Om501 Om502 Workshop Manual Abby

Engines O M 501, OM 502 (Mod. des. 541.9,542.9)

Order No. 6517 503002

From the library of Barrington Diesel Club

Contents

P a rti

Title

V alid ity

Technical data engine - com plete

ENGINE 541.920/921 /922 /923/924/925/926/927

Technical data engine - com plete

ENGINE 542.920 /921 /922 /923 /925 /926

Removing, installing engine

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 7923 /925 /926

P a ge

3 8 12

Inspecting engine fo r dust dam age

ENGINE 904 /, 906, 541, 542

21

Inspecting cylinders w ith lig h t probe

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923/925/926

23

Testing compression pressure

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 7921 /922 7923 7925 7926

25

Removing, installing cylinder head cover

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 7922 /923 /925 /926

28

Removing, installing protective sleeve

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925/926

29

Removing, installing cylinder head

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 7925 7926

32

Checking, facing cylinder head contact surface

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925 /926

37

Removing, installing tim ing case cover

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 792S 792G

41

Removing, installing fro n t radial seal in housing cover

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /9 2 t/922 /923/925/926

44

M easuring cylinder bores

ENGINE 541.920 /921 /922 /923 /924 7925 /926 /927, 542.920 /921 /922 /923 /925 /926

48

M easuring projection o f cylinder liner

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923/92S/926

51

Rem oving, installing, sealing cylinder liner

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920

53

/921 / 9 2 2 / 9 2 3 / 9 2 5 / 9 2 6

Rem oving and installing oil pan

ENGINE 541.920 /921 /922 /923 /924 7925 /926 /927, 542.920 /921 /922/923/925/926

57

Removing, installing decom pression brake valve

ENGINE 541.920/921 /922/923/924/925 /92 6 /9 2 7 ,542.920

61

/921

/922 19 2 3 1929 7926

Removing, installing tim ing case

ENGINE 541.920 /921 /922 /923 /924 /925 7926 /927, 542.920 /921 /922 /923 /925/926

63

Testing, repairing connecting rod

ENGINE 541.920 /921 7922 /923 /924 /925 /926 /927,542.920 /921/9 2 2 /9 2 3 /925/926

69

Removing, installing pistons

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /92 5/926

75

Rem oving and installing piston rings

ENGINE 541.920 /921 /922 /923 /924 7925 /926 /927, 542.920 /921 /922 /923 /925/926

82

Rem oving, installing race on crankshaft

ENGINE 541.920 /921 /922 /923 7924 /925 /926 /927,542.920 /921 /922 /923 /925 /926

84

Replacing rear crankshaft radial seal

ENGINE 541.920 /921 /922 /923 /924 /925 /926

1922. 542.920

85

ENGINE 541.920/921 /922 /923 /924 /925 /926/927, 542.920 /921 /922 /923 /92 5/926

87

ENGINE 541.920 /921 /922 7923 /924 /925 /926 /927, 542.920

92

/921 /922 7 9 2 3 / 9 2 5 / 9 2 6

Rem oving and installing crankshaft M easuring and m ounting crankshaft

7921 7922 7923 792 5 7926

Removing, installing belt pulley/vibration dam per

ENGINE 541.920 /921 /922 7923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925 7926

100

Removing, installing flyw heel

ENGINE 541.920 /921 7922 7923 /924 7925 /926 /927, 542.920 /921 /922 7923 7925 /926

102

Checking and re-machining flyw heel

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925 /926

105

E n gin es O M 501, O M 502 (m o d . des. 541.9, 542.9), A C T R O S - V e h ic le m o d . des. 9 50 -9 54 , F2

1

Part 2

Contents

Title

V alidity

Replacing ring gear o f flyw heel

ENGINE 5 4 1 .9 2 0 /921 /92 2 /9 2 3 / 9 2 4 /92 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0

Page 3

/921 /9 2 2 / 9 2 3 / 9 2 5 / 9 2 6

Removing, installing race o n flyw h eel

ENGINE 5 4 1 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 4 /9 2 5 / 9 2 6 /9 2 7 , 5 4 2 .9 2 0

5

/921 /9 2 2 /9 2 3 /9 2 S / 9 2 6 R e m o v in g , in s t a llin g g u id e b u s h in f ly w h e e l

E N G IN E 5 4 1 .9 2 0 /921 /9 2 2 /9 2 3 /9 2 4 /9 2 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 /9 2 3 /9 2 5 /9 2 6

6

Removing, installing rocker arm assembly

ENGINE 5 4 1 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 4 /9 2 5 /9 2 6 / 9 2 7 , 5 4 2 .9 2 0 / 9 2 1 / 9 2 2 /9 2 3 /92 5 /926

9

R e m o v in g a n d in s t a llin g c a m s h a f t

e n g i n e 5 4 1 .9 2 0 /921 /92 2 /9 2 3 / 9 2 4 /92 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 5 / 9 2 6

12

Replacing valve stem seals

ENGINE 5 4 1 .9 2 0 /921 /92 2 /9 2 3 / 9 2 4 /9 2 5 / 9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 5 / 9 2 6

17

R e m o v in g a n d in s t a llin g v a lv e s

E N G IN E 5 4 1 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 4 /9 2 S /9 2 6 / 9 27, 5 4 2 .9 2 0 /921 / 9 2 2 / 9 2 3 /9 2 5 / 9 2 6

18

Replacing valve guides

ENGINE 5 4 1 .9 2 0 / 9 2 1 / 9 2 2 / 9 2 3 / 9 2 4 / 9 2 5 / 9 2 6 / 9 2 7 , 5 4 2 .9 2 0

25

/921 /9 2 2 /9 2 3 /9 2 5 /9 26

Replacing valve seat rings

E N G IN E 5 4 1 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 4 /92 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 / 9 2 1 /9 2 2 /923 /9 2 5 / 9 2 6

28

G rinding valves

ENGINE 5 4 1 .9 2 0 /921 /92 2 /9 2 3 /9 2 4 /92 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0

41

/921 /9 2 2 /9 2 3 /9 2 5 /9 26

M achining valve seat rings

ENGINE 5 4 1 .9 2 0 / 9 2 1 / 9 2 2 / 9 2 3 / 9 2 4 / 9 2 5 / 9 2 6 / 9 2 7 . 5 4 2 .9 2 0 /921 /9 2 2 /9 2 3 /9 2 5 /9 2 6

44

Removing and installing fu el heat exchanger

ENGINE 5 4 1 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 4 /9 25 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 / 9 2 3 / 9 2 5 / 9 2 6

53

Removing and installing nozzle holder assembly

ENGINE 5 4 1 .9 2 0 /921 /9 2 2 /92 3 /9 2 4 /9 25 /9 2 6 /9 2 7 , 5 4 2 .9 2 0

55

/921 /9 2 2 /9 2 3 /9 2 5 /9 2 6

Removing and installing MR/PLD control module

ENGINE 5 4 1 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 4 /9 25 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 S / 9 2 6

58

Removing, adjusting and installing crankshaft angle position

ENGINE 5 4 1 .9 2 0 / 9 2 1 /9 2 2 /92 3 /9 2 4 /9 25 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 /9 2 3 /9 2 5 / 9 2 6

61

Removing and installing MR/PLD un it pump

ENGINE 5 4 1 .9 2 0 /921 /9 2 2 /92 3 /9 2 4 /92 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 1921 m i 1926

63

Removing and installing MR/PLD injection pipes

ENGINE 5 4 1 .9 2 0 /921 /92 2 /9 2 3 /9 2 4 /9 25 /9 2 6 /9 2 7 , 5 4 2 .9 2 0

66

s e n s o r b ra c k e t

/921 /9 2 2 /9 2 3 /9 2 5 /9 2 6

Removing and installing fu el filte r

ENGINE 5 4 1 .9 2 0 /921 /92 2 /9 2 3 /9 2 4 /92 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 5 / 9 2 6

69

Removing and installing intake m anifold

ENGINE 5 4 2 .9 2 0 /921 /92 2 /9 2 3 /9 2 5 /9 2 6

71

Inspecting turbocharger

ENGINE 5 4 1 .9 2 0 /921 /9 2 2 /9 2 3 / 9 2 4 /9 25 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 192119 2 5 /9 2 6

72

Removing and installing exhaust gas turbocharger

ENGINE 5 4 1 .9 2 0 / 9 2 1 / 9 2 2 / 9 2 3 / 9 2 4 / 9 2 5 / 9 2 6 / 9 2 7

75


ENGINE 5 4 2 .9 2 0 / 9 2 1 1922 1921 /9 2 5 /9 26

77

Removing and installing charge a ir pipe

ENGINE 5 4 2 .9 2 0 /921 1922 1921 /9 2 5 /9 2 6

80

Testing intercooler and charge air hoses fo r leaks

ENGINE 5 4 1 .9 2 0 /921 1922 1921 / 9 2 4 /9 2 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0

81

/921 /9 2 2 /9 2 3 /9 2 5 /9 2 6

Removing and installing charge air m anifold

ENGINE 5 4 1 .9 2 0 / 9 2 1 / 9 2 2 / 9 2 3 / 9 2 4 / 9 2 5 / 9 2 6 / 9 2 7 , 5 4 2 .9 2 0

83

/921 /9 2 2 /9 2 3 / 9 2 5 / 9 2 6

Removing and installing poly V-belt

ENGINE 5 4 1 .9 2 0 / 9 2 1 / 9 2 2 / 9 2 3 / 9 2 4 / 9 2 5 / 9 2 6 / 9 2 7 , 5 4 2 .9 2 0 /921 /9 2 2 / 9 2 3 / 9 2 5 / 9 2 6

86

Removing and installing poly V -belt tensioning device

ENGINE 5 4 1 .9 2 0 / 9 2 1 / 9 2 2 / 9 2 3 / 9 2 4 / 9 2 5 / 9 2 6 / 9 2 7 , 5 4 2 .9 2 0

88

/921 /9 2 2 /9 2 3 /9 2 5 /9 26

Disassembling and assembling compressor

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927,542.920 /921 /922 /923 /925/926

En gin es O M 501, O M 502 (m o d. des. 541.9, 542.9), A C T R O S -V e h ic le m od . des. 9 50-954, F2

89

1

Contents

Part 3

Title

Validity

Removing and installing exhaust m anifold

ENGINE 541.920 /922 /923 /924 /925 /926 /927

3

Removing and installing exhaust m anifold

ENGINE 542.920 /921 /922 /923 /925 /926

5

Removing and installing exhaust gas plenum chamber

ENGINE 541.920/921 /922 /923 /924 /925 /926 /927

6

Removing and installing transverse exhaust pipe

ENGINE 542.920 /921 /922 /923 /925 /926

8

Repairing engine brake flap connection

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925 /926

9

Removing, installing engine brake flap connection

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927

Removing, installing engine brake flap connection

ENGINE 542.920 /921 /922 /923 /925 /926

13

Removing and installing the generator support

ENGINE 541.920/921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925 /926

15

Filling engine oil circuit

ENGINE 541.920/921 /922/923/924/925/926/927, 542.920 /921 /922 /923 /925/926

17

Removing and installing oil spray nozzles (pistons)

ENGINE 541.920/921 /922/923/924/925/926/927, 542.920 /921 /922 /923 /925 /926

20

Removing and installing oil pressure relief valve

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /92S /926

22

Removing and installing oil pump

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923/925/926

23

Disassembling and assembling oil pump

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /971 /Q22 /933 W i /Q7fi

24

Removing and installing oil filter housing

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /92S/926

26

Removing and Installing the oil/water heat exchanger

ENGINE 541.920 /921 1922 /923 /924 /925 /926 1927, 542.920 /921 /922 /923 /925 /926

31

Checking cooling system fo r leaks

ENGINE 541.920/921 /922/923/924/925/926/927, 542.920 /921 1922 /923 /925 /926

32

Removing grease and scale in cooling system

ENGINE 541.920 /921 1922 1923 /924 /925 /926 1927, 542.920 /921 /922 /923 /92S/926

34

Removing and installing engine coolant pump

ENGINE 541.920 /921 /922 /923 /924 /925 /926 1927, 542.920 /921 1922 /923 /925/926

36

Disassembling, assembling coolant pump

ENGINE 541.920 /921 1922 1923 /924 /925 /926 /927, 542.920 /921 /922 /923/925/926

38

Testing coolant thermostat

ENGINE 904.905 /906 /907 /908 /909 /910 /911 >921 >922, 906.910 /911 /920 /921 /922 /923 ENGINE 541.920 2921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925 /926 ENGINE 906.940/941

41

Removing and engine installing cooiant therm ostat

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925 /926

43

Removing and installing radiator

ENGINE 541.920/921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922/923/92S/926

45

Removing and Installing fan

ENGINE 541.920 /921 1922 1923 /924 /925 /926 /927, 542.920 /921 /925 /926

48

Page

12

Removing and installing fan

ENGINE 542.922/923

50

Disassembling and assembling rear engine outpu t

ENGINE 541.920 /921 (922 /923 (924 (925 (926 (927,542.920 /921 /922 Z923/925/926 w ith CODE (N51) Rear engine output, outpu t torque 392 Nm w ith CODE (N52) Rear engine output, outpu t torque 600 Nm

52

Removing and installing power steering/fuel pump unit

STEERING 765.889 w ith ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /921 /922 /923 /925 /926

58

Removing and installing fuel pum p/power steering pump unit

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542,920 /921 /922/923/925/926

62

En gin es O M 501, O M 502 (mod. des. 541.9, 542.9), ACTRO S - V e h icle m od . des. 9 50 -954, F2

1

GF01.00-W-2000B

Technical data engine - complete

28.11.96

ENGINE 541.920/921/922/923/924/925/926/927

p âc* G F

Technical data engine

O M 501 LA (engine 541.9201926)

r-^ G F


O M 501 LA (engine 541.922/ 927)

Page 4

t t ìr - G F


O M 501 LA (engine 541.923/ 924)

Page5

SS*GF


O M 501 LA (engine 541.921/925)

Page 6

GF01.00-W-1000-01D


P M n

Engine o utput Engine torque Rated speed

b

Specific fu el consumption

Engine 541.920/926

PageS

D^GF

Additional Information E n g in e s O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h ic le m od. des. 9 50-954, F2

3

541.920 (low)

Engine m odel designation

541.926 (high) O M 501 LA. 11/1

Engine type Engine o u tp u t (P)

Engine to rq ue (M) max.

kW/HP

230/313

rpm

1800

Nm

1530

rpm

1080

Rated speed

rpm

1800

Bore

mm

130

Stroke

mm

150

Total displacement

cm*

11946

Com pression

e

17.25

Firing order

1-4-2-5-3-6

No. o f cylinders/arrangem ent Valves Operating method

6 in V arrangem ent Inlet

2

Exhaust

2

4-stroke diesel w ith direct injection

Com bustion method

Exhaust turbocharging and intercooling

Injection method

Single unit pum p w ith pum p-line-nozzle system (PLD)

Control

Electronic engine m anagem ent w ith solenoid valve-controlled injection

Specific fu el consumption (b)

g/kW h (see diagram)

GF01.00-W-1000-01E


P

Eng ine output

M n

Eng ine torque R ated speed

b

Specific fuel consum ption

Engine 541.922/927

G S -G F

Additional Information 4


541.922 (low) 541.927 (high)

Engine type

O M 501 LA. 11/2

Engine o utpu t (P)

Engine torque (M) max.

kW /HP

260/354

tp m

1800

Nm

1730

rpm

1080 1800

Rated speed

rpm

Bore

mm

130

Stroke

mm

150

Total displacement

cm3

11946

Compression

e

17.25

Firing order

1-4-2-5-3-6

No. o f cylinders/arrangem ent

6 in V arrangem ent

Valves

O perating m ethod

Inlet

2

Exhaust

2


Com bustion method

Exhaust turbocharging and intercooiing

Injection m ethod


C o n tro l

E le c tr o n ic e n g in e m a n a g e m e n t w it h s o le n o id v a lv e - c o n t r o lle d

injection Specific fuel consum ption (b)

GF01.00-W-1000-01F P



Engine 541.923/924

I S s 'G F

Engine o utput

M

Engine torque

n b

Rated speed Specific fu el consum ption

Additional Information En g in e s O M 501, O M 502 (m od. des. 541.9, 542.9), AC TR O S - V e h icle m od. des. 9 50 -9 54 , F2

5


541.923 (low) 541.924 (high)

Engine type

O M 501 LA. 11/3

Engine o u tp u t (P)

Engine to rq u e (M) max.

kW/HP

290/394

rpm

1800

Nm

1850

rpm

1080

Rated speed

rpm

1800

Bore

mm

130

S tro k e

mm

150

Total displacem ent

cm3

11946

Com pression

e

17.25

Firing order

1-4-2-5-3-6


6 in V arrangem ent

Valves

Operating method

Inlet

2

Exhaust

2


Com bustion method


Injection m ethod


C o n tro l


injection Specific fu e l consum ption (b)

GF01.00-W -1000-01G P M n b



Engine 541.921/925

[Ä -G F

Engine o utput Engine torque R ated speed Specific fuel consumption

Additional Information

6


541.921 (high) 541.925 (low)

Engine type Engine o utpu t (P)

O M 501 LA. II/4 kW/HP

315/428

rpm

1800


Nm

2000

rpm

1080

Rated speed

rpm

1800

Bore

mm

130

Stroke

mm

150

Total displacement

cm3

11946

Compression

e

17.25

Firing order

1-4-2-5-3-6


6 in V arrangement

Valves O perating m ethod

Inlet

2

Exhaust

2


Com bustion m ethod


Injection m ethod


Control


injection Specific fuel consum ption (b)


Additional Information En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h icle m od. des. 9 50 -9 54 , F2

7

GF01.00-W-2000C

Technical data engine - complete

28.11.96

ENGINE 542.920 /921 /922 /923 /925 /926

ll. o

k

P^GF

GF01.OO-W-10 0 0 -0 1 H


O M 502 LA (engine 542.920/926)

Page 8


O M 502 LA (engine 542.921/925)

Page 9


O M 502 LA (engine 542.922/ 923)

Page 10

Technical da la e n g in e

P

Engine o utput

M n

Engine torque Rated speed

b

Specific fu el consumption

E n g in e 542.920

PS t- G F


Engine model designation

542.920 (low)

Engine type

O M 502LA. II/2

Engine o utput (P)

kW/HP

390/530

rpm

1800


Nm

2400

rpm

1080

Rated speed

rpm

1800

Bore

mm

130

Stroke

mm

150

Total displacement

cm 3

15928

Compression

e

17.25

Firing order

1-5-7-2-6-3-4-8


8 in V arrangem ent

Valves

O perating method

Inlet

2

Exhaust

2


com bustion m ethod

fcxhaust turbocharging and intercooling

Injection m ethod

Single u n it pum p w ith pum p-line-nozzle system (PLD)

Control

Electronic engine managem ent w ith solenoid valve-controlled injection

Specific fuel consum ption (b)


GF01.00-W-1000-011


P M n

Engine o utpu t Engine torque Rated speed

b

Specific fu el consum ption

Engine 542.921/925

P -^ G F

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h ic le m od . des. 9 50 -9 54 , F2

9

542.921 (low)


542.925 (high) O M 502LA. II/1

Engine type

350/476

kW/HP

Engine o u tp u t (P)

rpm

1800

Engine to rq u e (M) max.

Nm

2300

rpm

10 8 0

Rated speed

rpm

1800

Sore

mm

130 150

S tro k e

mm

Total displacem ent

cm*

15928

Compression

e

17.25

Firing order

1-5-7-2-6-3-4-8


8 in V arrangem ent

Valves

Inlet

2

Exhaust

2


O perating m ethod Com bustion m ethod

Exhaust turbocharging and intercòoling

Injection m ethod


Control


Specific fu el consum ption (b)


GF01.00-W-1000-01J


P

Engine o u tp u t

M n

Engine torque R ated speed

b

Specific fu e l consum ption

Engine 542.922/923

K ä rG F



542.922 (low) 542.923 (high)

Engine type

O M 502LA. II/3

Engine o utpu t (P)

kW /HP

420/571

rpm

1800


Nm

2700

rpm

1080

Rated speed

rpm

1800

Bore

mm

130

Stroke

mm

150

Total displacement

cm3

15928

Compression

e

17.25

Firing order

1-5-7-2-6-3-4-8

No. o f cylinders/arrangem ent Valves

O p e ra tin g m etho d

8 in V arrangement Inlet

2

Exhaust

2


Com bustion m ethod


Injection m ethod


Control


Specific fuel consum ption (b)


Additional Information E n gin es O M 501, O M 502 (m od. des. 541 .9 ,54 2 .9 ), ACTRO S - V e h icle m od. des. 9 50 -9 54 , F2

11

A R 01.1Ô-W-2400B

Rem oving, installing engine

1S.1.96

ENGINE 541.920/921 /922/923Z924/925/926/927. 542.920/921 /922/923/925/926

W01.10*0006-09

1 1.1

Engine w irin g harness Connector

2 3

Compressed a ir regulator w ith a ir drier

1.2 1.3

Electric cable (red) C onn ector (EPS transmission)

4 5

Fuel p ip e (supply) Fuel p ip e (return flow)

1.4

C onn ector (retarder)

Cab-chassis connection p o in t

W01.10-0007-09


6

C o o la n t p ip e (retarder)

11

7

A T F pipes

12

G r o u n d cable (starter)

Hydraulic steering flu id delivery p ip e

8 9

A ir intake m an ifo ld Coolant p ip e (retarder)

13

Hydraulic steering flu id return flo w pipe

10

Starter cables

Mi

Starter

1 14

Engine w iring harness Engine

23 24

Plunger B olt

IS 16 17 IB

Front liftin g eyes

25 26

Exhaust pipe

R e a r lifting eyes

27 23

19

Compressed a ir p ip e (compressor)

29

Engine m ount

20

Chain tackle o r steel rope tackle Transmission

30

Refrigerant compressor (air conditioning) O il fille r guide

Chain block

ISEngine hoist

21 22

Clutch servo unit

33

Selector linkage (MPS transmission)

34

Relay lever (MPS transmission)

35 36

Linkage (MPS transmission) [ 3 Direction o f rotation

31 32

Compressed a ir p ipe (constant throttle) Compressed a ir p ip e (engine brake) Bolt

Dipstick g u id e tu b e

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h icle m od. des. 9 50 -9 54 , F2

13

M odification notes 6.2.97

Inspecting four-circuit protection valve fo r coking added

Page 12

Step 17

Tightening torque fo r engine m ounts added

Step 27

If a reconditioned engine or a new PLD control unit is

Step 37

installed, th e vehicle keys have to be reprogram med

29.6.98

Inspecting e n g in e oil level w ith electric d isp lay

Ste p 4 3 m o d ifie d

Enter engine num ber in FDOK after replacing engine

Step 45 added

mm

Rem oving, installing

@Installation

Replace all self-locking nuts and bolts

1

Disconnect battery

2

Open m aintenance flap

3

Take o ff cover at cab - chassis connection poin t (2)

4

Separate cable (red) (1 .2) and connectors

® Do no t dam age engine w iring harness

(1.1) at cab - chassis connection p oint (2).

(1)

[ D Installation: cover at cab - chassis connection p o in t must b e closed tig h t

Unclip engine w iring harness (1) and place dow n Æ Danger

Risk o f injury from bruises and jamming

No person should be in the tiltin g area o f

when tiltin g cab

th e cab w hen it is being tilted. Alw ays tilt cab as fa r as th e end position and secure

Page 18

w ith a safety prop. 5

T ilt cab

®

Notes on tiltin g cab

6

Detach air cleaner housing over engine (14) GQ O nly fo r plate-type air filte r

Page 18

M od el 950, 952, 953, 9 54

and remove bracket at fro n t left lifting eye (15) 7

Remove noise encapsulation at top, rear, on left and right

8

Remove trim panel over transmission

9

Remove radiator

10

Detach engine w iring harness (1) at fixture

11

If warm w a te r auxiliary heater fitted,

an d fra m e an d tie u p at e n g in e

re m o v e hea ter unit

Separate connectors (1 .3 ,1 .4 ) o f engine

DO If EPS transmission, retarder and PTO fitted

w iring harness (1) at transmission holder 12

AR20.20-W-3865B

R em o v e air in tak e m a n ifo ld (8) at

turbocharger 13

Separate compressed air lines (26,27) of engine brake and constant th rottle and detach bracket at transmission

14

Remove exhaust pipe (25) at engine brake

E

flap connection

inspect clip fo r wear; replace clip if

Installation: dean sealing surfaces and

necessary 15

Remove shift linkage (33) between shift

E

O nly w ith MPS transmission

lever and relay lever (34) 16

R em ove relay lever (34) at transm ission

E O n ly w ith M P S tran sm ission


17

Unbolt compressed air line (19) at

ED If coking present, it is then necessary to

compressor and inspect fo r coking

additionally inspect compressed air line between compressor and compressed air drier w ith integrated pressure regulator (3) and the 4-circuit protection valve. Replace coked parts.

EE Installation: inspect compressed air line fo r leaks 18

Tie up oil fille r lin e (31) and dipstick guide tube (32) at engine

19

Release poly V-belt and take o ff

20

Detach AC compressor (30) w ith bracket at engine

DOO nly on vehicles w ith AC ED Only on vehicles w ith AC.

AR13.25-W-3200B

Do not separate refrigerant lines. @ Supporting bracket o f AC compressor

BA01.40-N-1012-01D

to crankcase @ Support to fixture o f AC compressor

BA83.55-N-1Q02-01C

and supporting bracket o f generator 21

Separate starter cable (10) and ground cable (11) at starter (M 1)

22

Detach cables (10,11) a t tim ing case

23

24

Remove clutch servo unit (22) at

Do not separate hydraulic line and

transmission and tie up at fram e

compressed air line

Pull plunger (23) o u t o f the release lever o f

E E Installation: grease head o f plunger

BR00.45-Z-1001-06A

the clutch 25

Separate ATF lines (7)

26

Separate coolant lines (6,9) at transmission

ED Collect ATF which flow s out ED Collect coolant w hich flow s out

and retarder 27

Unscrew bolts (28) at both engine mounts

tiEll Engine support to engine m ount

BA22.10-N-1004-01D

(29)

A

Danger

Risk o f explosion from ig nition. Risk o f

No fire, naked flam e or smoking.

poisoning from inh alin g and sw allow ing

Pour fuels only into suitable and

fuel. Risk o f injury as a result o f fuel coming into contact w ith skin and eyes.

appropriately marked containers. W ear protective clothing when handling fuel.

Separate fuel feed line at fu el tank and fuel lines (4,5) at connection points in the

Collect fuel which flow s out ED Installation: pay attention to m arking

fram e longitudinal m em ber and seal

o f fuel lines

29

Separate steering flu id pressure line (12) and steering flu id return flo w line (13)

ED Collect hydraulic flu id which flow s out

30

Attach transmission (21) or support

28

31

P ag e 19

Unscrew bolts (24) at transmission housing (21)

32

Attach engine hoist (17)

WH58.30-Z-1001-07A Attach engine hoist to one o f the fro n t lifting eyes (15) and to th e rear liftin g eye (18); attach additionally w ith chain block and second fro n t liftin g eye (15) and secure engine (14) to prevent it tipping

33

Separate engine from transmission

ED Installation: if the splines o f the clutch plate and the transmission shaft are not aligned w hen fittin g together engine and transmission: J.

Additional Information E n g in es O M 501, O M 502 (m od, des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50-954, F2

15

Attach cranking device (35) fo r starter ring gear at tim in g case. Rotated starter ring gear sufficiently so that the internal splines o f the clutch are aligned w ith the splines o f the input shaft. ® Remove cranking device (35) before starting the engine.

m 0

407 589 00 63 00 Cover o f TDC inspection hole at tim ing

BA01.60-N-1001-01B

case 34

Lift o ut engine

[2 Installation: lig h tly grease transmission

BR00.45-Z-1001-06A

shaft. L ift engine into fram e and align so that the clutch p late is lined up w ith transmission shaft Inspect engine m ounts (29) fo r wear

35

E

If w ear present j

Replace engine mounts 0

Engine m ount to fram e

36

Remove clutch

E

If w ear present 4

BA22.10-N-1006-01D

Replace clutch

AR25.10-W-0050B

37

install in reverse order

E

AR80.57-W-0010A

If an exchange engine or only a new

PLD control unit is fitted, the vehicle keys have to be relearned 38

Fill brake system o f vehicle with

E

compressed air

up to governed pressure at tire inflation

Fill brake system from external source

connector o f pressure regulator (3) 39

B le e d b r a k e s y s te m

Page 19 ^

Danger

Risk o f accident as a result o f vehicle

Secure vehicle to prevent it starting off.

starting o ff when engine running. Risk of

W ear closed and close-fitting w ork clothes.

injury as a result o f bruises and burns if you

Do not grasp hot or rotating parts.

Page 20

insert your hands into engine when it is being started or w hen it is running. 40

Start engine

® Crank engine w ith starter fo r no t more than 20 seconds. W a it about 2 minutes

41

In s p e c t o il p re s s u r e w h e n e n g in e id lin g

@

before repeating attem pt at starting. D o n o t re v u p e n g in e (14) s o lo n g a s n o

B E 1 8 .0 0 - N .1 0 0 1 - 0 1 0

oil pressure is indicated.

E

The o il pressure gage should indicate

oil pressure after ab out 10 seconds. 42.1

Check engine oil level at electric gage

42.2

Check engine oil level w ith dipstick

ED Only if oil level sensor is parameterized. See ACTROS operating insctructions part 3

E

If oil level sensor is not parameterized.

See ACTROS operating insctructions part 4 43

Switch o ff engine and inspect for leaks

44

Check coolant level

45

Enter engine num ber in FDOK screen 1111

AP20.00-W-2010A E

O nly if exchange engine is fitted


T est d a ta e n g in e oil p re ssu re

Designation

Number

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927 BE18.00-N-1001-01D

Engine oil pressure at

925/926

idling speed

min. bar 0.5

0.5

maximum speed

min. bar 2.5

2.5

@ Crankcase, tim ing case cover, end cover Number

Designation

Engine 541.920/

Engine 542.920/

921/922/

921/922/

923/924/

923/925/ 926

925/926/ 927 BA01.40-N-1012-01D

Carrier o f refrigerant compressor/ hydraulic pum p/frigoblock to crankcase

Nm

160

160

® Tim ing case Designation

Number

BA01.60-N-1001-01B

Engine 541.920/ 921/922/923/ 924/925/926/927

End cover o f TDC inspection hole to

Nm 25

Engine 542.920/ 921/922/923/ 925/926 25

tim in g case

0

Engine mounts, engine support

Num ber

Designation

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

BA22.10 N 1004-01D

E n g in e su p p o rt to e n gin e m o u n t

fro n t

Nm

330

330

rear

Nm 330

330

B A22.10-N-1006-01D

Engine m ount to fram e

fro nt

Nm 150

150

rear

Nm 150

150

@ Refrigerant compressor Num ber

Designation

BA83.55-N-1002-01C

Support to fixture of refrigerant com pressor/frigoblock and generator

M o d el 950 Nm 50

M odel 952

M odel 953

M od el 954

50

50

50

carrier

Additional Information En g in e s O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h icle m od . des. 9 50-954, F2

17

Commercially available tools (see Workshop Equipment Manual)

Number

Designation

Make (e.g.)

Order num ber

WH58.30-Z-1001-07A

Engine hoist (self-locking)

Bäcker

3188

Herderstraße D-42853 Remscheid Repair products Number

Designation

Order num ber

BR00.45-Z-1001-06A

M B lon g life grease

000989 63 51

Bearbeitungsverm erk j Datum ÏÈiëiëHër................

AS60.80-Z-0001-01A

\ Vermërk"

.............................................................................................

Injury hazard fro m pinching and crushing

W hen tiltin g ensure th at no one is

w hen cab is tilted

present in th e tiltin g area o f the cab.

^

Danger!

Alw ays t ilt cab to end position and secure w ith safety brace. Injury hazard A damaged tiltin g mechanism or im proper handling of the tiltin g mechanism can lead to severe injuries w hen tiltin g the cab. Rules o f behavior/protective measures Before tiltin g cab: - Shut o ff engine.

W hen tiltin g cab: - Protect tiltin g area and particularly tiltin g device against un au th orized access, e.g. by blocking o ff or w ith human guard. A ttach safety cable before tiltin g when so specified in the vehicle operating instructions.

-

A p p ly parking brake.

-

Secure vehicle against rolling. On vehicles with m anual transmission m ove shift lever to

-

On vehicles w ith autom atic transmission m ove selection lever to position “N".

-

Never w ork under cab w hen partially tilted.

-

Alw ays t ilt cab to end position and secure w ith safety brace.

neutral position.

AH60.80-N-0003-01A

Notes on tiltin g th e cab

Models 673,674,675, 676,677, 678, 679,950, 952,953, 954, 957,970,971, 972,973,974, 975,976

Before tiltin g the cab e Switch o ff engine e e e

A p p ly parking brake Secure vehicle to stop it rolling aw ay Remove a ll loose objects (e.g. cans, bottles, tools, bags etc.)

On vehicles w ith a refrigerator box e

The refrigerator box must be switched o ff before the cab is

e

tilted . The retrigerator box may only be switched on i u minutes a fte r tiltin g the cab back again.

from the cab

E

e

On vehicles w ith m anual transm ission m ove sh ift lever to neutral position

O p erating Instructions and the red inform ation plate on the refrig erato r box.

A lso refer to the refrigerator box m anufacturer's

e

M odel 957: release steering colum n and open fro n t flap

The coupling pin must be inserted correctly.

CD A lw ays tilt cab up to its fin al position.


AS47.00-Z-0001-01A

Risk o f explosion from ig n itio n o f fuel, risk Fire, the creation o f sparks, naked o f poisoning If fu el is inhaled or sw allow ed

lights and smoking prohibited.

and risk o f injury if skin or eyes come into contact w ith fuel

O nly pour fuels into containers which are suitable and are correspondingly marked.

Danger!

W ear protective clothing w hen handling fuels. Potential dangers Risk o f explosion, poisoning and injury Fuels are highly flam m able and are poisonous if sw allowed. Fuel

-

Always put drained fuel into containers which are suitable and can be properly closed off.

example, removes the skin's natural oils. Fuel vapors are explosive

-

Immediately remove any fuel w hich has been spilt.

and Invisible, and spread o ut along the floor. They are poisonous if inhaled and can cause unconsciousness in high concentrations.

W orking on the vehicle using a naked flam e

can cause damage to the skin. Contact w ith gasoline fuel, fo r

(e.g. when w elding etc.). Protective measures/rules fo r handling fuels - Observe local national safety regulations. - Fire, the creation o f sparks, naked lights and smoking forbidden. - M ake sure th at the w ork area is sufficiently w ell ventilated.

First aid measures e Wash any fuel from skin using soap and water.

-

e

Change out o f clothing on which fuel has been spilt as soon as possible.

e

If fuel Is splashed into the eyes, rinse o u t the eyes im m ediately w ith water; consult a doctor if appropriate.

