Complete-Engine C

ENGINE
Complete Engine - Model 906
GENERAL INFORMATION
DETERMINE LOSS OF PRESSURE AT CYLINDER - AH01.00-N-1300-02A
ENGINE 102, 103, 104, 110, 111, 112, 113, 116, 117, 119, 120, 137, 152, 155, 156, 157, 159, 166, 266, 270,
271, 272, 273, 274, 275, 276, 278, 279, 285, 601, 602, 603, 604, 605, 606, 611, 612, 613, 617, 628, 629, 642,
646, 647, 648, 651, 668
ENGINE ALL
If an increased pressure loss was found with the cylinder leakage tester, inspect engine by listening at cylinder
head gasket, air intake area, exhaust, oil filler opening and prechamber or spark plug bores of the adjacent
cylinder or cylinders.
Check the coolant in the coolant expansion reservoir for air bubble formation.
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Possible causes of pressure loss given the following symptoms are:
1. Air escape via pre-combustion chamber or spark plug bore of adjacent cylinder, air bubbles in
coolant expansion reservoir:
Pressure loss at cylinder head gasket
2. Air escape via air intake area: Open throttle valve to listen Pressure loss at intake valve(s)
3. Air escaping via exhaust:
Pressure loss at exhaust valve(s)
4. Air escaping via oil filler opening:
Pressure loss through pistons and piston rings
Spraying in engine oil can limit the pressure loss from that cylinder. Engine oil temporarily seals the gap
between the piston and cylinder.
If a reduced pressure loss then occurs temporarily, the cause is highly likely to be the piston, the piston rings or
the cylinder barrel of the cylinder in question.
Troubleshooting the cause can be hampered by the position of the piston ring end gaps. If it is suspected that
pressure loss is being caused by the piston ring end gaps being directly over each other, reassemble the engine
and repeat the test after running the engine briefly.
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01A

ENGINE 112, 122, 134, 135, 166, 271.951, 272, 611, 612, 613, 628, 629, 639, 642, 646, 647, 648, 651
Glazing, smooth spots
Individual blank points, e.g. in the middle of the cylinder barrel or around the cylinder head bolts.
Reuse crankcase.
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Fig. 1: Identifying Cylinder Wall With Glazing & Smooth Spots
Visible stripes, friction marks
Starting from reverse area of the upper piston ring tapering downwards.
Traces of dry friction marks which cannot be felt, caused by oil film being washed off by fuel, for example from
many cold starts when driving short distances.
Friction marks occurring mainly around the cylinder head bolts and on the pressure side are not a problem
provided that they are smoothed out.
The piston rings are not damaged.
IMPORTANT: Reuse crankcase.

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Fig. 2: Identifying Visible Stripes, Friction Marks On Cylinder Wall
Ring shaped imprints
Visible imprints on cylinder barrel in the upper and lower reverse area of piston rings are not a cause for
complaint.

Fig. 3: Identifying Ring Shaped Imprints On Cylinder Wall
Rotary bright, reflective, polished upper surfaces of cylinder
Starting from the reverse area of the upper piston ring with measurable, partial cylinder wear.
The cylinder barrel is unusable.
IMPORTANT: Do not reuse the crankcase.
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Fig. 4: Identifying Rotary Bright, Reflective & Polished Upper Surfaces Of Cylinder
Rough streaks, friction scoring
Starting from first and second piston ring, tapering to an end only in bottom part of cylinder. Progressive signs
of friction lead to friction score marks.
Where these signs of friction are perceptible, the cylinder barrel is unusable.
The piston rings may be damaged.

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Fig. 5: Identifying Rough Streaks, Friction Scoring On Cylinder Wall
Continuous individual traces of scratch
Caused by soiling, for example, by the back-pulsation of soot particles from the catalytic converter or exhaust.
Piston seizure
Most of cylinder wall perceptibly roughened over the entire length. Material deposits and perceptible scoring
marks on cylinder wall and at piston skirt.
The cylinder barrel is unusable.
Brown coloring of cylinder upper surface
A brown coloration over large areas of the cylinder barrel is oil varnish and indicates that the engine has been
driven at a high temperature level.
Oil varnish above piston ring zone is normal and is not a reason for complaint.
IMPORTANT: Reuse crankcase provided no impermissible cylinder distortion is present.
GENERAL NOTES: COMMERCIAL VEHICLES: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - AH01.00-Z-9999TZ
MODEL all
GENERAL NOTES: COMMERCIAL VEHICLES: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE
Determine loss of pressure at ENGINE all, 102, 103, 104, 110, 111, 112, AH01.00-N-1300-02A
cylinder 113, 116, 117, 119, 120, 137, 152, 155, 156,
157, 159, 166, 266, 270, 271, 272, 273, 274,
275, 276, 278, 279, 285, 601, 602, 603, 604,
605, 606, 611, 612, 613, 617, 628, 629, 642,
646, 647, 648, 651, 668 ...
General information on ENGINE 112, 122, 134, 135, 166, 271.951, AH01.00-P-0300-01A
inspecting cylinder walls 272, 611, 612, 613, 628, 629, 639, 642, 646,
647, 648, 651
Information on working sealing ENGINE ALL AH01.10-N-0002-01A
surfaces when carrying out
engine repairs
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Notes for assessing wear to ENGINE ALL AH01.40-N-0001-01A
cylinder wall in the case of dust
damage
Notes on sealant path for ENGINE 642 in MODEL 639 ENGINE AH01.30-N-1000-08SE
cylinder head cover 642.896 /898/992/993 in MODEL 906
Notes on sealant path for oil pan ENGINE 642.896/898/992/993 in MODEL AH01.45-N-0001-01SF
906
Notes on sealant path for timing ENGINE 642.896/898/992/993 in MODEL AH01.40-N-1000-01SE
case cover 906 ENGINE 642 in MODEL 639
INFORMATION ON WORKING SEALING SURFACES WHEN CARRYING OUT ENGINE

REPAIRS - AH01.10-N-0002-01A
ENGINE ALL
Grinding material (emery cloth, etc.) may NOT be used when machining sealing surfaces on oil, coolants and
fuel components or interior components. Loose particles (e.g. corundum) can lead to impurities and damage on
crank assembly, connecting rod bearing and main bearing, as well as the fuel system and cooling system.
Seal residue, rust and combustion residue may only be removed using high-performance disks (cleaning
brushes) or scraping tools.
All oil, coolant and fuel bores should be carefully sealed before processing the sealing surfaces.
NOTES ON SEALANT PATH FOR CYLINDER HEAD COVER - AH01.30-N-1000-08SE
ENGINE 642 in MODEL 639

ENGINE 642.896 /898/992/993 in MODEL 906
The sealing surfaces must be free of oil and grease.
Leaks can occur otherwise.
The traced lines (A) identify the sealant path. Apply sealant evenly in the form of a bead (A) with a height
and width of 1.5 mm (± 0.5 mm) on the lines (A) of the cylinder head cover. The sealing compound must be
applied within 10 min.
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Fig. 6: Identifying Sealant Path For Cylinder Head Cover - Engine 642
NOTES FOR ASSESSING WEAR TO CYLINDER WALL IN THE CASE OF DUST DAMAGE -
AH01.40-N-0001-01A
ENGINE ALL
Cylinder Barrels Or Cylinder Liners Without Dust Damage
The honing pattern is more or less clearly recognizable over the entire running surface. The hone marks may be
partially worn away at the reversal point of the first piston ring.
Fig. 7: Cylinder Barrels or Cylinder Liners Without Dust Damage
Cylinder Barrels Or Cylinder Liners With Dust Damage
Traces of processing by honing are only just visible or are no longer visible. If the wear is substantial, than a
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ridge can be felt at the reversal point of the first piston ring.
Dust and particulate damage are caused by poor sealing, cracks and abrasion in the intake tract's collars, ducts
and hoses. Carefully inspect all intake ducts, collars and hoses, even in areas where access is difficult, when
performing service and maintenance operations.
Fig. 8: Cylinder Barrels or Cylinder Liners With Dust Damage
NOTES ON SEALANT PATH FOR TIMING CASE COVER - AH01.40-N-1000-01SE
ENGINE 642.896/898/992/993 in MODEL 906
Sealant path on timing case cover

NOTE: At sealing surfaces and transitions between the oil pan and crankcase, it is
particularly important to pay attention to cleanliness. The sealing surfaces must
be oil and grease-free otherwise leaks can occur.
The superimposed line (A) shows the sealant path.
Apply sealant evenly in the form of a bead with a height and width of 1.5 mm (± 0.5) mm on the line (A) of the
timing case cutout. The sealant must be applied within 10 min.
The sealant must be applied in the upper area of the timing case cutout in the center area of the sealing surface
because the sealant slides downwards due to placement of the timing case cover.
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Fig. 9: Identifying Sealant Path For Timing Case Cover - Engine 643
NOTES ON SEALANT PATH FOR OIL PAN - AH01.45-N-0001-01SF
ENGINE 642.896/898/992/993 in MODEL 906

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Fig. 10: Identifying Sealant Path For Oil Pan - Engine 642.896/898/992/993 in Model 906
Sealant path for the lower oil pan (1)
NOTE: The sealing surface must be free of oil and grease. Leaks can occur otherwise.
The traced line (A) identifies the sealant run. Apply sealant evenly in the form of a bead (A) with a height and
width of 1.5 mm (± 0.5 mm) on line (A) of the lower oil pan (1). The sealing compound must be applied within
10 min.
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Fig. 11: Identifying Sealant Path For Upper Oil Pan - Engine 642.896/898/992/993 in Model 906
Sealant path for the upper oil pan (2)
NOTE: The sealing surface must be free of oil and grease. Leaks can occur otherwise.
The traced line (B) identifies the sealant run. Apply sealant evenly in the form of a bead (A) with a height and
width of 1.5 mm (± 0.5 mm) on line (B) of the upper oil pan (2). The sealing compound must be applied within
10 min.
NOTES ON SEALANT PATH FOR OIL PAN - AH01.45-P-0001-01OM
ENGINE 642
General information:
 Sealing surface: - free of anticorrosion agent

 free of machining residue
 oil and grease-free
 dust-free
 The sealing surface must be flat (replace bent components).

 Line (A, F) designates sealant path.
 Discontinuity of the sealant bead is not permissible.
 Do not spread sealing bead.
 Component temperature: min. +7°C up to a max. of +25°C
 Sealant temperature: min. +7°C up to a max. of +25°C
 Maximum assembly time: 7 min.
 Sealant bead diameter: 2 mm
 Nozzle diameter: 1.5 mm
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Fig. 12: Identifying Oil Pan Sealing Applying Area (Engine 642.910/920/852)
Engine 642.910/920/852
Fig. 13: Identifying Oil Pan Sealing Applying Area (Engine 642.930/862)
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Engine 642.930/862
Fig. 14: Identifying Oil Pan Sealing Applying Area (Engine 642.921/932/961/868)
Engine 642.921/932/961/868
Fig. 15: Identifying Oil Pan Sealing Applying Area (Engine 642.940/950/970/872/886)
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Engine 642.975/884
Fig. 16: Identifying Oil Pan Sealing Applying Area (Engine 642.975/884)
Fig. 17: Identifying Oil Pan Sealing Applying Area (Engine 642.826)
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Engine 642.826
TESTING & REPAIR

CRANK ENGINE - AR01.00-D-0100SF
ENGINE 642.896 /898 /992 /993 in MODEL 906
Fig. 18: Screw & Vibration Damper Component Location - Engine 642
CRANK ENGINE - ENGINE 642.896 /898 /992 /993 IN MODEL 906

Remove/install
1 Turn transmitter key in EIS To prevent unintentional
control unit to position "0" starting of the engine.
and remove
2 Remove viscous fan clutch Do not remove fan shroud AR20.40-D-5660SF
from fan drive and lay in the and fan.
fan shroud
3 Lift/jack up vehicle AR00.60-D-1000H
Crank engine
4 Crank engine at vibration
damper (2) bolt (1) in
direction of engine rotation
5 Install in the reverse order
INSPECT CYLINDERS WITH A LIGHT PROBE - AR01.00-D-0200SD
ENGINES 651 in MODEL 900
ENGINES 642.896 /992, 646.984 /985 /986 /989 /990, 651.955 /956 /957 in MODEL 906
Shown on engine 646.985
Fig. 19: Inspecting Cylinders Using Light Probe - Shown on engine 646.985
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MODIFICATION NOTES - COUNTERHOLDER TOOL FOR ENGINE
21.6.11 Special tool for counterholder 651 589 08 40 00 Operation step 4
added
INSPECT CYLINDERS WITH A LIGHT PROBE - ENGINE 642, 651

Remove/install
Risk of explosion caused No fire, sparks, open flames AS47.00-Z-0001-01A
by fuel igniting, risk of or smoking. Only pour fuels
poisoning caused by into suitable and
inhaling and swallowing appropriately marked
fuel and risk of injury to containers.
eyes and skin caused by Wear protective clothing
contact with fuel when handling fuel.
control unit to position "0" starting of the engine.
and remove
2 Remove injectors Engine 642 AR07.16-D-1000SF
Checking
3 Lift/jack up vehicle With engine 646, 651. AR00.60-D-1000H
4 Set piston on cylinder to be Engine 642 AR01.00-D-0100SF
checked to bottom dead Engine 646:
center (UT) by turning the Socket wrench bit Fig. 20
crankshaft Engine 651:
Counterholder (with code Fig. 21
(H08) High performance
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A/C or with code (HK4)
Rear A/C, enhanced)
Counterholder (without Fig. 22
code (H08) High
performance A/C or without
code (HK4) Rear A/C,
enhanced)
5 Connect endoscope (2) to Endoscope (cold light)
injector well (1) and guide gotis://A_01_02.1
endoscope (2) through
injector shaft into cylinder
to be checked
6 Check cylindrical barrel for If there is wear to the
damage and wear cylinder, the cylinder wall
has become rough and the
honing marks are no longer
visible. Remove cylinder
head if cylinder wear or
damage is not clearly
detectable.
See: Engine 646:
Remove/install the cylinder AR01.30-D-5770SF
head
Remove/install right AR01.30-D-5780SF
General information on cylinder head AH01.00-P-0300-01A
inspecting cylinder walls
7 Inspect remaining cylinder
barrels in the same way
Fig. 20: Identifying Wrench Socket (001 589 65 09 00)
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Fig. 21: Identifying Counterholder (651 589 00 40 00)
Fig. 22: Identifying Counterholder (651 589 08 40 00)
TEST COMPRESSION PRESSURE - AR01.00-D-1200SF
ENGINES 642.896 /898 /992 /993 in MODEL 906

Fig. 23: Testing Compression Pressure
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MODIFICATION NOTES - TEST COMPRESSION PRESSURE
17.9.09 Value modified: Compression pressure permissible COMPRESSION PRESSURE
difference between the cylinders SPECIFICATIONS - ENGINES
642 IN MODEL 906
TEST COMPRESSION PRESSURE - ENGINES 642.896 /898 /992 /993 IN MODEL 906
Removing
Risk of injury to skin Wear safety gloves, AS00.00-Z-0002-01A
and eyes caused by protective clothing and
handling hot or glowing safety glasses, if necessary.
objects.
Risk of accident caused Secure vehicle to prevent it AS00.00-Z-0005-01A
by vehicle starting off by from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or rotating
burns during starting parts.
procedure or when
working near the engine
as it is running
1 Start engine and bring to Operating temperature is
operating temperature reached at an oil
temperature of approx.80 °
C.
Only test compression when
engine is at operating
temperature.
2 Remove blow plugs AR15.20-S-4111SE
(R9/1, R9/2, R9/3, R9/4,
R9/5, R9/6)
3 Install adapter (2) on Fig. 24
compression recorder (1) Fig. 25
4 Connect compression Do not actuate push AR01.10-D-0110SF
recorder (1) to crank button switch (arrow)
engine with starter
Checking
5 Screw in screw-in fitting Fig. 26
(3) into the glow plug
hole of the cylinder to be
tested
6 Attach compression
recorder (1) with adapter
(2) to screw-in fitting (3)
7 Actuate push button Compression pressure COMPRESSION
switch (arrow) for installation tolerance or new PRESSURE
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approx. 7 s to 10 s and value SPECIFICATIONS -
check for compression ENGINES 642 IN
pressure MODEL 906
Compression pressure COMPRESSION
permissible difference PRESSURE
between individual SPECIFICATIONS -
cylinders ENGINES 642 IN
MODEL 906
8 Unscrew compression Change compression
recorder (1) with adapter recorder (1) to next cylinder
(2) from screw-in fitting to be checked
(3)
9 Unscrew screw-in fitting
(3)
10 Check other cylinders in
same manner
Install
11 Remove adapter (2) from
compression recorder (1)
12 Disconnect compression AR01.10-D-0110SF
recorder (1) to crank
engine with starter
13 Install glow plugs (R9/1, AR15.20-S-4111SE
R9/2, R9/3, R9/4, R9/5,
R9/6)
COMPRESSION PRESSURE SPECIFICATIONS - ENGINES 642 IN MODEL 906

Number Designation Engine 642
BE01.00-N-1001-01L Compression pressure installation tolerance or new bar 27 to 32
value
BE01.00-N-1003-01L Compression pressure permissible difference bar < or =3
between individual cylinders
Fig. 24: Identifying Compression Tester (001 589 78 21 00)
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Fig. 25: Identifying Intermediate Piece (611 589 02 63 00)
Fig. 26: Identifying Screw-In Fitting (640 589 00 63 00)
CONNECT CYLINDER LEAKAGE TESTING UNIT - AR01.00-S-1300-01SE

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1. Calibrate cylinder leakage tester (4) according to the operating instructions. Cylinder leakage tester
2. Screw screw-in fitting (1) into spark plug hole.
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Fig. 29: Connecting Cylinder Leakage Tester To Screw In Fitting Or Intermediate Piece
3. Place intermediate piece (2) on the crew-in fitting (1) and attach connector (3) to intermediate piece (2).
Cylinder leakage tester
Only if the intermediate piece (2) is needed as an extension.
4. Connect cylinder leakage tester (4) to the screw-in fitting (1) or to the intermediate piece (2).
FIRING ORDER - AR01.00-S-1300-03SE
IMPORTANT: Cylinder 1 is located on the right cylinder bank opposite the power output side
when seen in the direction of travel.
Fig. 30: Engine Firing Order & Cylinder Identification
CHECK CYLINDERS FOR LEAKS - AR01.00-S-1300SE
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ENGINES 642.992 in MODEL 906
Fig. 31: Oil Filler Cap Component Location (Shown On Engine 642 In Model 639)
CHECK CYLINDERS FOR LEAKS - ENGINE 642

