 0315 00
5 Install flywheel (1) Page 45
22
AR03.20-W-4351 A Removing, installing crankshaft 21.11.95
ENGINE 904.905/906/907/908/909/910/911/921/922/923,906.910/911/920/921/922/923/940/941
1 Crankshaft
2 Top crankshaft bearing shell
3 Bottom crankshaft bearing shell
4 Thrust washer (fit bearing)
5 Main bearing cap
6 Main bearing cap (fit bearing)
7 M ain bearing cap bolt
8 Crankshaft gear
9 Pin
WOB.20-0038-06
i Crankshaft 7 M ain bearing cap bolt shank length (L)

2 Top crankshaft bearing shell 8 C ra n k s h a ft g e a r
3 Bottom crankshaft bearing shell 10 Camshaft gear
4 Thrust washers (fit bearing) 11 IS Dial gage
5 Main bearing cap 12 I S Dial gage holder
6 Main bearing cap (fit bearing)
m Removing
24
1 Remove engine Engine 904.905-907/921 AR01.10-W-2401A
Engine 904.908/923 AR01.10-D-2400D
Engine 904.909-911/922 AR01.10-W-2400D
Engine 906.920-923 AR01.10-W-2400F
Engine 906.940/941 AR01.10-W-2400C
2 Remove pistons Page 3

3 Remove oil pump AR18.10-W-6020A
4 Remove timing case Engine 904.905- 911/908/921/922/923, AR01.60-W-8200A

906.910/911 /920- 923/940/941
Engine 906.920- 923 with timing case SAE 1 AR01.60-W-8200F

or 2, prepared for engine output or
installed engine output
5 Pull crankshaft gear (8) off crankshaft

flange
6 R em o v e m a in b e a rin g caps (5, 6) H I M a r k th e o rd e r o f th e m ain hearing

caps
Engine 904:
the thrust washers of the fit bearing (4) are
installed at the 5th main bearing cap
Engine 906:
the thrust washers of the fit bearing (4) are
installed at the 7th main bearing cap
7 Take off crankshaft bearing shells (3) OD Mark crankshaft bearing shells to the
relative main bearing cap (5,6)
8 Use a tackle to lift crankshaft (1) out of the GD Attach tackle to the crankshaft using
crankcase existing bolts of the belt pulley and of the
flywheel
9 Take out crankshaft bearing shells (2) H Mark crankshaft bearing shells relative
to crankcase
10 Measure crankshaft and insert in bearings Page 30

mi Installing
h Install crankshaft (1) with a tackle
12 Measure main bearing bolts (7) Q j If the shank length (L) was exceeded J. BE01.40-N-1010-02B
rep la ce m ain b e arin g bolts.
13 Install main bearing cap (5) H All main bearing caps are fitted into the
crankcase at the side (off-centered) and
marked with numbers (arrows).
The main bearing caps should be installed
in accordance with the numbers beginning
at the front of the crankcase in ascending
order and must not be mixed up.
Oil main bearing bolts.
0 Main bearing bolts for main bearing BA01.40-N-1001-01C

caps to crankcase
14 Determine thickness of fit bearing thrust Page 28

washers and install main bearing cap (6)
Fit bearing journal width BE03.20-N-1002-02B
Axial play BE03.20-N-1006-02B
Wall thickness of fit bearing thrust washers BE03.20-N-1016-02B

0 Main bearing bolts for main bearing BA01.40-N-1001-01C
caps to crankcase
001 589 53 21 00
u 363 58902 2100
15 Attach crankshaft gear (8) to crankshaft SI Push on crankshaft gear; the marking
flange 1" on the crankshaft gear should be
positioned between the markings 1-1 of
the camshaft gear (10)
16 M o u n t co m od in b e aring s a n d install P a g e 13
17 Install pistons Page 3

18 Install oil pump AR18.10-W-6020A
19 Install timing case Engine 904.905- 911 /908/921/922/923, AR01-60-W-8200A

906.910/911/920- 923/940/941

or 2 , prepared for engine output or
20 Replace oil filter element Engine 904.905- 907/921 WH0101.40
Engine 904.908/923 AP18.00-D-0101A
Engine 904.909- 911/922 and AP18.00-W-0101B

906.910/911/920- 923/940/941
21 Replace oil-water heat exchanger @ Only in the case of material abrasion AR18.30-W-6840A
22 Install engine Engine 904.905- 907/921 A R01.10-W-2401A
Engine 904.908/923 AR01.10-D-2400D
Engine 904.909-911/922 ARQ1.1Q-W-24QQD
Engine 906.920- 923 AR01.10-W-2400F
En g in e 906.940/941 A R 0 1.10 W 2400C
23 Fill engine oil circuit AR18.Q0-W-1600A

906/907/909/910 923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BEm 40-N-1M0-01R M a in h e a rin g ra p h n lt* T h rea d QS M 14 14

when new
Fig.see - -
26

906/907/909/910 923
/911/921/922
6 E03.20-N-1002-026 Fit bearing journal width Standard mm 31.000-31.062 31.000-31.062
Oversize -0,3 mm 31.300-31.362 31.300-31.362
Oversize -0.5 mm 31.500-31.562 31.500-31.562
B E03.20-N-1006-02B Axial play mm 0.16-0.38 0.16-0.38
BE03.20-N-1016-02B Wall thickness of fit bearing thrust washers Standard mm 3.240-3.300 3.240-3.300
Oversize 0.3 mm 3.540-3.600 3.540-3.600
Oversize 0.5 mm 3.740-3.800 3.740-3.800

906.910/911/920/
921/922/923/940
/941
BE03.20-N-1002-02B Fit-bearing journal width Standard mm 31.000-31.062
O ve rsiz e 0.3 mm 31.300-31.362
Oversize-0.5 mm 31.500-31.562
BE03.20-N-1006-02B Axial clearance mm 0.16-0.38
BE03.20-N-1016-02B Fit-bearing thrust washers wall thickness Standard mm 3.240-3.300
Oversize 0.3 mm 3.540-3.600
Oversize 0.5 mm 3.740-3.800
Num ber D e sig n a tio n E n g in e E n g in e 304.905/

904.904/ 906/907/909/910
908/923 /911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.40-N-1001-01C Bolt of main bearing cap to 1st stage Nm 30 30

crankcase
2nd stage Nm 80 80
4th stage 90 90
AR03.20-W-4351-01B Determining thickness of fit bearing thrust
washers of crankshaft

906/907/909/910 923
/911/921/922
BE03.20-N-1002-02B Fit bearing journal width Standard mm 31.000-31.062 31.000-31.062
Ovprcbe -0.3 mm 31.300-31.367 31 300-31 367
Oversize-0.5 mm 31.500-31.562 31.500-31.562
BE03.20-N-1006-02B Axial play mm 0.16-0.38 0.16-0.38
BE03.20-N-1016-02B Fit bearing thrust washer wall thickness Standard mm 3.240-3.300 3.240-3.300
Oversize 0.3 mm 3.540-3.600 3.540-3.600
Oversize Q.5 TOTO 3.74Q-3CK1 3.14/1- i . e m

906.910/911/920/
921/922/923/940
/941
BE03.20-N-1002-02B Fit bearing journal width Standard mm 31.000-31.062
Oversize -0.3 mm 31.300-31.362
Oversize -0.5 mm 31.500-31.562
BE03.20-N-1006-02B A x ia l p lay mTO
BE03.20-N-1016-02B Fit bearing thrust washer wall thickness Standard mm 3.240-3.300
O versize 0.3 mm 3.540-3.600
Oversize 0.5 mm 3.740-3.800

904.904/ 906/907/909/910
908/923 /911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.40-N-1001-01C Bolt of main bearing cap to 1st stage Nm 30 30

crankcase
2nd stge Nm 80 80
3rd stag e Nm 155 155
4th stage A 90 90
28
363 589 02 21 00
Dial gage Dial gage holder
1 Measure fit bearing journal width (A) of crankshafts (1) and assign thrust washers to
match the installation stage measured.
m
The dimensions of the installation stages stated in the table have to be adhered to.
Thrust washers are factory-supplied ready for installation and also in oversizes for
repairs. It is not permitted to carry out any reworking.
2 Oil thrust washers (2) and insert into the grooves on the main bearing cap (fit bearing)
(3).
a
Only thrust washers (2) of the same wall thickness may be installed. Both oil grooves
(arrows) in the thrust washers should point toward the crankshaft webs.
3 @ Install main bearing cap (fit bearing) (3).
m
Oil main bearing bolts.
The main bearing cap is fitted into the crankcase at the side (off-centered) and marked
with numbers (arrow).
4 Rotate crankshaft by hand and inspect for ease of movement. ----- o 1
\NQ__ ~~
is s
W03.20-0036-01
5 Attach I S dial gage holder (4) and IS dial gage (5) to the crankcase with a preload. -------- \ e b------ rP r r v r r r
6 Move crankshaft (1) from stop to stop and read off measurement (axial play).
E The axial play must not be greater than the stated figure.
W03.20-0037-01
AR03.20-W-4355B Measuring and mounting crankshaft 13.6.97
ENGINE 904.905/906 /907/908/909/910/911/921 /922 /923,906.910/911 /920/921 /922 /923/940/941
W03.20-0042-09
J Crankshaft A Main bearing journal 0
2 S Drop hardness tester B Fit bearing journal width
3 IS M ic ro m e te r C M a in b e arin g jo u rn a l w id th
4 Main bearing cap D Conrod bearing journal 0
5 Main bearing bolt E Conrod bearing journal width
F Fillet radii o f main, conrod bearing journals
G Ci o w n o f m ain, c o n ro d beat ing jo u rn a ls
H Main bearing inner 0 when installed
1 Crankshaft
7 I S Dial gage
8 IS Dial gage holder
W03.20-0043-05
m Inspecting
1 Remove crankshaft Page 24

2 Clean crankshaft
30
3 Inspect crankshaft flange at front for wear S3 If wear is present, a radial seal with race
will shortly be available for repairs
4 Inspect main, conrod bearing journals for S3 Damage or cracks present J

signs of damage and cracks
Replace crankshaft.
5 Test hardness of main and conrod bearing IS 000 589 20 21 00

journals with drop hardness tester (2)
ED A base has to be placed below the BE03.20-N-1013-02B

bearing journal to be inspected for the
test. The hardness should be achieved at at
least two-thirds of the circumference of the
bearing journal.
If hardness is not achieved j
re-harden or replace crankshaft.
6 Measure radial runout of crankshaft (1) S3 Measured at middle main bearing BE03.20-N-1011-02B
journal, mounted on outer main bearing
journals.
IS 001 589 53 21 00
IS 363 589 02 21 00
7 Measure main, conrod bearing journals Measure main bearing journal 0 (A) at two BE03.20-N-1001-02B
points (offset approx. 90) with the
micrometer.
IES Micrometer WH58.30-Z-1013-12A
Main and conrod bearing journals BE03.20-N-1008-02B

permissible difference of out-of-roundness
Permissible conicity at main bearing BE03.20-N-1009-02B

journal and at conrod bearing journals
Permissible lateral runout at fit bearing BE03.20-N-1010-02B

journal
Main bearing journal width (C) BE03.20-N-1003-02B
Fit bearing journal width (B) BE03.20-N-1002-02B
Measure conrod bearing journal 0 (D) at BE03.20-N-1004-02B

two points (offset approx. 90) with
micrometer
SS Micrometer WH 58.30-Z-1006-12A
Conrod bearing journal width (E) BE03.20-N-1005-02B
Fillet radii (F) of main and conrod bearing BE03.20-N-1012-02B

jo u rn als
Crown (G) of main and conrod bearing BE03.20-N-1014-02B

journals
[3 If d a m a g e a n d w e a r p re sen t J,
machine crankshaft to next undersize.
Engine 904 BE03.20-N-1019-02B

Permissible Imbalance of crankshaft (with
pin for fixing flywheel but without
flywheel), mounted on the outer main
bearings.
Engine 906 B E03.20-N-1022-02B
Permissible imbalance of crankshaft (with
p in fo r fix in g fly w h e e l b u t w ith o u t
flywheel), mounted on main bearings two
and six.
Mounting in bearings
8 Mount crankshaft (1) radially Page 37

Main bearing journal 0 (A) BE03.20-N-1001-02B
Crankshaft main bearing inner 0 (H) when BE03.20-N-1015-02B

installed
@ Main bearing bolts for main bearing BA01.40-N-1001-01C

caps to crankcase
IS 001 589 53 21 00
I S Quick calipers WH58.30-Z-1001-12A
I S Micrometer WH58.30-Z-1013-12A
9 Install crankshaft (1) Page 24
32

906/907/909/910 923
/911/921/922
BE03.20-N-1001-02B Main bearing journal 0 Standard mm 85.990-86.010 85.990-86.010
Undersize -0.1 mm 85.890-85.910 85.890-85.910
Undersize-0.25 mm 85.740-85.760 85.740-85.760
Undersize-0.5 mm 85.490-85.510 85.490-85.510
Undersize-0.75 mm 85.240-85.260 85.240-85.260
U n d e rs iz e -1.0 mm 84.990-85.010 84.990-85.010
BE03.20-N-1002-02B Fit bearing journal width Standard mm 31.000-31.062 31.000-31.062
Undersize-0.3 mm 31.300-31.362 31.300-31.362
Undersize-0.5 mm 31.500-31.562 31.500-31.562
BE03.20-N-1003-02B Main bearing journal width mm 31.0-31.2 31.0-31.2
BE03.20-N-1004-02B Conrod bearing journal 0 S ta n d a rd mm 69.995-70.015 69.995-70.015
Undersize-0.1 mm 69.895-69.915 69.895-69.910
Undersize-0.25 mm 69.745-69.765 69.745-69.765
Undersize-0.5 mm 69.495-69.515 69.495-69.515
Undersize-0.75 mm 69.245-69.265 69.245-69.265
Undersize-1.0 mm 68.995-69.015 68.995-69.015
BE03.20-N-1 005-02B Conrod bearing journal width mm 34.0-34.2 34.0-34.2
BE03.20-N-1008-02B Main and conrod bearing journals Limit mm 0.005 0.005

permissible difference of out-of-roundness
BE03.20-N-1009-02B Permissible coniclty Main bearing mm 0.005 0.005

journals
Conrod bearing mm 0.005 0.005

journals
BE03.20-N-1010-02B Permissible lateral runout Fit bearing mm 0.015 0.015

journals
BE03.20-N-1011-02B Radial runout measured at middle main mm 0.11 0.11

bearing journal (mounted on outer main
bearing journals)
B E 03 .2 0 -N -1 01 2-02B F ille t radii M a in be arin g mm 2.5-3.0 2.5-3.0

journals
Conrod bearing mm 2.5-3.0 2.5-3.0

journals
B E03.20-N-1013-02B Hardness of main bearing and conrod bea min. HRC 52 52

ring journals (Rockwell hardness)
BE03.20-N-1014-02B Crown Main bearing mm 0.000-0.004 0.000-0.004

journals
Conrod bearing mm 0.000-0.004 0.000-0.004

journals
Test data or crankshaft

906/907/909/910 923
/911/921/922
BE03.20-N-1015-02B Main bearing inner 0 Standard mm 86.066-86.108 86.066-86.108
Undersize 0.1 mm 85.966-86.008 85.966-86.008
Undersize 0.25 mm 85.816-85.858 85.816-85.858
Undersize 0.5 mm 85.566-85.608 85.566-85.608
Undersize 0.75 mm 85.316-85.358 85.316-85.358
Undersize 1.0 mm 85.066-85.108 85.066-85.108
BE03.20-N-1019-02B Permissible imbalance of crankshaft (with gem 30 30

flywheel), mounted on outer main bea
rings
34

906.910/911/920/
921/922/923/940
/941
BE03.20-N-1001-02B Main bearing journal 0 Standard mm 85.990-86.010
Undersize-0.1 mm 85.890-85.910
Undersize-0.25 mm 85.740-85.760
Undersize-0.5 mm 85.490-85.510
Undersize -0.75 mm 85.240-85.260
Undersize-1.0 mm 84.990-85.010
BE03.20-N-1002-02B Fit bearing journal width Standard mm 31.000-31.062
Undersize-0.3 mm 31.300-31.362
Undersize-0.5 mm 31.500-31.562
BE03.20-N-1003-02B Main bearing journal width mm 31.0-31.2
B E03.20-N-1004-02B Conrod bearing journal 0 Standard mm 69.995-70.015
Undersize-0.1 mm 69.895-69.915
Undersize-0.25 mm 69.745-69.765
Undersize-0.5 mm 69.495-69.515
Undersize-0.75 mm 69.245-69.265
U nd er siê-1.0 nun 68.995-69.015
BE03.20-N-1005-02B Conrod bearing journal width mm 34.0-34.2
B E03.20-N-1008-02B Main and conrod bearing journals Limit mm 0.005

perm issible d iffe re n c e o f out-of-roundness
BE03.20-N-1009-02B Permissible conicity Main bearing mm 0.005

journals
conrod bearing mm 0.005

journals
BE03.20-N-1010-02B Permissible lateral runout Fit bearing mm 0.015

journals
BE03.20-N-1011-02B Radial runout measured at middle main mm 0.15

bearing journal (mounted on outer main
bearing journals)
BE03.20-N-1012-02B Fillet radii Main bearing mm 2.5-3.0

journals
Conrod bearing mm 2.5-3.0

journals
BE03.20-N-1013-02B Hardness of main bearing and conrod bea min. HRC 52

ring journals (Rockwell hardness)
BE03.20-N-1014-02B Crown Main bearing mm 0.000-0.004

journals
Conrod bearing mm 0.000-0.004

journals

906.910/911/920/
921/922/923/940
/941
E03.20-N-1015-02B Main bearing inner 0 Standard mm 86.066-86.108
U nd ersize 0.1 mm 85.966-86.008
Undersize 0.25 mm 85.816-85.858
Undersize 0.5 mm 85.566-85.608
Undersize 0.75 mm 85.316-85.358
Undersize 1.0 mm 85.066-85.108
BE03.20-N-1022-02B Permissible imbalance of crankshaft (with gem 30

flywheel), mounted on main bearings two
and six
@ Crankcase, timing case cover, end cover

904.904/ 906/907/909/910
908/923 /911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.40-N-1001 -01C Bolt of main bearing cap to 1st stage Nm 30 30

crankcase
2nd stage Nm 80 80
4th stage 90 90
W H S S .3 0 -Z -1 0 0 6 -1 2 A M ic ro m e te r 50-75 m m
WH58.30-Z-1013-12A Micrometer 75-100 mm
36
AR03.20-W-43 55-01B Positioning crankshaft in mounts radially

906/907/909/910 923
/911/921/922
BE03.20-N-1001-02B Main bearing journal 0 Standard mm 85.990-86.010 85.990-86.010
Undersize -Q._l p/i cS5185-85.910

umwrtize-0.25 mm 85JZ4O-85.760 85.740-85.760
Undersize-0.5 mm 85.490-85.510 85.490-85.510
Undersize-0.75 mm 85.240-85.260 85.240-85.260
Undersize-1.0 mm 84.990-85.010 84.990-85.010
BE03.20-N-1015-02B Main bearing inner 0 Standard mm 86.066-86.108 86.066-86.108
Undersize 0.1 mm 85.966-86.008 85.966-86.008
Undersize 0.25 mm 85.816-85.858 85.816-85.858
Undersize 0.5 mm 85.566-85.608 85.566-85.608
Undersize 0.75 mm 85.316-85.358 85.316-85.358
Undersize 1.0 mm 85.066-85.108 85.066-85.108

906.910/911/920/
921/922/923/940
/941
BE03.20-N-1001-02B Main bearing journal 0 Standard mm 85.990-86.010
Undersize-0.1 mm 85.890-85.910
Undersize-0.25 mm 85.740-85.760
Undersize-0.5 mm 85.490-85.510
Undersize-0.75 mm 85.240-85.260
Undersize-1.0 mm 84.990-85.010
BE03.20-N-1015-02B Main bearing inner 0 Standard mm 86.066-86.108
Undersize 0.1 mm 85.966-86.008
Undersize 0.25 mm 85.816-85.858
Undersize 0.5 mm 85.566-85.608
Undersize 0.75 mm 85.316-85.358
Undersize 1.0 mm 85.066-85.108
S Crankcase, timing case cover, end cover

904.904/ 906/907/909/910
908/923 /911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.40-N-1001-01C Bolt of main bearing cap to crancase 1st stage Nm 30 30
2nd stage Nm 80 80

4th stage *4 90 90
WH58.30-Z-1013-12A Micrometer 75 -100 mm
1 Clean bearing points of the crankshaft with a chamois leather.
2 Measure main bearing journal 0 (D) at two points (offset approx. 90) with the I S
m ic ro m e te r.
a
The figures stated in the table should be adhered to. If one of the measurements
obtained is beyond the tolerance, machine crankshaft.
38
3 Clean bearing points in the crankcase and main bearing cap with a chamois leather.
4 Insert crankshaft bearing shells (2) into the crankcase in the order marked.
e
The locking lugs (a r r o w ) o f th e cra n k sh a ft b e arin g shells (2) should b e lo cated in th e
slots of the crankcase basic bores. Oil drillings in the crankshaft bearing shell (2) and
crankcase should be aligned.
5 Insert cra n k sh a ft b e a rin g shells (1) In to t h e m ain b e a rin g caps (3, 4) in th e o rd ei

marked.
W03.20-0041-01
m
The locking lugs (arrows) of the crankshaft bearing shells (1) should be located in the
slots of the main bearing caps (3).
6 Attach main bearing caps (3,4) to the crankcase.
E
All the main bearing caps are fitted into the crankcase at the side (off-centered) and
marked with numbers (arrows).
They have to be installed in accordance with numbers beginning at the front of the
crankcase in ascending order and must not be mixed up.
Oil main bearing bolts (6).
W03.20-0004-01
7 Set dial gage and quick calipers with the micrometer to the nominal dimension of the
main bearing journal (preload 5 mm).
8 Measure crankshaft bearing bores in the crankwse at three points (A, B.C) (vertically
and each approx. 30 away from the separation points) with the dial gage and quick
calipers.
E
The figures stated In the table should be adhered to. If one of the readings obtained
(A, B, C) is not within the tolerance, replace main bearing shells in accordance with the
main bearing journals measured.
Main bearing shells are factory-supplied ready for installation and also in oversizes for W03.20-0005-01
repairs. It Is not permitted to carry out any reworking.
9 Take off main bearing caps (3,4) again.
AR03.20-W-4803A Removing, installing crankshaft sprocket 28.8.95
ENGINE 904.905/906/907/909/910/911/921/922,906.910/911/920/921/922/923
ENGINE 904.908/923 in MODEL 668, 670
1 Timing case
2 Crankshaft sprocket
3 Camshaft sprocket
W 03.20-0007-06
(S IIS I Removing, installing
1 Remove timing case (1) On engine 904.905- 911/908/921/922/923, AR01.60-W-8200A

906.910/911 /920- 923/940/941
On engine 906.920- 923 with timing case AR01.60-W-8200F

SAE 1 or 2, prepared for engine output or
in sta lled e n g in e uutpul
2 Rotate crankshaft 2] Until marking "1" on crankshaft

sprocket (2) is aligend with the marking
" 1-1" (arrow) on camshaft sprocket (3)
3 Pull crankshaft sprocket (2) off the cranks H I Installing: push crankshaft sprocket
haft over the dowel pin in the crankshaft.
The marking "1" on the crankshaft sproc
ket should be positioned between the mar
king 1-1" (arrow) on the camshaft sproc
ket.
4 Install in th e re ve rse o rd er
40
AR03.20-W-4841 A Removing, installing drive gear for oil pump on crankshaft 28.8.95
ENGINE 904.905/906/907/909/910/911 /921 /922,906.910/911 /920/921 /922/923

ENGINE 904.908/923 in MODEL 668, 670
1 Drive gear
2 Crankshaft
W 03.20-0006-10
Em u Removing, installing
1 Remove crankshaft Page 24
S Danger! Risk of injury to eyes and skin from Wear protective gloves, protective clothing Page 41
h a n d lin g h o t o r g lo w in g objects and, if necessary, eye p ro tectio n .
2 Pull drive gear (1) off the crankshaft (2) Heat drive gear to about 200 C.
CD Installing: heat new drive gear to
about 200 C and press onto the crankshaft.
Pay attention to installation position of
chamfer (arrow).
AS00.00-Z-0002-01A Risk of injury to skin and eyes from Wear heat resistant gloves, protective Danger!
handling hot or glowing objects clothing and protective goggles if
necessary
Injury hazard Protective measures/rules of behavior

C o n ta c t w ith h o t or g lo w in g o b jects w ith o u t suita b le p ro te c tive - W e a r p ro tec tive clo th in g , p ro te c tive g o g g le s an d h e at
clothing can cause severe burns to skin and eyes. resistant gloves.
When glowing objects make contact with water hot water vapor - Transport hot or glowing objects only with the aids provided
and droplets are produced which can lead to severe burns to skin for such purposes.
and eyes. - Avoid formation of sparks and contact with combustible
If hot or glowing objects come into contact with unprotected skin materials when handling glowing objects.
or eyes severe, possibly permanent damage can result,
First-aid measures
[ID C o n ta ct b e tw e e n g lo w in g objects a n d co m b u stib le m aterials * Rinse a ffe cte d a rea s o f skin w ith la rg e q u a n titie s o f cold w a te r
poses a fire hazard. and cover with sterile dressings.
Consult physician immediately.
< ^8* Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 41
AR03.30-W-1600A Removing, installing belt pulley/vibration damper 17.7.95
ENGINE 904.905/906/907/909/910/911/921/922, 906.910/911/920/921/922/923/940/941

1 Interm ediate piece
2 Hexagon socket bolts
3 Vibration damper
4 Multi-point socket bolts
5 Viscous fan
6 Poly V-belt
W 0 3 .30-0017-06
Modification notes
7.7.95 Use of new bolts for attaching vibration damper Step 6 Page 42
HHHSl Removing, installing
1 Slacken poly V-belt (6) and take off AR13.25-W-3200A
2 Detach cover at timing case 0 Bolt of end cover to timing case BA01.60-N-1002-01A
3 Install cranking and blocking device for U] Block cranking and blocking device by P ag e 44
engine at timing case inserting the pin.
904 589 04 63 00
4 Remove viscous fan (5) AR20.40-W -5614C
5 Remove intermediate piece (1) 0 Bolt of intermediate piece to vibration BA03.30-N-1003-01C

damper
6 Remove vibration damper (3) SI t-or bolt M14 904 589 01 10 00
SI For bolt M16 904 589 01 10 00
0 Bolt of vibration damper to crankshaft BA03.30-N-1002-01C
7 Measure length of shank of multi-point Multi-point socket bolt M14 BE03.30-N-1001-02B

socket bolts (4)
Multi-point socket bolt M16 BE03.30-N-1002-02B
0Q If length of shank exceeded J,
replace multi-point socket bolt
42
Belt pulley / vibration damper

904.905/906/907/
909/910/911/921
/922
906.910/911/920/
921/922/923/
940/941
B E03.30-N-1001-02B Bolt of vibration damper to Thread diameter M 14X1.5

crankshaft
Max. shank length mm 61.0
B E03.30-N-1002-028 Bolt of vibration damper to Thread diameter M 16X1.5

crankshaft
Max. shank length mm 61.8
E3 Timing case
Number Dsignation Engine 904.905/

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.60-N-1002-01A End coverof inspection holeto Nm 25

timing case
0 Flywheel, driven plate, vibration damper, starter ring gear

906/907/909/ 906.940/
910/911/921/922, 941
906.910/911/920/
921/922/923
BA03.30-N-1002-01C Bolt of vibration damper to M16 1st stage Nm 50 50

crankshaft
2nd stag e Nm 210 210
3rd stage 90 90
M14 1st stage Nm 50 50
2nd stage Nm 125 125
3rd stage 90 90
B A03.30-N-1003-01C Bolt of intermediate piece of Nm 60 -

vibration damper
device for engine
@ Timing case

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941

timing case
2 Remove cover (1) at flywheel housing (except engine 906.920-923/940/941).
3 Attach E l cranking and blocking device (2) tightto flywheel housing with bolts (4).
E Cranking and blocking device (2) can be blocked by inserting the pin (3).
Cranking and blocking device (2) must be removed before starting the engine.
44
AR03.30-W-8002A Removing, installing flywheel 18.7.95
ENGINE 904.905/906/907/909/910/9111921 /922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 In MODEL 668,670
ENGINE 906.940/941 In MODEL 957
1 Flywheel
2 Flywheel bolt
3 SI Cranking and blocking device
4 I S Centering drift
B 1S Crank angle position sensor

L Shank length o f flywheel bolt
W03.30-0018-06
sector op. no. operation text
F, T, S 03-8001- Flywheel
8042
mi [m Removing, installing
1 Remove clutch Engine 904.905-907/921 AR2 5.10-W-0050A
Engine 904.908/923

906.910/911/920- 923 with transmission
710.6 and 715.050/060/320
On engine 906.920- 923 with transmission AR25.10-W-0050B

715.5
2 Pull crank angle position sensor (B15) Do not damage crank angle position
approx. 8 mm out of timing case sensor with the ring gear when pulling off
the flywheel (1).
E Installation: press crank angle position
sensor into the housing as far as the stop.
3 Attach cranking and blocking device (3) to E Block cranking and blocking device by Page 44
the timing case inserting the pin.
0 Bolt of end cover to timing case BA01.60-N-1002-01A
904 589 04 63 00
4 Unscrew flywheel bolts (2) CD Installation: oil flywheel bolt lightly
and screw tight.
0 Bolt of flywheel to crankshaft A03.30-N-1001 -01C
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 Additional Information 45
El 904 589 0010 00
5 Screw centering drifts (4) into two opposite 904 589 02 63 00

threaded holes
6 Detach cranking and blocking device (3) 904 589 04 63 00
7 Remove flywheel (1) over the centering [2 If flywheel is tight, screw two bolts (M8)
drifts (4) into opposite threaded holes and pull off
flywheel.
E Installation: grease ring gear with BR00.45-Z-1001-06A

longlife grease
@ Inspecting
8 Measure flywheel bolts (2) E If the maximum shank length (L) was BE03.30-N-1010-03B
exceeded 4
replace flywheel bolt.
9 Inspect clutch surface on flywheel (1) E If scorches, scores or cracks are present
in the clutch surface J
re-machine flywheel. Page 48

If the scores or cracks are deeper than the BE03.30-N-1008-03B
maximum permissible stock removal, the
flywheel has to be replaced.
10 Inspect flywheel flange for signs of wear E If wear is present, a radial seal with race
and traces of hollowing caused by radial will soon be available for repairs.
seal
11 Inspect ring gear for wear E If wear is present 4
replace ring gear of flywheel. Page 51

Test data of flywheel
Number Designation Engine 904 with Engine 904 with Engine 904.908/
SAA 505.009/06 SAA 505.009/03 923
B E 0 3 .3 0 - M - 1 0 0 8 - 0 2 Q F ly w h e e l - m in im u m w id th mm 55 55 55
between friction surface and
Fig. see - - -
mounting flange for repairs
(E)
BE03.30-N-1010-03B Flywheel bolts Thread 0 M 1 4 X 1 .5 1 4 X 1 .5 1 4 X 1 .5
Length of shank mm 60.0 60.0 60.0

when new
Length of shank mm 61.0 61.0 61.0

max.
46
Number Designation Engine 906 with Engine 906 with

SAA 505.009/05 SAA 505.009/14
B E03.30-N-1008-036 Flywheel - minimum width mm 55 55

Fig. see - -
(E)
B E03.30-N-1010-03B Flywheel bolts Thread 0 M 14X1.5 14X1.5
Length of shank mm 60.0 60.0

when new
Max. length of mm 61.0 61.0

shank
0 T im in g case
Number Dsignation Engine 904.905/ Engine

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.60-N-1002-01 A End cover of inspection holeto Nm 25 25

timing case

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923
BA03.30-N-1001-01C Bolt of flywheel to crankshaft M14 1st stage Nm 50 50
3rd stage '4 90 90
904 589 02 63 00 904 589 04 63 00
Centering drift Cranking device
Repair products
BR00.45-Z-1001-06A MB long-life grease 000 989 63 51
AR03.30-W-8022A Inspecting, machining flywheel 21.11.95
ENGINE 904.905 /906 /907 /909 /910/911 /921 /922,906.910/911 /920 /921 /922 /923
ENGINE 904.903/923 in MODEL $38. 670
1.2K
1.3-
'7 7 /A
D A B C D A B C D A
7.7 Flywheel (engine 904 with SAA 505.009/06 and A Flywheel 0

en g in e 904.908/923 ) B F lyw h e e l 0 fo r m o u n tin g rin g g e a r
7.2 Flywheel (engine 904 with SAA 505.009/03) C Flywheel 0 at crankshaft flange
1.3 Flywheel (engine 906 with SAA 505.009/05/14) D Flywheel 0 for mounting clutch
2 Ring gear E Flywheel minimum width between friction surface and
3 US Knife-edge straightedge mounting flange fo r repairs
F Flywheel overall width
H Removing
1 Remove flywheel (1) P a g e 45
m Inspecting
2 Clean flywheel (1) and inspect clutch EL) If a fault exists, the clutch surface
surface (friction surface) for scorches, (friction surface) has to be machined by
scores and cracks and flatness using a grinding or precision-turning.
knife-edge straightedge (3)
m WH58.30-Z-1025-12A
If the scores or cracks are deeper than the BE03.30-N-1008-03B

maximum permissible stock removal J
replace flywheel
Machining
3 Machine flywheel (1) When machining the clutch surface BE03.30-N-1008-03B

(friction surface), the width of the flywheel
between the friction surface and mounting
surface must not be less than the flywheel
minimum width (E).
Flywheel outer 0 (A) BE03.30-N-1001-03B
48
Flywheel 0 for mounting starter ring gear BE03.30-N-1002-03B
(B)
Flywheel 0 at crankshaft flange (C) BE03.30-N-1003-03B
Flywheel 0 for mounting clutch (D) BE03.30-N-1004-03B
Pitch circle 0 for clutch BE03.30-N-1005-03B
Flywheel overall width (F) BE03.30-N-1007-03B
If peak-to-valley height of clutch friction BE03.30-N-1006-03B

surface is excessive, this increases the wear
of the clutch lining. If peak-to-valley height
is insufficient, this can cause separation
problems of the clutch.
After machining, the friction surface must
not have any cavities or chatter marks.
4 Inspect axial and radial runout of flywheel BE03.30-N-1009-03B
m Installing
5 Install flywheel (1) Pag e 45
N um ber D esignation En gine 904 w ith En g in e 904 w ith En gine 904.908/

SA A 505.009/06 S A A 505.009/03 923
BE03.30-N-1001-03B Flywheel outer 0 (A) mm 403 443 403
Fig. see - - -
BE03.30-N-1002-03B Flywheel 0 fo r m ounting mm 360.435-360.575 392.435-392.575 360.435-360.575

starter ring gear (B) Fjg sge
- - -
BE03.30-N-1003-03B Flywheel 0 at crankshaft mm 114,960-115,020 114,960-115,020 114,960-115,020

flan ge (C)
Fig. see - - -
BE03.30-N-1004-03B Flywheel 0 fo r m ounting mm 395.000-395.057 395.000-395.057 395.000-395.057

clutch (D) ..
Fig. see - - -
BE03.30-N-1005-03B Pitch circle 0 fo r clutch mm 375 375 375
BE03.30-N-1006-03B Peak-to-valley height (Rz) o f pm 16 16 16

clutch frictio n surface
BE03.30-N-1007-03B Overall w idth of flyw heel (F) mm 64 64 64
Fig. see - - -
BE03.30-N-1008-03B Flywheel m inim um w idth mm 55 55 55

betw een frictio n surface and ..
F ig.see - - -
m ounting flan g e for repairs
(E)
BE03.30-N-1009-03B Flywheel perm issible axial and mm 0.05 0.05 0.05

radial ru nout

SAA 505.009/05 SAA 505.009/14
BE03.30-N-1001-03B Flywheel outer 0 ( A ) mm 443 487
Fig.see - -
BE03.30-N-1002-03B Flywheel 0 for mounting mm 392.435-392.575 432,435-432,575

starter ring gear(B)
Fig. see - -
B E03.30-N-1003-03B Flywheel 0 at crankshaft mm 114,960-115,020 114,960-115,020

flange (C)
Fig. see - -

clutch (D)
Fig. see - -
BE03.30-N-1005-03B Pitch circle 0 for clutch mm 410 450
BE03.30-N-1006-03B Peak-to-valley height (Rz) of ym 16 16

clutch friction surface
BE03.30-N-1007-03B Overall width of flywheel (F) mm 64 64
Fig. see - -
B E 0 3 .3 0 -N 100 S 03 3 F ly w h e e l m in im u m w id th mm 55 55
Fig. see - -
(E)
BE03.30-N-1009-03B Flywheel permissible axial and mm 0.05 0,05

radial runout
WH58.30-2-1025-12A Knife-edge straightedge, 500 mm Hahn und Kolb 37 550 050