Never drain or add fuels over workshop pits.

AP47.00-W-1720-01A

-

Before carrying o ut such w ork, remove the relevant parts o f t h e f u e l s y ste m a n d s e a l n f f o p e n f u e l lin e s w it h p lu g s

Bleeding air in fu el system

1

Loosen handle on manual pump.

2

A ctu ate manual pump until overflow valve opens audibly.

3

Tighten handle on manual pump.

Additional Information En g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50-954, F2

19

AS00.00-Z-0Q05-01A

Secure vehicle to prevent it from Risk o f accident as a result o f vehicle starting o ff w hen engine is running. Risk o f moving off. injury as a result o f bruises and burns if you W ear closed and close-fitting w ork in s e r t y o u r h a n d s in t o e n g in e w h e n it is

c lo th e s .

being started or w hen it is running.

Do not grasp hot or rotatin g parts.

Possible dangers

A

Danger!

Rules o f conduct / Protective measures a s a general rule, carry o u t w o rk on th e running engine only if

Risk o f accident from vehicle starting o ff d urin g starting o peration (e.g. w hen

this is absolutely essential.

testing com pression pressure) as a result o f gear engaged o r w hen engine running and vehicles w ith autom atic transmission as a

On models w ith m anual transmission, m ove gearsh ift lever Into Neutral p osition.

result o f selector lever p ositio n "P ” o r "N " not engaged (exception: some vehicles d o n o t have a selector lever position

Before starting th e engine, apply parking brake.

-

On models w ith au tom atic transmission, m ove selector lever

-

a selector lever position "P"). On models w hich do not have selector lever position "P ",

into position “ P” o r " N " (exception: some vehicles do not have

” P").

secure selector lever to prevent it from being operated

Risk o f injury Severe Injuries may be caused by freely rotating parts in th e area

unintentionally.

o f th e running engine. The heat produced by the engine w h en it is operating can result in severe burns if contact is m ade w ith

-

W ear closed and close-fitting w ork clothes. Take o ff any jew elry, such as chains, rings etc.

individual, unshielded parts.

-

If you have long hair, w ear a suitable head cover.

-

-

Before com m encing w o rk on the running engine, check to o btain a general picture o f th e positioning o f parts w hich may be hot. W hen carrying o u t w o rk w hen starting the engine or w hen engine is running, d o not touch any h o t and rotating parts.

First aid measures in th e event o f burns • Do n o t rub the skin areas affected; flush w ith plenty o f cold w a te r and cover skin w ith sterile bandages. •

I m m e d ia t e ly c o n s u lt a p h y s ic ia n .


AR01.00-W-0001A

In s p e c tin g e n g in e f o r d u s t d a m a g e

30.11.95

ENGINE 904/. 906.541.542

Removing If the oil consum ption Is high or if the

ffl

engine fails, it is o fte n not clear w hether dust damage or normal w ear and tear exists 1

Remove pistons

Engine 904,906

AR03.10-W-7021A

Engine 541, 542

Page 75 0

Inspecting

2

Inspect intake tract between air cleaner and engine fo r dust deposits

[J] Severe dust deposits in the elbows of

Inspect pistons and cylinder wall fo r wear

QQ The w ear patterns o f the stems o f the

3

(dust damage)

the intake pipes and hoses are a reliable indication o f dust damage. a very fin e film is permissible on engines w ith oil bath air cleaner.

p isto ns a n d the h o n in g patterns o f the

cylinders make it possible to recognize dam age caused by severe dust deposits. If w ear exists i Install new cylinder liner Engine 904,906

AR01.40-W-9273A

Replace cylinder liner Engine 541, 542

Page 53

Replace piston, engine 904,906

AR03.10-W-7021A

Replace piston, engine 541,542 P ag e 75 Notes fo r assessing wear of cylinder walls in Engine 541,542,904,906

m

Page 21

the case o f dust damage m

N otes fo r assessing w e a r o f p istons in the

E n g in e 541, 542, 904, 9 06

Page 22

case o f dust damage

A H 0 1.40-N-0001-01A

Notes fo r assessing wear o f cylinder w all if dust dam age present

Engines 904,906, 541,542

EC

Cylinder w a lls and cylinder liners w ith o u t dust damage The honing is m ore or less clearly visible on the entire contact surface. The honing may be p artially w o rn at the reversal point o f the first piston ring.

W03.10-001401

Additional Information En g in e s O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V e h ic le m od . des. 9 5 0 -9 54 , F2

21

C ylinder w a lls and cylinder liners w ith dust dam age The traces o f machining from honing are only very fain tly visible or not at all. If the w ear is w ell advanced, a wear step can be fe lt at the reversal p oint o f the first piston ring.

m Dust dam age is caused by poor sealing, splits, chafing dam age o f the intake lines, seals and hoses. W hen carrying o u t repair and service w ork, m ake a careful inspection o f intake lines, seals and hoses, also at points no t easily accessible.

W03.10-001S41

AH03.10-N-0001-01A

Notes fo r assessing w ear to pistons in the case o f dust dam age

Engine 541, 542, 904,906

m

Pistons w ith o u t dust damage The contact surface o f the piston stem is visible over a large area and the m achining grooves can still be recognized w ithin this area.

ffl The m achining grooves at the circumference are intentional recesses which are filled w ith oil and contribute to better lubrication.

W03.10-0012-01

Pistons w ith dust damage The contact pattern at the stem has a mat (pumiced) appearance and the machining grooves are com pletely w orn away w ith in the contact surface. In th e advanced stage o f wear, slight traces o f seizure are already present on the stem and the piston rings are sharp-edged.


AR01.00-W-0200B

Inspecting cylinders with light probe

5.7.96

ENGINE S41.920/921 /922 /923 /924 /92S/926/927, 542.920/921 /922 /923 /92S/926 1

B

Test p ro b e

2

0

Cylinder inspection lig h t

W07.15-0008-02

Testing 1

Attach cranking device (7) to tim ing case

@ Cranking device should be removed before starting the engine. m

407 589 00 63 00

® End cover to tim ing case 2

Remove nozzle holder com bination

3

Rotate crankshaft w ith the cranking device

BA01.60-N-1001-01B AR07.03-W-6831B

Position piston o f cylinder to be inspected to B D C

Additional Information E ngines O M 501, O M 502 (m od. des. 541.9.542.9), A C TR O S - V e h ic le m o d . des. 9 5 0 -9 5 4 , F2

23

4

insert test p ro b e (1) through the protective

19 Cylinder inspection lig h t CD Connection o f cylinder inspection light,

sleeve b ore Into th e cylinder

see o perating instructions o f equipm ent

Connect cylin der inspection lig h t (2) and

WH58.30-Z-1028-05A

m a n u fa c tu re r.

5

Inspect cylin de r barrel and piston pin

B

Page 21

Cylinder barrels must not have any

scorch streaks and fre ttin g streaks. Isolated m inor d raw in g grooves are n o t critical. Inspect co n d ition o f piston crown, if necessary j

Page 32

Remove cylinder head. 6

Inspect rem aining cylinders in the same way

7

Install in th e reverse order

@ Tim ing case N um ber

BA01.60-N-1001-01B

Designation


Engine 541.920/

Engine 542.920/

9 2 1 /9 2 2 / 9 2 3 /

9 2 1 /9 2 2 / 9 2 3 /

924/925/926/927

925/926

Nm 25

25

t im in g c a s e

Com m ercially availab le tools (see W o rksh o p Equipm ent Manual) N um ber

Designation

M ake (e.g.)

WH58.30-Z-1028-05A

Cylinder inspection lig h t M otoskop T W (dichroic light) w ith lens probes 103 26 CW (570 mm) and 103 26 CT (210 mm)

Karl Storz GmbH D-78532 Tuttlingen

O rder num ber


AR01 .OO-W-1200B

Testing com pression pressure

5.7.96

ENGINE 541.920/921/922/923/924/925/926/927, 542.920/921/922/923/925/926

7

N ozzle h o ld e r com bination S ) Connection piece

5 6

3.2

S I Compression recorder S I A n g l e d co n n e ctio n

S10

Start switch

3.3

S I Diagram sheet

S11

Stop switch

4

Tensioning clamp

2 3.1

m

Bolt Seal

Removing

Æ û a n g e r!

Risk o f accident as a result o f vehicle Secure vehicle to prevent it moving off. starting o ff when engine running. Risk of W ear closed and close-fitting w ork clothes. injury as a result o f bruises and burns if you Do not grasp hot or rotating parts. insert your hands into engine w hen it is

Page 20

being started or w hen it is running. 1

Set valve clearance

Q ] Carry out setting only when engine is

AP05.30-W-0560A

cold, or thoroughly warmed through. W ait at least 30 minutes after sw itching o ff e n g in e .

2

Warm engine up to operating tem perature E

Coolant tem perature approx.

70 to 95 °C 9

R e m o v e n o 7 ? le h o ld e r c o m b in a t io n (1)

4

Install connection piece (2) w ith seal (6) and clamp tig h t w ith tensioning clamp (4)

A R 0 7 .0 3 -W -6 8 3 1 B

@ Tensioning clamp o f injection nozzle

S3 5

BA07.15-N-1003-01B

and constant throttle to cylinder head Q ] Install tensioning clamp turned through 180°. 904 58901 2100

Crank engine w ith starter by

E

simultaneously pressing the Start switch (S10) and Stop switch (S11).

combustion residues.

Crank engine several times to elim inate

Additional Information E n g in e s O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od. des. 950-954, F2

25

6

Assemble compression recorder (3.1) and

E 3 See operating instructions fo r

angled connection (3.2)

connecting th e compression recorder.

7

Connect compression recorder (3.1) to the connection piece (2)

8

Insert diagram sheet (3.7) into the compression recorder (3.1)

001 589 78 2100

m

001 589 78 2100

m m

904 5 8901 2100 001 589 78 21 00

Testing 9

Crank engine w ith starter by

Q ] at least 8 engine revolutions

simultaneously pressing the Start switch (S10) and Stop switch (S11). 10

Test remaining cylinders in the same way

11

Compare the measurements on the diagram sheet (3.2) w ith the specified

Compression pressure at starter speed.

BE01.00-N-1001-01B

Permissible difference between the

BE01.00-N-1002-01B

values

individual cylinders. If the compression pressure is b elo w the minimum or if the permissible difference between the individual cylinders is exceeded, determ ine cause and rectify J,

Page 32

Detach cylinder head Installing 12

Detach compression recorder (3.1) and connection piece (2) together w ith seal (6)

13

Install nozzle holder co m bination (1)

AR07.03-W-6831B

Test data o f compression pressure Number

Designation

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

BE01.00-N-1001-01B

Compression pressure at starter speed

bar £ 2 8

£28

BE01.00-N-1002-01B

Permissible difference betw een the individual cylinders

bar £ 4

£4

§ 3 Diesel injection system w ith unit pumps (MR/PLD) Number

B A07.15-N-1003-01B

Designation

Tensioning clamp o f injection nozzle

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/925 /926

Nm 50

50

and constant throttle to cylinder head


C o m p re ssio n re co rd e r

C o n n e cto r

Additional Information En g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A CTRO S - V e h icle m od. des. 9 50 -9 54 , F2

27

AR01.20-W-5014B

Removing, installing cylinder head cover

17.1.96

ENGINE 541.920/921 /922 /923 /924 /92S /926/927, 542.920/921/922/923/925/926 1 2

Bolt Seal

3

C y lin d e r h e a d c o v e r

4

Gasket

M o d ification notes 6.2.97

Tightening torque o f cylinder head cover m odified

Step 2

su es

Removing, installing

A

Risk o f injury from bruises and jamming when tiltin g cap

Danger!

Page 28

Page 18

No person should be in the tiltin g area o f the cab w hen it is being tilted. Alw ays tilt cab as fa r as the end position and secure w ith a safety prop.

1

Tilt cab

®

Notes re tiltin g cab

M odels 950, 952,953,954

Page 18 2

Unscrew bolts (1)

H I Installation: replace seals (2) 0

3

Take o ff cylinder head cover (3)

4


0

Cylinder head cover to cylinder head

BA01.20-N-1001-01C

H I Installation : clean sealing surfaces and replace gasket (4)

C ra n k ca se ventilation, cylin d er h ead cover

Number

BA01.20-N-1001-01C

Designation

Cylinder head cover to cylinder head

Nm

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

20

20


AR01.30-W-5461B

Removing, installing protective sleeve

5.2.96

ENGINE 541.920/921/922/923/924/925/926/927. 542.920/921 /922/923/92S/926 1 2 3 4

N ozzle ho ld er com bination Protective sleeve 0 -ring I S Pronged wrench

WOt .40 0012 06

H3H


/K D ange r!

Risk o f in jury to skin a n d eyes fro m

D o n o t o p e n the co o lin g system u nless the

scalding from ho t coolant w hich splashes out. Risk o f poisoning fro m sw allow ing

coolan t tem perature is below 90 °C. Open cap slow ly and allow the pressure to

coolant

P a g e 30

release. Do not pour coolant into containers fo r drinks. W ear protective gloves, protective clothes, and eye protection.

1

Drain coolant

Collect coolant.

®

Notes on coolant

A ll engines

2

Remove nozzle holder com bination (1)

3

Use p ro n g e d w re n ch (4) to rem ove

AP20.00-W-2080A P a g e 31 AR07.03-W-6831B

m

904 589 0 0 07 00

protective sleeve (2) ED Installation: clean sealing surfaces of the protective sleeves and o f the cylinder head.

4

Remove O-ring (3) from the cylinder head

5

Install in the reverse order

@ Protective sleeve to cylinder head

BA01.30-N-1001-01D

Q ] Installation: replace O-ring and coat w ith acid-free grease.

BR00.45-Z-1018-06A

@ Cylinder head Designation

BA01.30-N-1001-01D

Protective sleeve to cylinder

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/ 027

922/923/925/926

Nm 40

40

head

E n g in es O M 501, O M 502 (m od. des. 541.9,542,9), A C TR O S - V e h icle m od . des. 9 5 0 -9 5 4 , F2

Additional Information29

Repair products Number

Designation

Order number

B R00.45-Z-1018-06A

ATE grease

-

AS20.00-Z-0001-01A

Risk o f injury to skin and eyes from scalding from ho t coolant which splashes out..Risk o f poisoning from sw allowing coolant.

Do no t open the cooling system unless A the coolant tem perature is b elow 90 °C. Open cap slowly and allow the pressure to release. Do no t pour coolant into containers fo r drinks.

Danger!

W ear protective gloves, protective clothes, and eye protection. Possible dangers Risk o f injury

Protective measures/rules o f conduct - A llo w cooling system to cool dow n to a coolant tem perature o f less than 90 °C.

The cooling system is pressurized w h en the engine is warm. Risk o f scalding from hot coolant w hich splashes o u t if the cooling system is opened suddenly.

-

Risk o f poisoning If coolant is swallowed, the person affected is likely to show signs

-

o f poisoning such as headaches, giddiness and stomach aches, paralysis o f th e respiratory system, unconsciousness, nausea, and convulsions.

•

Pour large quantities of cold w ater over the affected area of skin and cover over w ith sterile bandages.

•

Have person affected drink plenty o f w ater to w hich m edicinal carbon has been added.

Open coolant system cap slowly; open a conventional type o f coolan t system cap to the first detent and open a screw-type coolan t system cap about ' I 2 turn, and allo w the pressure to release. W ear protective gloves, protective clothes, and eye protection. Do no t pour coolant into containers fo r drinks.

F irs t a id m e a s u r e s

•

Consult a doctor If the person affected has severe burns or has sw allow ed considerable quantities.


AH20.00-N-2080-01A

Instructions re coolant

Coolant com position Passenger car and commercial vehicle engine (normal case): 50 % by volum e w a te r and

® A concentration o f anticorrosion/antifreeze agent higher than 55 % by volum e should no t be used as the maximum antifreeze

50 % by volum e anticorrosion/antifreeze agent.

protection is thus reached. A n even higher concentration again

See M B Specifications fo r Service Products fo r d iffe rin g coolant com position fo r commercial vehicle engines.

reduces the antifreeze protection and impairs heat dissipation. W ater

Purposes o f anticorrosion/antifreeze agent e Corrosion and cavitation protection fo r all com ponents in the cooling system e A n tifree ze protection

Use w ater w hich is clean and n o t to o hard. Drinking water frequently, b ut no t always, satisfies the requirements. The contents o f dissolved substances in the w ater can be of

e

analyze the water. See M B Specifications fo r Service Products for

Increasing boiling p oint so that the coolant does no t evaporate so rapidly. Ejection o f coolant is avoided at high coolant

importance fo r th e occurrence o f corrosion. In cases o f doubt, fresh w ater regulations.

temperatures. Operation o f m onitoring o f coolant A n tifree ze protection 50 % by volum e o f anticorrosion/antifreeze concentration offers antifreeze protection dow n to approx. -37 *C. A higher concentration is only practical at even low er am bient temperatures. 55 % by volum e o f anticorrosion/antifreeze concentration offers antifreeze protection dow n to approx. -4 5 °C.

Inspect coolant fo r resistance to low tem peratures before the start of the cold season o f the year. In countries w ith high am bient temperatures, inspect the anticorrosion/antifreeze concentration once a year. The corrosion protection in the coolant is reduced during o p e r a t io n . S u c h c o o la n t s h a v e a s e v e re ly c o r r o s iv e effect. The maximum permissible period o f use o f the coolant is fo r passenger car and commercial vehicle engines (normal case) 3 years. S e e MB S p e c if ic a t io n s f o r S e r v ic e P r o d u c t s f o r t h e p e r io d o f u se for differing coolan t com position fo r commercial vehicle engines. Disposing o f coolants

B e f o r e p o u r in g f r e s h c o o la n t in t o t h e sy ste m , f lu s h t h e u se d

coolan t o u t o f the cooling system. Clean cooling system If severe soiling or o il contam ination exist.

O b s e rv e le g a l r e g u la t io n s a n d lo c a l w a s t e w a t e r r e g u la tio n s .

For workshops located in the Federal Republic o f Germany see: "Um weltschutz-Handbuch fü r Kfz-Reparaturbetriebe" (Environm entalprotection m anual fo r vehicle repair workshops) Publisher: Verband der Autom obilindustrie e.V. (VDA) D-60625 Frankfurt am M ain, Westendstraße 61

Additional Information E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h icle m od . des. 9 50-954, F2

31

17.1.96

Rem oving, installing cylinder head

AR01.30-W-5800B

ENGINE S41.920/9211922/923/924/92S/926/927.542.920/921 Z922/923/925/926 1

C ylin d er h e a d gaske t

2

Cylinder head

3

Injection pipe

4

Leak fu e l pipe

6

T a p pe t ro d

7

Rocker arm assembly

8

Cylinder head b o lt

9

Valve bridge

10

S p rin g

11

Packing

12

Decompression brake pipes

13 14

Exhaust m an ifo ld w ith turbocharger Bolts

15 16

Tensioning sleeves Exhaust m an ifo ld gasket

17

Centering sleeves

L

Shank length o f cylinder head b olt

W01.30-0010-06


mm A

Danger!

Tightening torques o f cylinder head bolts m odified

Step 11

Checking engine oil level w ith electric indication

Step 22 m odified

Page 32

Rem oving, installing Risk o f injury to skin and eyes from

Do no t Open the cooling system unless the

scalding from hot coolan t w hich splashes

coolant tem perature is below 90 °C. Open

out. Risk o f poisoning from sw allow ing coolant

cap slow ly and allo w the pressure to release. Do no t pour coolant into

Page 30

containers fo r drinks. W ear protective gloves, protective clothes, and eye protection. 1

Drain coolant

Collect coolant

®

Notes re coolant

A ll engines

2

Rem ove ch arge air h o u sin g

3

AP20.00-W-2080A

Page 31 A R09.41 -W -6 6 8 16

Remove noise encapsulation on right or left

4

Detach leak fuel pip e (4) at cylinder head

E D I n s t a lla t io n : r e p la c e se a ls

(2) ® A ir pipe o f constant th rottle to cylinder

BA01.30-N-1003-01D

head 5

Remove injection pipes (3)

6

Detach constant th rottle pipes (12) at cylinder head (2)

Q ] Installation: replace seals

Disconnect exhaust m anifold (13) at

On engine 541.920- 927

cylinder head (2)

CDDetach exhaust m anifold at the

7

AR07.15-W-9235B

AR14.10-W-3915B

rem aining cylinder heads

32


On engine 542.920- 923/925/926

AR14.10-W-3915C

CD Detach exhaust m an ifold at the remaining cylinder heads 8

Remove rocker arm assembly (7)

9

Take o ff valve bridge (9), springs (10) and packing (11)

AR05.00-W-5521B ® M ark valve bridge relative to the valves. If the valve seat rings in the cylinder head or the valves have been machined, it is then necessary to set th e valve bridges when removed.

10

Remove tappet rods (6)

ED Rotate ta p p e t rods w h en pulling out so that they are detached in the roller tappet and the roller tap pet is n o t pulled out o f the crankcase. In stallation : oil ta p p e t ro d s w ith e n gin e oil

and ensure they are correctly installed in the roller tappet. 11

Unscrew cylinder head bolts (8)

422 58902 0900

ill

@ It is necessary to m aintain all the tigh ten ing to rq ue stages to ensure even compression o f the cylinder head gasket

ED Installation: oil cylinder head bolts w ith

Page 35

engine oil. Pay atte ntio n to tightening instruction fo r cylinder head bolts. 0 12

Take o ff cylinder head (2)

Cylinder head bolts to crankcase

BA01.30-N-1002-01D

@ Place dow n cylinder head to the side so that the installed nozzle holder com bination is n o t damaged.

CD Installation: fit cylinder head over the centering sleeves (17) 13

Take o ff cylinder head gasket (1)

ED Seal oil and co olan t bores and crankcase. Clean and inspect crankcase contact surface.

CD Installation: fit new cylinder head g a ske t ove r the c e nterin g sleeves (17) on to

the face o f the crankcase. Pay attention to installation position of cylinder head gasket. 14

Take o ff exhaust m anifold gasket (16)

[D Installation: replace exhaust m anifold gasket S I Inspect exhaust m an ifold gasket at the rem aining cylinder heads, if necessary ) remove exhaust m anifold (13) and replace exhaust m anifold gasket

15

O n e n g in e 541.920 - 92 7

A R 1 4.10 -W -3 9 15B

O n engine 542.920 - 923/925/926

AR14.10-W-3915C

BE01.30-N-1001-01C

Clean threaded, oil and coolant bores in th e crankcase

Inspecting 16

17

Measure length o f shank o f cylinder head

If the maxim um shank length (L) has been

b olts (8)

exceeded, replace cylinder h ea d bolt

Clean cylinder head (2) and inspect for

ED If problem exists

(,

cracks and damage

E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C TR O S - V e h icle m od . des. 9 50 -9 54 , F2


replace cylinder head Inspect contact surface o f cylinder head (2)

18

E

If d istortion exists J,

BE01.30-N-1002-02C

fo r distortion

Page 37


Secure vehicle to prevent It moving off.

Page 20

starting o ff w hen en g in e running. Risk o f


injury as a result o f bruises and burns If you insert your hands in to engine w hen it is being started or w h en it is running.

Do no t grasp ho t or rotating parts.

Start engine and check oil pressure gage at id lin g speed

® Crank engine w ith the starter fo r not more than 20 seconds. W ait about


20 A

face cylinder head contact surface inspect seat o f roller tappets in crankcase

19

Danger!

21

BE18.00-N-1001-01D

2 m inutes before m aking a repeat attem pt at starting. Do no t rev up engine until oil pressure is indicated. O il pressure gage should indicate

E

pressure after about 10 seconds. 22.1

Check engine oil level w ith electric gage

E O nly If oil level sensor is parameterized. See ACTROS O perating Instructions Part 3

22.2

E If oil level sensor is not parameterized.


See ACTROS O perating Instructions Part 4 23

Sw itch o ff engine and check fo r leaks

24

Inspect coolant level

AP20.00-W-2010A

Test data o f cylinder head b olts Number

BE01.30-N-1001-01C

D esignation

Cylinder head bolts

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/

9 2 4 /9 2 5 /9 2 6 /9 2 7

9 2 3 /9 2 5

210

210

mm 212

212

shank length w hen new

mm

max. shank length

Test data o f cylinder head Number

Designation

BE01.30-N-1002-02C

Permissible difference o f flatness o f bottom contact surface in

Engine 541.920/921/922/923/ 924/925/926/927 542.920/921/9 over a length o f

mm £0.015

lo n g itud ina l direction

Test data o f engine oil pressure Number

BE18.00-N-1001-01D

Designation


Engine 541.920/

Engine 542.920/

9 2 1 / 9 2 2 /9 2 3 /

9 2 1 / 9 2 2 /9 2 3 /

924/925/926/927

925/926

idling speed

min. bar 0.5

0.5

max. speed

min. bar 2.5

2.5


0

Cylinder head

Number

Designation

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/

922/923/925/926

927 BA01.30-N-1002-01D

Cylinder head bolts to crankcase

1st stage

Nm 10

10

2nd stage

Nm 50

50

3rd stage

Nm

100

100

4th stage

Nm 200

200

5th stage

90

6th stage

°JL 90

Tightening

90 90

AR01.30-W-5800-07B

AR01.30-W-5800-07B

instructions see BA01.30-N-1003-01D

A ir pipe o f decom pression brake to

Nm 45

45

cylinder head

AR01.30-W-5800-07B

T ightening instructions fo r cylinder head bolts

M o d ifica tion notes 6.2.97

Tightening torques o f cylinder head bolts m odified

AR01.30-W-5800-07B

EÜÜ Cylinder head Num ber

D esignation

BA01.3 0-N-1002-01D

C ylinder head bolts to crankcase

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/ 927

922/923/925/926

1st stage

Nm 10

10

2nd stage

Nm 50

50

3rd stage

Nm 100

100

4th stage

Nm 200

200

5th sta ge

X ° 90

90

6th stage

90

90

Tightening

AR01.30-W-5800-07B

AR01-30-W-5800-07B

In struction

s see

Additional Information E n gin es O M 501, O M 502 (m o d. des. 541.9, 542.9), ACTRO S - V e h ic le m od. des. 9 50-954, F2

35

Use HQ wrench socket to tigh ten cylinder head bolts. @ It is im portant to observe all the tightening torque stages and to keep to the sequence stated in order to avoid tw isting th e cylinder head (2); see tigh ten ing diagram. a If the tightening torque o f a cylinder b olt is exceeded, unscrew the cylinder head bolts, inspect the shank length (replace cylinder head bolt, if necessary) and tighten again, starting w ith stage 1. The cylinder head bolts are not re-tlghtened.

W01.30-0009-02


AR01-30-W-71G2B

Checking, facing cylinder head contact surface

17.1.96

ENGINE 541.920/9211922 !923/924/925/926/927,542.920/9211922 /923/92S/926 1

cylin d e r head

2 3

Inlet valve exhaust valve

4 5 6 7

Decompression brake valve IWi D ial gauge [ S D ial gauge ho ld er Guide pin

A B

Projection o f guide pin A m o u n t by which valve stands back

H

H eight o f cylinder head

W01.30-0013-06

M o d ifica tio n notes 6.2.97

Measuring difference in am ount by w hich valve stands back, added

Step 12

P a g e 37

m

Removing

1

Remove cylinder head (1)

2


AR07.03-W-6831B

3

Rem ove valves (2,3)

A R 0 S.3 0 -W -3S1 1 B

4

Remove decompression brake valve (4)

Page 32

Page 61

Inspecting 5

Clean cylinder head (1)

6

Inspect cylinder head contact surface (com Permissible difference o f flatness o f bustion chamber side) fo r flatness bottom contact surface in longitudinal

7

Measure total height o f cylinder head (H)

BE01.30-N-1002-02C

direction Q ] If the height measured is less than the

BE01.30-N-1001-02C

permissible minimum he igh t (H), replace cylinder head(1) Machining 8

Face cylinder head contact surface (combustion chamber side)

® It is im portant to m ain tain the surface quality (surface roughness R3 Z/peak-tovalley height W t) o f th e cylinder head

BE01.30-N-1003-02C

contact surface.

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h ic le m od . des. 9 5 0 -9 54 , F2

37

I H O nly machine cylinder head contact

BE01.30-N-1002-02C

surface if measurement reveals impermissi ble difference o f flatness in longitudinal d i rection o r if porous, damaged points exist. The height afte r stock rem oval at the cylin der head (1) must no t be less th an the per missible m inim um height (H). 9

Clean cylinder head (1)

s

Measuring

10

O nce a g a in m easure total h e ig h t o f cylin

H e igh t o f cylinder heed (1)

BE01.30-N -1001-02C

der head 11

Insert valves (2,3) into the cylinder head

E l Pay attention to m arking o f the valves (2, 3)

12

Page 39

Measure am ount by w hich valve stands back (B) relative to cylinder head contact surface Measure am ount by which valve stands back at both inlet and exhaust valves, and note

BE05.30-N-1001-01C

Permissible difference between both valve pairs must n o t be exceeded

B E05.30-N-1009-01C

m

001 589 53 21 00

m

343 589 00 4000

El] If the reading obtained is not w ithin the permissible tolerance j @ machine valve seat rings on both inlet or exhaust valve seat ring

AR05.30-W-4511B

m

Installing

13

Install decompression brake valve (4)

14

Install valves (2,3)

AR05.30-W-3511B

15

Install nozzle holder com bination

AR07.03-W-6831B

16

Install cylinder head

Page 61

Page 32

Test data o f cylinder head Number

Designation

Engine 541.920/921/922/923/ 924/925/926/927 542.920/921/922/ 923/925/926

BE01.30-N-1001-02C

H eight o f cylinder head

BE01.30-N-1002-02C

Permissible difference o f flatness of bottom contact surface in

BE01.30-N-1003-02C

Surface quality o f cylinder head contact surface

w hen new

mm 113.85-114.15

a fte r stock rem oval

mm

a 113.5

over a length o f 150 mm

mm

£0.015

surface roughness R3 Z

pm

8

peak-to-valley he igh t W t

pm

5

longitudinal direction


Test data o f valves

Designation

Number

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/

922/923/925/926

927 BE05.30-N-1001-01C

A m oun t by w hich valve stands back

mm 0.70-1.05

0,70-1,05

mm £0.2

£0 ,2

mm

s 0 ,2

relative to cylinder head contact surface BE05.30-N-1009-01C

Permissible difference in am ount by which valve stands back relative to .................. , cylinder head contact surface fo r each cylinder

Inlet . Exhaust

£0.2

D ial g a u g e h o ld e r

AR05.30-W-4100-01B

M easuring am ount by w hich valve stands back relative to cylinder head

M o d ifictlo n notes 6.2.97

M easuring difference in am ount by w hich valve stands

Step 4 m odified

AR05.30-W-4100-01 B

back, added Test data o f valves Num ber

Designation

BE05.30-N-1001-01C

Am ount by w hich valve stands back

Engine 541.920/921/ 922/923/924/925/926/ 927

Engine 542.920/921/ 922/923/925/926

mm 0.70-1.05

0.70-1.05

Inlet

mm £0.2

£ 0.2

Exhaust

mm £0.2

£0.2

relative to cylinder head contact surface BE05.30-N-1009-01C

Permissible difference in am ount by which valve stands back relative to cylinder head contact surface fo r each cylinder

y

V

343 589 00 4 0 00 Dial gauge holder

Additional Information E n g in es O M S01, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h icle m od . des. 9 50-954, F2

39

1

A ttach dial gauge (4) to dial gauge h o ld er (5).

2

Fit dial gauge (4) w ith preload onto the plane face o f the cylinder head (1).

3

Set scale o f dial gauge to "0 “ .

A

M o v e d ia l g a u g e (4) s u f f ic ie n t ly t o

th a t th e tracer pin Is positioned on the valve disc o f the inlet valves (2) or of the exhaust valves (3). m Measure am ount by which valve stands back at both inlet and exhaust v a lv e s a n d n o te . P e rm is s ib le d if f e r e n c e

b etw een both valves must not be exceeded.

WQS.30-0O42.0G


AR01.40-W -8000A

Rem oving, installing tim in g case cover

5.2.96

ENGINE 541.920/921 /922 /923 /924 /92S /926 /927, 542.920/921 /922 /923 /92S /926 1

Tim ing case w ith crankcase breather

2

(oil separator) Bolt

3 4 5 6

Crankcase b reather hose Gasket Fuel pipe Coolant pipes

B16 TDC sensor cylinder 1

W 01.40-0013-06

i H and-held pressure gun


Sealing tim ing case and crankcase, added

m

Removing

1

Remove turbocharger

2

Remove boost air m anifold/boost air

Step 11

Page 41

AR09.41-W-8681B

housing 3.1

A

R e m o v e b o o s t a ir p ip e

Danger)

O n engine 5 4 2 .9 2 0 - 9 2 3 / 9 2 5 / 9 2 6

Risk o f injury to skin and eyes from

Do not open the cooling system unless the

scalding from hot coolant w hich splashes out. Risk o f poisoning from sw allow ing coolant

coolant tem perature is below 90 °C. Open cap slow ly and allo w the pressure to release. Do not pour coolant into

A R 0 9 .4 1 -W -1 3 1 1 B

P a g e 30

containers fo r drinks. W ear protective gloves, protective clothes, a n d eye p r o t e c tio n .

4

Drain coolant

E

Do no t drain coolant completely.

AP20.00-W-2080A

Collect coolant.

En gin es O M 501, O M S02 (m od. des. 541.9,542.9), AC TR O S - V e h ic le m od. des. 9 50-954, F2


® 5

Page 31

Notes on coolant

A ll engines

Remove both coolant pipes (5) at the

[ L l Collect coolant w hich flow s out.

compressor and crankcase DO Installation: replace seals.

/hx Danger!

6

7

@ C o olan t pipe to crankcase

BA01.40-N-1005-01D

0

BA13.30-N-1001-01B

C o olan t pipe to compressor

Fuel vapors present an explosion hazard. Fuel is to xic w h en inhaled or swallowed.

Fire, open lights and smoking prohibited. Fill fu el only into containers intended fo r

Contact w ith fu el can cause skin and eye

this purpose. W ear protective clothing

injury.

w h en handling fuel.