Removing
Risk of injury to skin Wear safety gloves, AS00.00-Z-0002-01A
and eyes caused by protective clothing and
handling hot or glowing safety glasses, if necessary.
objects.
by vehicle starting off from moving by itself.
by itself when engine is Wear closed and snug-fitting
running. Risk of injury work clothes.
caused by contusions Do not touch hot or rotating
and burns during starting parts.
procedure or when
working near the engine
as it is running
Risk of injury to skin Do not open cooling system AS20.00-Z-0001-01A
and eyes caused by unless coolant temperature is
scalding from contact below 90°C. Open cap
with hot coolant spray. slowly and release the
Risk of poisoning pressure. Do not pour
caused by swallowing coolant into beverage
coolant. containers. Wear protective
gloves, protective clothing
and safety glasses.
1 Bring engine to
operating temperature
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(approx. 80°C)
2 Open cap on expansion
reservoir for coolant,
relieve excess pressure
and remove cap
3 Remove oil filler cap (1)
4 Remove glow plugs AR15.20-S-4111SE
Checking
5 Position piston on the
cylinder to be tested by
turning the crankshaft
and set to ignition TDC
using the top dead center
search device (arrows)
The TDC detector is a Model 906 AR01.00-D-0100SF
part of the cylinder
leakage tester
6 Connect cylinder Cylinder leakage tester AR01.00-S-1300-01SE
leakage tester to cylinder (pressure loss)
to be tested Fig. 25
Fig. 26
(pressure loss)
7 Apply compressed air to If crankshaft has to be AR03.30-S-5000SE
cylinder to be tested turned further it must be
fixed in place using the
retaining lock.
See ?
Remove/install retaining
lock for crankshaft/ ring gear
8 Read off pressure loss at Cylinder leakage: CYLINDER LEAKAGE
cylinder leakage tester permissible loss total SPECIFICATIONS
and determine cause if indication
there is increased Cylinder leakage: CYLINDER LEAKAGE
pressure loss permissible losses at valves SPECIFICATIONS
and cylinder head gasket
Cylinder leakage: CYLINDER LEAKAGE
permissible losses at pistons SPECIFICATIONS
and piston rings
Determine pressure loss AH01.00-N-1300-02A
of cylinders
9 Relieve compressed air
pressure on checked
cylinder and detach
cylinder leakage tester
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10 Remove retaining lock Only if retaining lock was AR03.30-S-5000SE
installed to fix the crankshaft
in place.
11 Perform checking of AR01.00-S-1300-03SE
further cylinders on the Fig. 25
engine, according to the
firing order, in the same Fig. 26
way using the cylinder Cylinder leakage tester
leakage tester (pressure loss)
Install
12 Install glow plugs AR15.20-S-4111SE
13 Attach oil filler cap (1)
14 Attach screw cap for
coolant expansion
reservoir
CYLINDER LEAKAGE SPECIFICATIONS

Number Designation All engines
BE01.00-P-1001-02Z Cylinder leakage: permissible loss total indication % < or =25
BE01.00-P-1002-02Z Cylinder leakage: permissible losses at valves and % < or =10
cylinder head gasket
BE01.00-P-1003-02Z Cylinder leakage: permissible losses at pistons and % < or =20
piston rings
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TESTING & REPAIR WORK: LIGHT TRANSPORTERS: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9642EB
ENGINE 642
TESTING & REPAIR: LIGHT TRANSPORTERS: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - ENGINE 642
Check cylinders for leaks ENGINES 642 in MODEL 639 ENGINES AR01.00-S-1300SE
642.992 in MODEL 906
Remove/install cylinder head cover ENGINE 642 ... AR01.20-D-5015SF
trim panel
Remove/install cylinder head cover ENGINE 642 ... AR01.20-D-5015SG
trim panel
Remove/install oil separator ENGINES 642.8 in MODEL 639 ENGINES AR01.20-D-9750SG
642.898 in MODEL 906
Remove/install timing case cover ENGINES 642 in MODEL 639 ENGINES AR01.40-S-8000SE
642.896 /898 /992 /993 in MODEL 906
TESTING & REPAIR WORK: TRANSPORTERS: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9642FB
ENGINE 642
TESTING & REPAIR WORK: TRANSPORTERS: COMPLETE ENGINE, CRANKCASE
VENTILATION, CYLINDER HEAD, CRANKCASE - ENGINE 642
Check cylinders for leaks ENGINES 642 in MODEL 639 ENGINES AR01.00-S-1300SE
642.992 in MODEL 906
Crank engine ENGINE 642.896 /898 /992 /993 in MODEL AR01.00-D-0100SF
906
Crank engine with starter ENGINES 642.896 /898 /992 /993 in AR01.10-D-0110SF
MODEL 906
Inspect cylinders with a light ENGINE 642, 646, 651 ... AR01.00-D-0200SD
probe
Remove/install bottom part of oil ENGINES 642.896 /898 /992 /993 in AR01.45-D-7555SF
pan MODEL 906
Remove/install cylinder head ENGINE 642 ... AR01.20-D-5015SF
cover trim panel
Remove/install cylinder head ENGINE 642 ... AR01.20-D-5015SG
cover trim panel
Remove/install end cover together ENGINE 642 ... AR01.40-D-8920SF
with shaft seal
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Remove/install engine cover ENGINE 642.992 /993 in MODEL 906 AR01.10-D-2405SF
Remove/install engine with ENGINE 642 ... AR01.10-D-2401SF
transmission
Remove/install left cylinder head ENGINES 642.896 /898 /992 /993 in AR01.20-D-5013SF
cover MODEL 906
Remove/install oil pan ENGINES 642.896 /898 /992 /993 in AR01.45-D-7500SF
MODEL 906
Remove/install oil separator ENGINES 642.896 /992 /993 in MODEL 906 AR01.20-D-9750SF
Remove/install oil separator ENGINES 642.8 in MODEL 639 ENGINES AR01.20-D-9750SG
642.898 in MODEL 906
Remove/install right cylinder ENGINES 642.896 /898 /992 /993 in AR01.30-D-5780SF
head MODEL 906
Remove/install right cylinder ENGINES 642.896 /898 /992 /993 in AR01.20-D-5012SF
head cover MODEL 906
Remove/install the cylinder head ENGINES 642.896 /898 /992 /993 in AR01.30-D-5770SF
MODEL 906
Remove/install timing case cover ENGINES 642 in MODEL 639 ENGINES AR01.40-S-8000SE
642.896 /898 /992 /993 in MODEL 906
Test compression pressure ENGINES 642.896 /898 /992 /993 in AR01.00-D-1200SF
MODEL 906
CRANK ENGINE WITH STARTER - AR01.10-D-0110SF
ENGINES 642.896 /898 /992 /993 in MODEL 906

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Fig. 34: Cranking Engine Using Remote Starter Switch
CRANK ENGINE WITH STARTER - ENGINE 642 IN MODEL 906

Connect/disconnect
control unit to position "0" and starting of the engine.
remove
2 Open cable tie (8), expose
electrical connector on engine
wiring harness (X26/46) or engine
wiring harness connector 2
(X26/53) and disconnect
3 Connect adapter lines (4, 6) on Adapter lines (4, 6) with
clips (3) on compression recorder associated extension lines
(1) are included in the electrical
connection kit
Fig. 35
Fig. 36
4 Connect adapter line (6) to pin 3 Fig. 36
(arrow) on electrical plug
coupling (7)
5 Connect adapter line (4) with clip Clamp (5) can be taken
(5) to jump-start connection point from electrical connection
connector (X4/43) kit
Fig. 36
Crank engine
Risk of death caused by being Do not insert your hand into AS00.00-Z-0004-
drawn into rotating vehicle parts rotating parts. Wear closed 01A
and snug-fitting work
clothes. Secure area of
rotating vehicle components
against unauthorized access.
Risk of accident caused by Secure vehicle to prevent it AS00.00-Z-0005-
vehicle starting off by itself when from moving by itself. 01A
engine is running. Risk of injury Wear closed and snug-fitting
caused by contusions and burns work clothes.
during starting procedure or when Do not touch hot or rotating
working near the engine as it is parts.
running
6 Actuate push button switch (2) on Fig. 35
compression recorder (1) to crank
engine
7 Disconnect in reverse order
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Fig. 36: Identifying Electrical Connection Kit (220 589 00 99 00)
DISCONNECT/CONNECT HOSE & LINE CONNECTIONS - AR01.10-D-2400-02S
ENGINE 642.898/993
POWER STEERING PUMP HIGH PRESSURE HOSE FITTING TORQUE SPECIFICATIONS -
ENGINE 642.898/993
Model 906 with
Number Designation engine 642
BA46.30-N-1003- High pressure expansion hose to power - Nm 38
01A steering pump VDA pump Nm -
VT pump Nm -
VEHICLE SPEED SENSOR BOLT TORQUE SPECIFICATION - ENGINE 642.898/993

Model 906 with engine
Number Designation 642
BA54.00-N-1003-01A Bolt, vehicle speed sensor to Nm 10
transmission housing
REFRIGERANT COMPRESSOR LINE-TO-COMPRESSOR FITTING TORQUE

SPECIFICATION - ENGINE 642.898/993
Model 906 with engine Model 906 with engine
satelettronica
642.896/898/992/993 642.896/898/992/993
without code H08 or with code H08 or with
Number Designation without code N63 code N63
BA83.55-N-1004- Bolt, refrigerant lines Nm 22 22
01L to refrigerant
compressor
Fig. 37: Identifying Set Of Stop Plugs (129 589 00 91 00)
1. Unfasten grommet (5) on battery box (6).

Fig. 38: Grommet On Battery Box & Fuel Hose Component Locations
2. Remove positive line (3) from battery box (6) and expose up to the starter (M1).
3. Mark fuel hoses (10, 11) relative to the fuel lines (12, 13), disconnect and close off using suitable stop
plugs.
satelettronica
Collect escaping fuel in a suitable container.
4. Remove electrical line (16) from oil filler pipe (17).

5. Remove cover (9) from transmission (14).
6. Disconnect electrical connector (18) from transmission (14)
Fig. 39: Electrical Connector On Transmission Component Location

7. Remove lead seal (15).
On vehicles with code (BB3) Electronic stability program.
Installation: Replace lead seal (15).
8. Remove speed sensor (B6/12) from transmission (14) and lay down to side with electrical wiring harness
connected
On vehicles with code (BB3) Electronic stability program.
Installation: Observe tightening torques.
Fig. 40: Speed Sensor On Transmission Component Location satelettronica

9. Disconnect electrical connector (7) from NOx sensor upstream of SCR CAT control unit (A97/1)
10. Remove NOx sensor upstream of SCR CAT control unit (A97/1) from frame.
11. Expose electrical line (4) on NOx sensor upstream of SCR CAT control unit (A97/1) to sensor (1) on
frame.
12. Fasten NOx sensor upstream of SCR CAT control unit (A97/1) with electrical line (4) to catalytic
converter diesel particulate filter unit (2).
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Fig. 41: Electrical Connector, SCR CAT Control Unit & Catalytic Converter Diesel Particulate
Filter Unit Component Locations
Fig. 42: Oxygen Sensor Connector, Vacuum Hose, Vacuum Pump & Pressure Hoses Component
Locations
13. Disconnect oxygen sensor connector (B85/2x1 or B85/3x1) and expose electrical line (19) to oxygen
sensor.
On engine 642.898 fasten electrical line (32) together with electrical line (19) to engine with cable tie.
14. Remove coolant hose (20) from exhaust gas recirculation, lay upward and fasten with cable tie
15. Remove vacuum hose (21) from aneroid capsule (22).
16. Detach vacuum line (29) at vacuum pump (30).
17. Disconnect pressure hoses (34) on pressure lines (33) from diesel particulate filter differential pressure
sensors.
On engine 642.898
Installation: Check clamps, replace if necessary.
18. Open brackets (35), unclip automatic oil lines (36) and fasten to engine with cable tie.
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Fig. 43: Ground Line On Longitudinal Member With Engine Wiring Harness Component
Locations
19. Remove ground line (23) on longitudinal member (24).
Installation: The connecting point for ground line (23) on the longitudinal member (24) must be free
of paint, dirt or corrosion.
20. Open cable tie and expose engine wiring harness (25) in engine compartment.
21. Disconnect electrical connectors (26, 27).
22. Unlock electrical connector (28) and detach from CDI control unit (N3/20 or N3/30).
23. Fasten engine wiring harness (25) to engine with cable tie.
Fig. 44: High Pressure Expansion Hose On Power Steering Pump & Refrigerant Lines Component
Locations
24. Remove high pressure expansion hose (37) on the power steering pump (38).
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Collect hydraulic oil running out in suitable container. Close openings with suitable stop plug.
Installation: Replace sealing ring. Observe tightening torque of high pressure expansion hose (37).
25. Unscrew bolts (41, 42), remove refrigerant lines (39, 40) from AC compressor (A9) and plug openings
with suitable stop plugs.
With code (HH9) Regulated air conditioning (Tempmatic)
Installation: Replace sealing rings. Observe tightening torque for bolts (41, 42).
26. Connect in reverse order.
DISCONNECT/CONNECT HOSE & LINE CONNECTIONS - AR01.10-D-2400-02SF
ENGINE 642.992

ENGINE 642.992
Model 906 with
BA46.30-N-1003- High pressure expansion hose to - Nm 38
01A power steering pump VDA pump Nm -
VT pump Nm -
VEHICLE SPEED SENSOR BOLT TORQUE SPECIFICATION - ENGINE 642.992

BA54.00-N-1003-01A Bolt, vehicle speed sensor to transmission Nm 10
housing
REFRIGERANT COMPRESSOR LINE-TO-COMPRESSORE FITTING TORQUE

SPECIFICATION - ENGINE 642.992
642.896/898/992/993 642.896/898/992/993
BA83.55-N-1004- Bolt, refrigerant lines to Nm 22 22
01L refrigerant compressor
satelettronica

2. Remove positive line (3) from battery box (6) and expose up to the starter.
satelettronica
Fig. 46: Grommet On Battery Box Component Location
3. Pull out securing clamp (7).

4. Pull clutch line (9) out of central clutch release bearing (8) and close off using suitable stop plugs.
Collect brake fluid which runs out in a suitable container.
plugs.

satelettronica
Fig. 47: Fuel Hoses & Fuel Lines Component Locations
For vehicles with code (J19) Automatic 1 day / 2 driver tachograph (EU), with code (JD1) EU digital
tachograph or with code (JD2) EU digital tachograph with RPM and additional recorder.
7. Remove speed sensor (B6) on transmission (14).
For vehicles without code (J19) Automatic 1 day / 2 driver tachograph (EUC) or without code (JD1)
EU digital tachograph or without code (JD2) EU digital tachograph with rpm and additional recorder.
8. Remove speed sensor (B6/12) on transmission (14).
For vehicles with code (J19) Automatic 1 day / 2 driver tachograph (EUC), with code (JD1) EU digital
tachograph or with code (JD2) EU digital tachograph with rpm and additional recorder.

satelettronica
Fig. 48: Lead Seal With Speed Sensor On Transmission Component Locations
Fig. 49: Coolant Hose, Coolant Pipe, Vacuum Line With Ground Line On Longitudinal Member
Component Locations
9. Disconnect electrical connector (16) and expose wiring harness (17) to O2 sensor.
10. Remove coolant hose (18) from coolant pipe (19).
12. Remove coolant hose (22) on heat exchanger.
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Fig. 50: Engine Wiring Harness Cable Ties Component Locations
14. Open cable ties (arrows) and expose engine wiring harness (25) in engine compartment.
16. Unlock electrical connector (28) and detach from CDI control unit (N3/20).
Fig. 51: High Pressure Expansion Hose On Power Steering Pump Component Locations
Fig. 52: Brackets, Automatic Oil Lines With Refrigerant Lines Component Locations
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With transmission 722
DISCONNECT/CONNECT HOSE & LINE CONNECTIONS - AR01.10-D-2400-02SG
ENGINE 642.896

ENGINE 642.896
Model 906 with
BA46.30-N-1003- High pressure expansion hose to - Nm 38
01A power steering pump VDA pump Nm -
VT pump Nm -
VEHICLE SPEED SENSOR BOLT TORQUE SPECIFICATION - ENGINE 642.896

BA54.00-N-1003-01A Bolt, vehicle speed sensor to Nm 10
transmission housing
REFRIGERANT COMPRESSOR LINE-TO-COMPRESSORE FITTING TORQUE

SPECIFICATION - ENGINE 642.896
642.896/898/992/993 642.896/898/992/993
BA83.55-N-1004- Bolt, refrigerant lines to Nm 22 22
01L refrigerant compressor
satelettronica

2. Remove positive line (3) from battery box (6) and expose up to the starter.
Fig. 54: Grommet On Battery Box Component Location
plugs.
4. Pull out securing clamp (7).
5. Pull clutch line (9) out of central clutch release bearing (8) and close off using suitable stop plugs.
Collect brake fluid running out in suitable container.
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Fig. 55: Fuel Hoses & Fuel Lines Component Locations
6. Remove electrical line (16) from oil filler pipe (17).

7. Disconnect electrical connector (18) from transmission (14)
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Fig. 56: Electrical Line On Oil Filler Pipe & Electrical Connector On Transmission Component
Locations
For vehicles with code (J19) Automatic 1 day / 2 driver tachograph (EU), with code (JD1) EU digital
tachograph or with code (JD2) EU digital tachograph with rpm and additional recorder.
9. Remove speed sensor (B6) from transmission (14) and lay down to side with electrical wiring harness
connected
On vehicles with transmission 711 and without code (BB3) Electronic stability program, without code
(J19) Tachograph 1 day / 2 driver automatic (EU) or without code (JD1) EU digital tachograph or without
code (JD2) EU digital tachograph with rpm and additional recorder without code (ZG1) All-wheel drive,
engageable or without code (ZG2) Permanent all-wheel drive or without code (ZG3) All-wheel drive,
engageable with gear reduction or without code (ZG4) Permanent all-wheel drive with gear reduction.

satelettronica
Fig. 57: Identifying Lead Seal With Speed Sensor On Transmission
connected
On vehicles with transmission 722 and with code (BB3) Electronic stability program with code (J19)
Tachograph 1 day / 2 driver automatic (EU) or with code (JD1) EU digital tachograph or with code (JD2)
EU digital tachograph with rpm and additional recorder without code (ZG1) All-wheel drive, engageable
or without code (ZG2)) Permanent all-wheel drive or without code (ZG3) All-wheel drive, engageable
with gear reduction or without code (ZG4) Permanent all-wheel drive with gear reduction.
connected
On vehicles with transmission 711 and with code (BB3) Electronic stability program, with code (J19)
Tachograph 1 day / 2 driver automatic (EU) or with code (JD1) EU digital tachograph or with code (JD2)
EU digital tachograph with rpm and additional recorder without code (ZG1) All-wheel drive, engageable
or without code (ZG2)) Permanent all-wheel drive or without code (ZG3) All-wheel drive, engageable
with gear reduction or without code (ZG4) Permanent all-wheel drive with gear reduction.

connected
On vehicles with transmission 711 and with code (J19) Tachograph 1 day / 2 driver automatic (EU) or
with code (JD1) EU digital tachograph or with code (JD2) EU digital tachograph with rpm and additional
recorder without code (ZG1) All-wheel drive, engageable or with code (ZG2) Permanent all-wheel drive
or with code (ZG3) All-wheel drive, engageable with gear reduction or with code (ZG4) Permanent all-
wheel drive with gear reduction.
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Fig. 58: Lambda Sensor Connector, Diesel Particulate Filter Differential Pressure Sensor With
Hose & Line Connection Component Locations
13. Disconnect connector from lambda sensor (B85/3x1) and expose electrical line (19) to lambda sensor.
14. Remove coolant hose (20) from exhaust gas recirculation, lay upward and fasten with cable tie
15. Remove vacuum hose (21) from aneroid capsule (22).
17. Disconnect electrical connector (31) am diesel particulate filter differential pressure sensor (B28/20).
18. Remove diesel particulate filter differential pressure sensor (B28/20) from bracket (32).
19. Remove bracket (33) from bracket (32), remove pressure lines (34) and fasten to engine with cable tie.