Borsigstr. 50
D-70469 Stuttgart
50
AR03.30-W-8312A Replacing ring gear of flywheel 17.7.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911

ENGINE 904.908/923 in MODEL 668. 670
1 Starter ring gear
2.1 Flywheel (engine 904 with
SAA 505.009/06and engine 1
904.908/923) /
2.2 Flywheel (engine 904 with p?
SAA 505.009/03)
2.3 Flywheel (engine 906 with I
SAA 505.009/05/14) 2.1
1
A Hole for mounting clutch pressure
plate (M 10X1.5) -L*
B Flywheel 0 for mounting starter ring
gear f
2.2
1
2.3 -A
W03.30-0020-06
Replacing
Danger! Risk of injury to eyes and skin from W ear protective gloves, protective clothing Page 41
handling hot or glowing objects and, if necessary, eye protection.
1 Remove flywheel Page 45

2 Use a welding torch to rapidly heat ring
gear
3 Press ring gear (1) off the flywheel (2)
4 Measure flywheel 0 (B) for mounting the BE03.30-N-1002-03B

starter ring gear (1)
5 Measure ring gear inner 0 BE03.30-N-1001-04B
Overlap between starter ring gear and BE03.30-N-1002-04B

flywheel has to be adhered to
6 Heat new starter ring gear (1) E Temperature is reached once the ring BE03.30-N-1005-04B
gear has a bright yellow annealing color
7 Press starter ring gear (1) onto the flywheel E The permissible radial runout of the BE03.30-N-1003-04B
(2) as far as the contact surface pressed-on starter ring gear must not be
exceeded
Starter ring gear width BE03.30-N-1004-04B
8.1 Drill holes (A) for mounting the clutch Engine 906 with SAA 505.009/05/14
pressure plate in the ring gear (l)a n d tap
thread (M10X1.5)
9 Install flywheel Page 45
SAA 505.009/06 SAA 505.009/03 923
B E03.30-N-1002-03B Flywheel 0 for mounting mm 360.435-360.575 392.435-392.575 360.435-360.575

starter ring gear (B)
Fig.see - - -

SAA 505.0Q9/0S SAA 505.009/14

starter ring gear (B)
Fig. see - -
Test data of starter ring gear
Number Designation Engine 904 with Engine 904,906 Engine 904.908/

SAA 505.009/06 with SAA 923
505.009/03/05
BE03.30-N-1001-04B Starter ring gear inner 0 mm 359.690-359.830 392.000-392.140 359.690-359.830
BE03.30-N-1002-04B Starter ring gear/flywheel overlap mm 0.885-0.605 0.295-0.575 0.885-0.605
BE03.30-N-1003-04B Starter ring gear/flywheel mm 0.5 0,5 0.5

permissible radial runout
BE03.30-N-1004-04B Starter ring gear width mm 15,6-16,0 15,6-16,0 15,6-16,0
BE03.30-N-1005-04B Starter ring gear fitting temperature C 250-280 250-280 250-280
Test data of starter ring gear
Number Designation Engine 906 with

SAA 505.009/14
BE03.30-N-1001-04B Starter ring gear inner 0 mm 432,000-432,155
BE03.30-N-1002-04B Starter ring gear/flywheel overlap mm 0,575-0,385
BE03.30-N-1003-04B Starter ring gear/flywheel mm 0,5

permissible radial runout
BE03.30-N-1004-04B Starter ring gear width mm 15,6-16,0
BE03.30-N-1005-04B Starter ring gear fitting temperature e 250-280
52
AR03.30-W-8401 A Removing, installing guide bearing in flywheel 21.11.95
ENGINE 904.905/906/907/909/910/911 /921 /922. 906.910/911/920/921 /922/923/940/941

ENGINE 904.908/923 in MODEL 668,670
1 Flywheel bolt
2 Guide bearing
3 Flywheel
4 E Cranking and blocking device
5 E l Centering drifts
6 E Internal extractor
7 E Countersupport
8 Drift
L Shank length o f flywheel bolt
HH Removing, installing
1 Remove clutch Engine 904.905-907/921 AR25.10-W-0050A
Engine 904.908/923

906.910/911/920- 923 with transmission
710.6 and 715.050/060/320
On engine 906.920- 923 with transmission AR25.10-W-0050B

715.5
3 Attach cranking and blocking device (4) EE Block cranking and blocking device by Page 44
inserting the pin.
0 Bolt to timing case BA01.60-N-1002-01A
E 904 589 04 63 00
4 Unscrew flywheel bolts (1) CD Installation: lightly oil flywheel bolt

and screw tight.
0 Bolt of flywheel to crankshaft BA03.30-N-1001-01C
E 904 589001000
5 Measure shank length (L) of flywheel bolts If maximum shank length is exceeded | BE03.30-N-1010-03B
(1)
replace flywheel bolt
6 Screw centering drifts (5) into two opposite E 904 589 02 63 00

threaded holes
7 Remove guide bearing (2) Place bases, e.g. copper plates, below
the contact points of the countersupport to
avoid damaging the flywheel (3).
Engines OM904 LA, 906 LA {mod. des. 904.9,906.9), F4

000 589 26 33 00
n 000 589 33 33 00
[S Installation: use a suitable drift (8) to

install new guide bearing (2) flush to the
bolt contact surface.
Grease guide bearing. BR00.45-Z-1001-06A
SAA 505.009/06 SAA 505.009/03 923
BE03.30-N-1010-03B Flywheel bolts Thread 0 M 14X1.5 14X1.5 14X1.5
Shank length mm 60.0 60.0 60.0

when new
Max. shank length mm 61.0 61.0 61.0
Number Designation Engine 906 with Motor 906 with

SAA 505.009/05 SAA 505.009/14
R F03 3 0 -N -1 0 1 0 -0 3 B F ly w h e e l bolts T h read 0 M 1 4 X 1 .S 1 4 X 1 .5
Shank length mm 60.0 60.0

when new
Max. shank length mm 61.0 61.0
S Timing case

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941

timing case

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923
BA03.30-N-1001-01C Bolt of flywheel to crankshaft M14 1st stage Nm 50 50
3rd stage *4 90 90
54
"\ r S
904 589 00 10 00 J 904 589 02 63 00
Screwdriver bit Centering drift
Repair products
B R00.45-Z-1001-06A MB longlife grease 000 989 63 51
AR05.00-W-1500A Checking valve lift 28.8.95
ENGINE 904.905/906/907/909/910/911 /921 /922,906.910/911/920/921 Z922/923

E N G IN E 9 0 4 .9 0 8 /9 2 3 in M O D E L 66 8. 6 7 0
f Rocker arm
2 Valves
3 Tappet rods
4 E l] D ial gauge holder
5 I S D ial gauge
6 Valve spring (w ith valve spring
retainer)
7 Valve bridge
A V a lve clearance
B Valve lift
W05.00 1001-06
M o d ific a tio n no tes
7.7.98 Test value of valve lift modified Step 9
m Removing
1 Remove cylinder head cover AR01.20-W-5014A
2 Detach cover at timing case
3 Attach cranking and blocking device Page 44

0 Bolt to timing case B A01.60-N-1002-01A
s 904 589 04 63 00
s Checking
4 Rotate engine with cranking device until S3 904 589 04 63 00

the piston of the cylinder to be inspected is [S The rocker arms (1) of the cylinder to be
positioned at ignition TDC inspected overlap, both tappet rods can be
turned and valve clearance exists at both
rocker arms.
5 Adjust valve clearance (A) Engine 904.905/906/907/921 wh0560.30
Engine 904.908/923 AP05.30-D-0560A
Engine 904.909/910/911 /922 AP05.30-W-0560B

Engine 906.910/911/920-923/940/941
6 Mount dial gage holder (4) with dial gage E E Mount dial gage with a preload of
(5) on the valve spring retainer of the valve approx. 15 mm so that the travel is
spring (6) of the exhaust valve or valve adequate for the valve lift (B).
bridge (7) of the inlet valve
na 001 589 53 21 00
56
m 363 58902 2100
7 Set scale of dial gage to "0" m 001 589 53 21 00
8 Crank engine with cranking device in HI The maximum valve lift is indicated on
direction of rotation of engine and read the dial gage before the pointer moves in
off valve lift(B) the opposite direciton. The valves (2) are
fully open at this point.
9 Compare measurement obtained with CD if the valve lift (B) measured is less than BEO..-N-12-01B
specification specification, inspect cams of camshaft for
wear, if necessary 1
remove and inspect camshaft. AR05.20-W-6292A
10 Carry out check at all valves (2)
m Installing
h Install cylinder head cover AR01.20-W-5014A
12 Detach cranking and blocking device Pa g e 44
HI 904 589 04 63 00
13 Install cover at timing case @ Bolt of end cover to timing case BA01.60-N-1002-01A
Test data of valves
Number Designation Engine 904.905/ Engine Engine 904.909/

906/907/921 904.904/908/923 910/911/922,
906.910/911/919/
920/921/922/923
/940/941
B E05.30-N-1002-01B Max. valve lift at specified inlet mm 9.7 9.7 9.7

valve clearance
exhaust mm 10.7 10.7 10.7
Timing case
Num ber D signation En gine 904.905/ En gine

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941

tim ing case
'S
\\(o
]
^ ! r )
V 904 589 04 63 00 J
Cranking device
AR05.00-W-5521 A Removing, installing rocker arm assembly 17.7.95
ENGINE 904.905/906/907/908/921 # # up to 39739

2 Bolt
3 Clamping piece
4 Rocker arm assembly
5 Valve bridge
6 Tappet rod
7 Guide bolt o f valve bridge
A Projection o f guide bolt from cylinder

head
W 05.00-0015-06
Modification notes
11.11.97 Tightening torque for rocker arm assembly modified Step 2
Basic setting of valve bridges modified Step 3
num i Removing, installing
1 Remove cylinder head cover (1) AR01.20-W-5014A
2 Remove clamping piece (3) and rocker arm Inspect rocker arm assembly for wear, if ne
assembly (4) cessary I
disassemble rocker arm assembly and re Page 63

place worn parts.
[ 3 Installation: inspect tappet rods (6) to

ensure they are correctly positioned in the
tappets. Oil tappet rod sockets (6) with
e n g in e o il.
@ Bolt of rocker arm assembly to cylinder BA05.00-N-1001-01A

head
3 T ak e o ff v a lv e brid g es (5) M a r k v a lv e b rid g es a n d inspect fo r w e a r , if
necessary J,
replace valve bridges.
CD In s ta lla tio n : if th e v a lv e s ea t rings in

the cylinder head or the valves were
machined, the valve bridges have to be
adjusted.
Adjust valve bridges. Page 59

@ The valve bridges must not be locked in
the basic setting when they are installed.
58
0 Locking nut at adjusting screw of valve BA05.00-N-1003-01A
bridge
4 Measure projection (A) of guide bolts (7) If dimensional differences exist j, BE05.30-N-1003-04B
from cylinder head
withdraw guide bolt and replace
6 Set valve clearance Engine 904.905/906/907/921 wh0560.30
Engine 904.908 AP05.30-D-0560A

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE05.30-N-1003-04B Valve bridge -guide bolt projection mm 25.1-25.5 25.1-25.5

from cylinder head (A)
3 Fig. see - -
0 Engine timing, general

906/907/909/ 904 904/908/973
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA05.00-N-1001-01A Bolt of rocker arm assembly to Nm 30 30

cylinder head
B A 0 5 .0 0 - N - 1 0 0 3 - 0 1 A Lucking nuL a t a d ju stin g scre w o f Nm 25 23

valve bridge
AR05.00-W-5521-02B Adjusting valve bridge
Modification notes
11.11.97 Basic setting of valve bridges modified Steps 1 to 8
0 Engine timing, general

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA05.00-N-1002-01A Locking nut to adjusting screw of Nm 25 25

rocker arm
BA05.00-N-1003-01A Locking nut to adjusting screw of Nm 25 25

valve bridge
a
Carry out setting of valve bridges (3) only when engine is cold or thoroughly warmed
through. W ait at least 30 minutes after switching off the engine.
1 Clamp valve bridges (3) in a vise, slacken locking nut (1) and unscrew adjusting screw (2)
about 3 turns.
2 Install valve bridges (3) over the guide bolts on the cylinder head.
3 Press valve bridge (3) down. Valve bridge (3) should be making contact with valve stem
(arrow A).
4 With valve bridge (3) pressed down, screw in adjusting screw (2) by hand until the
adjusting screw (2) makes slight contact with the valve stem (arrow B).
a
Valve bridge (3) must not move up.
5 Screw on locking nut (1) by hand until it makes contact.
6 Take off valve bridges (3) at the cylinder head.
7 Clamp valve bridges (3) in a vise, tighten adjusting screw (2) and locking nut (1) to
specified torque.
8 Install valve bridges (3) over the guide bolt on the cylinder head.
60
ARO5,00-W-5521C Removing, installing rocker arm assembly 30.9.97
ENGINE 904.909/910/911 /922, 906.910/911/920/921 /922/923/940/941

2 Bolt
3 Clamping piece
4 Rocker arm assembly
5 Valve bridge
6 Tappet rod
7 Cap
W0S.Q0-0O16-06
1 Remove cylinder head cover (1) AR01.20-W-5014A
2 Remove clamping piece (3) and rocker arm Inspect rocker arm assembly for wear, if ne
assembly (4) cessary \
disassemble rocker arm assembly and re Page 63

place worn parts.
CDInstallation: inspect tappet rods (6) to

ensure they are correctly installed in the
tappets. Oil tappet rod sockets (6) with
engine oil.
0 Bolt of rocker arm assembly to cylinder BA05.00-N-1001-01A

head
3 Take off caps (7) at the exhaust valve stem

ends
4 Take off valve bridges (5) at the inlet valves Inspect valve bridges for wear, if necessary
I
replace valve bridges.
6 Set valve clearance AP05.30-W-0560B
S Engine timing, general

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA0S.00-N-1001-01A Bolt of rocker arm assembly to Nm 30

cylinder head
62
AR05.00-W-5541 A Disassembling, assembling rocker arm assembly 17.7.95
ENGINE 904.905/906/907/908/909/910/911 /921Z922/923,906.910/911/920/921 /922/923/940/941
1 C irri ip 8 Rocker a rm s h a ft
2 Rocker arm bracket (at front on outside) 9 Bolts
3 Rocker arm bracket (on inside) 10 Clamping piece
4 Rocker arm bracket (at rear on outside) 11 Washer
S Rocker a rm (in le t)
6 Rocker arm (exhaust) A Distance 122 mm
7 Springs B Distance 110 mm
0 Removing
1 Remove rocker arm assembly Engine 904.905-908/921 Page 58

Engine 904.909- 911/922 and AR05.00-W-5521B
906.910/911 /920- 923 /940/941
0 Disassembling
2 Remove circlips (1)
3 Take rocker arm brackets (2,3,4), rocker Inspect parts of rocker arm assembly for
arms (5, 6). washers (11) and sorinos (7) off wear, if necessary 1
the rocker arm shaft (8)
replace parts.
R ocker arm b e arin g bush in n e r 0 BE05.30-N-1001-04B
Rocker arm shaft 0 BE05.30-N-1002-04B
0 Assembling
4 Install cirdip (1) on one side of the rocker EL) Pay attention to installation position of
arm shaft (8), assemble rocker arm outer rocker arm brackets (2,4) and of
assem bly in t h e re ve rse o rd e r an d secure ro ck e r a rm b rack ets (3).
with the cirdip (1) Fix rocker arm brackets (2,3,4) in place
with the bolts (9) and the clamping pieces
(10).
P a y a tte n tio n t o d ista n c e o f holes o f o u te r
rocker arm brackets (2,4) to the inner
rocker arm bracket (3).
Distance "A " 122 mm
D ista n ce " D " 110 m m
m Installing
5 Install rocker arm assembly Engine 904.905-908/921 Page 58

Engine 904.909-911/922 and AR05.00-W-5521B
906.910/911/920- 923/940/941

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
B E 0 S .3 0 -N 10 01-01B R o c k e r a r m b e a r in g b u s h i n n e r 0 mm 2 2 .0 0 0 - 2 2 . 0 2 1 2 2 .0 0 0 -2 2 .0 2 1
when installed
BE05.30-N-10Q2-04B Rocker arm shaft 0 mm 21.967-21.980 21.967-21.980
64
AR05.30-W-3511A Removing, installing valves 21.11.95
ENGINE 9 0 4 .9 0 5 /9 0 6 /9 0 7 /9 0 9 /9 1 0 /9 1 1 /9 2 1 Z922/923.906.910/911/920/921 Z922/923

1 Valve collet
2 Valve spring retainer
3 Inlet valve spring
4 Exhaust valve spring
5 Cylinder head
6 Inlet valve
7 Exhaust valve
8 H I Valve lifter with adapter piece
9 Valve stem seal
W 0 5 .3 0 -M 5 7 -0 6
5 Cylinder head
6 Inlet valve
7 Exhaust valve
10 (Ml Dial gage
77 E l Dial gage holder
A Valve seat angle

B Valve disk 0
C7 Valve length (engine 904.905-
908/921)
C2 Valve length (engine 904.909- 9 71/922
and 906.910/911/920- 923/940/941)
E Valve stem 0
F Valve seat width at valve disk
G Valve seat surface 0
H Valve seat surface machining
dimension related to valve seat
surface diam eter
W 05.30-0064-06
H is Removing, installing
1 Remove cylinder head (5) Engine 904.905- 907/909- 911 /921/922 and AR01.30-W-5800A
906.910/911/920- 923/940/941
Engine 904.908 AR01.30-D-5800D
2 Remove nozzle holder combination Engine 904.905-908/921 AR07.03-W-6831A

Engine 904.909- 911 /922 and AR07.03-W-6831C
906.910/911 /920- 923/940/941
3.1 Measure amount by which valve stands Engine 904.905-908/921 Page 70

back (B) to cylinder head
Measure and note amount by which valve BE05.30-N-1001-01B

stands back at both inlet valves and at
exhaust valve.
IS Dial gage 001 589 53 21 00
Dial gage holder 343 589 0040 00
[2 If the measurement obtained is not

within the permissible tolerance J,
re-machine valve seat rings. AR05.30-W-4511A
3.2 Measure amount by which valve stands Engine 904.909- 911/922 and Page 71
back (B) to cylinder head, and permissible 906.910/911/920- 923/940/941
d iffe re n c e b e tw e e n b o th in le t v a lv e tem c
Measure and note amount by which valve BE05.30-N-1001-01B

stands back at both inlet valves and at
exhaust valve.
Permissible difference between both inlet BE05.30-N-1014-01B

valve stem ends must not be exceeded.
IS Dial gage 001 589 53 21 00
IS Dial gage holder 363 589 02 21 00
S Dial gage holder 343 589 00 40 00
[H If th e m ea su rem en ts o b ta in e d are n o t
within the permissible tolerance i
re-machine valve seat rings. AR05.30-W-4511A
4 A tta c h c y lin d e r h ead (5) to th e v a lv e IQ V a lv e rem o va l to o l WH58.30-Z-1001-14A

removal tool
5 Attach valve lifter (8) to the cylinder head 23 Screw stud bolt of valve lifter Into a
(5) free threaded hole in the cylinder head.
Attach adapter piece to the valve lifter.
S Valve lifter 442 589 00 3100
S Adapter piece 904 589 00 31 00
6 Press down valve spring retainer (2) with ID Counterhold valve at the valve disk.
valve lifter (8) and take off collets (1) with
the magnetic pin
S Magnetic pin 210 589 00 4000
E Installation: insert collets into the slot

of the valve stem.
Inspect valve spring (3), valve spring
retainer and collets to ensure correctly
installed.
7 Relieve pressure on valve lifter (8). take off

valve spring retainer (2) and valve springs
(3,4)
8 Pull valves (6,7) out of the cylinder head E Mark valves.

Installation: oil valve stems with engine oil.
Pay attention to marking of valves.
9 Pull off valve stem seals (9) E Installation: replace valve stem seals. Page 78
66
10 Inspect valve seat rings Measure valve seat width at all valve seat BE05.30-N-1007-03B
rings.
Measure amount by which valve stands BE05.30-N-1001-01B

back at both inlet valves and at exhaust
valve.
CD If valve seats are only slightly worn,

they can be reworked without replacing
the valve seat rings provided the valve
setback is not exceeded.
@ Engine 904.909- 911 /922 and BE05.30-N-1014-01B

906.910/911/920-923/940/941: the
difference between both inlet valve stem
ends must not be exceeded, if necessary [
M a c h in e v a lv e seat rings. AR05.30-W-4S11A
Replace valve seat rings. Page 80

11 Use plug gage to inspect valve guides for [Si Drift 102 589 00 23 00
w ear
BE05.30-N-1003-02B
BE05.30-N-1006-02B
ED If the side of the plug gage marked

with " + can be inserted into the valve
guide J
replace valve guide. Page 73

12 Inspect valves (6,7) to determine whether CDThe valve stem ends must not have any
they can be reused surface damage. Valve keyways must not
be worn and the chrome layer on the valve
stems must be complete. Valve seats must
not be scorched.
El Hardness tester 000 589 20 2100
Inspect hardness at valve stem end, if BE05.30-N-1010-01B

necessary J,
grind or replace valves. AR05.30-W-4202A
13 Inspect concentricity and dimensional Concentricity of valve seat to valve stem BE05.30-N-1011-01B
tolerance of valves (6,7)
Valve seat angle (A) BE05.30-N-1003-01B
Valve disk 0 (B) BE05.30-N-1004-01B
Valve length (C) BE05.30-N-1006-01B
Valve seat width at valve disk (F) BE05.30-N-1005-01B
Valve seat 0 (E) BE05.30-N-1007-01B
Inlet valve seat surface machining BE05.30-N-1008-01B

dimension (H) related to valve seat
surface 0 (G)
Exhaust valve seat surface machining BE05.30-N-1009-01B

surface 0 (G)
SS Micrometer WH58.30-Z-1005-12A
It is not permitted to straighten valves.
Minor differences in concentricity can be AR05.30-W-4202A

rectified by regrinding the valve seat on a
valve grinding machine.

14 Inspect valve springs (3,4) ELI If damaged, replace valve spring.
Test data of valves

906/907/921 904.904/908/923 910/911/922.
906.910/911/919/
920/921/922/923
/940/941
BE05.30-N-1001-01B Valve setback relative to cylinder mm 1.1-1.5 1.1-1.5 1.1-1.5

B C 0 3 .3 0 - N - 1 0 0 3 - 0 1 B V o lv c s ca t a n g le (A ) In let S 20 20 20
Exhaust 4 45 45 45
BE05.30-N-1004-01B Valve disk 0 (B) Inlet mm 33.9-34.1 33.9-34.1 33.9-34.1
Exhaust mm 37.9-38.1 37.9-38.1 37.9-38.1
B E05.30-N-1005-01B Valve seat width at valve disk (F) Inlet mm 3.3-4.3 3.3-4.3 3.3-4.3
Exhaust mm 3.5-4.2 3.5-4.2 3.5-4.2
BE05.30-N-1006-01B Valve length (C) Inlet mm 125.7-126.1 125.7-126.1 125.65-126.95
Exhaust mm 152.5-152.9 152.5-152.9 152.5-152.9
BE05.30-N-1007-01B valve stem 0 (fc) inlet mm 7.935-7.950 . 7.935-7.950 7.935-7.950
Exhaust mm 7.925-7.940 7.925-7.940 7.925-7.40
BE05.30-N-1008-01B Inlet valve seat surface machining Dim. G mm 31.0 31.0 31.0
Dim. H mm 2.7-3.1 2.7-3.1 2.7-3.1
surface 0 (G)
B E05.30-N-1009-01B Exhaust valve seat surface machining Dim. G mm 36.0 36.0 36.0
dim ensio n (H ) re la te d to v a lv e sc a t
Dim. H mm 2.5-3.2 2.5-3.2 2.S-3.2
surface 0 (G)
BE05.30-N-1010-01B Hardness at valve stem end Inlet HRC 54-60 54-60 54-60
Exhaust HRC 54-60 54-60 54-60
BE05.30-N-1011-01B Concentricity of valve seat to valve Inlet mm 0.03 0.03 0.03

stem
Exhaust mm 0.03 0.03 0.03
BE05.30-N-1014-01B Permissible difference of inlet valves 0.2 0.2 0.2

and valve stem end
Test data of valve guides
Number Designation Engine 904.905/ Engine 904.908

906/907/921
BE05.30-N-1003-02B Valve guide inner 0 (machining mm 8.000-8.022 8,000-8.022

dimension) (B)
Fig. see - -
BE05.30-N-1006-02B Valve guide clearance of valve stem Inlet mm 0.050-0.087 0.050-0.087
Exhaust mm 0.060-0.097 0.060-0.097
68

904.909/910/911/
922/923,
906.910/911/920/
921/922/923/940
(941
B E05.30-N-1003-02B Valve guide inner 0 (machining mm 8.000-8.022

dimension) (B)
Fig. see -
BE05.30-N-1006-02B Valve guide clearance of valve stem Inlet mm 0.050-0.087
Exhaust mm 0.060-0.037
Test data of valve seat rings

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
B E05.30-N-1007-03B Valve seat width at valve seat ring (F) Inlet mm 1.5-2.5 1.5-2.5
Exhaust mm 1.8-3.0 1.8-3.0
Fig. see - -
001 589 53 21 00
Dial gage
WHS8.30-Z-1005-12A Micrometer 0-25 mm Hahn und Kolb 31400 002

Borsigstr. 50
D-70469 Stuttgart
6 ^ ^ Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4

WH58.30-Z-1001-14A Valve removal tool Model K2000 221 00 200

Messrs. Hunger
D-81309 Mnchen

Test data of valves

906/907/921 904.904/908/923

surface
343 589 00 40 00
D ia l g a g a h o ld e r
DD
1 Attach I S dial gage (1) to I S dial gage holder (2).
2 Mount m dial gage (1) with a preload onto the plane face of the cylinder head.
4 Move S dial gage (1) sufficiently until the tracer pin is touching the valve disk (3).
m W05.30-0060-01
If th e rea d in g o h ta in e d (A ) is n o t w ith in th e perm issible to le ra n ce , inspect v a lv e seat
ring orthe valve disk.
70
Test d a ta o f v a lv e s

910/911/922, 906/907/921 904.904/908/923
906.910/911/919/
920/921/922/923
/940/941

surface
BE05.30-N-1014-01B Permissible difference of inlet valves 0.2 0.2 0,2

and valve stem ends
a r
Dial gage holder Dial gage holder
m
1 Attach ! S dial gage (1) to I S dial gage holder (2).
2 Mount H] dial gage (1) with a preload onto the plane face of the cylinder head.
4 Move I S dial gage (1) sufficiently until the tracer pin is touching the valve disk (3).
m W05.30-0060-01
5 Attach I S dial gage (1) to I S the dial
gage holder (4) and mount on the top
contact surface of the cylinder head.
6 P o s itio n S dial gage (1) with a

ends (5).
7 Set scale of dial gage to 0".
8 Pull back tracer pin on S dial gage

indication on gage.
m
be exceeded. W05.30-0058-05
If the readout obtained (C) is not

72
AR05.30-W-3731 A Inspecting, removing, installing valve guides 4.12.95
ENGINE 904.905/906/907/909/910/911 /921 /922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 in MODEL 668, 670
1 Valve guides
2 Cylinder head
A Valve guide bore diam eter in cylinder

head
A 1 Valve guide outer 0
R Valve g u id e in n e r 0
C Valve guide length
D Projection o f valve guide from base
relative to top edge o f valve guide
W 05.30-0003-06
W 05.30-0004.09
1 Valve guide 5 GS Reamer (adjustable)

2 Cylinder head 6 E l D rift with spacer sleeve
3 E Drift 7 E S Reamer (adjustable)
4 E Progressive drift g E Reamer
IE Removing

1 Remove valves Page 65
2 Clamp cylinder head (2) in vise
3 Inspect inner 0 dimension (B) of valve BE05.30-N-1003-02B

guides (1) with plug gage (3)
E Drift 102 589 00 23 00
[D If the side of the plug gage marked

with + * can be inserted into the valve
guide |
remove valve guide.
4 Take valve guides (1 ) out of the cylinder E Progressive drift 103 589 03 15 00
head (2) from the combustion side
m Installing
5 Measure bore of valve guides dimension E If the measurements differ from the BE05.30-N-1002-02B
(A) in cylinder head (2) test data 4
machine basic bores to the next oversize of

the valve guide bore 0 dimension (A).
Valve guide outer 0 (A1) BE05.30-N-1001-02B
6 Ream bore of valve guides dimension (A) in T u rn reamer only in clockwise direction. BE05.30-N-1002-02B
cylinder head (2) to the next larger oversize
Pay attention to overlap of valve guide (1) BE05.30-N-1005-02B

to cylinder head.
E Engine 904.905-908/921 with reamer WH 58.30-2-1015-12A

(012.0-13.5 mm)
E Engine 904.909- 911/922 and 000 589 18 53 00

906.910/911/920- 923/940/941 with reamer
(013.5-15.5 mm)
Danger! Risk of injury from handling liquid Wear heat-protective gloves, protective Page 77
nitrogen or from contact with severely clothing and full eye protection.
supercooled objects. Ensure adequate ventilation.
Risk of suffocation from inhaling nitrogen
gas.
7 Place valve guide (1) into supercooling box HD Supercooling box 346 589 00 63 00
and pour in liquid nitrogen E Supercool valve guide for approx.
20 lo 30 minutes.
8 Use pliers to remove valve guide (1) from E Support washers of the valve guide
the supercooling box and press into the should be removed.
heated cylinder head with the drift and the
spacer sleeve (6)
Valve guide length (C) BE05.30-N-1004-02B
E l Cleeue 904 18 9 01 1100
E Engine 904.909- 911 /922 and 904 589 08 63 00

906.910/911/920- 923/940/941: use sleeve
in addition.
Projection of valve guide from cylinder BE05.30-N-1007-028

head to top edge of valve guide (D).
Pay attention to marking on spacer sleeve.
In let v a lv e E 14.5 m m
Exhaust valve = A 18.0 mm
9 Widen bore of valve stems by reaming E Reamer (adjustable 07.5 - 8.0 mm) WH58.30-Z-1014-12A
E Ream to 07.95 mm
T u rn reamer only In clockwise direction.
74
10 Widen bore of valve guide to dimension (B) BE05.30-N-1003-02B
by reaming
I S Reamer 000 589 21 53 00

T u rn rea m er o n ly in clo ckw ise d irectio n .
11 Clean valve guide (1) with cleaning brush I S Valve seat turning kit 366 589 00 6900
12 Install valves Page 65

906/907/921
BE05.30-N-1001-02B Valve guide outer 0 (A1) Standard mm 13.028-13.046 13.028-13.046
Oversize 0.2 mm 13.228-13.246 13.228-13.246
Fig. see - -
B E05.30-N-1002-02B Valve guide bore 0 in cylinder Standard mm 13.000-13.018 13.000-13.018

head (A)
Oversize 0.2 mm 13.200-13.218 13.200-13.218
Fig. see - -
BE05.30-N-1003-02B Valve guide inner 0 (machining mm 8.000-8.022 8.000-8.022

dimension) (B)
Fig. see - -
B E05.30-N-1004-02B Valve guide length (C) mm 60.0 60.0
Fig. see - -
BE05.30-N-1005-02B Valve guide overlap in cylinder head mm 0.010-0.046 0.010-0.046
BE05.30-N-1007-02B Projection of valve guide from base Inlet mm 14.1-14.5 14.1-14.5

relative to top edge of valve guide
Exhaust mm 17.6-18.0 17.6-18.0
(D)
Fig. see - -

904.909/910/911/
922/923,
906.910/911/920/
921/922/923/940
/941
BE05.30-N-1001-02B Valve guide outer 0 (A1) Standard mm 14.028-14.046
Oversize 0.2 mm 14.228-14.246
Fig. see -
BE05.30-N-1002-02B Valve guide bore 0 in cylinder Standard mm 14.000-14.018

head (A)
Oversize 0.2 mm 14.200-14.218
Fig. see -
B E05.30-N-1003-02B Valve guide inner 0 (machining mm 8.000-8.022

dimension) (B)
Fig. see -
BE05.30-N-1004-02B Valve guide length (C) mm 60.0
Fig. see -
B E 0 5 .3 0 -N -1 0 0 5 -0 2 B V a lv e g u id e o v e rla p in cylin d er h e ad m m 0.010-0.046
BE05.30-N-1007-02B Projection of valve guide from base Inlet mm 13.7-14.5

relative to top edge of valve guide
(D)
Fig. see -
WH58.30-Z-1014-12A Reamer (adjustable 0 7.5 - 8.0 mm) Hunger 140 05 000

D-81309 Mnchen
76
WH58.30-Z-1015-12A Reamer (adjustable 0 12.0-13.5 mm) Hunger 11012 000

D-81309 Mnchen
AS00.00-Z-0003-01A Risk of injury from handling liquid Wear insulated gloves, protective A Danger!
nitrogen, or from contact with supercooled clothing and full protective goggles.
objects. Risk of suffocation from inhaling Provide for sufficient ventilation.
nitrogen gas
Possible dangers - Do not remove ice formed on containers with open flame or
glowing objects.
Injury hazard - When filling or pouring liquid nitrogen avoid spilling. Fill
Contact with liquid nitrogen or supercooled objects causes containers only up to full mark.
frostbite to skin similar to burns and severe injury to the eyes. - Wear protective clothing, full protective goggles, insulated
Suffocation hazard gloves (e.g.: leather, Kevlar).
Liquid nitrogen evaporates to produce nitrogen gas which has a - Store liquid nitrogen only in containers intended for this
suffocating effect at high concentration without any noticeable purpose.
warning.
First-aid measures
Rules of behavior/protective measures Do not rub affected areas of skin, rinse with large quantities of
- Eating, drinking, smoking and stowage of foodstuffs lukewarm water and cover with sterile dressings.
prohibited in work room. Remove contaminated clothing immediately.
- Provide for sufficient ventilation of work room, never use Move unconscious persons to fresh air immediately, perform
liquid nitrogen in area of assembly pits. artificial respiration if necessary.
- Handle containers, apparatus and fittings carefully, dry well Consult physician immediately.
before filling, secure against accidents.
Engines O M904 LA, 906 LA (mod. des. 904.9,906.9), F4 77
AR05.30-W-351 OA Replacing valve stem seals 11.10.95
ENGINE 904.905/906/907/908 /909 /910 /911 /921 /922, 906.910 /911 /920 /921 /922 /923 /940/941
iS j Spacer sleeve
Valve stem seal
S3 Sleeve
Supporting washer
Inlet valve
Exhaust valve
Valve guide
W05.30-0056-02
3 Removing
1 Remove cylinder head Engine 904.905- 907/909- 911/921/922 and AR01.30-W-5800A

906.910/911/920- 923/940/941
Engine 904.908 AR01.30-D-5800D
2 Remove valve springs Do not remove valves. Page 65

3 Pull off valve stem seals (2) Do not damage valve guides and valve
stems.
4 T ak e o ff sup p ortin g w a sh ers (4)
m Installing
5 Oil valve stems of valves (5, 6) with engine

oil
6 Push sleeve (3) over the valve stem until it n 346 589 01 61 00
makes contact with the valve guide
7 Fit o n sup p ortin g w a sh e r (4)
8 Install new valve stem seal (2) with spacer @ Press valve stem seal onto the valve
sleeve (1) guide as far as the stop and inspect that it is
tightly seated at the valve guide collar.
I S Engine 904.905-908/921 904 589 01 15 00
I S Engine 904.909- 911 /922 and 904 589 08 63 00

906.910/911/920- 923/940/941
9 Take off sleeve (3) m 346 589 01 6100
10 Install valve springs Page 65

11 Install cylinder head Engine 904.905- 907/909- 911/921/922 and AR01.30-W-5800A
906.910/911/920- 923/940/941
Engine 904.908 AR01.30-D-5800D
78
904 589 08 63 00
Sleeve
AR05.30-W-3831A Replacing valve seat rings 18.7.95
ENGINE 904.905/906 /907/909/910/911 /921 /922, 906.910/911 /920 /921 /9221923

ENGINE 904.908 /923 in MODEL 668, 670
1 In let valve seat rings
2 E xhaust valve seat rings
3 Cylinder head
4 SJ Plug gauge
A Valve seat ring outer diam eter

B Bore diam eter of valve seat rings in cy
linder head
C Bore depth o f valve seat rings in cylin
der head
D Distance between cylinder head con
tact surface and face o f valve seat ring
E Valve seat ring height
W 05.30-0005-06
1 Remove valves Page 65

2 Clamp cylinder head (3) on the valve IS Valve removal tool WH58.30-Z-1001-14A
removing tool
3 Inspect valve guide inner diameter for we S Drift 102 589 00 23 00

ar with the plug gauge
Valve guide inner 0 BE05.30-N-1003-02B
Clearance of valve stem and valve guide BE05.30-N-1006-02B
E ] If the side of the plug gauge marked

with " + " can be inserted into the valve
guide [
replace valve guide. Page 73

4 Remove valve seat rings (1,2) from the Page 84
cylinder head (3)
S I Valve seat turning kit 366 589 00 69 00
ID Puller 000 589 28 33 00
SI Internal extractor 000 589 29 33 00
SI Countering support 000 589 34 33 00
19 Cutting tool C7 WH58.30-Z-1025-05A
80
5 Measure valve seat ring bore diameter, size 0D It is important to ensure overlap bet
(B), in cylinder head ween valve seat ring, size (A), and basic bo
re, size (B).
If the sizes differ from the specifications,
the basic bores must be machined to the
next oversize of the valve seat ring diame
ter (A).
Rework basic bores to the next oversize of

the valve seat rings diameter (A).
Bore 0 (B) of inlet valve seat rings BE05.30-N-1009-03B
Bore 0 (B) of exhaust valve seat rings BE05.30-N-1010-03B
Inlet valve seat ring outer 0 (A) BE05.30-N-1001-03B
Exhaust valve seat ring outer 0 (A) BE05.30-N-1002-03B
Overlap of valve seat rings in cylinder head BE05.30-N-1004-03B
I S Dial gauge 001 589 53 21 00
E S Q u irk calipers fo r In te rn a l m e a su re W H 58.30-2-1003-12A

ments
I S Quick calipers for internal measure WH58.30-Z-1004-12A

ments
6 Machine valve seat ring basic bores in cylin Page 86

der head
Bore 0 (B) of inlet valve seat rings BE05.30-N-1009-03B
Bore 0 (B) of exhaust valve seat rings BE05.30-N-1010-03B
Bore depth of valve seat rings (C) BE05.30-N-1011-03B
In le t v a lv e s ea t ring o u te r 0 (A ) BE05.30-N-1001-03B
Exhaust valve seat ring outer 0 (A) BE05.30-N-1002-03B
Valve seat ring height (E) BE05.30-N-1003-03B
Overlap of valve seat rings in cylinder head BE05.30-N-1004-03B
Distance between cylinder head contact BE05.30-N-1005-03B

surface and face of valve seat ring (D)
I S Dial gauge 001 589 53 21 00
I S Valve seat ring turning tool WH58.30-Z-1025-05A
I S Quick calipers for internal measure WH58.30-Z-1003-12A

ments
US Quick calipers for internal measure WH58.30-Z-1004-12A

ments
Danger! Risk of injury from handling liquid W ear heat-protective gloves, protective Page 77
nitrogen or from contact with severely clothing and full eye protection.
supercooled objects. Ensure adequate ventilation.
Risk of suffocation from inhaling nitrogen
gas.
7 Insert valve seat rings in cooling box and GO Supercool valve seat rings for about 20
pour in liquid nitrogen to 30 minutes
S Su p e rco o lin g box 346 589 00 63 00
A Danger! Risk of injury to eyes and skin from Wear protective gloves, protective clothing Page 41
handling hot or glowing objects and, if necessary, eye protection.