Remove fu el pipe (6)

CL] Installation: replace seals

Page 19

l ^ Fuel p ip e to fuel p u m p

B A 47.25-N-1002-01B

® Screw connection between fuel pipes

BA47.25-N-1011-01B

Remove connector o f the camshaft sensor (B16) at the h ra rk e t a n d separate

8

Separate crankcase breather hose (3) at the crankcase breather (oil separator)

9

R em ove tim in g case cover (1)

HI Tilt tim in g case cover sligh tly w h e n p ulling out

CD Installation: pay attention to tigh ten ing diagram

Page 43

@ Tim ing case w ith o il separator to tim ing

BA01.40-N-1014-01D

case and crankcase 10

Take o ff gasket (4)

11

Clean sealing surfaces at tim ing case cover

0G Installation: replace gasket. HI Installation: seal both joints between

(1), tim ing case and crankcase

tim in g case and crankcase w ith sealant

ffl 12


13

Check coolant and adjust to correct level

0

BR00.45-Z-1026-01A

000 589 01 25 00

AP20.00-W-2010A

Crankcase, tim ing case cover, end cover

Number

Designation

Engine 541.920/

Engine 542.920/

921/922/ 923/924/

921/922/ 923/925/

925/926/

926

927 6 A01.40-N-1005-01D

Coolant pipe (compressor) to crankcase

8 A01.40-N-1014-01D

Timing case cover w ith oil separator to tim ing case in crankcase

M 1 4 X 1 .5

Nm

35

35

Nm

25

25

& Compressor (compressed air system) Number

BA13.30-N-1001-01B

Designation

Coolant pipe to compressor

E n g in e 541.920/

E n g in e 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

Nm 30

30


0

Fuel pipes/hoses

Designation

Number

BA47.25-N-1002-01B

Fuel pipe to fuel pum p

BA47.25-N-1011-01B

Screw connection between fuel pipes

M 16 X 1.5

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

Nm 40

40

Nm 45

45

Service products fo r repair Number

Designation

Order number

BR00.45-Z-1026-01A

Sealant

001 989 29 20

AR01.40-W-8000-02A

Tightening diagram o f tim ing case cover

C r a n k c a s e , t im in g c a s e c o v e r , e n d c o v e r

Number

Designation

Engine 541.920/ 921/922/ 923/924/ 925/926/ 927

BA01.40-N-1014-01D

Timing case cover w ith oil separator to tim ing case and crankcase

Nm

25

Engine 542.920/ 921/922/ 923/925/ 926

25

T ighten bolts at tim ing case cover.

m Pay attention to tightening sequence; see t ig h te n in g diagram .

Additional Information E n gin es O M SOI, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V e h ic le m od, des. 9 50 -9 54 , F2

43

AR01.A0-W -8810A

25.3.96

Rem oving, installing fro n t radial seal in hou sing cover

W 01.40-0006-06

12

Strut

13

Refrigerant compressor

G2

G e n e ra to r


s n n

Tightening torque fo r oil sump bolts m odified

Step 6

Checking engine oil level w ith electric gage

Step 12 m odified

Page 44

Rem oving, Installing

1

Remove vibration dam per (1)

2

T a k e o ff splash ring (2)

3.1

Remove connecting strut (12) at generator (G2) and at refrigerant compressor (13)

Page 100

If air conditioning fitted

@ Support to fixture o f refrigerant compressor and generator carrier 4.1

Remove refrigerant compressor (13) at

If air cond ition ing fitted

crankcase and tie up

E E Do no t separate refrigerant pipes 0 Carrier o f refrigerant compressor to crankcase

BA83.55-N-1002-01C

BA01.40-N-1012-01D


5

Unscrew fro n t bolts (9) at the sump (10) in the area o f the housing cover (5)

6

Slacken rem aining bolts (9) at the oil sump (10) and low er sump (10)

® Do n o t damage gasket (8); if damaged i Remove o il sump and replace gasket (8)

Page 57

S Installation; pay attention to tightening diagram.

Page 46

@ O il sump to crankcase Take o ff housing cover (5) and remove

7

B A01.45-N-1001 -01C

DO Cover over opening at oil sump

g a sk e t(6)

E Installation: clean contact surfaces. Oil contact surface at crankshaft w ith engine oil. Replace gasket (6) and fit housing cover over the dow el pins (7) onto the crankcase. @ Front end cover to crankcase 8

Inspect crankshaft flange at fro nt fo r signs o f wear and scoring produced by the radial

BA 0 1.40-N-1009-01D

0Q If w orn J

seal In s ta ll r a c e o n t h e c r a n k s h a f t f la n g e

9

Use d rift (11) to take radial seal (3) out of the housing cover (5)

P a g e 84

E

Installation: install radial seal into the housing cover dry. Place housing cover dow n fla t on an even surface and install radial seal flush into the housing cover using a d r ift as a base. ® If a race is installed on the front crankshaft flange, a radial seal w ith coil spring has to be installed. m

312 58913 15 00

10


Z Ü Danger!


Secure vehicle to prevent it moving off.

starting o ff w hen engine running. Risk of

W ear closed and close-fitting w ork clothes. Do not grasp hot or rotating parts.

injury as a result o f bruises and burns if you insert y o u r h a n d s into e n g in e w h e n it is

Page 20

being started or w hen it is running. 11

Start engine and check oil pressure gage at idling speed

@ Crank engine with the starter lor not

BE18.00-N-1001-01D

more than 20 seconds. Wait about 2 minutes before making a repeat attempt at starting. Do not rev up engine until oil pressure is indicated. Oil pressure gage should indicate

E

pressure after about 10 seconds. 12.1


E

12.2


E

Only if oil level sensor is parameterized. See ACTROS Operating Instructions Part 3 If oil level sensor is not parameterized.

See ACTROS Operating Instructions Part 4 13

Switch o ff engine and check fo r leaks

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9, S42.9), A C TR O S - V e h icle m od. des. 9 50 -9 54 , F2

45

T o s t d a t a o f e n g in e n il p re s s u r e

Designation

Num ber

BE18.00-N-1001-01D


Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

idle speed

m in. bar 0.5

0.5

maximum speed

m in. bar 2.5

2.5

@ Crankcase, tim ing case cover, end cover Designation

N um ber

Engine 541.020/ 921/922/

Engine 542.020/ 921/922/

923/924/ 925/926/

923/925/ 926

92 7

BA01.40-N-1009-01D

Front end cover to crankcase

Nm

25

25

B A01 .4 0 -N -1 01 2-01 D

C arrier o f refrig erant com pressor/hydraulic

Nm

160

160

pum p/frigoblock to crankcase

@ O il sump Num ber

Designation

Engine 541.920/ 921/922/923/ 924/925/926/927

BA01.45-N-1001-01C

Oil sump to crankcase

Engine 542.920/ 921/922/923/ 925/926

light alloy

Nm 55

55

plastic

Nm 35

35

£ 3 R efrigerant compressor Number

Designation

B A83.55-N-1002-01C

Support to fixture o f refrigerant

M od el 950 Nm 50

M odel 952

M od el 953

M o d e l 954

50

50

50

com pressor/frigoblock and generator carrier

AR01.45-W-7500-01A

Tightening diagram o f oil sump bolts


Tightening torque fo r oil sump bolts m odified

AR01.45-W-7500-01A


Oil sump Number

Designation

BA01.45-N-1001-01C

1

O il sump to crankcase

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

lig h t alloy

Nm 55

55

plastic

Nm 35

35

Tighten corner bolts (A, B) and (C, D) at the oil sump diagonally.

2Tighten rem aining bolts in their order around the circumference, starting from the corner b olt last tightened. 3

Retighten corner bolts (pay attention to sequence, see step 1).

W01.45-0002-01

Additional Information En g in e s O M 501, O M 502 (m od. des. 541.9, 542.9), AC TR O S - V e h icle m od. des. 9 50 -9 54 , F2

47

AR01.40-W-9202B

14.6.96

Measuring cylinder bores

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927,542.920 /921 /922 /923 /925/926 1

C ylin d er liner

2 3

W D ia l gage E S Q uick calipers fo r internal measurements

A. B Directions o f measurement o f cylinder liner I M easuring points in unw orn area (top la n d ¿o n e )

II

M easure points a t top reversal p o in t o f first p iston ring

W 0 7 .1 5-0008-02

El

Removing

i

Remove cylinder head

2

Thoroughly clean cylinder liner (1)

3

Attach cranking device (7) to tim ing case

Page 32

@ Cranking device should be removed before starting the engine.

4

Rotate crankshaft w ith cranking device

m

407 589 00 63 00

@ End cover to tim ing case

BA01.60-N-1001-01B

□D Set piston o f cylinder liner to be inspected (1)to BDC.


5

m

Inspect cylinder liners (1)

DOCylinder liners must no t have any scorch streaks. Isolated m inor draw ing grooves are no t critical.

Notes fo r assessing w ear o f pistons in the

Engine 541, 542,904

Page 22

event o f dust dam age Measuring

6

Set dial gage (2) and quick calipers (3) w ith the m icrometer to the inner diam eter o f

HI Preload 5 mm.

BE01.40-N-1001-03C

El 19 Quick calipers B Microm eter HI Measure in unworn area (top land

001 589 53 21 00

the cylinder liner

7

Measure inner diam eter o f cylinder liner and set dial gage (2) to "0"

WH58.30-Z-1019-12A WH58.30-Z-1028-12A BE01.40-N-1001-03C

zone) above to p reversal p oint o f first piston ring. Directions o f measuring in direction o f travel (A) and in transverse direction (B).

8

Measure difference in diam eter o f cylinder

HI Measure at to p reversal p oint o f first

liner

piston ring to to p land zone. Directions of measuring in direction o f travel (A) and in transverse direction (B).

BE01.40-N-1005-03C

@ The values must be m aintained. C ylinder liner must not be remachlned, it necessary J, Replace cylinder liner 9

Page 53

Install in th e reverse ord e r

Test data o f cylinder liner Number

Designation

BE01.40-N-1001-03C

Cylinder liner inner 0

Engine 542.920/921/ 922/923/925/926

Code letter A

mm

129.990-129.995

129.990-129.995

Code letter B

mm

129.995-130.005

129.995-130.005

mm

130.005-130.010

130.005-130.010

mm

fi 0.08

sc 0.08

Code letter C BEOI 40-N-1005-03C

Engine 541.920/921/ 922/923/924/925/926/ 927

W e a r o f cylinder liner at t o p reversal

p oint of first piston ring

FÜÎ T im in g r a s e

Number

Désignation

BA01.60-N-l 001-01B

End cover o f TDC inspection holder

Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 25

Engine 542.920/ 921/922/923/ 925/926 25

tim ingcase

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h icle m od . des. 9 50 -9 54 , F2

49

Com m ercially available tools (see W orkshop Equipm ent Manual) Number

Designation

W H 58.30-Z-1019-12 A

Quick calipers fo r internal measurements, 0 120-140 mm

W H 58.30-Z-1028-12 A

M icrom eter 125-150 mm

Make (e.g.)

Order number

Hahn und Kolb Borsigstr. 50 D-70469 Stuttgart

313346 125


AR01.40-W-9314A

Measuring projection of cylinder liner

23.1.96

ENGINE 541.920 /921 /922 /9231924 /925 /9261927. 542.92019211922192319251925 1.1 1.2

121 Measuring plate 12! Spacer tube

2 3 4

Cylinder head bolts 12¡D ial gauge 121 Dial gauge holder

A

Projection o f cylinder lin er

K

{M

L / > . \

)—

r n ^ r - / - r

......T

J

P

l A

s

f

e

V J

0

Measuring

1

Rem ove cylinder head o f the relevant

■■

■... u

P a g e 32

cylinder 2

Clean collar o f cylinder liner

3

Attach measuring plate (1.1) to the cylinder Screw measuring plate and spacer tube (1.2) tight w ith the cylinder head bolts (2), liner 50 Nm

4

Attach dial gauge (3) w ith the extension to the dial gauge holder (4) and insert w ith a preload through one of the recesses in the measuring plate (1.1)

541 589 00 21 00

121

5

6

H I Set scale of dial gauge to "0"

121

001 589 53 21 00

121

541 5 8 9 0 0 2 1 0 0

121

343 589 00 40 00

Move dial gauge (3) together w ith dial

E

gauge holder (4) from collar of cylinder liner to crankcase

800.98.452.00.

Conduct measurement of the projection at

E Set the scale of the dial gauge (3) to “0 ” fo r each measurement. Compare the measurements entered in the test sheet. Max. difference of the 4 measurement

each recess in the measuring plate (1.1)

Enter measurements in the test sheet

B E01.40-N -1003-03C

points fo r each cylinder liner 0,02 mm If the measurements differ J, Remove cylinder liners. 7

Take o ff measuring plate (1.1)

121

Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le m od. des. 950-954, F2

P a g e 53 541 589 0021 00


8


Page 32


Designation

Engine 541.920/921/ 922/923/924/925/926/ 927

BE01.40-N-1003-03C

Projection of cylinder liner w ith

mm 0,245-0,315

Engine 542.920/921/ 922/923/925/926

0,245-0,315

preloaded cylinder liner

_y

V

541 5 8 9 0 0 2 1 0 0 M e a s u rin g p la te

343 5 8 9 0 0 4 0 0 0 D ia l g a u g e h o ld e r


AR01.40-W-9324A

Removing, installing, sealing cylinder liner

24.1.96

ENGINE 541.920/921 /922/923/924/92S/926/927, 542.920/921 7922/923/925/926

W01.40-0014-09

r 2 3 4 5 6.1

Crankcase Cylinder liner Tombak ring O-ring O-ring

6.2 6.3 6.4 6.S 7

El Removal tool

8

m

Removing

1

Remove piston

2

Mark cylinder liner (2) relative to crankcase (1) (arrow)

3

Fit on removal tool (6.1) and pull out cylinder liner (2)

4

Take off tom bak ring (3)

[ 3 Stud bolts E) Counter-support E l Spindle El Insertion to o l El Dial gauge 19Quick-calipers fo r internal measurements

Page 75

® Cylinder liner collar seat must not be reworked

El 5

Page 55 541 58900 33 00

Remove O-rings (4, 5) from the crankcase (1)

6

Clean cylinder liner (2), cylinder liner contact surface and grooves fo r O-rings (4, 5)

m 7

8

Installing Insert O-rings (4, 5) fo r sealing the cylinder liner at the bottom into the crankcase (1)

f f l Replace O-rings and insert dry

Fit tom bak ring (3) over the cylinder liner

00 Installation: replace tom bak ring

(2) o n to the liner collar

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V e h ic le m od. des. 950-954, F2

53

9

Insert lin er (2) in to th e crankcase (1)

S

Lightly grease bottom f it surface and

BR00.45-Z-1018-06A

slip cham fer o f cylinder lin er (2). If cylinder lin er is re-used, install offset 90° (arrow s) relative to o ld installation

position.

Page 55

If a new cylinder lin er is installed, pay attention to m arking o f piston and liner. 10

Page 56

Fit on insertion to o l (6.5) and press in cylinder liner (2)

ffl 11

M easure projection o f cylinder lin er (2)

12

M easure inner diam eter o f cylinder lin er (2) a t 3 points, each offset 60°, in the area o f th e low er fit

541 589 00 33 00

Page 51 BE01.40-N-1004-03C

m

001 589 53 2 100 W H 5 8 .3 0 -Z -1 0 1 9 -1 2 A

Q u ick calipers fo r internal

measurements

SJlfan out-of-roundness is measured, remove cylinder liner (2) and check w hether O-rings (4, 5) are correctly installed in crankcase and replace. Clean both grooves in crankcase (1). 13

P a g e 75

Install p isto n

Test data o f cylinder liner Num ber

BE01.40-N-1004-03C

Designation

O ut-of-roundness o f cylinder w a ll a t b otto m tit

" \

mm

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/ 927

922/923/925/926

S 0.015

S 0.015

r

R e m o v a l a n d in s ta lla tio n to o l

Com m ercially available to o ls (see W orkshop Equipm ent Manual) Num ber

Designation

W M 5 8.30-Z -1019-12A

Q uick calipers fo r internal measurements, 0 1 2 0 -1 4 0 mm

O rder num ber

M ake (e.g.)

Repair products Num ber

D e s ig n a tio n

O rd e r n u m b e r

8 R00.45-Z-1018-06A

ATE grease

-


Removing cylinder liner

AR01.40-W-9324-01A

541 589 00 33 00 R e m oval a n d in se rtio n device

1

Screw stud bolts (1) Into opposite threaded holes for the cylinder head bolts.

2

Insert removal device (2) into the cylinder liner (3).

W01.40-0011-01

OD Guide collar o f the removal device (2) must be positioned in the cylinder liner (3); do not tw ist removal device. 3

Fit counter-support (5) onto the spindle and stud bolts (1) and screw tight.

4

Puli out cylinder liners (3) by turning the nut (6).

W01.40-0010-01

A R03.10-W-7021-02A

Assigning normal-size pistons to cylinder bore

Test data o f cyliner liner N um ber

D e sign atio n

B E01.40-N-1001-03C

Cylinder liner Inner 0

Engine 541.920/921/ 922/923/924/925/926/ 927

Engine 542.920/921/ 922/923/925/926

Code letter A

mm 129.990-129.995

129.990-129.995

Code letter B

mm 129.995-130.005

129.995-130.005

Code letter C

mm 130.005-130.010

130.005-130.010

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTROS - V eh icle m od. des. 950-954, F2

55

Check identification o f tolerance orouD on piston crow n (arrow) and assian the m arkina o f the cylinder liners (2) on the edge o f the liner (arrow). M arking Piston (1) BA BC

-*•

Cylinder liners (2)

-» —

A o rB B o rC

W 03.10-0029-02

A R 0 1.40-W-9324-02A

1

Inserting cylinder liner

Screw stud bolts (1) into opposite threaded holes fo r the cylinder head bolts.

w o i ao.onii.oi

2

Fit pressure plate (2) onto th e cylinder liner.

3

Place insertion device (spindle w ith counter-support) (3) onto stud bolts (1) and screw tight.

4

Press the cylinder liner (4) into the crankcase by turning the nut (5) at the spindle (3).

5

la k e o ff Insertion tool (3) and remove stud bolts (1) at the crankcase.


AR01.45-W-7500B

Removing and installing oil pan

17.1.96

ENGINE 541.920/921/922/923/924/925/926/927,542.920/92119221923 7925/926

W 01.43-0003-09

1 2 3

Carrier w ith generator and p oly V-belt tensioning device Dipstick guide tube O il filler pipe

12 13 14

4 5 6 7 8 9 10 11

Oil sump Gasket Bolt Refrigerant compressor (air conditioning) Bolt Seal O il drain plug Seal

15 16 17 18 19

Ducting (engine w iring harness) Engine wiring harness Connecting strut (air conditioning) Bolt Poly V-belt M ounting bracket fo r ATFpipes O il extraction tube Bolt

B14 Engine o il level sensor


Tightening torques fo r oil pan bolts m odified

Step 13

Checking engine oil level w ith electric gage

Step 16 m odified

sana

Removing, metalling

/ h Danger!

Risk o f injury from bruises and jamming when tilting cap

1

Tilt cab

® 2

Page 57

No person should be in the tiltin g area of the cab when it is being tilted. Always tilt cab as far as the end position and secure w ith a safety prop.

Page 18


M odels 950,952,953,954

Page 18

Remove bottom noise encapsulation

CD Installation: quick-locks must engage properly.

3

Drain or extract engine oil

4.1

Remove poly V-belt (16)

AP18.00-W-0101A If air conditioning fitted

AR13.22-W-1202B

Additional Information Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V eh icle m od. des. 9 50-954, F2

57

5

Remove dipstick guide (2) at oil sump (4)

0

Connection o f dipstick guide tu b e to oil

BA01.45-N-1003-01C

pan 0 6

Take o ff o il fille r pipe (3) at oil sump (4)

7.1

Remove connecting strut (14) at carrier (1) and at refrigerant (7)

Dipstick guide tube to connection

BA01.45-N-1006-01C

If air conditioning fitted

0


BA83.55-N-1002-01C

com pressor/frigoblock and generator carrier 8.1

Remove refrigerant compressor (7) at

0D If air conditioning fitted

crankcase and tie up at frame

Do not separate coolant a t refrigerant compressor

0

Refrigerant compressor carrier to

BA01.40-N-1012-01D

crankcase 9

Take o ff m ounting bracket (17) fo r ATF p ip es at carrier (1)

10

Separate connector o f engine oil level sensor (B14) at engine w iring harness (13)

11

Take o ff engine w iring harness (13) at left of oil sump (4)

12

Take o ff ducting (12) o f engine w iring

® Do not dam age engine w iring harness.

harness (13) a t oil sump and tie up to the fro n t at viscous fan

0 13

Unscrew bolts (6) and take o ff oil sump (4)

Cable duct to oil pan

BA01.45-N-1005-01C

Clean oil sump and contact surface at crankcase. [ D Installation: replace gasket (5). Pay attention to installation position H ] Pay attention to tightening diagram of oil sump bolts

0

Oil pan to crankcase

Page 46 BA01.45-N-1001-01C

Replace seal (11). Tighten oil drain plug (10). 0

Oil drain plug to oil pan

BA01.45-N-1002-01C

OD Replace seal (9). Screw engine oil level sensor (B14) tight.

0

O il level sensor to oil pan

BA18.40-N-1002-01D

QD The dipstick is guided in the oil sump by an oil extraction pipe (18) which is attached to the oil sump by the b olt (19)

0

B A 0 1 .4 5-N -1 00 4 -0 1 C

D ip stick g u id e tub e t o oil pan

14


Æ> Danger!


Secure vehicle to prevent It moving off.

starting o f f w h e n e n g in e run n in g. R isk o f

W e a r closed a n d close-fitting w o rk clothes.

injury as a result o f bruises and burns if you

Do not grasp ho t or rotating parts.

Page 20

Insert your hands into engine w hen it is being started or w hen it is running.


15

Start engine and check oil pressure gage at idling speed

@ Crank engine w ith the starter fo r not more than 20 seconds. W ait about 2 minutes before making a repeat attem pt at starting.

BE18.00-N-1001-01D

Do not rev up engine until oil pressure is indicated. H I Oil pressure gage should indicate pressure after about 10 seconds. 16.1


HI Only if oil level sensor is parameterized. See ACTROS Operating Instructions Part 3

16.2


0 0 If oil level sensor is not parameterized. See ACTROS Operating Instructions Part 4

17


Test data o f engine oil pressure Number

Designation

BE18.00-N-1001 -01D


Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

idling speed

min. bar 0.5

0.5

max. speed

min. bar 2.S

2.5

£ 3 Crankcase, timing case cover, end cover Number

Designation

BA01.40-N-1012-01D

Carrier o f refrigerant compressor/ hydraulic pum p/f rigoblock to crankcase

Nm

Engine 541.920/ 921/922/ 923/924/ 925/926/ 927

Engine 542.920/ 921/922/ 923/925/ 926

160

160

£ 3 O il s u m p

Number

Engine 541.920/ 921/922/923/ 924/925/926/927

Designation

BA01.45-N-1001-01C

BA01.4S-N-100Î-01C

BA01.45-N-1003-01C

O il sump to crankcase

Oil drain p lu g to oil sum p

Connection o f dipstick guide tub e to oil sum p

Engine 542.920/ 921/922/923/ 925/926

lig h t alloy

Nm 55

55

plastic

Nm 35

35

ligh t alloy

Nm SO

80

plastic

Nm 40

40

lig h t alloy

Nm 50

50

plastic

Nm 35

35

BA01.45-N-1004-01C

Dipstick guide tube to oil sump

Nm 25

25

BA01.45-N-1005-01C

Cable ducting to oil sump

Nm 10

10

BA01.45-N-1006-01C

Dipstick guide tube to connection

Nm 20

20

Additional Information 9 ^ *

En gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h icle m od. des. 950-954, F2

59

0

Oil level sensor, oil pressure sensor

Number

BA18.40-N-1002-010

0

Designation

Oil le v e l s e n s o r t o o il s u m p

Nm

Engine 542.920/

Engine 541.920/ 921/922/923/

921/922/923/

924/925/926/927

925/926

25

25

Refrigerant com pressor

Number

Designation

BA83.55-N-1002-01C


M odel 950 Nm 50

M od el 952

M o d el 953

M odel 954

50

50

50

com p ressor/frigob lock e n d ge n e rato r

carrier


AR01.50-W-1000B

Removing, installing decompression brake valve

14.6.96

ENGINE 541.920 /9211922 /923 /924 /925 /926/927.542.920 /921 /922 /923 /92S1926 Screw cap O-ring Piston Seal Locking wedge Spring retainer

10

Spring Spring guide Valve Spacer

3 5 6

Piston Locking wedge Spring retainer

7

Sp rin g

11 12 13

US Pliers K 1 Spring retainer depressor W\ M agnetic pin

W01.50-0009-06

i s na


1

Remove cylinder head

2

Remove nozzle holder combination

3

Remove end cover (1)

QD Installation: Replace O-ring (2).

Insert a suitable spacer (10) between valve

H I Spacer should have a height o f about 6.0 mm.

4

disk and base

Page 32 AR07.03-W-6831B

Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le mod. des. 950-954, F2


5

Use pliers (11) to remove piston (3)

6

Inspect seal (4) at piston (3) fo r signs of wear and damage

m GOIf w o rn or dam aged

442 589 00 37 00 J,

Replace piston w ith seal

[H Installation: Oil piston, seal and d o not da m a ge.

7

Remove spring (7)

ELI Use spring retainer depressor (12) to compress spring and use m agnetic pin (13) to take out locking wedges (5).

ED Installation: Fit spring retainer depressor (12) onto the to p spring retainer (6) and compress spring sufficiently until the locking wedges engage.

m m 8

210 589 00 40 00 442 589 05 63 00

Release pressure on spring (7), take out to p

DODo no t mix up to p spring retainer and

spring retainer (6), spring and spring guide

spring guide.

(8)

EU Installation: Fit spring guide, spring and spring retainer onto the stem o f the valve o f the constant throttle. Insert locking wedges (5) into the spring retainer.

9

Turn cylinder head and pull out valve (9)

LU M ark valve. Q] In stallation : Oil valve stem, insert valve and place spacer (10) (height ab out 6.0 mm) b elow the valve disk.

10



AR01.60-W-8200B

Removing, installing timing case

14.6.96

ENGINE 541.920/921 Z922/923/924/925/926/927.542.920/921 /92219231925/926

W 0 1 .60-0003-09

1

16

Nut

2

Engine w iring harness Bolt

17

3

Clip

18

4

O -ring

5

Securing bush Bolt Engine w iring harness bracket

30

throttle) Bracket

6 7 8

9 10 11 12 13 14 IS

Resonance tank Bolt Bolt Bracket Timing case Hose Hose O il return flo w pipe (turbocharger)

34 40

Gasket Connection strut

41

Refrigerant co m pressor

42 43

O il pan gasket I S Hand-operated pressure gun

C2

G enerator

Compressed air pipe (compressor) B olt ( M l2X167)

31 32 33

Bolt Bracket w ith gear o il pipes Bolt

19

Bolt (M 1 2 X S 7 )

34

G askets

20 21 22 23 24 25 26 27 28 29

Securing bush O-ring Lifting eye

35 36 37

Bracket Bolt Radial seal A n g le d connection fittin g Nut Compressed a ir p ipe (engine brake) Compressed a ir pipes (constant

38 39

Bolt O il pan B olt Electric cables (Starter) Bracket w ith fuel pipes

BIS Crankshaft position sensor B16 TDC sensor cylinder 1

WOA .6Q-000S-Q1

E S H


1

Remove noise encapsulations

2

Remove starter

S ] A t top, rear, on left and right.

En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V eh icle m od. des. 9 50 -9 54 , F2

AR15.30-W-7100B


63

3

Remove flyw heel

4.1

Take o ff resonance tank (8)

Page 102 On engine 541.920 - 927 ®

E n d cover o f co m p ressor o p e n in g o n

B A 0 1 .6 0 -N -1 0 0 3 -0 1 B

side o f tim in g case BA13.30-N-1010-01B

£ 3 Resonance tank to bracket 5 6

A R 4 6 .3 0 -W -0 4 0 0 A

R e m o v e p o w e r steering, fuel p u m p unit

U n b o lt compressed a ir pipe (17) and com pressor

7

Inspect compressed a ir pipe (17) betw een

® If coked I

com pressor and pressure regulator fo r coking Replace compressed air pipe or pressure regulator. 8.1

Remove intake m anifold

9

Remove tim in g case cover

10

Take o ff propshaft or hydraulic pum p at

AR09.20-W -1310A

On engine 542.920 - 923/925/926

Page 41 W ith rear engine output

rear en g in e o utpu t 11

12

Detach bracket w tih fu el pipes (39) at tim in g case (12)

£ 3 Bracket o f fu el pipe to tim ing case cover and tim ing case

BA47.25-N-1008-01B

@ B o lt o f w iring harness to tim in g case

BA15.18-N-1003-01A

Detach bracket w ith gear oil pipes (32) at tim in g case (12)

13

Detach bracket (7) w ith engine w iring harness (1) and attached parts at tim ing case (12)

14

Pull o u t crankshaft position sensor (B15)

[ H Installation: Replace O-ring (4), press in

and ta ke o ff clip (3) at tim ing case (12)

securing bush (5) and crankshaft position sensor as fa r as the stop. B o lt o f w irin g harn ess to tim in g case

15

Pull o u t cam shaft TDC sensor (B16)

S

B A 1 S.18-N -1003-01 A

Installation: Replace O-ring (21), press

in securing bush (20) and cam shaft TDC sensor as fa r as the stop. 16.1

Remove exhaust plenum chamber at

AR14.10-W -3920A

On engine 541.920 - 927

tim in g case (2) 16.2

Remove liftin g eye (22) and bracket (23) at rear o f tim in g case

On engine 542.920 - 923/925/926

0 18.1

Remove connection strut (40) a t generator (G2) and a t refrig erant compressor (41)

Rear liftin g eyes to tim ing case

If A C fitted

BA83.55-N-1002-01C

E33 Support to fixture 18.2

Remove refrig era nt compressor (41) at crankcase and tie up

BA22.10-N-1003-01D

If A C fitte d [ S Do n o t separate refrigerant pipes. 0

Carrier o f refrigerant compressor to

BA01.40-N-1012-01D

crankcase 19

Unscrew bolts (35) a t the oil pan (36) in the

BA01.45-N-1001-01C

® Oil pan to crankcase

area o f th e tim in g case (12) 20

Slacken rem aining bolts (35) at th e oil pan (36) and lo w e r oil pan (36)

® Do not dam age oil pan gasket, if necessary J, Remove o il pan and replace oil pan gasket.

64

Page 57


E

Page 46

Installation: Pay attention to tightening diagram

0 21

Separate compressed air pipes (28,29) o f engine brake and constant throttle and take o ff bracket (30)

22.1

Detach oil return flo w pipe (15) at tim ing case(12)

Oil pan to crancase

BA01.43-N-1001-01C

On engine 541.920 - 927

0

Nut fo r oil return flo w o f turbocharger on left at tim ing case 22.2

Detach both oil return flo w pipes (15) at tim ing case (12)

O n engine 542.920 - 923/925/926

0

Nut fo r o il return flo w of turbocharger on left at tim ing case

23

Detach timing case (12)

BA01.60-N-1004-01B

BA01.60-N-1004-01B

E

Cover over opening at oil pan. Inspect timing case fo r signs of damage and wear, if necessary J Replace tim ing case and use all existing attached parts Use existing compressor

AR13.30-W-5511A

Remove, install, set bracket of crankshaft position sensor

AR07.15-W-1640A

Use existing rear engine output

AR23.20-W-9440A

0

End cover o f TDC inspection hole to timing case

BA01.60-N-1001-01B

0

End cover o f compressor opening on side to tim ing case

BA01.60-N-1003-01B

0

Nuts (16,27) and angled connection fitting (26) fo r oil return flo w pipe (turbocharger to tim ing case)

BA01.60-N-1004-01B

0

BA01.60-N-1005-01B

End cover (engine output) to tim ing

case

0

Screw plug of oil return flo w of turbocharger in timing case

BA01.60-N-1006-01B

E Installation: Fit tim ing case onto the crankcase over the dowel pins

24

Replace gaskets (34)

0 Bolts of tim ing case to crankcase E Installation: Clean contact surfaces. Fit

BA01.60-N-1002-01B BR00.45-Z-1026-01A

gaskets over the dowel pins onto the crankcase and cut to length. Seal timing case gasket and oil pan gasket w ith sealant.

m 25

000 589 01 25 00

Page 68

Replace radial seal (25) in tim ing case (12)

m

403 589 04 15 00

E Inspect flywheel fo r signs of scoring of radial seal, if necessary J. install radial seal w ith coil spring in flywheel housing AR03.30-W-8350A

Install race on the flywheel

En gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h icle m od. des. 950-954, F2

A d d

\t l 0

f l 3 1 I f l f 0 P I T l 3 t l 0 PI


26 ^

Danger!



starting o ff when engine running. Risk o f injury as a result o f bruises and burns if you

W ear closed and close-fitting w o rk clothes. Secure vehicle to prevent it starting off.

Page 20

insert your hands in to engine w h en it Is being started or w hen it is running. 27

Start engine and observe oil pressure gage

® Crank engine w ith starter fo r n o t m ore

w hen engine idling

th an 20 seconds. W ait a b o ut 2 m inutes before m aking repeat attem pt a t starting.

B E 1 8 .0 0 -N -1 0 01 -0 1 D

Do n o t rev up engine so long as o il pressure Is n o t Indicated. Oil pressure gage should Indicate o il pressure after ab out 10 seconds. CD Oil pressure gage should Indicate oil pressure afte r about 10 seconds. 28.1


0D O nly if oil level sensor is param eterized. See ACTROS O perating Instructions Part 3

28.2


QD If oil level sensor Is not param eterized. See ACTROS O perating Instructions Part 4

29


Test data o f engine oil pressure Num ber

Designation

8E18.00-N-1001-01 D


S

Engine 541.920/ 921/922/923/ 924/925/926/927

Engine 542.920/ 921/922/923/ 925/926

idle speed

m in. bar 0.5

0.5

maxim um speed

min. bar 2.5

2.5


Number

Designation

Engine 541.920/

Engine 542.920/

921/922/

921/922/ 923/925/ 926

923/924/ 925/926/ 927 BA01.40-N-1012-010

Carrier o f refrigerant compressor/

Nm

160

160

h yd rau lic p u m p to crankcase

0

Oil pan

Number

BA01.45-N-1001-01C

Designation

O il pan to crankcase

Engine 541.920/ 921/922/923/

921/922/923/

Engine 542.920/

924/925/926/927

925/926

lig h t alloy

Nm 55

55

plastic

Nm 35

35


0

Timing case

Number

BA01.60-N-1001-01B

Designation

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

Nm 25


25

tim in g case BA01.60-N-1002-01B

BA01.6Q-N-1003-016

BA01.60-N-1004-01B

Bolts of tim ing case to crankcase

M 12X 57

Nm 100

100

M 12X 167

Nm 80

80

Nm 50

50

Nm 50

50

End cover o f compressor opening on si de to tim ing case Nut fo r oil return flo w on turbocharger

M 26X1.5

on left to tim ing case BA01.60-N-1005-01B

End cover (engine output) to tim ing case

Nm 25

25

BA01.60-N-1006-01B

Screw plug of oil return flo w of turbocharger in tim ing case

Nm 80

80

0

Compressor (compressed air system)

Number

BA13.30-N-1010-01B

0

Designation

Resonance tank to bracket

Designation

BA15.18-N-1003-01A

Bolt o f w iring harness to tim ing case

Designation

BA22.10-N-1003-01D

Rear lifting eyes to tim ing case

25

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

Nm 25

25

Engine 542.920/ 921/922/923/ 925/926 Nm 150

Fuel pipes/hoses

Num ber

Designation

BA47.25-N-1008-01B

0

925/926

Engine mounts, engine supports

Number

0

Nm 25

Engine 542.920/ 921/922/923/

Engine w iring harness

Number

0

Engine 541.920/ 921/922/923/ 924/925/926/927

Bracket o f fuel pipe to tim ing case cover and tim ing case

E n g in e 5 4 1 .9 2 0 /

E n g in e 5 4 2 .9 2 0 /

921/922/923/ 924/925/926/927

921/922/923/

Nm 25

925/926 25

Refrigerant compressor

Number

Designation

BA83.55-N-1002-01C

Support to fixture o f refrigerant compressor/Frigoblock and generator carrier

M o del 950 Nm 50

Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h icle m od . des. 950-954, F2

M odel 952

M odel 953

M o d el 954

50

50

50



D esignation

O rder num ber

BR00.4S-Z-1026-01 A

Sealant

001989 29 20

A R 0 1.60 -W -8 2 0 0-01 B

R e p lacin g seal in t im in g case

1

Place on tim ing case (1) flat.