Fig. 59: Engine Wiring Harness, Electrical Connectors With Ground Line On Longitudinal
Member Component Locations
satelettronica
22. Open cable tie and expose engine wiring harness (25) in engine compartment.
24. Unlock electrical connector (28) and detach from CDI control unit (N3/30).
25. Fasten engine wiring harness (25) to engine with cable tie.
Fig. 60: Refrigerant Lines, High Pressure Expansion Hose On Power Steering Pump With
Mounting Bolts Component Locations
ATTACH, DETACH ENGINE REMOVAL FIXTURE - AR01.10-D-2400-09SF
satelettronica
Fig. 61: Identifying Support Plate (906 589 01 62 00)
1. Hook in removal fixture for engine (1) with mounting plate (2) in the engine crane (3).
Mobile workshop crane
Engine removal fixture for cars and vans

satelettronica
Fig. 62: Hooking Removal Fixture For Engine With Mounting Plate In Engine Crane
2. Position mounting plate (2) via the engine and hook into lifting eyes (arrows) on the engine.
Bolt (4) for the mounting plate (2) must be in the middle assembly position.
3. Remove in the reverse order.

satelettronica
Fig. 63: Locating Lifting Eyes With Mounting Plate
REMOVE/INSTALL ENGINE WITH TRANSMISSION - AR01.10-D-2401SF
ENGINES 642.896 in MODEL 906 with TRANSMISSION 711.685, 722.683
ENGINES 642.898 in MODEL 906 with TRANSMISSION 722.683

satelettronica
Fig. 64: Removing/Installing Engine With Transmission - Shown On Engine 642.992 With Transmission
711.660
Fig. 65: Identifying Engine With Transmission Remove/Install Components - Shown On Engine 642.992
With Transmission 711.660
MODIFICATION NOTES - CATALYTIC CONVERTER CLAMP
17.9.09 Value changed: Bolt, catalytic Engine 642.896 DIESEL PARTICULATE
converter clamp with diesel FILTER CLAMP TORQUE
particulate filter to muffler SPECIFICATIONS -
ENGINE 642
REMOVE/INSTALL ENGINE WITH TRANSMISSION - ENGINE 642 IN MODEL 906 WITH 711.6 &
722.6 TRANSMISSIONS
Remove/install
Risk of explosion caused No fire, sparks, open AS47.00-Z-0001-01A
by fuel igniting, risk of flames or smoking. Only
poisoning caused by pour fuels into suitable and
Risk of poisoning caused Only pour brake fluid into AS42.50-Z-0001-01A
by swallowing brake fluid. suitable and appropriately
satelettronica
Risk of injury caused by marked containers. Wear
brake fluid coming into protective clothing and eye
contact with skin and eyes. protection when handling
brake fluid.
Brake fluid notes AH42.50-P-0001-01A
Information on preventing AH54.00-P-0001-01A
damage to electronic
components due to
electrostatic discharge
1 Remove air filter housing AR09.10-D-1150SF
2 Remove engine hood AR88.40-D-3000SD
3 Remove front module AR88.30-D-1064SE
4 Remove holder (13) for air AR09.10-D-1150-03SF
filter housing on front plate
5 Remove trim panel on right AR01.20-D-5015SF
cylinder head cover
6 Remove trim panel on left AR01.20-D-5015SG
cylinder head cover
7 Place gearshift into neutral
8 Disconnect ground line, Do not remove bleed AR54.10-D-0005SD
terminal for positive line to line, do not remove battery,
the battery and unfasten only push battery to side.
battery Disconnect positive line
from terminal and expose
Risk of explosion caused No fire, sparks, open AS54.10-Z-0001-01A
by escaping oxyhydrogen flames or smoking. Wear
gas. Risk of injury caused acid-resistant gloves and
by caustic burns to eyes, clothing and safety glasses
skin and mucous with side guards.
membranes from battery Do not place any
electrolyte (contains diluted conductive objects on the
sulfuric acid) or metal battery and avoid any short
spatter due to short circuit. circuit from battery positive
Risk of burn injuries to ground.
caused by short circuit. Only fill liquid battery
Risk of poisoning caused electrolyte (diluted sulfuric
by swallowing battery acid) into suitable and
electrolyte (contains diluted appropriately marked
sulfuric acid) or absorption containers.
of lead over the skin or
orifices
9 Disconnect ground cable With code (E28) Additional
from additional battery battery 12 V 88 Ah
Notes on battery AH54.10-P-0001-01A
10 Lift/jack up vehicle and AR00.60-D-1000H
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secure against falling down
11 Disconnect hose and line Engine 642.896 AR01.10-D-2400-02SG
connections
Fig. 37
Engine 642.898/993 AR01.10-D-2400-02S
Fig. 37
Engine 642.992 AR01.10-D-2400-02SF
Fig. 37
12 Remove 2nd refrigerant With code (H08) High- AR83.55-D-5300WE
compressor performance air
conditioning with 2nd
refrigerant compressor
Hang 2nd refrigerant
compressor to side and
fasten. Do not separate
refrigerant lines.
13.1 Detach shift cables (1) from Transmission 711
transmission (4) Long-life grease
13.2 Unhook Bowden cable Transmission 722 AR27.60-D-0100-02C
selector lever from
transmission (4) Long-life grease
14 Remove clamp (8) and Engine 642.896
disconnect front exhaust
Engine 642.898/992
system (7) and rear exhaust
system (9) Engine 642.993
15 Remove propeller shaft
center support bearing (10)
on frame floor assembly
(11)
16 Detach power take-off With code (N05) PTO
connections countershaft (2c) without
flange or with code (N07)
PTO countershaft (2b) with
flange
17.1 Remove bolts (2), remove On vehicles without code
satelettronica
propeller shaft (3) on (ZG1) All-wheel drive,
transmission (4) and hang engageable, without code
to the side outside the (ZG2) Permanent all-wheel
working area drive, without code (ZG3)
All-wheel drive gear
reduction or without code
(ZG4) Permanent all-wheel
drive with gear reduction
17.2 Remove transfer case On vehicles with code AR28.10-D-0100H

(ZG1) All-wheel drive,
engageable, with code
(ZG2) Permanent all-wheel
drive, with code (ZG3) All-
wheel drive gear reduction
or with code (ZG4)
Permanent all-wheel drive
with gear reduction
18 Insert suitable wooden The transmission (4)
block between transmission must not lie on the
(4) and crossmember (12) crossmember (12) after
(arrow) loosening the rear engine
mount (6).
19 Unscrew bolts (5) and
detach rear engine mount
(6) on transmission (4)
20 Attach engine removal AR01.10-D-2400-09SF
fixture with engine crane Fig. 61
(18) to engine (17) Mobile workshop crane
Engine removal fixture for
passenger cars and
transporters
21 Remove bolts (14) on right
and left engine mount at the
front (15)
22 Lift engine (17) with Carefully lift out engine
transmission (4) and move (17) with transmission (4)
out to the front in order not to damage
surrounding components.
Aid of helper required.
Installation: When
replacing the engine (17),
modify detachable parts.
Ensure correct seating of
right and left engine mount
at the front (15) on front
satelettronica
axle carrier (16).
Mobile workshop crane
Engine removal fixture for
passenger cars and
transporters
24 Attach STAR Only if flywheel or
DIAGNOSIS, read out fault clutch plate has been
memory, delete if necessary replaced.
and perform initialization in
menu item Control unit
adaptation
Connect STAR AD00.00-D-2000-04SD
DIAGNOSIS and read out
fault memory
Risk of accident caused by Secure vehicle to prevent it AS00.00-Z-0005-01A
vehicle starting off by itself from moving by itself.
when engine is running. Wear closed and snug-
Risk of injury caused by fitting work clothes.
contusions and burns during Do not touch hot or rotating
starting procedure or when parts.
working near the engine as
it is running
25 Conduct engine test run and Carry out a visual
inspect engine (17) for inspection only.
leaks
DIESEL PARTICULATE FILTER CLAMP TORQUE SPECIFICATIONS - ENGINE 642.896,

642.898
Number Designation Engine 642.896 Engine 642.898
BA14.40-N-1003-01B Clamp connecting diesel Nm - 35
particulate filter to catalytic
converter
BA14.40-N-1012-01B Clamp, catalytic converter with Nm 35 -
diesel particulate filter to muffler
DIESEL PARTICULATE FILTER CLAMP TORQUE SPECIFICATIONS - ENGINE 642.992 &

642.993
Number Designation Engine 642.992 Engine 642.993
BA14.40-N-1003-01B Clamp connecting diesel particulate Nm 35 -
filter to catalytic converter
BA14.40-N-1018-01B Bolt, catalytic converter clamp to Nm - 35
diesel particulate filter
ENGINE MOUNTS, ENGINE SUPPORT TORQUE SPECIFICATIONS - ENGINE 642.9
satelettronica
Number Designation Engine 642.9
BA22.10-N-1004-01S Bolt, engine mount to front engine support Nm 58
BA22.10-N-1006-01S Bolt, rear engine mount to transmission Nm 40
PROPELLER SHAFT TORQUE SPECIFICATIONS - MODEL 906 WITHOUT CODES ZG1, ZG2,
ZG3, ZG4
Model 906
without code
ZG1/ZG2/
Number Designation ZG3/ZG4
BA41.10-N-1001- Propeller shaft on M10X1 Stage 1 Nm 15
01B transmission Stage 2 Degree 90
Screw head Stage 1 Nm 15
E14 Stage 2 Degree 70
M12X1.5 Screw Stage 1 Nm 15
headE14 Stage 2 Degree 50
E18 Stage 2 Degree 60
PROPELLER SHAFT TORQUE SPECIFICATIONS - MODEL 906 WITH CODES ZG1, ZG2, ZG3,
ZG4
Model 906 with code
Number Designation ZG1/ZG2/ZG3/ZG4
BA41.10-N- Propeller shaft on M10X1 Stage 1 Nm -
1001-01B transmission Stage 2 Degrees -
Screw headE14 Stage 1 Nm -
Stage 2 Degrees -
M12X1.5 Screw head Stage 1 Nm -
E14 Stage 2 Degrees -
Screw head Stage 1 Nm -
E18 Stage 2 Degrees -
PROPELLER SHAFT TORQUE SPECIFICATIONS - MODEL 906 WITH CODE ZL3

Model 906
with code
Number Designation ZL3
BA41.10-N- Propeller shaft on M10X1 Stage 1 Nm -
1001-01B transmission Stage 2 Degrees -
Screw headE14 Stage 1 Nm -
Stage 2 Degrees -
M12X1.5 Screw headE14 Stage 1 Nm 15
Stage 2 Degrees 50
satelettronica
E18 Stage 2 Degrees 60
PROPELLER SHAFT INTERMEDIATE BEARING TORQUE SPECIFICATIONS - MODEL 906

Number Designation Model 906
BA41.40-N-1001-01A Bolt, propeller shaft intermediate M10 Nm -
bearing to frame floor M12X1.5 Nm 135
POWER STEERING PUMP HIGH PRESSURE HOSE-TO-PUMP FITTING TORQUE

SPECIFICATIONS - MODEL 906 WITH ENGINE 642
Model 906 with
BA46.30-N-1003-01A High pressure expansion hose to - Nm 38
power steering pump VDA pump Nm -
VT pump Nm -
VEHICLE SPEED SENSOR TORQUE SPECIFICATIONS - MODEL 906 WITH ENGINE 642
BA54.00-N-1003-01A Bolt, vehicle speed sensor to transmission Nm 10
housing
REFRIGERANT COMPRESSOR LINE FITTING TORQUE SPECIFICATIONS - MODEL 906

WITH ENGINE 642, CODES H08, N63

642.896/898/992/993 Model 906 with engine
without code H08 or 642.896/898/992/993
Number Designation N63 with code H08 or N63
BA83.55-N-1004- Screw/bolt, refrigerant Nm 22 22
01L lines to refrigerant
compressor
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REPAIR MATERIALS - LONG LIFE GREASE

Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11
REMOVE/INSTALL ENGINE COVER - AR01.10-D-2405SF
ENGINE 642.992 /993 in MODEL 906

Fig. 68: Engine Cover Remove/Install Component Locations - Shown On Engine 642.992
satelettronica
REMOVE/INSTALL ENGINE COVER - ENGINE 642.992 /993 IN MODEL 906
Remove/install
1 Remove air intake hose downstream of air filter AR09.10-D-8030SF
2 Unhook coolant hose (4) on engine cover (1) (arrow)
3 Open quick-release couplings (2)
4 Lift engine cover (1) at the front and pull out of guides
(3)
REMOVE/INSTALL RIGHT CYLINDER HEAD COVER - AR01.20-D-5012SF
ENGINES 642.896 /898 /992 /993 in MODEL 906

satelettronica
Fig. 69: Right Cylinder Head Cover Remove/Install Component Locations - Shown On Engine 642.992
Fig. 70: Cylinder Head Cover Remove/Install Component Locations - Shown on Engine 642.992
REMOVE/INSTALL RIGHT CYLINDER HEAD COVER - ENGINES 642.896 /898 /992 /993 IN
MODEL 906
Remove/install
-
1 Remove rail (4) on right AR07.03-D-1010SF
cylinder head (18)
2 Remove bolts (2) and oil With engine 642.896/992/993
separator (3) Installation: Check sealing
ring and replace if necessary.
3 Remove injectors for right AR07.16-D-1000SF

cylinder head (18)
4 Disconnect electrical
connector (5) from
camshaft sensor (B6/20 or
B6/24)
5 Remove camshaft sensor Only when replacing
(B6/20 or B6/24) from cylinder head cover (1).
cylinder head cover (1)
6 Remove vacuum pump (7) AR43.05-S-1320SE
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7 Pull drain hose out of drain On engine 642.898 with
line (8) code (KL5) Fuel filter with
water separator
8 Remove bolt (9), remove With code (KL5) Fuel filter
drain pipe (8) from holder whit water separator
(10) and swivel to the side
9 Remove bolt (11) and turn
oil dipstick guide tube (12)
to the side
10 Remove engine wiring
harness (6) to cylinder head
cover (1) and expose
11.1 Unscrew bolts (14), remove With engine 642.898
oil separator (20) and vent Installation: Clean sealing
hose (21) from cylinder surfaces on oil separator (20)
head (18) and vent hose (21) and replace
sealing ring (16).
Check radial shaft sealing ring
(17) for damage, if applicable,
replace oil separator (20).
11.2 Remove bolts (14) and With engine 642.896/992/993

detach connection fitting Installation: Clean sealing
(15) from cylinder head surfaces on connecting fittings
(18) (15) and replace sealing ring
(16).
Check radial shaft sealing ring
(17) for damage; replace
connection fitting (15) if
necessary.
12 Loosen and remove bolts Installation: Pay attention AR01.20-D-5014-

(13) in stages and in to tightening procedure and 03SF
reverse order of the tightening instructions for bolts
tightening procedure, for a (13) so that cylinder head cover
cooled engine (1) is not warped and camshafts
are not damaged.
13 Press of cylinder head Press off cylinder head

cover (1) to the corners cover (1) from cylinder head
(arrows) carefully from the (18) with the greatest of care. If
cylinder head (18) using a cylinder head cover (1) is
suitable tool damaged then it can only be
replaced in combination with
the cylinder head (18).
Installation: Replace cover
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(19). Remove sealant residue
from sealing surfaces on
cylinder head cover (1) and
cylinder head (18).
Lubricate bearing points for
camshaft bearing.
Loctite sealant 5970
Notes on sealant path for AH01.30-N-1000-
cylinder head cover 08SE
Risk of accident caused by Secure vehicle to prevent it AS00.00-Z-0005-
vehicle starting off by itself from moving by itself. 01A
when engine is running. Wear closed and snug-fitting
Risk of injury caused by work clothes.
contusions and burns Do not touch hot or rotating
during starting procedure parts.
or when working near the
engine as it is running
15 Conduct engine test run
and check engine for leaks
in the area of the cylinder
head cover (1)
CRANKCASE VENTILATION, CYLINDER HEAD COVER TORQUE SPECIFICATIONS -

ENGINE 642
BA01.20-N-1001-01O Bolt, cylinder head cover to Stage 1, apply Nm 4
cylinder head Stage 2, initial Nm 6
torque
Stage 3, final Nm 8
torque
BA01.20-N-1005-01O Bolt connecting oil separator to cylinder head cover Nm 14
BA01.20-N-1006-01O Bolt, oil separator connection fitting on cylinder head Nm 9
BA01.20-N-1007-01O Bolt, oil separator to cylinder head Nm 9
CAMSHAFT POSITION SENSOR TORQUE SPECIFICATIONS - ENGINE 642

BA15.10-N-1002-03B Camshaft position sensor at cylinder head cover Nm 8
OIL DIPSTICK GUIDE TUBE TORQUE SPECIFICATIONS - ENGINE 642

BA18.40-N-1003-01L Bolt for oil dipstick guide tube Nm 12
REPAIR MATERIALS
satelettronica
BR00.45-Z-1013-01A Loctite sealant 5970 A 003 989 98 20
REMOVE/INSTALL LEFT CYLINDER HEAD COVER - AR01.20-D-5013SF
ENGINES 642.896 /898 /992 /993 in MODEL 906
Fig. 71: Left Cylinder Head Cover Remove/Install Component Locations - Shown On Engine 642.992
Fig. 72: Left Cylinder Head Cover Remove/Install Component Locations - Shown On Engine 642.896
satelettronica
REMOVE/INSTALL LEFT CYLINDER HEAD COVER - ENGINES 642.896 /898 /992 /993 IN MODEL
906
Remove/install
Risk of explosion caused No fire, sparks, open flames AS47.00-Z-0001-01A
by fuel igniting, risk of or smoking. Only pour fuels
poisoning caused by into suitable and
1 Drain coolant On engine 642.992/993 AR20.00-D-1140SD
2.1 Unscrew bolt (7) and push Engine 642.896/898
bracket (25) with coolant
hose (26) toward front
2.2 Remove screw/bolts (7, 9) Engine 642.992/993
and push coolant pipe (8)
to one side
3 Remove screw/bolts (3, 5)
and bracket (4)
4 Pull vacuum line (30) out Installation: Check seal
of brake booster (31) and on brake booster (31),
lay vacuum line (30) down replace seal if necessary.
to side
5 Remove rail (10) on left AR07.03-D-1010SF
cylinder head
6 Remove engine charge air
duct (2) and hang up to side
7 Remove steering reservoir
(6) and hang up to side
8 Remove injector on left AR07.16-D-1000SF
cylinder head
9 Remove bracket (29) with On engine 642.896/898
glow output stage (N14/3) Unclip coolant hose (27)
and lay down to side from bracket (28). Do not
disconnect electrical
connectors from glow
output stage (N14/3).
10 Remove pressure line (13)

from cylinder head cover
(1) and high-pressure pump
(19)
11.1 Pull retainer (33) and Engine 642.896/898/993
disconnect leak oil line (32) Plug connections with
from fuel line (12) stop plugs
satelettronica
Installation: Check
sealing rings for damage, if
necessary, replace leak oil
line (32).
Fig. 37
11.2 Open clamp and remove Engine 642.992
leak oil line (32) from fuel Plug connections with
line (12) stop plugs
Installation: Check
clamps, install new ones if
necessary.
Fig. 37
12 Remove fuel hose (14) to Close off fuel hoses (14,
high pressure pump (19) 15) using suitable stop
and fuel hose (15) on fuel plugs.
filter (16) Installation: Check
clamps, install new ones if
necessary.
Fig. 37
13 Remove engine wiring Installation: Check
harness (18) to cylinder retaining clips for engine
head cover (1) and expose wiring harness (18); replace
retaining clips if necessary.
14 Remove screw/bolts (11,
17) and push fuel line (12)
to one side
15 Undo screw/bolts (23) and
remove bracket (22)
16 Loosen and remove bolts Installation: Pay AR01.20-D-5014-03SF
(20) in stages and in attention to tightening
reverse order of the procedure and tightening
tightening procedure, for a instructions for bolts (20) so
cooled engine that cylinder head cover (1)
is not warped and camshafts
are not damaged.
17 Press off cylinder head Press off cylinder head

cover (1) to the corners cover (1) from cylinder
(arrows) carefully from the head with the greatest of
cylinder head using a care. If the cylinder head
suitable tool cover (1) is damaged then it
can only be replaced in
combination with the
cylinder head.
Installation: Remove
satelettronica
sealant residue from sealing
surfaces on the cylinder
head cover (1) and cylinder
head.
Lubricate bearing points for
camshaft bearing. Replace
cover (21, 24). Loctite 5970
sealant
Notes on sealant path for AH01.30-N-1000-08SE
cylinder head cover
and check engine for leaks
in the area of the cylinder
head cover (1)
CYLINDER HEAD COVER-TO-CYLINDER HEAD TORQUE SPECIFICATIONS - ENGINE 642