8 Heat cylinder head in water bath HITemperature about 80 C
9 Use pliers to remove valve seat rings (1,2)
from the cooling box and fit onto the bores
of the heated cylinder head
10 Knock in valve seat rings (1,2) with a suit HI

The valve seat rings must be inserted
able drift without any delay.
11 Machine valve seat rings (1,2) AR05.30-W-4511A
12 Install valves HI Use new valves or J, Page 65

grind used valves before installing. AR05.30-W-4202A
Number Designation Engine Engine 904.908

904.905/906/907/
921
B E 0 5 .3 0 -N -1 0 0 3 -U 2 B Valve guide inner 0 mm 8.000-8.022 8.000-8.022

(machining dimension) (B)
Fig. see - -
BE05.30-N-1006-026 Valve guide play of valve stem Inlet mm 0.050-0.087 0.050-0.087
Exhaust mm 0.060-0.097 0.060-0.097

904.909/910/911/
922/923,
906.910/911/920/
921/922/923/940
/941
BE05.30-N-1003-02B Valve guide inner 0 mm 8.000-8.022

Fig. see -
BE05.30-N-1006-028 Valve guide play of valve stem Inlet mm 0.050-0.087
82

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE05.30-N-1001-03B Inlet valve seat ring outer 0 (A) Standard mm 35.07-35.08 35.07-35.08
Oversize 0,3 mm 35.37-35.38 35.37-35.38
Oversize 0.5 mm 35.57-35.58 35.57-35.58
Fig. see - -
B E05.30-N-1002-038 Exhaust valve seat ring outer 0 (A) Standard mm 40.07-40.08 40.07-40.08
Oversize 0.3 mm 40.37-40.38 40.37-40.38
o v e rsiz e 0.5 mm 40.57-40.58 40.57-40.58
Fig. see - -
BE05.30-N-1003-03B Valve seat ring height (E) Inlet mm 7.6-7.7 7.6-7.7
Exhaust mm 8.0-8.1 8.0-8.1
Fig. see - -
BE05.30-N-1 Q04-03B Valve seat rings -overlaD in cylinder Inlet mm 0.045-0.080 0.045-0.080
head
Exhaust mm 0.045-0.080 0.045-0.080
B05.30-N-1005-03B Distance between cylinder head Inlet mm 3.7-4.0 3.7-4.0

contact surface and end face of valve
Exhaust mm 3.3-3.6 3.3-3.6
seat ring (D)
Fig. see - -
BE05.30-N-1009-03B Bore 0 of inlet valve seat rings in Standard mm 35.000-35.025 35.000-35.025

cylin d er h e ad (B)
Oversize 0.3 mm 35.300-35.325 35.300-35.325
Oversize 0.5 mm 35.500-35.525 35.500-35.525
Fig. see - -
BE05.30-N-1010-03B Bore 0 of exhaust valve seat rings in Standard m m 40.000-40.025 40.000-40.025

cylinder head (B)
Oversize 0.3 mm 40.300-40.325 40.300-40.325
O versize 0.5 mm 40.500-40.525 40.500-40.525
Fig. see - -
BE05.30-N-1011-03B Bore depth of valve seat rings in Inlet mm 11.4-11.6 11.4-11.6

cylinder head (C)
Exhaust mm 11.4-11.6 11.4-11.6
Fig.see - -
JE
346 589 00 63 00 366 589 006900
Supercooling box Valve seat turning kit
WH58.30-Z-1005-05A Cutting tool C7 Hunger 217 69 210

D-81309 Mnchen 70
WH58.30-Z-1025-05A Valve seat ring turning tool Model RD52 220 00100
Hunger
D-81309 Mnchen 70
WH58.30-Z-1003-12A Quick calipers for internal measurements, 0 20 - 40 mm
WH58.30-Z-1005-12A Micrometer 0-25 mm Hahn und Kolb 31 400002

Dorsigstr. 50
D-70469 Stuttgart
WH58.30-Z-1007-12A Micrometer 25-50 mm Hahn und Kolb 33520 080

Borsiqstr. 50
D-70469 Stuttgart
WH58.30-Z-1001 -14A Valve removal tool Model K2000 22100 200

Hunger
D-81309 Mnchen
AR05.30-W-3831-01 A R em o v in g v a lv e s e a l n n gs
a r
000 589 29 33 00
Internal extractor
C o m m e rc ia lly a v a ila b le to o ls (see W o rk s h o p E q u ip m e n t M a n u a l)
WH58.30-Z-1005-05A Cutting tool C7 Hunger 217 69 210

D-81309 Mnchen 70
84
1 Insert pilot (2) (8 mm 0 ) into the valve guide (1) until the stop (arrow) of the tensioning
pliers (3) makes contact with the valve guide (1). Push clamping pliers (3) down with
screwdriver, if necessary. Screw tight with the drift inserted into the top and bottom of
the pilot (2).
W 05.30-0007.01
2 A tta c h tu rn in g h e ad 02/20 (4) to t h e tu rn in g to o l (5), scre w in b o th hex a g o n socket

screws (6) loosely, align turning head (4) so that the distance between the tooth side,
the rack and the opposite side is about 0.5 to 0.8 mm. Then, tighten both hexagon
socket screws (6).
m
It must be possible to move the tool slide (8) relatively easily back and forward with the
quick-adjuster (9).
3 Attach cutting tool C7 (7) to the turning head (4).
4 Moisten pilot (2) with oil.
5 Insert turning tool (5) over the pilot (2) until the stop pin on the pilot (2) or the cutting
tool (7) touches the cylinder head.

The cutting tool must not strike the cylinder head otherwise the carbide metal tip will
he d am ag ed .
W05.30 0009 01
6 Turn quick adjustment (8) until the cutting tool (7) makes
contact with the pilot (2) or is positioned ahead of the valve
seat ring, but not touching.
7 Hold turning tool (5) tight, slacken clamping screw (12) of the
stop pin (10), carefully lower turning tool (5) until the blade
of the cutting tool (7) is about 1 mm above the inner edge of
the valve seat ring (11), size (X). Press stop pin against pilot
(2), tighten clamping screw(12).
8 Clamp pendulum guide (13) tight horizontally, approximate

ly in the middle of the guide with the steady rest clamp (14).
ffl
It must now be possible to just as easily turn the turning tool
as before.
9 Hold knurled plate (15) for the infeed control tight and turn
hand crank (16) clockwise. This usually produces an irregular
stock removal.
0
Check d istance (X ) a b o u t 1 m m a t v a lv e s ea t ring (11).
10 Turn hand crank (16) clockwise and at the same time hdld the knurled plate (15) tight.
As the turning resistance increases, briefly release knurled plate. Depth of annular
groove, size Y, about 2 to 3 mm.
m
Do not remove too large a chip. It must be possible to easily rotate the turning tool,
which is achieved by briefly releasing the knurled plate.
11 Take off US turning tool.
12 Attach 03 internal extractor (17) for inlet and exhaust valve seat ring (8) in the annular
groove and remove valve seat ring using I S countersupport (18).

Place copper plates (arrows) below the contact surfaces of the 03 countersupport so as
not to damage the cylinder head surface.
AR05.30-W-3831-02A Machining valve seat ring basic bore

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE05.30-N-1001-03B Inlet valve seat ring outer 0 (A) Standard mm 35.07-35.08 35.07-35.08
Oversize 0.3 mm 35.37-35.38 35.37-35.38
Oversize 0.5 mm 35.57-35.58 35.57-35.58
Fig. see - -
BEOS 3 0 - N - l0 0 2 - 0 3 B E xhaust v a lv e seat ring o u te r 0 (A ) S ta n d a rd mm 40.07-40.08 40 07-40 08
Oversize 0.3 mm 40.37-40.38 40.37-40.38
Oversize 0.5 mm 40.57-40.58 40.57-40.58
Fig.see - -
BE05.30-N-1003-03B Valve seat ring height (E) Inlet mm 7.6-7.7 7.6-7.7
Exhaust mm 8.0-8.1 8.0-8.1
Fig. see - -
BE05.30-N-1004-03B Valve seat ring overlap in cylinder Inlet mm 0.045-0.080 0.045-0.080

head
Exhaust mm 0.045-0.080 0.045-0.080
BE05.30-N-1005-03B Distance between contact surface of Inlet mm 3.7-4.0 3.7-4.0

cylinder head and face end of valve
Exhaust mm 3.3-3.6 3.3-3.6
seat ring (D)
Fig. see - -
86

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE05.30-N-1006-03B Valve seat angle at valve seat ring (E) Inlet 04 20 20
Exhaust "X 45 45
Fig. see - -
BE05.30-N-1007-03B Valve seat width at valve seat ring (F) Inlet mm 1.5-2.5 1.5-2.5
Exhaust mm 1.8-3.0 1.8-3.0
Fig. see - -
B E05.30-N-1008-03B Valve seat 0 at valve seat ring (final Inlet mm 31 31

ly machined) (G)
Exhaust mm 36 36
Fig. see - -
BE05.30-N-1009-03B Bore 0 of inlet valve seat rings in Standard mm 35.000-35.025 35.000-35.025

cylinder head (B)
Oversize 0.3 mm 35.300-35.325 35.300-35.325
Oversize 0.5 mm 35.500-35.525 35.500-35.525
Fig. see - -
BE05.30-N-1010-03B Bore 0 of exhaust valve seat rings in Standard mm 40.000-40.025 40.000-40.025

cylinder head (B)
Oversize 0.3 mm 40.300-40.325 40.300-40.325
Oversize 0.5 mm 40.500-40.525 40.500-40.525
Fig. see - -
BE05.30-N-1011-03B Bore depth of valve seat rings in Inlet mm 11.4-11.6 11.4-11.6

cylinder head (C)
Exhaust mm 11.4-11.6 11.4-11.6
Fig. see - -
WH58.30-Z-1025-05A Valve seat turning tool Model RDS2 220 00100

Hunger
D-81309 Mnchen 70
WH58.30-Z-1005-12A 0-25 mm micrometer Hahn und Kolb

Borsigstr. 50
D-70469 Stuttgart
WH58.30-Z-1007-12A 25-50 mm micrometer Hahn und Kolb 33520 080

Borsigstr. 50
D-70469 Stuttgart
WH58.30-Z-1001 -14A Valve removal tool Model K2000 221 00 200

Hunger
D-81309 Mnchen
2 Screw 13 cutting tool (16) tight to turning tool (4).
3 Moisten pilot (2) with oil, insert turnin tool (4) over the pilot until the stop pin (5) on
the pilot or the cutting tool (16) touches the cylinder head.

T h e c u ttin g to o l m ust M u ls h ike th e cy lin d e r h e a d o th e rw is e th e ca rb id e m e ta l t ip W ill
be d a m a g e d .
4 Turn quick adjustment (5) until the cutting tool (16) moves horizontally beyond the
hole, then push the turning tool (4) down until the cutting tool makes contact with the
cylinder head.
88
5 Hold turning tool (4) tight, slacken clamping screw (6) of the
stop pin (7), carefully lower turning tool. Tighten clamping
screw.
6 Turn the knurled plate (8) in order to set the height of the
cutting tool (16) so that it is still just free.
7 Clamp pendulum guide (9) tight horizontally approximately

in the middle of the guide with the steady rest clamp (10). It
must now be possible to just as easily turn the turning tool (4)
as before.
m
For this step, the working depth (X) should be set between
setting ring (11) and pendulum guide.
8 Calculating the setting "G ": basic bore dimension B" and
pilot diameter dimension F" divided by 2.
Example:
Dimension B = 35 mm (basic bore)
Dimension F = 14.55 mm (pilot diameter)
Dimension G = B + F
2
Dimension G = 35 mm + 14.55 mm = 24.775 mm

2
9 Set E micrometer to the setting G".
10 Slacken quick adjustment (5), raise turning tool slightly and position B micrometer
against pilot. Use the quick adjustment to set the cutting tool (16) to the setting G".
Screw quick adjustment tight.
m
It is good practice to set the cutting tool 0.1 mm less in diameter for the first cut.
11 Slacken clamping screw (12). Screw in horizontal stop screw (13) until it touches the
housing and screw clamping screw (12) tight.
12 Fix knurled screw (8) in place with hexagon bolt.
13 Turn out the basic bore for the valve seat ring by turning the hand crank (14) and at the
same time holding tight the top knurled plate (11) for the vertical infeed until the
setting ring (arrow) is making contact with the steady rest bearing (9).
ffl
Re-set cutting tool (16) as often as necessary until the calculated setting "G " is
achieved. After this, once again turn without any cutting infeed.
14 Raise turning tool (4) slightly. Slacken quick adjustment (5) and move back cutting tool
(16).
15 Face the end surface at the bottom by turning the hand crank (14) and at the same time
holding tightthe bottom knurled plate (15) forthe horizontal infeed until the stop
screw (13) makes contact with the turning tool (4).
16 Remove m turning tool.
17 Gage the basic bores (B) for the valve seat rings in the cylinder head with the 13 quick
calipers for internal measurement and I S dial gage.
s
Overlap between valve seat ring dimension (A) and basic bore dimension (B) should be
assured.
90
AR05.30-W-4511A Machining valve seat rings 21.11.95
ENGINE 904.905/906/907/909/910/911/921 Z922/923,906.910/911/920/921 Z922/923

ENGINE 904.908 in MODEL 668. 670
1 Inlet valve
2 Exhaust valve
3 Cylinder head
4 I S Turning tool
5 19 Valve removal tool
6 Valve seat rin g
7 I S D ial gage
8 I S Dial gage holder
W 0 5 .30-0062-06
6 Valve seat rin g
E Valve seat angle at valve seat ring

F Valve seat width at valve seat ring
G valve seat surface 0 at valve seat ring
related to machining dimension (H)
H Machining dimension (inspection
surface 0 (G)
W 05.30-006S-06
IE! Removing
1 Remove cylinder head Engine 904.905- 907/909- 911 /921/922 and AR01.30-W-5800A
906.910/911/920-923/940/941
Engine 904.908 AR01.30-D-5800D
2 Remove valve spring AR05.30-W-3511A
En g in es O M 9 0 4 LA , 906 LA (m o d . des. 904.9, 9 06.9), F4

AR07.03-W-6831C Removing and installing nozzle holder combination 7.11.97
ENGINE 904.905/906/907/921 # # as o f40488

ENGINE 904.908 # # as o f40488,
904.923
in MODEL 668,670
ENGINE 904.909/910/911/922, 906.910/911/920/921 /922 /923 /940 /941
1 Nozzle holder combination 8 Seal

2 S J Adapter 9 O-ring
3 H3 Im pact extractor 10 Pressure pipe connection
4 Hexagon socket screw 11 Thrust bolt
5 Spherical washer 12 Injection line
6 Tensioning arm 13 End cover o f constant throttle
7 O-ring
Revisions
7.7.98 Pay attention to installation position of seal Step 10
Tightening torque for bolt of tensioning arm at cylinder Step 12

head modified
US Removal
. Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 29
fuel.
2 Remove injection line (12) Page 27

3 Remove pressure pipe connection (10)
4 Remove tensioning arm (6)
5 Attach adapter (2) and impact extractor (3) Ill 355 589 01 63 00
to the female thread (M 8) of the nozzle
holder combination (1)
34
3 Clamp cylinder head (3) on valve removal I S Valve removal tool WH58.30-Z-1001-14A
tool (5)
Inspecting
4.1 Measure amount by which valve stands Engine 904.905-908/921 Page 8

back to cylinder head (3)

back at exhaust valve and at both inlet
valves and note.
Dial gage 001 589 53 21 00
IS ] Dial gage holder 343 589 004000
[33 If the readout obtained is not within

the permissible tolerance, the valve (1,2)
has to be inspected.
If wear is present, replace valve and inspect
valve seat rings (6).
4.2 Measure amount by which valve stands Engine 904.909- 911/922 and Page 8
back and permissible difference to cylinder 906.910/911 /920- 923/940/941
head (3)

back at exhaust valve and at both inlet
valves and note.
Perm issible d iffe re n c e b e tw e e n h n th in le t RF05.30-N-1014-01R

valve stem ends must not be exceeded.
Dial gage 001 589 53 2100
I S Dial g a g e h o ld er 343 589 00 40 00
I S Dial gage holder 363 589 02 2100
S If the readout obtained is not within

th e perm issible to le ra n ce , th e va lve s (1, 2)
should be inspected.
If wear is present, replace valve and valve
seat rings (6).
5 Pull valves (1, 2) out of the cylinder hfead (3) B Mark valves.
6 Inspect valve seat rings (6) Q3 If valve seats are only slightly worn, it is
possible to machine both inlet or exhaust
valve rings without replacing the valve seat
rings.
Amount by which valve stands back at all
valves and permissible difference between
b o th in let v a lv e stem en ds m ust n o t b e
exceeded.
If wear is present |
replace valve seat rings. AR05.30-W-3831A

7 Use a plug gage to inspect valve guidb E l Drift 102 589 00 23 00
inner diameter for wear
Valve guide inner 0 BE05.30-N-1003-02B
Play of valve stem in valve guide BE05.30-N-1006-02B
Valve stem 0 BE05.30-N-1007-01B
QQ It it is possible to insert the side ot the

plug gage marked with " + into the valve
guide J,
replace valve guide. AR05.30-W-3731A
4
Machining
8 Machine valve seat ring (6) in cylinder head Engine 904.909- 9111922 and Page 10
(3) 906.910/911/920-923/940/941: both inlet
valve seat ringsshould be machined to the
same depth. The permissible difference
between both valve stem ends must not be
exceeded.
US Valve seat turning kit 366 589 00 69 00
Valve seat angle at valve seat ring (E) BE05.30-N-1006-03B
Valve seat width at valve seat ring (F) BE05.30-N-1007-03B
Inlet valve seat surface at valve seat ring BE05.30-N-1011-03B

machining dimension (H) related to valve
seat surface 0 (G)
Exhaust valve seat surface at valve seat ring BE05.30-N-1012-03B

machining dimension (H) related to valve
seat surface 0 (G)
ED If the measurements obtained during

machining are less than the test data J.
replace valve seat ring. AR05.30-W-3831A
Inspecting
9 Inspect concentricity of valve seat to valve Page 13

guide
Off-center of valve seat ring to valve guide BE05.30-N-1008-02B
Concentricity of valve seat to valve guide B E05.30-N-1009-02B
O Valve seat turning kit 366 589 00 69 00
S Inspection kit for valve seats WH58.30-Z-1019-05A
OD If difference from test data |
once again machine valve seat ring (6) Page 10

m Installing
10 Install valves (1,2) IXI Install new valves or | AR05.30-W-3511A
grind used valves before Installing. Page 15

11 Install cylinder head Engine 904.905- 907/909- 9111921/922 and AR01.30-W -S800A
906.910/911/920- 923/940/941
Engine 904.908 AR01.30-D-5800D
Engines OM904 LA, 906 LA (mod. des. 904.9.906.9). F4 5
Test data o f valves

906/907/921 904.904/908/923 910/911/922,
906.910/011/010/
920/921/922/923
/940/941
BE05.30-N-1001-018 Amount by which valve stands back mm 1.1-1.5 1.1-1.5 1.1-1.5

surface
BE05.30-N-1007-01B Valve stem 0 (E) Inlet mm 7.935-7.950 7.935-7.950 7.935-7.950
Exhaust mm 7.925-7.940 7.925-7.940 7.925-7.940
BE05.30-N-1014-01B Permissible difference of inlet valves 0,2 0,2 0,2

and valve stem end

906/907/921
8E05.30-N-1003-02B Valve guide inner 0 mm 8.000-8.022 8.000-8.022

Fig. see - -
B E05.30-N-1006-028 Valve guide play of valve stem Inlet mm 0.050-0.087 0.050-0.087
Exhaust m m 0.060-0.097 0060-0 097
BE05.30-N-1008-02B Valve seat to valve guide - mm 0.02 0.02

off-center
B E 0 5 .3 0 -N -1 0 0 9 -0 2 B V a lv e se a t to v a lv e g u id e - m m 0.04 0.04
concentricity
T est d a ta o f v a lu e g u id es

904.909/910/911/
922/923,
906.910/911/920/
921/922/923/940
/941
BE05.30-N-1003-02B Valve guide inner 0 mm 8.000-8.022

Fig. see -
BE05.30-N-1006-02B Valve guide play of valve stem Inlet mm 0.050-0.087
BE05.30-N-1008-02B Valve seat to valve guide - mm 0.02

off-center
BE05.30-N-1009-02B Valve seat to valve guide - mm 0.04

concentricity
6

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
B E05.30-N-1006-03B Valve seat angle at valve seat Inlet 4 20 20

ring (E)
Exhaust 45 45
Fig. see - -
BE05.30-N-1007-03B Valve seat width at valve seat Inlet mm 1.5-2.5 1.5-2.5

ring (F)
Exhaust mm 1.8-3.0 1.8-3.0
Fig. see - -
BE0S.30-N-1011-03B Inlet valve seat surface at valve seat Dim. G mm 31.0 31.0
ring machining dimension (H)
Dim. H mm 4.2-4.4 4.2-4.4
re la te d to v a lv e s e a t surface 0 (G )
BE05.30-N-1012-03B Exhaust valve seat surface at valve Dim. G mm 36.0 36.0

seat ring machining dimension (H)
Dim. H mm 4.3-4.5 4.3-4.S
related to valve seat surface 0 (G)
S 3
^ 343 589004000 J
Dial gage Dial gage holder Drift Dial gage holder
WH58.30-Z-1019-05A Inspection kit for valve seats Hunger 216.93.300

D-81309 Mnchen 70
WH58.30-Z-1001-14A Valve removal tool Model K2000 221 00200

Hunger
D-81309 Mnchen
Test data of valves

906/907/921 904.904/908/923

surface
m
1 Attach H3 dial gage (1) to IS! dial gage holder (2).
2 Mount [S I dial gage (1) with a preload onto the plane face of the cylinder head.
4 Move S I dial gage (1) sufficiently until the tracer pinis touching the valve disk (3).
ffl W05.30-0060-01
If th e re a d in g o b ta in e d (A ) is n o t w ith in th e p erm issible to le ra n c e , inspect v a lv e seat

Test data of valves

910/911/922, 906/907/921 904.904/908/923
906.910/911/919/
920/921/922/923
/940/941

re la tiv e to cy lin d e r h e a d co n ta ct
surface
BE05.30-N-1014-01B Permissible difference of inlet valves 0.2 0,2 0,2

and valve stem ends
8
f \
343 589004000 J
Dial gage holder
m
1 Attach SI dial gage (1) to I S dial gage holder (2).
2 Mount IS ] dial gage (1) with a preload onto the plane face of the cylinder head.
3 Set scale of dial gage to 0 .
4 Move IS ] dial gage (1) sufficiently until the tracer pin is touching the valve disk (3).
m W05.30-0060-01
5 Attach ISj dial gage (1) to ISj the dial

gage holder (4) and mount on the top
contact surface of the cylinder head.
6 Position S I dial gage (1) with a

ends (5).
7 Set scale of dial gage to 0".
8 Pull back tra c e r pin o n IS] dia l g a g e

indication on gage.
m
be exceeded.
If the readout obtained (C) Is not

AR05.30-W-4532-01A Machining valve seat rings with turning
tool
Test data valve seat rings

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
B E05.30-N-1006-03B Valve seat angle at valve seat Inlet 20 20

ring (E)
Exhaust . 45 45
ng. see - -
BE05.30-N-1007-03B Vale seat width at valve seat Inlet mm 1.5-2.5 1.5-2.5

ring (F)
Exhaust mm 1.8-3.0 1.8-3.0
Fig. see - -
BE05.30-N-1011-03B Inlet valve seat surface at valve seat Dim. G mm 31,0 31.0
ring machining dimension (H)
Dim. H mm 4 .2 - 4 4 4 .2 - 4 4
BE05.30-N-1012-03B Exhaust valve seat surface at valve Dim. G mm 36.0 3.6

seat ring machining dimension (H)
Dim. H mm 4.3-4.5 4.3-4.5
1 Insert pilot (2) (8 mm 0 ) into the valve guide (1) until the stop (arrow) of the tensioning
damp (3) is touching the valve guide (1); push tensioning damp (3) down with a
screwdriver, if necessary. Tighten with the drift inserted at the top and bottom of the
pilot (2).
10
2 Attach turning head (4) to the turning tool (5), screw in bothhexagon socket screws (6)
loosely, align turning head (4) so that the distance between the rack and the opposite
side is about 0.5 to 0.8 mm. Then, tighten both hexagon socket screws (6).
Inlet valve - * turning head D2/20
Exhaust valve--turning head D2/45
m
It must be possible to move the tool slide (8) relatively easily back and forward with the
quick-adjuster (9).
3 Attach cutting tool C8 (7) to the turning head (4).

W 05.30-0027.01
4 Moisten pilot (2) with oil.
5 Insert turning tool (5) over the pilot (2) until either the stop pin (10) on the pilot (2) or
liie cu ttin g lu u l (7) is to uch in g the c y lin d e i head .

Cutting tool (7) must not strike the cylinder head otherwise the carbide metal tip will
be damaged.
6 Turn quick-adjuster (9) until the cutting tool (7) is positioned

above the middle of the valve seat ring.
7 Hold turninq tool (5) tight, slacken clamping screw (17) of the
stop pin (10), carefully lower turning tool (5) until the blade
of the cutting tool (7) is touching the middle of the valve seat
ring (11). Press stop pin (10) against pilot (2), tighten dam
ping screw (12).
8 Clamp pendulum guide (13) tight horizontally, approximate

ly in the middle of the guide with the steady rest clamp (14),
DD
It must be possible now to rotate the turning tool (5) just as
easily as before.
9 Use a marker pen to make three colored markings on the val

ve seat ring (11) offset about 120 (arrows).
10 Raise turning tool (5) and position cutting tool (7) next to the
inner valve seat edge by turning the quick-adjuster (9).
m W 05.30-0029-12
Do not set any cut feed.
11 Hold knurled plate (15) for infeed control tight and turn
hand crank (16) clockwise. This usually produces an irregular
stock removal.
12 After this turning operation, move the cutting tool (7) back again next to the inner
valve seat edge with the quick-adjuster (9).
13 Slacken locking screw (17) and turn the knurled plate (18) anti-clockwise about 1/2 to
1 g ra d u a tio n (a rro w ). T ig h te n lo c k in g scre w (17).
m
1 graduation = 0.1 mm infeed
14 Hold the knurled plate (15) for the infeed control tight and turn hand crank (18) clock
wise. Turn the outside diameter of the valve seat with the tip of the cutting tool (7).
m
A stock removal should be performed as often as necessary
(steps 13 and 14) until the valve seat is smooth and free of
chatter marks and the valve seat width (F) and valve seat
diameter (G) are achieved; see test data.
E Valve seat angle at valve seat ring

F Vale seat width at valve seat ring
G Valve seat surface 0 at valve seat ring related to
machining dimension (H)
H Machining dimension (inspection dimension related to
v a lv e s e a t su rfa ce 0 (G )

Engine 904.909-911/922 and 906.910/911: both inlet valve
s e a t ring s sh o u ld be m a c h in e d t o t h e s a m e d e p th . The
permissible difference between both inlet valve stem ends
must not be exceeded.
15 Correct valve seat (11) on the outside.
15.1 Raise turning tool (5) and slacken clamping screw (12) of the stop pin (10).
15.2 Turn quick adjustment (9) so that the cutting tool (7) is touching the outer valve seat
edge.
Carefully position cutting tool on the valve seat edge.
15.3 Press stop pin (10) down until it is touching the pilot. Tighten clamping screw (12).
7-
11 Hi
W OS.30-0091-02
12
15.4 Sla ck e n lo c k in g s c re w (17) a n d tu rn th e k n u rle d p la te (18) a b o u t 1/2 g ra d u a tio n
(arrow) in an anti-clockwise direction. Tighten locking screw again.
15.5 Hold crank arms with both hands and move turning tool (5) down in stages with slight
pressure around the pilot.
15.6 Repeat steps 15.4 and 15.5 until the required valve seat width is achieved; see test data
a
After that, once again turn without any chip feed.
16 Take off turning tool.
m
Do not remove pilot (2).
AR05.30-W-4532-02A Inspecting concentricity of valve seat to

valve guide
Num ber D e sig n a tio n Engine E n g in e 904.908

904.905/906/907/
921

off-center

concentricity

904.909/910/911/
922/923,
906.910/911/920/
921/922/923/940
/941
B E05.30-N-1008-02B Valve seat to valve guide- mm 0,02

off-center
BE05.30-N-1009-02B Valve seat to valve guide- mm 0,04

concentricity
366 589 00 6900
Valve seat turning kit
Commercially available tools (see workshop Equipment Manual)
WM58.30-Z-1019-05A Inspection kit for valve seats Hunger 216.93.300

D-81309 Mnchen 70
WH58.30-Z-1001-HA Valve removal tool Model K2000 22100200

Hunger
d -81309 Mnchen
1 Insert E damping ring (1) over the installed pilot of the valve turning tool and clamp
tight.
2 Mount 13 tester (2) onto the clamping ring (1).
3 Position tracer pin of the tester (2) on the middle of the valve seat with a preload.
m
Slowly turn tester around the pilot and, in so doing, check the radial runout of the
valve seat; see test data.
4 Take off 3 tester (2), clamping ring (1) and pilot. W 05.30-0063-01
14
AR05.30-W-4202A Grinding valves 18.7.95
ENGINE 904.905/906/907/909/910/911/921Z922/923,906.910/911/920/921 Z922/923

ENG IN E 904.908 in M ODEL 668.670
EN GIN E 906.940/941 in M ODEL 957
1 Valve
2 IH V alve g rin d in g m achine
A Valve seat angle

B Valve disk diam eter
Cl V alve le n g th (e n g in e 904.905-
908/921)
C2 Valve length (engine 904.909- 911/922
and 906.910/911/920- 923/940/941)
C V alve stem d ia m e te r
F Valve seat width at valve disk
6 Valve seat surface diam eter
H Valve seat surface machining
surface diam eter (G)
W05.30-0061-06
Grinding
1 Clean valves (1) S Remove any oil carbon deposits
2 Clamp valve (1) in machine E The valve should be clamped in the

valve grinding machine (2) as close as
possible behind the valve disk in order to
avoid vibration problems.
S3 Valve grinding machine WH58.30-Z-1022-05A
3 Set valve seat grinding angle on valve Valve seat angle (A) BE05.30-N-1003-01B
grinding machine (2)
4 Slowly move valve (1) with the infeed

toward the rotating grinding wheel until
the wheel comes into contact with the seat
surface of the valve (1)
5 Continue grinding with a small infeed until E The measurements must not be less
the entire circumference of the valve seat is than the test data after this operation.
smooth and free of chatter marks
Valve disk 0 (B) BE05.30-N-1004-01B
Valve length (C) BE05.30-N-1006-01B
Valve stem 0 (E) BE05.30-N-1007-01B
Valve seat width at valve disk (F) BE05.30-N-1005-01B
Inlet valve seat surface machining BE05.30-N-1008-01B

surface 0 (G)
Engines OM904 LA. 906 LA (mod. d et 904.9, 906.9), F4 15
Outlet valve seat surface machining BE05.30-N-1009-01B
surface 0 (G)
Concentricity of valve seat to valve stem BE05.30-N-1011-01B
m 001 589 53 21 00
m 363 589 02 21 00
6 Remove valve (1) from clamp at valve I S Valve grinding machine WH58.30-Z-1022-05A
grinding machine
7 Fit valve (1) onto valve grinding machine CD The valve length (C l, C2) must not be BE05.3Q-N-1006-01B
device (2) and face the end of the valve less than the specification after this
stem operation.
Test data of valves

906/907/921 904.904/908/923 910/911/922,
908.910/911/919/
920/921/922/923
/940/941
BEDS 3 0 -N .1 0 0 3 -0 1 B V a lv e s e a t a n g le (A ) In le t X 20 20 20
Exhaust A. 45 45 45
BE0S.30-N-1004-01B Valve disk 0 (B) Inlet mm 33.9-34.1 33.9-34.1 33.9-34.1
Exhaust mm 37.9-38.1 37.9-38.1 37.9-38.1
BE05.30-N-1005-01B Valve seat width at valve disk (F) Inlet mm 3.3-4.3 3.3-4.3 3.3-4.3
Exhaust mm 3.S-4.2 3.5-4.2 3.5-4.2

BE05.30-N-1006-01B Valve length (C) Inlet mm 125.7-126.1 125.7-126.1 125.65-126.95
Exhaust mm 152.5-152.9 152.5-152.9 152.5-152.9
B E 0 5 .3 0 -N 1 0 0 7 -0 1 D V a lv e stem 0 (E) In le t mm 7.935-7.950 7.935-7.950 7.935-7.950
Exhaust mm 7.925-7.940 7.925-7.940 7.925-7.940
BE05.30-N-1008-01B Inlet valve seat surface machining Dim. G mm 31.0 31.0 31.0
Dim. H mm 2.7-3.1 2.7-3.1 2.7-3.1
surface 0 (G)
BE05.30-N-1009-01B Exhaust valve seat surface machining Dim. G mm 36.0 36.0 36.0
Dim. H mm 2.5-3.2 2.53.2 2.5-3.2
surface 0 (G)
BE05.30-N-1010-01B Hardness at valve stem end Inlet HRC 54-60 54-60 54-60
Fxh au st HRC 54-60 54-60 54-60
BE05.30-N-1011-01B Concentricity of valve seat to valve Inlet mm 0.03 0.03 0.03

stem
Exhaust mm 0.03 0.03 0.03
16
r
y 001 589 53 2100 J y 363 589 02 21 00 J
Dial gage Dial gage holder
WH58.30-Z-1022-05A Valve grinding machine Model VKM1A 231 00001

Hunger 231 00002
D-81309 Mnchen 70
AR05.20-W-6292A Removing, installing cam shaft 17.7.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 In M O D E L 668. 670
ENGINE 906.940/941 In MODEL
957
WOS .20-0001-09
1 C am shaft w ith cam shaft s p rocket E Tim in g ease

2 O-ring 7 Guide sleeve
3 Tappet rod
4 Valve tappet B16 Camshaft TDC sensor
5 C ra nksh a ft sp rocket
gum Removing, installing
1 Extract or drain engine oil Engine 904.905- 907/921 wh0101.40
Engine 904.908 AP18.00-D-0101A
Engine 904.909- 911/922 and AP18.00-W-0101B

906.910/911 /920- 923/940/941
2 Remove engine Engine 904.905-907/921 AR01.10-W-2401A
Engine 904.908 AR01.10-D-2400D
Engine 904.909-911/922 AR01.10-W-2400D
Engine 906.920-923 AR01.10-W-2400F
Engine 906.940/941 AR01.10-W-2400C
3 Insert engine into engine repair stand I S Engine repair stand WE58.40-Z-1001-11A
I S Adapter WE58.40-Z-1002-11A
4 Remove rocker arm assembly Engine 904.905- 907/908/921 AR05.00-W-5521A
Engine 904.909- 911 /922 and AR05.00-W-5521C

906.910/911/920- 923/940/941
5 Pull out tappet rods (3) E Installation: oil tappet rods.
6 Remove fuel pump AR47.20-W-5713A
7 Remove all unit pumps Pa g e 37
18
8 Rotate engine in engine repair stand E Rotate engine approx. 180 so that the
tappets (4) detach from the camshaft (1).
9 Remove oil pan Engine 904.905- 907/921 AR01.45-W-7500A
Engine 904.908 AR01.45-D-7500D
Engine 904.909- 911/922 and AR01.45-W-7500C

906.910/911/920-923
10 Pull out camshaft TDC sensor (B 16) at E Installation: replace O-ring (2) and
crankcase press in camshaft TDC sensor until it makes
contact with camshaft sprocket.
11 Remove timing case (6) Engine 904.905-911 /908/921 /922, AR01.60-W-8200A

906.910/911/920- 923/940/941

or 2, prepared for engine output or
12 P u ll ca m sh a ft (1) o u t o f th e crankcase Page 21
904 589 02 14 00
13 Pull valve tappets (4) out of the crankcase E Mark valve tappets relative to
cronkcose.
Inspecting
14 Inspect valve tappets (4) If damage or wear is present J,
replace roller tappets.
Valve tappet outer diameter BE05.30-N-1004-04B
Valve tappet bore in crankcase BE05.30-N-1005-04B
15 Inspect hardness, runout and cam rise of Page 21

camshaft (1)
Hardness of cams and bearing journals BE05.20-N-1005-04B
Camshaft radial runout BE05.20-N-1006-04B
Cam rise of valve cams B E05.20-N-1007-04B
cam rise of unit pump BE05.20-N-1008-04B
000 589 202100
m 001 589 53 21 00
363 58902 2100
17 Fill p n ginp nil rir r u it AR18.00-W-1600A
Test data of camshaft

906/907/909/910 923
/911/921/922
BE05.20-N-10Q5-04B Hardness of cams and bearing HRC 57-63 57-63

journals
6E05.20-N-1006-04B Camshaft radial runout when Timing gear seat max. mm 0.020 0.020
mounted on outer bearing journals
Cam base circle max. mm 0.025 0.025
Bearing point 1-5 max. mm 0.030 0.030
BE05.20-N-1007-04B Cam rise -valve cams over Inlet min. mm 7.3 7.3
base circle 0
Exhaust min. mm 8.2 8.2
B E05.20-N-1008-04B Cam rise - unit pump over min. mm 13.8 13.8

base circle 0
T e s t data of valve tim ing

906/907/909/910 923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE05.30-N-1004-U4B Valve tappet outer 0 Standard mm 17.944-17.965 17.944-17.965
Oversize 0.25 mm 18.194-18.215 18.194-18.215
BE05.30-N-1005-046 Valve tappet bore in crankcase Standard mm 18.000-18.018 18.000-18.018
Oversize 0.25 mm 18.250-18.268 18.250-18.268
Workshop equipment/MB testers (see Workshop Equipment Manual)
WE58.40-Z-1001-11A Engine repair stand
WE58.40-Z-1002-11A Adapter
20
AR05.20-W-6292-02A Removing, inserting camshaft
1 Attach I S guide sleeve (2) to front of camshaft (1) and carefully pull camshaft out of
the crankcase.
@
Do not damage camshaft bearings in crankcase.
2 Attach IS guide sleeve (2) to the camshaft (1).
3 Rotate camshaft (1) until the marking ''1-1 (arrow) on the camshaft sprocket is aligned
with the marking 1 on the crankshaft sprocket (3).
4 Carefully insert camshaft (1) into the crankcase.