2

Use a suitable d rift to remove radial seal (2).

3

U se t h e drift I S (3) to press n e w radial seal (2) in to th e tim in g

case cover (1) flush.

m Press in radial seal (2) d ry a n d axis parallel a n d eve nly a ro u n d

th e entire circumference. Pay atte ntio n to installation p osition o f radial seal (2). Do n o t dam age radial seal (2) w hen installing.


AR03.10-W-6111B

Testing, repairing connecting rod

17.1.96

ENGINE 541.920/921 /922/923/924/92S/925/927,542.920/921 /922/923/92S/926 1 2 3 4 5

Conrod Conrod bearing cap Conrod bearing shells C o nro db o lt Conrod bush

L

Shank length o f con rod bolt

1

Conrod

3 5 6 7

Conrod bearing shells Conrod bush S ! D ial gauge B D ial gauge holder

A

B

Distance from center o f conrod bearing bore to center o f conrod bush bore Permissible difference o f axial parallelism between conrod bearing bore an d conrod bush bore, related to measured distance

C

Measured distance

m

Removing

1

Remove piston

s i

Inspecting

2

inspect conrod bearing seat in conrod (1) fo r blue discoloration, cross scores at notches

Page 75

Q ] Conrod with blue discoloration (caused by bearing damage), w ith cross scores at notches must not be re-used. Conrod must be replaced.

En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), ACTROS - V e h icle m od. des. 950-954, F2


3

Inspect conrod (1) fo r tw isting and

Permissible difference (size B) o f axial

dim ensional tolerance

parallelism betw een conrod bearing and

BE03.10-N-1002-01C

conrod bush bore to measure distance (size C) BE03.10-N-1003-01C Distance (size A) from center o f conrod bearing bore to center o f conrod bush bore ŒI If th e specifications are exceeded, replace conrod (1). Conrod (1) must not be straightened. 4

Inspect inner diam eter o f conrod bush (5)

IT] If th e specification is exceeded, replace conrod (1).

BE03.10-N-1004-01C

m

001 589 53 21 00

US Q uick calipers fo r internal

W H 58.30-Z-1004-12A

measurements 5

Install conrod bearing (3), gauge

ÜD Pay atte ntio n to installation position o f

Page 72

conrod bearing shell halves. @ Never screw conrod bearing cap (2) tig h t w ith o u t conrod bearing shells (3) Inserted a t conrod (1); only fit on Conrod bearing inner diam eter

BE03.10-N-1001-01C

Conrod b o lt shank length (L)

BE03.10-N-1005-01C

Conrod bearing journal diam eter

BE03.20-N-1004-02C

0

BA03.10-N-1001-01C

Bolts o f conrod bearing caps to conrod

m

422 589 02 09 00

m

001 589 53 21 00

1 9 Q uick calipers fo r internal

WH58.30-Z-1001-12A

measurements I® M icrom eter m

Installing

6

Install piston

WH58.30-Z-1013-12A

Page 75


Test data of conrod

Engine 541.920/

Designation

Number

BE03.10-N-1001-01C

921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

Conrod bearing inner 0 with conrod Standard bearing shells inserted Undersize 0.10

mm 94.054-94.096 mm 93.954-93.996

93.954-93.996

Undersize 0.25

mm 93.804-93.846

93.804-93.846

Undersize 0.5

mm 93.554-93.596

93.554-93.596

BE03.10-N-1002-01C

Permissible difference o f axial parallelism between conrod bearing bore and conrod bush bore over

BE03.10-N-1003-01C

Distance from center o f conrod bearing bore to center o f conrod bush bore

BE03.10-N-1004-01C

Conrod bush inner 0

BE03.10-N-1005-01C

Conrod bolt

94.054-94.096

Undersize 0.75

mm 93.304-93.346

93.304-93.346

Undersize 1.0

mm 93.054-93.096

93.054-93.096

mm £0,025

£0,025

mm 273.00-273.02

273.00-273.02

mm 52.055-52.065

52.055-52.065

length of 50 mm

Thread 0 Max. shank length

16X1.5

M 16X1.5 mm 74.5

74.5

T e s t d a ta o f c ra n k s h a ft

Number

Designation

BE03.20-N-1004-02C

Conrod bearing journal 0

Standard

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

mm 93.98-94.00

93.98-94.00

Undersize 0.1

mm 93.88-93.90

93.88-93.90

Undersize 0.25

mm 93.73-93.75

93.73-93.75

Undersize 0.5

mm 93.48-93.50

93.48-93.50

Undersize 0.75

mm 93.23-93.25

93.23-93.25

Undersize 1.0

mm 92.98-93.00

92.98-93.00

ËÜÜ Conrod Designation

Number

BA03.10-N-1001-01C

Bolts of conrod bearing cap to conrod

1st stage 2nd stage

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

Nm 110 90

110 90

Additional Information Engines O M 501, O M 502 (mod. des. 541.9, 542.9), ACTRO S - V e h icle m od. des. 950-954, F2

71

\

r

4 2 2 589 02 0 9 0 0

J

\

J

_______ 001 589 53 21 0 0

Wrench socket

Dial gauge

Com m ercially available to o ls (see W orkshop Equipm ent M anual) M ake (e.g.)

Num ber

Designation

WH58.30-Z-1001-12A

Quick calipers fo r internal m easurements 0 80 - 1 0 0 mm

WHS8.30-Z-1004-12A

Quick calipers fo r internal measurements 0 4 0 - 6 0 mm

WH58.30-Z-1013-12A

M icrom eter 7 5 -1 0 0 mm

AR03.10-W -6111-06B

Order num ber

Installing, gauging conrod bearings

Test data o f conrod N um ber

BE03.10-N-1001-01C

Designation

BE03.10-N-1005-01C

Conrod b olt

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

mm 94.054-94.096

94.054-94.096

Undersize 0.10

mm 93.954-93.996

93.954-93.996

Undersize 0.25

mm 93.804-93.846

93.804-93.846

Undersize 0.5

mm 93.554-93.596

93.554-93.596

Undersize 0.75

mm 93.304-93.346

93.304-93.346

Undersize 1.0

mm 93.054-93.096

93.054-93.096

Conrod inner 0 w ith conrod bearing Standard shells inserted

Engine 541.920/ 921/922/923/

Thread 0 Max. shank length

M

16X1.5

16X1.5

74.5

mm 74.5

T e st d a ta o f c ra n k s h a ft

Num ber

Designation

BE03.20-N-1004-02C


Engine 541.920/ 921/922/923/ 924/925/926/927

Engine 542.920/ 921/922/923/ 925/926

mm 93.98-94.00

93.98-94.00

Undersize 0.1

mm 93.88-93.90

93.88-93.90

Undersize 0.25

mm 93.73-93.75

93.73-93.75

Undersize 0.5

mm 93.48-93.50

93.48-93.50

Undersize 0.75

mm 93.23-93.25

93.23-93.25

Undersize 1.0

mm 92.98-93.00

92.98-93.00

Standard


0

Conrod

Number

Designation

Engine 541.920/ 921/922/923/ 924/925/926/927

BA03.10-N-1001-01C

Bolts of conrod bearing caps to conrod

Engine 542.920/ 921/922/923/ 925/926

1st stage

Nm 110

110

2nd stage

•2

90

90


Designation

WH 58.30-Z-1001 -12A

Quick calipers fo r internal measurements 0 80 - 100 mm

WH58.30-Z-1013-12A


1

Make (e.g.)

O rdernum ber

Use a m icrometer to measure conrod bearing journal at tw o points (A, B) and note the measurements. Calculate the average o f th e conrod bearing journal diam eter from these tw o measurements.

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTR O S - V e h ic le m od . des. 9 50 -9 54 , F2

73

Use a c h am ois leather to clean th e b earin g p o in ts o f the con rod (1) a n d the co n rod b e a rin g cap (2).

Insert conrod bearing shells (3) into the conrod (1) and the conrod bearing cap (2).

ffl Pay attention to marking on the conrod bearing shells (3) and the code numbers o f the conrod (1) relative to the conrod bearing cap (2). If the conrod bearings are replaced, install conrod bearing shells (3) o f a matching repair size; pay attention to measured conrod bearing journal diam eter. The locking lugs (arrows) o f the conrod bearing shells (3) m ust be located in the slots of the basic bore o f th e conrod bearing cap (2) and o f the conrod (1). 4

Fit conrod bearing cap (2) o nto the conrod (1) so th at it is exactly located. ® T he c o d e n u m b e is o n the co n ro d (1) a n d o n the co nrod b e a rin g cap (2) m ust be a lign e d

and be positioned on one side. The cracked contact surface must not be damaged. 5

0

Lightly oil the thread o f the conrod b olt (4) and screw tig h t w ith wrench socket.

HI Press on conrod bearing cap conrod b o lt (4).

(2)and the conrod (1) by hand w hen screwing in the

® Clamp th e conrod (1) just b elow the conrod bearing in order to prevent the conrod (1) being twisted.

6

Set dial gauge and quick-calipers w ith 5 mm preload to the previously calculated m easurement (average value) o f the conrod bearing journal diameter.

7

Use dial gage and quick calipers to measure conrod bearing bore at three points (A, B, C) (vertically and each ab out 30° up and dow n from the separation points). Note the measurements. If one o f the measurements obtained (A, B, C) is not w ith in the tolerance, replace conrod bearing shell. Conrod bearing shells are factory-supplied ready fo r installation. It is no t perm itted to perform any machining work.

8

Take o ff conrod bearing cap (2) again.

® Never screw conrod bearing cap (2) tig h t w ith o u t the conrod bearing shells (3) being inserted at the conrod (1); fit on only. Before re-installing the conrod bolts (4), it is necessary to measure the shank length.


AR03.10-W-7021B

R em oving, installing pistons

17.1.96

ENGINE 541.920 /921 /9221923 /924 /92S /926 /927, S42.920 /921 /922 /923 /925 /926 1 2 3 4 5 6 7

Piston Piston pin Circlip Conrod Conrod bearing cap Conrod b olt Conrod bearing shells

L

Shank length o f conrod b o lt

I 4

Piston Conrod

W03.10-0022-06

8

O il spray nozzle

9

C ylinder liner

W 03.10-0023-06

Additional Information E ngines O M 501, O M 502 (m o d. des. 541.9, 542.9), ACTRO S - V e h icle m od . des. 950-954, F2

75

I 10

Piston S I Tensioning strap

II

I S Cranking device

A

Piston projection

W03.10-0024-06


Inspecting crankshaft flange fo r damage and w ear

Page 75

Step 13 included fo r the first tim e

El 1

Rem oving Remove cylinder head

Page 32

2

Remove o il sump

Page 57

3

Use a scraper to carefully remove

00 This ensures th at th e piston rings are

com bustion residues above th e to p land zone in th e cylinder wall

not dam aged when rem oving the pistons

(6)

4

Unscrew conrod b o lt

5

Take o ff conrod bearing cap (5)

(1)

m

422 589 02 0 900

© T h e cracked contact surface must not be dam aged, if necessary J, replace conrod (4)

IXI Ensure that th e m atching conrod bearing caps and conrods (4) are m arked

6

Take piston (1) together w ith conrod (4)

® Use a w ooden handle positioned at

o u t o f the crankcase

edge at piston stem to press piston o u t o f crankcase. The cracked contact surface at the conrod must not be damaged; if necessary, replace conrod.

® Do n o t damage oil spray nozzle (8). if necessary | remove o il spray nozzle (8) and inspect 7

M ark conrod bearing shells (7) to conrod

® Never tig h ten conrod bearing caps

bearing cap (5) and conrod (4) and remove

w ith o u t conrod bearing shells inserted at

AR18.0Q-W-4000B

conrod 8

Clam p conrod (4) w ith piston (1) in a vice

9

Remove circtip (3)

10

Press o u t piston pin (2) and take piston (1)

HI Use soft protective jaws fo r clam ping Piston p in bore

BE03.10-N-1002-02D

o ff the conrod (4)

76


m 11

Piston pin outer 0

BE03.10-N-1003-02D

Conrod bush inner 0

BE03.10-N-1004-01C

Inspecting Inspect piston (1) and cylinder walls for

If worn j

Page 21

replace cylinder liner

Page 53

dust damage

replace piston 12

Inspect used pistons (1) at piston stem, piston crown and piston rings before reinstalling

Always inspect piston rings visually for signs o f spalling of the coating, if necessary I

Page 82

replace piston rings inspect piston crown and piston stem fo r signs o f damage; replace piston if necessary 13

Inspect crankshaft flang e fo r signs of

damage and wear m

Installing

14

A ssem ble piston (1) and co nrod (4)

GD If necessary, m ea sure crankshaft a n d install in new bearings

P a g e 92

QQ If n e w pistons are Installed j

Page 55

assign piston to cylinder liner

BE01.40-N-1001-03C

Cylinder liner inner 0 I B insert conrod into the piston so that the longer side of the conrod which is split at an angle is aligned w ith the recess (arrow) fo r the oil spray nozzle at the piston 15

Oil piston pin (2) and insert by hand into the piston (1) and conrod (4)

16

Install cirdips(3)

17

Oil piston (1) and offset piston ring gaps (arrows) in turn by 120°

18

Guide tensioning strap (10) loosely over the I B The seal o f the tensioning strap must piston rings and pull tight to the outer still be able to be moved diameter o f the piston (1)

19

20

Insert conrod bearing shell (7) into the conrod (4) and oil contact surface

SI

000 589 38 31 00

I B Pay attention to marking, lug on

BE03.10-N-1001-01C

conrod bearing shell should be located in the slot on the conrod

Insert piston (1) into the crankcase until the ED The recess for the oil spray nozzle at the tensioning strap (9) is touching the piston should be facing in toward center o f crankcase engine ® Turn piston slightly w hen inserting to ensure the oil spray nozzle (8) is not damaged when installing the conrod (4). If damaged |

21

remove oil spray nozzle (8) and inspect

AR18.00-W-4000B

s

000 589 38 3100

Press piston (1) into the crankcase until the conrod bearing shell (7) is touching the conrod journal o f the crankshaft

22

Take o ff tensioning strap (10)

En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V e h icle m od. des. 950-954, F2


23

ED If the max. shank length (L) is exceeded

Measure conrod b olt (6)

BE03.10-N-1005-01C

1 replace conrod bolt 24

25

surface

CD Pay attention to marking, lug on conrod bearing shell should be located In the slot o f the conrod bearing cap

Fit conrod (4) and bearing cap (5) o n to the

GO Code numbers on conrod and conrod

crankshaft

bearing cap should agree and be

Insert conrod bearing shell (7) into the conrod bearing cap (5) and oil contact

BE03.10-N-1001-01C

positioned on the same side. C o n ro d a n d c o n ro d b e a rin g caps s h o u ld be

accurately touching the crankshaft journal; apply pressure by hand when inserting the conrod bolt (6) 26

Lightly oil thread o f conrod b olt (6) w ith engine oil and tigh ten

0

27

Install cranking device (11) fo r th e engine

@ Cranking device should be removed

at the t im in g cate

b efore starting th e e n gin e

28

Rotate crankshaft and check to ensure it rotates freely

29

Measure piston projection a t all pistons

Bolts o f conrod bearing caps to conrod

BA03.10-N-1001-01C

m

407 589 00 63 00


BA01.60-N-1001-01B

CD Remove deposits on piston (1) and

Page 80

crankcase SI

001 589 53 21 00

SI

541 589 01 21 00

If the dimensions fo r piston projection are

B E03.10-N-1001-02D

no t achieved, inspect conrod (4) and replace If necessary 30

Fit o n oil sum p

Page 57

31


Page 32


BE01.40-N-1001-03C

Designation


Engine 541.920/921/ 922/923/924/925/926/ 927

Engine 542.920/921/ 922/923/925/926

Code letter A

mm 129.990-129.995

Code letter B

mm 129.995-130.005

129.995-130.005

C o d e letter C

mm

130.0 0 5 -1 3 0.01 0

130.005-130.010

129.990-129.995


Test data o f conrod Engine 541.920/ 921/922/923/ 924/925/926/927

Number

Designation

BE03.10-N-1001-01C

Conrod bearing inner 0 with conrod bearing shells inserted

Standard

mm 94.054-94.096

925/926 94.054-94.096

Undersize 0.10

mm 93.954-93.996

93.954-93.996

U ndersize 0.25

m m 93.804-93.846

93.804-93.846

Undersize 0.5

mm 93.554-93.596

93.554-93.596

Undersize 0.75

mm 93.304-93.346

93.304-93.346

Undersize 1.0 BE03.10-N-1003-01C

Engine 542.920/ 921/922/923/

Distance from center of conrod bea

mm 93.054-93.096

93.054-93.096

mm 273,00-273,02

273,00-273,02

mm 52.055-52.065

52.055-52.065

ring bore to center of conrod bush bore BE03.10-N-1004-01C

Conrod bush inner 0

B E03.10-N-1005-01C

Conrod b o lt

Thread 0

M 16X1.5

Max. shank length

16X1.5 74.5

mm 74.5

Test data o f pistons Number

Designation

BE03.10-N-1001-02D

Piston projection in TDC relative to

Engine 541.920/ 921/922/923/ 924/925/926/927

Engine 542.920/ 921/922/923/ 925/926

mm 0.27-0.61

0.27-0.61

contact surface of crankcase BE03.10-N-1002-02D

Piston pin bore

mm 52.004-52.012

52.004-52.012

BE03.10-N-1003-02D

Piston pin o uter 0

mm 51.992-52.000

51.992-52.000

@ Timing case Number

Designation

BA01.60-N-1001 -01B

End cover TDC inspection hole to tim ing case

Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 25

Engine 542.920/ 921/922/923/ 925/926 25

E 3 Conrod Number

Designation

BA03.10-N-1001-01C

Bolts of conrod bearing cap to conrod

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/

1st stage

Nm 110

2nd stage

°X

90

925/926 110 90

Additional Information E n gin es O M 501, O M 502 (m o d. des. 541.9,542.9), ACTRO S - V e h ic le m od . des. 9 50 -9 54 , F2

79

0 0 0 5 8 9 3 8 31 0 0 T e n sio n in g strap

407 589 00 63 00

J

C ra n k in g device

A R 0 3 .1 0 -W -7 0 4 1 -0 1 B

M e a s u r in g p is to n p r o je c t io n

Test data o f pistons Num ber

D e s ig n a t io n

E n g in e 5 4 1 .9 2 0 /

E n g in e 5 4 2 .9 2 0 /

9 2 1 / 9 2 2 /9 2 3 /

9 2 1 /9 2 2 / 9 2 3 /

9 2 4 / 9 2 5 /9 2 6 / 9 2 7 BE03.10-N-1001-02D

Piston projection in TDC relative to contact surface o f crankcase

mm 0 .2 7 -0 .6 1

9 2 5 /9 2 6 0 .2 7 -0 .6 1

M e a s u rin g b rid g e

ffl Measure projection between piston crown and contact surface o f crankcase w itho ut cylinder head gasket fitted. T he m e a su re m e n t sh o u ld be cond u cted in the p isto n pin d irectio n in o rd e r to elim inate

the piston rock. 1

Rotate crankshaft until the piston to be measured is positioned a b o ut 1 cm before TDC.


2

3

A t t a c h IS1 d ia l g a g e (1) w it h p r e lo a d t o IS ) m e a s u rin g b r id g e (2).

M ount measuring bridge (2) onto the contact surface o f the crankcase (arrow) and set scale o f dial gage to “0".

W03.10*0025-01

4

Move measuring bridge (2) from the contact surface o f th e crankcase until it is positioned over the cylinder bore.

m Pull back tracer pin on dial gauge (1) when m oving dial gauge holder. 5

Rotate crankshaft until the piston to be measured is at TDC.

6

Tracer pin o f dial gage (1) is pushed back by the piston crown (arrow); the reading obtained is the am ount o f the piston projection. W03.10-0026-01

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h icle m od . des. 9 50 -954, F2

81

A R 0 3 .1 0 W 7 3 1 1 B

R e m o v in g a n d in s t a llin g p is t o n r in g s

17.1.96

ENGINE 541.920/921/922/923/924/925/926/927. 542.920/921/922/923/92S/926 / 2

Keystone ring (groove 1) Tapered compression ring w ith

3.1

interna l angle (groove II) O il c o n tro l ring w ith coiled spring (groove III) C oiled spring

4

Piston

5 6

1 3 Pliers E S Feeler gauge

3

W03.10-0027-06

Rem oving, installing 1 2

Page 75

Remove piston (4) Remove piston rings (1,2,3) in the

SI

000 589 37 37 00

sequence from top to bottom S Installation: it is im portant to inspect the piston rings fo r spalling o f the coating before re-installing and after installing; replace piston rings if necessary Pay atte n tio n to installation position; m arking "TO P” must face tow ard piston crow n 3

Measure gap clearance o f the piston rings

Insert piston rings in the unw orn area

(1.2)

(above th e to p reversal p oint o f the 1st

BE03.10-N-1001-05D

piston ring) o f the cylinder liner and measure gap clearance w ith feeler gauge 4

Measure gap clearance o f the piston ring

Remove coiled spring (3.1) from the piston

(3)

ring.

BE03.10-N-1001-05D

Insert piston ring in the unw orn area (above th e to p reversal p oint o f the 1st piston ring) o f the cylinder liner and measure gap clearance w ith feeler gauge fTI In sta lla tio n : install roiled s p rin g (3.1) into the piston ring. Gap o f coil spring must be offset 180° relative to piston ring gap. 5



Test data o f piston rings

Number

Designation

BE03.10-N-1001-05D

Max. piston ring gap clearance

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/925

924/925/926/927

/926

Groove 1keystone ring W hen new

mm 0.60-0.75

0.60-0.75

Groove 1keystone ring W ear lim it

mm £ 1 .0

£ 1.0

Groove II tapered compression

mm 0.40-0.55

0.40-0.55

mm

£ 1.0

ring w ith internal angle w h e n new Groove II tapered compression

<1.0

ring w ith internal angle W ear lim it Groove III o il control ring w ith coiled spring

mm 0.30-0.45

0.30-0.45

mm £ 0 .8

£0.8

W hen new Groove III o il control ring w ith coiled spring W ear lim it

Commercially available tools (see W orkshop Equipm ent Manual) Number

Designation

M ake (e.g.)

Order number

WH58.30-Z-1008-12A

Feeler gauge

Stiefelmayer D-73734 Esslingen

59

Additional Information En gin es O M 501. O M 502 (m od. des. 541.9,542.9), ACTR O S - V e h icle m od . des. 9 50 -954, F2

83

AR03.70.W-7570A

Removing, installing race on crankshaft

20.1.97

W03.20-0020-06

m

Removing

i

R em ove h o u sin g cover (1)

2

Pull o ff race (2) on crankshaft

Page 44 m

442 589 00 33 00

H Fit on both halves o f puller over the race and tig h ten bolts (arrows), and pull o ff race. M

Installing

3

Insert new race (2) w ith rounded edge in direction o f d rift and heat

m CD Tem perature max. 200°C

403 589 03 15 00

4

Fit race (2) onto the crankshaft

m

403 589 03 15 00

5

Install housing cover (1)

Q ] Install new radial seal w ith coil spring into the fro n t housing cover.

Page 44

442 58900 33 00 Puller


AR03.20-W-3063B

Replacing rear crankshaft radial seal

17.1.96

ENGINE 541.920/921/922/923/924/925/926/927,542.920/921/922/923/925/926

W03.20-0015-09

1 2

Radial seal Flywheel

3 4

Spacer sleeve S I D rift

S3

Removing

1

Remove flyw heel (2)

2

Press o u t radial seal (1)

m

Installing

3

Fit spacer sleeve (3) over the crankshaft

m

4

Fit radial seal (1) onto the crankshaft and

[ D Install radial seal dry and inspect

3 ] Inspect flyw heel flange fo r signs of wear and scoring resulting from radial seal, if necessary J, install race and flyw heel flange

Page 102

AR03.30-W-8350A

@ Cover over crankshaft w ith a cleaning rag as a protection

403 589 04 15 00

press in w ith the d rift (4) until the d rift (4) sealing lips to ensure they are correctly is making contact w ith the spacer sleeve (3) p ositioned o n the cra n ksha ft after installing @ If a race is installed on the front flywheel flange, a radial seal w ith a coil spring has to be fitted IS 5

Install flywheel (2)

403 589 0415 00

Page 102

Additional Information Engines O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V eh icle m od. des. 950-954, F2

85


AR03.20-W-4351B

14.6.96

Removing and installing crankshaft

ENGINE 541.920 /921 /922 /923 /924 /92S /926 /927, 542.920 /921 /922 /923 /925/926 1 2 3

Crankshaft Top crankshaft bearing shells Bottom crankshaft bearing shells

4 5 6 7 8

Thrust washers (fit bearings) M ain bearing caps M ain bearing cap (fit bearing) M ain bearing cap bolts M ain bearing cap bolts (side)

9

Crankshaft gear

L

Length o f shank o f main bearing cap bolts

W 03.20 0017 06

W03.20-0018-09

I

Crankshaft

8

M ain bearing cap bolts (side)

4 5 6 7

Thrust washers (fit bearings) M ain bearing caps M ain bearing cap (fit bearing) M ain bearing cap bolts

11 12 13

W1 D ial gage I S Dial gage holder Crankshaft gear

Removing 1

Remove engine

Engines O M 501, O M 502 (m od. des. 541.9,542.9), A CTRO S - V e h ic le m od. des. 950-954, F2

Page 12


2

Remove tim ing case

Page 63

3

Remove housing cover at fro n t

Page 44

4

Remove pistons

P a g e 75

5

Remove PLD control unit

6

Remove o il pump

7

Remove m ain bearing caps (5,6)

AR07.15-W-1628B AR18.10-W-6020B Q ] M ark m ain bearing caps according to the sequence On engine 541.920 - 927 the tit bearing thrust washers (4) are installed at the 4th m ain bearing cap. On engine 542.920 - 923/925/926 th e fit b e a rin g th ru st w a sh e rs (4) are

installed at the 5th m ain bearing cap. 8

Take o ff crankshaft bearing shells (3)

ED M ark crankshaft bearing shells to the relevant main bearing cap (5,6).

9

Lift crankshaft (1) o u t o f the crankcase w ith m a liftin g tackle

10

Take out crankshaft bearing shells (2)

403 589 02 63 00

GD M ark crankshaft bearing shells to the crankcase.

11

M easure crankshaft and fit into bearings

m

Installing

12

install cra n ksh a ft(l) w ith a tackle

Page 92

[XI M arking on crankshaft gear (9) should be between the m arkings o f the camshaft gear (13). 403 589 02 63 00

13

M easure central m ain bearing bolts (7)

!X] If the shank length (L) is exceeded,

BE01.40-N-1002-02C

replace main bearing bolt. 14

Install m ain bearing caps (5)

Q ] A ll m ain bearing caps have dow el pins and are identified w ith numbers (arrows). The m ain bearing caps should be installed in accordance w ith th e n u m b e rs in

ascending order, starting from the front, and must not be mixed up. O il main bearing bolts. I H Pay attention to the tightening sequence; first o f all fu lly tig h ten the central m ain bearing bolts (7), then the side m ain bearing bolts (8). 0

BA01.40-N-1013-01D

central main bearing bolts (7)

BA01.40-N-1016-01D

@ side m ain bearing bolts (8) 15

P a g e 90

D eterm ine thickness o f the fit bearing thrust washer and install m ain bearing cap (6) Fit bearing journal w idth

BE03.20-N-1002-02C

A xial play

BE03.20-N-1006-02C

W all thickness o f fit bearing thrust washers

BE03.20-N-1013-02C

[ H P ay a tte ntion t o t ig h te n in g sequence, first o f all, fu lly tig h ten central main bearing bolts (7), then the side main bearing bolts (8).

88


0

8A01.40-N-1013-01D

central main bearing bolts (7)

BA01.40-N-1016-01D

side main bearing bolts (8)

GO m 16

M ount conrod in bearings and install

17

Install pistons

18

Install oil pump

001 589 53 21 00 363 5890221 00

Page 69 Page 75 AR18.10-W-6020B

19

In sta ll t im in g c ase

Page 63

20

Install housing cover at front

Page 44

21

Install PLD control unit

23.1

Replace oil-w ater heat exchanger

24

Replace oil filte r element

25

Install engine

26

Fill engine oil circuit

AR07.15-W-1628B ® Only in th e case o f material abrasion.

AR18.30-W-6840B AP18.00-W-0101A

Page 12 AR18.00-W-1600B

Test data o f crankcase Num ber

Designation

DEO1,40-N-1002-02C

M a in b earin g cop bolts

thread 0

M

length of shank when

Engine 542.920/ 921/922/923/

Engine 541.920/ 921/922/923/ 924/925/926/927

925/926

10

10

mm 173

173

mm

176

176

Engine 541.920/ 921/922/923/ 924/925/926/927

Engine 542.920/ 921/922/923/ 925/926

new max. sh a n k length

Test data o f crankshaft Num ber

Designation

6C03.ZO-N-100Î-02C

Fit b earin g journal w idth

Stand ard

m m 42.000—42.062

42.000-42.062

Oversize 0.5

mm 42.500-42.562

42.500-42.562

Oversize 1.0

mm 43.000-13.062

43.000-43.062

B E03.20-N-1003-02C

M ain bearing journal width

mm 42.000-42.016

42.000-42.016

B E03.20-N-1006-02C

Axial play

mm 0.150-0.351

0.150-0.351

8E03.20-N-1013-02C

Fit bearing thrust washers wall thickness

Standard

mm 5.375-5.425

5.375-5.425

Oversize 0.5

mm 5.625-5.675

5.625-5.675

Oversize 1.0

mm 5.875-5.925

5.875-5.925

Engines O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V eh icle m od. des. 950-954, F2


® Crankcase, tim ing case cover, end cover Number

Designation

Engine

Engine

541.920/

542.920/

921/922/ 923/924/ 925/926/

921/922/ 923/925/ 926

927 BA01.40-N-1013-01 D

C entral b o lt o f m a in b earin g cap to

BA01.40-N-1016-01D

Nm

1st sta ge

crankcase

2nd stage Nm

Side b olt o f m ain bearing cap to crankcase

8k

y

363 589 02 2100

J

320

90

125

125

<6

403 589 02 63 00

Dial gage holder

AR03.20-W-4351-01A

320

90

Drift

Determ ining thickness o f fit bearing thrust washers o f crankshaft

Test data of crankshaft Number

BE03.20-N-1002-02C

Designation

Fit bearing journal w idth

BE03.20-N-1006-02C

A xial play

BE03.20-N-1013-02C

Fit bearing thrust washers w all thickness

Engine 541.920/ 921/922/923/

921/922/923/

Engine 542.920/

924/925/926/927

925/926

Standard

mm 42.000-42.062

42.000-42.062

Oversize 0.5

mm 42.500-42.562

42.500-42.562

Oversize 1.0

mm 43.000-43.062

43.000-43.062

mm 0.150-0.351

0.150-0.351

Standard

mm 5.375-5.425

5.375-5.425

Oversize 0.5

mm 5.625-5.675

5.625-5.675

Oversize 1.0

mm 5.875-5.925

5.875-5.925

@ Crankcase, tim in g case, end cover Num ber

BAQ1.40-N-1013*010

Designation

Central b olt o f m ain bearing cover to crankcase

BA01.40-N-1016-01D

Side b olt o f main bearing cover to

Engine

1st stage

Nm

2nd stage Nm

Engine

541.920/

542.920/

921/922/

921/922/

923/924/

923/925/

925/926/ 927

926

320

320

90

90

125

125

crankcase

90


^

001 589 53 21 0 0

J

\ ^

D ial g a g e

1

3 03 509 02 2 1 0 0

J

D ial g a g e h o ld e r

Measure crankshaft fit bearing journal w idth (A) and assign thrust washers to match the installation stage measured.

ffl The dimensions o f the installation stages stated in the table should be m aintained. Thrust washers are factory-supplied ready fo r installation and also in oversizes for repairs. It is not perm itted to carry out any reworking.

2

Oil thrust washers (1) and push into the guides between crankshafts (fit bearings) and the contact surface in the crankcase. m Only thrust washers (1) of the same wall thickness should be installed.

3

Oil thrust washers (2) and insert into the groove at the m ain bearing cap (fit bearing) (6).

4

@ Install m ain bearing cap (fit bearing) (3) and b olt tight.

m The m ain b e arin g cap has d o w e i pins an d is identified w ith a num ber. Oil m a in b earing

bolts. Pay attention to tightening order; first of all tig h ten the central bolts fully, then the side main bearing bolts.

5

Rotate crankshaft by hand and inspect ease of operation.

6

Attach E 0 dial gage holder (4) and E l dial gage (5) w ith preload to crankcase. Move crankshaft (6) from stop to stop and read o ff measurement on gage (axial play).

E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h ic le m od . des. 9 50 -9 54 , F2


AR03.20-W-4355A

Measuring and mounting crankshaft

30.11.96

ENGINE S41.920 /921 /922 /923 /924 /92S /926 /927, 542.920 /921 /922 /923 /925 /926

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

J

Crankshaft

A

M ain b ea rin g jo u rn a l d iam eter

2

8

Fit bearing jo u rn a l w idth

3

IS! D ro p hardness tester E M icrom eter

C

M a in bearing jo u rn a l w idth

A

M a in b e a rin g cap

D

C o n r o d b e a r in g jo u r n a l diam eter

5 6

C entral main bearing bolts

E

Conrod bearing jo u rn a l w idth

Side m ain bearing bolts

F G

M ain, co nrod bearing jo u rn a l fille t rad ii M ain, co nrod bearing jo u rn a l roundness

H

M a in b e a rin g In n e r d ia m e te r w h e n installed

1

Crankshaft

7 S

S I D ia l gage HÜ D ia l gage ho ld er

W03.20-0031-05

0

Inspecting

1

Remove crankshaft

2

Clean crankshaft

92

Page 87


3

Inspect crankshaft flange at fro n t fo r w ear

4

Inspect main, conrod bearing journals fo r

CD If worn or grooves caused by radial seal, a race should be fitted onto the crankshaft

Page 84

flange. [ S If damaged or cracked J,

damage and cracks Replace crankshaft. 5

Test hardness of main and crankshaft bearing journals w ith drop hardness tester (2)

0 1 A base should be placed below the bearing journal to be tested fo r the test.