BA01.20-N-1001- Screw/bolt, cylinder head cover to Stage 1, apply Nm 4
01O cylinder head
Stage 2, initial Nm 6
torque
Stage 3, final Nm 8
torque
HIGH-PRESSURE LINE TORQUE SPECIFICATIONS - ENGINE 642

Engine
Number Designation 642.896/898/992/993
BA07.16-N- Pressure line to high- M14X1.5 Stage 1 Nm 20
1008-01B pressure pump Stage 2 Degrees 60
BA07.16-N- Screw/bolt, retaining clamp of high-pressure line to Nm 14
1015-01B cylinder head cover
CHARGE AIR PIPE/CHARGE AIR COOLING TORQUE SPECIFICATIONS - ENGINE 642

BA09.41-N-1002-01O Screw/bolt, holder to charge air distribution line Nm 9
BA09.41-N-1005-01O Screw/bolt from engine charge air duct upstream of Nm 9
satelettronica
charge air cooler to holder
OIL FILTER HOUSING TORQUE SPECIFICATIONS - ENGINE 642

BA18.20-N-1003-01O Bracket to oil filter housing and cylinder head Nm 14
cover
POWER STEERING PUMP TORQUE SPECIFICATIONS - ENGINE 642

BA46.30-N-1018-01A Screw/bolt, power steering oil reservoir to Nm 14
cylinder head cover and oil filter
REPAIR MATERIALS
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
BOLT TIGHTENING PROCEDURE FOR CYLINDER HEAD COVER - AR01.20-D-5014-03SF
CYLINDER HEAD COVER TORQUE SPECIFICATIONS - ENGINE 642

BA01.20-N-1001- Bolt, cylinder head cover to cylinder Stage 1, apply Nm 4
01O head Stage 2, initial Nm 6
torque
Stage 3, final torque Nm 8
The bolts must be tightened according to the sequence specified in the diagram. Loosen bolts in reverse
order. The bolts must not be retightened.
Right cylinder head cover
1. Tighten bolts (8 to 11) according to Stage 1.
satelettronica
2. Tighten bolts (1 to 30) to stage 2.
Fig. 74: Identifying Right Cylinder Head Cover Bolt Tightening Sequence
Left cylinder head cover

satelettronica
Fig. 75: Identifying Left Cylinder Head Cover Bolt Tightening Sequence
REMOVE/INSTALL CYLINDER HEAD COVER TRIM PANEL - AR01.20-D-5015SF
ENGINES 642 in MODEL 639 Cover on the right cylinder head cover
ENGINES 642.896 /898 /992 /993 in MODEL 906 Cover on right cylinder head cover
satelettronica
Fig. 76: Cylinder Head Cover Trim Panel Remove/Install Component Locations - Shown On Engine 642
In Model 906
REMOVE/INSTALL CYLINDER HEAD COVER TRIM PANEL - ENGINE 642, RIGHT CYLINDER
HEAD COVER
Remove/install
1 Remove air intake hose Model 906 AR09.10-D-8030SF
downstream of air filter
2 Remove engine trim panel Only with engine AR01.10-D-2405SF
642.992/993 in model 906
3 Unclip electric wiring Only with engine
harness (7) 642.896/898 in model 906
Installation: Make sure
that routing of electrical
wiring harness (7) is
correct.
4 Remove bolt (2)
5 Turn oil filler neck (1) anti-
clockwise and remove
upwards
6 Unclip cover (3) upward Installation: Position
soundproofing (4) correctly
in cover (3). Mounts (5) on
cover (3) must engage in
ball heads (6).
7 Unscrew oil filler cover (8)
on oil filler neck (1)
8 Insert oil filler cover (8) into For continuing work for
the opening on the cylinder which dirt can fall into the
head cover (9) camshaft case.
REMOVE/INSTALL CYLINDER HEAD COVER TRIM PANEL - AR01.20-D-5015SG
ENGINES 642 in MODEL 639 Cover on the left cylinder head cover
ENGINES 642.896 /898 /992 /993 in MODEL 906 Cover on left cylinder head cover
satelettronica
Fig. 77: Cylinder Head Cover Trim Panel Remove/Install Component Locations - Shown On Engine
642.992 In Model 906
Fig. 78: Wiring Harness & Front Soundproofing Component Locations
REMOVE/INSTALL CYLINDER HEAD COVER TRIM PANEL - ENGINE 642, LEFT CYLINDER
HEAD COVER
Remove/install
1 Remove windshield fluid Only on model 906 AR82.35-D-6000SD
reservoir windshield washer Do not detach lines
system and hand up to side connected
2 Remove turbocharger (1) Engine 642.896/898/993 in AR09.40-D-6920SG
noise damper model 906
3 Remove rear engine cover Only with engine 642 in model
639
4 Remove bolts (3, 4) Model 639
Model 906
5 Undo screw (5) by about 3 Model 639

revolutions
Model 906
satelettronica
6 Push engine charge air duct Carefully push engine
(6) to side charge duct (6) to side to
prevent damaging adjacent
components.
7 Remove wiring harness (10) Only on model 639
from bracket
8 Unclip cover (2) upward Installation: The sound
dampening (9) must be
correctly positioned in the
cover (2). Mounts (8) on cover
(2) must engage in ball heads
(7).
9 Remove front Only on model 639
soundproofing (11)
CHARGE AIR PIPE/CHARGE AIR COOLING TORQUE SPECIFICATIONS - ENGINE 642

BA09.41-N-1004-01O Bolt from engine charge air duct Nm 9
upstream of charge air cooler to cylinder
head cover
upstream of charge air cooler to holder
upstream of charge air cooler to engine
support
REMOVE/INSTALL OIL SEPARATOR - AR01.20-D-9750SF
ENGINES 642.896 /992 /993 in MODEL 906
satelettronica
Fig. 79: Oil Separator Remove/Install Component Locations - Shown On Engine 642.992
REMOVE/INSTALL OIL SEPARATOR - ENGINES 642.896 /992 /993 IN MODEL 906

Remove/install
1 Remove trim panel to right AR01.20-D-5015SF
cylinder head cover
2 Remove bolts (2) and pry Installation: Check
off oil separator (1) from sealing ring (3) and
cylinder head cover replace if necessary.
3 Remove clamp (5) and pull Only if oil separator (1)

vent hose (4) off of oil is replaced.
separator (1) Installation: Check
hose clamp (5), replace if
necessary.
Risk of accident caused by Secure vehicle to prevent AS00.00-Z-0005-01A
vehicle starting off by itself it from moving by itself.
contusions and burns during Do not touch hot or
starting procedure or when rotating parts.
it is running
5 Perform engine test run and
check engine around oil
separator (1) for leaks
OIL SEPARATOR TORQUE SPECIFICATIONS - ENGINE 642

BA01.20-N-1005-01O Bolt connecting oil separator to cylinder Nm 14
head cover
REMOVE/INSTALL OIL SEPARATOR - AR01.20-D-9750SG
satelettronica
Fig. 80: Oil Separator Remove/Install Component Locations - Shown On Engine 642.898 In Model 906
MODIFICATION NOTES - REMOVE/INSTALL OIL SEPARATOR

10.5.10 Method extended Operation step 2
REMOVE/INSTALL OIL SEPARATOR - ENGINES 642.898 IN MODEL 906

Remove/install
1 Remove trim panel to right AR01.20-D-5015SF
cylinder head cover
connector from vent line
heater element
3 Unscrew bolts (2), remove Installation: Clean
oil separator (1) and vent sealing surfaces on oil
hose (5) from cylinder head separator (1) and cylinder
head and replace sealing
ring (3).
Check radial shaft sealing
ring (4) for damage, if
applicable replace oil
separator (1).
4 Remove clamp (6) and Only if oil separator (1)

disconnect vent hose (5) is replaced.
from oil separator (1) Installation: Check
hose clamp (6), replace if
necessary.
satelettronica
it is running
check engine around oil
separator (1) for leaks
OIL SEPARATOR TORQUE SPECIFICATIONS - ENGINES 642.898 IN MODEL 906

BA01.20-N-1007-01O Bolt, oil separator to cylinder head Nm 9
REMOVE/INSTALL THE CYLINDER HEAD - AR01.30-D-5770SF
ENGINES 642.896 /898 /992 /993 in MODEL 906

Fig. 81: Cylinder Head Remove/Install Component Locations - Shown On Engine 642.992
satelettronica
Fig. 82: Identifying Left Cylinder Head, Gasket, Crankcase With Cylinder Head Bolts
REMOVE/INSTALL THE CYLINDER HEAD - ENGINES 642.896 /898 /992 /993 IN MODEL 906
Remove/install
1 Remove charge air Engine 642.896/898 AR09.41-D-1310SG
manifold
2 Remove oil filter housing AR18.20-S-3471SE
(2)
3 Remove high-pressure AR07.02-D-1020SF
pump (16)
4 Remove camshafts in left AR05.20-D-6992SF
cylinder head (10)
5 Remove hydraulic valve Installation: Hydraulic
play compensation element valve play compensation
in left cylinder head (10) elements must be installed
again in the same position
when using the old left
cylinder head (10).
6 Remove bolts (6, 7) and Installation: Install
shield (8) different sizes of bolts (6,
7).
7 Remove bolt (3) and lay
fuel lines (4) to one side
8 Remove bracket (9)
9 Pull out slide rail bolt at left Installation: Screw AR01.30-S-5800-04SE
cylinder head (10) suitable bolt into slide rail
bolt, drive slide rail bolt
into left cylinder head (10)
and remove bolt again.
satelettronica
Fig. 83
10 Loosen and remove Installation: Observe AR01.30-S-5800-01SE
cylinder head bolts (13, 14) tightening procedure and
in stages and in reverse tightening instructions of
order of the tightening cylinder head bolts (13,
procedure, for a cooled 14), so that a distortion of
engine the left cylinder head does
not arise. 10
Installation: Lightly
lubricate thread and bolt
head contact surface for
cylinder head bolts (13,
14).
11 Remove left cylinder head Installation: Replace

(10) and cylinder head cylinder head gasket (12).
gasket (12) from crankcase
(15)
12 Remove exhaust manifold Only when replacing
(5) from left cylinder head left cylinder head (10).
(10) Installation: Install
new seal
13 Cover cylinder bores and

contact surface on cylinder
crankcase (15)
Clean
14 Clean threaded hole for Blow dirt or fluid out of
cylinder head bolts (13, 14) the threaded holes.
in crankcase (15)
15 Clean sealing surfaces at
left cylinder head (10) and
at crankcase (15)
Checking
16 Check stud bolts on exhaust Installation: Replace
manifold (5) on left damaged stud bolts.
cylinder head (10) for
damage
17 Inspect cylinder head bolts AR01.30-S-5800-03SE
(13), replace if necessary
18 Check left cylinder head Reworking of sealing
(10) and cylinder crankcase surfaces on the left
(15) for damage cylinder head (10) or on
crankcase (15) is not
permissible; replace left
satelettronica
cylinder head (10) or
crankcase (15).
it is running
check engine around left
cylinder head (10) for leaks
CYLINDER HEAD BOLT LENGTH SPECIFICATIONS - ENGINE 642 IN MODEL 906

Engine 642 in
Number Designation model 906
BE01.30-N-1001-04A Cylinder head bolt Thread diameter M 12
Length (L) when new mm 205
Max. length (L) mm 207
See picture Fig. 95
CYLINDER HEAD BOLT TORQUE SPECIFICATIONS - ENGINE 642 IN MODEL 906

Engine 642 in
BA01.30-N-1001-01Q Bolt, cylinder head to M8 Nm 20
crankcase M12 Stage 1 Nm 10
Stage 2 Nm 60
Stage 3 Degrees 90°
EXHAUST MANIFOLD NUT TORQUE SPECIFICATIONS - ENGINE 642 IN MODEL 906

Engine 642 in
BA14.10-N-1001-01O Nut, exhaust manifold to cylinder Stage 1 Nm 25
head Stage 2 Nm -
BA14.10-N-1002-01O Stud bolt, exhaust manifold to cylinder head Nm 20
satelettronica
Fig. 83: Identifying Puller (605 589 00 33 00)
REMOVE/INSTALL RIGHT CYLINDER HEAD - AR01.30-D-5780SF
ENGINES 642.896 /898 /992 /993 in MODEL 906

Fig. 84: Right Cylinder Head Remove/Install Component Locations - Shown On Engine 642.992
Fig. 85: Exhaust Manifold, Engine Wiring Harness, Ground Line With Mount Component Locations -
Shown On Engine 642.896
satelettronica
Fig. 86: Identifying Right Cylinder Head, Gasket, Crankcase With Cylinder Head Bolts
REMOVE/INSTALL RIGHT CYLINDER HEAD - ENGINES 642.896 /898 /992 /993 IN MODEL 906
Remove/install
1 Remove mixing chamber Engine 642.896/898 AR09.20-D-1320SG
(9)
2 Remove charge air Engine 642.896/898 AR09.41-D-1310SG
manifold
3 Remove exhaust gas With engine AR14.20-D-1050SG
recirculation 642.896/898/993
4 Remove engine wiring With engine 642.896
harness (8) from bracket
(16)
5 Remove bracket (16) on With engine
exhaust gas recirculation 642.896/898/993
from right cylinder head
(1)
6 Remove ground line (18) With engine
from right cylinder head 642.896/898/993
(1)
7 Remove bracket (17) on With engine
exhaust pipe from right 642.896/898/993
cylinder head (1)
8 Remove exhaust manifold With engine
(5) from right cylinder 642.896/898/993
head (1) and lay down to Installation: Install new
side gasket
9 Remove camshafts in right AR05.20-D-6992SF
satelettronica
cylinder head (1)
10 Remove hydraulic valve Installation: Hydraulic
play compensation element valve play compensation
in right cylinder head (1) elements must be installed
again in the same position
when using the old right
cylinder head (1).
11 Unscrew bolt (6) from With engine 642.992
bracket (7)
12 Disconnect electrical With engine 642.992
connector to glow output
stage (N14/3) and remove
glow output stage (N14/3)
with holder (7)
13 Disconnect electrical Fig. 88
connector to glow plugs
(arrows) and expose engine
wiring harness (8) on right
cylinder head (1)
14 Pull out slide rail bolt (1) at Installation: Screw AR01.30-S-5800-04SE
right cylinder head suitable bolt into slide rail
bolt, drive slide rail bolt into
right cylinder head (1) and
remove bolt again.
Fig. 83
15 Loosen and remove Installation: Observe AR01.30-S-5800-01SE
cylinder head bolts (13, 14) tightening procedure and
in stages and in reverse tightening instructions of
order of the tightening cylinder head bolts (13, 14),
procedure, for a cooled so that a distortion of the
engine right cylinder head does not
arise 1.
Installation: Lightly
lubricate thread and bolt
head contact surface for
cylinder head bolts (13, 14).
16 Remove right cylinder head Installation: Replace

(1) and cylinder head cylinder head gasket (11).
gasket (11) from crankcase
(15)
17 Remove exhaust manifold With engine 642.992
(5) from right cylinder Only when replacing the
head (1) right cylinder head (1).
Installation: Install new
satelettronica
gasket
18 Remove bolts (4) and Only when replacing the

holder (3) for exhaust right cylinder head (1).
system on right cylinder
head (1)
19 Cover cylinder bores and
contact surface on cylinder
crankcase (15)
Clean
20 Clean threaded hole for Blow dirt or fluid out of
cylinder head bolts (13, 14) the threaded holes.
in crankcase (15)
21 Clean sealing surfaces at
right cylinder head (1) and
at crankcase (15)
Checking
22 Check stud bolts on On engine 642.896/898/993,
exhaust manifold (5) on on engine 642.992, if
right cylinder head (1) for exhaust manifold (5) is
damage removed.
Installation: Replace
damaged stud bolts.
23 Check exhaust manifold (5) Installation: If there is

for crack formation and damage or crack formation,
damage replace exhaust manifold
(5).
24 Inspect cylinder head bolts AR01.30-S-5800-03SE
25 Check right cylinder head Reworking of sealing
(1) and cylinder crankcase surfaces on the right
(15) for damage cylinder head (1) or on
crankcase (15) is not
permissible; replace right
cylinder head (1) or
crankcase (15).
satelettronica
check engine around right
cylinder head (1) for leaks
CYLINDER HEAD BOLT LENGTH SPECIFICATIONS - ENGINES 642.896 /898 /992 /993 IN
MODEL 906
Engine 642 in
Length (L) when mm 205
new
See picture Fig. 95
CYLINDER HEAD BOLT TORQUE SPECIFICATIONS - ENGINES 642.896 /898 /992 /993 IN
MODEL 906
Engine 642 in
BA01.30-N-1001- Bolt, cylinder head to M8 Nm 20
01Q crankcase M12 Stage 1 Nm 10
Stage 2 Nm 60
EXHAUST MANIFOLD NUT TORQUE SPECIFICATIONS - ENGINES 642.896 /898 /992 /993 IN
MODEL 906
Engine 642 in
BA14.10-N-1001-01O Nut, exhaust manifold to cylinder Stage 1 Nm 25
head Stage 2 Nm -
BA14.10-N-1002-01O Stud bolt, exhaust manifold to cylinder head Nm 20
FRONT EXHAUST SYSTEM BRACKET TORQUE SPECIFICATIONS - ENGINES

642.896 /898 /992 /993 IN MODEL 906
Number Designation Engine 642.896/898 Engine 642.992/993
BA49.10-N-1004- Bolt, front exhaust system Nm 8 8
01M bracket to cylinder head
satelettronica
Fig. 88: Identifying Pliers (611 589 00 37 00)
REMOVE/INSTALL CYLINDER HEAD AT CRANKCASE - AR01.30-D-5800-11WE
REPAIR MATERIALS - SEALANT

Take off cylinder head.

1. Attach timing chain (2) with cable tie (3) to the tensioning rail (4).
2. Lift out cylinder head (1) upwards.
Carefully lift out cylinder head (1) upwards. The surrounding components can get damaged otherwise.
Aid of helper required.
satelettronica
Fig. 89: Connecting Timing Chain With Cable Tie To Tensioning Rail
Install cylinder head.
3. Apply sealant evenly in the form of a bead with a height of about 1.0 mm and a width of about 2.0 mm
along the lines (arrows).
Do not spread the sealant. Put cylinder head gasket in place on the cylinder crankcase (6) and the
timing case cover (5) within a period of 10 minutes.
satelettronica
Fig. 90: Locating Cylinder Head Sealant Applying Areas At Rear of Engine Block
4. Place cylinder head gasket (8) on the cylinder crankcase.
Pay attention to installation position of cylinder head gasket (8).
5. Place cylinder head (1) on the crankcase
The dowel pins (7) must engage in the fitted bores in the cylinder head (1).
6. Remove cable tie (3), remove timing chain (2) from tensioning rail (4) and take out of the timing chain
chamber.
Secure timing chain (2) against falling down.

satelettronica
Fig. 91: Cylinder Head, Gasket, Cable Tie, Timing Chain & Tensioning Rail Component Locations
REMOVE/INSTALL CYLINDER HEAD - AR01.30-D-5800SD
ENGINES 646.984 /985 /986 /989 /990 in MODEL 906

satelettronica
Fig. 92: Cylinder Head Remove/Install Component Locations - Shown On Engine 646.985
MODIFICATION NOTES
20.1.10 "Detach/attach bracket of oil dipstick guide tube for automatic transmission at Step 9
cylinder head" added
REMOVE/INSTALL CYLINDER HEAD - ENGINES 646.984 /985 /986 /989 /990 IN MODEL 906
Remove/install
1 Drain coolant AR20.00-D-1140SD
2.1 Remove top section of With engine 646.984/985/986
charge air manifold
2.2 Remove charge air On engine 646.989/990
manifold
3 Remove camshaft housing Engine 646
4 Remove intermediate gear Engine 646
of high-pressure pump
5 Remove screws/bolts (3)
and place rail (2) to one
side
6 Disconnect electrical With code (Z42) Qualification
connector (4) as passenger car
7 Remove coolant hoses (5) Catch escaping coolant
on temperature control with rags.
switch housing (6)
Installation: Check
coolant hose clamp (5) for
damage; replace if necessary.
8 Remove oil feed line of Engine 646.984/985/989/990
turbocharger (7) and seal
openings with suitable stop Set of stop plugs Fig. 37
plugs
9 Remove bracket of oil With transmission 722
dipstick guide tube (1) for
A/T on cylinder head (11)
10.1 Remove screws/bolts (8) at Engine 646.984/985/989/990
exhaust manifold (9)
10.2 Remove turbocharger (7) With engine 646.986
with exhaust manifold (9)
11 Loosen cylinder head bolts Loosen cylinder head bolts
(10) and bolts (arrows) in (10) and bolts (arrows) for a
stages and remove (Engine cooled off engine in reverse
646)) order to the tightening
satelettronica
procedure in order to avoid
stress in cylinder head (11).
See Tightening procedure for
cylinder head bolts
12 Take off cylinder head Aid of helper required.