Do not damage camshaft bearings.
AR05.20-W-6292-03A Inspecting camshaft
Num ber D e sig n a tio n Engine 904.905/ Engine 904.908/

906/907/909/910 923
/911/921/922
B E05.20-N-1 OOS-04B Hardness of cams and bearing HRC 57-63 57-63

journals
BE05.20-N-1006-04B Camshaft radial runout when Timing gear seat max. mm 0.020 0.020
Cam base circle m ax. mm 0.025 0.025
Bearing point max. mm 0.030 0.030
BE05.20-N-1007-04B Cam rise - valve cams over Inlet min. mm 7.3 7.3
base circle 0
Exhaust min. mm 8.2 8.2
BE05.20-N-1008-04B Cam rise - unit pump over min. mm 13.8 13.8

base circle 0


906.910/911/920/
921/922/923/940
/941
BE05.20-N-1005-04B Hardness of cams and bearing HRC 57-63

journals
BE05.20-N-1006-04B Camshaft radial runout when Timing gear seat max. mm 0.020
Cam base circle max. mm 0.025
All bearing points max. mm 0.030
BE05.20-N-1007-04B Cam rise - valve cams over Inletmin. mm 7.3

base circle 0
Exhaust min. mm 8.2
BE05.20-N-1008-04B Cam rise - unit pump over min. mm 13.8

base circle 0
1 Inspect hardness of the cams and bearing journals at the

camshaft (1) with the E l drop hardness tester (2).
a
A hard base should be placed below the cam or bearing
journal to be inspected during the test.
W 05.20-001S-10
22
2 Mount camshaft (l) at the outer bearing journals.
3 Measure radial runout of cam base circle or bearing points (L)

with the I S dial gage (3).
4 Measure cam rise of the valve cams of the inlet valves (E) and
exhaust valves (A) as well as of the unit pump cams (S) with
I S dial gage (3).
WOS .20-0016-12
AR07.15-W-1628A Removing, installing MR/PLD control unit 1.9.95
ENGINE 90 4.9 0 5 /9 0 6 /9 0 7 /9 0 9 /9 1 0 /9 1 1 /921 /9 2 2 ,90 6.91 0/91 1/92 0/92 1 Z922/923
1 Spacer
2 Rubber damper
3 Washer
4.1 Nut (ENGINE 904.905 -907/921)
4.2 Bolt (ENGINE 904.909- 911 /922,
906.910/911/920- 923)
5 Vehicle wiring harness connector
6 Engine wiring harness connector
7 Fuel heat exchanger
(ENGINE 904.905 -907/921)
8 Bolt (ENGINE 904.905 - 907/921)
9 Engine trim panel
10 Oil level sensor cable
A6 MR/PLD control unit
W07.15-0080-06
m M Removing, installing
1 Switch off ignition
with a safety prop.
2 Tilt cab
Notes on tilting cab Model 673- 679,950- 954,970- 976 Page 26

3 Remove engine trim panel (9)
4 Remove fuel heat exchanger (7) On engine 904.905- 908/921 AR47.21-W-5621A

00 Fuel lines remain attached at fuel heat
exchanger
5 Detach electric cable of oil level sensor (10) On engine 904.909- 911/922 and
at MR/PLD control unit (A6) 906.910/911/920-923
6 Release and separate plug connector of Q ] Release plug connector by pressing

vehicle wiring harness (5) at MR/PLD locking bar
co n tro l u n it (A 6)
7 Release and separate plug connector of [2 Release plug connector by swiveling

engine wiring harness (6) at MR/PLD locking bar
control unit (A6)
8 Remove MR/PLD control unit (A6) at @ The MR/PLD control unit must not be
crankcase disassembled
ED Installation: install spacers (1) fitted to
rubber damper (2) and at MR/PLD control
unit. Pay attention to installation position
of rubber dampers (2)
9 Install in t h e reverse o rd er
24
10 Learn transponder keys CD Only If a new MR/PLD control unit (A6) AR80.57-W-0010A
has been installed
Bearbeitungsvermerk
. . . . . . ........ ........................ l'Sit"";
AS60.80-Z-0001-01A Injury hazard from pinching and crushing When tilting ensure that no one is A Danger!
Always tilt cab to end position and
Injury hazard
mechanism can lead to severe injuries when tilting the cab. When tilting cab:
Rules of behavior/protective measures unauthorized access, e.g. by blocking off or with h u m a n
- Apply parking brake. vehicle operating Instructions.
- Secure vehicle against rolling. N e ve r w o rk u n d e r cah w h e n p a rtia lly tilted .
neutral position.
to position "N".
AH60.80-N-0003-01A Notes on tilting the cab Models 673,674, 675, 676, 677, 678,
679, 950, 952,953, 954, 957,970,971,
972,973, 974, 975,976

S w itc h o f f e n g in e T h e r e frig e ra to r box m ust b e sw itch e d o ff b e fo re th e cab is
Apply parking brake tilted.
Secure vehicle to stop it rolling away The refrigerator box may only be switched on 10 minutes
Remove all loose objects (e.g. cans, bottles, tools, bags etc.) after tilting the cab back again.
from the cab S Also refer to the refrigerator box manufacturer's
On vehicles with manual transmission move shift leverto Operating Instructions and the red information plate on the
Model 957: release steering column and open front flap
E Always tilt cab up to its final position.
26
AR07.15-W-9235A Removina and installing MR/PLD injection lines
ENGINE 904.905/906/907/909/910/911/921/922,906.910/911/920/921 Z922/923

ENGINE 904.908 in MODEL 668, 670
1 Engine panel
2 In je c tio n lin e
Engine 9QS.920-923 w ith " h y d ra u lic " transm issio n s h ift code CS3
30 Hydraulic lines
31 Securing dips
32 M o u n tin g p la te
33 Bolt
W 2 6 .6 0 -1 0 U -1 1
3 Removal
Danger! Danger of pinching and catching when cab Ensure that no one is present in the tilting Page 26
is tilte d a re a of th e cab w h e n tiltin g . A lw a y s t ilt cab
all the way to the final position and secure
with safety brace.
1.1 Tilt cab
Notes on tilting the cab Models 673- 679,950- 954,957,970- 976 Page 26
1.2 Remove maintenance hood Models 668,670
8 ^ ^ Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 27
2 Remove hydraulic lines (30) with mounting On engine 906.920- 923 with code (GS3)
plate (32) and mounting clamps (31) from hydraulic gearshift.
engine and lay down to side LLI D o n o t sep ara te h y d ra u lic lines.
3 Remove engine paneling (1)
A Dangerl Fuel presents an explosion hazard and is Fire, open lights and smoking prohibited. Page 29
toxic when inhaled or absorbed. Contact Avoid sparks. Fill and store fuel only in
with fuel can cause skin and eye injury. containers intended for this purpose and
marked accordingly.
Wear protective clothing when handling
fuel.
4 Remove injection line (2) Do not bend injection line.
SI 000 58907 03 00
SI 000 589 50 03 00
m 000 589 68 03 00
IE Installation
5 Install injection line (2) @ Do not bend injection line, observe

installation position.
SI 000 589 07 03 OO
SI 000 589 5003 00
SI 000 589 68 03 00
Ezl B A07.15-N-1004-01A
6 Bleed fuel system On engine 904.905- 908/921 AP47.00-W-1720-01A
A Danger! Accident hazard resulting from vehicle Secure vehicle against starting to move Page 30
starting to move by itself with engine unintentionally.
running. Danger of Injury resulting from Wear closed and tight fitting work
engine running.
7 Start engine and allow to run Crank engine for max. 90 seconds with
starter, if it does not start wait approx. 2
minutes and attempt to start again.
8 Check both screwed connections on E Replace injection line if leaky

injection line (2) for leakage
9 Install engine paneling (1)
10 Install hydraulic lines on engine On 906.920- 923 engine with code (GS3)
hydraulic" gearshift
0 Diesel Injection system with MR/PLD unit pumps

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BA07.15-N-1004-01A Injection line to delivery line connection of Nm 25 25

unit pump
28
y v . 000 589 50 03 00 J v_ 000 589 68 03 00
Serrated wrench Box wrench socket
AS47.00-Z-0001-01A Risk of explosion from ignition of fuel, risk Fire, the creation of sparks, naked A Danger!
of poisoning if fuel is inhaled or swallowed lights and smoking prohibited.
marked.
W ear protective clothing when
handling fuels.
P o te n tia l d a n g e rs

ca n cause d a m a g e t o t h e skin. C o n ta ct w ith g aso lin e fu e l, fo r can be properly closed off.
example, removes the skin's natural oils. Fuel vapors are explosive - Immediately remove any fuel which has been spilt.
if inhaled and can cause unconsciousness in high concentrations. Working on the vehicle using a naked flame
forbidden. First aid measures
- Never drain or add fuels over workshop pits. Change out of clothing on which fuel has been spilt as soon as
possible.
If fuel is splashed Into the eyes, rinse out the eyes Immediately
ASOO.OO-Z-OOO5-01A Risk of accident as a result of vehicle Secure vehicle to prevent it from A Dangerl
starting off when engine Is running. Risk of moving off.
injury as a result of bruises and burns if you W ear closed and close-fitting work
Insert your hands into engine when it is clothes.
P o ss ib le d a n g e rs R u les o f co n d u c t / P r o te c tiv e m ea su res

As a general rule, carry out work on the running engine only if
from vehicle starting off during starting operation (e.g. when Before starting the engine, apply parking brake.
testing compression pressure) as a result of gear engaged or when On models with manual transmission, move gearshift lever
result of selector lever position P" or N" not engaged On models with automatic transmission, move selector lever
(exception: some vehicles do not have a selector lever position into position "P " or N" (exception: some vehicles do not have
..p..)
a selector lever position "P").
On models which do not have selector lever position "P",
Severe injuries may be caused by freely rotating parts in the area unintentionally.
of the running engine. The heat produced by the engine when it W ear closed and close-fitting work clothes.
is operating can result in severe burns if contact is made with Take off any jewelry, such as chains, rings etc.
individual, unshielded parts. If you have long hair, wear a suitable head cover.
Before commencing work on the running engine, check to
be hot.
W hen carrying out work when starting the engine or when
engine is running, do not touch any hot and rotating parts.

w a te r a n d co v e r ckin w ith s te rile b a n d a g es.
30
AR07.03-W-6831A Removing and installing nozzle holder combination 7.11.97
ENGINE 904.905/906/907/921 # # up to 40487

ENGINE 904.908 # # up to 40487 in MODEL 668. 670
W 0 7 .03-0001-09
1 Nozzle holder combination 6 Seal

2 Hexagon socket screw 7 O -ring
3 Spherical washer 8 Pressure pipe connection
4 Tensioning arm 9 Thrust bolt
5 O-ring 10 Injection line
1 Nozzle holder combination

2 Hexagon socket screw
3 Spherical washer
4 Tensioning arm
7 O-ring
8 Pressure pipe connection
9 Thrust bolt
11 End cover o f constant th ro ttle
W 0 7 .03-0002-06
Revisions

head modified
m Rem oval
L Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 29
coming into contact with skin and eyes. Wear protective dothing when handling
fuel.

5 Press out nozzle holder combination (1) Nozzle holder combination must not be
turned and pulled with a wrench or pliers
otherwise the settings may be altered.
S Insert screwdriver into the top groove
(arrow) of the nozzle holder combination
and press out.
Place protective base on the cylinder
head.
@ Nozzle holder combination must not be
disassembled.
If wear or problem exists 1
replace nozzle holder combination
6 Take off seal (6)
3 In s la lla liu n
7 Replace O-ring (5) at the nozzle holder I B Coat O-ring with lubricant BR00.45-2-1018-06A
combination (1)
8 Fit on seal (6 ) a t th e n o zz le h o ld e r DD Replace seal.

combination (1) Pay attention to installation position and
thickness of seal; small ring surface on seal
points in direction of nozzle holder
combination.
9 Install nozzle holder combination (1) [ Pay attention to installation position of

nozzle holder combination relative to
pressure pipe connection.
Turn nozzle holder combination in the
cylinder head with the tensioning arm (4)
until the interference-fit ball (arrow) in the
te n s io n in g a rm Is a lig n e d w ith t h e lo catin g
element in the end cover (11) of the
constant throttle.
10 Screw spherical washer (3) and tensioning @ Bolt of tensioning arm, nozzle holder BA07.15-N-1003-01A
arm (4) tight combination and constant throttle to
cylinder head
11 Replace O-ring (7) at the pressure pipte I Coat O-ring with lubricant. BR00.45-Z-1018-06A
c o n n e c tio n (8)
32
12 Install pressure pipe connection (8) and The interference-fit ball (arrow) at the
screw thrust bolt (9) tight pressure pipe connection should be
inserted in to th e slo t (a rro w ) In th e c y lin d er
head.
Pressure pipe connection to cylinder BA07.15-N-1005-01A

head
13 Install injection line (10) P a g e 27
14 Install cylinder head cover AR01.20-W-5014A
@ Diesel injection system with unit pumps (MR/PLD)

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
B A07.15-N-1003-01A Bolt of tensioning arm of nozzle holder Allen bolt Nm 30 30

combination to cylinder head
Bolt with twelve 35 35
point head with
spherical collar
BA07.15-N-1005-01A Thrust bolt of pressure pipe connection to Nm 40

cylinder head
Service products for repair
BR00.45-Z-1018-06A ATE-grease -
AR07.03-W-6831 C Removing and installing nozzle holder combination 7.11.97
ENGINE 904.905/906/907/921 # # a s o f40488

ENGINE 904.908 # # as o f40488.
904.923
in MODEL 668,670
ENGINE 904.909/910/911/922, 906.910/911/920/921 /922/923/940/941
I Nozzle holder combination 8 Seal

2 I S Adapter 9 O-ring
3 S Im pact extractor 10 Pressure pipe connection
4 Hexagon socket screw 11 Thrust bolt
5 Spherical washer 12 Injection line
6 Tensioning arm 13 End cover o f constant throttle
7 O-ring
Revisions

head modified
m Removal
i Remove cylinder head cover AR01.20-W-5014A
A D a n g e r! Risk o f e x p lo sio n fro m ig n itio n . R isk Of N o fire , n a k e d fla m e o r sm oking. P a g e 29

fu e l.
2 Remove injection line (12) P a g e 27

5 Attach adapter (2) and impact extractor (3) El 355 589 01 63 00

to the female thread (M 8) of the nozzle
holder combination (l)
34
m 904 589 0063 00
6 Pull out nozzle holder combination (1) @ Nozzle holder combination must not be
disassembled.
If wear or problem exists j,
replace nozzle holder combination.
7 Remove adapter (2) and impact extractor

(3) at the nozzle holder combination (1)
8 Take off seal (8)
M Installation
9 Replace O-ring (7) at the nozzle holder IB Coat O-ring with lubricant. B R00.45-Z-1018-06A
combination (1)
10 Fit on seal (8) at the nozzle holder IB Replace seal.

combination (1) Pay attention to installation position and
thickness of seal; small ring surface on seal
points in direction of nozzle holder
combination.
11 Install nozzle holder combination (1) IB Pay attention to installation position of

nozzle holder combination relative to
pressure pipe connection.
Turn nozzle holder combination in the
cylinder head with the tensioning arm (6)
until the interference-fit ball (arrow) in the
tensioning arm is aligned with the locating
element in the end cover (13) of the
constant throttle.
12 Screw spherical washer (5) and tensioning @ Bolt of tensioning arm of nozzle holder BA07.15-N-1003-01A
arm (6) tight combination and constant throttle to
cylinder head
13 Replace O-ring (9) at the pressure pipe 3] Coat O-ring with lubricant. BR00.45-Z-1018-06A
connection (10)
14 Install pressure pipe connection (10) and The interference-fit ball (arrow) at the
screw thrust bolt (11) tight pressure pipe connection should be
inserted into the slot (arrow) in the cylinder
head.
Pressure pipe connection to cylinder BA07.15-N-1005-01A

head
15 Install injection line (12) P a g e 27
16 Install cylinder head cover AR01.20-W-5014A
@ Diesel injection system with unit pumps (PLD)

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BA07.1S-N-1003-01A Bolt of tensioning arm of nozzle holder Allen bolt Nm 30 30

combination to cylinder head ,
Bolt with twelve 35 35
point head with
spherical collar
BA07.15-N-1005-01A Thrust bolt of pressure pipe connection to Nm 40 40

cylinder head
B R00.45-Z-1018-06A ATE grease -
36
m
ui I
1.
*
g
S

3
<0
SF
"g
53 #
vosw-M-srzouv
crisartUOM
IS
tn
AR07.15-W-8950A Removing and installing MR/PLD unit pump 1.9.95
ENGINE 904.905/906/907/908/909/910/911 /921 /922,906.910/911 /920/921 /922/923/940/941
W 07.15-0061 -09
1 MR/PLD unit pump 5 Multi-point bolt

2 O-ring 6 Injection pipe
3 O-ring 7 Engine wiring harness
4 O-ring 8 [8j Impact extractor
Division Op. no. Operation text
F, T, S 07-8950- Unit pump

8960
mM Removal, installation
1 Remove end cover at timing case Bolt of end cover to timing case BA01.60-N-1002-01A
2 Attach cranking and blocking device for @ Cranking device should be removed Page 39
engine to timing case before starting engine.
HI 904 589 04 63 00
A Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 29
fuel.

4 Remove hydraulic line mount for gearshift E] Only when removing unit pump (1)
from cylinder head from cylinder 1 on engine 609.920-923 with
code (GS3) "hydraulic gearshift
En g in es O M 9 0 4 LA, 906 LA (m o d . des. 904.9, 906.9), F4 37
5 Detach engine wiring harness (7) at unit Slacken bolts at solenoid valve and
pump(1) separate both clips.
L U W h e n rem o vin g th e u n it p u m p o f
cylinder 1 or 2, the attachment strip for the
engine wiring harness with start and stop
switch has to be detached additionally at
the crankcase.
6 Unscrew multi-point bolts (5) SI Only approx. 4 to 5 mm
7 Remove unit pump (1) S] Rotate crankshaft with the cranking

device u n til th e p u m p cam o n th e ca m sh a ft
pushes the unit pump out of the crankcase.
@ If the unit pump is tight, it must not be

pressed out at the solenoid valve or
housing flange J
Use Impact extractor (8) to pull out unit

pump.
355 589 01 63 00
S] Installation: rotate crankshaft with the

cranking device until the pump cam on the
camshaft is positioned in the base circle.
Press unit pump by hand into the crankcase
against the spring pressure (distance
approx. 4 mm).
The fuel feed pipe at the unit pump acts as
a guide when fitting on the unit pump at
the crankcase.
8 U n s cre w m ulti-p oint b o lt (5) a n d pull o u t

unit pump(1)
Unit pump must not be disassembled.

If wear or problem exists ].
replace unit pump.
9 Remove O-rings (2,3,4) at the unit pump [T] Installation: replace O-rings, pay B R00.45-Z-1018-06A
(1) attention to diameter of O-rings and coat
with lubricant.
0 T im ing case
Number Dsignation Engines 904.905/ Engines

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.60-N-1002-01A End coverof inspection holeto Nm 25 25

timing case
38
S D ie se l in je c tio n s y s te m w it h u n it p u m p s (M R / P L D )

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BA07.15-N-1001-01A Bolt of MR/PLD unit pump to crankcase Nm 65 65
Q04 5RQ 04 63 00
Cranking device
BR00.45-Z-1018-06A ATE grease -
AR03.30-W-1 G00-03A A tta c h in g , d e ta c h in g cra n k in g /b lo ckin g I

device fo r engine I
@ Timing case

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941

timing case
1 R e m o ve noise e n ca p su la tio n b e lo w th e fly w h e e l ho using.
2 Remove cover (1) at flywheel housing (except engine 906.920- 923/940/941).
3 A tta c h I S ] cranking and blo ckin g device (2) t ig h t to fly w h e e l ho using w ith b o lts (4).
I3H Cranking and blocking device (2) can be blocked by inserting the pin (3).
cranking and blocking device (2) must be removed before starting the engine.
W 03.30.Q001-02
40
AR07.15-W-1640B Removing, adjusting and installing crankshaft angle position sensor bracket 7.8.97
ENGINE 904.905/906/907/909/910/911/921/922,906.910/911/920/921/922/923/940/941
1 Bracket
2 Shear bolt
3 Securing bush
4 Flywheel
5 I S Cranking device
B15 Crank angle position sensor
W07.15-0081 -06
Id Removing
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954,957,970- 976 Page 26

2 Remove noise encapsulation LU on right
3 Pull out crank angle position sensor (B15)

at bracket (1)
4 Pull out securing bush (3)
5 Remove end cover at timing case
E A tta c h cra n k in g a n d b lo cking d e v ic e (S ) to Pago 39

timing case
El 904 58904 63 00
H B o lt to tim in g case BA01.60-N 1002 01A
7 Rotate crankshaft with the cranking device H I Until a mounting hole (arrow) of crank
angle position sensor (B15) is positioned In
the middle at the flywheel (4).
8 Block crankshaft to prevent it turning
9 Mark flywheel (4) relative to edge in Cl] W ith flywheel removed, mark vibration
inspection hole damper relative to crankcase.
10 Use a suitable tool to slacken shear bolts (2)

and remove; take off bracket (1)
Adjusting

11 Attach bracket (1) and align [D Marking at flywheel (arrow) should be
positioned in the middle of the mounting
hole of the crank angle position sensor
(B15).
Inspect marking at flywheel (4) relative to
edge in inspection hole or vibration
damper to crankcase.
12 Tighten shear bolts (2) until they shear off
m Installing
13 Press securing bush (3) in as far as the stop
14 Press crank angle position sensor (B15) into

the timing case as far as the stop
15 Remove cranking and blocking device (5) Cranking device should be removed
before starting the engine.
m 904 589 04 63 00
16 Install end cover at timing case Bolt of end cover to timing case B A01.60-N-1002-01A
17 Install noise encapsulation
18 T ilt ca b in to d riv e po sition
@ Timing case
Number Dsignation Engine 904.905/

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA01.60-N-1002-01A End cover of inspection hole to Nm 25

timing case
42
AR07.15-W-2000D Testing low pressure fuel circuit 22.7.98
ENGINE 904.905/906/907/921 # # up to 040487
1 Fuel feed pump (KFP) 18.2 Throttle (threaded throttle) in flam e start fuel line
1.1 Pressure re lief valve In fuel feed pump (9.2 bar) 19 Short-circuit cable with valve
1.2 N o n -re tu rn valve in fu e l feed pum p (0.2 bar) 20 Fuel m anual feed pum p
2 Fuel filter (KF) 21 Fuel heat exchanger
2.1 Fuel filter drain valve
2.2 Continuous ventilation in fuel filter (as o f engine end no. B 10 Fuel tempera ture sensor
027674) R3 Flam e s ta il plug
3.1 Bypass from fuel supply port to fuel return port Y5 Solenoid valve
5 Nozzle-and-holder assembly
8 Bypass valve up to engine end no. 002 604 6.5 bar Fuel circuit
as o f engine end no. 002 605 4.5 bar A Fuel supply (intake-vacuum side)
8.1 Continuous ventilation (0.5 mm) B Fuel return (leak fuel)
10 PLD unit pumps (Y6 to Y11) C Fuel supply (pressure side)
12 Fuel p refilter (KVF) D Fuel high-pressure side (to PLD unit pumps)
12.1 Non-return valve in fuel pre filter E Fuel return (fuel filter drain)
14.1 Assembly valve in fuel supply (forced opening)
15.1 Assembly valve in fuel return (forced opening) Fuel ports in crankcase
17 Fuel tank Fuel lines
17.1 Ventilation valve
18.1 Throttle (0.5 mm) in flam e start fuel line
Test points, test data
C Pressure gauge test III Fuel return flo w quantity at outlet of fuel filter housing
H Fuel return quantity test Idle speed and breakaway speed:
Up to engine end no. 027673 0.1 l/min
I Fuel pressure downstream o f fuel filter As o f engine end no. 027674 0.3 l/min
Idle speed: Up to engine end no. 002604 > 6.0 bar, Fuel return quantity at bypass valve
As o f engine end no. 002605 s 4.3 bar Idle speed: Up to engine end no. 027673 0.9-1.4 l/min
Breakaway As o f engine end no. 027674 0.9-1.7 l/min
speed: Up to engine end no. 002604 6.2 - 7.5 bar, Breakaway
As o f engine end no. 002605 4.0 -6.5 bar. speed: Up to engine end no. 027673 2.0-4.0 l/min
As o f engine end no. 027674 2.7 - 7.5 l/min
II Fuel return flow quantity to nozzle-and-holder assemblies
Testing tim e: 5 minutes IV Fuel intake pressure upstream o f fuel pump
Idle speed: Moist with oil Idle speed: -0.09 to -0.12 bar
Breakaway speed: Max. only drips Breakaway speed: = - 0.35 bar
V Low-pressure fuel circuit leaktightness

Test pressure: 5.0 bar
Testing tim e: 5 minutes
Pressure drop: 0. 1bar
Diagram o f fuel circuit

1 Fuel feed pump (KFP)
2 Fuel filter (KF)
3 Fuel supply port to PLD unit pumps
4 Leak fuel port
6 Pressure pipe connector
7 Injection line
8 Bypass valve
9 Fuel return port -PLD unit pump
p u rg in g fu e l
10 PLD unit pumps (Y6to Y11)
11 Return leak fuel line
12 Fuel pre filter (KVF)
13 Fuel lin e to fu e l feed pum p
14 Fuel supply from tank
14.1 Assembly valve in fuel supply
15 Fuel return to tank
15.1 Assembly valve in fuel return
19 Short-circuit valve
20 Fuel manual feed pump
A Fuel supply
B Fuel return/leak fuel
C Fuel supply (pressure side downstream
o f fuel feed pump and fuel filter)
D Fuel high-pressure side
g in n Removing, installing
/h. Danger! Risk of injury due to being trapped and No-one should be within the tilting range Page 26
crushed when tilting the cab of the cab during tilting. Always tilt the cab
up to its final position and secure with
safety support.
1 Tilt cab
Notes on tilting the cab Models 670-679 Page 26

2 Remove engine encapsulation on left side
44
Danger! Risk of explosion due to ignition, Fire, sparks, naked flame and smoking Page 29
risk of poisoning due to inhaling and forbidden.
s w a llo w in g fu e l a n d risk o f in ju ry d u e to O n ly p o u r fu els In to s u itab le, a p p ro p ria te ly
fuel coming into contact with skin and marked containers.
eyes. W ear protective clothing when handling
fuel.
3 Carry out visual inspection at all fuel lines, H a IIo w engine to run at breakaway
bolted connections and components speed for approx. 2-3 minutes.
Replace any damaged or leaking parts. If

necessary retighten bolted connections.
4 Test fuel prefilter element H I Replace fuel prefilter If necessary. WH0730
5 Test fuel filter element HlReplace fuel filter element if necessary. WH0780.30
6 Connect Hand-Held Tester and read out

DTC memory
Page 47
7 Parameterize stationary engine speed H I Only on engines with stationary engine

limiter up to 4000 rpm with the Hand-Held speed limiter.
Tester (HHT). Note parameterized value.
Hllnstallatlon: Parameterize stationary

engine speed limiter back down with HHT
Testing
m Conditions for testing The engine must be at operating

temperature. Fuel temperature in fuel tank
< 40C.
C o lle ct a n y fu e l w h ic h runs out. T h e fu e l
flowing through must be free from
bubbles during the tests.
8 Open cap on fuel tank
9 Test fuel pressure downstream of fuel filter Attach test and measuring equipment to Page 48
low-pressure fuel circuit.
P -^ A D Carry out test Page 49

up to engine end no. 002604
PÂD As of engine end no. 002605 Page 49

El 123 589 04 21 18
E 541 58902 21 00
El 541 589 009100

10 M ea su re fu e l retu rn flu w q u a n tity lo A tta c h tes t a n d m ea su rin g e q u ip m e n t to Pa g e 50
nozzle-and-holder assemblies low-pressure fuel circuit.
PÂD Carry out test Page 51

m 000 589 07 03 00
El 000 589 50 03 00
El 000 589 68 03 00
E 541 589 00 9100
@ Injection line to pressure pipe BA07.15-N-1004-01A

. connector and unit pump.
@ Banjo bolt, fuel line to cylinder head. BA07.15-N-1006-01A
H I If the fuel return flow quantity is within

tolerance range no further tests need to be
carried out.

11 Measure fuel return flow quantity at Attach test and measuring equipment to Page 51
engine low-pressure fuel circuit.
| ~ A D Carry out test Page 53

Up to engine end No. 027675
As of engine end No. 027674 Page 54

m 541 589009100
0 Banjo bolt, fuel line to fuel pressure BA07.15-N-1007-01A

relief valve.
12 Test fuel intake pressure upstream of fuel Attach test and measuring equipment to Page 55
pump. low-pressure fuel circuit.
r^ A D Carry out test. Page 55

ID 617 58904 2100
ID 541 589 0091 00
13 Test low -pressure fu e l c ircu it in e n g in e fo r Attach test and measuring equipment to Page 56
leaks low-pressure fuel circuit.
l A D Carry out test Page 57

E! 173 589 04 21 18
El 541 589 02 21 00
El 541 589 009100
15 Bleed fuel system
16 Check vehicle performance on chassis ED Only after all the tests or measurements I
dynamometer. have been carried out and any defects have
been eliminated: 1
If no improvement in fuel consumption or
performance has been achieved a fuel
consumption measuring system is to be
connected.
0 Diesel injection system with unit pumps (MR/PLD)
Number Designation Engines

904.905/906/907/
909/910/911/
921/922,
906.910/911/920/
921/922/923/
940/941
BA07.15-N-1004-01A Injection line to pressure pipe connector of Nm 25

unit pump
BA07.15-N-1006-01A Banjo bolt, fuel line to cylinder head Nm 40
BA07.15-N-1007-01A Banjo bolt, fuel line to bypass valve Nm 40
46
r \ r A r
000 589 50 03 00 000 589 68 03 00 123 589 04 21 18
Serrated socket wrench Box wrench insert High pressure hose
ADOO.OO-W-2QOO-03A Connecting hand-held tester (HHT), All models

reading fault memory
1 HHT
2 M ultiplexer
3 Adapter cable
4 D iagnostic socket
a Ignition: OFF d Ignition: ON
b First of all connect multiplexer (2) and adapter cable (3) to the e S ta r t te s t p ro g ra m (se e o p e ra tin g in stru ctio n s o f H H T ).
HHT (1).
ED Pay attention to differences related to specific systems which
c Then, connect adapter cable (3) to the diagnostic socket (4). are listed in the relevant diagnosis description in the chapter
"B a s ic k n o w le d g e o f d ia g n o s is ".
Failure to follow the order described may result in the Stored faults which may result from disconnecting cables or
multiplexer being damaged. simulation during test operations, have to be erased in the fault
The HHT program recognizes the control unit type. memory after completing the work.
AR07.15-W-2000-011 Installing test/measuring equipment in low Testing fuel pressure downstream of
pressure fuel circuit fuel filter (fuel circuit)
V 123 5890421 18 J
High-pressure hose
W07.15-1006-09
Shown on engine 904.909 5 Install ring piece HQ (5.2), pressure gauge E (3) and
measuring hose E l (4) on adapter piece (5.1)
1 On MPS or HPS gearshift:
Unscrew lower bolt on bracket/cylinder head. 6 Connect fuel temperature sensor (B10) removed to engine
wiring harness (2) and attach on engine.
2 Remove engine compartment lining (1).
3 Remove fuel temperature sensor (B10).
4 Install adapter piece H3(5.1) with sealing ring on crankcase.
48
AD07.15-W-7001-01D MR (PLD) test of hydraulic system fuel Engines 904.905-907/921 up to engine
pressure downstream of fuel filter end No. 002604
Scope of test Measuring instrument/ Operation/Requirement Specified Possible cause/Remedy

Test connection value
1.0 Check fuel pressure Engine: Start Fuel pressure too high
<s>
downstream of fuel filter Idle speed 600 -650 rpm : > 6.0 bar &(AD07.15-W-5001-09F)
Install testers and
measuring instruments in Breakaway speed Fuel pressure too low
low pressure fuel circuit 2500 rpm: 6.2 to 7.5 bar &(AD07.15-W-7001-06D)
&(AR07.15-W-2000-011)
Fuel pressure within

tolerance range
&(AD07.15-W-7001-07F)
AD07.15-W-7001-01F MR (PLD) test of hydraulic system fuel Engines 904.905-907/921 as of engine

pressure downstream of fuel filter end No. 002605
Engines 904.909-911/922 and
906.910/911/920-923/940/941
=> Scope of test Measuring instrument/ Operation/Requirement Specified e Possible cause/Remedy

1.0 Check fuel pressure

. Engine: Start e Fuel pressure too high
downstream of fuel filter Idle speed 600 - 650 rpm: > 4.3 bar &(AD07.15-W-5001-09F)
Install testers and
measuring instruments in Breakaway speed e Fuel pressure too low
low pressure fuel circuit 2500 rpm: 4.0 to 6.5 bar Up to engine end No.
& (A R 0 7 .15-W-2000-011) 027673
&(AD07.15-W-7001-06D)
As of engine end No.