BE03.20-N-1009-02C

Specified hardness should be achieved a ro u n d at least th w o -th ird s o f the

circumference of bearing journal. m

000 589 2021 00

[ E If specified hardness is not achieved |

BE03.2Q-N-1009-02C

Reharden crankshaft or replace. Measuring 6

Measure crankshaft (1) fo r radial runout

On engine 541.920 - 927

BE03.20-N-1007-02C

EE Measured at the tw o m iddle main bearing journals, m ounted at outer main bearing journals. On engine 542.920 - 923/925/926 [L i Measured at m iddle main bearing journal, m ounted at outer main bearing journals. 7

Measure main, conrod bearing journals

BE03.20-N-1007-02C

Measure main bearing journal diam eter (A) BE03.20-N-1001-02C w ith the m icrometer at tw o points (offset about 90°). B

Microm eter

WH58.30-Z-1027-12A

M ain bearing journal w idth (C)

BE03.20-N-1003-02C

Tit b e a rin g jou rnal w idth (B)

BE03.20-N-1002-02C

Measure conrod bearing journal diameter

BE03.20-N-1004-02C

(D) w ith m icrometer at tw o points (offset about 90°). B

M icrom eter

WH58.30-Z-1013-12A

Conrod bearing journal w idth (E)

BE03.20-N-1005-02C

Fillet radii (F) o f m ain, co n ro d b earing

BE03.20-N 1008 02C

journals Roundness (G) o f main, conrod bearing

BE03.20-N-1010-02C

journals CD If damaged and worn, machine crankshaft to the next undersize. The balancing weights should be taken off for machining the crankshaft (1) and recentered again after fittin g on. M ounting 8

Page 97

M o un t crankshaft (1) radially M ain bearing journal diam eter (A)

BE03.20-N-1001-02C

Crankshaft main bearing inner diameter (H) when installed.

BE03.20-N-1012-02C

Additional Information En gin es O M 501, O M 502 (m od, des. 541.9,542.9), A C T R O S -V e h ic le m od . des. 9 50 -954, F2

93

E l Pay attention to tigh ten ing sequence; first o f all, tighten fu lly the central main bearing bolt (5), then the side main bearing bolts (6). 0

central main bearing bolts

0

side main bearing bolts

m

9

Install crankshaft (1)

BA01.40-N-1013-01D BA01.40-N-1016-01D 001 589 53 21 00

0

Q uick calipers

WH58.30-Z-1009-12A

0

M icrom eter

WH58.30-Z-1027-12Â

Page 87


Test data o f crankshaft Number

Designation

BE03.20-N-1001-02C

M ain bearing journal 0

BE03.20-N-1002-02C

Fit bearing journal w idth

BE03.20-N-1003-02C

M ain bearing journal width

BE03.20-N-1004-02C


Standard

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/027

925/926

mm 107.98-108.00

107.98-108.00

Undersize 0.10

mm 107.88-107.90

107.88-107.90

Undersize 0.25

mm 107.73-107.75

107.73-107.75

Undersize 0.5

mm 107.48-107.50

107.48-107.50

Undersize 0.75

mm 107.23-107.25

107.23-107.25

Undersize 1.0

mm 106.98-107.00

106.98-107.00

Standard

mm 42.000-42.062

42.000-42.062

Oversize 0.5

mm 42.500-42.562

42.500-42.562

Oversize 1.0

mm 43.000-43.062

43.000-43.062

mm 42.000-42.016

42.000-42.016

Standard

mm 93.98-94.00

93.98-94.00

Undersize 0.1

mm 93.88-93.90

93.88-93.90

Undersize 0.25

mm 93.73-93.75

93.73-93.75

Undersize 0.5

mm 93.48-93.50

93.48-93.50

Undersize 0.75

mm 93.23-93.25

93.23-93.25

Undersize 1.0

mm 92.98-93.00

92.98-93.00

BE03.20-N-1005-02C

Conrod bearing journal width

mm 37.000-37.010

81.000-81.014

BE03.20-N-1007-02C

Radial runout measured at middle main bearing journal (mounted at outer main bearing journals)

mm £0.06

£0.06

BE03.20-N-1008-02C

Fillet radii

main bearing journals

mm 3.5-4.0

3.5-4.0

conrod bearing journals

mm 3.5-4.0

3.5-4.0

HRC 53-59

53-59

main bearing journals

mm 0.002 ±0.002

0.002+0.002

conrod bearing journals

mm 0.002 + 0.002

0.002 ±0.002

Standard

mm 108.056-108.102

108.056-108.102

Undersize 0.10

mm 107.956-108.002

107.956-108.002

Undersize 0.25

mm 107.806-107.852

107.806-107.852

Undersize 0.5

mm 107.556-107.602

107.556-107.602

Undersize 0.75

mm 107.306-107.352

107.306-107.352

mm 107.056-107.102

107.056-107.102

BE03.20-N-1009-02C

Hardness o f main bearing and conrod bearing journals (Rockwell hardness)

BE03.20-N-1010-02C

BE03.20-N-1012-02C

Round ness

Crankshaft main bearing inner 0 when installed

Undersize 1.0

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTROS - V eh icle m od. des. 9 50-954, F2

95

® Crankcase, tim ing case cover, end cover Num ber

Engine

Designation

Engine

541.920/

542.920/

921/922/ 923/924/

921/922/ 923/925/

925/926/

926

927 BA01.40-N-1013-01D

BA01.40-N-1016-01D

Central b o lt o f m ain bearing cap to crankcase

1st stage

Nm

320

320

2nd stage

“X

90

90

Nm

125

125

Side b olt o f m ain bearing cap to crankcase

Dial gage

Com m ercially available tools (see W orkshop Equipm ent M anual) Number

Designation

WH58.30-Z-1009-12A

Quick calipers fo r internal measurements, 0 1 0 0 - 120 mm

WH58.30-Z-1013-12A


WH58.30-Z-1027-12A

M icrom eter 100-125 mm

M ake (e.g.)

O rd ern u m b er

Hahn und Kolb Borsigstr. 50

313346100

D-70469 Stuttgart


AR03.20-W-4355-01A

Positioning crankshaft in mounts radially

T e s t d a ta o f c r a n k s h a f t

Designation

Number

Engine 541.920/ 921/922/923/ 924/925/926/927

BE03.20-N-1001-02C

BE03.20-N-1012-02C

M ain bearing journal 0

Crankshaft main bearing inner 0 when installed

Standard

mm 107.98-108.00

Engine 542.920/ 921/922/923/ 925/926 107.98-108.00

Undersize 0.10

mm 107.88-107.90

107.88-107.90

Undersize 0.25

mm 107.73-107.75

107.73-107.75

Undersize 0.5

mm 107.48-107.50

107.48-107.50

Undersize 0.75

mm 107.23-107.25

107.23-107.25

Undersize 1.0

mm 106.98-107.00

106.98-107.00

Standard

mm 108.056-108.102

108.056-108.102

Undersize 0.10

mm 107.956-108.002

107.956-108.002

Undersize 0.25

mm 107.806-107.852

107.806-107.852

Undersize 0.5

mm 107.556-107.602

107.556-107.602

Undersize 0.75

mm 107.306 107.352

107.306-107.352

Undersize 1.0

mm 107.056-107.102

107.056-107.102

E3Crankcase, tim ing case cover, end cover Designation

Number

BA01.40-N-1013-01D

BA01.40-N-1016-01D

V

001 589 53 21 00

Central b olt o f main bearing cap to crankcase

1st stage

Nm

2nd stage

Side b olt o f main bearing cap to crankcase

Nm

Engine 541.920/

Engine 542.920/

9 2 1 /9 2 2 /

9 2 1 /9 2 2 /

923/924/ 925/926/ 927

923/925/ 926

320

320

90

90

125

125

J

D ia l g a g a

Commercially available tools (see W orkshop Equipment Manual) Number

Designation

WH58.30-Z-1009-12A

Quick calipers fo r internal measurements, 0 100 - 1 2 0 mm

WH58.30-Z-1027-12A

Microm eter 100-125 mm

Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A CTRO S - V eh icle m od. des. 9 50 -9 54 , F2

M ake (e.g.)

Order number

Hahn und Kolb Borsigstr. 50 D-70469 Stuttgart

313346 100


1

Clean bearing points o f the crankshaft w ith a chamois leather.

2

Use th e m icrom eter to measure m ain bearing journal 0 to tw o points (offset about 90°.

33 The dimensions stated in the ta b le should be m aintained. If one o f the readings obtained is not w ith in the tolerance range, machine crankshaft.

W03.20-0022-01

3

C le an b e a rin g p oin ts in crankcase a n d m a in b earin g caps w ith a ch a m ois leather.

4

Insert crankshaft bearing shells (2) into the crankcase in the sequence marked. m The locking lugs (arrow) o f th e crankshaft bearing shells (2) should be positioned in the slots o f th e crankcase basic bores. O il d rillings in the crankshaft bearing shell (2) and crankcase should be aligned.

S

Insert crankshaft bearing shells (1) into the m ain bearing caps (3,4) in the sequence marked.

ffl The locking lugs (arrows) o f th e crankshaft bearing shells (1) should be located in the slots o f the m ain bearing caps (3).

6

A ttach m ain bearing caps (3,4) to the crankcase.

ffl A ll the main bearing caps (3,4) have d ow el pins and are id entified w ith numbers. They should be installed in accordance w ith th e numbers in ascending order, starting from the front. O il m ain bearing bolts (6,7) and pay attention to tightening order; first o f all fully tigh ten the central m ain bearing bolts (6,7) and then the side bolts.

W03.20-0025-01


7

Set dial gage and quick calipers to the nominal dimension of the main bearing journal with the m icrometer (preload 5 mm)

8

Use the dial gage and quick calipers to measure crankshaft bearing bores in the crankcase at three points (A, B, C) (vertically and each about 30° away from the separation points). m The dimensions stated in the tables should be observed. If one of the readings obtained (A, B, C) is not w ithin the tolerance range, replace main bearing shells in accordance with the measured m ain bearing journals. Main bearing shells are factory-supplied ready fo r installation and also in oversizes for repairs. It is not permitted to carry out any reworking.

9

Attach main bearing caps (3,4) again.

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h icle m od. des. 950-954, F2

99

AR03.30-W-1600B

17.1.96

Rem oving, installing belt pulley/vihration Hamper

ENGINE 541.920/921 /922 /923 /924 Z925/926/927,542.920 /921 /922 /923 Z925/926 1

In term ed iate p iece

2

Bolt

3 4

Vibration dam per Splash ring

5

Bolt

6 7

Poly V-belt Viscous fan

8

Bolt

W03.30-0011-06

Rem oving, installing 1

Slacken poly V -belt (6) e n d ta k e off

O n e n g in e 542.920-923/925/926

A R 1 3.25 -W -3 2 0 0B

2

Detach cover at tim in g case

0

BA01.60-N-1001-01B

3

Block engine at flyw heel

0D Use a suitable to o l to block flyw heel at

4.1

Remove viscous fa n (7)

End cover to tim ing case

rin g g e a r

On engine 541.920 - 927;

AR20.40-W-5614A

542.920/921/925/926 4.2

R em ove viscous fa n (7) a n d fa n drive

O n e n g in e 542.922/923

5.1

Remove interm ediate piece (1)

On engine 541.920 - 927;

A R 2 0.40 -W -5 6 1 4B

542.920/921/925/926

6

Unscrew bolts (2) and take o ff vibration dam per (3)

7

Take o ff splash ring (4)

8

Install In the reverse order

¡“ 3 interm ediate piece to vibration dam per

BA03.30-N-1003-01F

@ V ib ratio n damper to crankshaft

BA03.30-N-1002-01F

T im ing case

Number

Designation

Engine 541.920/ 921/922/923/ 924/925/926/927

BA01.60-N-1001 -01B


Nm 25

Engine 542.920/ 921/922/923/ 925/926 25


0

F ly w h e e l, d riv e n p la t e , v ib r a t io n d a m p e r , s t a rt e r r in g g e a r

Number

Engine 541.920/

Designation

921/922/923/ 924/925/926/927 BA03.30-N-1002-01F BA03.30-N-1003-01F

Engine 542.920/ 921/922/923/ 925/926

V ibration dam per to crankshaft

Nm 200

200

Intermediate piece to vibration dam per

Nm 30

30

Additional Information Engines O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V e h icle m od. des. 9 50 -954, F2

101

AR03.30-W-8002B

Removing, installing flywheel

17.1.96

ENGINE 541.920/921 /922 /923 /924 /9 2 S /9 2 6 /9 2 7 , 542.920 /921 /922 /923 /925/926 1 2 3

Flyw heel Flywh e el b o lt 12 } D rifts

BIS Crankshaft p ositio n sensor L Shank length o f flyw heel b o lt

W03.30-0012-06

Ü


1

Remove clutch

2

Pull crankshaft position sensor (BIS) about 8 mm out o f the tim ing case

@ Do not damage crankshaft position sensor w ith the ring gear when pulling o ff the flyw heel (1) GO Installation: press crankshaft position sensor into the tim ing case as far as a stop

AR25.10-W-0050B

3

Detach cover at tim ing case

0

4

Block engine at flyw heel (1)

ED Use a suitable tool to block flywheel at ring gear

5

Unscrew flywheel bolts (2) at flyw heel (1)

Screw drifts (3) into tw o opposite threaded

BA01.60-N-1001-01B

[ D Installation: lightly oil flywheel bolts 0

6


Flywheel to crankshaft

BE03.30-N-1004-03C BA03.30-N-1001 -01F 403 589 02 63 00

m

holes 7

Remove flyw heel (1) over the drifts (3)

CD If flyw heel is tight, screw tw o bolts (M 1 0 X 1.5) into opposite threaded holes and pull o ff flywheel [ D Installation: grease ring gear with lo n g life grease

BR00.45-Z-1001-06A

Inspecting 8

Measure flyw heel bolts (2)

Q ] If the max. shank length (L) is exceeded, B E03.30-N-1004-03C replace flywheel bolt

9

Inspect clutch surface at flyw heel (1)

[ U If scorching, scores or cracks are present in th e clutch surface ) machine flywheel

P a g e 105


If the scores or cracks are deeper than the maximum permissible stock removal, the flyw heel has to be replaced Inspect flyw heel flange fo r w ear and

10

GD If wear or scoring present j

scoring produced by radial seal AR03.30-W-8350A

install race at flywheel flange 11

Inspect ring gear for wear

12


111 If w orn j replace ring gear o f flyw heel (1)

AR03.30-W-8312B

Test data o f flyw heel Engine 541.920/921/

D esignation

Number

922/923/924/925/926/ 927 BE03.30-N-1004-03C

M 16X1.5

Thread 0

Flywheel bolt

Shank length when new

mm 74.0

Max. shank length

mm 75.0

Test data o f flyw h eel D esignation

Num ber

Engine 542.920/921/ 922/923/925/926

B E03.30-N-1004-03C

0

Thread 0

Flywheel bolt

M 16X1.5


mm 74.0

Max. shank length

mm 75.0

Tim ing case

Num ber

D esignation

B A01.60-N-1001-01B

Engine 541.920/ 921/922/923/ 924/925/926/927

End cover TDC inspection hole to

Nm 25

Engine 542.920/ 921/922/923/ 925/926 25

tim in g case

0

Flyw heel, driven plate, vib ration damper, starter ring gear

Num ber

Designation

BA03.30-N-1001-01F


Engine 541.920/

Engine 542.920/

9 2 1 /9 2 2 /9 2 3 /

9 2 1 /9 2 2 /9 2 3 /

924/925/926/927

925/926

1st stage

Nm 21 0

2 n d stage

“A

90

21 0

90

Additional Information i E n g i n e s

O M 501, O M 502 (m od. des. 5 41.9,542.9), ACTR O S - V e h icle m od . des. 950-954, F2

103


Designation

O rder num ber

BR00.45-Z-1001-06A

MB lon g life grease

000989 63 51


AR03.30-W-8022B

Checking and re-machining flywheel

29.2.96

ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927, 542.920 /9 2 1 /922 /923 /9 2 S /926 1 2

Flywheel Ring gear

3

Knife-edge straightedge

A B

Flywheel o uter diam eter Flywheel diam eter fo r m ounting ring

D E

F

gear Flywheel diam eter fo r m ounting dutch Flywheel minim um width between friction surface and contact flange when perform ing repairs Flyw heel overall width

W03.30-0013-0*

El i

Removing P a g e 102

Rem ove flyw heel (1)

Inspecting

2

Clean flyw heel (1) and inspect clutch

If a fa u lt exists, the clutch surface (friction

surface (friction surface) fo r sig n s o f

surface) m ust be m a ch ine d by g rin d in g or

scorching, scores and cracks and inspect flatness w ith knife-edge straightedge (3)

precision turning. Before machining the flyw heel, check w hether stock removal is still possible. If th e scores or cracks are deeper than the maximum permissible stock removal, the flyw heel should be replaced.

M achining 3

Machine flyw heel (1)

Flywheel outer diam eter (A)

BE03.30-N-10Q1-03C

Flywheel diam eter fo r m ounting starter ring gear (B) Flyw heel diam eter fo r m o u n tin g clutch (D)

Flywheel overall w id th (F) W hen machining the clutch surface (friction surface), th e w id th between

BE03.30-N-1003-03C

friction surface and contact surface must not be less than flyw heel minim um w idth (E) If th e surface ro u g h n e s s o f th e clutch

B E03.30-N -1002-03C

friction surface is excessive, this increases the w ear of the clutch lining. If th e surface roughness is insufficient, this m ay result in clutch se p a ra tio n problem s.

The friction surface must not have any shrink holes or chatter marks after machining.

En gin es O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h icle m od . des. 9 50 -9 54 , F2


m

Installing

A

Install flyw h eel (1)

Page 102

Test data o f fly w h ee l Num ber

Designation

BE03.30-N-1001-03C

Flywheel 0

Engine 541.920/921/ 922/923/924/925/926/ 927 O uter (A)

mm 487

For m oun ting starter

Standard

mm 432.490-432.645

ring gear (B)

Undersize 0.5

mm 431.990-432.145

For m o un ting clutch (D)

mm 475.000-475.063

Fig. see BE03.30-N-1002-03C

Surface roughness

Clutch frictio n surface

AR03.30-W-8022-01A pm 16

(Rz) Flatness BE03.30-N-1003-03C

Flywheel

mm

<0,03

Overall w id th (F)

mm 70

M inim u m w id th betw een frictio n surface

mm 60

and contact flan g e w hen p erform ing repairs (E) Fig. see

mm AR03.30-W-8022-01A


D esignation

Engine 542.920/921/ 922/923/925/926

BE03.30-N-1001-03C

Flywheel 0

O uter (A)

mm 487

For m o un ting starter

Standard

ring gear (B)

Undersize 0.5

For m o u n t in g clutch (D)

mm 432.490-432.645 mm 431.990-432.145 mm

Fig. see BE0 3.3 0 N 1003 03C

Clutch friction surface

Surface ro u g h n e ss

4 7 5 .0 0 0 -4 7 5.06 3

AR03.30-W-8022-01A pm

16

(RZ> Flatness B E03.30 N 1003 03C

Flyw heel

mm

£0,03

O verall w id th (F)

mm 70

M inim u m w id th

mm 60

betw een frictio n surface and contact flan g e when perform ing repairs (E) Fig. see

mm AR03.30-W-8022-01 A


AR03.30-W-8312B

29.2.96

Replacing ring gear o f flyw h eel

ENGINE 541.920/921 /9 2 2 /9 2 3 /9 2 4 /9 2 5 /9 2 6 /9 2 7 , 5 4 2 .9 2 0 /9 2 1 /9 2 2 /9 2 3 /9 2 5 /9 2 6 1

R in g g e a r

2

Flywheel

A

Bore 0 fo r m ounting clutch pressure plate ( M 1 0 X 1.5)

B

Flyw heel 0 fo r m ounting starter ring gear

m

Removing

1

Remove flywheel

AR03.30-W-8002B

Replacing 2

Use w elding torch to rapidly heat ring gear (1) and press o ff from the flyw heel (2)

3

Measure flyw heel diam eter (B) fo r

OD If the diam eter is less than the standard

m ounting the ring gear (1)

diam eter (B), the flyw heel diam eter must be re-machined fo r m ounting the ring gear

B E03.30-N-1001-03C

. Pay attention to undersize. 4

Measure inner diam eter o f ring gear

Pay attention to size o f overlap at ring gear BE03.30-N-1002-04C (1) relative to flyw heel (2)

5

Heat new ring gear (1)

00 Tem perature is reached once ring gear

BE03.30-N-1002-04C

has a bright yellow annealing color 6

Press ring gear (1) onto the flyw heel (2) as

00 The permissible radial runout o f the

far as the contact face

fitted rin g g e a r m ust n o t be exceeded

B E03.30-N-1002-04C

Drill holes (A) in ring gear (1) fo r m ounting the clutch pressure plate and tap thread (M 1 0 X 1.5)

m

Installing

7

Install flywheel

AR03.30-W-8002B

Test data o f flyw h eel Number

Designation

BE03.30-N-1001-03C

Flywheel 0

Engine 541.920/921/ 922/923/924/925/926/ 827 O uter (A)

mm 487

For m ounting starter

Standard

mm 432,490-432,645

ring gear (B)

Undersize 0,5

mm 431,990-432,145

For m ounting clutch (D)

mm 475,000-457,063

Fig. see

AR03.30-W-8022-01A

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h ic le m od . des. 9 50 -9 54 , F2

3

Test data o f flywheel

N um ber

Designation

Engine 542.920/921/ 922/923/925/926

BE03.30-N-1001-03C

Flywheel 0

O uter (A)

mm 487

For m ounting starter

Standard

mm 432,490-432,645

ring gear (B)

Undersize 0,5

mm 431,990-432,145 mm 475,000-457,063

For m o u n t in g clutch (D)

Fig. see

AR03.30-W-8022-01A

Test data o f starter ring gear Num ber

Designation

BE03.30-N-1002-04C

Starter ring gear

Engine 541.920/ 921/922/923/ 924/925/926/927 Inner 0

Engine 542.920/ 921/922/923/ 925/926

Standard

mm 432,000-432,115

432,000-432,115

Undersize 0,5

mm 431,500-431.615

431,500-431,615

Flyw heel overlap

mm 0,375-0,645

0,375-0,645

Permissible radial runout

mm

ï S0,5

<0,5

o f flyw heel W id th Fitting tem perature

mm 18,4-18,6 °C 200-230

18,4-18,6 200-230


AR03.30-W-8350A

Removing, installing race on flywheel

23.10.96

ENGINE 541.920/921 Z922/923/924/925/926/927,542.920/921 /922 /923/92S/926 1

Pace

2 3 4 5

Flyw heel IS Puller I S Thrust piece IS D rift

W03 50-n01«-0s

m

Rem oving

1

Remove flyw h eel (2)

2

Pull o ff race (1) on flyw heel (2)

El

Installing

3

Use d r ift (5) to Insert new race (1)and heat

AR03.30-W-8002B

m m

000 589 45 33 00 312 5 8 90 015 00

m

403 589 03 15 00

HI W ith rounded edge facing drift. T em p era tu re m ax. 2 0 0 °C

IS

4

Fit race (1) o nto flyw heel (2)

5

Install new radial seal w ith coll spring In tim ing case

AR03.20-W-3063B

6

Install flyw h eel (2)

AR03.30-W-8002B

403 589 03 15 00

T

312 589 0 0 1 5 0 0

000 589 4 5 33 00

T h ru st pie ce

P u lle r

Additional Information En g in es O M 501, O M 502 (m od. des. 5 41 .9,542.9), A C T R O S - V e h ic le m o d . des. 9 50 -9 54 , F2

5

AR03.30 W 8401B

R em oving, installing g u id e bush in fly w h eel

7.2.96

ENGINE 541.920/921 /922 1923/924/925/9261927.542.920/921 /922 Z923/925/9 2 6

W 03.30-0015-09

1 2

Flyw heel b o lt G uid e bush

5 6

I S Internal extractor IS Counter-support

3 4

Flyw heel IS D rift

7

IS D rift


Tightening torque/tightening angle o f flywheel bolts m odified

Step 4

mm


1

Remove clutch

2

Take o ff cover at tim ing case


3

Block engine at flywheel (3)

CD Use a suitable to o l to block flyw heel at

AR25.10-W-0050B RA01.60-NI-1001-01R

ring gear 4

U nscrew flyw h ee l bolts (1) at flyw h ee l (3)

IS

In stallation : lightly oil flyw h e e l b olt

BA03.30-N-1001-01F

Flywheel to crankshaft 5

Measure shank length (L) o f flyw heel bolts

If max. shank length is exceeded J

BE03.30-N-1004-03C

(1) replace flyw heel bolts 6

Screw drifts (5) into tw o opposite threaded holes

7

Install internal extractor (6) into guide bush

m m

403 58902 63 00

000 589 27 33 00

(2) 8

A ttach c o u n te r-su p p o rt (7) to internal

®

extractor (6) and pull out guide bush (2)

the ends o f the counter-support to avoid

Place bases, e.g. co p p er plates, b e lo w

dam aging the flyw heel (3)

m 6

000 589 27 33 00


m

000 589 34 33 00

CD In stallation: use d rift (8) to install new guide bush (2) flush relative to b o lt contact surface. G uide bush must n o t project.

9

Grease guide bush

B R00.45-Z-1001 -06A

m

403 589 0515 00


Test data o f fly w h e e l Num ber

Designation

Engine 541.920/921/ 922/923/924/925/926/ 927

BE03.30-N-1 UU4-U3C

Flywheel bolt

Thread 0

M

16 X 1,5


mm 74,0

Max. shank length

mm 75,0


Designation

Engine 542.920/921/ 922/923/925/926

B E03.30-N-1004-03C

Thread 0

Flywheel bolt

M

16X 1,5


mm 74,0

Max. shank length

mm 75,0

@ Tim ing case D é sig n a tio n

Num ber

BA01.60-N-1001-01B


Nm

E n g in e 541.920/

E n g in e 542.920/

9 2 1 / 9 2 2 /9 2 3 /

9 2 1 /9 2 2 /9 2 3 /

92 4 /9 2 5 /9 2 6 /9 2 7

9 2 5 /9 2 6

25

25

ÏÜ Flyw heel, driven plate, vibration damper, starter ring gear Num ber

Designation

BA03.30-N-1001-01F


1st stage

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/

Nm 210

2nd stage

90

925/926 210 90

Additional Information 9 ^

^

E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50 -9 54 , F2

7

r

\

r

J

V.

\

r

a

000 589 27 33 00

000 589 34 33 00

In tern al e x tra cto r

Co u n te r-su p p o rt

jq

\

4 03 389 07 83 00 D rift


Designation

O rdernum ber

B R00.45*Z-1001 -06A

MB lo n g life grease

000989 63 51


8

AR05.00-W-5521B

Removing, installing rocker arm assembly

17.1.96

ENGINE 541.920/921 Z 9 2 2 /9 2 3 /9 2 4 /9 2 5 /9 2 6 /9 2 7 , 542.920/921 /9 2 2 /9 2 3 /9 2 S /9 2 6 1 2 3

Cylinder head cover Bolt Rocker arm assembly

4

Valve bridge

5

Sp rin gs

6 7

Packing Tappet ro d

8

Guide p in o f valve b rid g e

A

Projection o f g uid e p in from cylinder head

L

Shank len gth o f b o lt (2)

W05.00-0004 06

O peration no. o f operation texts o r standard texts and fla t rates O p .n o.

O peration text

05-5312-5542

Rocker arms

M o d ifica tion notes 6.2.97

T ig h te n in g a n g le nf rnelcer a rm asse m h ly h n lts arlrier!

Çtep

7 revised

M easuring shank length o f rocker arm assembly bolts

Step 3 included fo r first tim e

Basic setting o f valve bridges m odified

Step 4

Tightening to rq ue o f locknut o f valve bridge m odified

Step 4

mm

R e m o v in g ! in sta llin g

1

Remove cylinder head cover (1)

2

Remove rocker arm assembly (3)

Page 9

ÂR01.20-W-5014B Inspect rocker arm assembly fo r signs of w e ar; d isa ssem b le rocker arm assem bly if

necessary and replace w o rn parts

CD Installation; Ensure tappet rods (7) are correctly located in roller tappet. O il tappet rod sockets (7) w ith engine oil. 0

Pay atte ntio n to tig h ten ing order.

3

Measure shank len gth o f bolts (2)

If max. shank length (L) was exceeded, replace bolt

4

Take o ff valve bridges (4)

CD Inspect valve bridges fo r wear, if

BA05.00-N-1003-01B BE05.30-N-1002-04C

necessary J replace valve bridges.

CD Installation: Set valve bridges.

E n g in es O M 501, O M 502 (m o d. des. 541 .9 ,54 2 .9 ), A C T R O S - V e h ic le m od. des. 9 50 -9 54 , F2

Page 10


0

Lock nut at adjusting b olt o f valve

B A05,00-N-1002-01B

bridge @ Basic setting o f valve bridges must not b e carried o u t w h e n installed.

E

If the valve seat rings in the cylinder

head o r the valves have been machined, the valve bridges have to be set Carry out setting only w hen engine cold or thoroughly w arm ed through. W ait a t least 30 minutes after switching o ff engine. Take o ff springs (5) and packing (6)

5 6

Measure projection (A) o f guid e pins (8)

BE05.30-N-1001-04C

If differences in dimensions J.

from cylinder head Take out guide pins and replace

E Installation: pay attention to

BE05.30-N-1001-04C

projection (A) o f guide pins 7


8

Adjust valve clearance

AP05.30-W-0560A

Test data o f valve tim ing Num ber

Designation

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/925/926

924/923/926/927 BE05.30-N-1001-04C

Valve bridge - guide pin projection from cylinder head (A)

BE05.30-N-1002-04C

mm 36.5 Fig see

B olt o f rocker arm bearing

Thread

bracket to cylinder head

diameter

M

Rhank

mm

36.5

AR05.00-W-5521-01A

AR05.00-W-5521-01A

10

10

<91

<91

length

^

E n g in e tim in g - ge ne ral

Num ber

Designation

BA05.00-N-1002-01B

Engine 541.920/

Locknut to setting b olt of valve

921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

Nm 25

25

1st stage

Nm 60

60

2nd stage

U

90

90

bridge BA05.00-N-1003-01B

AR05.00-W-5 521-02A

Rocker arm bearing bracket to cylinder head

Adjusting valve bridge

M o difiction notes 6.2.97

Basic setting o f valve bridges m odified

AR05.00-W-5521-02A

Tightening torque of locknut o f valve bridge m odified


0

Engine timing general

Designation

Number

Engine Engine 541.920/921/922/ 542.920/921/922/ 923/ 923/ 924/925/926/927

BA05.00-N-1002-01B

Locknut to adjusting b olt o f valve bridge

Nm 25

925/926

25

m Carry o u t setting o f valve bridges (3) only w hen engine cold or thoroughly warmed through. W ait at least 30 m inutes after switching o ff the engine. 1

Clamp valve bridges (3) in a vise, slacken locknut (1) and unscrew setting bolt (2) about 3 turns.

2

Install valve bridges (3) over the guid e pins o f the cylinder head.

3

Press valve bridge (3) dow n (against spring force) and hold. Valve bridge (3) should be

W05.00-0009-01

touching the valve stem (arrow A). m Setting b olts (2) p o in t to w a rd e x h a u st m anifold.

4

W ith valve bridge (3) pressed dow n, screw In setting b olt (2) by hand until the setting bold (2) just touches the valve stem (arrow B).

.

IS Valve bridge (3) must no t move up.

5

Tighten locknut (1) by hand un til it makes contact.

6

Take o ff valve bridges (3) at cylinder head.

7

Clamp valve bridges (3) in a vise, tig h ten setting b olt (2) and locknut (1) to tightening

W05.00-0010-01

2

torque.

8

Install valve bridges (3) over the guide pins on the cylinder head.

* r 6

V

-

B iir n i I W05.00-0010-01

Additional Information E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od. des. 9 50 -9 54 , F2

11

AR05 70-W-6797R

14.6.96

Rem oving and installing cam shaft

ENGINE 541.920/921 /922 /923 /924 /92S /926/927,542.920/921 Z922/923/925/926

1

R oller tappet

3

Camshaft w ith camshaft gear

2

Tappet rods

4

Crankshaft gear

1

R oller tappet

3 5

Cam shaft with camshaft gear 121 Clam p holder

6

121 Installation sleeve

lE H


1

R em ove e n gin e

2

Attach engine to engine repair stand

3

Remove oil pan

AR01.45-W-7500B

4

Remove tim ing case

AR01.60-W-8200B

5

Remove oil filte r housing

AR18.20-W-3471B

6

Remove all PLD unit pumps

7

Remove all cylinder heads

A R 0 1 .10 -W -2 4 0 0 B

13 Engine repair stand IS Attachm ent angle bracket

WE58.40-Z-1001-11A WE58.40-Z-1005-11A

Page 63 AR01.30-W-5800B


8

Remove tappet rods (2)

E

Rotate tappet rods when p ulling o u t so

th at th ey are detached in the roller tappet and the roller tappet is not pulled o u t o f the crankcase. Installation: Oil tappet rods w ith

E

engine oil and ensure that they are correctly Installed in the roller tappet. 9

Use assembly to o l to pull roller tap pet (1) out o f crankcase

E

M ark roller tappet relative to crankcase.