(11) Loosen a firmly seated
cylinder head (11) through
slight blows with a plastic
mallet at the outer edges.
Installation: Clean and
check sealing surface on
cylinder head (11), if
necessary, replace cylinder
head (11).
When fitting on the cylinder
head (11) pay attention to
fitting sleeves.
When fitting on the cylinder
head (11) pay attention to
detachable parts.
13 Remove cylinder head Installation: Clean sealing
gasket surface on cylinder crankcase.
Replace cylinder head gasket
and observe correct
installation position of
cylinder head gasket.
14 Inspect cylinder head bolts AR01.30-S-5800-03SD
itself when engine is Wear closed and snug-fitting
running. Risk of injury work clothes.
caused by contusions and Do not touch hot or rotating
burns during starting parts.
procedure or when
it is running
16 Perform engine test run
and check engine around
cylinder head (11) for
leaks
satelettronica
CYLINDER HEAD BOLT LENGTH SPECIFICATIONS - ENGINES 646.984 /985 /986 /989 /990 IN
MODEL 906
Engine 646 in
Length (L) when new mm 102
See picture Fig. 95
CYLINDER HEAD BOLT TORQUE SPECIFICATIONS - ENGINES 646.984 /985 /986 /989 /990 IN
MODEL 906
Engine 646 in
BA01.30-N-1003-01K Bolt, cylinder head to timing M8 Nm 20
case cover
BA01.30-N-1004-01K Bolt, cylinder head to M12 Stage 1 Nm 15
crankcase Stage 2 Nm 60
Stage 5 - -
Stage 6 - -
COMMON RAIL RAIL-TO-CYLINDER HEAD BOLT TORQUE SPECIFICATIONS - ENGINES

646.984 /985 /986 /989 /990 IN MODEL 906
Number Designation Engine 646 in model 906
BA07.16-N-1007-01A Bolt, rail to cylinder head Nm 14
TURBOCHARGER-TO-EXHAUST MANIFOLD TORQUE SPECIFICATIONS - ENGINES
646.984 /985 /986 /989 /990 IN MODEL 906
Engine 646.984/985 Engine 646.989/990
Number Designation in model 906 in model 906
BA09.40-N-1001- Flange connection, exhaust Nm 30 30
01O manifold to turbocharger
satelettronica
TIGHTENING PROCEDURE FOR CYLINDER HEAD BOLTS - AR01.30-S-5800-01SE
CYLINDER HEAD BOLT TORQUE SPECIFICATIONS - ENGINE 642 IN MODEL 906

Engine 642 in Engine 642 in
Number Designation model 906 model 639
BA01.30-N- Bolt, cylinder head to M8 Nm 20 20
1001-01Q crankcase M12 Stage 1 Nm 10 10
Stage 2 Nm 60 60
Stage 3 Degrees 90° 90
Cylinder Head Tightening Procedure

Fig. 94: Cylinder Head Bolt Tightening Sequence & Bolt Identification - Engine 642 in Model 906
satelettronica
The following sequence of work steps must be observed to avoid consequential damage.
Loosen bolts (10 to 11) in reverse order.
1. Tighten bolts (10) according to Stage 1.

2. Tighten bolts (10) according to Stage 2.
3. Tighten bolts (11).
4. Tighten bolts (10) with specified tightening angle according to Stage 3.
7. Retighten bolts (11).
CHECK CYLINDER HEAD BOLTS - AR01.30-S-5800-03SD
CHECK VALUES FOR CYLINDER HEAD BOLT TORQUE - ENGINES 646 & 651 IN MODELS 636,
639, 900, 906
model 636, Engine 646 in models 639,
Number Designation 639 model 906 900, 906
BE01.30-N- Cylinder head Thread diameter M 12 12 12
1001-04A bolt Length (L) when mm 102 102 226 (± 0.5)
new
Max. length (L) mm 104 104 227.5
See picture AR01.30-S- AR01.30-S- AR01.30-S-
5800-03SD 5800-03SD 5800-03SD
1. Measure length (L). See Fig. 95.
If the length (L) exceeds the maximum permissible dimension then the cylinder head bolts must be
replaced.
Fig. 95: Identifying Cylinder Head Bolt Length L Measuring Points
satelettronica
CHECK CYLINDER HEAD BOLTS - AR01.30-S-5800-03SE
CYLINDER HEAD BOLT LENGTH INSPECTION - ENGINE 642 IN MODELS 639, 906
BE01.30-N-1001- Cylinder head bolt Thread diameter M 12 12
04A Length (L) when mm 205 205
new
Max. length (L) mm 207 207
See picture AR01.30-S-5800- AR01.30-S-5800-
03SD 03SD
1. Measure length (L). See Fig. 96.
If the length (L) of cylinder head bolts exceeds the maximum permissible dimension then the cylinder
head bolts must be replaced.
Fig. 96: Identifying Cylinder Head Bolt Length L Measuring Points
PULL OUT GUIDE RAIL PINS AT CYLINDER HEAD - AR01.30-S-5800-04SE
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1. Pull out guide rail pin (7) using extractor.
Fig. 98: Guide Rail Pin Component Location
REMOVE/INSTALL END COVER TOGETHER WITH SHAFT SEAL - AR01.40-D-8920SF

satelettronica
Fig. 99: End Cover, Oil Pan, Cylinder Case With Screw Component Locations - Engine 642, Model 906;
Transmissions 711.6, 722.6
REMOVE/INSTALL END COVER TOGETHER WITH SHAFT SEAL - ENGINE 642, MODEL 906;
TRANSMISSIONS 711.6, 722.6
Removing
1.1 Remove flywheel Transmission 711 AR03.30-D-8002SF
1.2 Remove driven plate Transmission 722 AR03.30-S-8003SE
2 Remove bolts (4) for end
cover (1)
3 Warm up end cover (1) Use a hot air blower.
and remove Hot air blower
Fig. 100
Install
4 Apply sealant on the end Replace end cover (1). AR03.20-S-3063-01SE
cover (1) and tighten end Clean sealing surfaces on
cover (1) using bolts (4) crankcase (3) and oil pan
(2).
Fig. 101
Cleaner from package
Loctite 7200
5.1 Install flywheel Transmission 711 AR03.30-D-8002SF
5.2 Install drive plate Transmission 722 AR03.30-S-8003SE
Checking
6 Check engine oil level, The engine oil level
correct if necessary must not be above the
maximum mark. This can
lead to engine damage.
Engine oil,
Specifications for
Operating Fluids
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
it is running
satelettronica
and check engine in the
area of joint between
transmission and engine
for leaks
CRANKCASE REAR END COVER TORQUE SPECIFICATIONS - ENGINE 642, MODEL 906
Engine 642 in
BA01.40-N-1001-01S Bolt connecting rear end cover to Stage 1 Nm 8
crankcase Stage 2 Nm 10
ENGINE OIL CAPACITY & SPECIFICATION - ENGINE 642, MODEL 906

Engine 642 in
model 906 Engine 642 in
without model 906 with
Number Designation particulate filter particulate filter
BF18.00-N- Engine oil Filling capacity (oil Liters 12.5 12.5
1001-01L and filter change)
Specifications for Sheet BB00.40-P-0228- -
Operating Fluids 03A
Sheet BB00.40-P-0228- -
05A
Sheet BB00.40-P-0228- BB00.40-P-0228-
51A 51A
Sheet BB00.40-P-0229- -
03A
Sheet BB00.40-P-0229- -
05A
Sheet BB00.40-P-0229- BB00.40-P-0229-
31A 31A
Sheet BB00.40-P-0229- BB00.40-P-0229-
51A 51A
Fig. 100: Identifying Removal & Installation Tool (116 589 01 62 00)
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Fig. 101: Identifying Insertion Tool (271 589 00 43 00)
REPAIR MATERIALS
BR00.45-Z-1028-04A Cleaner from package Adolf Wurth GmbH & Co. KG
Reinhold-Wurth-Str. 12-17
74653 Kunzelsau-Gaisbach
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
REMOVE/INSTALL TIMING CASE COVER - AR01.40-S-8000SE
ENGINES 642.896 /898 /992 /993 in MODEL 906
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Fig. 102: Timing Case Cover Remove/Install Component Locations - Shown On Engine 642 In Model 639
MODIFICATION NOTES
3.3.10 Remove viscous fan clutch - added Step 1
REMOVE/INSTALL TIMING CASE COVER - ENGINES 642.896 /898 /992 /993 IN MODEL 906, 639
Remove/install
1 Remove viscous fan clutch AR20.40-D-5660SF
2 Crank engine and place The top dead center
piston of cylinder 1 to marking on the vibration
ignition TDC damper must be flush with
the stay on the timing case
cover (2).
Model 906 AR01.00-D-0100SF
3 Remove front radial shaft Installation: Only AR03.20-S-3000SE
sealing ring install front radial shaft
sealing ring after installing
timing case cover (2).
4 Remove fan drive Model 906 AR13.22-D-3370SF
5 Remove poly-V belt AR13.25-S-3200SE
tensioning device
6 Remove guide pulley (1)
7 Remove oil pan bottom Model 906 AR01.45-D-7555SF
section
8 Remove timing case cover The fitting sleeves (3)
(2) with fitting sleeves (3) are no longer required.
and sealing surfaces Installation: Apply
sealant, then place timing
case cover (2) in place and
tighten bolts (4) on timing
case cover (2) finger-tight.
Loosen lower bolts (4)
again and insert centering
sleeve in the timing case
cover (2). Tighten all bolts
on timing case cover (2)
and remove centering
sleeve.
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Model 639
Model 906
Centering sleeve Fig. 103
Sealant
Notes on sealant path for AH01.40-N-1000-01SE
timing case cover
TIMING CASE COVER-TO-CRANKCASE TORQUE SPECIFICATIONS - ENGINES 642 IN

MODEL 906, 639
BA01.40-N-1002- Bolt, timing case cover to Nm 10 10
01S cylinder crankcase
OIL PAN-TO-TIMING CASE COVER BOLT TORQUE SPECIFICATIONS - ENGINE 642 IN

MODEL 906
Engine 642 in
BA01.45-N-1007-01Q Bolt, oil pan to timing case cover M6 Nm 14
OIL PAN-TO-TIMING CASE COVER BOLT TORQUE SPECIFICATIONS - ENGINE 642 IN

MODEL 639
Engine 642 in
BA01.45-N-1010-01R Bolt, oil pan to timing case cover M6 Nm 14
GUIDE PULLEY TO TIMING CASE COVER BOLT TORQUE SPECIFICATIONS - ENGINE 642
BA13.25-N-1002-01Q Bolt, guide pulley to timing case cover Nm 28
Fig. 103: Identifying Centering Sleeve (642 589 00 14 00)
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REPAIR MATERIALS
REMOVE/INSTALL OIL PAN - AR01.45-D-7500SF
ENGINES 642.896 /898 /992 /993 in MODEL 906

Fig. 104: Oil Pan Remove/Install Component Locations - Engines 642.896 /898 /992 /993 in Model 906
satelettronica
Fig. 105: Removing/Installing Oil Pan Component Locations - Engines 642.896 /898 /992 /993 in Model
906
REMOVE/INSTALL OIL PAN - ENGINES 642.896 /898 /992 /993 IN MODEL 906
Remove/install
1 Remove the oil dipstick AR18.40-D-3510SF
guide tube
2 Remove refrigerant For code (HH9) Regulated AR83.55-D-5300US
compressor (A9) and hang air conditioning,
up to the side with (Tempmatic)
connected lines Do not suction off
refrigerant.
3 Remove electrical wiring
harness (6) with holder (7)
to oil pan (1) and expose
4 Remove electrical wiring
harness (6), electrical line
(13) from bracket (12) and
expose
5 Detach the bracket (12) at
the oil pan (1)
6 Remove oil pan bottom AR01.45-D-7555SF
section (2)
7 Remove bolts (3, 5) and oil Installation: Clean oil
intake tube (4) strainer in oil intake tube
(4). Replace sealing ring
on oil intake tube (4).
8 Remove end cover (9) with AR01.40-D-8920SF
radial shaft sealing ring
9 Attach supports (11) to both The supports (11) serve
sides of crankcase (8) and as stop for the oil pan (1).
remove wooden block (10) They must not get bent
under the oil pan (1) and must lie evenly on the
crankcase (8).
Fig. 106
10 Remove bolts for oil pan Installation: Observe
(1) different bolt lengths and
bolt diameters.
11 Pry off oil pan (1) to the Installation: Clean

cutouts (arrows) and take sealing surfaces to oil pan
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off (1) and on crankcase (8).
Apply sealing compound.
Lay oil pan (1) on both
supports (11), center on
the left and right on
crankcase (8) and push
upwards to crankcase (8).
Helper required
Fig. 106
Notes on sealant path for oil AH01.45-N-0001-01SF
pan
it is running
check engine in area of the
oil pan (1) for leaks
OIL PAN TORQUE SPECIFICATIONS - ENGINE 642 IN MODEL 906
Engine 642 in
BA01.45-N-1001-01Q Oil pan top section to cylinder block top M6 Nm 14
at front
BA01.45-N-1002-01Q Oil pan top section to cylinder crankcase M8 Nm 20
on transmission side
BA01.45-N-1004-01Q Bracket on top part of oil pan M6 Nm 8
BA01.45-N-1006-01Q Bolt, oil pan to cylinder crankcase M6 Nm 14
M8 Nm 20
BA01.45-N-1007-01Q Bolt, oil pan to timing case cover M6 Nm 14
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Fig. 106: Identifying Support (642 589 03 40 00)
REPAIR MATERIALS
REMOVE/INSTALL BOTTOM PART OF OIL PAN - AR01.45-D-7555SF
ENGINES 642.896 /898 /992 /993 in MODEL 906

Fig. 107: Oil Pan Bottom Part Remove/Install Component Locations - Engines 642.896 /898 /992 /993 in
Model 906
Fig. 108: Oil Pan Bottom Section Component Location - Engines 642.896 /898 /992 /993 in Model 906
satelettronica
REMOVE/INSTALL BOTTOM PART OF OIL PAN - ENGINES 642.896 /898 /992 /993 IN MODEL 906
Remove/install
1 Drain off engine oil; catch it AP18.00-D-0101H
if necessary
2 Remove carrier for 2nd Only for code (H08) AR83.55-D-5301WE
refrigerant compressor Heavy duty air
conditioning
connector (3) from engine
oil sensor (B40 or B40/8)
4 Remove bolts (2)
5 Pry off oil pan bottom Installation: Clean
section (1) in the area of the sealing surfaces of oil pan
cutouts (arrow) (1) and oil pan bottom
section and apply sealant.
Notes on sealant path for oil AH01.45-N-0001-01SF
pan
vehicle starting off by itself it moving off.
when engine is running. Wear closed and close-
satelettronica
it is running
7 Conduct engine test run and
check engine for leaks in
the area of the oil pan
bottom section (1)
OIL PAN BOTTOM SECTION TO OIL PAN TOP SECTION TORQUE SPECIFICATIONS -
ENGINE 642 IN MODEL 906
Engine 642 in
BA01.45-N-1003- Oil pan bottom section to oil pan top M6 Nm 12
01Q section
REPAIR MATERIALS
TEST & ADJUSTMENT VALUES

COMPRESSION PRESSURE - BE01.00-N-1000-01L
ENGINE 611.980 in MODEL 638

ENGINE 646 in MODEL 636, 639
ENGINE 642, 646.984/985/986/989/990, 651 in MODEL 906
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 642, ENGINE 611.980 IN MODEL 638

ENGINE 611.980 in
Number Designation MODEL 638 ENGINE 642
BE01.00-N-1001-01L Compression pressure: bar 29...35 27...32
installation tolerance or new
value
BE01.00-N-1002-01L Compression pressure: wear bar approx.18 -
limit or limit value
BE01.00-N-1003-01L Compression pressure: bar < or =3 < or =3
permissible difference between
individual cylinders
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COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 646 IN MODELS 636, 639, 906
ENGINE 646 in ENGINE
MODEL 636, 646.984/985/986/989/990 in
Number Designation 639 MODEL 906
BE01.00-N-1001- Compression pressure: bar 29...35 29...35
01L installation tolerance or new
value
BE01.00-N-1002- Compression pressure: wear bar 18 18
01L limit or limit value
BE01.00-N-1003- Compression pressure: bar 3 < or =3
01L permissible difference
between individual
cylinders
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 651 IN MODELS 639, 900, 906

ENGINE 651 in
Number Designation MODEL 639, 900, 906
BE01.00-N-1001-01L Compression pressure: installation bar 23...30
tolerance or new value
BE01.00-N-1002-01L Compression pressure: wear limit or bar -
limit value
BE01.00-N-1003-01L Compression pressure: permissible bar < or =3
difference between individual cylinders
COMPRESSION PRESSURE - BE01.00-P-1000-01A
ENGINE 601, 602 (except 602.98), 603, 604, 605, 606, 611.960/961/962/981/983/987,
612.961/962/963/965/966/967/981, 613.960/961, 628.960/961/962/963, 629, 640, 642,
646.8/951/961/962/963/966, 647.961/981, 648.960/961, 651
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 601, 602 (EXCEPT 602.98), 603

ENGINE 601, 602 ENGINE 601, 602
(except 602.98), 603 (except 602.98), 603
With compression With compression
recorder 001 589 47 recorder 001 589 78
Number Designation 21 00 21 00
BE01.00-P-1001- Compression pressure: bar 26...32 29...35
01A installation tolerance or new
value
BE01.00-P-1002- Compression pressure: wear bar approx.18 approx.18
01A limit or limit value
BE01.00-P-1003- Compression pressure: bar < or =3 < or =3
01A permissible difference
between individual
cylinders
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COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 604, 605, 606, 611.960/.961
ENGINE 604, ENGINE
Number Designation 605, 606 611.960/961
BE01.00-P-1001- Compression pressure: installation bar 29...35 29...35
01A tolerance or new value
BE01.00-P-1002- Compression pressure: wear limit or bar approx.18 approx.18
01A limit value
BE01.00-P-1003- Compression pressure: permissible bar < or =3 < or =
01A difference between individual
cylinders
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 611.962, 611.981/.983/.987

ENGINE ENGINE
Number Designation 611.962 611.981/983/987
BE01.00-P-1002- Compression pressure: wear limit bar approx.18 approx.18
01A or limit value
01A permissible difference between
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 612.961, 612.962/.967