027674
&(AD07.15-W-7001-06F)
e Fuel pressure within

tolerance range
&(AD07.15-W-7001-07F)
AR07.15-W-2000-01L Installing test/measuring equipment in low Measuring fuel return flow quantity
pressure fuel circuit of nozzle-and-holder assemblies.
En g in es 904.9, 906.9

904.905/906/907/
909/910/911/
921/922,
906.910/911/920/
921/922/923/
940/941
BA07.1S-N-1004-01A Injection line to unit pump pressure pipe Nm 25

connector
a r \ r
000 589 68 03 00 541 589 00 9100
Box wrench insert Adaption part
Shown on engine 904.909
1 Remove engine compartment lining.
2 Remove injection line.

E On engine 904 at 2 nd cylinder; on
engine 906 at 4h cylinder
3 Remove fuel return line (2) on cylinder

head (leak oil bore) and install adapter
piece (3.1) with fuel return line (2).
E Install U-seal or Usit sealing ring

(3.2) between fuel return line and
cylinder head.
4 Install injection line.
5 Place a clean cloth underneath the

adapter piece (3.1) and collect any fuel
leaking out.
50
AD07.15-W-7001-07F MR (PLD) test of hydraulic system fuel Engines 904.905-907/909-911 /921/922
return flow quantity at nozzle holder and 906.910/911/920-923/940/941
co m b in a tio n s
=P Scope of test Measuring instrument/ Operation/Requirement Specified Possible cause/Remedy

1.0 Check fuel return flow Engine: Start e Fuel or coolant leak at
quantity at nozzle-and- leak oil bore or leak oil line
holder assemblies Idle speed 600 - 650 rpm &(AD07.15-W-5001-05F)
Install testers and Testing time 5 minutes: Moist with oil

measuring instruments in
low pressure fuel circuit Breakaway speed
&(AR07.15-W-2000-01L) 2500 rpm
Testing time 5 minutes: Max. only
drips
AR07.15-W-2000-01N Installing test/measuring equipment in low Measuring fuel return flow quantity
pressure fuel circuit Engines 904.905-907/921 up to engine
end No. 040487
@ Diesel injection system with unit pumps (MR/PLD)

904.905/906/907/
909/910/911/
921/922,
906.910/911/920/
921/922/923/
940/941
W 0 7 .1 5 -1 0 1 3 -0 9
1 Remove engine compartment lining (1). 5 Install transparent fuel line (7) on I S ring piece (5) and
guide into a clean container (8).
2 Disconnect fuel return line (3) on bypass valve (6).
@ Steady bypass valve (6) when loosening the fuel return 6 Disconnect fuel return line (12) on connection (11) and
line (3). install transparent fuel line (10).
3 Seal fuel return line (3) with banjo bolt (2.1) and I S lock nut [XIThe support (10.1) with opening clamp (arrow) must
W. press the non-return valve into the connection (i i).
4 Detach I S ring piece (5) from bypass valve (6). 7 Guide fuel return line (10) into a clean container (9).
@ Steady bypass valve (6) when tightening bolts.
52
AD07.15-W-7001-06D MR (PLD) test of hydraulic systems fuel Engines 904.905-907/921 up to engine
return flow quantity end NO. 027673
=* Scope of test Measuring instrument/ Operation/Requirement Specified Possible cause/Remedy

1.0 Fuel return flow quantity Engine: Start e Fuel return flow quantity
at fuel filter housing at bypass valve too low,
o u tle t Idle speed 600 650 rpm w ith in to le ra n ce ra n g e a t
Install testers and Measuring time fuel filter housing outlet
measuring instruments in > 1 minute s 0.1 l/min &(AD07.15-W-5001-08A)
low pressure fuel circuit
&(AR07.15-W-2000-01N) B r e a k a w a y speed Fuel retu rn f lo w q u a n tity
2500 rpm at bypass valve too low,
Measuring time too high at fuel filter
> 30 seconds: 0.1 l/min housing outlet
& (A D 0 7 .15-W-5001-OBB)
Measuring point:
Bypass valve
1.1 Fuel return flow quantity Engine: Start Fuel return flow quantity
at bypass valve at bypass valve, within
Idle speed 600 - 650 rpm tolerance range at bypass
Measuring time valve and fuel filter
> 1 minute 0.9- 1.4 l/min housing outlet
&(AD07.15-W-5001-08D)
Breakaway speed
2500 rpm Fuel return flow quantity
Measuring time at bypass valve and fuel
> 30 seconds: 2.0-4.0 l/min filter housing outlet too
low
&(AD07.15-W-7001-03D)
Engines O M904 LA, 906 LA (mod. des. 904.9, 906.9), F4 53
AD07.15-W-7001-06F MR (PLD) test of hydraulic systems fuel Engines 904.905-907/921 as of engine
return flow quantity end No. 027674
En g in es 904.909 911/922 a n d
906.910/911/920-923/940/941
Scope of test Measuring instrument/ Operation/Requirement Specified e Possible cause/Remedy

1.0 Fuel retu rn f l o w q u a n tity E n g in e ! S ta r t F u e l re tu rn f lo w q u a n tity

W a it until the fuel at bypass valve too low,
at fuel filter housing
flowing out of the within tolerance range at
outlet measuring fuel line Is fuel filter housing outlet
Install testers a n d v ir tu a lly fr e e fro m &(AD07.15-W -5001-08A)
bubbles
measuring instruments in
e Fuel return flow quantity
low pressure fuel circuit Idle speed 600 -650 rpm at bypass valve too low,
& (A R 0 7 .15-W-2000-01K) M e a s u rin g tim e too high at fuel filter
> 1 minute 0.3 l/mln housing outlet
&(AD07.15-W-5001-08B)
Breakaway speed
2500 rpm
Measuring time
> 30 seconds: 0.3 l/min
Measuring point:
Bypass valve
1.1 Fuel return flow quantity Engine: Start Fuel return flow quantity
at bypass valve in order,
at bypass valve
Idle speed 600 - 650 rpm cannot be measured at fuel
Measuring time filter housing outlet
> 1 minute 0.9-1.7 l/mln &(AD07.15-W-5001-08C)
Breakaway speed Fuel return flow quantity

2500 rpm at bypass valve and at fuel
Measuring time filter housing outlet within
> 30 seconds z.7-7.5 l/min tolerance range
&(AD07.15-W-5001-08D)
Fuel return flow quantity

at bypass valve and at fuel
filter housing outlet too
low
&(AD07.15-W-7001-03F)
54
AR07.15-W-2000-01P Installing test/measuring equipment in low Testing fuel intake pressure upstream
pressure fuel circuit of fuel supply pump
En g in e 904.905-907/921 up to e n g in e
end no. 040487
\ f
541 589 00 91 00
Adaption parts
1 E l Install tester (2) with test cables

(2.1) and connectors (2.3) between
fuel supply line (3) and connection
(1.1) to fu e l p re filte r housing (1).
H I E The support (2.2) with opening

clamp (arrow) must press the non
re tu rn v a lv e in to th e c o n n e ctio n (1.1).
Check sealing ring on support (2.2) for
damage and replace if necessary.
2 B lee d fu e l system .
3 E Attach tester (2) to frame.
W07.15-1009-06
AD07.15-W-7001-03D MR (PLD) test of hydraulic system fuel Engines 904.905-907/921, up to

intake pressure upstream of fuel pump engine end no. 040487

1.0 Check fuel intake Engine: Start Fuel intake pressure too

pressure upstream of Idle speed 600 - 650 rpm: -0.09 to low (->0 bar)
fuel pump -0.12 bar &(AD07.15-W-5001-01D)
Install testers and Breakaway speed
measuring instruments in 2500 rpm: =-0.35 bar Fuel Intake pressure too
low pressure fuel circuit high (--1 bar)
&(AR07.15-W-2000-01P) &(AD07.15-W-5001-02F)

AR07.15-W-2000-01S Installing test/measuring equipment in low Test low-pressure fuel circuit in
pressure fuel circuit engine for leaks
E n g in es 904.905-907/921 up to e n g in e
end No. 040487.
123 589 04 21 18
High pressure hose Tester Adaption parts
W07.15-1011-09
1 Remove engine compartment lining (1). 5 Detach fuel return line (7) on connection (9) and seal with
S I cap (6.3).
2 Remove fuel temperature sensor (BIO).
6 Detach fuel supply line (5) on fuel prefilter housing (8)
3 Install S I adapter piece (6.5) with sealing ring on crankcase. connection and install S I connection line (6.2) with S I shut-
off cock (6.1).
4 Install S I ring piece (6.4), measuring hose (4) and pressure
gauge (3) on adapter piece (6.5).
56
AD07.15-W-7001-08D MR (PLD) test of hydraulic system low Engines 905.905-907/921 up to engine
pressure fuel circuit leaks end no. 040487

1.0 Check low pressure fuel

9 Fill low pressure fuel e with greater drop in
circuit for leaks circuit in engine with pressure or fuel In engine
Install testers and compressed-air oil
measuring instruments in Fuel circuit without PLD &(AD07.15-W-5001-06F)
low pressure fuel circuit heat exchanger
&(AR07.15-W-2000-01S) Test pressure 5.5 bar:
Test time 5 minutes: 0.1 bar
AR07.15-W-2000F Testing low pressure fuel circuit 13.7.98
ENGINE 904.905/906/907/921 # # as o f040488

ENGINE 904.909/910/911/922, 906.910/911/920/921 /922/923/940/941
W07.15-1015-09
Fuel circuit diagram
1 Fuel feed pump (KFP) D Fuel high-pressure side (downstream o f PLD unit pumps)
1.1 Pressure relief valve in fuel feed pump (9.2 bar) E Fuel return (fuel filter drain)
1.2 Non-return valve In fuel feed pump (0.2 bar)
2 Fuel filter (KF) Fuel ports in crankcase
2.1 Fuel filter drain valve Fuel lines
2.2 Continuous ventilation in fuel filter
3.1 Bypass from fuel supply port to fuel return port Test points, test data
5 Nozzle-and-holder assembly G Pressure gauge test
0 Bypass vo/ve (4.5 bar) H Fuel return flow quantity test
8.1 Continuous ventilation (0.5 mm)
10 PLD unit pump (Y6 to Y11) I Fuel pressure downstream o f fuel filter
12 Fuel pre filter (K VF) Idle speed: a 4.3 bar
12.1 Non-return valve In fuel prefllter Breakawayspeed:4.0-6.5bar
14.1 Assembly valve in fuel supply (forced opening) II Fuel return flow quantity to nozzle-and-holder assemblies
15.1 Assembly valve in fuel return (forced opening) Test time 5 minutes
17 Fuel tank Idle speed: M oist w ith oil
17.1 ventvalve Breakaway speed: Max. drips only
18.1 Throttle (0.5 mm) in the flam e start fuel line III Fuel return flow quantity a t outlet o f fuel filter housing
18.2 Throttle (threaded throttle) in flame start fuel line Idle speed and breakaway speed: 0.31/mln
BIO Fuel temperature sensor Fuel return flo w quantity a t bypass valve
R3 Flame start plug Idle speed: 0.9-1.7 l/min
Y5 Solenoid valve Breakaway speed: 2.7- 7.5 l/min
IV Fuel intake pressure upstream o f fuel pump
Fuel circuit Idle speed: -0.09 to -0.12 bar
A Fuel supply (intake/vacuum side) Breakaway speed: -0.4 to -0.5 bar
B Fuel return (leak fuel) V Low-pressure fuel circuit leaktightness
C Fuel supply (pressure side) Test pressure: 10 bar/Testing time 5 minutes:
Pressure drop: s 0.25 bar
58
Fuel circuit diagram
Shown on engine 906
1 Fuel feed pump (KFP)

2 Fuel filter (KF)
3 Fuel supply port to PLD unit pumps
4 Leak fuel port
6 Pressure pipe connector
7 Injection line
8 Bypass valve (4.5 bar)
9 Fuel return port PLD unit pump
purging fuel
10 PLD unit pumps (Y6 to Y11)
11 Return leak fuel line
12 Fuel pre filter (KVF)
13 Fuel line fuel p refilter to fuel feed
pump
14 Fuel supply from tank
15 Fuel re tu rn t o ta n k
16 Fuel supply to flame start system
A Fuel supply
B F u e l re tu rn /le a k fu e l W07.15-0083-06
C Fuel supply (pressure side downstream
o f fuel feed pump and fuel filter)
D Fuel high-pressure side (downstream
o f PLD unit pumps)
] HD Removing, installing
/ K Danger! Risk of injury due to being trapped and No-one should be within the tilting range Page 26
crushed when tilting the cab of the cab during tilting. Always tilt the cab
up to its final position and secure with
safety support.
1 Tilt cab
Notes on tilting the cab Models 670-679,950-954,957,970-976 Page 26

2 Remove engine encapsulation on left side
A Danger! Risk of explosion due to ignition, Fire, sparks, naked flame and smoking Page 29
risk of poisoning due to inhaling and forbidden.
swallowing fuel and risk of injury due to Only pour fuels into suitable, appropriately
fuel coming into contact with skin and marked containers.
eyes. W ear protective clothing when handling
fuel.
3 Carry out visual inspection at all fuel lines, [D Allow engine to run at breakaway
bolted connections and components speed for approx. 2-3 minutes.
Replace any damaged/leaking parts.

Retighten bolted connections if necessary.
4 Test fuel prefilter element ED Replace fuel prefilter if necessary. AP47.20-W-0730B
5 Test fuel filter element CD Replace fuel filter element if necessary. AP47.20-W-0780B
6 Connect Hand-Held Tester and read out

DTC memory
[^ A D Page 47
7 Parameterize stationary engine speed CD Only on engines with stationary engine
limiter up to 4000 rpm with the Hand-Held speed limiter.
Tester (HHT). Note parameterized value.

EE Installation: Parameterize stationary
engine speed limiter back down with HHT
Testing
m Conditions for testing If a Racor fuel prefilter is installed,

disconnect this and connect fuel lines to
the fuel prefilter.
The engine must be at operating

temperature. Fuel temperature in fuel tank
< 40C.
Collect any fuel which runs out. The fuel
flowing through must be free from
bubbles during the tests.
8 Open cep on fuel tank
9 Test fuel pressure downstream of fuel filter Attach test and measuring equipment to Page 48
low-pressure fuel circuit.
t^ A D Carry out test P a g e 49
El 123 589 04 21 18
ll 541 589 02 21 00
El 541 589 00 91 00
nozzle-and-holder assemblies low-pressure fuel circuit.
S3 000 589 07 03 00
El 000 589 50 03 00
El 000 589 68 03 00
El 541 589 00 91 00
0 Injection line to pressure pipe BA07.15-N-1004-01A

connector and unit pump.
0 Banjo bolt, fuel line to cylinder head. BA07.15-N-1006-01A
ED if the fuel return flow quantity Is In

order no further tests need to be carried
out.
engine low-pressure fuel circuit.
t^ A D Carry out test Page 54

El 541 589 00 91 00
0 Banjo bolt, fuel line to fuel pressure BA07.15-N-1007-01A

relief valve.
12 Test fuel intake pressure upstream of fuel Attach test and measuring equipment to P a g e 63
pump low-pressure fuel circuit.

El 617 589 04 2100
El 541 589009100
13 Test low-pressure fuel circuit in engine for Attach test and measuring equipment to Page 65
leaks low-pressure fuel circuit.
l^ A D Carry out test Page 66
El 123 589 04 21 18
60
m 541 58902 21 00
El 541 589 0091 00
15 Bleed fuel system
16 Check vehicle performance on a E Only after all the tests or measurements

dynamometer stand have been carried out and any defects have
been eliminated: |
If no improvement in fuel consumption or
p e rfo rm a n c e has b e e n a ch ie v e d a fu e l
consumption measuring system is to be
connected.

904.905/906/907/
909/910/911/
921/922,
906.910/911/920/
921/922/923/
940/941
BA07.15-N-1004-01A Injection line to pressure pipe connector of Nm 25

unit pump
000 589 SO 03 00 000 589 6803 00 123 589 04 21 18
Serrated socket wrench Box wrench insert High pressure hose
AR07.15-W-2000-01K Installing test/measuring equipment in low Measuring fuel return flow quantity
pressure fuel circuit Engines 904.909-911/922 and
906.910/911 /9 20-923/940/941.
Engines 904.905-907/921 as of engine
end no. 040488.
D ie s e l in jectio n system w ith u n it p u m p s (M R / P L D )

904.905/906/907/
909/910/911/
921/922,
906.910/911/920/
921/922/923/
940/941
B A07.15-N-1007-01A B a n jo b o lt, fu el lin e to bypass va lve Nm 40
62
1 Remove engine compartment lining (1). Disconnect fuel return line (12) on fuel filter housing (11),
connection R l" and install transparent fuel line (10).
2 Disconnect fuel return line (3) on bypass valve (6). CDThe support (10.1) with opening clamp (arrow) must
Steady bypass valve (6) when loosening the fuel return press the non-return valve into the connection.
line (3).
Guide fuel return line (10) into a clean container (9).
3 Seal fuel return line (3) with banjo bolt (2.1) and E l lock nut
(4).
Detach E l ring piece (5) from bypass valve (6).

@ Steady bypass valve (6) when tightening bolts.
Install transparent fuel line (7) on E l ring piece (5) and

guide into a clean container (8).
AR07.15-W-2000-01J Installing test/measuring equipment in low Testing fuel intake pressure upstream
pressure fuel circuit of fuel supply pump
Engines 904.909-911/922 and
906.910/911/920-923/940/941.
end no. 040488.
1 Install tester [E l (2) with test cables

(2.1) and connectors (2.3) between
fuel supply line (3) and fuel prefilter
housing (1).
H I H I The support (2.2) with opening

clamp (arrow) must press the non
return valve into the connection (1.1).
Check sealing ring on support (2.2) for
damage and replace if necessary.
2 Bleed fuel system.
3 [E l Attach tester (2) to frame.
AD07.15-W-7001-03F MR (PLD) test of hydraulic system fuel Engines 904.905-907/921 as of engine

intake pressure upstream of fuel pump end no. 040488
Engines 904.909-911/922 and
906.910/911/920-923/940/941

1.0 Check fuel intake Engine: Start Fuel intake pressure too
<$>
pressure upstream of Idle speed 600 - 650 rpm: -0.09 to low (-0 bar)
fu e l pum p - 0 .1 2 b ar & (A D 0 7 .15-W-5001 -01T)
Install testers and Breakaway speed

measuring instruments in 2500 rpm: - 0.4 to Fuel intake pressure too
lo w pressure fu e l circu it - 0 .5 bar h ig h (- -1 b a r)
&(AR07.15-W-2000-01J) &(AD07.15-W-5001-02F)
64
AR07.15-W-2000-01M Installing test/measuring equipment in low Testing low-pressure fuel circuit in
pressure fuel circuit engine for leaks
Engines 904.909-911/922 and
906/910/911/920-923/940/941.
end No. 040488.
123 589 04 21 18
High pressure hose
W 07.15-1010-09
S how n an engine 9 0 4 0 0 0
1 On MPS or HPS gearshift: 6 Detach fuel return line (7) on fuel filter housing (8),
Unscrew lower bolt on bracket/cylinder head connection "RL" and seal with S cap (6.3).
2 Remove engine compartment lining (1)

7 Detach fuel supply line (5) on fuel prefilter housing (8),
3 Remove fuel temperature sensor (BIO). connection VL" and install I S connection line (6.2) with S
shut-off co ck (6.1).
H I Installation: Bleed fuel system.
4 Install I S adapter piece (6.5) with sealing ring on crankcase.
5 Install I S ring piece (6.4), measuring hose (4) and pressure

gauge (3) on adapter piece (6.5)
f t s p Engines OM904 LA, 906 LA (m od. des. 904.9,906.9), F4 65
AD07.15-W-7001-08F MR (PLD) test of hydraulic system low Engines 904.905-907/921 as of engine
pressure fuel circuit leaks end No. 040488
E ngin es 904.909-911/922 a n d
906.910/911/920-923/940/941
=b Scope of test Measuring instrument/ Operation/Requirement Specified Possible cause/Remedy

1.0 Check lo w p re ssu re fu e l Fill lo w pressure fu e l e w ith g re a te r d ro p in
circuit for leaks circuit in engine with pressure or fuel in engine

Install testers and compressed-air oil
measuring instruments in Fuel circuit without PLD &(AD07.15-W-5001-06F)
low pressure fuel circuit heat exchanger
&(AR07.15-W-2000-01M) Test pressure 10 bar:
Test time 5 minutes: 0.25 bar
66
AR09.40-W-591 OA Inspecting turbocharger 18.7.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921/922/923/940/941

7 Turbocharger
3 Rotor shaft
4 Control flap
5 Control flap shaft
6 Control unit
W 0 9 .40*0012-06
Inspecting
1 Remove engine brake flap connection AR14.15-W-6302A
2 Remove air intake hose
3 Inspect clearance of rotor shaft (3) EX] If there is no sign of the rotor shaft rub Page 68
bing on either side of the turbocharger
housing, the axial play and radial play are
o.k.
If the rotor shaft is rubbing on the turbo

charger housing |
Replace turbocharger. Page 70

4 Inspect control flap (4) and Control flap If wear exists |
shaft (5) for signs of damage and play

5 Test control unit (5) On engine 904.907/911 and Page 69
906.911/921/923/940/941
H-] Without radiator connection. 124 58915 21 00
E E If pressure drop exists 4

6 Install air intake hose
7 Install engine brake flap connection AR14.15-W-632A
AR09.40-W-5910-01A Inspecting axial play and radial play at If there is any indication of the rotor
rotor shaft shaft touching the turbocharger
housing J
Replace turbocharger
On engine 904.905- 907/909- 911/921/ AR09.40-W-6020A

922 and 906.910/911/920-923/940/
941
O n e n g in e 904.908/923 AR09.40-D-6020D
On engine 541.920-927 AR09.40-W-6020B
On engine 542.920-923/925 AR09.40-W-6020C
Rotate rotor shaft (1) at the shaft nut

or at the turbine wheel; inspect rotor
shaft to ensure that it rotates without
obstruction and evenly. Move the
rotor shaft back and forward for this
purpose until it is free of oil carbon
deposits.
m
The rotor shaft is centrifugally
stabilized and is guided in its mount
with a relatively large play.
Inspecting axial play: move rotor shaft

(1) in longitudinal direction and
in sp e ct w h e th e r th e re is a n y sign o f it
touching the turbine or compressor
wheel.
If there is no indication of the rotor

shaft touching the turbocharger
housing on either side, the axial play is
ok. If there is any sign of it touching,
replace the turbocharger.
68
Inspecting radial play: deflect rotor
shaft (1) in radial direction; turn it
when doing this and inspect whether
there is any indication of the turbine
or compressor wheel touching.
m
If there is no sign of the rotor shaft
touching the turbocharger housing on
either side, the radial play is ok. If
there is a sign of it touching, replace
the turbocharger.
AR09.40-W-5910-02A Testing control unit If drop in compressed air exists |
replace turbocharger
On engine 904.905- 907 /909- 911/921/ AR09.40-W-6020A

922 and 906.910/911/921/923/940/
941
1 Inspect control unit (1) for signs of damage at outside.
m
If the control unit is misshapen, the turbocharger has to be
replaced.
2 Attach S priming pump (2) (without coolant connection) to

the hose connection (3) of the control unit (1) and pressurize
with max. 1 bar.
m
If the diaphragm is damaged, compressed air escapes
between valve rod (arrows) and control unit mounting.
Replace turbocharger.
3 Disconnect I S priming pump (2) and screw hose connection

(3) tight.
AR09.40-W-6020A Removing and installing turbocharger 21.11.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 /922/923/940/941
1 Exhaust m anifold
2 Turbocharger
3 Nut
4 Hexagon socket b o lt
5 O il delivery pipe
6 Gasket
7 Gasket
0 O il re tu rn flo w pipe
10 Bolt
11 Heat shield
12 Mounting
13 Nuts
14 Engine brake flap connection
W09.40-0005-06
F, S 09-5910-6043 Turbocharger
Revisions
11.11.97 Installation sequence changed Page 70
gnHU Removing, installing
Z LD anger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 73

A Danger Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
with a safety prop.

3 Remove noise encapsulation CD On right and at bottom
4 Remove charge air pipe (11) On engine 904.905- 907/921 Page 75
On engine 904.909- 911/922 and Page 76
906.910/911/920- 923/940/941
5 Detach air intake hose (12) ? t turbocharger
(6)
6 Detach exhaust pipe (1) at engine brake Installation: clean sealing surfaces
flap connection (4)
7 Detach compressed air line (17) at engine

brake cylinder
8 Detach heat shield (13) at turbocharger (6) S Installation: on engine 904.905-

and crankcase 907/921: attach heat shield and
compressor intake line together to
crankcase
9 Detach oil return flow hose (15) at 00 Collect engine oil which flows out
turbocharger (6)
10 Detach oil pressure line (7) at oil filter and E Seal hole at turbocharger and
turbocharger (6) crankcase.
E Installation: before fitting on the oil
pressure line, fill the turbocharger bearing
housing through the oil filler hole with
engine oil. Rotate turbocharger shaft by
hand during this step so that the bearing
p o ints a re p ro v id e d w ith a n oil film .
Replace seals.
0 Oil pressure line to turbocharger BA09.40-N-1002-01B
0 Oil retu rn f l o w lin e to tu rb o c h a rg e r BA09.40-N-1003-01B
11.1 Detach connection fitting of oil pressure On engine 904.905- 907/921

line (7) at turbocharger (6)
11.2 Take off gasket of oil pressure line at On engine 904.909- 911 /922 and
turbocharger (6) 906.910/911 /920- 923/940/941
E Installation: replace gasket
12 Detach turbocharger (6) together with Seal holes at turbocharger with caps
engine brake flap connection (4) at exhaust E
Installation: replace nuts (5)
manifold
@ Nut of turbocharger to exhaust BA09.40-N-1001-01B

manifold
13 Detach engine brake flap connection (14) E Installation: replace nuts (3)
together with bracket (16)
0 Engine brake flap connection to BA14.10-N-1002-01B

turbocharger
15.1 Check engine oil level with dipstick On engine 904.905- 907/921 WH0101.40
15.2 Check engine oil level at electric gage On eng ine 904.909- 911 /922 and
906.910/911/920- 923/940/941
S e e ATEGO / ECONIC o p e ra tin g instructions
part 3
A Danger Risk ofaccident as a result o( vehicle Secure vehicle to prevent it starting off. Page 30
starting off when engine running. Risk of W ear closed and dose-fitting work clothes.
16 Start engine and observe oil pressure gage @ Crank engine with starter for not more BE18.00-N-1001-01C
when engine idling than 90 seconds. W ait about 2 minutes
b e fo re re p e a tin g a tte m p t a t starting.
U J The oil pressure gage should indicate
T e st v a lu e s fo r e n g in e o il pressure

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE1B.00-N-1O01-01C Engine oil pressure at Idle speed bar a0.5
Max. speed bar a 2.5
@ Turbocharger

906/907/909/ 906.910/911/920/
910/911/921/922 921/922/923/940
/941
BA09.40-N-1001 -01B Nut of turbocharger to exhaust manifold Nm 30 50
BA09.40-N-1002-01B B o lt o f oil d e liv e ry p ip e to tu rb o c h a rg e r m b Nm 40 -
M6 Nm 10 10
BA09.40-N-1003-01B Bolt of oil return flow pipe to turbocharger Nm 10 10
@ Exhaust manifold
Number Designation Engines QA.95/

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/023/940
/941
BA14.10-N-1002'018 Nut of engine brake flap connection M8 Nm 30

to turbocharger
M10 Nm 50
72
AS 54.10-Z-0001-01A Explosion hazard from explosive gas. Flames, sparks, open light and A Danger!
Danger of poisoning and acid burns when smoking prohibited. Wear acid
battery acid is s w a llo w e d . D a n g e r o f acid resistant g loves, clo th in g a n d g o g g les.
batteries.
Possible dangers
Injury hazard
Explosion hazard Battery acid contains sulfuric acid, which can cause severe burns
A highly explosive gas mixture is generated when lead-acid to skin and eyes. When handling damaged lead-acid batteries
batteries are charged (removing from accident vehicle) increased care is necessary due
W hen battery acid is taken orally toxic symptoms can occur such
Battery acid vapor can burn eyes. Inhalation can result in burns to - Fire, sparks, open light and smoking prohibited.
pole first.
- Switch on charger only after connecting to poles; switch off
K e e p lead-acid b a tte rie s e n d b a tte ry a cid a w a y from First-aid m easures

Store battery acid only in suitable, appropriately marked e Rinse eyes immediately with large quantities of water.
Store lead-acid batteries only in upright position. e Remove affected clothing.
Ensure that gassing line is properly connected. Neutralize acid on skin or clothing immediately with acid
Check gassing line for kinks and proper passage. neutralizer or soap solution and rinse with large quantities
Observe instructions for applicable lead-acid battery and of water.
W ear acid protective clothing and protective goggles with side Move affected person to fresh air
guard. Swallowing battery acid
activated charcoal.
Generally medical services or a physician should be contacted


P54.10-0270-08
W arning note s on lead a d d b atteries
7 Fire, sparks, open light and smoking 3 Observe operating instructions 6 Keep aw ay from children
prohibited 4 Danger o f acid burns 7 First aid
2 txplosion hazard 5 w ear eye protection
AH 54.10-P-0001-01A Notes on battery All models
Do not store lead-acid batteries for extended periods of time Do not switch on battery chargers until they have been
therefore, ensure that they are stored at temperatures above During rapid charging it must be insured that the casing of the
Avoid mixing up positive and negative poles and avoid short- It is advisable to grease the poles lightly with battery pole
circuits. grease.
74
AR09.41 -W-1311A Removing, installing boost air pipe 22,11.95
ENGINE 904.90S/906/907/921
1 Boost air pipe

2 Bolt
3 Nut
4 Bolt
5 Flame starting system/solenoid valve
6 Boost a ir hose (red)
7 Nut
8 Flame glow plug
9 O-ring
10 Clip
11 Coolant pipe
W 09.41-0001-06
when tilting cap the cab when it is being tilted. Always tilt
with a safety prop.
Notes re tilting cab Page 26

1 Tilt cab
2 Remove boost air hose (6) Installation: boost air hoses must not be
mixed up.
Red boost air hose is temperature-
resistant and should always be installed
between boost air pipe and intercooier.
3 Take off boost air pipe (1)
A Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking.
poisoning from inhaling and swallowing Pour fuels only into suitable and Page 29
fuel.
4 Detach solenoid valve (5) together with t ilIf flame starting system fitted collect
bracket fuel which flows out.
5 D iscon n ect c o o la n t p ip e (11) a t b o o s t air OD D o n o t rem o ve c o o la n t pipe.
pipe (1)
6 Remove boost air pipe (1) H I Seal holes at turbocharger.

[H Installation: replace O-ring (9)
AR09.41 -W-1311C Removing, installing boost air pipe 30.7.97
W09.41-0012-06
mm Removing, installing
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954, 957, 970- 976 Page 26
2 Remove noise encapsulation on right
3 Remove charge air hose, red (8) ED Installation: the charge air hoses must
not be mixed up.
T he red ch arg e a ir hose is tem p e ratu re-
between charge air pipe and intercooler.
4 Remove charge air hose (warm air) (1) 0 BA09.41 -N-1005-01B
Seal holes at turbocharger.

12 Installation: replace O-ring (4).
0 Boost air pipe/intercooler

910/911/922,
906.910/911/920/
921/922/923
BA09.41-N-1005-018 Nut of boost air pipe to boost air pipe Nm 30
76
AR09.41-W-1311D Removing, installing boost air pipe 31.7.97
ENGINE 904.909/910/911/922,906.910/911/920/921 Z922/923

From in te rc o o le r to b o o s t a ir m a n ifo ld
1 Boost air hose, black

2 Boost a ir pipe (cold air)
3 B olt
4 Bolt
5 Wiring harness
6 Fuel line
7 rla m e g lo w p lug
8 Clip
9 Boost air pipe (warm air)
10 Nut
H U HU Removing, installing
Danger! Risk of injury from bruises and jamming No person should be In the tilting area of Page 26
cab as fa r as th e end p o sition a n d secure
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954,957, 970- 976 Page 26
2 Remove noise encapsulation on right
3 Remove black charge air hose (1) DO Installation: boost air hoses must not
be mixed up.
The red charge air hose is temperature-
between charge air pipe and intercooler.
fuel.
4 Detach wiring harness (5) and fuel line (6) Flame starting system (code M89) fitted
at the flame glow plug (7) C E Collect fuel which flows out
5 Remove charge air pipe (2) 3 Bolt of charge air pipe to generator BA09.41-N-1004-01B
support
@ Nut of charge air pipe to charge air pipe BA09.41 -N-1005-01B
E E Clean sealing surface at charge air

manifold
SR P Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4

@ Boost air pipe/intercooler

910/911/922,
906.910/911/920/
921/922/923
BA09.41-N-1004-01B Bolt of boost air pipe to generator support Nm 30
B A 0 9 .4 1 -N -1 0 0 5 -0 1 B N u t o f bo o st a i r p ip e t o b o o st a i r p ip e Nm 30
78
AR09.41 -W-8681A Removing and instailing boost air manifold 1.9.95
ENGINE 904.905/906/907/921
W 09.41-001S-09
7 Boost air manifold 8 Nut

2 Screw 9 Gasket
3 Boost air hose 70 Engine wiring harness
4 Screw 11 Cover
5 Coolant line/vent
6 Nut B9 Boost air temperature sensor
7 coolant line B73 Boost pressure sensor
is m u Removal, installation
2 Remove boost air line Page 75

3 Remove boost air hose (3) (XI Installation: boost air hoses must not
be mixed up.
@ Red boost air hose is temperature-
resistant and should be installed between
boost air line and intercooler
, Danger! Danger of severe burns to skin and eyes Open cooling system only when coolant Page 80
from hot coolant spewing out. Coolant is temperature is below 90 C. Open cover
toxic when swallowed slowly and reduce pressure. Do not fill
beverage containers with coolant. Wear
protective gloves, protective clothing and
protective goggles.
4 Drain coolant Collect coolant. WH2080
5 Disconnect coolant line/vent (5) at connec

tor
6 Detach coolant line (5.7) at boost air mani

fold (1)
7 Disconnect coolant line (11) at boost air

manifold (1)

8 Release and separate engine wiring har
ness (10) at boost air temperature sensor
(B9) an d bo o st pressure sen sor (B13)
9 Take off boost air manifold (1) Clean sealing surfaces.