E Installation: Use assembly to o l to push in roller tappet; pay a ttention t o g r o o v e in

crankcase during this step. 541 589 00 63 00 10

inspect roller tapp e t (1) fo r sig n s of

If d a m a g e d o r w o rn |

damage and wear Replace roller tappet 11

R em ove cam shaft (3)

Use assem bly sleeve to carefully pull

camshaft out o f crankcase. Installation: Use assembly sleeve to

E

carefully Insert camshaft into crankcase. Do n ot dam age camshaft bearings. Rotate camshaft until the markings "1-1" (arrow) on the camshaft gear are aligned w ith the m arking "1" on the crankshaft gear (4).

m

541 5890014 00

Inspecting 12

Inspect camshaft (3)

E

For hardness, concentricity and cam elevations

P a g e 15

Hardness o f cams and bearing journals

B E05.20-N-1006-04C

Cam shaft radial runout

BE05.20-N-1007-04C

Cam elevation of inlet and exhaust valve

BE05.20-N-1008-04C

cams

13


14


Cam elevation of unit pump cams

BE05.20-N-1009-04C

m

000 589 20 21 00

E

001 589 53 21 00

m

363 589 02 21 00

AR18.00-W-1600B

Additional Information En g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50 -9 54 , F2

13

Test data o f camshaft

Number

BE05.20-N-1006-04C

Designation

Hardness of cams and bearing

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

HRC 58-62

58-62

Cam base circle

mm £0.050

£0.050

Bearing p oint

mm £0.050

£0.050

journals BE0S.20-N-1007-04C

BE05.20-N-1008-04C

BE05.20-N-1009-04C

Cam shaft radial runout when m ounted at outer bearing journals Cam elevation - valve cams over base circle 0

Inlet

mm 8.0-8.3

8.0-8.3

Exh au st

m m 8.3-8.5

8.3-8.5

mm 17.7-18.0

17.7-18.0

Cam elevation - unit pum p over base circle 0

W orkshop equipm ent/M B testers (see W orkshop Equipm ent M anual) WE58.40-Z-1001-11A

Engine repair stand

WE58.40-Z-1005-11A

Attachm ent angle bracket, Schairer GmbH, W eidenstraBe 5,72459 Albstadt (Laufen); MSW / V 500


AR05.20-W-6292-03B

Inspecting camshaft

Test data o f camshaft Designation

Num ber

BE05.20-N-1006-04C

Hardness o f cams and bearing

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

HRC 58-62

58-62

journals 8E05.20-N-1007-04C

BE05.20-N-1008-04C

Camshaft radial runout w hen m ounted at outer bearing journals

Cam base circle

mm

£0.050

£0.050

Bearing point

mm

£0.050

£0.050

Cam elevation - valve cam over

Inlet

mm 8.0-8.3

8.0-8.3

Exhaust

mm 8.3-8.5

8.3-8.5

mm 17.7-18.0

17.7-18.0

base circle 0 BE05.20-N-1009-04C

Cam elevation - unit pum p over base circle 0

y

V

001 589 53 21 00 Dial gage

1

y

v

363 589 02 21 00 Dial gage holder

Test hardness o f the cams and bearing journals at the camshaft (1) w ith the I S hardness tester. m Place a hard base b elow the cam or bearing jou rnal to be tested fo r the test.

W05.20-0008-10

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h ic le m od . des. 9 50-954, F2

15

2

3

M o u n t camshaft (1) at the outer bearing journals. M easure radial runout at all the cam base circles or bearing points (L) w ith the I S dial gage (2).

4

M easure cam elevation of all the valve cams o f th e in le t valves (E) and exhaust valves (A) and also o f the unit pum p cams (S) w ith the IS dial gage (2).

WOS.20-0007-06


AR05.30-W -3510B

Replacing valve stem seals

8.2.96

ENGINE 541.920/921 Z922/923/924/925/926/927, 542.920/921 /922/923/92S/926 1

Valve stem seals

2

Base washers

3

E l Sleeve

4

Valve stem

W 0 5 .30-0041-1 2

m

Rem oving

1

Remove valve springs

HI Do not remove valves.

2

Pull o ff valve stem seals (1)

® Do n o t dam age valve guide (2).

3

Push sleeve (3) over the valve stem (4) onto the valve guide (2) as far as the stop

4

Press n e w valve stem seal (1) o n to the valve guide (2)

Page 18

Installing

m

346 589 0 1 6 1 0 0

® Use a suitable d rift to press on valve stem seal by hand over th e sleeve (3) as far as the stop. Inspect valve stem seal (1) to ensure it is tig h tly installed at valve guide collar.

5

Take o ff sleeve (3)

6

Install valve springs

m

346 589 0 1 6 1 0 0

Page 18

Additional Information En g in es O M 501, O M 502 (m o d. des. 541.9, 542.9), A C T R O S - V e h ic le m o d . des. 9 50 -9 5 4 , F2

17

AR05.30-W-3511B

7.2.96

Rem oving and installing valves

ENGINE 541.920/921 7922/923/924/925/926/927, 542.920/921 /922/923/92S/926 1 2

Collets Valve spring retainer

3 4 5 6 7

Inlet valve springs Exhaust valve springs Cylinder head Inlet valves Exhaust valves

8

I S Valve lifte r w ith ad d ition al piece

5 6 7 9 10

Cylinder head Inlet valves Exhaust valves Valve stem seals IS D ial gauge

12

IS G auging drift

A B C E

Valve seat angle Valve disc diameter Valve length Valve stem diameter

F G H

Valve seat width a t valve disc Valve seat surface diam eter Valve seat surface machining dimen sion related to valve seat surface dia m eter

W05.30-0043-06

11 IS

D ial gauge holder

M odifiction notes 6.2.97

Measuring difference o f am ount by which valve stands back, added

m m

R e m o v in g, installing

1

Remove cylinder head (5)

2


18

Step 3 m odified

Page 18

AR01.30-W-5800B

Page 55


3

Page 23

Measure am ount by which valve stands back relative to cylinder head contact surface Inspect am ount by which valve stands back a t both inlet and exhaust valve.

BE05.30-N-1001-01C

Permissible difference betw een both valves BE05.30-N-1009-01C m u st n ot b e exceeded.

m m E

001 589 53 21 00 343 5 8 9 0 0 4 0 0 0 If the measurement obtained is not

w ith in the permissible tolerance j Inspect on machined valve seat rings at

Page 44

b o th inlet o r e xha u st valve rin g pairs.

Replace valve seat rings at both inlet or

Page 28

exhaust valve ring. 4

Fit cylin d er h ead (5) o n t o th e s u p p o r t of

B

W H 5 8 .3 0 -Z -1 0 0 1 -1 4 A

Va lve rem oval tool

th e valve removal to o l and attach w ith the clam ping claws

s

Screw stud b olt o f the valve lifte r (8) into a free threaded hole in th e cylinder head (5) unscrew in valve lifte r (8) at th e stud b olt

IS

442 589 00 3100

m

6

Press dow n valve spring retainer (2) w ith

904 58900 3100

DO Counterhold valves (6,7) a t valve disk

valve lifte r (8) and take o ff collets (1) w ith the m agnetic pin 210 589 00 40 00

m

E Installation: Insert collets in to the groove o f the valve stem. Qi' Inspect valve spring (3), valve spring retainer and collets to ensure correctly installed 7

Relieve pressure on valve lifte r (8) and take o ff valve spring retainer (2) and valve springs (3,4) Pull valves (6, 7) o u t o f cylinder head

8

HE M ark valves. Installation: O il valve stems w ith engine oil. Pay attention to marking o f valves.

9 10

Page 17

Pull o ff valve stem seals (9)

Installation: Replace valve stem seals.

Inspect valve guides w ith g aging d rift (12)

IS

117589 03 23 00

Valve stem 0 (E)

BE05.30-N-1003-01C

Valve guide

BE05.30-N-1001-02C

fo r w ear

DD If it is possible to Insert th e side o f the gaging d rift mark w ith “+ " into the valve guid e I Replace valve guides.

Page 25

Additional Information i H

P

E n g in e s O M 501, O M 502 (m o d. des. 541.9, 542.9), A C T R O S - V e h ic le m o d . des. 9 50 -9 54 , F2

19

11

Inspect w hether valves (6,7) can be reused

U j th e valve stem ends must not have any surface damage. Valve collet grooves must not be w o rn and the chrome layer on the valve stems must be complete. Valve seats must not be scorched, if necessary j,

Page 41

Grind or replace valves. 12

Inspect valves (6,7) fo r concentricity and

Concentricity o f valve seat to valve stem

BE05.30-N-1006-01C

Valve stem
B E03.30-N -10 0 3 -0 1 C

M achining dim ension o f inlet valve seat

BE05.30-N-1004-01C

dim ensional tolerance

surfaces (H) relative to valve seat surface 0 (G) M achining dim ension o f exhaust valve

B E05.30-N-1005-01C

surfaces (H) relative to valve seat surface 0 (G) 1 3 Microm eter

WHS8.30-Z-1005-12A

III It Is no t perm itted to straighten valves. M inor differences in concentricity can be corrected by regrinding the valve seat on the valve grinding m achine, or replacing valves. 13

Inspect valve seat rings at both inlet or

Q ] if valve seats are slightly worn, this can

exhaust valve ring

be corrected by rew orking w itho ut

Page 41

replacing valve seat rings M achining valve seat rings.

P age 44

Replacing valve seat rings.

Page 28

14

Inspect valve springs (3.4)

15


16

The am ount by which the valve stands back Q ] If the reading obtained is not w ithin and the permissible difference have to be measured at the machined valves (6,7)

If fault exists, replace valve springs.

the permissible tolerance J

Inspect valves at both inlet or exhaust valve.


Test data o f valves

Num ber

D esignation

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/

922/923/925/926

927 BE05.30-N-1001-01C

A m o u n t by w hich valve stands back

mm 0.70-1.05

0.70-1.05

relative to cylinder head BE05.30-N-1003-01C

V a lv e seat a n g le (A)

Inlet Exhaust

Valve length (C)

V a lve stem 0 (E)

BE05.30-N-1005-01C

R Fn4 9 n - N . io n q .n ir

45 45.4-45.6

Exhaust

mm 40.9-41.1

40.9-41.1

Inlet

mm 3.5-3.6

3.5—3.6

Exhaust

mm 3.5-3.6

3.5-3.6

Inlet

mm 2 145

2 145

Exhaust

mm

2145

a 145

Inlet

mm 8.935-8.950

8.935-8.950

Exhaust

mm 8.925-8.940

8.925-8.940

AR05.30-W-4202-01A

AR05.30-W-4202-01A

M achining dim ension o f Inlet valve SizeG seat surface (H) relative to valve seat Size H surface 0 (G) Fig. see

mm 42

42

mm 2.8-3.0

2.8-3.0

M achining dim ension o f exhaust

SizeG

mm 39

valve seat surface (H) relative to valve seat surface 0 (G)

SizeH

mm 2.9-3.1

AR05.30-W-4202-01A

Fig. see B E05.30-N-1006-01C

45 mm 45.4-45.6

Fig. see BE05.30-N-1004-01C

30

Inlet Valve disc 0 (B)

Valve seat w idth at valve disc (F)

30

AR05.30-W-4202-01A 39

2.9-3.1

AR05.30-W-4202-01A

AR05.30-W-4202-01A


Inlet

mm £0.03

Exhaust

mm

£0.03

£0.03

Perm issible d lffe re n re o f a m o u n t hy

lnlf»t

mm

<0 2

< 0 .2

Exhaust

mm

£0.2

£0.2

w hich valve stands back relative to cylinder head contact surface fo r

£0.03

each cylinder

Additional Information En g in e s O M 501, O M 502 (m o d. des. 541.9. 542.9), A C TR O S - V e h ic le m od . des. 9 5 0 -9 5 4 , F2

21

Test data o f valve guides Number

Designation

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/

922/923/925/926

927 BE05.30-N-1001-02C

Valve guide

O uter 0 ( A 1 )

Standard

mm

15.028-15.046

15.028-15.046

O'ersizeO.2 mm

15.228-15.246

15.228-15.246

O'ersizeO.4 mm

15.428-15.446

15.428-15.446

Bore 0 In

Standard

mm

15.000-15.018

15.000-15.018

cylinder head (A)

O'ersize 0.2 mm

15.200-15.218

15.200-15.218

O'erslzeO.4 mm

15.400-15.418

15.400-15.418

9.000-9.022

9.000-9.022

Inner 0 (machln.

mm

dimension) (B) Length (C) Distance o f valve

Inlet

g uide to p edge to . , .. . Z " Exhaust cylinder head

mm

61.7-62.3

61.7-62.3

mm

21.1-21.5

21.1-21.5

mm

21.1-21.5

21.1-21.5

AR05.30-W-3731-07A

AR05.30-W-3731-07A

contact surface (D) Fig. see

Additional piece

Dial gauge holder


Designation

WH58.30-Z-1005-12A

M icrom eter 0 - 2 5 mm

M ake (e.g.)

O rder num ber

Hahn und Kolb Borsigstr. SO D-70469 Stuttgart

WH58.30-Z-1001-14A

Valve removal tool

M od el K2000

221 00 200

Hunger D-81309 M ünchen

22


AR05.30-W-4100-01B

M easuring am ount by w hich valve stands back relative to cylinder head

M o d iflctlo n notes 6.2.97

M easuring difference In am ount by w hich valve stands back, added

AR05.30-W-4100-01B

Step 4 m odified

Test data o f valves Designation

N um ber

BE0S.30-N -1001-01C

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/ 927

922/923/925/926

mm 0.70-1.05

0.70-1.05

Inlet

mm

£0.2

£0 .2

Exhaust

mm

£0.2

<0.2

A m o u n t by w hich valve stands back relative to cylinder head contact surface

BE05.30-N -1009-01C

Permissible difference in am oun t by w hich valve stands back relative to cylinder head contact surface fo r each cylinder

343 589 0 0 4 0 00 D ial g a u g e h o ld e r

Additional Information f li- V

E n g in es O M 501, O M 502 (m o d. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 5 0 -9 5 4 , F2

23

1

2

Attach dial gauge (4) to dial gauge h o ld er (5). Fit dial gauge (4) w ith preload onto th e plane face o f the cylinder head (1).

3

Set scale o f dial gauge to “O” .

4

M ove dial gauge (4) sufficiently so th at the tracer pin is positioned on the valve disc o f the inlet valves (2) or of th e exhaust valves (3). m M easure am ount by w hich valve stands back at both inlet and exhaust valves and note. Permissible difference betw een both valves must no t be exceeded.

W 0 5 .30-0042-06


AR05.30-W-3731 B

Replacing va lve guides

14.6.96

ENGINE 541.920/921 /922/923/924/92S/9261927,542.920/921 /922/923/92S/926 1

Valve g u id e s o f inlet valve

2

Valve g uid es o f exhaust valve

3

Cylinder head

A

v a lv e g u i d e b o r e d ia m e t e r in c y lin d e r head

A1

Valve g u id e o u ter diam eter

8 C D

Valve g u id e in n er diam eter Valve g u id e length Distance from valve guid e top edge to contact surface o f valve springs

W 0 5 .30-0048-06

W 0 5 .30-0049-09

7

C y lin d e

4

D rift

IS S t e p p e d d r ift

5

8

I H Reamer (adjustable)

9

IS

Ream er

19Ream er (adjustable)

6

m

Removing

1

Remove valves

2

Clamp cylinder head (3)

O

12J D rift w ith bush

B I*

E n g in e s O M 501, O M 502 (m od. des. 5 41 .9,542.9), A CTRO S - V e h icle m od. des. 9 50-954, F2

Page 18


3

Inspect valve guides (1,2)

Inner 0 dim ension (B)

BË05.30-N-1001-02C

m

117 589 03 2300

[XI If it is p ossible t o in se rt th e sid e o f the gage m arke w ith " + ” into the valve guide I Remove valve guide

4

m

Remove valve guides (1,2) from the cylinder head (3) from th e com bustion side

m

103 589 03 15 00

Installing

5

Measure bores of valve guides dim ension (A) in cylinder head (3)

6

Ream bore of valve guides dim ension (A) in

Q ] If th e measurements d iffe r from th e test data, the basic bores th en have to be machined to the next oversize o f th e valve guide», d im e n sio n (A).

CD Turn reamer only clockwise.

BE05.30-N-1001-02C

Pay a tte n tio n to o v e rla p o f valve g u id e

B E05.30-N -1002-02C

cylinder head (3) to th e next oversize

relative to cylinder head.

7

8

9

SI

000 58918 53 00

insert valve guide ( i) into supercooling box and fill w ith liquid nitrogen

S I

346 589 0 0 63 00

Use d rift and spacer bush (6) to press in

E

new valve guide (1)

guide to p edge to contact surface o f valve springs.

W iden bore o f valve guid e by reaming

0D Supercool valve guide fo r a bo ut 20 to 30m in. Do not touch the liquid nitrog en o r th e supercooled valve guide. Pay attentio n to distance (D) fro m valve

SI 19 Reamer [D W id e n b o re d ia m eter to 8.95 m m

BE05.30-N-1001-02C

541 589 0043 00 WH58.30-Z-1014-12A by

reaming. Turn reamer only clockwise. 10

Ream bore o f valve g u id e to the dim ension (B)

IS

Turn reamer only clockwise.

BE05.30-N-1001-02C

SI

000 589 10 53 00

m

366 589 00 6900

11

Clean valve guide (1) w ith cleaning brush

12

M achine valve seat rings

Page 44

13

Install valves

Page 18


26

Test data o f valve guides

N um ber

Designation

BE05.30-N -1001-02C

Valve guide

O uter 0 (A1)

Standard

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/ 927

922/923/925/926

mm

15.028-15.046

15.028-15.046

Oversize 0.2 mm

15.228-15.246

15.228-15.246

Oversize 0.4 mm

15.428-15.446

15.428-15.446

Bore 0 in

Standard

15.000-15.018

15.000-15.018

cylinder head (A)

Oversize 0.2 mm

15.200-15.218

15.200-15.218

Oversize 0.4 mm

15.400-15.418

15.400-15.418

9.000-9.022

9.000-9.022

Inner 0 (machin

mm

mm

ing dimension) (B) Length(C) Distance (D) from

Inlet

v aive g u iae top edge to valve spring contact surface

Exhaust

mm

61.7-62.3

61.7-62.3

mm

21.1-21.5

21.1-21.5

mm

21.1-21.5

21.1-21.5

Fig. see BE05.30-N -1002-02C

Valve guide overlap In cylinder head

mm

AR05.30-W-3731-07A

AR05.30-W-3731-07A

0.010-0.046

0.010-0.046

" \

IE S u p e rc o o lin g box

V a lv e s ea t tu rn in g k it

Com m ercially available tools (see W orkshop Equipm ent Manual) N um ber

Designation

M ake (e.g.)

O rder num ber

W H 58 .3 0-Z -1 01 4-12 A

Reamer (adjustable 0 7.5 - 8.0 mm)

Hunger

140 05 000

D-81309 M ünchen 70

E n g in es O M 501, O M 502 (m od. des. 541.9,542.9), A C TR O S - V eh icle m od. des. 9 50-954, F2


27

AR05.30-W-3831 B

14.6.96

Replacing vaive seat rings

ENGINE 541.920/921 Z922/923/924/925/926/927, 542.920/921 Z922/923/925/926 1

Exhaust valve seat rings Inlet valve seat rings Cylinder head S I Plug gage Va lve g u id e

W05.30-0050-05 1

E x h a u s t va lv e s e a t r in g

2

Inlet valve set rings

A

Valve seat ring o u ter diam eter

B

B o re diam eter o f valve seat rin g s in cylinder h e a d

C

Bore depth o f valve seat rings in cylinder head

D

Distance between contact surface o f cylinder head a n d face en d o f valve seat ring

E

Va lve seat ring h e igh t

W05.30-0039-11

E l US


1

Remove valves

2

Clamp cylinder head (3) on the valve removal tool

3

Use plug gage (4) to inspect inner diam eter of valve guid e (5) fo r wear

Page 18 WH58.30-Z-1001-14A

I S Valve removal to o l

BE05.30-N-1001-02C

117 589 03 23 00

S I D rift punch I H If it is possible to insert the side o f the dial g a g e m a rk e d w ith “ + " in to the valve

guide J, Replace valve guide 4

Page 25 P a g e 33

R em ove valve seat rin g s (1, 3) fro m the

cylinder head (3)

28

S I Puller

000 589 28 33 00

S ] Internal extractor

000 589 29 33 00


5

Measure valve seat ring b ore diam eter, dim ension (B)

S3Countering support IS]V alve seat turning kit USV a lv e seat ring tu r n in g to o l S O verlap between valve seat ring

000 589 34 33 00 366 589 00 69 00 W H 5 8 .3 0 -Z -1025-05A

BE05.30-N-1003-03C

dim ension (A) and basic bore in cylinder head dim ension (B) should be assured. If th e dim ensions diffe r from th e test data

I M achine basic bores to the next oversize of th e valve seat rings diam eter (A). Bore 0 (B) o f inlet and exhaust valve seat rings

BE05.30-N-1007-03C

inlet valve seat rings outer 0 (A)

BEOS.30-N-1001-U3C

Exhaust valve seat rings outer 0 (A)

BE05.30-N-1002-03C

IS Dial gauge 19Q uick calipers fo r internal

001 589 53 21 00 WH 58.30-Z-1004-12A

measurements 6

Machine valve seat ring basic bores in cylinder head

Page 35 Inlet valve seat rings outer 0 (A) and h e ig h t (E)

BE05.30-N-1001-03C

Exhaust valve seat rings outer 0 (A) and

BE05.30-N-1002-03C

h e ig h t (E) O verlap o f valve seat rings in cylinder head

B E05.30-N-1003-03C

Distance between contact surface of

BE05.30-N-1004-03C

cylinder head and face end o f valve seat ring (D) B o re 0 (B) o f inlet, a n d e x h a u st valve scat

8E05.30-N -1007-03C

rings Bore depth o f valve seat rings (C)

[13D ia l g a u g e IS Valve seat ring turning to o l 19Q uick calipers fo r internal

BE05.30-N-1008-03C 001 589 53 21 00

WH58.30-Z-1025-05A W H 58.30-Z-1004-12A

m e a su re m e n ts

7

Insert valve seat rings (1,2) Into supercooling box and pour in liquid nitrogen

8

Heat cylinder head (3) In w ater bath

9

Use pliers to remove valve seat rings (1,2) from th e supercooling box and place onto the bores o f th e heated cylinder head (3)

10

Use a suitable d rift to press in valve seat rings (1,2)

11

M aching valve seat rings (1,2)

12

Install valves

SI M icrom eter 19V alve removal tool i£JSupercooling box E Supercool valve seat rings fo r ab o u t 20

W H 58.30-Z-1007-12A WH58.30-Z-1001-14A 346 5 89006 3 00

to 30 m in. Do not touch the liq u id nitrogen or th e supercooled valve seat ring.

E Tem perature approx. 80° C

E

V alve seat rings should be pressed in

im m ediately.

Page 44

E

Use new valve or I

E n g in es O M 501, O M 502 (m o d. des. 541.9,542.9), A C T R O S - V e h ic le m od . des. 9 5 0 -9 5 4 , F2

Page 18


P a g e 41

G rind w orn valves before installing Test data o f valve guides Number

BE05.30-N-1001-02C

Engine 541.920/921/ 922/923/924/925/926/ 927

D esignation

V alve guide

mm

15.028-15.046

15.028-15.046

Oversize 0.2 mm

15.228-15.246

15.228-15.246

Oversize 0.4 mm

15.428-15.446

15.428-15.446

Standard

mm

15.000-15.018

15.000-15.018

cylinder head (A) Oversize 0.2 mm

15.200-15.218

15.200-15.218

O versize 0.4 m m

15.400-15.418

15.400-15.418

O uter 0 ( A 1 )

Bore 0 In

Standard

Engine 542.920/921/ 922/923/925/926

Inner 0 (machining dimension) (B)

mm

9.000-9.022

9.000-9.022

Length (C)

mm

61.7-62.3

61.7-62.3

Inlet

mm

21.1-21.5

21.1-21.5

Exhaust

mm

21.1-21.5

21.1-21.5

AR05.30-W-3731-07A

AR05.30-W-3731-07A

Distance (D) from to p e d g e o f valve

guide to contact surface o f valve spring Fig. see


Test data o f valve seat rings

Num ber

Designation

Engine 541.920/921/ 922/923/924/925/926/ 927

BE05.30-N-1001-03C

Inlet valve seat rings

O uter 0 (A)

H eight (E)

Standard Oversize 0.2

mm 47.58-47.59

O versize 0 4

m m 4 7 7 8 -4 7 .7 9

Standard

mm 7.7-7.8

Oversize 0.2

mm 7.9-8.0

Oversize 0.4

mm 8.1-8.2

Fig. see BE05.30-N-1002-03C

Exhaust valve seat rings Outer 0 (A)

H eight (E)

BE05.30-N-1004-03C

AR05.30-W-3831-Û3A

Standard

mm 43.08-43.09

Oversize 0.2

mm 43.28-43.29

Oversize 0.4

mm 43.48-43.49

Standard

mm 8.0-8.1

Oversize 0.2

mm 8.2-8.3

Oversize 0.4

mm 8.4-8.5

Fig. see B E05.30-N-1003-03C

mm 47.38-47.39

AR05.30-W-3831-03A

Valve seat ring overlap in cylinder head

Inlet

mm 0.055-0.090

Exhaust

mm 0.055-0.090

Distance between contact surface of cylinder head and face

Inlet

mm 3.1-3.4

Exhaust

mm 2.8-3.1

end o f valve seat ring

Fig. see

AR05.30-W-3831-03A

(D) 8 E05.30-N-1007-03C

Bore 0


Standard

mm 47.300-47.325

In cylinder head (B)

O versize O.Z

mm 47.500-47.525

Oversize 0.4

mm 47.700-47.725

Exhaust valve seat rings in cylinder head (B)

Standard

mm 43.000-43.025

Oversize 0.2

mm 43.200-43.225

Oversize 0.4

mm 43.400-43.425

Fig. see BE05.30-N-1008-03C

Bore depth o f valve seat rings in cylinder head (C)

AR05.30-W-3831-03A

Standard

mm 10.9-11.1

Oversize 0.2

mm 11.1-11.3

oversize u.4

mm 11.3-11.5

Fig. see

AR05.30-W-3831-03A

Additional Information E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h icle m od . des. 9 50-954, F2

31

Test data o f valve seat ring Number

Designation

Engine 542.920/921/ 922/923/925/926

BE05.30-N-1001-03C


O uter 0 (A)

H e ig h t (E)

Standard Oversize 0.2

m m 47.58-47.59

Oversize 0.4

mm 47.78-47.79

Standard

mm 7.7—7.8

Oversize 0,2

mm 7.9-8.0

Oversize 0.4

mm 8.1-8.2

Fig. see BE05.30-N-1002-03C

Exhaust valve seat rings O uter 0 (A)

Height (E)

BE05.30-N-1004-03C

AR05.30-W-3831-03A

Standard

mm 43.08-43.09

O versize 0.2

mm 4 3 . 2 8 - 4 3 2 9

Oversize 0.4

m m 43.48-43.49

Standard

mm 8.0-8.1

Oversize 0.2

mm 8.2-8.3

Oversize 0.4

mm 8.4-8.S

Fig. see BE05.30-N-1003-03C

m m 47.38-47.39

AR05.30-W-3831 -03A


Inlet

m m 0.055-0.090

Exhaust

m m 0.055-0.090


Inlet

mm 3.1-3.4

Exhaust

mm 2.8-3.1


Fig. see

(D) BE05.30-N-1007-03C

Bore 0


Standard

in cylinder head (B)

Oversize 0.2

mm 47.500-47.525

Oversize 0.4

m m 47.700-47.725


Standard

mm 43.000-43.025

Oversize 0.2

mm 43.200-43.225

Oversize 0.4

mm 43.400-43.425

Fig. see BE05.30-N-1008-03C

B ore dep th o f valve seat

rings in cylinder head (C)

mm 47.300-47.325

ARQ5.3Q-W-3831-03A

Sta n d a rd

mm 10.9-11.1

Oversize 0.2

mm 11.1-11.3

Oversize 0.4

mm 11.3-11.5

Fig. see

AR05.30-W-3831-03A

117 589 03 23 00 D rift


y

r

3 4 6 589 0 0 63 0 0 Supercooling box

3 6 6 5 89 0 0 69 00 Vatve seat turning kit

Com m ercially available to o ls (see W orkshop E quipm ent Manual) Number

Designation

M ake (e.g.)

WH58.30-Z-1025-05A

Valve seat tu rning tool

M od el RDS2 220 00100 Hunger D-81309 M ünchen 70

W H S 8 .3 0 Z 1004 12A

Q u ic k calipers fo r internal m easurem en ts, 0 4 0 - 6 0 m m

WH58.30-Z-1007-12A

Microm eter 2 5 - 5 0 mm

Hahn und K olb Borsigstr. 50

Order number

33520080

D-70469 Stuttgart WH58.30-Z-1001-14A

AR05.30-W-3831-01B

Valve removal to o l

M od el K2000 Hunger D-81309 M ünchen

221 00 200

Removing valve seat rings

Com m ercially available to o ls (see W orkshop E quipm ent Manual) Num ber

D e sig n a tio n

M ake (e.g.)

O rder num ber

WH58.30-Z-1025-05A

Valve seat ring turning tool

M o d el RDS2

22000100

Hunger D-81309 M ünchen 70

Additional Information E n g in es O M S01, O M 502 (m od. des. 5 41 .9,542.9), A C T R O S - V e h ic le m od . des. 9 50 -9 5 4 , F2

33

1

Insert p ilo t (2) (9 mm 0 ) into the valve guide (1) un til the stop (arrow) o f the co llet chuck (3) Is positioned on the valve guid e (1); press collet chuck (3) dow n w ith the screwdriver, if necessary. Turn tig h t w ith the d rift Insert into the p ilo t (2) at to p and bottom .

W05.30-0007-01

2

A ttach t u rn in g h ead D 2/20" (4) to th e tu r n in g to o l (3), loosely screw in b oth h e x a g o n

socket screws (6), align turning head (4) so th at the distance between the to o th ed side, the rack and the opposite side is a b o ut 0.5 to 0.8 mm. Then tighten both hexagon socket screws fully.

ffl It should be possible to move the to o l slide (8) back and forw ard relatively easily w ith the quick-adjustm ent (9). 3

Screw cutting to o l C6 (7) tig h t onto the turning head (4).

4

M oisten pilot (2) w ith oil.

5

Insert turning tool (5) over th e p ilo t (2) until the stop pin is resting on the p ilo t (2) or the cu ttin g to o l (7) is resting on the cylinder head. ® The cutting to o l must not strike the cylinder head, otherwise the carbide m etal tip w ill be d a m a ge d .

W 05.30-0009-01

6

Turn quick-adjustm ent (8) until the cutting to o l (7) is touching the p ilo t (2) or until it is positioned in fro n t o f the valve seat ring, b ut not touching.

7

Hold turning tool (5) tight, slacken clam ping screw (12) o f the stop pin (10), carefully low er turning to o l until th e blade o f the cutting to o l (7) dim ension (X) is positioned ab o u t 1 mm above the inner edge o f the valve seat ring (11). Press stop pin against p ilot (2), tighten clam ping screw (12).

8

Clam p pendulum guide (13) tig h t horizontally, approxim ately in the m iddle o f the guide, w ith the steadyrest clamp (14). m It should now still be possible to easily tu rn the tu rnin g tool as before.

3

I lold k n u rle d disk (13) fo r in fe ed m ech an ism t ig h t a n d rotate

handcrank (16) clockwise. This usually produces an irregular chip removal. m Inspect distance dim ension (X) approx. 1 mm a t valve seat ring (11).


10

Turn handcrank (16) clockwise and a t the same tim e hold th e knurled disk (15) tight. As th e turning resistance increases, briefly release knurled disk. A n n u lar groove depth dim ension Y approx. 2 to 3 mm.

m Do not take o ff to o large a chip. It should be possible to easily rotate the turning tool, w hich is achieved by b riefly releasing the knurled disk. 11

12

Position S I internal extractor (17) fo r inlet o r exhaust valve seat ring (8) in the annular groove and use S lc o u n te rs u p p o rt (18) to remove valve seat ring.

® Place copper plate (arrow) b elo w the contact surfaces o f the countersupport ( 2 so that the cylinder head surface is not damaged.

W 05.30-0011.01

AR05.30-W-3831-02B

M achining valve seat ring basic bore

Test values o f valve seat rings N um ber

Designation

BE05.30-N-1001-03C


Engine 541.920/921/ 922/923/924/925/926/ 927 O uter 0 (A)

H eight (E)

Standard

mm 47.38-47.39

Oversize 0.2

mm 47.58-47.59

Oversize 0.4

mm 47.78-47.79

Standard

mm 7.7-7.S

Oversize 0.2

mm

Oversize 0.4

mm 8.1-8.2

Fig. see BE05.30-N-1002-03C

Exhaust valve seat rings O uter 0 ( A )

H eig ht (E)

BE05.30-N-1004-03C

ARQ5.30-W-3831-03A

Standard

mm 43.08-43.09

Oversize 0.2

mm 43.28-43.29

Oversize 0.4

mm 43.48-43.49

Standard

mm 8.0-8.1

Oversize 0.2

mm 8.2-8.3

Oversize 0.4

mm 8.4-8.5

Fig. see BE05.30-N-1003-03C

7.9-8.0

AR05.30-W-3831-03A

mm 0.055-0.090


Inlet Exhaust

mm 0.055-0.090


Inlet

mm 3.1-3.4

Exhaust

mm 2.8-3.1


Fig. see

AR05.30-W-3831-03A

(D)

Q

b

V '

E n gin es O M 501, O M 502 (m o d. des. 541.9,542.9), A C T R O S - V e h ic le m o d . des. 9 50 -9 54 , F2


Test values o f valve seat rings

Number

Engine 541.920/921/

Designation

922/923/924/925/926/ 927 BE05.30-N-1007-03C

B o re 0

Inlet valve seat rings in

Standard

cylinder head (B)

Oversize 0.2

mm 47.500-47.525

Oversize 0 4

m m 47 7 0 0 -4 7 725

Exhaust valve seat rings

Standard

mm 43.000-43.025

in cylinder head (B)

Oversize 0.2

mm 43.200-43.225

Oversize 0.4

mm 43.400-43.425

Fig. see BE05.30-N-1008-03C

Bore depth for valve seat rings in cylinder head (C)

m m 47.300-47.325

AR05.30-W-3831-03A

Standard

mm 10.9-11.1

Oversize 0.2

mm 11.1-11.3

Oversize 0.4

mm 11.3-11.5

Fig. see

AR0S.30 W -3Ö 31-03A


Test values of valve seat rings

N um ber

Designation

Engine 542.920/921/ 922/923/925/926

BE05.30-N-1001-03C


O u te r 0 (A)

H eight (E)

S ta n d a rd

mm 4 7 .3 8 -4 7 .3 9

Oversize 0.2

mm 47.58-47.59

Oversize 0.4

mm 47.78-47.79

Standard

mm 7.7-7.8

Oversize 0.2

mm 7.9-8.0

Oversize 0.4

mm 8.1-8.2

Fig. see BE05.30-N-1002-03C

Exhaust valve seat rings O uter 0 (A)

H eight (E)

Standard

mm 43.08-43.09

O versize 0.2

mm 4 3 .2 8-43.29

Oversize 0.4

mm 43.48-43.49

Standard

mm 8.0-8.1

Oversize 0.2

mm 8.2-8.3

Oversize 0.4

mm 8.4-8.5

Fig. see BE05.30-N-1003-03C


B E05.30-N-1004-03C

Distance between contact surface of cylinder head and face end o f valve seat ring

AR05.30-W-3831-03A

AR05.30-W-3831-03A

Inlet

mm 0.055-0.090

Exhaust

mm 0.055-0.090

Inlet

mm 3.1-3.4

Exhaust

mm 2.8-3.1

Fig. see

(D) B E05.30-N-1007-03C

Bore 0

Inlet valve seat rings in

Standard

mm 47.300-47.325

cylinder head (B)

Oversize 0.2

mm 47.500-47.525


Oversize 0.4

mm 47.700-47.725

Standard

mm 43.000-43.025

Oversize 0,2

mm 43.200-43.225

Oversize 0.4

mm 43.400-43.425

Fig. see BE05.30-N-1008-03C

Bore depth for valve seat rings in cylinder head (C)

AR05.30-W-3831-03A

Standard

mm 10.9-11.1

Oversize 0.2

mm 11.1-11.3

Oversize 0.4

mm 11.3-11.5

Fig. see

AR05.30-W-3831-03A

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C TR O S - V e h ic le m od. des. 9 50 -9 54 , F2

37

Com m ercially available to o ls (see W orkshop Equipm ent M anual) Num ber

Designation

M ake (e.g.)