ENGINE ENGINE
Number Designation 612.961 612.962/967
BE01.00-P-1001-01A Compression pressure: installation bar 29...35 29...35
tolerance or new value
BE01.00-P-1002-01A Compression pressure: wear limit or bar approx.18 approx.18
limit value
BE01.00-P-1003-01A Compression pressure: permissible bar < or =3 < or =3
difference between individual
cylinders
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 612.963/.965/.966, 612.981

ENGINE ENGINE
Number Designation 612.963/965/966 612.981
BE01.00-P-1002- Compression pressure: wear limit bar approx.18 approx.18
01A or limit value
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COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 613.960/.961, 628.960/.961/.962/.963
ENGINE ENGINE
Number Designation 613.960/961 628.960/961/962/963
value
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 629, 640 (WITHOUT CODE 928))

ENGINE 640
without CODE 928
(Emission control
system with EU5
Number Designation ENGINE 629 technology)
BE01.00-P-1001- Compression pressure: installation bar > or =21 27...32
BE01.00-P-1002- Compression pressure: wear limit bar > or =17 approx.18
01A or limit value
BE01.00-P-1003- Compression pressure: permissible bar < or =3 < or =3
01A difference between individual
cylinders
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE CODE 640 (WITH CODE 928), 642.9
ENGINE 640 with
CODE 928 (Emission
control system with
Number Designation EU5 technology) ENGINE 642.9
value
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 642.8, 646.951/.961/.962/.963/.966

ENGINE ENGINE
Number Designation 642.8 646.951/961/962/963/966
satelettronica
value
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 646.8, 647.961

ENGINE
Number Designation ENGINE 646.8 647.961
BE01.00-P-1002- Compression pressure: wear limit or bar approx.17 approx.18
01A limit value
BE01.00-P-1003- Compression pressure: permissible bar < or =3 < or =3
01A difference between individual cylinders
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 647.981, 648.960/.961

ENGINE ENGINE
Number Designation 647.981 648.960/961
BE01.00-P-1002- Compression pressure: wear limit or limit bar approx.18 approx.18
01A value
BE01.00-P-1003- Compression pressure: permissible bar < or = < or =3
01A difference between individual cylinders
COMPRESSION PRESSURE SPECIFICATIONS - ENGINE 651
Number Designation ENGINE 651
BE01.00-P-1001-01A Compression pressure: installation tolerance or new bar 23...30
value
BE01.00-P-1002-01A Compression pressure: wear limit or limit value bar approx.17
BE01.00-P-1003-01A Compression pressure: permissible difference bar < or =3
CYLINDER LEAK TIGHTNESS - BE01.00-P-1000-02Z
ENGINE 000, 104, 112, 161, 166, 272, 611, 642, 646, 651, 661, 662, 668
ENGINE 000, 102, 115, 271, 272, 602, 611, 612, 615, 616, 617, 632, 642, 646, 647, 651
ENGINE ALL
CYLINDER LEAKAGE SPECIFICATIONS

Number Designation ENGINE ALL
satelettronica
BE01.00-P-1001-02Z Cylinder leakage: permissible loss total Percent < or =25
indication
BE01.00-P-1002-02Z Cylinder leak tightness: permissible losses Percent < or =10
at valves and cylinder head gasket
BE01.00-P-1003-02Z Cylinder leak tightness: permissible losses Percent < or =20
at pistons and piston rings
TEST & ADJUSTMENT VALUES: LIGHT TRANSPORTERS: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - BE01.00-Z-9999EZ
MODEL all
TEST AND ADJUSTMENT VALUES: LIGHT TRANSPORTERS: COMPLETE ENGINE,

CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE
Check values for cylinder head ENGINE 611.980, 642 ENGINE 629 in BE01.30-P-1000-02B
MODEL 211
Check values for cylinder head ENGINE 642, 646 ... BE01.30-N-1000-02O
Compression pressure ENGINE 611, 642, 646, 651 ... BE01.00-N-1000-01L
Cylinder head/cylinder head ENGINE 601, 602, 603, 604, 605, 606, BE01.30-P-1000-04A
bolts 611, 612, 613, 628, 629, 642, 646, 647,
648 ...
Cylinder head/cylinder head ENGINE 642, 646, 651 ... BE01.30-N-1000-04A
bolts
Cylinder leak tightness ENGINE all, 000, 102, 104, 112, 115, 161, BE01.00-P-1000-02Z
166, 271, 272, 602, 611, 612, 615, 616,
617, 632, 642, 646, 647, 651, 661, 662,
668 ...
Inspection data of crankcase ENGINE 642 BE01.40-N-1000-02P
TEST & ADJUSTMENT VALUES: TRANSPORTERS: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - BE01.00-Z-9999FZ
MODEL all
TEST AND ADJUSTMENT VALUES: TRANSPORTERS: COMPLETE ENGINE, CRANKCASE

Check values for cylinder head ENGINE 642, 646 ... BE01.30-N-1000-02O
Compression pressure ENGINE 601, 602, 603, 604, 605, 606, 611, BE01.00-P-1000-01A
612, 613, 628, 629, 640, 642, 646, 647, 648,
651 ...
Compression pressure ENGINE 611, 642, 646, 651 ... BE01.00-N-1000-01L
Cylinder head/cylinder head ENGINE 642, 646, 651 ... BE01.30-N-1000-04A
bolts
Cylinder head/cylinder head ENGINE 601, 602, 603, 604, 605, 606, 611, BE01.30-P-1000-04A
bolts 612, 613, 628, 629, 642, 646, 647, 648 ...
satelettronica
Cylinder leak tightness ENGINE all, 000, 102, 104, 112, 115, 161, BE01.00-P-1000-02Z
166, 271, 272, 602, 611, 612, 615, 616, 617,
632, 642, 646, 647, 651, 661, 662, 668 ...
Inspection data of crankcase ENGINE 642 BE01.40-N-1000-02P
CHECK VALUES FOR CYLINDER HEAD - BE01.30-N-1000-02O
ENGINE 642.896/898/992/993, 646.984/985/986/989/990 in MODEL 906
ENGINE 642.890/990 in MODEL 639
ENGINE 646.980/981/982/983 in MODEL 639
CHECK VALUES FOR CYLINDER HEAD - ENGINES 642; ENGINE 646.980/.981/.982/.983 IN

MODEL 639; ENGINE 646.980 IN MODEL 636
ENGINE
646.980/981/982/983
in MODEL 639
ENGINE 646.980 in
Number Designation Engine 642 MODEL 636
BE01.30-N- Valve setback Exhaust valve mm 0,7...1,1 1,0...1,4
1001-02O (a) with new
valves and new Intake valve mm 1,0...1,4 1,1...1,5
valve seat rings
BE01.30-N- Distance from Exhaust valve mm - 21,8...22,6
1002-02O end of valve Intake valve mm - 21,7...22,5
stem to base of
camshaft
bearing (T)
BE01.30-N- Height of New mm 128,35...128,65 126,85...127,15
1003-02O cylinder head
(H), without Wear limit after mm - 126,65
camshaft machining
Picture - AR01.30-P-7162HB
housing
CHECK VALUES FOR CYLINDER HEAD - ENGINE 646.984/985/986/989/990 IN MODEL 906

ENGINE
646.984/985/986/989/990 in
Number Designation MODEL 906
BE01.30-N-1001- Valve setback (a) with Exhaust valve mm 1,0...1,4
02O new valves and new
valve seat rings Intake valve mm 1,1...1,5
BE01.30-N-1002- Distance from end of Exhaust valve mm 21,8...22,6
satelettronica
02O valve stem to base of
camshaft bearing (T) Intake valve mm 21,7...22,5
BE01.30-N-1003- Height of cylinder head New mm 126,85...127,15
02O (H), without camshaft Wear limit after mm 126,65
housing machining Picture -
CYLINDER HEAD/CYLINDER HEAD BOLTS - BE01.30-N-1000-04A
ENGINE 642.890/990 in MODEL 639
ENGINE 642.896/898/992/993, 646.984/985/986/989/990, 651.955/956/957 in MODEL 906
ENGINE 646.980/981/982/983 in MODEL 639
CHECK VALUES FOR CYLINDER HEAD BOLT LENGTH - ENGINE 642.890/990 IN MODEL 639;
ENGINE
642.890/990 in Engine 642 in
Number Designation MODEL 639 model 906
BE01.30-N- Cylinder head Thread diameter M 12 12
1001-04A bolt Length (L) when mm 205 205
new
For picture, AR01.30-S-5800- AR01.30-S-
see Fig. 95 03SD 5800-03SD
CHECK VALUES FOR CYLINDER HEAD BOLT LENGTH - ENGINE 646 IN MODEL 636, 639;
Number Designation model 636, 639 model 906
BE01.30-N- Cylinder head Thread diameter M 12 12
1001-04A bolt Length (L) when mm 102 102
new
For picture, see AR01.30-S- AR01.30-S-
Fig. 95 5800-03SD 5800-03SD
CHECK VALUES FOR CYLINDER HEAD BOLT LENGTH - ENGINE 651 IN MODEL 639, 900, 906
satelettronica
Engine 651 in
Number Designation model 639, 900, 906
BE01.30-N-1001- Cylinder head bolt Thread diameter M 12
04A Length (L) when mm 226 (±0,5)
new
Max. length (L) mm 227,5
For picture, see Fig. AR01.30-S-5800-
95 03SD
CHECK VALUES FOR CYLINDER HEAD - BE01.30-P-1000-02B
ENGINE 642
CHECK VALUES FOR CYLINDER HEAD HEIGHT & VALVE SETBACK - ENGINE 642
BE01.30-P-1001- Height of cylinder head (H), New mm 128,35...128,65
02B without camshaft housing Wear limit after mm -
machining For picture, Fig. 109
see
BE01.30-P-1002- Valve setback (a) with new Exhaust valve mm 0,7...1,1
02B valves and new valve seat Intake valve mm 1,0...1,4
rings For picture, Fig. 109
see
satelettronica
Fig. 109: Identifying Cylinder Head Height (H) & Valve Setback Dimension (a)
CYLINDER HEAD/CYLINDER HEAD BOLTS - BE01.30-P-1000-04A
ENGINE 601, 603, 604, 605, 606, 611.960/961/962/980/981/983/987, 612.961/962/963/965/966/967/981/990,

613.960/961, 628.960/961/962/963, 629, 642, 646.8/9, 647.961/981, 648
ENGINE 602 (except 602.98)
CYLINDER HEAD BOLT LENGTH SPECIFICATIONS - ENGINE 629; ENGINE 642

Number Designation ENGINE 629 ENGINE 642
BE01.30-P- Cylinder head Thread diameter M 12 12
1001-04A bolt Length (L) when mm 201...202 205
new
Max. length (L) mm 203,5 207
For picture, see - -
Fig. 95
BE01.30-P- Prechamber Dimension (c) mm - -
1002-04A projection
INSPECTION DATA OF CRANKCASE - BE01.40-N-1000-02P
ENGINE 642
TEST & ADJUSTMENT VALUES FOR CYLINDER CRANKCASE - ENGINE 642
ENGINE 642 in ENGINE 642 in
Number Designation MODEL 639 MODEL 906
BE01.40-N- Crankshaft Basic bore - mm 80,000...80,522 80,000...80,522
1001-02P bearing Diameter Code 1st stage mm 80,500...80,507 80,500...80,507
number 52 blue
Code 2nd stage mm 80,507...80,514 80,507...80,514
number 54 yellow
Code 3rd stage mm 80,514...80,522 80,514...80,522
number 56 red
Basic bore width at fitted bearing mm 24,979...25,000 24,979...25,000
Permissible out-of-roundness and mm 0,02 0,02
taper of basic bore
BE01.40-N- Cylinder Peak-to-valley height (RZ) of top mm 0,015...0,025 0,015...0,025
1002-02P crankcase contact surface
Wave depth (Wt) of top contact mm 0,001...0,007 0,001...0,007
surface
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Unevenness of contact surface in mm 0,03 0,03
longitudinal direction
Unevenness of contact surface in mm 0,03 0,03
transverse direction
Variation of parallelism of top mm - -
contact surface to bottom in
longitudinal direction
REMOVAL & INSTALLATION

SERVICE MEASURES (CAMPAIGNS) WORK INSTRUCTIONS FOR SPECIAL CASES: LIGHT
TRANSPORTERS: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD,
CRANKCASE - SM01.00-Z-9999EZ
MODEL all
SERVICE MEASURES (CAMPAIGNS) WORK INSTRUCTIONS FOR SPECIAL CASES: LIGHT

TRANSPORTERS: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD,
CRANKCASE
Replace oil filler neck ENGINE 642 in MODEL 639.### ## as of 545124 up to SM01.20-S-0003A
569599
SERVICE MEASURES (CAMPAIGNS) WORK INSTRUCTIONS FOR SPECIAL CASES:

TRANSPORTERS, HEAVY-DUTY TRANSPORTERS: COMPLETE ENGINE, CRANKCASE
VENTILATION, CYLINDER HEAD, CRANKCASE - SM01.00-Z-9999JZ
MODEL all
SERVICE MEASURES (CAMPAIGNS) WORK INSTRUCTIONS FOR SPECIAL CASES:
TRANSPORTERS, HEAVY-DUTY TRANSPORTERS: COMPLETE ENGINE, CRANKCASE
Modify engine cover MODEL 906 ... SM01.10-D-0001AK
Replace oil filler neck ENGINE 642 in model 906.### #N as of 433227 SM01.20-D-0003A
up to 444445, 906.### #S as of 421603 up to
457428
MODIFY ENGINE COVER - SM01.10-D-0001AK
MODEL 906.### #N as of 414924 up to 421905 with CODE (MG5) Engine OM 642 DE 30 LA, 140 kW
(190 hp) 3800 rpm
MODEL 906.### #S as of 373045 up to 395557 with CODE (MG5) Engine OM 642 DE 30 LA, 140 kW
(190 hp) 3800 rpm
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Fig. 110: Engine Cover Center Part Component Location
Fig. 111: Line Bracket Component Location

OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES
Category Op. no. Operation text Acc. no. Code
O 026990 Remove the engine cover 01 93055 MOTORABDE
MODIFY ENGINE COVER - MODEL 906 WITH CODE MG5

Removing
1 Remove air filter housing AR09.10-D-1150SF
2 Remove center part of engine The engine cover center
cover (1) part (1) is a part that is no
longer required and it is not
reinstalled.
Install
3 Install line bracket (2) for
coolant line
4 Install air filter housing AR09.10-D-1150SF
PARTS ORDERING NOTES - LINE BRACKET
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Part no. Designation Quantity
A 000 995 50 14 Line bracket 1
REPLACE OIL FILLER NECK - SM01.20-D-0003A
ENGINE 642 in model 906.### #N as of 433227 up to 444445, 906.### #S as of 421603 up to 457428
OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category Op. no. Operation text Time Acc. no. Code
N 027341 Replace oil filler neck - 0194054 NCV3-STUTZ
Fig. 112: Cover, Oil Filler Neck, Gasket With Screw Component Locations
REPLACE OIL FILLER NECK - ENGINE 642 IN MODEL 906

Remove/install
1 Remove cover (1) from oil filler
neck (2)
2 Remove bolt (6)
3 Rotate oil filler neck (2) half a turn Installation: Clean sealing
to the left and remove surface on cylinder head cover, coat
seal (7) with oil, oil filler neck (1)
must engage.
OIL FILLER NECK TO BRACKET OF GLOW OUTPUT STAGE TORQUE SPECIFICATION -

ENGINE 642
BA01.20-N-1008-01O Bolt, oil filler neck to bracket of glow output Nm 9
stage
PARTS ORDERING NOTES - OIL FILLER NECK
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Part no. Designation Quantity
A 642 016 01 29 05 Oil filler neck 1
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: LIGHT TRANSPORTERS: COMPLETE ENGINE, CRANKCASE
VENTILATION, CYLINDER HEAD, CRANKCASE - BA01.00-Z-9999EZ
MODEL all
TORQUE SPECIFICATIONS: LIGHT TRANSPORTERS: COMPLETE ENGINE, CRANKCASE

Crankcase, timing case cover, end ENGINE 642 in MODEL 906 ENGINE 642 BA01.40-N-1000-01S
cover in MODEL 639
Crankcase ventilation, cylinder ENGINE 642 BA01.20-N-1000-01O
head cover
Cylinder head ENGINE 642 in MODEL 639 ENGINE 642 BA01.30-N-1000-01Q
in MODEL 906
Oil pan ENGINE 651 in MODEL 639 ENGINE 651 BA01.45-N-1000-01Q
in MODEL 900 ENGINE 642, 651 in
MODEL 906
TIGHTENING TORQUES: TRANSPORTERS: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - BA01.00-Z-9999FZ
MODEL all
TORQUE SPECIFICATIONS: TRANSPORTERS: COMPLETE ENGINE, CRANKCASE
Crankcase, timing case cover, end ENGINE 642 in MODEL 906 ENGINE BA01.40-N-1000-01S
cover 642 in MODEL 639
Crankcase ventilation, cylinder ENGINE 642 BA01.20-N-1000-01O
head cover
Cylinder head ENGINE 642 in MODEL 639 ENGINE BA01.30-N-1000-01Q
642 in MODEL 906
Oil pan ENGINE 651 in MODEL 639 ENGINE BA01.45-N-1000-01Q
651 in MODEL 900 ENGINE 642, 651 in
MODEL 906
CRANKCASE VENTILATION, CYLINDER HEAD COVER - BA01.20-N-1000-01O
ENGINE 642
CRANKCASE VENTILATION, CYLINDER HEAD COVER TORQUE SPECIFICATIONS -

ENGINE 642
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BA01.20-N-1001- Screw/bolt, cylinder head cover Stage 1, apply Nm 4
01O to cylinder head Stage 2, initial torque Nm 6
Stage 3, final torque Nm 8
BA01.20-N-1002- Screw/bolt, cylinder head cover trim to cylinder head Nm 9
01O
BA01.20-N-1003- Screw/bolt, bracket to cylinder M6X12 Nm 9
01O head
BA01.20-N-1004- Screw/bolt, bracket to cylinder M6X12 Nm 9
01O head cover
BA01.20-N-1005- Screw/bolt, oil separator to cylinder head cover Nm 14
01O
BA01.20-N-1006- Screw/bolt, oil separator connection fitting to cylinder Nm 9
01O head
BA01.20-N-1007- Screw/bolt, oil separator to cylinder head Nm 9
01O
BA01.20-N-1008- Screw/bolt, oil filler neck to bracket of glow output Nm 9
01O stage
CYLINDER HEAD - BA01.30-N-1000-01Q
CYLINDER HEAD TORQUE SPECIFICATIONS - ENGINE 642 IN MODELS 906, 639

ENGINE 642 ENGINE 642
in MODEL in MODEL
Number Designation 906 639
BA01.30-N- Bolt, cylinder head to M8 Nm 20 20
1001-01Q crankcase M12 Stage 1 Nm 10 10
Stage 2 Nm 60 60
Stage 3 Degrees 90° 90°
Stage 4 Degrees 90° 90°
Stage 5 Degrees° 90° 90°
BA01.30-N- Bracket, oil suction pipe to cylinder head Nm 12 -
1002-01Q cover
BA01.30-N- Bracket, oil suction pipe to oil suction pipe Nm 12 -
1003-01Q
BA01.30-N- Bracket, camshaft retainer to cylinder head Nm 8 8
1004-01Q
CRANKCASE, TIMING CASE COVER, END COVER - BA01.40-N-1000-01S
satelettronica
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER TORQUE SPECIFICATIONS -