00 Installation: replace gaskets (9).
Pay attention to installation position.
0 Bolt for charge air manifold on cylinder BA09.41 -N-1001 -01B

head
10 Remove boost air temperature sensor (B9) 12 Installation: Replace sealing rings.
and boost pressure sensor (B13)
0 Boost air line/intercooler

906/907/921
BA09.41-N-1001-01B Bolt of boost air manifold to cylinder head Nm 25
AS20.00-Z-0001-01A Risk of injury to skin and eyes from Do not open the cooling system unless Danger!
out..Risk of poisoning from swallowing C. Open cap slowly and allow the
co o la n t. pressure to release.
Do not pour coolant Into containers
for drinks.
W ear protective gloves, protective

release.
Risk of poisoning - W ear protective gloves, protective clothes, and eye protection.
convulsions. e Pour large quantities of cold water over the affected area of
80
AR09.41 -W-8681C Removing, installing boost air manifold 31.7.97
ENGINE 904.909/910/911 /9 2 2 ,906.910/911/920/921 /9 2 2 /9 2 3 /9 4 0 /9 4 1

2 Cover
3 Bolt
4 Boost air manifold
5 Clip
6 Boost a ir pipe
7 Gasket
F, S 14-1320 Intake manifold
sum Removing, installing
2 Remove boost air pipe (6) at boost air Page 77

manifold (4)
3 Take off cover (2) at boost air manifold (4)
4 Release engine wiring harness (1) at boost

pressure, boost air temperature sensor and
disconnect
5 Detach boost air manifold (4) at the Clean sealing surfaces.

cylinder head GO Installation: replace gaskets (7); pay
attention to installation position.
63 Bolt of boost air manifold to cylinder BA09.41-N-1001-01B

head
6 Remove boost pressure, boost air Page 83

temperature sensor
0 Boost air pipe/intercooler

910/911/922.
906.910/911/920/
921/922/923/940
/941
BA09.41-N-1001-01B Bolt of boost air manifold to cylinder head Nm 25
82
AR09.41 -W-2003A Removing, installing boost pressure, boost air temperature sensor 4.8.97
ENGINE 904.909 /910/922 /911, 906.910/911 /920 /921 /922 /923

1 Cap
3 Boost pressure, boost air temperature
sensor
4 Bolt
W09.41-0017-05
Modification notes
7.7.98 Tightening torque, bolt of boost air pressure, boost air Step 4 Page 83
temperature combination sensor to bootair manifold
added
E IIS I Removing, installing
with a safety prop.
1 Tilt cab

2 Remove cap (1) at boost air manifold
3 Separate connector of engine wiring

harness (2) at boost pressure, boost air
temperature sensor (3)
4 Remove boost pressure, boost air BA09.41-N-1008-01B

temperature sensor (3)
S Boost air pipe / intercooier

910/911/922,
906.910/911/920/
921/922/923
B A09.41-N-1008-01B Bolt of boost air pressure, boost air temperature Nm 10

combination sensor
AR09.41 -W-6800B Testing intercooler and boost air hoses for leaks 6.8.97
ENGINE 904.909/910/911 /922,906.910/911 /920/9211922/923

1 Intercooler
2 Boost a ir hose (red)
3 HD Test flange with compressed air
connection
4 I S Tester with display
5 I S Test flange
6 Boost air hose (black)
7 S c re w plug
W09.41-0014-06
Testing
^ Danger! Risk of injury from bruises and jamming No person should be in the tilting area of P a g e 26
w ith a s a fe ty prop.
1 Tilt cab
Notes on tilting cab Models 950-954,970-976 P a g e 26
2 Remove noise encapsulation Q ] on right and at bottom
3 Remove screw plug (7) at intercooler (1) CDCollect oil which flows out.
and drain any oil which may have gathered
4 Detach boost air hoses (2,6) at both boost

air pipes
5 Install test flanges (3, 5) at the boost air 03 Inspect clips for wear.
hoses (2, 6) Test fla n g e s sho uld be s u p p o rted
additionally at the openings of the two
boost air pipes.
SI 904 589 07 63 00
6 Attach tester (4) to the test flange (5) IS 442 589 01 21 00
7 Fill intercooler (1) and boost air hoses (2,8) CDTest pressure 1.5 bar.
at test flange (5) with compressed air
8 Observe readout on tester (4) to see CD If pressure drops, inspect intercooler

whether pressure drops (1), screw plug (7) and boost air hoses (2,6)
when damaged; replace if necessary.
9 Remove tester (4) and test flanges (3,5) E Release pressure.
10 Attach boost air hoses (2,6) to both boost

air pipes
84
11 Install noise encapsulation H3 on right and at bottom
with a safety prop.
12 T ilt cab into d riv e position
AR13.22-W-1202A Removing, installing poly V-belt 1.9.95
ENGINE 904.905/906/907/909/910/911 /921 /922,906.910/911/920/921 Z922/923

1 Tensioning device with tensioning
pulley
2 T handle with socket wrench bit
3 P oly V-belt
W 1 3 .2 2 -0 0 M .0 6
W13.22-0005-09
Poly V-belt running diagrams
A Standard C W ith ad d itional generator
B W ith AC compressor D W ith AC compressor and additional generator
F, S 13-1202- Poly V-belt

1206
86
m Removing
s Danger) Risk of injury from bruises and jamming No person should be in the tilting area of Rage 26
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954,970- 976 Page 26

2 Remove noise encapsulation DO at side and bottom
3 Use Tommy arm and socket wrench bit (2) Swivel tensioning pulley up only by
to swivel tensioning pulley (1) up and hold means of the bolt (against spring tension)
4 Take off poly V-belt (3) Do not kink poly V-belt when
removing.
Inspect condition of poly V-belt, if
necessary J
On engine 904.905-907/921 WH1351
On engine 904.909-911 /922 and AP13.22-W-1351A

906.910/911/940/941
Replace poly V-belt
5 Swivel back tensioning pulley
6 Inspect vibration damper, belt pulleys of Replace parts which are damaged and/or
the generator and of coolant pump and worn: 1
also tensioning device and tensioning
pulley (1)
Vibration damper AR03.30-W-1600A
Tensioning device with tensioning pulley Page 88

Belt pulley of coolant pump AR20.10-W-1271A
m Installing
7 Fit poly V-belt (3) onto the belt pulleys and CD Do not fit poly V-belt onto tensioning
the vibration damper pulley (1).
8 Swivel tensioning pulley (1) Up and fit poly @ Swivel tensioning pulley up only by
V-belt (3) onto the tensioning pulley means of the bolt.
[D Inspect correct installation of poly
V-belt on the belt pulleys.
9 Install noise encapsulation CD at side and bottom
cab as fa r as th e en d p o sitio n a n d secure
with a safety prop.
10 Tilt cab into drive position
AR13.25-W-3200A Removing, installing poly V-belt tensioning device 18J.95
ENGINE 904.905/906/907/909/910/9111921 /922,906.910/911/920/921 7922/923

ENGINE 904.908/923 in MODEL 668. 670
1 Bolt
2 Tensioning device with tensioning
pulley
3 O il filter housing
4 Poly V-belt
W 1 3 .25 00 01 -0 6
B IE S Removing, installing
1 Remove poly V-belt (4) Engine 904.905- 909/910- 921/922 and Page 86
906.910/911/920- 923/940/941
Engine 904.908/923 AR13.22-D-1202D
2 Take off tensioning device (2) [D Installation: fix pins at the tensioning
d e vice in to t h e h o les a t th e o il filte r hou-
sing (3).
0 Bolt of tensioning device to crankcase BA13.25-N-1001-01C
3 Install in th e reverse o rd e r
@ Belt tensioning device

906/907/909/ 904.908/ 921/922/923/
910/911/921/922, 923 940/941
906.910/911
BA13.Z5-N-1001-01C Bolt or poly-v belt tensioning device to crankcase ivm 50 50 50
88
AR13.30-W-551 OA Removing, installing compressor 18.7.95
ENGINE 904.905/906/907/909/910/911/9217922,906.910/911/920/921 Z922/923

I Compressor
3 Coolant line (return flow )
4 connection fitting
5 Compressed air line
6 Suction line
8 Coolant line (feed)
9 O-ring
10 Drive gear
II Nut
13 Cross p late
14 Power steering pump
16 Steering line (pressure)
17 steering line (suction)
B IS Crankshaft angle position sensor

B16 TDC sensor cylinder 1
I Compressor
9 O-ring
10 Drive gear
II Nut
13 Cross plate
18 W1 Blocking device
18a Nut
19 S3 Puller
W 13.30-0039-06
30 Hydraulic lines
31 Securing clips
32 M ounting plate
33 Bolt
W 26.60 -1 01 1-11
Modification notes
7.7.98 Tightening torque of nut of drive gear to compressor Step 13 Page 89

modified
Operaton no. of operation texts or standard texts and flat rates
f.s 13-5000- Air compressor

5517
m M Removing, installing
with a safety prop.
1 Tilt cab
@ Notes on tilting cab Model 673- 679,950- 954,970- 976 Page 26

2 Remove noise encapsulation E On left and at bottom
3.1 Detach shift rod at transmission Engine 904.905-907/921
3.2 Remove shift rod at cylinder head Engine 904.909- 911/922 and 906.910/911
3.3 Detach hydraulic lines (30) together with Engine 906.920-923 with "hydraulic" shift
mounting plate (32) and securing dips (31) code GS3
at engine and place to the side S Do not separate hydraulic lines
4.1 Remove MR 1PLD control unit Engine 904.905- 907 /909- 911 /921 /922 Page 24
906.910/911/920-923
4.2 Separate plug connection at control valve Engine 906.910/911/920- 923
of constant throttle
5 Pull out crankshaft angle position sensor S Installation: press in TDC sensor
(B is ) at timing case, detach cable and cable cylinder 1 and crankshaft angle position
of TDC sensor cylinder 1 (B16) sensor as far as a stop
90
, Danger Risk of injury to skin and eyes from Do not open the cooling system unless the Pa g e 80
and eye protection.
6 Drain coolant and collect Engine 904.905-907/921 WH2080
Engine 904.909- 911 /922 and AP20.00-W-2080A

906.910/911/950- 923
7 Detach coolant lines (3,8) at compressor Q j Installation: replace seals

cylinder head (1)
0 B a n jo b o lt o f co o la n t line t o co m presso r BA13.30-N-1004-01A
8 Unbolt compressed air line (5) at CO If coking present, it is then necessary to

compressor (1) and inspect additionally inspect compressed air line
drier with integrated pressure regulator
and the four-circuit protection valve.
H I In s ta lla tio n : inspect co m pressed a ir line

for leaks
0 Connection of compressed air line to BA13.30-N-1007-01A

compressor
9 Detach suction line (6) at compressor (1) 0 Connection of suction line to BA13.30-N-1008-01A
compressor
A\ D a n g e r Risk o f in ju r y to skin o r eyes as a resu lt o f R e n d e r system pressureless b e fo re P a g e 93

10 Separate both steering lines (16,17) at the Counterhold connection fitting in power
separation point steering pump when slackening and collect
hydraulic fluid which flows out
LU Installation: top up hydraulic fluid and
bleed steering
Engine 904.905-907/921 WH4611
Engine 904.909- 911/922 and AP46.00-W-4611A

906.910/911/920-923
11 Remove compressor (1) together with Collect engine oil which flows out
power steering pump (14) from the I I I Installation: fully tighten the inner top
crankcase hexagon bolt (12) first of all, then the
remaining bolts
0 Bolt of compressor to crankcase BA13.30-N-1006-01A
12 Remove power steering pump (14) at AR46.30-W-0500A

compressor (1)
13 Slacken nut (11) and pull off drive gear (10) Attach blocking device (18) at compressor
at compressor (1) and then unscrew nut
(11)
G2 904 589 03 63 00
IS Three-legged puller WH58.30-Z-1001-17A
0 Nut of drive gear to compressor BA13.30-N-1005-01A
14 Remove O-ring (9) at compressor flange Q ] Installation: replace O-ring
Engines OM904 LA, 906 LA (m od, des. 904.9,906.9), F4

15 Detach connection fittings (4,7) at L Installation: replace seal
compressor cylinder head
17.1 Check engine oil level with dipstick Engine 904.905-907/921 WH0101.40
17.2 Check engine oil level at electric gage Engine 904.909- 911/922 and
906.910/911/920-923
See ATEGO opration instructions part 3
@ Compressor (compressed air system)

906/907/909/
910/911/921/922,
900.910/911/920/
921/922/923
BA13.30-N-1004-01A Banjo bolt of coolant line to Nm 40

compressor
BA13.30-N-1005-01A Nut of drive gearto compressor Nm 270
BA I 3.30-N-1006-01A Bolt of compressor to crankcase Nm 40
B A 1 J . 3 U - N - 1 U U /- U 1 A Connection fitting of compressed air Nm 100

line to compressor
BA I 3.30-N-1008-01A Connection fitting of suction line to Nm 100

compressor
WH58.30-2-1001-17A Three-legged puller (300 mm width) Hahn und Kolb 55 051 040
Borsigstr. 50
D-70469 Stuttgart
92
ASOO.OO-Z-O013-01A Risk of injury to skin or eyes from Before starting work on the hydraulic A Danger!
pressurized hydraulic fluid spraying out. system, depressurize the system. Wear
hydraulic fluid
Potential danger
due to the very high pressures (above 200 bar). Damage to the - Wear safety gloves, protective clothing and safety glasses.
symptoms of poisoning including headaches, dizziness, stomach
- Before starting work on hydraulic systems they should be After swallowing larger quantities .consult a doctor.
depressurized and the system must be emptied if necessary. If hydraulic fluid gets into the eyes, rinse out the eyes
hydraulic fluid. In the event of injuries to skin or eyes from a jet of hydraulic
fluid, consulta doctor immediately.
AR14.10-W-3915A Removing, installing exhaust manifold 22.11.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 /922 /923 /940 /941
1 Gasket 11 O il return flow hose

2 Exhaust m anifold 12 Heat shield
3 Exhaust m a n ifo ld b o lt 13 Bolt
4 Boost air pipe 14 Engine brake flap connection
5 Clip 15 Compressed a ir line
6 Banjo bolt 16 Clip
7 Seal 17 Exhaust pipe
8 Oil delivery line
9 Turbocharger L Shank length o f exhaust m anifold bolt
10 A ir intake hose
Operatori no. of operation texts or standard texts and flat rates
F, S 14-3600 Exhaust manifold
Removing, Installing
b a tte ry e lec tro ly te. Risk o f in ju ry to eyes eye p ro te c tio n . P o u r b a tte r y e le c tro ly te

with a safety prop.

2.1 Tilt cab into repair position Model 673-679 AR60.80-W-0010A
2.2 Tilt cab Model 950- 954,957,970- 976
Notes on tilting cab Model 673- 679,950- 954,957,970- 976 Paged

3 Remove noise encapsulation IH On right and at bottom
4 Remove boost air pipe (4) Engine 904.905-907/921 AR09.41-W-1311A
Engine 904.909/910- 922 and AR09.41-W-1311C

906.910/911/920- 923/940/941
5 Detach exhaust pipe (17) at engine brake Installation: clean sealing surfaces
flap connection (14)

brake cylinder
7 Detach heat shield (12) at turbocharger (9) LAJ Installation: Engine 904.905-907/921:
and crankcase attach heat shield and compressor suction
line together at crankcase
8 Detach oil return flow hose (11) at [ E Collect engine oil which flows out
turbocharger (9)
9 Detach oil delivery line (8) at oil filter and Seal hole at turbocharger in crankcase.
turbocharger (9) HI Installation: before attaching the oil
pressure line, fill the turbocharger bearing
housing through the oil filler hole with
engine oil. Rotate turbocharger shaft by
hand during this step so that the bearing
points are provided with a film of oil.
Engine 904.909- 911 /922 and

906.910/911/920- 923/940/941
EE Installation: replace gasket (7)
0 Oil pressure line to turbocharger RA09.40-N-1002-01R
10 Detach air intake hose (10) at turbocharger

(9)
11 R e m o v e ex haust m a n ifo ld (7). IT] O n ly slacken rea r e x haust m a n ifo ld h o lt
turbocharger (9) and engine brake flap (3) in the bottom row; exhaust manifold is
connection (14) together suspended at this bolt
S Bolt of exhaust manifold to crankcase BA14.10-N-1001-01B
12 Inspect exhaust manifold bolts (3) CD Installation: if the max. shank length BE14.10-N-1001-01A
(L) was exceeded j
replace exhaust manifold bolts

13 Take off gaskets (1) [El Installation: replace gaskets
14 Detach turbocharger (9) together with EE Seal holes at turbocharger with caps
exhaust brake flap connection (14) at
exhaust manifold (2)
Installation: replace nuts
Nut of turbocharger to exhaust BA09.40-N-1001-01B

manifold
16.1 Check engine oil with dipstick Engine 904.905-907/921 WH0101.40
16.2 Check engine oil at electric gage Engine 904.909/910- 922 and
906.910/911 /920- 923/940/941
See ATEGO operating instructions part 3
4
17 Start engine and observe oil pressure gage Crank engine w ith starter for not more BE 18.00-N-1001 -01C
when engine idling than 90 seconds. W ait about 2 minutes
before repeating attempt at starting.
LU The oil pressure gage should indicate
Test data of exhaust manifold

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE14.10-N-1001-01A Exhaust manifold bolts Thread diameter M 10
Shank length (L) when mm 47.0

new
Max. shank length (L) mm 47.5

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idle speed bar a0.5
0 Turbocharger

906/907/909/ 906.910/911/920/
910/911/921/922 921/922/923/940
/941
BA09.40-N-1001-01B Nut of turbocharger to exhaust manifold Nm 30 50
BA09.40-N-1002-01B Bolt of oil delivery line to turbocharger M8 Nm 40 -
M6 Nm 10 10

0 Exhaust manifold

906/907/909/910
/911/921/922.
906.910/911/920/
921/922/923/940
/941
BA14.10-N-1001-01B Bolt of exhaust manifold to cylinder Iststage Nm 10

head ..
2nd stage Nm 55
3rd stage 90
AS 54.10 -Z -0 0 0 1-01A Explosion hazard from explosive gas. Flames, sparks, open light and A Danger!
Danger of poisoning and acid burns when smoking prohibited. Wear acid
battery acid is swallowed. Danger of acid resistant gloves, clothing and goggles.
batteries.
Possible dangers
Injury hazard
Explosion hazard Battery acid contains sulfuric acid, which can cause severe burns
A highly explosive gas mixture is generated when lead-acid to skin and eyes. When handling damaged lead-acid batteries
batteries are charged (removing from accident vehicle) Increased care is necessary due
When battery acid is taken orally toxic symptoms can occur such
Battery acid vapor can burn eyes. Inhalation can result in burns to Fire, sparks, open light and smoking prohibited.
pole first.
Switch on charger only after connecting to poles; switch off
6
- Keep lead-acid batteries and battery acid away from First-aid measures
- Store battery acid only in suitable, appropriately marked Rinse eyes immediately with large quantities of water.
- Store lead-acid batteries only in upright position. Remove affected clothing.
- Ensure that gassing line is properly connected. Neutralize acid on skin or clothing immediately with acid
Check gassing line fo r kinks and proper passage neutralizar o r soap solution and rinse w ith large quantities
- Observe instructions for applicable lead-acid battery and of water.
- Wear acid protective clothing and protective goggles with side Move affected person to fresh air
guard. Swallowing battery acid
activated charcoal.
Generally medical services or a physician should be contacted


P54.10-0270-08
Warning notes on lead acid batteries
Fire, sparks, open light and smoking 3 Observe operating instructions 6 Keep aw ay from children
p rohibited 4 D anger o f od d burns 7 First aid
2 Explosion hazard 5 W ear eye protection
AH 54.10-P-0001 -01A Notes on battery All models
Do not store lead-add batteries tor extended periods of time Do not switch on battery chargers until they have been
therefore, ensure that they are stored at temperatures above During rapid charging it must be insured that the casing of the
Avoid mixing up positive and negative poles and avoid short- It is advisable to grease the poles lightly with battery pole
circuits. grease.
Bearbeitungsvermerk
[ Datum j rsteiier Vermerk [Seite
AS60.80-Z-0001-01A Injury hazard from pinching and crushing W hen tilting ensure that no one is A Danger!
A lw ays tilt cab to end position and
Injury hazard
mechanism can lead to severe injuries when tilting the cab. W hen tilting cab;
Rules of behavior/protective measures unauthorized access, e.g. by blocking off or with human
- Apply parking brake. vehicle operating instructions.
- Secure vehicle against rolling. - Never work under cab when partially tilted.
neutral position.
to position N".
8
AH60.80-N-0003-01A Notes on tilting the cab Models 673,674,675,676,677,678,
679,950,952,953,954,957,970,971,
972, 973, 974, 975, 976

Switch off engine e The refrigerator box must be switched off before the cab is
e Apply parking brake tilted.
e Secure vehicle to stop it rolling away e The refrigerator box may only be switched on 10 minutes
e Remove all loose objects (e.g. cans, bottles, tools, bags etc.) after tilting the cab back again.
from the cab GO Also refer to the refrigerator box manufacturer's
On vehicles with manual transmission move shift lever to Operating Instructions and the red information plate on the
Model 957: release steering column and open front flap
CD Always tilt cab up to its final position.
ASOO-00-Z-0005-01A Risk of accident as a result of vehicle Secure vehicle to prevent it from A Danger!
starting off when engine is running. Risk of moving off.
injury as a result of bruises and burns if you Wear closed and close-fitting work
insert your hands into engine when it is clothes.
Possible dangers Rules of conduct / Protective measures

- As a general rule, carry out work on the running engine only if
from vehicle starting off during starting operation (e.g. when - Before starting the engine, apply parking brake.
testing compression pressure) as a result of gear engaged or when - On models with manual transmission, move gearshift lever
result of selector lever position HP" or " N " not engaged On models w ith autom atic transmission, m ove selector lever
(exception: some vehicles do not have a selector lever position into position "P or "N (exception: some vehicles do not have
"P"). a selector lever position P").
- On models which do not have selector lever position P",
Severe injuries may be caused by freely rotating parts in the area unintentionally.
of the running engine. The heat produced by the engine when it - Wear closed and close-fitting work clothes.
is operating can result in severe burns if contact is made with - Take off any jewelry, such as chains, rings etc.
individual, unshielded parts. - If you have long hair, wear a suitable head cover,
- Before commencing work on the running engine, check to
be hot.
W h e n carrying o u t w o r k w fie ri sta rtin g th e e n g in e o r w h e n
engine is running, do not touch any hot and rotating parts.

water and cover skin with sterile bandages.
AR14.15-W-6302A Removing, installing engine brake flap connection 20.11.95
ENGINE 904.905/906/907/909/910/911 /921 /922

1 Exhaust pipe
2 Clip
4 Nut
5 Fixture
6 Turbocharger
7 H eat shield
8 B o lt
9 Bolt
10 Compressed air pipe
W 1 4 ,15-0001-12
F 14-5810- Engine brake

7010
1 1 Removing, installing

when tilting cab the cab when it Is being tilted. Always tilt
2 Tilt cab
Notes on tilting cab Model 673-679,970-976 Page 9

3 Remove noise encapsulation 2 ] On right and at bottom
4 Detach heat shield (7) [ U Installation: attach heat shield and air
intake line of compressor together to
crank case
5 Detach exhaust pipe (1) at engine brake 2 ] Installation: clean sealing surfaces
flap connection (3)
10
brake cylinder
7 Detach engine brake flap connection (3) CH! Installation: replace nuts (4)
and fixture (5)
@ Nut of engine brake flap connection to BA14.10-N-1002-01B

turbocharger
0 Exhaust manifold

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BA14.10-N-1002-01B Nut of engine brake flap connection M8 Nm 30

to turbocharger M1Q
Nm 50
iM j* Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4

ARI 4.15-W-6302F Removing, installing engine brake flap connection 9.7.98
ENGINE 906.910/911/920/921 /922/923/940/941

1 Exhaust pipe
2 Clip
4 Compressed air line
5 H eat shield
W14.15-1002-06
U HU Removing, installing

with a safety prop.
2 Tilt cab
Notes on tilting cab Model 950-954,957,970-976 Page 9

3 Remove noise encapsulation E On right and at bottom
4 Remove fixture at engine brake flap On engine 906.940/941

connection (3) and at air intake manifold
5 Remove exhaust pipe (1) at engine brake EX] Installation: clean sealing surfaces and
flap connection (3) and at the rear lifting inspect clip (2) for wear, replace clip if
eye necessary
6 Detach heat shield (5) at engine brake flap

connection (3) and turbocharger

brake cylinder
8 Detach engine brake flap connection (3) E Installation: replace nuts
12
0 Nut of engine brake flap connection to BA14.10-N-1002-01B
turbocharger
0 Exhaust manifold

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BA14.10-N-1002-01B Nut of engine brake flap connection M8 Nm 30

to tu rb o c h a rg e r
M10 Nm 50
AR14.15-W-581OA Repairing engine brake flap connection 1.9.95
ENGINE 904.905/906/907/908/909/910/911/921 Z922/923

2 Bearing bush
3 Engine brake shaft
4 Engine brake flap
5 Bolt
6 Bracket
7 Bolt
e Bolt
9 Adjusting lever
10 Nut
11 Ball socket
12 N ut
13 Engine brake cylinder
14 Nut
15 Washer
16 Pin
17 Nut
18 Locking element
Position o f engine brake flap/

adusting lever
B Open
C Closed

2 Bearing bush
4 Engine brake flap
5 Bolt
A xial play o f engine brake shaft
Disassembling
1 Remove engine brake flap connection (1) Page 10

2 Remove engine brake cylinder (13) Release ball socket (18)
3 Take off adjusting lever (9)
4 Takeoff bracket (6)
5 Remove engine brake flap (4) CD Close engine brake flap for this step.
6 R em o v e e n g in e b ra k e sh a ft (3) a n d b e a rin g C l] Use a suitable drift.
bushes (2)
0 Assembling
14
7 Install bearing bush (2) on the bracket side tilw ith a projection (approx. 3 mm) to the
inner contact surface.
Use a suitable drift.
19 Depth slide gage WH58.30-Z-1012-12A
Coat bearing point with hot lubricating BR00.45-Z-1006-06A

paste.
8 Insert engine brake flap (4) into the engine iXI Coat bearing point with hot lubricating B R00.45-Z-1006-06A
brake flap connection (1) and push engine paste.
brake shaft (3) through
9 Knock in second bearing bush (2) EE Center engine brake shaft (3) to brake
flap connection diameter. Projection of
both bearing bushes to inner contact
surface should be the same.
Use a suitable drift.
10 Knock back bearing bushes (2) evenly on in Use a suitable drift. BE14.15-N-1004-01B
both sides until the axial play (A) of the
engine brake shaft (3) is achieved
19 Feeler gage WH58.30-Z-1008-12A
11 Bolt engine brake flap (4) tight [I] When engine brake flap closed, bolt
heads (5) should be pointing toward
engine. Center engine brake flap in engine
brake flap connection (1). In closed
position, engine brake flap should be
resting against flap connection stop.
12 Measure annular gap at engine brake QJ Engine brake flap must not be making
flap (4) contact radially at flap connection passage
when closed.
19 Feeler gage WH58.30-Z-1008-12A
13 Attach bracket (6)
14 Install adjusting lever (9) 0D Fit adjusting lever onto the splines of
the engine brake shaft (3) so that the
adjusting lever stop is resting against
bracket (6) when engine brake flap (4) is
fully open (position B).
15 Inspect setting of engine brake flap (4) When engine brake flap is closed
(position C). adjusting lever stop must not
be touching the bracket (6) (distance
approx. 1 mm).
16 Install engine brake cylinder (13) 0D Replace nut (14) BE14.15-N-1001-01B
17 Set preload of engine brake cylinder (13) HI When engine brake flap (4) opened BE 14.15-N-1002-01B
and secure engine brake cylinder (position B), turn the ball socket (11)
(approx. 2 turns) until the specified setting
is achieved
18 Install engine brake flap connection (1) Page 10
Tesi data of engine brake

906/907/908/909
/910/911/921/
922/923.
906.910/911/920/
921/922/923/940
/941
BE14.15-N-1001-01B Setting of engine brake cylinder mm 180.3
BE14.15-N-1002-01B Engine brake cylinder preload mm 1.0-2.0
BE14.15-N-1004-01B Engine brake shaft axial play between mm 0.3-0.5

bushes
W H 8 3 0 -Z -1 0 0 8 -1 3 A E e e le r g a g e Stie fe lm o y c r 59
D-73734 Esslingen
WH58.30-Z-1012-12A Depth slide gage, range 0 -200 mm Stiefelmayer 040 202

D-73734 Esslingen
Repair products
BR00.45-Z-1006-06A Hot lubricating paste 000989 76 51
16
AR14.15-W-5810F Repairing engine brake flap connection 9.7.98
ENGINE 906.910/911/920/921 /922/923/940/941

I Engine brake throttle valve housing
2. 1 Bearing socket
2.2 Bearing socket
3 Enyine b ia ke shaft
4 Engine brake flap
5 Screw
6 Bracket
7 screw
8 Spacer socket
9 Nut
10 Engine brake cylinder
10.1 Nut
10.2 Ball socket
II Retainer
12 Adjustment lever
13 Nut
14 Screw
Position o f engine brake flap/adjustment

lever
B open
C closed
1 Engine brake throttle valve housing

2.1 Bearing socket
2.2 Bearing socket
4 Engine brake flap
5 Screw
A Engine brake shaft axial play
Disassembling
1 Remove engine brake throttle valve Page 12

housing (1)
2 Remove engine brake cylinder (1) Release ball socket (10.2).
3 Remove spacer socket (8)
4 Remove adjustment lever (12)
5 Remove bracket (b)
6 Remove engine brake flap (4) E For this purpose close engine brake flap
7 Remove engine brake shaft (3) and bearing E Use suitable punch.
sockets (2.1, 2.2)
Engines OM904 LA, 906 LA (mod. des. 904.9.906.9), F4

Assembling
8 Install bearing socket (2.2) on retainer side E With protrusion (approx. 3 mm)
pointing toward Inner contact surface
Use suitable punch.
IS Depth gauge WH58.30-Z-1012-12A
Coat bearing surface with high BR00.45-Z-1006-06A

temperature lubricating paste
9 Install engine brake flap (4) in engine E Coat bearing surface with high BR00.45-Z-1006-06A
brake throttle valve housing (1) and slide temperature lubricating paste.
engine brake shaft (3) through
10 Knock in second bearing socket (2.1) E Center engine brake shaft (3) in
throttle valve housing diameter. The
protrusion of both bearing sockets
pointing toward the inner contact surface
must be uniform. Use suitable punch.
11 Drive back bearing sockets (2.1,2.2) E Use suitable punch. BE14.15-N-1004-01B

uniformly on both sides until axial play (A)
on engine brake shaft (3) is achieved
IS Feeler gauge WHS8.30-Z-1008-12A
12 Tighten engine brake flap (4) E Bolt heads (5) should point toward
engine with engine brake flap closed.
Center engine brake flap in engine brake
throttle valve housing (1).
Engine brake flap should be In contact with
throttle valve housing stop In closed
position.
13 Measure annular gap on engine brake flap E Engine brake flap should not make
(4) radial contact with throttle valve housing
passage in closed position.
14 Install bracket (6)
15 Install adjustment lever (12) B Position adjustment lever on splines of

engine brake shaft (3) so that when fully
open the engine brake flap (4) (position B)
makes contact with the adjustment lever
stop on the bracket (6).
16 Check engine brake flap (4) adjustment When the engine brake flap is open
(position B) the adjustment lever should
not make contact with the bracket (6)
(interval approx. 1 mm)
17 Install spacer socket (8)
18 Install engine brake cylinder (10) E Replace nut (9).
19 Adjust initial tension of engine brake S Turn ball socket (10) (approx. 2 turns) BE14.15-N-1002-01B
cylinder (13) and secure engine brake with engine brake flap (4) open (position
cylinder B) until predefined adjustment value is
reached.
Observe adjustment dimension for engine BE14.15-N-1001-01B

brake cylinder
20 Install engine brake throttle valve housing Page 10

(1)
18
Test values for engine brake

906/907/908/909
/910/911/921/
922/923,
906.910/911/920/
921/922/923/940
/941
BE14.15-N-1001-01B Adjustment dimension for engine brake mm 180.3

cylinder
B E14.15-N-1002-01B Engine brake cylinder - initial tension mm 1.0-2.0
BE14.15-N-1004-01B Engine brake shaft - axial play between mm 0.3-0.5

sockets
Number Designation Company (e.g.) Order number
WH58.30-Z-1008-12A Feeler gauge Stiefelmayer 59

D-73734 Esslingen
WH58.30-Z-1012-12A Depth gauge, measuring range 0 - 200 mm Stiefelmayer 040 202

D-73734 Esslingen
B R00.45-Z-1006-06A High temperature lubricating paste 000989 76 51
AR15.30-W-7100A Removing, installing starter 19.7.95
W 15.30-0004'1 2
F,S 15-7100- Removing, installing / replacing starter

7170
M M Removing, installing
Notes on battery All models Page,8

when tilting cab the cab when It is being tilted. Always tilt
with a safety prop.
2 Tilt cab
3 Remove noise encapsulation H I At bottom and on side
4 Detach wiring harness (6) at bracket (5) On engine 904.909- 911/922 and
906.910/911/920- 923/940/941
5 Detach bracket (5) at crankcase On engine 904.909- 911/922 and

906.910/911/920-923/940/941
6 Detach ground cables (7) at timing case
7 Detach cables (1,2) at starter (M1)
8 Detach starter (M l) [ U Installation: apply a thin film of grease BR00.45-Z-1001-06A

to starter pinion of starter and ring gear of
flywheel
0 Nut of starter to timing case BA15.30-N-1001-01B
9 Inspect starter pinion in starter (M1) for Q ] If wear present J.

wear
replace starter
10 Inspect ring gear of flywheel for wear 111 If wear present J,
replace ring gear of flywheel AR03.30-W-8312A
@ Starter

906/907/909/
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BA15.30-N-1001-01B Nut of starter to timing case Nm 50
Repair products
BR00.45-Z-1001-06A MB longlife grease 000 989 63 51
AR15.40-W-5032A Removing and installing generator 22.11.95
ENGINE 904.905 /906 /907 /909 /910/911 /921 /922.906.910/911 /920 /921 /922 /923 /940 /941
1 A ir intake hose
2 Bolt
3 Poly V-belt
4 Nut
5 Bolt
6 Supporting bracket
7 Bolt
e W iring harness
9 Bracket
G1 Generator
W 15.40.0004-0$
F, S 15-5030- Generator
5076
101IEI Removing, installing

when tilting cab the cab when It is being tilted. Always tilt
2 Tilt cab

3 Remove noise encapsulation CDOn rightand at bottom
4 Remove air intake hose (1)
5 Remove charge air pipe from intercooler to On engine 904.909- 911/922 and AR09.41-W-1311D
charge air manifold 906.910/911/920- 923/940/941
6 Remove bracket (9) at supporting bracket On engine 904.909- 911/922 and

(6) 906.910/911/920-923/940/941
22
7 Slacken poly V-belt (3) and take off H I At tensioning pulley and belt pulley of AR13.22-W-1202A
generator
8 Disconnect wiring harness (8) at generator E Pay attention to color coding of cables
(G1)
9 Detach generator (G1) at bracket 0 Bolt of generator to bracket BA15.40-N-1003-01 B
10 Remove generator (G 1) together with 0 Bolt of generator support to crankcase BA01.40-N-1003-01C

support (6)
11 Take out generator (G1) together with

support (6)
12 Take generator (G1) off support (6) 0 Nut of generator to support BA15.40-N-1002-01 B
13 Inspect belt pulley of generator for H If wear present J

damage and concentric running
replace belt pulley P a g e 24

906/907/909/910
/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
B A01.40-N-1003-01C Bolt of generator supporting bracket Nm 100

to crankcase
0 Generator

906/907/909/
910/919/921/922,
906.910/911/920/
921/922/923/940
/941
BA1S.40-N-1002-01B Nut of generator to supporting Nm 50

bracket
BA15.40-N-1003-016 Bolt of generator to bracket Nm 65
E n gin es O M 9 4 LA . 90fi I A (m o d d es 94 9. 906.9). 64 23
AR15.40-W-571 OA Removing and installing the generator poly V-belt pulley 1.8.97
ENGINE 904.905/906/907/909/910/911/921 /922.906.910/911/920/921 Z922/923

7 Poly V-belt
2 Nut
3 Belt pulley
a Fan wheel
67 Generator
W 15.40-0006-06
Modification notes
7.7.98 Tightening torque of nut of belt pulley to generator Step 4 Page 24

modified
sector op. no. operation text
F, S 15-5710 Belt pulley
1111 Removing, installing
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954, 970- 976 Page 9
2 Remove noise encapsulation S on right and at bottom
4 Slacken nut (2) at the belt pulley (3) E Counterhold generator shaft with
hexagon socket wrench
0 Nut of belt pulley to generator BA15.40-N-1004-01B
5 Slacken poly V-belt (1) and take off E at tensioning pulley and belt pulley (3) AR13.22-W-1202A
of generator
6 Detach belt pulley (3) and fan wheel (4) at
generator
24
H Generator

906/907/909/
910/919/921/922,
906.910/911/920/
921/922/923/940
/941
BA15.40-N-1004-01B Nut of belt pulley to generator M 16x1.5 Nm 80
M 27x1.5 Nffl 150
AR18.10-W-6020A Removing, installing oil pump 22.11.95
ENGINE 904.905/906/907/909/910/91119211922.906.910/911/920/9211922/923
ENGINE 904.908/923 in MODEL 668. 670
1 OH pump
2 B olt
3 Dowel pins
4 O-ring
6 Drive gear
7 Dipstick guide tube
8 Bracket
9 Bolt
10 Nuts
11 Bolts
12 Intake pipe
13 Bolt
14 Radial seal
WI8.10-0002-06
1 Oil pump
3 Dowel pin
14 Radialseal
15 IS D rift
16 Guide sleeve
17 Base
A Am ount by which radial seal stands

back relative to o il pump housing
W 18.10*0006-06
u s in i Removing, installing
1 R e m o v e v ib ra tio n d a m p e r E n g in e 904.905-907/909- 911/921/922 and AR03.30-W-1600A

906.910/911/920- 923/940/941
Engine 904.908/923 AR03.30-D-1600D
2 R e m o v e o il sum p E n g in e 904.905-907/921 AR01.45-W-7500A
Engine 904.908/923 AR01.45-D-7500D
Engine 904 909/- 911/922 and AR01.45-W-7500C

906.910/911/920-923
3 Take off dipstick guide tube (7) and brac H I Installation: attach dipstick guide tube
ket (8) at suction pipe (12) and bracket free of stress.
0 Bolt of bracket of oil pump suction pipe BA18.10-N-1004-01B

to crankcase
4 Take off suction pipe (12) 0 Bolt of suction pipe to oil pump BA18.10-N-1002-01B
5 Take off oil pump (1) @ Do not damage sealing surface.
[2 Installation: clean contact surface at oil BR00.45-Z-1010-01A

pump (1) and coat with sealant.
Position guide sleeve (16) onto the
crankshaft flange and install oil pump.
Do not damage radial seal when installing.
El 904 589 02 15 00
0 Bolt of oil pump to crankcase BA18.10-N-1001-01B
6 Remove radial seal (14) f f l Installation: use a drift to knock in new

radial seal as far as stop.
m 904 589 02 15 00
7 Remove O-ring (4) H I Installation: install new O-ring.

