a Engine removal and installation AR01.10-B-2400G.

fm 1

AR01.10-B-2400G.fm Engine removal and installation 27.11.98

Engines 904.918/919/925/938/957, 906.924 (truks with forward cab)

B01.10-0011-09
1 Engine deaerating hose 4 Heating system hose
2 Exhaust pipe 5 Starter cables
3 Ground cables 6 Alternator wiring harness wires
a Engine removal and installation AR01.10-B-2400G.fm 2
8 Exhaust-brake cylinder compressed air line 18 Bolt
16 Lifting bracket, front 19 Engine mount
17 Lifting brackets, rear

7 Vehicle wiring harness

9 Decompression brake valve compressed
air line
9.1 Boot
9.2 Connection
9.3 Socket
10 Air compressor discharge line
11 Hydraulic steering fluid supply line
12 Hydraulic steering fluid return line
13 Fuel line (inlet)
14 Fuel line (outlet)
15 Shifter assembly
18 Bolt
19 Engine mount
20 Hose on coolant pump inlet

B01.10-0004-06
a Engine removal and installation AR01.10-B-2400G.fm 3

ed Removing and installing

1 Disconnect master switch or detach battery

ground lead.

a Danger! Risk of personal injuries and material Be sure the cabin tilting and returning area is AS60.80-B-0001-01A
damage when tilting and returning vehicle clear of objects and persons. Always tilt cabin
cabin. as far as the end position. Return cabin to its
correct locked position for vehicle operation.

2 Tilting the cabin. AR60.80-B-0010B

3 Remove turbocharged air pipe, between AR09.41-B-1311E

turbocharger and aftercooler.

4 Remove turbocharged air pipe, between AR09.41-B-8620C

intake manifold and aftercooler.

5 Remove intake duct between turbocharger AR09.10-B-8030A

and air cleaner.

6 Remove the coolant radiator with the AR20.20-B-3865E

aftercooler.

7 Disconnect engine deaerating hose (1). i Installation: Check securing clamp,

replace if necessary.

8.1 Disconnect hose (4) at cabin heating system. Vehicles fitted with cabin heating system.

9 Detach exhaust pipe (2). i Installation: Clean the contact surfaces.

Check the securing clamp, replace if
necessary.
a Engine removal and installation AR01.10-B-2400G.fm 4

10.1 Detach compressed air line (4) at exhaust- Vehicles fitted with exhaust-brake.
brake cylinder.

11 Disconnect ground leads (3) at timing case.

12 Disconnect wiring harness wires (5) at starter.

13 Detach wiring harness wires (6) at alternator. Mark wiring harness wires to avoid mistakes
when installing.

14 Disconnect vehicle wiring harness wires (7) at AR07.15-B-1628-01A

the control unit.

15 Remove shifter assembly (15) from bracket

on engine.

16 Detach hose (20) at coolant pump inlet pipe. i Installation: Check the securing clamp,
replace if necessary.

17.1 Disconnect decompression brake valves Engine 904, fitted with decompression brake
compressed air line (9). valves (top brake).
i Detach boot 9.1 lengthwise, unlock socket
9.3 latches and separate connection 9.2.

18 Disconnect compressed air discharge line n BA13.30-B-1004-01C

(10) on air compressor.

19 Disconnect hydraulic steering lines (11/12) at Plug connections (11/12) openings to avoid
power steering hydraulic pump. hydraulic fluid leakage. Collect fluid which runs
out.
i Installation: Replace seals.
a Engine removal and installation AR01.10-B-2400G.fm 5

a Danger! Follow safety measures when dealing with Risks of explosion and injuries. AS47.00-B-0001-01A
fuel.

20 Detach fuel lines (13/14). Mark lines (inlet and outlet) to avoid mistakes
when installing. Collect fuel which runs out.

21 Support engine at lifting brackets, front (16) Use a steel rope or chain and a suitable device.
and rear (17).

22 Remove the gearbox.

23 Remove bolts (18) on engine front mounts n BA22.10-B-1001-01C

(19).

24 Lift engine out of vehicle. p Lift engine slowly, guiding it carefully.

Be careful and do not damage components
due to impacts during its removal. After
removal, place the engine on a suitable
engine stand or holding device.

25 Remove engine mounts (19). i Check condition, if necessary change

engine mounts (19).

n BA22.10-B-1002-01C

26 Install in the reverse order.

27 Bleed the fuel system. Operate manual prime pump handle until a AP47.00-B-1720-01C
strong counterpressure is felt.
a Engine removal and installation AR01.10-B-2400G.fm 6

a Danger! Risk of personal injuries and material
losses when starting engine with
transmission shifted in gear. Risk of
personal injuries when working at a hot and
running engine.
Be sure transmission is in neutral. AS00.00-B-0005-01A
Wear appropriate clothing and watch engine
hot and rotating parts.

28 Run engine. p Do not crank engine continuously for

more than 30 seconds. If engine does not
start within this interval, wait for
approximately 1 minute before trying again.

29 Check engine oil pressure with engine idling. p Do not accelerate engine until oil gauge BE18.00-B-1001-01A
indicates pressure. The oil pressure should
build-up in approximately 10 seconds.

30 Check power steering hydraulic fluid level, Engine must be idling. AP46.00-B-4611C
replenish if necessary.

31 Shut down engine and check for eventual i Check engine oil level 5 minutes after AP18.00-B-0101B
leaks. engine shutdown.

32 Check coolant level. Add if necessary. AP20.00-B-2010B

Test data on engine oil pressure

Number Designation Engine 904.918/919/

920/924/925/938/957,
906.924

BE18.00-B-1001-01A Engine oil pressure, minimum at idling speed bar 0.5

permissible
at maximum speed bar 2.5
a Engine removal and installation AR01.10-B-2400G.fm 7

n Air compressor, compressed air system

Number Designation Engine 904.918/919/

920/924/925/938/957,
906.924

BA13.30-B-1004-01C Compressed air pipe to compressor Nm 100

n Engine mount, engine support

Number Designation Engine 904.918/919/

924/925/938/957,
906.924

BA22.10-B-1001-01C Engine to front engine mount M14x1,5 Nm 180

M16x1,5 Nm 270

BA22.10-B-1002-01C Front engine mount to mount support M12x1,5 Nm 110

(mount assembly)
M16x1,5 Nm 180