ENGINE 642 IN MODELS 906, 639
in MODEL in MODEL
Number Designation 906 639
BA01.40-N- Screw/bolt, rear end cover Stage 1 Nm 8 8
1001-01S to cylinder crankcase Stage 2 Nm 10 10
BA01.40-N- Screw/bolt, timing case cover to cylinder Nm 10 10
1002-01S crankcase
BA01.40-N- Screw plug, water feed, M24X1.5 Nm 45 45
1003-01S left water jacket
BA01.40-N- Screw plug for pressure oil M18X1.5 Nm 30 30
1004-01S feed upstream of oil filter,
external
BA01.40-N- Screw plug for balance M20X1.5 Nm 35 35
1005-01S shaft, front M18X1.5 Nm 30 30
BA01.40-N- Screw plug for balance M20X1.5 Nm 35 35
1006-01S shaft, rear
BA01.40-N- Screw/bolt, oil spray nozzle Nm 8 8
1007-01S
BA01.40-N- Screw/bolt, lower M6 Nm - 8,5
1008-01S crankcase section M8 Nm - 20
M11 Stage 1 Nm - 20
Stage 2 Nm - 50
Stage 3 Degrees - 90°
Stage 4 Degrees - 90°
OIL PAN - BA01.45-N-1000-01Q
ENGINE 642, 651 in MODEL 906
OIL PAN TORQUE SPECIFICATIONS - ENGINE 642 IN MODEL 906, ENGINE 651 IN MODEL
906
Number Designation in MODEL 906 in MODEL 906
BA01.45-N- Oil pan top section to cylinder M6 Nm 14 -
1001-01Q block top at front
BA01.45-N- Oil pan top section to cylinder M8 Nm 20 -
1002-01Q crankcase at transmission end
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BA01.45-N- Oil pan bottom section to oil M6 Nm 12 13
1003-01Q pan top section
BA01.45-N- Bracket to oil pan top section M6 Nm 8 -
1004-01Q
BA01.45-N- Oil drain screw to oil pan M14 Nm 30 30
1005-01Q
BA01.45-N- Bolt, oil pan to cylinder M6 Nm 14 9
1006-01Q crankcase M8 Nm 20 20
BA01.45-N- Bolt, oil pan to timing case M6 Nm 14 -
1007-01Q cover
BA01.45-N- Screw/bolt, heat shield to oil pan Nm - 9
1008-01Q
BA01.45-N- Bolt, oil line bracket to oil pan Nm - -
1009-01Q
FORMS
FORMS: LIGHT TRANSPORTERS: COMPLETE ENGINE, CRANKCASE VENTILATION,
CYLINDER HEAD, CRANKCASE - OF01.00-Z-3999EZ
MODEL all
FORMS: LIGHT TRANSPORTERS: COMPLETE ENGINE, CRANKCASE VENTILATION,

CYLINDER HEAD, CRANKCASE - ENGINE 651
Engine analysis sheet, ENGINE 651 in MODEL 639 ENGINE 651 in OF01.00-D-3000-02B
form MODEL 906
FORMS: TRANSPORTERS, HEAVY-DUTY TRANSPORTERS: COMPLETE ENGINE,
CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - OF01.00-Z-3999JZ
MODEL all
FORMS: TRANSPORTERS, HEAVY-DUTY TRANSPORTERS: COMPLETE ENGINE,

CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - ENGINE 651
Engine analysis sheet, ENGINE 651 in MODEL 639 ENGINE 651 in OF01.00-D-3000-02B
form MODEL 906
SPECIAL TOOLS
001 589 76 21 13 GRAPH SHEETS - WS01.00-N-0004-01A
FG 01/Set A
ENGINE all
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Use/specification:
Graph sheets (100 each) 3.5 - 17.5 bar
Fig. 113: Identifying Graph Sheets (001 589 76 21 13)
001 589 76 21 21 GRAPH SHEETS - WS01.00-N-0004-02A
FG 01/Set A
ENGINE all
Use/specification:
Graph sheets (100 each) 10 - 40 bar

Fig. 114: Identifying Graph Sheets (001 589 76 21 21)
001 589 76 21 23 CONNECTORS - WS01.00-N-0004-03A
FG 01/Set A
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ENGINE all
Use/specification:
Connectors (3 each), M12 x 1.25 for glow plug hole, M18 x 1.5 for glow plug hole, M24 x 2 for injection
nozzle hole
Fig. 115: Identifying Connectors (001 589 76 21 23)
001 589 76 21 00 COMPRESSION TESTER - WS01.00-N-0004A
ENGINE 111.979/984, 112, 161, 270, 272, 601.943, 602, 607, 611.981/987, 612.981, 642, 646, 647.981, 651,
661, 662
001 589 76 21 00 COMPRESSION TESTER
001 589 76 21 13 Graph sheets FG 01/Set A WS01.00-N-0004-01A
001 589 76 21 21 Graph sheets FG 01/Set A WS01.00-N-0004-02A
001 589 76 21 23 Connectors FG 01/Set A WS01.00-N-0004-03A
FG 01/05/Satz A
Compression recorder complete for gasoline engines and diesel engines, measuring range 3.5 to -17.5 and
10 - 40 bar
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001 589 78 21 00 COMPRESSION TESTER - WS01.00-N-0006A
FG 01/03/05/Set A
ENGINES all
Only diesel engines
Use:
Compression recorder for diesel engines, measuring range 10...40 bar, without connector.
001 589 00 91 00 SET OF PROTECTIVE COVERS - WS01.00-N-0110B
FG 01/03/05/07/08/09/13/14/15/18/20/23/43/46/47/49/54/Set B
ENGINE all
satelettronica
Use:
Protective hood set, 5 pieces, 25 mm dia., length 75 mm, to close off openings while performing repair work.
Fig. 118: Identifying Set Of Protective Covers (001 589 00 91 00)
001 589 02 91 00 SET OF PROTECTIVE COVERS - WS01.00-N-0112B
FG 01/03/05/07/08/09/13/14/15/18/20/23/43/46/47/49/54/Set B
ENGINE all
Use:
Protective hood set, 5 pieces, 60 mm dia., length 60 mm, to close off openings while performing repair work.
000 589 01 25 00 HAND PRESSURE GUN - WS01.00-N-3060B
satelettronica
FG 01/Set B
ENGINES all
Use:
Hand pressure gun for cartridges
Fig. 120: Identifying Hand Pressure Gun (000 589 01 25 00)
667 589 03 63 00 PULLER - WS01.00-N-3082B
FG 01/07/Set B
ENGINE 601, 602, 611, 612, 613, 616, 617, 628, 640, 642, 646, 647, 648, 651, 668
Use:
Impact extractor
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646 589 00 62 00 ADAPTER PLATE - WS01.00-N-3104B
FG 01/Set B
ENGINE 642
ENGINE 642, 646 in MODEL 639
Use:
Adapter plate to install and remove the engine with the transmission together with the C-clamp 639 589 01 62
00.
Fig. 122: Identifying Adapter Plate (646 589 00 62 00)
639 589 00 61 00 ENGINE LIFTING DEVICE - WS01.00-N-3106C
FG 01/33/Set C
ENGINE 112, 271, 272, 642, 646, 651, 132
satelettronica
Use:
Engine lifting device for lifting engine.
Fig. 123: Identifying Engine Lifting Device (639 589 00 61 00)
906 589 01 61 00 MOUNTING PLATES - WS01.00-N-3108B
FG 01/22/33 Set B
MODEL 900, 906
Use:
The mounting plates are used when lifting the engine.
NOTE: Use mounting plates in combination with the engine hoist 639 589 00 61 00.
Fig. 124: Identifying Mounting Plates (906 589 01 61 00)
satelettronica
906 589 01 62 00 SUPPORT PLATE - WS01.00-N-3109B
FG 01/08/Set B
ENGINES 272, 642, 780.994
Use:
The adapter plate is used for removal/installation of the engine with transmission.
NOTE: Model 639: The adapter plate may only be used in combination with C-bracket
639 589 01 62 00.
Model 906: adapter plate may only be used in combination with a C-bracket (co.
Schairer/Order No. 0304.01).
906 589 03 61 00 STRUT - WS01.00-N-3110B
FG 01/03/15/22/31/32/33/46/Set B
MODEL 639 with ENGINE 642
satelettronica
MODEL 906 with ENGINE 642
Use:
Additional connection to existing lifting eye, for lifting engine.
NOTE: Use only in combination with engine lifting device 639 589 00 61 00 and
additionally for model 906 in combination with support plates 906 589 01 61 00.
Fig. 126: Identifying Strut (906 589 03 61 00)
639 589 06 62 00 LIFTING DEVICE - WS01.00-N-3112B

FG 01/Set B
ENGINE 642
Use:
Lifting device for engine at the rear for installing and removing oil pan.
NOTE: Only use in combination with a 639 589 00 62 00 holding device.
satelettronica
Fig. 127: Identifying Lifting Device (639 589 06 62 00)
642 589 03 40 00 SUPPORT - WS01.00-N-3113B
FG 01/Set B
ENGINE 272, 642, 646 in MODEL 906
Use:
Support for rear of engine when installing and removing the oil pan.
Fig. 128: Identifying Support (642 589 03 40 00)
001 589 76 21 00 COMPRESSION TESTER - WS01.00-P-0004A
FG 01/13/Set A
ENGINE all
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001 589 76 21 00 COMPRESSION TESTER
Part 001 589 76 21 13 Diagram FG 01/Set A WS01.00-P-0004-01A
charts
Part 001 589 76 21 21 Graph sheets FG 01/Set A WS01.00-P-0004-02A
Part 001 589 76 21 23 Connectors FG 01/Set A WS01.00-P-0004-03A
Use:
Compression recorder complete for gasoline engines 3.5 - 17.5 bar and diesel engines 10 - 40 bar
NOTE: Connectors M22 1.5 mm/R1/4" for injection nozzle hole, see 602 589 00 63 00,
604 589 00 63 00
001 589 78 21 00 COMPRESSION TESTER - WS01.00-P-0006A
ENGINE 270, 601, 602, 603, 604, 605, 606, 607, 611/980, 612, 613, 615, 616, 617, 628, 629, 642, 646, 647,
648, 651, 668
FG 01/05/Satz A
Compression recorder for diesel engines, measuring range 10-40 bar without connectors.
NOTE: Connectors: see 001 589 76 21 23, 602 589 00 63 00, 604 589 00 63 00. Diagram
sheets (100 pieces) 10-40 bar as a separate part, see 001 589 76 21 21.
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601 589 00 10 00 SCREWDRIVER BIT - WS01.00-P-0033B
FG 01/15/Set B
ENGINES all
Use:
Screwdriver bit 1/2" square, 140 mm long for double hexagon socket screw M 10 on cylinder head.
Additional use
For counter holding alternator shaft when removing belt pulley.

Fig. 131: Identifying Screwdriver Bit (601 589 00 10 00)
602 589 00 33 02 THREADED BOLT - WS01.00-P-0039-01B
FG 01/03/07/18 / Set B
ENGINES 272, 470.9, 471.9, 473.9, 601, 602.91 /93 /94 /96 /98, 603.91 /93 /96 /97, 604, 605, 606, 611, 612,
satelettronica
613, 615, 616, 617.91 /93 /95, 628, 629, 640, 642, 646, 647, 648, 668
Use:
Threaded bolts M 22 1/ M 22 1.5
Fig. 132: Identifying Threaded Bolt (602 589 00 33 02)
602 589 00 33 00 IMPACT EXTRACTOR - WS01.00-P-0039B
FG 01/03/07/18/Set B
ENGINES 271.9, 470, 471, 473, 272, 601, 602.91 /93 /94 /96 /981 /983, 603.91 /93 /96 /97 /97, 604, 605, 606,
611 /980, 612, 613, 615, 616, 617.91 /93 /95, 628, 629, 640, 642, 646, 647, 648, 651, 668
Part 602 589 00 33 02 Threaded FG 01/Set B WS01.00-P-0039-01B
bolt
Use:
Impact extractor for the prechamber and for oil spray nozzle.
On engine 611, 612, 613, 628, 629, 646, 647, 648 together with 611 589 00 33 00 extraction claw.
On engine 612.966, 640, 668 together with 668 589 00 34 00 clamping pliers.
Use a knock-on balancing weight together with the 604 589 00 34 00 extraction claw to eject the crankcase oil
spray nozzle.
Use the extraction claw 651 589 00 33 00 for engine 651.
For engine 642 in combination with 642 589 01 33 00 thread adapter.
satelettronica
For engine 271.9 in combination with 271 589 02 33 00 extractor.
Knock-on balancing weight in combination with 611 589 01 33 00 extraction claw in order to deflect oil
dipstick guide tube for engine 646 in model 636, 639.
With engine 470, 471, 473 Impact extractor to remove the crankshaft thrust bearing and components with an
interference fit.
Fig. 133: Identifying Impact Extractor (602 589 00 33 00)
611 589 01 63 00 FEMALE CONNECTOR - WS01.00-P-0056B
FG 01/05/Set B
ENGINE 611 /980, 612 /965 /966, 613, 628 /962, 642, 646, 647, 648, 668
Use:
Screw-in piece M10 x 1 mm with connection nipple for quick-coupling and integrated check valve length 173
mm for pencil-type glow plug hole.
For compression recorders 001 589 76 21 00 and 001 589 78 21 00, and for building up pressure in combustion
chamber after removing integrated check valve.
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Fig. 134: Identifying Female Connector (611 589 01 63 00)
611 589 00 63 00 CONNECTOR - WS01.00-P-0057B
FG 01/05/Set B
ENGINES 611 /980, 612 /965 /966, 613, 628, 629, 639, 642, 646, 647 /981, 648, 651, 668
ENGINES 646
Use:
Connector for inserting into an injector bore for measuring pressure loss. In combination with adapter R1/4" to
connection nipple for quick-coupling from compression recorder set 001 589 76 21 00 or 001 589 78 21 00 also
for measuring compression.
Attachment is with the original tensioning claw.
NOTE: Not for engines 611.981/687, 612.981, 647.981.

For engines 611.981/987, 612.981, 647.981 in model 906:
only use for AR05.30-D-3510B and AR05.30-D-3510NA For engines 646 in model
906:
only use for AR05.30-D-3510SD 611 589 00 63 00
For engine OM 651:
Only use in combination with genuine clamping claw OM 642. Drill the fastening
bore to a diameter of 7.5 mm.
Fig. 135: Identifying Connector (611 589 00 63 00)
satelettronica
611 589 02 63 00 INTERMEDIATE PIECE - WS01.00-P-0058B
FG 01/05/Set B
ENGINE 611 /980, 612 /965 /966, 613, 628 /962, 629, 640, 642, 646, 647 /981, 648, 651, 668
Use:
Intermediate piece for connection of the locally available compressed air line (quick-coupling) to the quick-
coupling of the screw-in union 611 589 01 63 00 or the screw-in union 640 589 00 63 00.
611 589 00 68 10 ROUND BRUSHES (3 X) - WS01.00-P-0059-01B
FG 01/05/07/15/Set B
ENGINE 611 /980, 612 /965 /966, 613, 628, 629, 640, 642, 646, 647, 648, 651, 668
satelettronica
Use:
Brushes (3 in total)
Brass wire 0.2 mm
Wear part of round brush
Fig. 137: Identifying Round Brushes (3 X) (611 589 00 68 10)
611 589 00 68 00 ROUND BRUSH - WS01.00-P-0059B

FG 01/07/15/Set B
ENGINE 611 /980, 612 /965 /966, 613, 628, 629, 640, 642, 646, 647, 648, 651, 668
611 589 00 68 00 ROUND BRUSH

Part 611 589 00 68 10 Round FG 01/05/07/15 / Set B WS01.00-P-0059-01B
brushes (3 x)
Use:
Round brush (brass wire 0.2 mm) with bristle length adjustable by means of sliding sleeve, and rotary handle,
including plug.
To clean the sealing surface of the injector in the cylinder head and surface on the cylinder crankcase.
satelettronica
Fig. 138: Identifying Round Brush (611 589 00 68 00)
668 589 00 68 05 CYLINDER BRUSHES - WS01.00-P-0061-01B
FG 01/05/07/Set B
ENGINE 611 /980, 612 /965 /966, 613, 628, 629, 640, 642, 647, 651, 668
ENGINE 646, 648
Use:
Cylinder brushes 20 mm (3 in total) with steel bristles 0.1 mm.

Fig. 139: Identifying Cylinder Brushes (668 589 00 68 05)
668 589 00 68 00 CYLINDER BRUSH - WS01.00-P-0061B
FG 01/05/07/Set B
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ENGINE 611 /980, 612 /965 /966, 613, 628, 629, 640, 642, 647, 651, 668
ENGINE 646, 648
668 589 00 68 00 CYLINDER BRUSH

Part 668 589 00 68 05 Cylinder FG 01/05/07/Set B WS01.00-P-0061-01B
brushes
Use:
Cylinder brush for cleaning fuel injectors.

Fig. 140: Identifying Cylinder Brush (668 589 00 68 00)
001 589 01 91 00 SET OF PROTECTIVE COVERS - WS01.00-P-0111B
FG 01/08/09/14/15/46/54/83/Assembly B
ENGINES all
Use:
Set of protective covers, set (5 pcs) protective covers, 40 mm dia., length 100 mm for closing of openings
during repair work.
satelettronica
003 589 03 37 00 HOSE CLAMP PLIERS - WS01.00-P-0113B
FG 01/07/09/18/20/32/46/54/Set B
ENGINES all
Use:
Pliers with braced Bowden cable and multiple arrester for actuation of self-tensioning spring bracket and space-
saving clamps, particularly in areas that are difficult to access.
Fig. 142: Identifying Hose Clamp Pliers (003 589 03 37 00)
271 589 00 43 00 INSTALLATION TOOL - WS01.00-P-0120B
FG 01/03/Set B
ENGINE 157, 271, 272, 273.92# ## up to 300193, 273.96# /97# ## up to 300345, 276, 278, 629, 642
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Use:
Insertion tool for installing rear crankshaft radial shaft sealing ring, with crankshaft flange diameter of 93 mm.
Fig. 143: Identifying Installation Tool (271 589 00 43 00)
640 589 00 63 00 SCREW-IN FITTING - WS01.00-P-0130B
FG 01/Set B
ENGINE 629, 640, 642, 651

Use:
Screw-in piece for checking compression pressure through glow-plug opening (M8 1).
NOTE: In combination with compression recorders 001 589 76 21 00 and 001 589 78 21
00
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629 589 01 63 00 ENGINE TURNING DEVICE - WS01.00-P-0137B
FG 01/03/05/27/ Set B
ENGINE 629, 642
MODIFICATION NOTES - 629 589 01 63 00 ENGINE TURNING DEVICE

30.6.06 Replaced by W 629 589 02 63 00.
629 589 01 63 00 ENGINE TURNING DEVICE

Use:
Turning device for turning engine at starter annulus.
Fig. 145: Identifying Engine Turning Device (629 589 01 63 00)
629 589 02 63 00 ENGINE TURNING DEVICE - WS01.00-P-0142B
FG 01/03/05/27/ Set B
ENGINE 629, 642
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MODIFICATION NOTES - 629 589 02 63 00 ENGINE TURNING DEVICE
30.6.06 Replacement for W 629 589 01 63 00.
Use:
Turning device for turning the engine at the starter annulus.
Fig. 146: Identifying Engine Turning Device (629 589 02 63 00)
642 589 00 63 00 SCREW-IN FITTING - WS01.00-P-0151B
FG 01/Set B
ENGINE 629, 640, 642, 651
Use:
Screw-in fitting for checking cylinder leakage
NOTE: Use in combination with W 611 589 02 63 00.
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SPECIAL TOOLS: COMMERCIAL VEHICLES: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE - WS01.00-Z-9999TZ
MODEL all
SPECIAL TOOLS: COMMERCIAL VEHICLES: COMPLETE ENGINE, CRANKCASE