11 Inspecting
8 Inspect contact surface of crankshaft for ED If wear exists, a radial seal with race has
signs of scoring or rubbing been available from about 10/96 for
repaiis.
0 Timing case

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
B A 1 S .1 0 -N 1 0 0 1 -0 1 B B o lt o f o il pu m p to crankcase Nm 25 25
BA18.10-N-1002-01B Bolt of intake pipe to oil pump Nm 25 25
BA18.10-N-1004-01B Bolt of bracket of oil pump suction Nm 50 50

pipe to crankcase
Repair products
BR00.45-Z-1010-01A Loctite 574 sealant 001 989 89 70
28
AR18.30-W-6840A Removing, installing oil-water heat exchanger 19.7.95
ENGINE 904.905/906/907/909 /910 /911 /921 /922, 906.910/911 /920 /921 /922 /923 /940 /941
1 Oil-water heat exchanger 6 Oil filter housing

1.1 Bolt 6.1 O il filter elem ent
1.2 Housing cover 6.2 Seal
1.3 Heat exchanger 6.3 Oil filter cap
1.4 Gasket 7 Oil delivery pipe
2 Gasket 8 Banjo bolt
3 Bolt 9 Hexagon socket bolt
4 Vent pipe 10 A ir intake hose
5 Bolt 11 Gasket
12 Screw plug
Sector Op.no. Operation text
F.S 18-6840 Oil-water heat exchanger
is m s Removing, installing
with safety prop.
1 Tilt cab
Notes re tilting cab Models 673- 679, 950- 954,957,970- 976 Page 9
2 Remove noise encapsulation on right [ S on right
A Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
and eye protection.
3 Drain coolant Collect coolant.
Engine 904.905-907/921 WH2080
Engine 904.909-911/922 and AP20.00-W-2080A

906.910/911/920- 923
Notes on draining coolant Page 33

4 Unscrew oil filter cap (6.3) from the oil EE When oil filter cap is removed, the
filter housing (6) engine oil flows back into the sump.
e 366 589 0107 00
Q] Installation: inspect seal (6.2) at oil fil

ter cap and replace if necessary.
El 366 589 01 07 00
0 Oil filter cap to oil filter housing BA18.20-N-1003-01 B
5 Remove boost air pipe from intercooler to Engine 904.909-911/922 and AR09.41-W-1311D
boost air manifold 906.910/911 /920- 923/940/941
7 Remove vent pipe (4) at oil separator
8 Remove vent pipe (4) at oil separator
9 Disconnect oil delivery pipe (7) at turbo EE Collect engine oil which flows out.
charger and take off gasket (11) Seal oil drilling in turbocharger.
(U Installation: replace seals and gasket

(11).
0 Oil delivery pipe to turbocharger BA09.40-N-1002-01B
10 D rain en g in e oil a t o il- w a te r h e a t C o lle ct e n g in e oil.

exchanger (1) EE Installation: replace seal.
0 Screw plug to oil-water heat exchanger BA18.30-N-1003-01C
11 Slacken ex haust m a n ifo ld a n d push a w a y ED U n s cre w ex haust m an ifo ld bolts
from cylinder head approx. 4 mm.
S Exhaust manifold bolt of exhaust BA14.10-N-1001-01B

manifold to cylinder head
IXI Installation: inspect shank bolts; BE14.10-N-1001-01A

replace If necessary.
Inspect gaskets for damage, if necessary J,
remove exhaust manifold and replace Page 3

gaskets
12 Remove oil-water heat exchanger (1) at ED Collect coolant and engine oil which
crankcase flows out.
0 Bolt of oil-water heat exchanger to BA18.30-N-1001-01C

crankcase
0 B o l l o f ho using cover to oil-w ater h e a t BA1S.30-N-1002-01C

exchanger
13 Take off gasket (2) at oil-water heat ex EE Installation: replace gasket (2).
changer (1)
30
14 Detach housing cover (1,2) from the heat HI Installation: do not tighten bolt (1.1)
exchanger (1.3) until after attaching the oil-water heat ex
changer to the crankcase.
15 Remove gasket (1.4) from housing cover H i Installation: replace gasket (1.4).
(1.2)
16 install In the reverse order
17 Check coolant level and adjust to correct Engine 904.905.907/921 WH2080

level
tngme 904.909-9111922 and AP20.00-W-2080A

906.910/911/920-923
18 Fill engine oil circuit Page 49
Test data of exhaust manifold
Number Designation Engines 904.905/ Engine 904.908

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE14.10-N-1001-01 A Exhaust manifold bolts Thread diameter M 10 10
Shank length when new mm 47.0 47.0
Max. shank length mm 47.5 47.5
@ Turbocharger

906/907/909/910 906.910/911/920/
/911/921/922 921/922/923/940
/941
BA09.40-N-1002-01B Bolt of oil delivery pipe to turbocharger M8 Nm 40 -
M6 Nm 10 10
0 Exhaust manifold

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BA14.10-N-1001-018 Bolt of exhaust manifold to cylinder 1st stage Nm 10

head ,
2nd stage Nm 55
3rd stage "4 90
Eng ines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 31
0 Oil filter
906/907/909/
910/911/921/922.
906.910/911/919/
920/921/922/923
/940/941
BA18.20-N-1003-01B Oil filter cap to oil filter housing Nm 25
@ Oil cooling system

906/907/909/
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BA18.30-N-1001-01C B o lt o f o il- w ate r h e a t e x c h a n g e r to crank case Nm 25
B A18.30-N-1002-01C Bolt of housing cover to oil-water heat exchanger Nm 25
B A18.30-N-1003-01C Screw plug to oil-water heat exchanger Nm 20

906/907/921 910/911/922
906.910/911/920/
921/922/923/940
/941
B A20.10-N-1003-01C Bolt of connection piece of coolant pump to cylinder Nm 25 25

head
32
AS20.00-Z-0001 -01A Risk of injury to skin and eyes from Do not open the cooling system unless Danger!
out..Risk of poisoning from swallowing C. Open cap slowly and allow the
coolant. pressure to release.
Do not pour coolant into containers
for drinks.
Wear protective gloves, protective

release.
Risk of poisoning - Wear protective gloves, protective clothes, and eye protection.
convulsions. Pour large quantities of cold water over the affected area of
AH20.00-N-2080-01A Instructions re coolant
Coolant composition
Passenger car and commercial vehicle engine (normal case): @ A concentration of anticorrosion/antifreeze agent higher than
50 % by volume water and 55 % by volume should not be used as the maximum antifreeze
50 % by volume anticorrosion/antifreeze agent. protection is thus reached. An even higher concentration again
See MB Specifications for Service Products for differing coolant reduces the antifreeze protection and impairs heat dissipation.
composition for commercial vehicle engines.
W ater
Purposes of anticorrosion/antifreeze agent Use water which is clean and not too hard. Drinking water
Corrosion and cavitation protection for all components in the frequently, but not always, satisfies the requirements. The
cooling system contents of dissolved substances in the water can be of
A n tifre e z e p ro tection im p o rta n c e fo r th e o ccu rren ce o f co n u sio n . In cases o f d o ub t,
Increasing boiling point so that the coolant does not evaporate analyze the water. See MB Specifications for Service Products for
so rapidly. Ejection of coolant is avoided at high coolant fresh water regulations.
temperatures.
operation of monitoring of coolant
Antifreeze protection Inspect coolant for resistance to low temperatures before the start
50 % by volume of anticorrosion/antifreeze concentration offers of the cold season of the year.
antifreeze protection down to approx. -37 C. In countries with high ambient temperatures, inspect the
A higher concentration is only practical at even lower ambient anticorrosion/antifreeze concentration once a year.
temperatures. The corrosion protection in the coolant is reduced during
55 % by volume of anticorrosion/antifreeze concentration offers operation. Such coolants have a severely corrosive effect.
antifreeze protection down to approx. -45 C. The maximum permissible period of use of the coolant is for
passenger car and commercial vehicle engines (normal case)
3 years.
See MB Specifications for Service Products for the period of use
for differing coolant composition for commercial vehicle engines.
i e v Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 33
Disposing of coolants
Before pouring fresh coolant into the system, flush the used Observe legal regulations and local wastewater regulations.
coolant out of the cooling system. Clean cooling system if severe For workshops located in the Federal Republic of Germany see:
soiling or oil contamination exist. "Umweltschutz-Handbuch fr Kfz-Reparaturbetriebe"
(Environm ental protection manual for vehicle repair
workshops)
Publisher: Verband der Automobilindustrie e.V. (VDA)
D-60625 Frankfurt am Main, Westendstrae 61
34
AR18.20-W-3471A Removing, installing oil filter housing 22.11.95
ENGINE 904.90S/906/907/909 /910/911 /921 /922,906.910/911 /920 /921 /922 /923 /940 /941

2 Bolt
3 Bolt
4 Bracket
5 Bolt
6 Bolts
7 Oil filter housing
7.1 Oil filter element
7.2 Oil filter cap
7.3 Seal
8 Oil delivery pipe (turbocharger)
9 Banjo bolt
10 Gasket
12 A ir intake hose
13 Bracket
B11/B12 Oil temperature, o il pressure

sensor (engine 904.909- 911/922
and 906.910/911/920-
923/940/941)
B12 Oil pressure sensor (engine
904.905- 907/921)
G2 Generator W 18.20-0001-06
O p e ra tio n no. o f o p e ra tio n te x ts o r sta n d a rd tex ts a nd fla t ra tes
F, S 18-3030 Oil filter complete
(S ig n Removing, installing

D a n g er Risk o f in ju ry fro m bruises a n d ja m m in g N o person should be in th e tiltin g a re a o f Page 8
with a safety prop.
2 Tilt cab
4 Remove charge air pipe On engine 904.909- 911/922 and AR09.41-W-1311C

906.910/911 /920- 923/940/941
5 Detach bracket (13) at coolant pump On engine 904.909- 911/922 and BA20.10-N-1005-01C
906.910/911/920- 923/940/941
6 Remove poly V-belt tensioning device AR13.25-W-3200A
7 Unscrew oil filter cap (7.2) [2 When the oil filter cap is unscrewed,
the engine oil flows back Into the oil pan
366 5890107 00
@ Oil filter cap to oil filter housing BA18.20-N-1003-01 B
8.1 Remove oil pressure sensor (B12) On engine 904.905- 907/921

[ID Counterhold screw plug; collect engine
oil which flows out
QQ Installation: replace seal, counterhold

screw plug
@ Oil pressure sensor to oil filte housing BA18.40-N-1001 -01C
8.2 Unplug connector of engine wiring harness On engine 904.909- 911/922 and
(14) at oil temperature, oil pressure sensor 906.910/911 /920- 923/940/941
(B11/B12)
9 Detach bracket (4) at oil filter housing (7) 0 Bolt of bracket ot oil filter housing BA15.40-N-1001-01B
10 Detach generator (G2) and swivel bracket 0 Bolt of generator to bracket BA 15.40-N-1003-01B
(4) and generator away from oil filter
housing (7)
11 D e ta ch oil d e liv e r y p ip e (8) a t oil filte r

S3
C o lle ct e n g in e o il w h ic h flo w s o u t
housing (7) Installation: replaces seals
12 Take out oil filter cap (7.2) together with IX] Collect engine oil which drips out of oil
oil filter element filter element (7.1)
Inspect oil filter element for damage and

soiling, if necessary |
replace oil filter element (7.1)
On engine 904.905-907/921 with modified WH0101.40

supporting dome (integrated filter bypass
valve) in oil filter housing, only the
modified oil filter element (with central
opening) may be installed
On engine 904.909- 911/922 and AP18.00-W-0101B

906.910/911/920 923/940/941
[0 Installation: inspect seal (7.3) at oil

filter cap, if necessary J,
re p la c e seal (7.3)
13 Detach oil filter housing (7) at crankcase S3 Collect engine oil which flows out
0 Bolt of oil filter housing to crankcase BA18.20-N-1001-01B
Cit Bolt of support of oil filter housing to BA18.20-N-1002-01B

crankcase
14 Take gasket (10) out of oil filter housing (7) S3 Installation: replace seal
16 Adjust engine oil to correct level On engine 904.905- 907/921 Wartung LKW Band 1,
0101.40
On engine 904.909- 911/922 and AP18.00-W-0101B

906.910/911 /920- 923/940/941
starting off when engine running. Risk of W ear closed and dose-fitting work clothes.
36
17 Start engine and observe oil pressure gage Crank engine with the starter for not B E18.00-N-1001 -01C
when engine idling more than 90 seconds. W ait about 2
minutes before repeating attempt at
starting. Do not rev up engine so long as no
oil pressure is indicated.
B ] The oil pressure gage should indicate

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idling speed bar a0.5
maximum speed bar S2.5
@ Generator

906/907/909/
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
BA15.40-N-1001-01B Bolt of generator bracket to oil f ilter Nm 40
BA15.40-N-1003-01B Bolt of generator to bracket Nm 65.
0 Oil filter

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA18.20-N-1001-01B Bolt of oil filter housing to crankcase Nm 25
BAI 8.20-N-1002-01B Bolt of support of oil filter housing to crankcase Nm 25
Oil le v e l sensor, o il pre ssu re sensor

906/907/909/
910/911/921/922,
906.910/911/920/
921/922/923/940
/941
B A 1 8 .4 0 - I M - 1 0 0 1 - O IC O il pi c is u ic sensui to oil filter Nm 25

housing
a Coolant pump, coolant thermostat

910/911/922
906.910/911/920/
921/922/923/940
/941
B A20.10-N-1005-01C Bracket to coolant pump Nm 50
38
AR18.20-W-5050A Removing, installing oil filter bypass valve 1.9.95
ENGINE 904.905/906/907/921 ## up to 16109

ENGINE 904.908 ## up to 16109 in MODEL 668, 670
f Oil filter housing
1.1 Oil filter cap
1.2 Oil filter element
1.3 Seal
2 Oil filter bypass valve
3 Spring
A Seal
5 Screw plug
6 Seal
B12 Oil pressure sensor
W 18.20-0002-06
n a gn Removing, Installing
A Danger! Risk of Injury from bruises and jamming No person should be in the tilting area of Page 8
with a safety prop.
1.1 Tilt cab Model 673-679
@ Notes re tilting cab Page 9

1.2 Remove service cover Model 668,670
2.1 Remove noise encapsulation on right Engine 904.905-907/921
2.2 Remove air intake hose Engine 904.908 AR09.10-D-8030D
3 Unscrew oil filter cap (1.1) from oil filter U | when oil filter cap is unscrewed, the
housing (1) engine oil flows back into the oil pan
366 5890107 00
E Installing: inspect seal (1.3) at oil filter

cap and replace if necessary.
Replace seal (1.3).
m 366 589 01 07 00
Oil filter cap to oil filter housing BA18.20-N-1003-01B
5 Remove screw plug (5) H The screw plug is pressed out by the
spring (3).
CD In s ta lla tio n : rep lace seal (4).
@ Screw plug of oil filter bypass valve to BA18.20-N-1004-01B

oil filter housing
S9^ Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 39
6 Take out spring (3) and oil filter bypass 00 Installing: check that oil filter bypass
valve (2) and inspect for damage valve is correctly located in oil filter
housing (1); install spring for this purpose.
When installed, spring should project
about 1 cm at oil filter housing.
8 Adjust engine oil to the correct level Engine 904.905- 907/921 WH0101.40
Engine 904.908 AP18.00-D-0101A
Danger! Risk o f a c c id e n t as a resu lt o f v e h ic le Se cu re v e h ic le t o p r e v e n t it m o v in g o ff. Page 9

starting off when engine running. W ear closed and close-fitting work clothes.
Risk of injury as a result of bruises and Do not grasp hot or rotating parts.
burns if you insert your hands into engine
when it is being started or when it is
running
9 Start engine and check oil pressure gauge @ Crank engine w ith the starter for not BE18.00-N-1001-01C
w ith e n g in e id lin g m o re th a n 20 seconds. W a i t ap p ro x.
2 minutes before making a repeat attempt
at starting.
pressure is in d ica te d .
LLI The oil pressure gage should indicate
11 Switch off engine and check for leaks

906/907/909/910 904.908/
/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idling speed bar >0.5 >0.5
maximum speed bar 2.5 2.5
0 Oil filter
N um ber D e sig n a tio n E n g in e E n g in e 904.905/

904.904/ 906/907/909/
908/923 910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
BA18.20-N-1003-01B Oil filter cap to oil filter housing Nm 25 25
BA18.20*N-1004-01B Oil filter bypass valve screw plug to oil filter Nm 50 50

housing
40
S Oil level sensor, oll pressure sensor

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BA18.40-N-1001-01C Oil pressure sensor to oil filter Nm 25 25

housing
AR18.40-W-4133A Removing, installing oil pressure, oil temperature sensor 4.8.97
ENGINE 904.909/910/922/911, 906.910/911/920/921 /922/923/940/941

2 O il pressure, oil temperature sensor
3 Bolt
Modification notes
7.7.98 Tightening torque for oil pressure and oil temperature Step 6 Page 42
combination sensor to oil filter housing added
F, S 18-4132 Sensor at engine for oil pressure
M M Removing, Installing
Danger! Risk of injury from bruises and jamming No person should be In the tilting area of Page 8
cab os fo r as th e e n d p o sition a n d secure
with a safety prop.
1 Tilt cab
N o tes o n tiltin g cob M o d e l 673- 679, 950- 954, 957, 970- 976 Page 9
2 Remove noise encapsulation IH On right
4 Unscrew oil filter cap from oil filter housing ID The engine oil flows back into the oil
pan when the oil filter cap is removed.
IS 366 589 0107 00
S Installation: inspect seal at oil filter cap,

if necessary i
replace seal.
0 Oil filter cap to oil filter housing BA18.20-N-1003-01B
5 Unplug connector of engine wiring harness

(1) at oil pressure, oil temperature sensor
(2)
6 Remove oil pressure, oil temperature E l Collect engine oil which flows o u t.
sensor (2)
0 Combination sensor to oil filter housing BA18.40-N-1003-01C
42
/h> Danger! Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 9
8 Start engine and check oil pressure gage Crank engine with the starter for not BE18.00-N-1001-01C
when engine idling more than 90 seconds. Wait approx.
at starting.
Li] The oil pressure gage should indicate

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
B C 1 8 .0 0 -N -1 0 0 1 -0 1 C En g in e oil pressure a t idle speed bar =0.5
maximum speed bar 2.5
0 Oil filter

906/907/909/
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
0 Oil level, oil pressure sensor

906/907/909/ 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
BA18.40-N-1003-01C Bolt of combination sensor for oil Nm 8 8

pressure and oil temperature to oil
filter housing
AR18.40-W-4111A Removing and installing oil level sensor 6.8.97
ENGINE 904.909/910/911/922, 906.910/911/920/921 /922/923/940/941
1 Oil pan
2 Clip
4 seal
B I4 Engine oil level sensor
F, S 18-4112 Sensor for engine oil level gage
Removing, installing
1 Extract or drain engine oil AP18.00-W-0101B

2 unplug connector of engine oil level sensor
(B14) at engine wiring harness (3)
3 Detach electric cable of engine oil level

sensor (B14) at the oil pan (1)
4 Remove oil level sensor (B14) at the oil pan EDInspect seal (4), if necessary J,
(1)
rep la ce seal
m WH 58.30-Z-1037-06A
@ Oil level sensor to oil pan BA18.40-N-1002-01 C

6 Inspect engine oil level at electric indicator LLi See ATEGO / ECONIC operating
instructions Part 3
A Danger! Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 9
starting off when engine running. Risk of W ear closed and close-fitting work clothes.
7 Start engine and check oil pressure gage Crank engine with the starter for not BE18.00-N-1001-01C
when engine idling more than 90 seconds. W ait approx.
2 m in u tes b e fo re m ak in g a re p e a t a tte m p t
at starting.
LLI T h e o il pressure g a g e sho uld in d ic a te
8 Switch off engine and inspect the leaks

906/907/909/910
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at id le speed bar 2 0 .5
m ax im u m speed bar 2 2 .5
0 Oil level, oil pressure sensor

906 / 907 / 909 / 904.908/
910/911/921/922, 923
906.910/911/920/
921/922/923/940
/941
B A18.40-N-1002-01C Oil level sensor to oil pan Nm 50 50
WH58.30-Z-1037-06A Special socket (waf 27) Friweg 493 45850

Stormsweg 12
D-220B5 Hamburg
46
AR18.00-W-4000A Removing, installing oil spray nozzles (piston cooling) 22.11.95
ENGINE 904.905/906/907/909/910/911/921/922,906.910/911/920/921/922/923
EN G IN E 9 0 4 .9 0 8 /9 2 3 in M O D E L 66 8, 6 7 0
1 OH spray nozzle
2 D anjo b o lt
W18.O0-OQQ2-OS
M Removing, installing
1 Remove oil sump Engine 904.905-907/921 AR01.45-W-7500A
Engine 904.908/923 AR01.45-D-7500D
Engine 904.909- 911 /922 and AR01.45-W-7 500C

906.910/911/920-923
3 Attach cranking and blocking device (3) to G] Block cranking and blocking device by Page 48
the timing case inserting the pin
[3 904 589 04 63 00
0 Bolt to timing case BA01.60-N-1002-01A
4 Rotate crankshaft until the oil spray nozzle

to be removed (1) is accessible
5 Remove oil spray nozzle (1) CO Installation: the dowel pinatthe oil
spray nozzle should engage in the hole in
the crankcase (arrow).
6 Inspect oil spray nozzle (1) If damage is present J,
replace oil spray nozzle.
0 Timing case

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941

timing case
904 58904 63 00 J
Cranking device

device for engine
0 Timing case

906/907/909/ 904.904/908/923
910/911/921/922,
906.910/911/919/
920/921/922/923
/940/941
B A01.60-N-1002-01A End cover of Inspection hole to to Nm 25 25

timing case
2 Remove cover (1) at flywheel housing (except engine 906.920- 923/940/941).
3 Attach 13 cranking and blocking device (2) tight to flywheel housing with bolts (4).
Q ] Cranking and blocking device (2) can be blocked by inserting the pin (3).
@ Cranking and blocking device (2) must be removed before starting the engine.
W 0 3 .30.0001-02
AR18.00-W-1600A Filling engine oil circuit 19.7.95
ENGINE 90 4.90 5/90 6/90 7/90 9 /910 /911 /921 /9 2 2 ,906.910 /9 1 1 /920 /921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
1 Screw plug
2 Seal
3 I S Union fitting (M 14X1.5)
4 m o u reservoir
5 I S Shutoff valve
6 O il-w ate r heat exchanger
W lS .00 -0 00 1-0 6
S3 Removing
i Remove cylinder head cover AR01.20-W-5014A
2.1 Remove noise encapsulation on right Model 904.905- 907/909- 911/921 /922 and
906.910/911 /92Q- 923/940/941
2.2 Remove air intake hose Engine 904.908/923 AR09.10-D-8030D
3 Remove the screw plug (1) at the oil-water LU Installation: replace seal (2).
heat exchanger (6)
@ Screw plug to oil-water heat exchanger BA18.30-N-1003-01C
4 Screw adapter fitting (3) tight E l Use adapter fitting (M14X1.5) 352 58911 63 00
5 Screw connection hose of oil reservoir (4) E 352 589 11 63 00

tight to adapter fitting (3)
Filling
6 Fill oil reservoir (4) with 5 liters of approved El 352 58911 63 00

engine oil and seal
7 Produce a pressure of approx. 3 bar with HI Shutoff valve (5) closed.

the integral priming pump
8 Open shutoff valve (S) long enough until E l The pressure in the oil reservoir should
approx. 4 liters of engine oil has been not drop below 1.5 bar; re-pump if
pumped from the oil reservoir (4) into the necessary.
oil galleries and the engine oil flows out Do not completely empty oil reservoir
free of bubbles at the rocker arms (arrows) otherwise air will be forced in.
El 352 589 11 63 00
10 Top up remaining engine oil at the filler Engine 904.905-907/921 WH0101.40
neck
Engine 904.908/923 AP18.00-D-0101A
Engine 904.909- 911 /922 and AP18.00-W-0101B

906.910/911/920- 923/940/941
11.1 Check engine oil level with dipstick Engine 904.905-907/921 WH0101.40
Engine 904.908/923 AP18.00-D-0101A
11.2 Check engine oil level at electric indicator Engine 904.909- 911 /922 and
906.910/911/920- 923/940/941
See ATEGO Operating Instructions Part 3
A Danger! Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Pa g e 9
12 Start engine and check oil pressure gage at @ Crank engine with the starter for not BE18.00-N-1001-01C
idle speed more than 90 seconds. W ait approx.
a t starting .
0D The oil pressure gage should indicate
oil pressure a fte r ap p ro x. 10 seconds.
Number Designation Engines Engine

904.905/ 904.908/
906/907/909/910 923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE18.00-N-1001-01C Engine oil pressure at idling speed bar >0.5 >0.5
maximum speed bar >2.5 a 2.5
B Oil cooling system

906/907/909/ 923
910/911/921/922,
906.910/911/920/
9217922/923/940
/941
BA18.30-N-1003-01C Screw plug to oil-water heat exchanger Nm 20 20
50
V 352 589 11 63 00 y
Adapter fitting
AR20.10-W-1271A Removing and installing coolant pump 22.11.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 /922/923/940/941

1 Poly-V-belt
2 Screw
3 Pulley
4 C oolant pump
5 Screw M 8X90
6 Screw M 8X45
7 Coolantline
(engines304.905-907/921)
8 Screw
9 Connector
10 Gasket
11 Crankcase vent
14 Gasket
15 Thermostat
16 Coolant line
17 H ollow screw
18 Coolant line
19 Bracket (engines 904.905- 907/921)
20 Coolant hose
21 Bracket (engines 904.909/- 911/922
and 906.910/911/920- 923/940/941)
W 20.10-0013-06
Se cto r Op. no. O p e ra tio n tex t
F,S 20-1290- Coolant pump

1300
M M Removal, installation
/K Danger! D a n g e r o f p inching an d r a tr h in g w h e n cah Ensure t h a t no o n e is p re se n t in th e tiltin g Page 8

is tilted area of the cab when tilting. Always tilt cab
all the way to the final position and secure
with safety brace.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954, 957,970- 976 Page 9
2 Remove sound proofing capsule S on left and right
3 Remove thermostat (15) Page 58

4 Loosen pulley (3) L U Hold pulley.
0 Bolt for pulley on coolant pump BA20.10-N-1002-01C
5 Release tension on poly-V-belt (1) and AR13.22-W-1202A

remove
6 R em o ve p u lle y (3)
7.1 Remove bracket (19) on boost air manifold Engines 904.905- 907/921
or boost air pipe
7.2 Remove bracket (21) on boost air pipe and Engines 904.909/- 911/922 and
coolant pump (4) 906.910/911/920- 923/940/941
0 Bolt for bracket on coolant pump BA20.10-N-1005-01C
52
8 Disconnect engine wiring harness
connector (13) from coolant temperature
sensors
9 Remove connector (9) 5 ] Installation: Replace gasket (10). Page 53

0 Screw for connector BA20.10-N-1003-01C
Coolant pump on cylinder head
10 Remove connection fitting (12) [13 Replace connection fitting.

11 Remove coolant hose (20) and coolant line [XI Catch coolant runnning out.
(16) from coolant pump (4) Installation: Replace sealing rings.
12 Remove coolant pump (4) and gasket (14) IX! Installation: Replace gasket.
0 Bolt for coolant pump on crankcase BA20.10-N-1001-01C
13 Clean sealing surfaces on crankcase and

coolant pump (4)
15 Check coolant level and check cooling Engines 904.905-907/921 WH2080

system for leakage
Engines 904.909- 911/922 and AP20.00-W-2080A

906.910/911/920- 923/940/941
0 Coolant pump, thermostat

906/907/921 910/911/922
906.910/911/920/
921/922/923/940
/941
BA20.10-N-1001-01C Bolt for coolant pump on crankcase Nm 25 25
B A20.10-N-1002-01C Bolt for pulley on coolant pump Nm 25 25
B A20.10-N-1003-01C Bolt for coolant pump connector on cylinder head Nm 25 25
B A20.10-N-1005-01C Bracket on coolant pump Nm - 50
AR20.10-W-1290-02A Removing and installing connector coolant

0 Coolant pump, thermostat
N u m b er Designation Engines 904.905/ Engine Engines 904.909/

906/907/921 904.908/ 910/911/922
923 906.910/911/920/
921/922/923/940
/941
B A20.10-N-1003-01C Bolt for connector coolant pump to cylinder head Nm 25 25 25
Engines OM904 LA, 906 1A (mnri Hec 904 9. 906.9), F4 53
1 Remove coolant lines (1,2) from connector (3).
2 Unscrew screws (4) and remove crankcase vent line (5).
3 Remove connector (3) upward out of connection fitting (6).
4 Replace gasket (7) and connection fitting (6).
W 2 0 .1 0 -0 0 1 4 -H
54
AR20.10-W-1401A Disassembling and assembling coolant pump 19.7.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 in MODEL 668, 670
1 Flange
2 Cirdip
3 Bearing and shaft
4 Coolant pump housing
5 Cassette-type seal
6 Im peller
7 E3 Puller
8 I S Thrust piece
W 20.10-0003 06
1 Flange
2 Retaining ring
3 Bearing and shaft
5 Cassette-type seal
6 im peller
9 S Punch
A Gap between im peller and coolant

pump housing
B Interval between coolant pump
housing and flange
C Im peller extension beyond coolant
pump housing
s Disassembly
1 Remove coolant pump Engines 904.905- 907/909- 911/921 /922 Page 52

and 906.910/911/920- 923/940/941
Engine 904.908/923 AR20.10-D-1271D
Engines QM9Q4 LA. 906 LA (m n ri Hpc qn Q, Q06 Q). FA 55
2 Use puller (7) and thrust piece (8) to pull 000 589 65 33 00
flange (1) off the bearing shaft (3)
m 321 589 0063 00
3 Remove circlip (2)
4 Use a suitable drift to press bearing (3) out IS Stationary workshop press WE58.40-Z-1001-12A
of the impeller (6) and coolant pump
housing (4)
5 Remove cassette-type seal (5)
0 Assembling
6 Oil bearing (3) with engine oil at bearing Press in bearing only at bearing outer
outer race and use a suitable drift to press race.
it into coolant pump housing (4)
IBstationary workshop press WE58.40-Z-1001-12A
7 Install circlip (2)
/ h Danger! Injury hazard to skin and eyes when Wear protective gloves, protective clothing Page 57
handling hot or glowing objects and, if required, protective goggles
8 Heat flange (1) and press onto bearing @ Counter-hold at shaft when pressing BE20.1Q-N-1002-01B
with shaft (3) on.
Measure size (B) distance between coolant
pump housing (4) and flange (contact
surface of belt pulley).
IS Stationary workshop press WE58.40-Z-1001 -12A
9 Fit new cassette-type seal (5) over the shaft m 352 5890815 00
(3) and use a drift to press in as far as D inspect seat of cassette-type seal on
coolant pump housing (4) shaft and in coolant pump housing.
10 Press impeller (6) onto the shaft (3) Counter-hold at shaft when pressing
on.
Measure size (C) projection of impeller to BE20.10-N-1003-01B

coolant pump housing.
Measure size (A) gap between impeller and BE20.10-N-1001-01B

coolant pump housing (4).
IS Feeler gage WH58.30-Z-1008-12A
11 Rotate coolant pump at flange (1) and

check that it rotates freely
12 Install coolant pump Engines 904.905- 907/909- 911 /921 /922 Page 52
and 906.910/911 /920- 923/940/941
Engine 904.908/923 AR20.10-D-1271D
56
Test data of coolant pump

906/907/909/910 904.908/923
/911/921/922,
906.910/911/920/
921/922/923/940
/941
BE20.10-N-1001-01B Gap between impeller and coolant mm 0.6-1.0 0.6-1.0

pump housing (A)
Fig. see - -
B E 2 0 .I0 - N -1002-0 IB Distance between coolant pump mm 112.7-113.3 112.7-113.3

housing and flange (B)
Fig. see - -
B E20.10-N-1003-01B Projection between coolant pump mm 0.5 0.5

housing (C)
Fig. see - -
'N r
Puller Thrust piece
Number Designation Company (e.g.) Ordernumber
WH58.30-2-1008-12A Feeler gage Stiefelmayer 59

D-73734 Esslingen
Workshop equipment / MB testers (see Workship Equipment Manual)
WE58.40-Z-1001-12A Stationary workshop press 651 , e.g. Matra-Werke GmbH, D-60314 Frankfurt/Main
ASOO.OO-Z-O0O2-O1A Risk of injury to skin and eyes from Wear heat resistant gloves, protective A Danger!
handling hot or glowing objects clothing and protective goggles if
necessary
Injury hazard Protective measures/rules of behavior

Contact with hot or glowing objects without suitable protective - Wear protective clothing, protective goggles and heat
clothing can cause severe burns to skin and eyes. resistant gloves.
W h e n g lo w in g objects m ak e co n ta ct w ith w a te r h o t w a te r v a p o r - T ran sp o rt h o t o r g lo w in g objects o nly w ith th e aids pro vid ed
a n d d ro p le ts a re pro d uced w h ich can lead to severe burns to skin for such purposes.
a n d eyes. - Avoid formation of sparks and contact with combustible
If hot or glowing objects come into contact with unprotected skin materials when handling glowing objects.
or eyes severe, possibly permanent damage can result.
First-aid measures
31 Contact between glowing objects and combustible materials a Rinse affected areas of skin with large quantities of cold water
poses a fire hazard. and cover with sterile dressings.
e Consult physician immediately.
AR20.10-W-2460A Removing and installing engine coolant thermostat 22.11.95
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 Z922/923

ENGINE 904.908/923 in MODEL 668, 670
1 Coolant pump
2 Coolant thermostat
3 O-rlng
4 Coolant pipe
5 Bolt
6 Coolant hose
W 20.10-0015-12
O p e ra tio n no. o f o p e ra tio n te x t o r s ta n d a rd te x ts a n d fla t ra tes
Sector Op.no. Operation text
F, T, S 20-2470- Coolant thermostat

2472
ElEl R e m o v in g , in sta llin g
scalding from hot coolant which splashes coolant temperature Is below 90 C. Open
and eye protection.
1 Drain coolant and collect Engine 904.905-907/921 WH2080
Engine 904.908/923 AP20.00-D-2080A
Engine 904.909- 911 /922 and AP20.00-W-2080A

906.910/911 /920- 923/940/941
Note coolant Page 33

/ h Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
with a safety prop.
2,1 Tiit cab Model 673-679,970-976
@ Notes re tilting cab Model 673- 679,950- 954,957,970- 976 Page 9

2.2 R e m o v e service co v er Model 668, 670
58
3 Remove coolant pipe (4) Q ] Collect coolant which flows out.
@ Bolt of coolant line of coolant BA20.10-N-1004-01C

thermostat to coolant pump.
4 Remove coolant thermostat (2) U ! Installing: replace O-ring (3).