WH58.30-Z-1025-05A

Valve seat ring turning to o l

220001 00 M od el RDS2 Hunger D-81309 München 70

WH58.30-Z-1004-12A

Quick calipers fo r internal measurements, 0 40 - 60 mm

WH58.30-Z-1007-12A

M icrom eter 2 5 - 5 0 mm

Hahn und Kolb

Order num ber

33520 080

Borsigstr. 50 D-70469 Stuttgart WH58.30-Z-1001-14A

Valve removal tool

M od el K2000 Hunger

221002 00

D-81309 München 1

Insert p ilo t (2) (9 mm 0 ) into the valve guide (1) u n til the stop (arrow) of the collet chuck (3) is resting on the valve guide; press co llet chuck dow n if necessary w ith the screwdriver. Turn tig h t w ith the d rift inserted into th e p ilo t at to p and bottom.

2

Attach Ikd cutting to o l (16) tig h t to the turning to o l (4).

3

M oisten p ilot (2) w ith oil. Insert turning to o l (4) over the p ilo t until the stop pin (5) is resting on the p ilot or the cutting tool (16) is resting on the cylinder head.

W 05.30-0007-01

W05.30-0013*01

® Cutting tool must no t strike the cylinder head, otherw ise the carbide metal tip w ill be damaged. 4

T u rn quick-od justm cnt (5) until th e cu ttin g to o l (10) has m ove d horizon ta lly b e yo n d

th e bore, then push the turning to o l (4) dow n until the cutting tool touches the cylinder head. W05.30-0014-01


5

Hold turning toot (4) tig h t, slacken clam ping screw (6) o f the stop pin (7), carefully low er tu rnin g to o l and tighten clam ping screw.

6

Set the heigh t o f the cutting to o l (16) so th at it is just clear by turning the knurled disk (8).

7

Clamp pendulum guide (9) tig h t horizontally, approxim ately in the m iddle o f the guide, w ith the steadvrest clamp (10). It should no w still be possible to rotate the turning tool (4) as easily as before. m The w orking depth (X) should be set betw een positioning ring (11) and pendulum guide d uring this step.

8

C alculatin g setting " G " basic b o re oversize " B ” an d pilot

diam eter dim ension "F” divid ed by 2. Example: Dimension B = 47.50 mm (basic bore) Dimension F = 14.55 mm (pilot diameter) B+ F Dim. G =

D im .G =

47.50 mm + 14.55 mm ------------------------------- =31.025 mm

B m icrom eter to the setting "G ".

9

Set

10

Slacken quick-adjustment (5), raise turning to o l slightly and position

B m icrometer on

pilot. Use the quick-adjustm ent to set the cutting tool (16) to setting "G ." Tighten quick-adjustment.

It is good practice to set the cutting to o l 0.1 mm less in diam eter fo r the first cut.

W 0S .30-0016-01

11

Slacken clam ping screw (12), screw in horizontal stop screw (13) until it makes contact w ith the h o u sin g end th e n t ig h te n clam p in g screw.

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S -V e h ic le m od . des. 9 50 -9 54 , F2

39

12

Fix knurled screw (8) w ith th e hexagon bolt.

13

Turn o u t the basic bore fo r the valve seat ring by turning the handcrank (14) and at the same tim e holding the upper knurled disk (11) fo r vertical infeed tight, un til the p ositioning ring (arrow) is resting against the steadyrest bearing (9). m Reset cutting tool (16) as often as necessary until the calculated setting "G " is achieved. A fte r this, turn fu lly once again w ith o u t any cut infeed.

14

Raise turning tool (4) slightly. Slacken quick-adjustment (5) and move back cutting to o l (16).

15

Turn th e face end at the b ottom by turning the handcrank (14) and at the same tim e hold in g the bottom knurled disk (15) fo r horizontal infeed tight, until the stop screw (13) is touching the turning to o l (4).

16

1 9 Take o ff turning tool.

17

Use th e 1 3 quick calipers fo r internal m easurement and I S dial gage to measure the basic bores (B) fo r the valve seat rings in the cylinder head. m O verlap between valve seat ring dim ension (A) and basic bore dim ension (B) should be assured.


AR05.30-W-4202B

28.3.96

G rinding valves

ENGINE 541.920 /9 2 1 /922 /923 /924 /92S /926 /927, 542.920 /921 /922 /923 /925 /926 1

Valve

2

B

A

Valve seat angle

Valve grin din g machine

B

Valve disc diameter

C E

Valve length Valve stem diam eter

F G

Valve seat w idth a t valve disc valve seat surface diam eter

H

Valve seat surface m achining dim en sion related to valve seat surface d ia m eter (G)

W 05.30-0023-06

Grinding 1

Clean valves (1)

CD Remove any adhering oil carbon.

2

Clamp valve (1)

Q ] As close as possible behind valve disk into valve grinding machine (2). This avoids disturbing vibrations.

3

Set valve grinding angle on the valve

WH58.30-Z-1022-05A

m

BE05.30-N-1003-01C

g rin d in g m ach ine (2)

WH58.30-Z-1022-05A

M 4

Slowly move valve (1) w ith the infeed to w a rd the ro ta tin g g r in d in g w h e e l until

the wheel comes into contact w ith the seat surface o f the valve (1) 5

Continue grinding w ith a small infeed until CD The measurements obtained must not the entire circumference o f the valve seat is be less th an the specification after this smooth and free o f chatter marks operation Valve disk 0 (6) and valve seat w id th at

BE05.30-N-1003-01C

valve d isk (F)

Inlet valve seat surface m achining

BE05.30-N-1004-01C

dim ension (H) related to valve seat surface 0 (G ) Exhaust valve seat surface m achining

BE05.30-N-1005-01C

dimension (H) related to valve seat surface 0 (G ) Concentricity o f valve seat relative to valve stem

BE05.30-N-1006-01C

IS

001 589 53 21 00

E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), AC TR O S - V e h ic le m od . des. 9 50-954, F2


m

363 589 02 2100

B

WH58.30-Z-1022-05A

Face-grinding o f th e valve stem end must

53 The length o f the valve (C) must not be

BE05.30-N-1003-01C

be perform ed on th e device attached to

less than the specified length after this

the valve grinding machine

operation

Remove valve (1) from clam p at valve

6

grinding machine 7

B

WH58.30-Z-1022-05A

Test data o f valves Number

Designation

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/

922/923/925/926

927 BEOÇ 30-N-1003.01 C

•2

30

Exhaust

”4

45

Inlet

mm 45.4-45.6

45.4-45.6

Exhaust

mm 40.9-41.1

40.9-41.1

Inlet

mm 3.5-3.6

3.5-3.6

Inlet

V alve seat angle (A)

Valve disk 0 (B)

Valve seat w id th at valve disc (F)

Exhaust

mm 3.5-3.6

3.5-3.6

mm a 145

a 145

Exhaust

mm a 145

a 145

Inlet

mm 8.935-8.950

8.935-8.950

Exhaust

mm 8.925-8.940

8.925-8.940

Fig. see B E05.30-N-1004-01C

M achining dim ension o f inlet valve

Size G

seat surface (H) relative to valve seat Size H surface 0 (G) Fig. see BE05.30-N-1005-01C

M achining dim ension o f exhaust valve seat surface (H) relative to valve seat surface 0 (G)


>

AR05.30-W-4202-01A mm 42.0

AR05.30-W-4202-01A 42.0

mm 2.8-3.0

2.8-3.0

AR05.30-W-4202-01A

AR05.30-W-4202-01A

Size G

mm 39

39

Size H

mm 2.9-3.1

2.9-3.1

Fig. see BE05.30-N-1006-01C

45

Inlet Valve length (C)

Valve stem 0 (E)

30

AR05.30-W-4202-01A

AR05.30-W-4202-01A

Inlet

mm <0.03

£0.03

Exhaust

mm <0.03

£0.03

r

363 58902 2100 D iet g a u g e h o l d e r


C o m m e r c ia lly a v a ila b le to o l« («ee W o r k s h o p E q u ip m e n t M a n u a l)

Number

Designation

M ake (e.g.)

O rder number

WH58.30-Z-1022-05A

Valve grinding machine

M o d el V K M 1 A Hunger

23100001 231 00002


Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h ic le m od . des. 9 5 0 -9 54 , F2

43

AR05.30-W-4511B

M ach inin g value «eat ring«

14.6.96

ENGINE 541.920 /921 /922 /923 /924 /92S /926 /927, 542.920 /921 /922 /923 /92S /926 1

Valve seat rings - exhaust valve

2 3 4

Valve seat rings • in le t valve Cylinder head IS Turning to o l Valve rem oving to o l

s HE 6 7

Exhaust valve Inlet valve

8

I S D ia l gage

9

IS Diet gage holder IS Plug gage

10

U

V O

M

^

0

W 05.30-0051-06

1 2

Valve seat rin g -e x h a u s t valve Valve seat ring - Inlet valve

F

Valve seat width at valve seat ring (inspection dimension related to depth (Hj)

6

Valve seat diam eter a t valve seat ring

H

Depth (inspection dim ension related to valve seat w id th (F))

J

Valve seat angle at valve seat ring

m

Removing

1

Remove valve spring

2

Clamp cylinder head (3) o n valve rem oving

Page 18 I B V alve rem oving to o l

WH58.30-Z-1001-14A

to o l (5) Inspecting 3

Measure am ount by w hich valve stands

Page 23

back to cylinder head (3)

44


® Measure am ount by which valve stands

BE05.30-N-1001-01C

back at both inlet and exhaust valves and note. Permissible difference between both valves BE05.30-N-1009-01C must not be exceeded. m

001 589 53 21 00 343 5890040 00

IXI If the measurement obtained is no t w ithin the permissible tolerance, the valve (6,7) has to be inspected. If worn, replace valve and inspect valve seat rings (1,2). 4

Remove valves (6,7) from the cylinder head

ED M ark valves.

(3) 5

Inspect valve seat rings (1,2)

QD If valve seats are slightly worn, it is possible to machine both inlet or exhaust valve rings w itho ut replacing the valve seat rings. The am ount by which the valve stands back and the permissible difference between both valves must no t be exceeded. If w orn 1

Page 28

Replace valve seat ring. 6

Inspect valve g uid e inner diam ter fo r wear w ith plug gage (10)

BE05.30-N-1001-02C

IS

117589 03 23 00

i n If it is possible to insert the side o f the plug gage marked w ith " + " into the valve guide 1 Replace valve guide.

Page 25

M achine valve seat ring (1,2) in cylinder

@ Machine valve seat rings at both inlet or

Page 48

head (3)

exhaust valve seat ring.

M achining 7

IS

366 589 00 69 00

Valve seat angle at valve seat ring (J) and valve seat w id th at valve seat ring (F)

BE05.30-N-1005-03C

Valve seat 0 at valve seat ring (finish-

B E05.30-N-1006-03C

machined) machining dim ension (G) related to depth (H) o f cylinder head contact surface i n If the measurements obtained after machining are less than the test data J

Page 28

Replace valve seat ring. a

Inspecting

8

Inspect concentricity o f valve seat relative to valve guide

Page 51 BE05.30-N-1003-02C (S

366 5 8900 6900

I S inspection kit for valve seats

WH58.30-Z-1019-05A

[I] If measurements diffe r from test data I

E n gin es O M 501, O M 502 (m od. des. 5 41 .9,542.9), A CTRO S - V e h icle m od . des. 950-954, F2


m

Installing

9

Install valves (C, 7)

10

Once again m achine valve seat ring (1,2).

Page 48

GO Use new valves or j

Page 18

Grind used valves before installing.

Page 41

Once again measure am ount by which valve stands back and permissible difference at both inlet and exhaust valves

Test data o f valves Number

Designation

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/

922/923/925/926

927 BE05.30-N-1001-01C

A m o u n t by which valve stands back relative to cylinder head contact

mm 0.70-1.05

0.70-1.05

mm f i 0.2

fi 0.2

mm

f i 0.2

fi 0.2

Engine 541.920/921/ 922/923/924/925/926/ 927

Engine 542.920/921/ 922/923/925/926

mm

15.028-15.046

15.028-15.046

Oversize 0.2 mm

15.228-15.246

15.228-15.246

surface BE05.30-N-1009-01C

Permissible difference of am ount by Inlet w hich valve stands back relative to .................. , cylinder head contact surface fo r each cylinder

_ . Exhaust

Test data o f valve guides N um ber

Designation

BE05.30-N-1001-02C

V alve guide

O uter 0 (A1)

Standard

Oversize 0.4 mm

15.428-15.446

15.428-15.446

Bore 0 in

Standard

15.000-15.018

15.000-15.018

cylinder head (A)

Oversize 0.2 mm

15.200-15.218

15.200-15.218

Oversize 0.4 mm

15.400-15.418

15.400-15.418

9.000-9.022

9.000-9.022

Inner 0 (machin

mm

mm

ing dimension) (B) Length (C) Distance (□) from valve guide top edge to valve

mm

61.7-62.3

61.7-62.3

inlet

mm

21.1-21,5

21.1-21.5

Exhaust

mm

21.1-21.5

21.1-21.5

AR05.30-W-3731-07A

AR05.30-W-3731-07A

f i 0.04

fi 0.04

spring contact surface Fig. see BE05 30-N-1003-02C

Valve seat

mm

concentricity relative to valve guide


Test data of valve seat rings

Number

Designation

Engine 541.920/921/ 922/923/924/925/926/ 927

BE05.30-N-1005-03C

Valve seat

Valve seat angle at

Inlet

°A

valve seat ring (J)

Exhaust

Valve seat w id th at

Inlet

mm 2.2

Exhaust

mm 2.2

valve seat ring (F)

45

Fig. see BE05.30-N-1006-03C

Valve seat 0 at valve

30

Inlet

seat ring (finishmachined), machining dimension (G) related to depth (H) o f cylinder Exhaust head contact surface

AR05.30-W-3831-03A

Dim. (G)

mm 41.99-42.01

Dim. (H)

mm 4.00-4.15

Fig. see

AR05.30-W-3831-03A

Dim. (G)

38.99-39.01

Dim. (H)

3.80-3.95

Fig. see

AR05.30-W-3831-03A

Test data o f valve seat ring Number

Designation

BE05.30-N-1005-03C

Valve seat

Engine 542.920/921/ 922/923/925/926 Valve seat angle at

Inlet

valve seat ring (J) Valve seat w id th at valve seat ring (F)

°A

30

Exhaust

°A

45

Inlet

mm 2.2

Exhaust

mm 2.2

Fig. see BE05.30-N-1006-03C

Valve seat 0 at valve seat ring (finishmachined), machining

Inlet

AR05.30-W-3831-03A

Dim. (G)

mm 41.99-42.01

Dim. (H)

mm 4.00-4.15

dimension (G) related

Fig. see

AR05.30-W-3831-03A

to depth (H) o f cylinder Exhaust head contact surface

Dim. (G)

38.99-39.01

Dim. (H)

3.80-3.95

Fig. see

AR05.30-W-3831-03A


Designation

WH58.30-Z-1019-05A

Inspection kit for valve seats

M ake (e.g.)

Order number

Hunger

216.93.300


E n g in e s O M 501, O M 502 (m od. des. 541.9,542.9), A C TR O S - V e h icle m od . des. 950-954, F2


Commercially available tools (see Workshop Equipment Manual)

Number

Designation

Make (e.g.)

O rdernum ber

WH58.30-Z-1001-14A

Valve rem oving tool

M odel K2000 Hunger D-81309 M önchen

221 00 200

M achining valve seat rings w ith turning to o l

AR05.30-W-4532-01 B

U ] If the measurements obtained during m achining are less than the test data J, Replace valve seat rings

AR05.30-W-3831B

Test data o f valve seat rings Number

Designation

Engine 541.920/921/ 922/923/924/925/926/ 927

BE05.30-N-1005-03C

Valve seat

Valve seat angle at

Inlet

valve seat ring (J)

Exhaust

45

Valve seat w id th at valve Inlet seat ring (F) Exhaust

mm 2.2

°A

mm 2.2

Fig. see BE05.30-N-1006-03C

Valve seat 0 a t valve seat ring (finish-

Inlet

machined), m achining dim ension (6) related to depth (H) o f cylinder head contact surface

Exhaust

30

AR05.30-W-3831-03A

Dim. (G)

mm 41.99-42.01

Dim. (H)

mm 4.00-4.15

Fig. see

AR05.30-W-3831-03A

Dim. (G)

38.99-39.01

Dim. (H)

3.80-3.95

Fig. see

AR05.30-W-3831-03A

Test data o f valve seat rings Number

D esignation

BE05.30-N-1005-03C

V alve seat

Engine 542.920/921/ 922/923/925/926 Valve seat angle

Inlet

at valve seat ring (J)

Exhaust

45

Valve seat w id th a t valve Inlet seat ring (F) Exhaust

mm 2.2

Fig. see BE05.30-N-1006-03C

V alve seat 0 at valve seat ring (finish-

Inlet

machined), m achining d im e n sio n (G) related to depth (H) o f cylinder head contact surface

Exhaust

°X

30

mm 2.2

AR05.30-W-3831-03A

Dim. (G)

mm 41.99-42.01

Dim. (H)

mm 4.00-4.15

Fig. see

AR05.30 W 3831 03A

Dim. (G)

38.99-39.01

Dim. (H)

3.80-3.95

Fig. see

AR05.30-W-3831-03A


V a lv e seat tu rn in g k it

1

Insert p ilo t (2) (9 mm 0 ) into the valve guid e (1) until the stop (arrow) o f the collet chuck (3) is resting on the valve guide; press collet chuck dow n, if necessary, w ith a screwdriver. Turn tig h t w ith the d rift inserted into the pilo t at top and bottom .

2

Attach turning head (4) to the turning to o l (5), screw in both hexagon sockets screws (6) loosely, match up turning head so th a t th e distance between the rack and the side opposite is about 0.5 to 0.8 mm. Then, tig h ten both hexagon socket screws. Inlet valve -* turning head 02/30° Exhaust valve —►turning head D2/45°

m It must be possible to move the tool slide (8) back and forw ard relatively easily w ith the quick-adjustm ent (9). 3

Screw cutting to o l (7) at the turning head (4).

4

M oisten p ilot (2) w ith oil.

5

Introduce turning tool (5) over the p ilo t (2) until either the stop pin (10) is resting on

W05.30-0027-01

the p ilo t or the cutting to o l (7) is resting on the cylinder head.

® Cutting tool must not strike the cylinder head otherwise the carbide metal tip w ill be damaged.

Additional Information E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od. des. 9 50 -9 54 , F2

49

Turn quick-adjustm ent (9) until the cutting tool (7) is p ositioned over the m iddle o f the valve seat ring. H old tu rnin g tool (5) tight, slacken clam ping screw (12) o f the stop p in (10), carefully low er turning to o l until the blade o f th e cutting tool (7) is resting on the m id d le o f the valve seat ring (11). Press stop pin against p ilo t (2), tighten clamping screw. Clam p pendulum guide (13) tig h t horizontally, approxim ately in the m iddle o f the guide, w ith the steadyrest clamp (14).

CD It should now be possible to rotate the tu rnin g tool (5) just as easily as before. M ake three colored markings (arrows) on the valve seat ring (11) w ith a marker pen, offset about 120°. 10

Raise t u rn in g t o o l (5) a n d p osition cu ttin g to o l (7) next to the

inner valve seat edge by turning the quick-adjustm ent (9).

03 D o n o t m a k e a n y cut infeed.

11

Hold knurled disk (15) fo r infeed mechanism tig h t and turn handcrank (16) clockwise. This usually produces an Irregular sto ck rem oval.

12

A fte r turning fully, move the cutting to o l (7) back again next to the inner valve seat edge w ith the quick-adjustm ent (9).

13

Slacken locking screw (17) and turn the knurled disk (18) ab out 1/2 to 1 g raduation (arrow) counter-clockwise. Tighten locking screw. a 1 g rad uation = 0.1 mm infeed

14

Hold knurled disk (15) fo r infeed mechanism tig h t and turn handcrank (16) clockwise; over-turn the valve seat to the outside w ith the tip of the cutting tool (7).

15

Stock removal has to be carried out as ofte n as necessary (steps 13 and 14) un til the

W05.30-0012-01

valve seat is smooth and free o f chatter marks and valve seat w idth and valve seat d iam eter is achieved, see test data.


16

C o r re c t v a lv e se a t ( 1 1) o n o u ts id e .

17

Raise turning tool (5) and slacken clamping screw (12) o f the stop pin (10).

18

Turn quick-adjustment (9) so that the cutting tool (7) is resting on the outer valve seat edge.

® Lower cutting tool onto the valve seat edge carefully. 19

Press stop pin (10) dow n until it is resting on the pilot. Tighten clamping screw(12).

20

Slacken locking screw (17) and tu rn knurled disk (18) ab o ut 1/2 graduation (arrow) counter-clockwise. Tighten locking screw again.

21

Hold crank arms w ith both hands and move turning to o l (5) around p ilo t by applying slight pressure downward.

22

Repeat steps 20 and 21 until the required valve seat w id th is achieved, see test data. m A fter this, tu rn fu lly once again w ithout any infeed.

23

Take off turning tool. m Do not remove p ilo t (2).

AR05.30-W-4532-02B

Inspecting concentricity o f valve seat to valve guide

S3 If measurement differs from test values | Machine valve seat ring.

AR05.30-W-4532-01 B

Test data of valve guides Designation

Num ber

BC03.30-N-1003-02C

Concentricity o f valve seat to

mm

Engine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/ 927

922/923/925/926

^0.04

=50.04

valve guide

Additional Information Engines O M 501, O M 502 (m od. des. 541.9,542.9), ACTR O S - V e h ic le m od . des. 9 50 -954, F2

51

Com m ercially available to o ls (see W orkshop Equipm ent Manual) Number

Designation

M ake (e.g.)

Order number

WH58.30-Z-10J9-05A

Inspection k it fo r valve seats

Hunger

216.93.300

D-81309 M ünchen 70 1

Insert I S d am pinq ring (1) over the installed valve turning to o l p ilot and clam p tight.

2

M o u n t H inspection tool (2) onto the clam ping ring (1).

3

Set tracer pin o f inspection to o l (2) onto the m iddle o f the valve seat w ith a preload.

4

Slowly turn inspection to o l around the pilot.

5

Inspect radial runout o f valve seat relative to valve guide, see test data.

6

Take o ff inspection to o l (2), clamping ring (1) and pilot. WOS.30-0026*01


AR47.21-W-5621B

Rem oving and installing fu el heat exchanger

14.6.96

ENGINE 541.920/921 /922 /923 /924 /92S /926/927.542.920/921 /922 /923 /92S /926

1

Fuel heat exchanger

2 3

Bolts Seals

4 5 6

Fuel p ip e Banjo bolts Fuel pipe

A6

PLD control unit

W07.10-0008-06

s a is i


1

Remove noise encapsulation

E

¿ t i Dangerl

Risk o f explosion from ignition. Risk of poisoning from inhaling and sw allow ing

No fire, naked flam e or smoking.

fuel. Risk o f injury as a result o f fuel coming into contact w ith skin and eyes.

appropriately marked containers. W ear protective clothing w hen handling

a t bottom

Page 54

Pour fuels only into suitable and

fuel. 2

Detach fuel pipes (4,6) at fuel heat

DOCollect fuel w hich flow s out.

ex ch ange r (1)

E Installation: Replace seals (3). 0 3

Detach fuel heat exchanger (1) PLD control unit(A6)

Fuel pipe to fu el heat exchanger

@ Fuel heat exchanger must no t be disassembled! @ Fuel heat exchanger to PLD control unit

4


5

Bleed fuel system

0

BA47.25-N-1001-018

BA07.15-N-1006-01B

Page 54

D ie s e l in je c tio n s y s t e m w it h u n it p u m p s (M R / P LD )

N um ber

Designation

BA07.15-N-1006-01B

Fuel heat exchanger to M R/PLD control unit

Nm

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/925

924/925/926/927

/926

8

8

Additional Information E n g in es O M 501, O M 5 0 2 (m o d .d e s. 541.9,542.9), A C T R O S - V e h ic le m od . des. 9 50-954, F2

53

0

Fuel pipes/hoses

Number

BA47.25-N-1001-01B

AS47.00-Z-0001-01A

Designation

Fuel pipe to fuel heat exchanger

M 16X1.5

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

Nm 40

40

Risk o f explosion from ig n itio n o f fuel, risk Fire, the creation o f sparks, naked o f poisoning if fu el is inhaled or sw allowed lights and smoking prohibited. and risk o f injury if skin or eyes come into

Only pour fuels into containers which

contact w ith fu el

are suitable and are correspondingly marked.

A

Danger!

W ear protective clothing when handling fuels. P o t e n t ia l d a n g e r s

Risk o f explosion, poisoning and iniury Fuels are hig h ly flam m able and are poisonous if sw allowed. Fuel

-

can cause dam age to the skin. Contact w ith gasoline fuel, fo r example, removes the skin's natural oils. Fuel vapors are explosive

Always put drained fuel into containers which are suitable and can be properly closed off.

-

Immediately remove any fuel w hich has been spilt.

and invisible, and spread o u t along the flo or. They are poisonous if inhaled and can cause unconsciousness in high concentrations. P r o t e c t iv e m e a s u r e s / r u le s f o r h a n d lin g f u e ls

W orking on th e vehicle using a naked flam e (e.g. when w elding etc.). -

Before carrying out such w ork, remove th e relevant parts of

-

Observe local national safety regulations.

-

Fire, the creation o f sparks, naked lights and smoking forbidden.

-

M ake sure th at the w ork area is sufficiently well ventilated.

First aid measures • Wash any fuel from skin using soap and water.

-

Never drain or add fuels over workshop pits.

e

the fuel system and seal o ff open fuel lines w ith plugs.

•

Change out o f clothing on w hich fuel has been spilt as soon as possible. If fuel is splashed into the eyes, rinse out the eyes im m ediately w ith water; consult a doctor if appropriate.

AP47.00-W-1720-01A

Bleeding air in fu el system

1


2

A ctuate m anual pum p until overflow valve opens audibly.

3

Tighten handle o n manual pump.


AR07.03-W-6831 B

Rem oving and installing n ozzle h old er assem bly

10.10.96

ENGINE 541.920 /921 /922 /923 /924 /925 /926/927.542.920 /921 /922 /923 /925 /926

1

injection pipe

2 3 4

Leak fu e l pipe Thrust screw O-ríng

5 6 7 8

Pressure p ip e fitting N ozzle ho ld er com bination O-ring B olt

9 10

Tensioning p late Seal

12

IWi A d ap ter

13

I S Impact extracter

L

Length o f shank o f b o lt (8)

I

Injection pipe

3 4

Thrust screw O-ring

5 6 7 8

Pressure pipe fitting N ozzle ho ld er com bination O-ring B olt

9

Tensioning plaie

10

Seal

II

End cover o f constant throttle

W07.SO-0006-06

m

Removing

1

Remove cylinder head cover

A

Danger)

Risk o f explosion from ignition. Risk of poisoning from inhaling and sw allow ing fuel. Risk o f injury as a result o f fuel com ing into contact w ith skin and eyes.

AR01.20-W-5014B No fire, naked flam e or smoking. Pour fuels only into suitable and appropriately marked containers. W ear protective clothing w h en handling

Page 54

fuel.

En gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S -V e h ic le m o d . des. 9 50 -9 54 , F2


;2

Detach leak fu el pipe (2) at cylinder head

3

Remove injection pipe (1)

4

Take o u t thrust screw (3) and rem ove

Page 66

delivery pipe fittin g (5) 5

Remove tensioning plate (9)

6

Attach adapter (12) and impact extractor (13) to inner thread (M 8) o f nozzle holder com bination (6)

7

Pull out n o zzle holder com bination (6)

m

355 58901 63 00

m

904 589 00 63 00

® N ozzle holder com bination must not be disassembled. If w ear or problem exists, nozzle holder co m b in a tio n sh o u ld b e replaced.

8

Detach adapter (12) and impact extractor (13) at the nozzle holder com bination (6)

9

T ake o ff seal (10)

m

Installing

10

Measure b olt (8)

Q ] If max. shank length is exceeded J,

BE07.10-N-1002-01C

Replace bolt. 11

Replace O-ring (7) at no zzle holder com bination (6)

12

Fit seal (10) onto nozzle holder com bination (6)

13

Install nozzle holder com bination (6)

QD Coat O-ring w ith lubricant.

BR00.45-Z-1018-06A

Ill Replace seal. @ Pay attention to thickness o f seal removed (produces nozzle projection relative to cylinder head contact surface).

[XI Pay attention to installation position of nozzle holder com bination relative to delivery pipe fittin g hole. Turn nozzle holder com bination w ith clam ping plate (9) in cylinder head un til clam ping plate (9) engages at the locating p oin t on the end cover o f the constant th ro ttle (11).

14

Attach clam ping plate (9).

0

Tensioning plate o f injection nozzle

BA07.15-N-1003-01B

and constant th ro ttle to cylinder head. 15

Replace O-ring (4) at pressure pipe fittin g

S I Coat O-rlng w ith lu b ric a n t

BR00.45-Z-1018-06A

@ Pressure pipe fittin g to cylinder head.

BA07.15-N-1005-018

(5) 16

Install pressure pipe fittin g (5) and tighten thrust screw (3)

0D Pay attention to Installation position o f inserted b olt (arrow) at pressure pipe fitting; it should be Inserted into the groove (arrow) in th e cylinder head. 17

Install Injection pipe (1)

18

Install leak fuel pipe (2)

19

Install cylinder head cover

Page 66

[D Replace seals. 0 Leak fuel pip e t o cylinder head.

BA 0 1 .3 0-N -1 0 0 4-0 I D

AR01.20-W-5014B


Test and setting data of injection nozzles

Number

Designation

BE07.10-N-1002-01C

B olt o f tensioning plate o f nozzle holder com bination/constant th rottle to cylinder head

0

Thread diam eter

Shank length

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

M 10

10

mm S91

s91

Cylinder head

Number

Designation

E ngine 541.920/921/

Engine 542.920/921/

922/923/924/925/926/

922/923/925/926

927 BA01.30-N-1004-01D

0

Leak fuel pipe

Nm 15

15

Diesel injection system w ith unit pumps (PLD)

Num her

D e s ig n a t io n

BA07.15-N-1003-01B

Tensioning plate o f injection nozzle and constant th rottle to cylinder

BA07.15-N-1005-01B

Pressure pipe fittin g to cylinder head

E n g in e 5 4 1 .9 2 0 /

E n g in e 5 4 2 .9 2 0 /

921/922/923/ 924/925/926/927

921/922/923/ 925/926

Nm 50

50

Nm 4 0

40

head


Designation

BR00.45-Z-1018-06A

ATE grease

Order number

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 S 0 -9 5 4 , F2

57

AR07.15-W-1628B

14.6.96

R em oving and installing MR/PLD control m odule

ENGINE 541.920/921 /922 /923 /924 /92S/926/927.542.920 /921 /922 /923 /925/926 / 2 3 4 5

Spacer Rubber dam p en W ashen Bolts vehicle w iring harness connector

6

Engine w iring harness connector

7

Fuel heat exchanger

A6

MR/PLD control m odule

W 0 7.1 5-0078-06

O peration no. o f operation texts or standard texts and fla t rates Division

Op. no.

O peration text

S

07-1628

Control m odule

El El

Rem oval, installation

i

Switch o ff ig nition

/ h Danger!

Risk o f injury from bruises and jam m ing w hen tiltin g cap

No person should be in the tiltin g area o f the cab when it is being tilted. Alw ays tilt

Page 60

cab as far as the end position and secure w ith a safety prop. ®


2

T ilt cab

3

Remove fuel heat exchanger (7)

M odels 950. 952. 953. 454

P a g e 60

0 0 Fuel pipes remain attached to fu el heat

Page 53

oxchanger.

4

5

6

Release and unplug vehicle w iring harness

[ D Release connector by pressing the

connector (5) at PLD control m odule (A6)

locking arm.

Release a n d u n p lu g e n g in e w irin g h arness

DO Release co n n e c to r by sw iv e lin g the

connector (6) at PLD control m odule (A6)

locking arm.

Remove PLD control unit (A6) at crankcase

® The PLD control unit must not be disassembled. HI Installation: install spacers (1) w ith rubber dampers (2) fitted on and at PLD control unit. Pay attention to installation position o f rubber dampers (2). 0

7


PLD control m odule to crankcase.

BA07.15-N-1002-01B

Q ] If a new PLD control m odule is installed

1 58


program transponder keys. 0

AR80.57-W-0010A

Diesel injection system w ith unit pumps (MR/PLD)

N um ber

Designation

B A 0 7 .15-N-1002-01B

MR/PLD control m odule to crankcase

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/925

924/925/926/927

/926

Nm 15

15

Bearbeitungsverm erk

Additional Information Engines O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h ic le m od . des. 9 50 -9 54 , F2

59

AS60.80-Z-0001-01A

Injury hazard from pinching and crushing w hen cab is tilted

W hen tiltin g ensure that no one is present in the tiltin g area o f the cab.

A

Danger)

A lw a y s tilt cab to end p o sitio n a n d

secure w ith safety brace. Injury hazard A d a m a g e d tiltin g m e ch a n ism o r im p ro p e r h a n d lin g o f th e tilting

mechanism can lead to severe injuries w hen tiltin g the cab.

W hen tiltin g cab: - Protect tiltin g area and particularly tiltin g device against

Rules o f behavior/protective measures

unauthorized access, e.g. by blocking o ff or w ith human

B efore tiltin g cab:

guard.

-

Shut o ff engine. A p p ly parking brake.

-

-

Secure vehicle against rolling.

-

O n vehicles w ith m a n u a l tran sm ission m o v e shift lever to

-

-

On vehicles w ith autom atic transmission move selection lever

Attach safety cable before tiltin g w hen so specified in the vehicle operating instructions. Never w ork under cab w hen partially tilted. Always T ilt cab to end position and secure w ith safety brace.

neutral position. to position “ N".