000 589 00 21 00 Test FG 00/01/07/Set B WS00.00-P-0034B
box
000 589 01 10 00 Torx FG 00/01/14/20/25/46 68/72/77/91/Set B WS00.00-N-0001Z
bit set
000 589 01 25 00 Hand FG 01/Set B WS01.00-N-3060B
pressure gun
000 589 07 03 00 Box FG 01/07/09/14/ Set A WS07.00-N-3002A
wrench
000 589 26 01 00 Open FG 00 FG 01/05/41/set A -
wrench
000 589 40 37 00 Clamp FG 00 FG 01/07/14/83/26 Set B WS00.00-N-0005Z
000 589 40 37 00 Clamp FG 00/01/07/18/20/ 47/82/88 WS00.00-P-0005Z
000 589 54 37 00 Clamp FG 00/01/07/08/13/ WS00.00-P-0006Z
14/18/20/22/28/33/46/47/54/82/83/Set B
000 589 68 03 00 Box FG 01/07/09/14/set A WS07.00-N-0004A
wrench bit
001 589 00 91 00 Set of FG 01/03/05/07/08/ WS01.00-N-0110B
protective covers 09/13/14/15/18/20/23/43/46/47/49/54/ Set B
001 589 01 91 00 Set of FG 01/08/09/14/15/46/ 54/83/Assembly B WS01.00-P-0111B
protective covers
001 589 02 91 00 Set of FG 01/03/05/07/08/ WS01.00-N-0112B
protective covers 09/13/14/15/18/20/23/43/46/47/49/54/Set B
001 589 32 21 00 Dial FG 01/03/Set B WS03.00-P-0007B
gage
001 589 35 21 00 FG 00 FG 01/Set B WS00.00-N-3017Z
Torque wrench handle
001 589 44 21 00 FG 00 FG 01/07/26/41/ 42/Set A WS00.00-N-3018Z
Torque wrench handle
001 589 53 21 00 Dial FG 00/01/03/05/09/ WS00.00-N-0013Z
gage 13/18/23/26/28/33/35/41/42/46/83/Set B
001 589 65 09 00 FG 03/01/05/27Set B WS03.00-P-0006B
Socket
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001 589 65 09 00 FG 01/03/05/Set B -
Socket wrench bit
001 589 72 21 00 FG 00 FG 01/20/88/ WS00.00-N-0017Z
Torque wrench
001 589 73 21 00 Hand FG 00/01/07/09/14/15/ 20/30 WS00.00-P-0018Z
vacuum pump
001 589 76 21 00 WS01.00-N-0004A
Compression tester
001 589 76 21 00 FG 01/13/Set A WS01.00-P-0004A
Compression tester
001 589 76 21 13 Graph FG 01/Set A WS01.00-N-0004-
sheets 01A
001 589 76 21 21 Graph FG 01/Set A WS01.00-N-0004-
sheets 02A
001 589 76 21 21 Graph FG 01/Set A -
sheets
001 589 76 21 23 FG 01/Set A WS01.00-N-0004-
Connectors 03A
001 589 76 21 23 FG 01/Set A -
Connectors
001 589 77 21 00 FG 01/Set A -
Compression recorder
001 589 78 09 00 FG 01/15/Set B -
Socket wrench
001 589 78 21 00 FG 01/03/05/Set A WS01.00-N-0006A
Compression tester
001 589 78 21 00 WS01.00-P-0006A
Compression tester
001 589 80 09 00 FG 01/15/Set B WS15.00-P-0043B
Wrench socket
001 589 80 21 00 FG 00 FG 01/07/26/46/ Set B WS00.00-N-3012Z
Torque screwdriver
001 589 81 09 00 Set of FG 00/01/07/09/14/15/ 20/Set B WS00.00-P-0251B
flexible head wrenches
001 589 83 21 00 Tester FG 01/20/Set A WS20.00-N-3000A
001 589 83 21 04 FG 01/20/Set A WS20.00-N-3000-
Pressure control valve 01A
001 589 83 21 06 FG 01/20/Set A WS20.00-N-3000-
Pressure gage 02A
003 589 01 16 00 Pry FG 00/01/03/Set C WS00.00-P-0180Z
bar
003 589 03 37 00 Hose FG 01/07/09/18/20/ 32/46/54/Set B WS01.00-P-0113B
clamp pliers
003 589 05 09 00 FG 00 FG 01/09/14/15/20/ Set A -
satelettronica
Torque tool set
055 589 00 61 00 -
Removal and
installation tool
102 589 00 15 00 Drift FG 01/Set C -
102 589 00 34 00 FG 01/05/Set B WS05.00-P-0009B
Threaded bolt
102 589 00 99 00 HELI- FG 01/Set C -
COIL repair set
102 589 03 15 00 Drift FG 01/Set C -
102 589 12 15 00 Drift FG 01/Set C -
103 589 01 39 00 FG 01/14/49/Set B WS14.00-N-0001B
Caulking bolt
103 589 02 09 00 FG 01/18/Set A -
Wrench socket
110 589 03 59 00 FG 00/01/05/13/18/26/ WS00.00-P-0274K
Mounting wedge 30/42/43/46/54/67/68/72/77/80/82/83/ 88/91/Set K
111 589 00 91 00 FG 01/Set B -
Connector
111 589 03 15 00 FG 01/03/05/Set B WS05.00-N-0072B
Retaining pins
111 589 12 31 00 FG 01/18/Set C -
Support
112 589 00 25 00 FG 00/01/05/18 WS00.00-P-0052Z
Squeeze gun
112 589 00 40 00 FG 01/03/Set B -
Counterholder
112 589 00 72 00 Hand FG 01/27/43/Set A WS27.00-N-0003A
pump
112 589 01 03 00 FG 05/01/Set B -
Insertion tool
112 589 01 62 00 FG 01/Set B -
Adapter plate
112 589 03 40 00 FG 01/03/05/27/ Set B WS03.00-P-0037B
Retaining lock
116 589 01 34 00 FG 01/03/05/ Set B WS05.00-N-0083B
Threaded bolt
116 589 01 62 00 FG 42/01/03/26/27/ 28/29/33/35/54/68/77/88/91/ Set B WS42.00-P-0017B
Removal and
installation tool
116 589 03 07 00 T- FG 01/Set B -
handle Allen wrench
116 589 20 33 00 FG 01/03/05/07/Sat B WS05.00-N-0089B
Impact extractor
119 589 04 63 00 FG 01/09/07/47/ Set B -
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Pressure hose
120 589 07 21 00 FG 18/01/05/09/Set B -
Measuring rod
129 589 01 21 00 FG 40/01/Set B WS40.00-P-0025B
Retainer device
163 589 00 37 00 Pliers FG -
01/03/05/07/09/14/15/18/20/32/33/35/42/46/47/54/82/91/
Set B
210 589 00 40 00 FG 01/05/15/18/25/ Set B WS05.00-N-0155B
Magnetic pin
210 589 00 71 00 Hand FG 00/01/07/09/20/25/ 27/32/33/43/46/88 WS00.00-P-0280Z
pump
210 589 00 91 00 Test FG 01/20/Set B -
cap
220 589 00 99 00 FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B
Electrical connection kit
220 589 05 99 00 FG 00/01/09/13/15/ 20/25/42/43/47/54/ 72/ Set B WS00.00-P-0279Z
Electrical connection kit
271 589 00 43 00 FG 01/03/Set B WS01.00-P-0120B
Installation tool
271 589 01 62 00 FG 01/Set B -
Adapter
272 589 00 91 00 FG 01/05 Set B -
Threaded adapter
312 589 01 31 00 FG 01/Set D -
Handle
312 589 07 31 00 Cable FG 01/Set D -
312 589 13 15 00 Drift FG 01/Set B FG 03/Set C -
314 589 01 03 00 Box FG 01/07/09/43/ 47 /Set C -
wrench bit
343 589 00 40 00 Dial FG 01/05/Set C -
indicator holder
352 589 00 21 00 FG 01/Set B -
Connector
352 589 02 61 00 Sleeve FG 01/05/Set B -
355 589 01 63 00 FG 01/05/07/18 /Set C WS07.00-N-3016C
Impact extractor
363 589 02 21 00 Dial FG 00/01/03/05/09/ 13/18/26/28/33/35/41/42/ Set B WS00.00-N-0033Z
gage holder
364 589 00 01 00 FG 01/Set B -
Wrench
366 589 00 21 05 FG 00/01/03/05/09/13/18/23/26/28/33/35/41/42/83/Set B WS00.00-N-0013-
Extension 01Z
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402 589 00 03 00 Box FG 01/Set B -
wrench socket
402 589 00 21 00 FG 01/Set C -
Measuring plate
403 589 00 21 00 FG 01/Set B -
Connector
403 589 00 28 00 Tap FG 01/Set C -
set
403 589 00 33 00 FG 01/Set C -
Removal and insertion
device
403 589 02 03 00 Box FG 01/Set B -
wrench bit
403 589 04 15 00 Drift FG 03/01/Set C -
403 589 05 63 00 FG 01/Set D -
Assembly bracket
407 589 00 63 00 FG 01/03/07/13/18/ 27/46/47/Set B -
Turning device
415 589 00 62 00 -
Support fixture
422 589 00 09 00 FG 01/Set B -
Socket
422 589 00 55 00 Group 01/Set D -
Turning tool
422 589 01 09 00 FG 01/Set B -
Wrench socket
422 589 02 09 00 FG 01/03/Set C -
Socket
442 589 00 14 00 Sleeve FG 01/Set C -
442 589 00 15 00 Drift FG 01/Set C -
punch
442 589 00 37 00 Pliers FG 01/Set C -
442 589 01 14 00 Guide FG 01/Set C -
sleeve
442 589 02 14 00 FG 01/Set C -
Assembly sleeve
442 589 04 63 00 FG 01/Set C -
Mounting plate
442 589 05 63 00 Spring FG 01/Set C -
cup compressor
442 589 06 63 00 FG 01/Set C -
Centering tool
447 589 00 15 00 Drift FG 03/01/Set C -
450 589 07 21 07 FG 01/20/54/Set B -
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Adapter
457 589 00 09 00 FG 01/15/18/Set B -
Socket
457 589 00 21 00 FG 01/Set C -
Measuring plate
457 589 00 33 00 FG 01/Set C -
Additional set
457 589 00 43 00 FG 01/03/Set B -
Removal and
installation tool
470 589 00 01 00 FG 01/07/09/47/ Set B -
Counterholder
470 589 00 07 00 Claw- FG 01/07/Set B -
type wrench
470 589 00 91 00 FG 01/03/05/Set B -
Adapter
470 589 00 91 04 Seal FG 03/01/05/Set B -
set
470 589 01 33 00 FG 01/07/Set B -
Extraction tool
470 589 01 61 00 FG 01/Set C -
Alignment pin
470 589 04 33 00 FG 01/07/Set B -
Extraction tool
470 589 04 62 00 FG 01/05/Set B -
Removal and fitting
device
470 589 05 33 00 FG 01/03/Set C -
Removal and
installation tool
470 589 12 91 00 Plug FG 01/07/Set B -
541 589 00 21 00 FG 01/Set C -
Measuring plate
541 589 00 40 00 Dial FG 01/03/05/Set C -
indicator holder
541 589 01 33 00 FG 01/Set C -
Removal and
installation tool
541 589 04 63 00 FG 01/Set C -
Hexagon wrench
601 589 00 10 00 FG 01/15/Set B -
Screwdriver bit
601 589 00 10 00 FG 01/15/Set B WS01.00-P-0033B
Screwdriver bit
601 589 00 53 00 FG 01/Set C -
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Reamer
601 589 00 61 00 FG 01/Set D -
Bracket
601 589 00 62 00 FG 01/Set D -
Mounting fixture
601 589 00 66 00 FG 01/Set C -
Countersink
601 589 00 66 03 FG 01/Set C -
Milling cutter
601 589 04 33 00 Puller FG 01/33/Set B -
601 589 05 63 00 FG 01/Set D -
Adapter
601 589 06 63 00 FG 01/Set D -
Adapter
601 589 08 15 00 Drift FG 01/Set C -
601 589 09 15 00 Drift FG 01/Set C -
602 589 00 25 00 FG 01/Set A -
Adapter
602 589 00 33 00 FG 01/03/07/18/Set B WS01.00-P-0039B
Impact extractor
602 589 00 33 02 FG 01/03/07/18 / Set B WS01.00-P-0039-01B
Threaded bolt
602 589 00 40 00 FG 01/03/05/27 / Set B -
Retaining lock
602 589 00 63 00 FG 01/Set B -
Connection piece
603 589 00 09 00 FG 01/Set B -
Socket
603 589 00 15 00 Drift FG 01/Set D -
punch
603 589 00 15 00 Drift FG 01/Set C -
punch
603 589 00 40 00 FG 01/20/46/Set B WS20.00-N-0015B
Counterholder
604 589 01 09 00 FG 01/Set B -
Socket
605 589 00 33 02 Puller FG 05/01/Set B WS05.00-P-0154-01B
bolt
607 589 00 91 00 -
Screw-in piece
607 589 01 15 00 Drift -
611 589 00 25 00 FG 01/Set B -
Connector
satelettronica
611 589 00 37 00 Pliers FG 01/15/Set A -
611 589 00 37 00 Pliers FG 01/15/20/Set B WS15.00-N-3033B
611 589 00 40 00 FG 01/03/20/46/ Set B WS20.00-N-3032B
Counterholder
611 589 00 63 00 FG 01/05/Set B WS01.00-P-0057B
Connector
611 589 00 66 00 FG 01/Set C -
Milling cutter
611 589 00 68 00 Round FG 01/07/15/Set B WS01.00-P-0059B
brush
611 589 00 68 10 Round FG 01/05/07/15/Set B WS01.00-P-0059-01B
brushes (3 x)
611 589 01 14 00 FG 03/01/Set B -
Assembly sleeve
611 589 01 63 00 FG 01/05/Set B WS01.00-P-0056B
Female connector
611 589 02 63 00 FG 01/05/Set B WS01.00-P-0058B
Intermediate piece
611 589 04 63 00 FG 01/Set B -
Connection piece
615 589 00 07 00 Puller FG 01/Set B -
615 589 00 33 00 Puller FG 01/Set B -
617 589 00 10 00 FG 01/Set B -
Screwdriver bit
617 589 00 53 00 FG 01/Set C -
Reamer
617 589 01 25 00 FG 01/Set C -
Pressure testing plate
617 589 01 25 12 FG 01/Set C -
Rubber plates
629 589 01 63 00 FG 01/03/05/27/ Set B WS01.00-P-0137B
Engine turning device
629 589 02 63 00 FG 01/03/05/27/ Set B WS01.00-P-0142B
Engine turning device
639 589 00 61 00 FG 01/33/Set C WS01.00-N-3106C
Engine lifting device
639 589 00 62 00 FG 01/Set C -
Retaining device
639 589 01 62 00 C- FG 01/08/Set B -
clamp
639 589 01 63 00 Strut FG 01/03/22/31/32/33/ 46/60/Assembly B -
639 589 03 62 00 FG 01/03/31/33/ 46/Set C -
Adaptation
639 589 04 62 00 FG 01/26/27/28 Set B -
satelettronica
Support
639 589 06 62 00 FG 01/Set B WS01.00-N-3112B
Lifting device
639 589 07 63 00 FG 01/03/27/Set B -
Turning device
639 589 08 62 00 FG 01/Set C -
Holding fixture
639 589 09 62 00 FG 01/Set B -
Adaptation
640 589 00 63 00 FG 01/Set B WS01.00-P-0130B
Screw-in fitting
642 589 00 14 00 FG 01/03/Set B WS03.00-P-0094B
Centering sleeve
642 589 00 63 00 FG 01/Set B WS01.00-P-0151B
Screw-in fitting
642 589 03 40 00 FG 01/Set B WS01.00-N-3113B
Support
646 589 00 62 00 FG 01/Set B WS01.00-N-3104B
Adapter plate
651 589 00 61 00 FG 01/03/Set B -
Insertion tool
651 589 02 40 00 FG 01/03/05/Set B -
Retaining lock
667 589 03 63 00 Puller FG 01/07/Set B WS01.00-N-3082B
668 589 00 68 00 FG 01/05/07/Set B WS01.00-P-0061B
Cylinder brush
668 589 00 68 05 FG 01/05/07/Set B WS01.00-P-0061-01B
Cylinder brushes
906 589 01 61 00 FG 01/22/33 Set B WS01.00-N-3108B
Mounting plates
906 589 01 62 00 FG 01/08/Set B WS01.00-N-3109B
Support plate
906 589 03 61 00 Strut FG 01/03/15/ 22/31/32/33/46 /Set B WS01.00-N-3110B
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Complete-Engine C

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Complete-Engine C

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ENGINE

Complete Engine - Model 906

Pressure loss at cylinder head gasket

Pressure loss at exhaust valve(s)

4. Air escaping via oil filler opening:

Pressure loss through pistons and piston rings

GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01A

Glazing, smooth spots

Visible stripes, friction marks

The piston rings are not damaged.

IMPORTANT: Reuse crankcase.

Ring shaped imprints

IMPORTANT: Reuse crankcase.

Rotary bright, reflective, polished upper surfaces of cylinder

The cylinder barrel is unusable.

IMPORTANT: Do not reuse the crankcase.

Rough streaks, friction scoring

The piston rings may be damaged.

IMPORTANT: Do not reuse the crankcase.

Continuous individual traces of scratch

IMPORTANT: Reuse crankcase.

The cylinder barrel is unusable.

IMPORTANT: Do not reuse the crankcase.

Brown coloring of cylinder upper surface

IMPORTANT: Reuse crankcase provided no impermissible cylinder distortion is present.

GENERAL NOTES: COMMERCIAL VEHICLES: COMPLETE ENGINE, CRANKCASE

GENERAL NOTES: COMMERCIAL VEHICLES: COMPLETE ENGINE, CRANKCASE

INFORMATION ON WORKING SEALING SURFACES WHEN CARRYING OUT ENGINE

NOTES ON SEALANT PATH FOR CYLINDER HEAD COVER - AH01.30-N-1000-08SE

ENGINE 642 in MODEL 639

The sealing surfaces must be free of oil and grease.

Leaks can occur otherwise.

Cylinder Barrels Or Cylinder Liners Without Dust Damage

Cylinder Barrels Or Cylinder Liners With Dust Damage

Fig. 8: Cylinder Barrels or Cylinder Liners With Dust Damage

NOTES ON SEALANT PATH FOR TIMING CASE COVER - AH01.40-N-1000-01SE

ENGINE 642.896/898/992/993 in MODEL 906

ENGINE 642 in MODEL 639

Sealant path on timing case cover

The superimposed line (A) shows the sealant path.

NOTES ON SEALANT PATH FOR OIL PAN - AH01.45-N-0001-01SF

ENGINE 642.896/898/992/993 in MODEL 906

Sealant path for the lower oil pan (1)

Sealant path for the upper oil pan (2)

NOTES ON SEALANT PATH FOR OIL PAN - AH01.45-P-0001-01OM

 Sealing surface: - free of anticorrosion agent

 oil and grease-free

 The sealing surface must be flat (replace bent components).

TESTING & REPAIR

ENGINE 642.896 /898 /992 /993 in MODEL 906

CRANK ENGINE - ENGINE 642.896 /898 /992 /993 IN MODEL 906

INSPECT CYLINDERS WITH A LIGHT PROBE - AR01.00-D-0200SD

ENGINES 651 in MODEL 900

Shown on engine 646.985

INSPECT CYLINDERS WITH A LIGHT PROBE - ENGINE 642, 651

Fig. 20: Identifying Wrench Socket (001 589 65 09 00)

Fig. 22: Identifying Counterholder (651 589 08 40 00)

TEST COMPRESSION PRESSURE - AR01.00-D-1200SF