Pay attention to installation position of
coolant thermostat; the vent opening
(arrow) should always face up.
5 Test coolant thermostat (2) Page 60

7 Inspect coolant level and Inspect cooling Engine 904.905-907/921 WH2080

system for leaks
Engine 904.908/923 AP20.00-D-2080A
Engine 904.909- 911 /922 and AP20.00-W-2080A

906.910/911 /920- 923/940/941
S Coolant pump, thermostat
Number Designation Engines 904.905/ Engine Engines 904.909/

906/907/921 904.908/ 910/911/922
923 906.910/911/920/
921/922/923/940
/941
BA20.10-N-1004-01C Coolant pipe of coolant thermostat to coolant pump Nm 25 25 25
AR20.10-W-2455A Testing coolant thermostat 19.7.95
E N G IN E 904.905/906/907/908/909/910/911/921 /922,906.910/911/920/921 Z922/923

EN G IN E 5 4 1 .9 2 0 /9 2 1 /9 2 2 /9 2 3 / 9 2 4 / 9 2 5 /9 2 6 /9 2 7 . 5 4 2 .9 2 0 / 9 2 1 1922 / 9 2 19 25 / 9 2 6
EN G IN E 906.940/941
1/1 M a in valve
1/2 Bypass valve
W 2 0 .10-0005*04
Shown on engine 906.920- 923
1/1 M ain valve
W 2 0 .10-1001-01
SI Testing
1 Remove coolant thermostat (1) On engine 904.905 -907/909- 911/9211922 Page 58

and 906.910/911/920- 923/940/941
On engine 904.908 in model 668,670
On engine 541.920 -927 AR20.10-W-2460B

O n e n g in e 542 920 - 923/925/926
2 Suspend coolant thermostat (1) with a wire

in a vessel filled with water
Danger! Risk of injury to skin and eyes through Wear safety gloves, protective clothes and Page 57
handling hot or glowing objects if necessary, eye protection.
3 Use a suitable source of heat to heat the On no account use a welding torch or
water. Stir water so that the water soldering iron for heating the coolant
temperature is the same at all points. thermostat (1).
4 Measure water temperature CDThe rate at which the water is heated BE20.10-N-1001-02A
up should not be more than 1to 2C/min.
fro m a b o u t 8 C b e lo w th e sta rt o f o p e n in g
of the coolant thermostat. Pay attention to
standard or tropical version of coolant
thermostat (1).
BE20.10-N-1001-02B
5.1 Heat water to the full opening CDExcept engine 906.920-923 BE20.10-N-1003-02A
temperature of the bypass valve (112)
BE20.10-N-1003-02B
6 Heat water to the full opening CDThe main valve (1/1) must be fully open BE20.10-N-1002-02A
temperature of the main valve (1/1) and after 6 to 8 minutes. If the test values are
measure stroke not achieved J,
BE20.10-N-1002-026
Replace coolant thermostat (1). B E20.10-N-1002-02A
7 Install coolant thermostat (1) On engine 904.905 -907/909- 911/921 /922 Page 58
and 906.910/911/920- 923/940/941
On engine 904.908 in model 668,670
On engine 541.920 -927 AR20.10-W-2460B

On engine 542.920 -923/925/926
T est d a ta o f c o o la n t th e rm o s ta t
Number Designation Engines 904.904/905/

906/907/908/909/910/
911/915/916/917/921/
922/923/926/932,
906.910/911/915/916/
919/9229/932/933
DE20.10-N-1001-02A C o o la n t th e rm o s ta t - sta rt o f o p en in g C 83 + 2
B E20.10-N-1002-02A Coolant thermostat -main valve fully open at C 95

temperature and min. stroke (A)
mm 8
BE20.10-N-1003-02A Coolant thermostat - bypass valve closed at C 92
Test data of coolant thermostat

921/922/923/ 921/922/923/925
924/925/926/927 /926
BE20.10-N-1001-02B Coolant thermostat -start of opening C 83 + 2 83 + 2
BE20.10-N-1002-02B Coolant thermostat - main valve fully open atC 95 95
Stroke in mm S 8 a8
BE20.10-N-1003-02B Coolant thermostat -bypass valve closed at C 92 92
AR20.40-W-6800A Removing and installing fan shroud 4.8.97
ENGINE 904.909/910/911 /922, 906.910/911
W20.40-0004-09
1 Radiator with intercooler 5 Coolant hose (heating)
2 Fan shroud 6 Coolant hose (coolant pum p)
3 C oolant hose (coolant line) 7 Cable strap
4 Coolant hose (heating)
O lJ Removing, installing
and eye protection.
1 Drain coolant at radiator (1) GD Collect coolant. AP20.00-W-2080A

w ith a s a fe ty p ro p.

3 Remove noise encapsulation CD On side and at bottom
4 Detach coolant hose (3) at the coolant line H I Collect coolant which flows out.
and at radiator (1)
5 Separate coolant hoses (4,5) and detach H I Collect coolant which flows out.
coolant hose (5) at connection piece
6 Detach coolant hose (6) at the side of the E Engine 904.909-911/922

fan shroud (2)
62
7 Remove coolant hose (4) at radiator (1)
8 Remove fan shroud (2) at radiator (1) H I Fan shroud is secured at the two top
radiator mounting brackets and inserted at
bottom.
9 Lift fan shroud (2) up and out Do not damage radiator.

ED Installation: engine 904.909-911/922:
feed in both cable straps (7) at the fan
shroud before installing.
10 Inets 11 in th e reverse o rdor
11 Check coolant level and inspect cooling AP20.00-W-2080A

system for leaks
AR20.40-W-5614C Removing and installing fan 5.8.97
ENGINE 904.909/910/911/922, 906.910/911 /920/921 /922/923/940/941

1 Viscous fan clutch
2 Nut
3 Fan
4 N u t (engine 904)
5 Bolt (engine 906)
6 Coolant hose
W20.40-0003-06
F, S 20-5630- Fan with viscous fan

5634
@ 1 Removing, installing
with a safety prop.
1 Tilt cab in to repair position

2 Remove noise encapsulation E At bottom
3 Remove boost air pipe from turbocharger Engine 904.909- 911/922 and AR09.41-W-1311C
to intercooler 906.910/911/920- 923/940/941
4 Remove boost air pipe from intercooler to Engine 904.909- 911 /922 and AR09.41-W-1311D
boost air manifold 906.910/911/920- 923/940/941
out. Risk of poisoning from s w a llo w in g cap slo w ly a n d a llo w th e p ressure to
an d ey e p ro te c tio n .
5 Drain coolant Engine 904.909- 911/922 and AP20.00-W-2080A

906.910/911 /920- 923/940/941
IXI Collect coolant.
64
6 Remove coolant hoses at the coolant oumo Engine 904.909- 911 /922 and
and connector piece 906.910/911 /920- 923/940/941
7 Detach viscous fan clutch (1) together with E E Installation: viscous fan clutch together
fan (2) at intermediate piece and take out with fan should be stored upright for at
least 1 hour before being installed.
@ Nut of viscous fan clutch to BA20.40-N-1002-01B

intermediate piece
8 Detach viscous fan clutch (1) at fan (2) @ Fan to viscous fan clutch BA20.40-N-1001 -01B
0 Fan, fan clutch

906/907/910/911,
906.910/911/920/
921/922/923
BA20.40-N-1001-01B Fan to viscous fan clutch Nm 25
BA20.40-N-1002-01B Nut of viscous fan clutch to intermediate piece Nm 25
AR20.20-W-3865A Removing, installing radiator 23.10.95
ENGINE 904.905/906/907/921
1 Radiator with intercooler 9 Coolant hose (coolant pump)

2 Oil filler pipe 10 Coolant hose (coolant pump)
3 Bracket w ith m o un tin g bracket 11 B olt
4 Coolant hose (ventilation) 12 Wut
5 Coolant hose (heating) 13 Radiator mounting
6 Boost air hose 14 Support
7 Boost a ir hose (red) 15 B olt
8 Dipstick guide tube
Removing, installing
& Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
and eye protection.
1 Drain coolant fully QD Collect coolant. WH2080
Notes re coolant Page 33

2 Open service flap
3 Remove dipstick guide tube (8) at radiator

bracket
4 Remove support (14) at radiator bracket

and waistrail
with a safety prop.
5 Till cab
66
6 Tilt cab Into repair position AR60.80-W-0010A
7 Remove noise encapsulation at side and [Li On side and at bottom

below
8 Remove boost air hoses (6,7) H I Installation: boost air hoses must not
be mixed up.
@ Red boost air hose (7) is temperature-
between boost air pipe and intercooler.
9 Detach coolant hoses (4, 5,9,10) at the [E l Collect coolant which flows out.
coolant lines and at radiator (1)
10 R e m o v e b ra ck e t (3) o n rig h t o f ra d ia to r, t a
ke off mounting bracket with coolant pi
pes, oil filler pipe (2) and place to the front
and tie up
11 Remove radiator and intercooler (1) @ Do not damage radiator and

downward intercooler.
Q ] Inspect radiator mounting for signs of
wear; replace mounting if necessary.
14 Inspect coolant level and check cooling WH2080

system for leaks
iS S fl* Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 67
AR20.20-W-3865C Removing and installing radiator 4.8.97
ENGINE 904.909/910/911 /922
1 Radiator with intercooler 9 Cable strap

2 Boost air hose (red) 10 O il filler line
3 Boost air hose (black) 11 Radiator mounting
4 Fan shroud 12 Heat exchanger (air conditioning)
5 Coolant hose (coolant line) 13 Clamp
6 Coolant hose (heating) 14 Protectiv e grille
7 Coolant hose (heating) 15 Coolant hose (expansion reservoir)
8 Coolant hose (coolant pump) 16 Coolant hose (heating)
Op. no. Operation text
20-3925-4067 Radiator with intercooler
S S Removing, installing
1 O p e n service flap
2 Remove protective grille (14) in front of ED Remove from front
intercooler
3 R e m o v e h e a t e x ch a n g er (12) a t in te r c o o le r If A C fitte d
HI Do not damage heat exchanger and tie
up at cab mounting. Do not disconnect
coolant lines.
with a safety prop.
68
Dangerl Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
and eye protection.
5 Drain coolant at radiator (1) [LI Collect coolant. AP20.00-W-2080A

6 Remove noise encapsulation ED On side and at bottom
7 Remove boost air hoses (2,3) CD Installation: boost air hoses must not
be mixed up.
Red boost air hose (2) is temperature-
between boost air pipe and intercooler.
8 R em o ve oil fille r p ip e (10) a t r a d ia to r (1) E Tie up at chassis.
9 Detach coolant hoses (5,7,8,16) at the CD Collect coolant which flows out.
coolant lines and at radiator (1)
10 Detach coolant hoses (5,7) at engine E collect coolant which flows out.
11 Remove coolant hose (8) at the fan shroud

(2) on the side and coolant hose (15) at
radiator (1)
12 Detach both brackets (intercooler) at the

cab mounting
13 Remove radiator with intercooler (1) at CD Inspect radiator mountings (11) for
bottom at frame crossmember signs of wear, if necessary j
replace radiatormountings(ll).
14 Lift ra d ia to r a n d in te rco o le r (1) u p a n d o u t @ D o n o t d a m a g e ra d ia to r and

intercooler.
CD Installation: insert both cable straps (9)
at the fan shroud (4) before installing.
15 Remove fan shroud (2) at radiator (1) CD Fan shroud is secured at the two top
radiator mounting brackets and inserted at
bottom.
16 R em o ve in te r c o o le r a t ra d ia to r (1) E In te rc o o le r is secured a t th e t w o side

radiator mounting brackets and inserted
on right.
18 Check coolant level and inspect cooling AP20.00-W-2080A

system for leaks
Engines OM904 LA, 906 LA (mod. de$. 904.9,906.9), F4 69
AR20.20-W-3865F Removing and installing radiator 4.6.98
ENGINE 906.920/921 Z922/923
7 Radiator with intercooler and coolant expansion reservoir 10 Coolant hose

2 O il filler neck 11 Coolant hose (coolant pump)
3 C o o la n t h o s e ( h e a t in g s y s te m ) 12 O il f i l l e r h o s e
4 Tension relief linkage o f UPS hydraulic lines 13 Bracket
5 HPS hydraulic line 14 Transmission o il line
6 Connector 15 Bracket
7 C h a rg e a ir h o s e (re d ) 16 Bracket
8 Charge air hose (black) 17 Bracket
9 Coolant hose (coolant thermostat) 18 Protective grille
mm Removing, installing
1 Remove engine encapsulation below

radiator and engine
Danger Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
and eye protection.
Notes on coolant All engines Page 33

2 Drain coolant at radiator and engine [D Collect coolant AP20.00-W-2080A
3 Open maintenance flap
4 Remove front grille m 000 589 01 1000
5 Remove protective grille (18), brackets (16,

17) at intercooler (1) and bumper
6 Remove bracket (13) at intercooler and ITl te r u r e r a d ia to r to p re v e n t It tip p in g

bottom left of radiator (1)
70
7 Detach transmission oil lines (14) at bottom E Collect transmission oil which flows
of radiator(1) out. Seal openings with plugs.
with a safety prop.
8 Tilt cab
Notes on tilting cab Model 950, 952,953,954 Page 9

9 Remove noise encapsulation on side
10 Unplug connector (6) of coolant level gage

at coolant expansion reservoir
n Remove charge air hoses (7,8) 00 inspect condition of charge air hoses
and hose clips, replace if necessary
ED Installation: charge air hoses must not

hp mivprt up.
@ The red charge air hose (7) is
temperature-resistant and should always
be installed between charge air pipe and
intercooler (1)
12 Detach coolant hoses (3,9,10,11) at [XI Collect coolant which flows out. Inspect
radiator and cooling expansion reservoir or condition of coolant hoses and hose clips,
engine (1) replace If necesssary
13 Detach tension relief linkage (4) of HPS With HPS transmission

hydraulic lines (5) at cab DO Do not separate HPS hydraulic lines
14 Remove oil filler neck (2) III Turn oil filler neck (2) at the bayonet
connection at radiator and pull out
15 Detach oil filler hose (12) at radiator and GOSeal opening

tie up at engine
16 Remove bracket (15) at bottom right of f f i Secure radiator

radiator
17 Lift radiator up and out together with Do not damage radiator, intercooler
in terco o ler a n d c o o la n t expansion a n d c o o la n t ex p an sion reservoir
reservoir (1)
[X Installation: after inserting the

radiator, center radiator relative to viscous
fan until the same clearance exists between
the radiator shroud and the viscous fan on
all sides
18 Detach intercooler and fan shroud at

radiator
20 inspect coolant level and inspect cooling AP20.00-W-2010 A

system for leaks
21 Inspect transmission oil level IX Top up oil to bottom edge of oil filler AP26.00-W-2601A
opening
/223-T
<2) < ) <8>@
@ @ @ @ 0
2224-T
n n
40 40 45 45
UL UU UJ
CDCDiDCDCl]
000 589 01 1000
T o rx b it set
72
AR20.00-W-1030A Removing grease and scale in cooling system 1.9.95
ENGINE 904.905/906/907/909/910/911 /921 /922,906.910/911 /920/921 /922/923

ENGINE 904.908/923 in MODEL 668.670
2 Dichtring
3 Coolant line
4 Bolt
W2O.OO-0OO1-12
Degreasing
i Danger! Danger of severe burns to skin and eyes Open cooling system only when coolant Page 33
from hot coolant spewing out. Coolant is temperature is below 90 C. Open cover
toxic when swallowed slowly and reduce pressure. Do not fill
beverage containers with coolant. Wear
protective gloves, protective clothing and
protective goggles.
1 Completely drain coolant and catch Engines 904.905- 907/921 WH2080
Engine 904.908/923 AP20.00-D-2080A
Engines 904.909- 911 /922 and AP20.00-W-2080A

906.910/911/920- 923/940/941

2 Remove thermostat (1) Page 58
3 Arrest main valve on thermostat (1) in open
position
4 Install coolant line (3) and O-ring (2) @ Coolant line bolt BA20.10-N-1004-01C
Thermostat on coolant pump
5 Fill cooling system with 5 % solution of Mixing ratio: 50 g cleaner in 1 liter of

mildly alkaline cleaner and fresh water water.
P3 Croni BR00.45-Z-1011-04A
Grisiron 7220 BR00.45-Z-1012-04A
Engines OM904 LA. 906 LA (mod. des. 904.9.906 9), F4 73
> Danger! Accident hazard resulting from vehicle Secure vehicle against starting to move Page 9
starting to move by Itself with engine unintentionally.
ru n n in g . D a n g e r o f in ju ry re su ltin g fro m W e a r closed a n d t ig h t fitt in g w o rk
engine running.
6 Allow engine to warm up to a coolant H I If necessary, cover radiator

temperature of approx. 80 C at medium
speed and then hold It at this temperature
for approx. 5 minutes
7 Shut off engine and allow to cool down to

a coolant temperature of approx. SO C
8 Completely drain solution from cooling E Dispose of solution ecologically.

system
9 Flush coolant system twice with fresh E Dispose of water ecologically.

water, for this purpose, allow engine to
run for approx. 5 minutes with each water
filling
Removing lime deposits
10 Drain cooling system with 10 % solution of E Before descaling, always degrease

water and citric acid, tartaric acid or oxalic cooling system even If no visible signs of oil
acid or grease are present.
Do not use chromic add or products
containing chromium to avoid water
pollution.
LU Use of citric acid Is preferable.
Mixing ratio: 100 g of citric add in 1 of
water.
CD Chemicals for mixing the solution can
be obtained through commercial chemical
ch an n el. C o m m ercial p ro d u cts c o n ta in in g
the previously mentioned acids can be used
for removing lime deposits and rust.
11 Allow engine to warm up to approx. 80 C

at medium speed and hold at this
temperature for approx. 10 minutes
12 Shut off engine and allow to cool down to

50 C
13 Completely drain solution E Dispose of solution ecologically.
14 Flush cooling system at least 3 times with E Dispose of water ecologically.

fresh water allowing the engine to run for
5 minutes with each water filling
15 Remove thermostat Page 58

16 R e m o v e a rrest o n th e rm o s ta t (1) C heck th e rm o s ta t fo r d a m a g e , If
necessary 4
Replace thermostat.
17 Install th e rm o s ta t P a g e 58
18 Fill cooling system with specified coolant Engines 904.905- 907 WH2080
and check for leakage
E n g in e 904.908/923 AP20.00-D-Z080A
Engines 904.909- 911/922 and AP20.00-W-2080A

906.910/911/920- 923/940/941
74
Number Designation Engines 904.905/ Engine Engines 904.909/

906/907/921 904.908/ 910/911/922
923 906.910/911/920/
921/922/923/940
/941
BA20.10-N-1004-01C Coolant line of thermostat to coolant pump Nm 25 25 25
BR00.45-Z-1011-04A P3 Croni Henkel
BR00.45-Z-1012-04A Grisiron 7220 Hoechst
AR20.00-W-101 OB Cheeking cooling system for leaks 4.8.97
ENGINE 904.909/910/911/922, 906.910/911/940/941
W20.00-0004-11
Testing
and eye protection.
1 Open cap (1) at expansion reservoir (2)
Notes of coolant Page 33

2 Set heating switch to maximum heating
capacity
3 Inspect coolant level CD Adjust coolant to correct level if AP20.00-W-2010A

necessary
4 Attach adapter (3) and tester (4) to the El 001 589 83 21 00

expansion reservoir (2)
m 655 589 00 63 00
5 Fill cooling system at tester (4) with CD Test pressure approx. 1.0 bar. A
compressed air pressure drop is visible at the pressure gage
if there is a leak in the cooling system, if
necessary J,
inspect the cooling and heating hoses,

coolant lines and the connection points for
proper condition and loss of coolant;
inspect hose clips for proper condition and
fitting
6 Remove adapter (3) and tester (4) at El 655 589 00 63 00
expansion reservoir CD Release pressure.
7 Rectify any leak in cooling system CD Retighten or replace hose clips.
Replace gaskets, cooling and heating
hoses.
76
8 Screw on cap (1) tight at expansion E Adjust coolant to correct level AP20.00-W-2010A
reservoir(2)
AR20.30-W-4392A Removing and installing coolant level sensor 1.8.97
ENGINE 904.909/910/922/911, 906.910/911

1 Radiator cap
2 W iring harness connector
B6 Coolant level switch
Op. no. Operation text
20-3732 Coolant level sensor
is m Removing, installing
1 Open service flap
, Danger Risk of injury to skin and eyes from Do not open the cooling system unless the Pa g e 33
scalding fro m h o t c o o la n t w h ich splashes c o o la n t te m p e ra tu re Is b e lo w 90 C. O p e n
W e a r p ro te c tive g loves, p ro te c tiv e clothes,
and eye protection.
2 Open radiator cap (1)
N o tes o n c o o la n t P a g e 33
3 Unplug connector of wiring harness (2)

from coolant level switch (B6)
4 T u rn c u u la n l level sw itch (B6 ) clo ckw ise

through 90 and pull out
78
AR46.30-W-0500A Removing and installing power steering pump 20.6.97
STEERING 765.820/821 /830/840/844 with ENGINE 904.905/906/907/909/910/911 /921 /922.906.910/911/920/921

/922/923
1 Steering line (pressure)
2 Steering line (return flow )
3 P ow er steering pum p
4 Cross plate
W 46.30-0009-06
l) E 3 Removing, installing
A Danger! Risk of injury from bruises and jamming No person should be In the tilting area of Page 8
when tilting cab the cab when it Is being tilted. Always tilt
cab as fa r as th e e n d po sitio n a n d secure
with a safety prop.
1 Notes re tilting cab
Tilt cab Model 673- 679,950- 954,957,970- 976 Page 9

2 Remove noise encapsulation on left and at
bottom
A Danger! Risk of injury to skin or eyes as a result of Render system pressureless before Page 80
3 Separate both hoses at the steering lines Collect hydraulic fluid which flows out.
(16,17) E E Installation: top up hydraulic fluid.
4 Detach power steering pump (14) at the @ Bolt of power steering pump to com BA46.30-N-1001-01B
compressor (1) pressor
5 Take off cross plate (13) E Installation: rotate compressor

crankshaft until the guides of the cross
p la te a re po sitio n e d u p rig h t. S e cu re cross
plate with grease to prevent It slipping.
6 Detach hoses at the power steering pump E Counterhold connection fitting In the
(14) power steering pump when slackening;
collect hydraulic fluid which flows out.
8 Bleed steering Engine 904.905-907/921 WH4611

Engine 904.909- 911/922 and AR46.25-W-3300C
906.910/911/920-923
Power steering pump
Number Designation Steering Steering

765.602/604/605/ 765.840/844/861
865 with engine with engine
904.905/906/907/ 904.909/910/911/
921 922,
906.910/911/920/
921/922/923
BA46.30-N-1001-01B Bolt of power steering pump to compressor Nm 40 40
ASOO.OO-Z-0013-01A Risk of injury to skin or eyes from Before starting work on the hydraulic A Danger!
pressurized hydraulic fluid spraying out. system, depressurize the system. Wear
hydraulic fluid
Potential danger
due to the very high pressures (above 200 bar). Damage to the - W ear safety gloves, protective clothing and safety glasses.
symptoms of poisoning including headaches, dizziness, stomach
- Before starting work on hydraulic systems they should be After swallowing larger quantities .consult a doctor.
depressurized and the system must be emptied if necessary. If hydraulic fluid gets into the eyes, rinse out the eyes
hydraulic fluid. In the event of injuries to skin or eyes from a jet of hydraulic
fluid, consult a doctor immediately.
80
AR47.20-W-1070A Removing, installing fuel full-fiow filter 7.11.97
ENGINE 904.905/906/907/921 # # up to 33991

E N G IN E 9 0 4 .0 0 8 # # u p to 3 3 9 9 1 In M O D E L 668. 6 7 0
1 Fuel filter cap

2 Seal
3 Fuel filte r elem ent
4 Dirt collection reservoir
5 Fuel filter housing
6 Gasket
7 B olt
8 Bolt
9 Seal
10 Fuel line
11 Banjo bolt
12 Seal p i
13 Fuel line (flam e starting system) L i
14 Banjo bolt f i

W 4 7 .20-0002-06
Modification notes
7.7.98 Tightening torque of bolt of fuel filter housing to Step 6

crankcase added
w h e n tiltin g cab th e cab w h e n it is b e in g tilte d . A lw a y s tilt
with a safety prop.
1.1 Tilt cab Model 673- 679

1.2 Remove service hood Model 668,670
fuel.
2 Unscrew fuel filter cap (1) together with ID When the fuel filter cap is removed, the
fuel filter element (3) fuel flows out of the fuel filter housing
b ack a lo n g th e fu e l re tu rn f lo w lin e in to
the fuel tank.
D Installation: inspect seal (2), replace if
necessary.
Cap to fuel filter housing BA47.20-N-1001 -02A
3 Pull dirt collection reservoir (4) out of the D Dispose of fuel and the impurities
fuel filter housing (5) which have gathered in the dirt collection
reservoir

4 Detach fuel lines (10) at fuel filter housing GD Collect fuel which flows out.
(5) Installation: replace seals (9).
@ Banjo bolt of fuel line to fuel filter BA47.20-N-1002-02A
5 Detach fuel line (15) at fuel filter housing E if flam e starting system fitted
(5) collect fuel which flows out.
Installation: replace seals (12).
6 Detach fuel filter housing at crankcase S Collect fuel which flows out.
Installation: replace gasket (6).
@ Bolt of fuel filter housing to crankcase BA47.20-N-1005-02A
8 Bleed fuel system See Operating Instructions
S Fuel filter

906/907/921 904 904/
908/923
BA47.20-N-1001-02A Cap to fuel filter housing Nm 25 25
BA47.20-N-1002-02A Banjo bolt of fuel line to fuel filter Nm 40 40
BA47.20-N-1005-02A Bolt of fuel filter housing to Nm 25 25

crankcase
AS47.00-Z-0001-01A Risk of explosion from ignition of fuel, risk Fire, the creation of sparks, naked A Danger!
o f p o iso n in g if fu e l is in h a le d o r s w a llo w e d lights a n d smoking prohibited.
marked.
Wear protective clothing when
handling fuels.
Potential dangers

can cause damage to the skin. Contact with gasoline fuel, for can be properly closed off.
example, removes the skin's natural oils. Fuel vapors are explosive - Immediately remove any fuel which has been spilt,
if inhaled and can cause unconsciousness in high concentrations. Working on the vehicle using a naked ftame
fo rb id d e n . First a id m ea su res
- Never drain or add fuels over workshop pits. e Change out of clothing on which fuel has been spilt as soon as
possible.
If fu e l is splashed in to t h e eyes, rinse o u t t h e eyes im m e d ia te ly
82
AR47.20-W-1070C Removing, installing fuel full-flow filter 7.11.97
ENGINE 904.909/910/911 /922, 906.910/911/920/921 /922/923/940/941

1 Fuel filter cap
2 Seal
3 Fuel filter element
4 Dirx Lullet-lion rcservvii
5 Fuel filter housing
6 Gasket
7 Fuel line
8 Banjo bolt
9 Bolt
10 Fuel line (feed)
11 Fuel line (return flow )
12 Fuel line
13 Bolt
14 Fuel line (flam e starting system)
15 Banjo bolt
W47.20-0003-06
Modification notes
7.7.98 Tightening torque of bolt of fuel filter housing to Step 7 Page 83

crankcase added
IE! SU R e m o v in g , in stallin g
/is Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954,957, 970- 976 Page 9
poisoning from Inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers,
coming into contact with skin and eyes. w ear protective clothing when handling
fuel.
2 Unscrew fuel filter cap (1) together with E When the fuel filter cap is removed, the
fupl filtp r p lpm pnt ( ? ) fuel flows out of the fuel filter housing
back along the fuel return flow line into
the fuel tank.
E Installation: inspect seal (2), replace If
necessary.
@ Cap to fuel filter housing BA47.20-N-1001-02A
3 Pull dirt collection reservoir (4) out of the E Dispose of fuel and the impurities
fu e l filte r h o u sin g <S) w h ic h h a v e g a th e re d in th e d irt co llectio n
reservoir.
4 Detach fuel lines (10,11) at fuel filter E Mark fuel lines and collect fuel which
housing (5) flows out.
8 ^ ^ Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4

5 Detach fuel lines (7,12) at fuel filter H I Collect fuel which flows out.
housing (5) Installation: replace seals.
@ Banjo bolt of fuel line to fuel filter BA47.20-N-1002-02A
6 Detach fuel line (14) at fuel filter housing H I If flame starting system fitted
(5) collect fuel which flows out.
Installation: replace seals.
7 Detach fuel filter housing at cranltcase H Collect fuel which flows out.
B o lt o f fu e l filte r h o u sin g t o crankcase BA47.20-N-1005-02A
Fuel filter

910/911/922,
906.910/911/919/
920/921/922/923
/940/941
BA47.20-N-1001-02A Cap to fuel filter housing Nm 25
B A47.20-N-1002-02A Banjo bolt of fuel line to fuel filter Nm 40
BA47.20-N-1005-02A Bolt of fuel filter housing to Nm 25

crankcase
84
AR47.21-W-5621A Removing, installing fuel heat exchanger 7.11.97
ENGINE 904.90S/906/907/921 # # up to 33991

2 Bolt
3 Seal
4 Fuel priming pump
5 Banjo bolt
6 Fuel line
7 Banjo bolt
8 Fuel filter cap
9 Seal
10 Fuel filter element
A6 PLD control unit
[S U E ] Removing, installing
S Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
ca b as fa r as th e en d p o sition a n d secure
with a safety prop.
1.1 Tilt cab Model G73- 679,970-976

1.2 Remove service hood Model 668,670
fuel.
2 Unscrew fuel filter cap (8) from the fuel E E When the fuel filter cap Is removed, the
filter housing fuel flows out of the fuel filter housing
th e fu e l tank.
E E Installation: replace seal (9).
Fuel filter cap to fuel filter housing BA47.20-N-1001-02A
3 D e ta ch fu e l p rim in g p u m p (4) a n d fu e l line C o lle c t fu e l w h ic h flo w s o ut.

(6) at fuel heat exchanger (1) E E Installation: replace seals (3).
@ Banjo bolt of fuel priming pump to fuel BA47.20-N-1003-01A

heat exchanger
@ Banjo bolt of fuel line to fuel heat BA47.20-N-1004-01A

exchanger
4 Detach fuel heat exchanger (1) at PLD @ Fuel heat exchanger must not be
controil unit(A6) disassembled.

6 Bleed fuel system Engine 904.905- 908/921 /923

See Operating Instructions 4=*, or 4 9
0 Fuel pump
Number Designation Engine 9 0 4 .9 0 5 / Engine

906/907/921 904.908/
923
r A 47 7 n .N - m n 7 .n 1 a Ranjn hnit nf fuel priming pump tn Nm 40 40
fuel heat exchanger
BA47.20-N-1004-01A Banjo bolt of fuel line to fuel heat Nm 40 40
exchanger
0 Fuel filter
Num ber D e s ig n a tio n E n g in e 904.905/ E n g in e

906/907/921 904.904/
908/923
BA47.20-N-1001-02A Cap to fuel filter housing Nm 25 25
86
AR47.20-W-5713A Removing and installing fuel pumps 7.11.97
ENGINE 904.905/906/907/909/910/911,906.910/911 /920/921Z922/923

ENGINE 904.908 /923 In MODEL 668, 670
1 Poly V-belt
3 Guide pulley (only If AC fitted)
4 Bolt
5 Fuel pump
6 Gasket
7 Seal
8 Fuel line
9 Banjo bolt
W huel filter cap
11 Seal
W 47.20-0001-06
HH Removing, installing
A Danger! Risk of Injury from bruises and jamming No person should be in the tilting area of Page 8
w h e n liiiin g td b th e cub w h e n it is being tilted . A lw a y s tilt
with a safety prop.
1.1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954, 957, 970- 976 Page 9
1.2 Remove service hood Model 668, 670
2 Slacken poly V-belt (1) and take off ax belt Engine 904.905- 907/909- 911/921 /922 and AR13.22-W-1202A
pulley of coolant pump 906.910/911 /920- 923/940/941
Engine 904.908/923 AR13.22-D-1202D
3.1 Detach guide pulley (3) at the fuel pump E If At. fitted
(5)
A Danger! Risk of explosion from Ignition. Risk of No fire, naked flame or smoking. Page 82
fuel. Risk of Injury as a result of fuel appropriately marked containers.
coming Into contact with skin and eyes. W ear protective clothing when handling
fuel.
4 Unscrew fuel filter cap (10) from the fuel H When the fuel filter cap is removed, the
filter housing fuel flows out of the fuel filter housing
the fuel tank.
E Installation: replace seal (11).
@ Cap to fuel filter housing BA47.20-N-1001-02A
5 Detach fuel line (8) at the fuel pump (5) H Collect fuel which flows out.
Installation: replace seals (7).

@ Banjo bolt of fuel line to fuel pump BA47.20-N-1002-01A
6 Detach fuel pump (5) H I Collect fuel which flows out.

When attaching the fuel pump, the
driver at the fuel pump must not be
positioned against the dowel pin of the
camshaft.
0 Bolt of fuel pump to crankcase B A47.20-N-1001 -01A
8 Bleed fuel system Engine 904.905/906/- 908/921/923

See Operating Instructions
s3 Fuel pump

906/907/921 904.908 910/911/922/923
906.910/911/920/
921/922/923/940
/941
BA47.20-N-1001-01A Bolt of fuel pump to crankcase Nm 25 25 25
BA47.20-N-1002-01A Banjo bolt of fuel line to fuel pump Nm 40 40 40
0 Fuel f ilte r

906/907/921 904.904/ 910/911/922,
908/923 906.910/911/919/
920/921/922/923
/940/941
BA47.20-N-1001-02A Cap to fuel filter housing Nm 25 25 25
88
From the Library of Barrington Diesel Club

Mercedes Om904 Et om906LA PDF

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Mercedes Om904 Et om906LA PDF

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I

Engines OM 904 LA, OM 906 LA

Order No. 6517 5031 02

From the library of Barrington Diesel Club

Title Validity________________________________________________________ Page

Removing, installing engine ENGINE 904.909/910/911 /922,906.910/911 17

Removing, installing oil separator ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 53

Engines OM904 LA, 906 LA (m od. des. 904.9,906.9), F4 1

Title Validity Page

ENGINE 904.908/923 in MODEL 668,670

Removing, installing crankshaft sprocket ENGINE 904.905/906/907 /909/910/911 /921 /922,906.910 40

Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 1

Title Validity Page

@ *3 ^ Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 1

Title validity Page

Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 1

ENGINE 904.905/906/907/908/909/911/921 Z922/923,906.910/911/920/921 Z922/923

Technical data engine OM904LA (engine 904.905) Page 3

G F01.00-W-1000-01A Technical data engine Engine 904.905 r- ^ G F

Engines O M904 LA, 906 LA (m od. des. 904.9, 906.9), F4 3

Rated speed rpm 2300

GF01.00-W-1000-01C Technical data engine Engine 904.907

Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 5

Rated speed rpm 2300

Working method 4-stroke diesel with direct injection

GF01.00-W-1000-01K Technical data - engine Engine 904.909 C -GF

G F01,00-W-1000-01L Technical data -engine Engine 904.911 PS^G F

Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 7

GF01.00-W-1000-01M Technical data - engine Engine 904.921/922/923 r-s-'GF

Combustion method Exhaust turbocharger and intercooler

GF01.00-W-1000-01N Technical data -engine Engine 906.910/920/922 p^ g f

Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 9

Engine type OM 906 LA 11/1

Total displacement cm3 6370

GF01.00-W-1000-010 Technical data -engine Engine 906.911/921/923 M s-G F

Combustion method Exhaust turbocharger and intercooler

SB* Engines OM904 LA, 906 LA {mod. des. 904.9, 906.9), F4 11

ENGINE 906.920/921 Z922/923

7 Cab -chassis connector

Notes on battery All models Page 15

3 Remove front grille S3 000 589 01 1000

5 Separate cable (red) (3) and the connectors

Notes on tilting cab Model 950,952,953,954 Page 16

9 Install in the reverse order

Bflu ufl flfl 0 0

Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 13

G e n e r a lly m edical services o r a p h ysicia n sh o u ld b e co ntacted

Fire protection measures

Warning notes on lead add batteries

Before tilting the cab On vehicles with a refrigerator box

The coupling pin must be inserted correctly.

E3Always tilt cab up to its final position.

ENGINE 904.909/910/911/922, 906.910/911

Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), E4 17

30 Sh ift lever with shift rod (engine 906.910/911)

nnu Removing, installing

Installation Replace all self-locking nuts and bolts

No tes on b a tte ry A ll m od els P a g e 15

2 Tilt cab into repair position

Notes on tilting cab Model 970- 976 Page 16

5 Remove charge air pipe from turbocharger AR09.41-W-1311C

6 Remove fan shroud AR20.40-W-6800A

10 Detach air intake hose (24) at air cleaner