AH60.80-N-0003-01A

Notes on tiltin g th e cab

Models 673,674,675, 676, 677,678, 679,950,952,953,954,957,970,971, 972, 973,974, 975,976

Before tiltin g the cab • Sw itch o ff engine e A p p ly parking brake

On vehicles w ith a refrigerator box e The refrigerator box must be switched o ff before the cab is

e

Secure vehicle to stop it rolling aw ay

e

e

Rem ove all loose objects (e.g. cans, bottles, tools, bags etc.) from the cab

e

On vehicles w ith m anual transm ission m ove shift lever to neutral position M od el 957: release steering column and open fro n t flap

e

tilted. The refrigerator box may only be switched on 10 minutes after tiltin g the cab back again. CD Also refer to the refrigerator box m anufacturer's Operating Instructions and the red inform ation plate on the refrigerator box.

The coupling pin m ust be inserted correctly.

CDA lw a y s tilt cab up to its fin a l position.


AR07.15-W -1640A

Rem oving, adjusting and installing crankshaft angle position sensor bracket

16.1.97

ENGINE 541.920/921 Z922/923/924/925/926/927.542.920/921 Z922 Z923Z925Z926

1

Bracket

2 3

Shear bolts I S Cranking device

4 5 6

O-ring Securing bush Flyw heel

B15 Crankshaft position sensor

m

Removing

i


2

Pull o ut crankshaft position sensor (B15) at bracket (1)

3

Pull o u t securing bush (5)

4

Take o ff end cover of TDC inspection hole

OD A t bottom

at tim ing case 5

6

A ttach c ra n kin g device (3) to tim in g case

Rotate crankshaft w ith the cranking device (3)

IS

407 589 0 0 63 00

0 End cover o f TDC inspection hole to tim ing case

BA01.60-N-1001-01B

H I Until the TDC marking on the flywheel (arrow) is positioned in the m iddle o f the m ounting hole of the crankshaft position sensor (B15). The TDC marking is located in one o f the lon g itud inal grooves.

7 8

9

Block crankshaft to prevent it turning M ark flywheel (6) relative to reference

Q ] It flyw heel is taken off, mark vibration

edge in TDC inspection hole

dam per relative to crankcase.

Use a suitable to o l to slacken shear bolts (2) a n d rem ove, take o ff bracket (1) toge th er

w ith O-ring. Setting

Additional Information E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V e h icle m od . des. 9 50 -9 54 , F2

61

10

A ttach bracket (1) together w ith O-ring

ED TDC m arking o n flyw heel (arrow)

and align

should be positioned in the m iddle o f the m ounting hole o f th e crankshaft position sensor (B15). Inspect m arking on flywheel relative to reference edge in TDC inspection hole or vibration damper relative to crankcase.

11

Tighten shear bolts (2) until they shear o ff Installing

12 13

14

Press securing bush (5) in as far as the stop Press crankshaft position sensor (B15) into

GQInspect O-ring (4) fo r signs o f damage,

th e tim in g case as far as the stop

replace if necessary.

Remove blocking and cranking device (3)

® Cranking device should be removed before starting the engine.

m 15


407 589 00 63 00

@ End cover o f TDC inspection hole to tim ing case

BA01.60-N-1001-01B

@ Timing case Number

B A 0 1.60-N -1001 -01B

Désignation

End cover of TDC inspection hole to tim in g case

Engine 541.920/ 921/922/923/

921/922/923/

924/925/926/927

925/926

Nm 25

Engine 542.920/

25


AR07.15-W-8950B

Rem oving and installing MR/PLD u n it pum p

17.1.96

ENGINE 541.920/921/922/923/924/925/926/927,542.920/921/922/923/925/926

W07.15-0003-09

1 2 3

PLD u n it pum p O-ring (black) O-ring (brown)

1 4

PLD un it pum p Serrated b olt

7

4

Serrated b olt

5

Injection pipe

6

Engine w iring harness

I S Cranking device

W 07 15-0004-02

El El 1

Removing, installing Install cranking device (7) fo r the engine at

© Cranking device must be removed

the tim ing case

before starting the engine

S3 0 2

Remove injection p ipe (5j

3.1

Remove charge air pipe

407 589 00 63 00 End cover to tim ing case

B A01.60-N-1001-01B

Page 66 On engine 542.920-923/925/926

En g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h icle m o d . des. 9 5 0 -9 54 , F2

Page 80


Disconnect engine w irin g harness (6) a t all

Slacken bolts at solenoid valve and

th e le ft o r righ t PLD un it pumps (1)

separate both dips

5

Unscrew serrated b olt (4) ab out 6 mm

0

6

Remove PLD u n it pum p (1)

OD Rotate crankshaft w ith the cranking device un til the pum p cam a t th e camshaft

4

BA07.15-N-1001-01B

pushes th e PLD unit pum p o u t o f the crankcase.

® If th e PLD unit pum p (1) is tight. It must n o t be pushed out a t the solenoid valve and housing flange j. Carefully press out PLD unit pum p (1) a t the recess (arrow) in the unit pum p housing [ D Installation: rotate crankshaft w ith the cranking device until the pum p cam a t the cam shaft is positioned in the base circle. Press PLD unit pump into th e crankcase by hand against the force o f th e spring (clearance about 4 mm). 7

Unscrew serrated b olt (4) and pull o u t PLD

@ PLD u n it pump must not be

u n it p u m p (1)

disassembled. If it is w o rn o r if a problem exists, the PLD u n it pum p must be replaced.

8

Remove O -rlngs (2,3) a t th e un it pum p (1)

E

Installation: replace O-rings. Pay

BR00.45-Z-1018-06A

a tte n tio n to color c o d in g o f O -rin g s an d

coat w ith lubricant. 9 0

Install In the reverse order Tim ing case

N um ber

BA01.60-N-1001-01B

D esignation


Engine 5 4 1 .9 2 0 /

Engine 5 4 2 .9 2 0 /

9 2 1 /9 2 2 /9 2 3 /

9 2 1 /9 2 2 /9 2 3 /

9 2 4 / 9 2 5 /9 2 6 / 9 2 7

9 2 5 /9 2 6

Nm 2 5

25

tim in g case

@ Diesel injection system w ith u n it pum ps (MR/PLD) N um ber

D esignation

BA07.15-N-1001-01B

MR/PLD u n it pum p to crankcase

Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 65

Engine 542.920/ 921/922/923/925 /926 65


Repair products

Number

Designation

O rdernum ber

B R00.45-Z-1018-06A

ATE grease

-

Additional Information En gin es O M 501, O M 502 (mod. des. 541.9, 542.9), A C T R O S -V e h ic le m od. des. 950-954, F2

65

AR07.15-W-9235B

17.1.96

Rem oving and installing MR/PLD injection pipes

ENGINE 541.920/921/922/923/924/925/926/927,542.920/921/922/923/925/926 1

C h a r g e a ir h o u s i n g

2

Injection pipe

W07.10.000S-I2

Removing 1

Remove charge air housing (1)

Æ Danger!

Risk o f explosion from ignition. Risk o f poisoning from inhaling and sw allowing fuel. Risk o f injury as a result o f fuel coming into contact w ith skin and eyes.

Page 83 No fire, naked flam e or smoking. Pour fuels only into suitable and appropriately marked containers. W ear protective clothing w hen handling

Page 54

fuel. 2

Remove injection pipe (2)

® Injection pipe must no t be detached for bleeding th e fuel system. Injection pipe must not be bent.

m

Installing

3

Install injection pipe (2)

m

000 589 07 03 00

w

000 589 68 03 00

@ Injection pipe must not be bent. Pay atte ntio n to installation position. 000 58907 03 00 m 0

000 589 68 03 00 Injection pipe to delivery pipe

BA07.15-N-1004-01B

connection fittin g or unit pum p 4

Install charge air housing (1)

5

Bleed fuel system

¿^ Danger!


Page 83 AP07.57-W-0780A

Secure vehicle to prevent it m oving off. starting o ff when engine running. Risk of W ear closed and close-fitting w o rk clothes. injury as a result o f bruises and bums if you Do not grasp ho t or rotating parts. insert your hands into engine when it is

Page 68


66


6

Start engine and run

@ Crank engine w ith the starter fo r not m ore than 20 seconds. W ait about 2 m inutes before repeating the attem pt at starting.

7

Pay attention to injection pipe (2). Check

Q ] Use a m irror to inspect injection pipe at

both screw connections fo r leaks.

the un it pum p (below charge air housing). If a leak exists, replace relevant injection pipe.

8

Switch o ff engine

6 3 Diesel injection system w ith unit pumps (MR/PLD) Num ber

Designation

BA07.15-N-1004-01B

/

y

Injection pipe to delivery pipe connection fittin g o r unit pump

Engines 541.920/ 921/922/923/

Engines 542.920/ 921/922/923/925

924/925/926/927

/926

Nm 30

30

\

000 589 07 03 00 Ring wrench

J Box wrench socket

Additional Information Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h ic le m od. des. 9 5 0 -9 5 4 , F2

67

AS00.00-Z-0005-01A

Secure vehicle to prevent it from Risk o f accident as a result o f vehicle starting o ff w h en engine is running. Risk of moving off. injury as a result o f bruises and burns if you W ear closed and close-fitting work clothes. insert your hands into engine w hen it is being started o r w hen it is running.

Possible dangers

A

Danger!

Do not grasp hot or rotating parts. Rules o f conduct / Protective measures

Risk o f accident from vehicle starting o ff d uring starting operatio n (e.g. w hen

-

As a general rule, carry out w ork on the running engine only if this is absolutely essential. Before starting the engine, apply parking brake.

testing compression pressure) as a result o f g ear engaged or when

-

On models w ith manual transmission, m ove gearshift lever

engine running and vehicles w ith autom atic transmission as a result o f selector lever position "P " or “ N " no t engaged

-

On models w ith autom atic transmission, m ove selector lever

into N eutral position.

(exception: some vehicles d o no t have a selector lever position “ P“).

into position “ P” or “ N " (exception: some vehicles d o not have a selector lever position “ P"). On m odels which do not have selector lever position “ P” ,

Risk o f injury


Severe injuries may be caused by freely rotatin g parts in the area of the running engine. The heat produced by the engine w hen it is operating can result in severe burns if contact is m ade w ith individual, unshielded parts.

unintentionally. -

W ear closed and close-fitting w ork clothes. Take o ff any jewelry, such as chains, rings etc.

-

If you have long hair, wear a suitable head cover.

-

Before commencing w ork on the running engine, check to o b ta in a ge ne ral picture o f the p o sitio n in g o f parts w h ich may be hot. W hen carrying out w ork when starting th e engine or when

-

engine is running, do not touch any hot and rotating parts.

First aid measures in the event o f burns e

Do no t rub the skin areas affected; flush w ith plenty o f cold w a te r and cover skin w ith sterile bandages.

•

Im m ed iately consu lt a physician.


AR47.20-W-551 OB

Removing and installing fuel filter

14.6.96

ENGINE 541.920/921 /922 /9 2 3 /9 2 4 /9 2 5 /9 2 E /9 2 7 , 542.920/921 /922 /923 /92S /926

1

Bolts

2 3 4

Fuel filte r housing Fuel filte r elem ent Gasket

5

Fuel filter cap

6 7 8 9

Seals Fuel pipes (feed) Banjo b o lt Fuel pipes (to fu el p on s)

10

Banjo bolts

11

Seals

12 13

Fuel pipes (flame starting system) Banjo bolts

14

Fuel pipe (return flow )

15

Fuel pipe (leak fu el pipe)

W 07.S7-0002 OS

HHIHl A D a n ge rl

Removing, installing Rick o f injury from bruises a n d jam m in g

N o person sho uld be in the tilting orca o f

w hen tiltin g cap

the cab when it is being tilted. Always tilt

Page 60

cab as far as the end position and secure w ith a safety prop. 1

Tilt cab

®


M odel 950,952,953,954

/ h Danger!

Risk o f explosion from ignition. Risk of poisoning from inhaling and sw allow ing fuel. Risk of injury as a result o f fuel coming into contact w ith skin and eyes.

No fire, naked flam e or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling

Page 60 Page 54

fuel. 2

Unscrew fuel filte r cap (5) together w ith fuel filte r elem ent (3).

0 0 w h e n fuel filte r is removed, the fuel flows back out of the fuel filter housing along the fuel return flo w pipe into the fuel tank.

E Installation: Inspect seal (4), replace if necessary.

3

Detach fuel pipes at fuel filte r housing (2)

63Cap to fuel filte r housing. E Collect fuel which flo w s out.

8A47.20-N-1002-02C

Installation: Replace all seals.

0 Fuel pipe to fuel filte r housing 63Leak fuel pipe to banjo bolt 63Fuel pipe (flame starting system) to

BA47.25-N-1003-01B BA47.25-N-1006-01B BA47.25-N-1007-01B

banjo b olt 4

Detach fuel filte r housing (2) at o il filte r housing

63Fuel filte r housing to o il fitter housing

En gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S -V e h ic le m od . des. 950-954, F2

BA07.57-N-1001-01C


5


6

Bleed fuel system

Page 54

@ Fuel filte r Number

Designation

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

BA47.20-N-1001-02C

Fuel filte r housing to oil filte r housing

Nm 25

924/925/926/927

925/926

25

BA47.20-N-1002-02C

Cap to fuel filte r housing

Nm 25

25

@ Fuel plpes/hoses Number

Designation

Engine 541.920/ 921/922/923/ 924/925/926/927

Engine 542.920/ 921/922/923/ 925/926

BA47.25-N-1003-01B

Fuel pipe to fuel filte r housing

M 16X 1.5

Nm 40

40

BA47.25-N-1006-01B

Leak fuel pipe to banjo b olt o f fuel filte r housing

M8X1

Nm 15

15

BA47.25-N-1007-018

Fuel pipe (flame starting system) to banjo b olt and valve

M 8X1

Nm 15

15


AR09.20-W-1310A

Removing and installing intake manifold

8.10.96

ENGINE 542.920 /921/922 /923 /92S/926 1 2

Intake p ipe

3 4 5

Intake m anifold Bolt Bracket

6

Resonance tank

Connectors

W09.20-0001 -OC

(m s A D an ge r!

Removing, installing Risk o f in jury fro m bruises a n d ja m m in g

N o p erson sho uld be in th e tilting area o f

when tiltin g cap

the cab when it is being tilted. Always tilt cab as far as the end position and secure with a safety prop.

1

Tilt cab

®


M odel 950,952,953, 954

2


GO on side right and a t rear

P a g e 60

P a g e 60

Detach intake pipe (1) at intake m anifold

3

(3) 4

Separate hose from resonance tank at intake m anifold (3)

5

Detach intake m anifold (3) at bracket (5)

fi

Slacken connectors (2) at intake m anifold (3) and at both turbochargers and push

B A ir intake m anifold to bracket [H Installation', clean sealing surfaces.

BA09.20-N-1001-02C

tow ard intake m anifold or turbocharger 7

Take o ut intake m anifold (3)

8


@ Intake m anifold. Intake m anifold preheater Number

Designation

Engine 542.920/ 921/922/923/ 925/926

BA09.20-N -1001-02C

A ir intake m anifold to bracket

Nm 50

Additional Information En g in es O M 501, O M 5 0 2 (m o d .d e s. 541.9,542.9), A C T R 0 5 - V e h ic le m od. des. 9 50-954, F2

71

AR09.40-W-591 OB

14.6.96

Inspecting turbocharger

ENGINE 541.920/921 /922 /923 /924 /92S/926/927542.920 /921 /922 /923 /92S/926

W09.40-0007-06

E3H


1.1

Remove engine brake fla p connection

1.2

R em ove transverse exhaust pip e

On engine 541.920 - 927

AR14.15-W-6302B

On engine 542.920 - 923/925/926 S] A t left-hand turbocharger

AR14.15-W-6302C

O n e n g in e 542.920 - 923/925/926

A R 1 4 .1 0 -W -3 9 2 5 A

21 A t right-hand turbocharger 2.1

Detach intake m anifold (3)

On engine 541.920 - 927 w ith air intake above cab 2J Do no t detach connection piece w ith integrated com pensating ring at turbocharger.

0 2.2

Detach intake hose


BA 0 9 .2 0-N -1 0 0 1 -02C

On engine 541.920 - 927 w ith plate-type air filte r Take o ff c o m p e n sa tin g ring.

2] Installation: compensating ring should rest against turbocharger flange. 2.3

Remove intake m anifold

On engine 542.920 - 923/925/926

Page 71

Q] A xle play and radial play are correct if there is no indication o f rotor shaft rubbing against turbocharger housing on

Page 73

Inspecting 3

Inspect turbocharger rotor shaft (1.1) fo r unobstructed operation

either side. If there is an indication o f rotor shaft ru b b in g a g a in st tu rb o ch a rge r h o u sin g 1

replace turbocharger On engine 541.920-927

72

Page 75


On engine 542.920 - 923/925/926 4 B

Page 77

Install in th e reverse order Intake m anifold, intake m anifold preheater

Number

Designation

BA09.20-N-1001-02C

AR09.40-W-5910-01A

A ir intake m an ifold to bracket

Engine 542.920/ 921/922/923/ 925/926

Nm 50

Inspecting axial play and radial play at rotor shaft

Engine 541.920/ 921/922/923/ 924/925/926/927

50

If there is any indication o f the rotor shaft touching the turbocharger housing J, Replace turbocharger On engine 904.905- 907/909- 911/921 / AR09.40-W-6020A 922 and 906.910/911/920- 923/940/ 941

1

On engine 904.908/923

AR09.40-D-6020D

On engine 541.920-927

AR09.40-W-6020B

On engine 542.920-923/925

AR09.40-W-6020C

Rotate rotor shaft (1) at the shaft nut or at the turbine wheel; inspect rotor shaft to ensure th at it rotates w ith o u t obstruction and evenly. M ove the rotor shaft back and forw ard fo r this purpose until it is free o f oil carbon deposits. s The rotor shaft is centrifugally stabilized and is guided in its m ount w ith a relatively large play.

2

Inspecting axial play; move rotor shaft (1) in longitudinal direction and inspect w hether there is any sign o f it to u c h in g the tu rb in e or co m p ressor

wheel.

m if there is no indication o f the rotor shaft touching the turbocharger housing on either side, the axial play is ok. If there is any sign o f it touching, replace the turbocharger.

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50-954, F2

73

Inspecting radial play: deflect rotor shaft (1) in radial direction; turn it w hen doing this and inspect w hether there is any indication o f the turbine or compressor wheel touching.

m If there is no sign o f the rotor shaft touching the turbocharger housing on either side, th e radial play is ok. If there is a sign o f it touching, replace the turbocharger.


AR09.40-W-6020B


25.10.96

ENGINE 541.920/921 /922/923/924/92S/926/927

7 2 3 4 5 6

Intake pipe Intake m anifold Bolt connector Compensating rings Bolt

7 8 9

Gasket O il delivery pipe Intermediate piece

10

Turbocharger

11 12 13

Gasket O il return flo w pipe Bolt

14

Nuts Engine brake flap connection Banjo b olt Seals Suction hose (with plate-type a ir filte r)

15 16 17 18

HIE


i

Remove engine brake flap connection (15)

2.1

R em ove intake pipe (1)

3

Separate resonance tank hose and

AR14.15-W-6302B W ith air intake ab ove cab

breather hose at intake m anifold (2) 4.1

D etach intake m anifold (2)

W ith air intake ab ove cab

4.2

Detach intake hose (18)

W ith plate-type air filter

5

Remove oil delivery pipe (8)

HI Seal opening at turbocharger (10) and at crankcase.

[H Installation: before attaching the oil delivery pipe, fill turbocharger bearing housing through oil inlet opening with e n g in e oil. Rotate tu rb o ch a rge r shaft by

hand when pouring in oil so that the bearing points are provided w ith a film of oil. Replace ga ske t (7) a n d seal (17).

® O il delivery pipe fo r turbocharger to

BA01.40-N-1011-01D

crankcase

E ngines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le m od. des. 9 50 -954, F2


0 6

Detach oil return flo w pipe (12) at

1 2 Installation: replace gasket (11).

turbocharger (10)

Seal opening. 0

Detach turbocharger (10) at exhaust

7

BA09.40-N-1001-01C

O il delivery pipe to turbocharger

O il return flo w pipe to turbocharger

B A09.40-N-1003-01C

1 2 Installation: replace nuts (14).

plenum chamber ED Seal openings at turbocharger and exhaust plenum chamber. 0

BA09.40-N-1002-01C

Turbocharger to exhaust plenum

chamber 8.1

Detach connector (4) w ith compensating

W ith air intake above cab.

ring (5) at turbocharger (10)

( 2 Installation: attach connector to turbocharger, then install the compensating ring. Pay attention to installation position. Com pensating ring should rest against turbocharger.

8.2

Detach intake hose (18) w ith compensating W ith plate-type air filte r ring (5) at turbocharger (10)

[ 2 Installation: pay attention to installation position. Compensating ring s h o u ld re s t a g a in s t t u r b o c h a r g e r .

9

Pull o ut interm ediate piece (9) at

2

turbocharger (10) or charge air m anifold

piece.

Installation: replace interm ediate

10

Fit existing heat insulation to turbocharger (10)

0 2

11


2 Installation: inspect intake m anifold, charge air pipe, charge air m anifold, exhaust m anifold, oil delivery pipe, oil return flo w pipe fo r foreign bodies,

BA09.40-N-1004-01C

Insulation above turbocharger W hen replacing turbocharger.

im purities and damage. 0


Number

Designation

Engine 541.920/ 921/922/

923/924/ 925/926/ 927 BA01.40-N-1011-01D

0

O il delivery pipe fo r turbocharger to crankcase

M 14X 1.5

Nm

35

Turbocharger

Number

Designation

Engine 541.920/ 921/922/923/ 924/925/926/927

BA09.40-N-1001-01C


Nm 25

BA09.40-N-1002-01C

Turbocharger to exhaust plenum chamber

Nm 50

BA09.40-N-1003-01C


Nm 25

BA09.40-N-1004-01C

Insulation above turbocharger

Nm 50


AR09.40 W 6020C

R em oving and installing exhaust gas turbocharger

25.10.96

ENGINE 542.920 /921 /922 /923 /92S/926

1 2

Intermediate pieces Nuts

9

Gaskets

10

3.1 3.2 4

Turbocharger (right) O il delivery pipe

11 a 13

O il return flo w pipes Bolts intake m an ifold

5 6 7

Bolts

14

Intermediate flange Gaskets

15 16

8

Transverse exhaust pipe

Turbocharger (left)

[M 1


O il delivery p ipe Engine brake flap connection Banjo bolts Seals

Remove intake m anifold (12)

2.1

Remove transverse exhaust pipe (8)

2.2 3

P a g e 71 A t right-hand turbocharger (3.1)

AR14.10-W-3925A


A t left-hand turbocharger (3.2)

AR14.15-W-6302C

Detach oil delivery pipe (4 or 13) at

B O il delivery pipe to turbocharger QOSeal op e n in gs.

BA09.40-N-1001-01C

in te rm e diate fla n g e (£)

Installation: before attaching the oil delivery pipe, fill turbocharger bearing housing through oil in le t opening w ith e n g in e oil. Rotate tu rb o c h a rg e r shaft by

hand when pouring in oil so th at the bearing points are provided w ith a film of oil. 4.1

Detach oil delivery pipe (4) at tim ing case

A t right-hand turbocharger (3.1) Seal openings.

4.2

Detach oil delivery pipe (13) at crankcase

A t left-hand turbocharger (3.2)

E

Installation: replace seal (17).

Seal openings.

IS

Q

t^

P

Installation: replace seal (17).

E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le m od . des. 9 50-954, F2


0

O il delivery pipe fo r turbocharger to

BA01.40-N-1011-01D

crankcase Detach oil return flo w pipe (10) at turbocharger (3.1 or 3.2)

s

A. Seal opening. H I Installation: replace gasket (9). 0

6

Detach turbocharger (3.1 o r 3.2) at exhaust m anifold


BA09.40-N-1003-01C

[ D Seal openings at turbocharger and exhaust m anifold. [ D Installation: replace nuts (2).

7

0

Turbocharger to exhaust m anifold

Pull out interm ediate piece (1) at

E

Installation: replace interm ediate

turbocharger (3.1 or 3.2) o r a t charge air

piece.

B A 0 9 .4 0 - N - 1 005*01 C

pipe 8

Fit on existing flange (6) o f o il delivery

E

W hen replacing turbocharger

0


E

W hen replacing turbocharger

pipe. Replace gasket (7)

9

Fit on existing heat insulation at turbocharger (3.1 or 3.2)

10

Rotate turbine and compressor housing at turbocharger (3.1 or 3.2) accordingly

0


E

O nly one turbocharger version is

B A09.40-N-1001 -01C

BA09.40-N-1004-01C

stocked in th e Parts Sector. 0

Bolt o f compressor housing to bearing

BA09.40-N-1006-01C

housing BA09.40-N-1007-01C

0 B olt o f turbine housing to bearing housing 11


E

Installation: inspect intake manifold,

charge air pipe, charge air manifold, exhaust m anifold, oil delivery pipe, oil return flo w pipe fo r fo reig n bodies, im purities and damage. 0


Number

Designation

Engine 542.920/ 921/922/ 923/925/ 926

BA01.40-N-1011-01D

O il delivery pipe fo r turbocharger to crankcase

M 1 4 X 1 .5

Nm

35


0

Turbocharger

Number

D esignation

Engine 542.920/ 921/922/923/ 925/926

BA09.40-N-1001-01C


Nm 25

BA09.40-N-1003-01C

Oil return flo w pipe to turbocharger

Nm 25

BA09.40-N-1004-01C


Nm 50

BA09.40-N-1005-01C

Turbocharger to exhaust m anifold

Nm 50

BA09.40-N-1006-01C

Bolt o f compressor housing to

Nm 10

bearing housing BA09.40-N-1007-01C

Bolt o f tu rb in e housing to bearing housing

Nm 20

Additional Information E n g in es O M 501, O M 502 (m o d . des. 541.9,542.9), A C T R O S -V e h ic le m od. des. 9 5 0 -9 54 , F2

79

AR09.41-W-1311B

17.1.96

Rem oving and installing charge air pipe

ENGINE 542.920/921 /922 /923 /92S/926 7

Charge a ir m anifold/charge air housing

2 3 4

Charge a ir hose (red) Charge a ir pipe Bolts

S

A d a p te r piece

W09.41-0003-06

M M 1

Rem oving, installing Page 83

R em ove ch arge air m anifold/charge air

housing (1) 2

Remove charge air hose (2)

H I Installation: charge air hose must not be mixed up. @ The red charge air hose is temperatureresistant and must always be installed betw een charge a ir pipe (3) and intercooler. @

Charge air hose to charge air

BA09.41 -N-1006-01C

housing/charge air pipe and intercooler 3

Remove charge air pipe (3) and adapter p ieces(5)

OD Inspect adapter piece fo r signs o f wear and replace if necessary. @ Charge air pipe to charge air housing

4 0

BA09.41-N-1005-01C

Install in the reverse order Charge a ir pipe/intercooler

N um ber

D esign ation

BA09.41-N-1005-01C

Charge air pipe to charge air housing

Nm 25

BA09.41-N-1006-01C


Nm 7.5

Engine 542.920/ 921/922/923/ 925/926

housing/charge air pipe and intercooler


AR09.41 -W-6800A

Testing intercooler and charge air hoses for leaks

21.11.96

ENGINE 541.920/9211922/923/924/925/926/927,542.920/921 /922/923/925/926

1

Charge air hose (black)

2

Charge a ir hose (red)

3

Clips

4

Test flange w ith compressed air

5 6

connection Test flange Tester w ith gage

W09.41 -0008-02

Testing 1

Detach charge air hoses (1,2) at charge air m anifold and charge air pipe

2

Install test flanges (4, 5) at the charge air hoses (1,2)

E

Inspect clips (3) fo r signs o f wear.

Test flanges should be additionally supported at the openings o f th e charge air m an ifold or charge air pipe.

m

541 589 01 63 00

0

BA09.41 -N-1006-01C

Charge air hose to charge air housing/ charge air pipe and Intercooler

IS E Test pressure 1.5 bar gage.

3

Attach tester (6) to the test flange (4)

4

Fill intercooler and charge air hoses at test flange (5) w ith compressed air

5

Observe indication on tester (6) to

B

determ ine w hether pressure drops

and charge air hoses (1,2) fo r damage, replace if necessary.

Remove tester (6) and test flanges (4, 5) Install charge air hoses (1,2) at charge air

E Release pressure. 0 Charge air hose to charge air housing/

m anifold and charge air pipe

charge air pipe and intercooler

6 7

0

442 589 0 1 2 1 0 0

If pressure drops, inspect Intercooler

BA09.41-N-1006-01C

Charge air pipe/intercooler

Number

D esignation

BA09.41-N-1006-01C

Charge air hose to charge a ir housing/

Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 7.5

Engine 542.920/ 921/922/923/ 925/926 7.5

ch arge air pipe a n d intercooler

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50 -9 54 , F2

81

541 589 01 63 00 Test flange


AR09.41 -W-8681B

17.1.96

Removing and installing charge air manifold

ENGINE 541.920/921 /922 /923 /924 /925 /926/927, 542.920/921 /922 /923 /92S /926

W09.41 *0004-09

1 2

Charge a ir m anifold/charge a ir housing Engine w iring harness

3

Gaskets

4 5

Nuts Tensioning elem ent

6

Gasket

7 a 9

Bolt

77

Threaded pin

12 13

Charge a ir hose (black) Charge a ir hose (red)

14

Flange of flame starting system

IS

Gasket

Flange

B9

Charge a ir temperature sensor

Adapter piece

B13 Charge air pressure sensor


Gasket getween charge air m anifold/charge air housing and cylinder head m odified; the headless setscrews in

Page 83

Step 9

the cylinder head are thus discontinued.

m m


A

Risk o f injury from bruises and jam m ing when tiltin g cap

Danger!

Page 60

No person should be in the tiltin g area o f the cab w hen it is being tilted. Always tilt cab as far as the end position and secure w ith a safety prop.

7

Tilt cab

®


M odels 950, 952,953,954

2.1

Remove air filte r housing

If plate-type air filte r fitted

Page 60

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h icle m od. des. 9 5 0 -9 54 , F2

83

3.1

Remove charge air hoses (12,13)

On engine 541.920-927

ELIInstallation: charge air hoses (12,13) must no t be mixed up. @ T he red c h a rg e air h ose (13) is

tem perature-resistant and must always be installed betw een charge air pipe and intercooler.

0

BA09.41-N-1Q06-01C


housing/charge air pipe and intercooler 3.2

Remove charge air hose (12)

On engine 542.920-923/925/926

0


BA09.41-N-1006-01C

housing/charge air pipe 4

Remove flange (14) o f flam e starting system com plete w ith flam e plug

[2 Installation: replace gaskets (15). 0

Bolt o f flam e starting system bracket to

BA09.30-N-1001-01A

charge air pipe 5.1

Remove flange (7) and adapter piece (8)

On engine 541.920 - 927

ODReplace gasket (6). Inspect adapter piece fo r signs o f w ear and replace if necessary.

0

Connection fitting to charge air housing

6

BA09.41-N-1004-01C

Separate connector (2) o f engine w iring harness at charge air tem perature sensor (B9) and charge air pressure sensor (B13)

7.1

8

Disconnect charge air m anifold/charge air housing (1) at charge air pipe

Unscrew nuts (4) and pull tensioning elem ent (5) out o f charge air housing (1)

On engine 542.920-923/925/926

0 Charge air pipe to charge air housing QQCounter-hold threaded pin (11).

Take out charge air m anifold/charge air housing (1)

Charge air housing to threaded pin

BA09.41-N-1001-01C

L il Installation: Replace gaskets (3) bet ween charge air m anifold/charge air hou sing and cylinder head. Pay attention to in stallation position

10

Tighten threaded pin (11) at crankcase

11

Tighten threaded pin (11) at bracket o f oil

0 Threaded pin to crankcase 0 Threaded p in to bracket of oil filte r

filter h o u sin g

h o u sin g

12

BA09.41-N-1005-01C

Inspect tensioning elements fo r signs of wear and replace if necessary.

0 9

Page 80

BA09.41 -N-1002-01C B A09.41 -N-1003-01C


@ Intake air preheater Number

BA09.30-N-1001-01A

Designation

Bolt o f bracket o f flam e starting system to charge air pipe

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/

Nm 20

925/926 20


0

Charge air plpe/intercooler

Number

D esignation

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

BA09.41-N-1001-01C

Charge air housing to threaded pin

Nm 40

40

BA09.41-N-1002-01C

Threaded pin to crankcase

Nm 40

40

BA09.41-N-1003-01C

Threaded pin to bracket o f o il filter housing

Nm 40

40

BA09.41-N-1004-01C

Connection fitting to charge air housing

Nm 25

-

BA09.41-N-1005-01C

Charge air Dipe to charge air housing

Nm -

25

Charge air hose to charge air housing/

Nm 7.5

7.5

BA09.41-N-1006-01C


Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h icle m od . des. 9 5 0 -9 54 , F2

85

AR13.22-W-1202B

17.1.96

Removing and installing poly V-belt

ENGINE 541.920 /9 2 1 /922 /923 /924 /92S /926 /927, 542.920/9 2 1 /922 /923 /92S /926 Running diagram o f p o ly V-belt A

Engine w ith o u t refrigerant compressor

B

Engine w ith refrigerant compressor

1 2

Vibration dam per Generator b elt p ulley

3 4

Coolant pum p b e lt pulley Tensioning device w ith tensioning

5

pulley Refrigerant compressor/hydraulic pum p b elt p ulley

6 7 8

Poly V-belt

19Tommy bar US 1/2’ extension (approx. 90mm)

w i 3 ??.ann9.nA


Safety note for springs o r sprung bodies included for

Page 86

Step 3 m odified

first tim e Removal/installation sequence o f poly V-belt m odified

El

Removing

/ h Danger!

Risk o f injury from bruises and jamming when tiltin g cap

1

Tilt cab

®

N otes re tiltin g cab

Steps 6 and 7 m odified

Page 60

No person should be in the tilting area of th e cab w hen it is being tilted. Always tilt cab as fa r as th e end position and secure w ith a safety prop.

M o d e ls 950, 952, 953, 954

Page 60 2

A

Remove noise encapsulation at side and bottom Danger!

Risk o f injury from fingers being pinched or jammed when w orking on springs or sprung bodies which are tensioned

3

Swing tensioning pulley up

Use only approved tensioning devices;

Page 87

ad d ition ally shield o ff hazardous area, if necessary. inspect special tools fo r damage and proper operation (visual inspection). W ear protective gloves.

fTI insert t o m m y h ar (7) w ith 117” extension (8) into the tensioning device (4)

4

86

Take poly V-belt

(6)o ff the tensioning

© Do not kink or damage poly V-belt

pulley (4), b elt pulleys (2,3,5) and vibration clamper (1) and remove through

w hen removing; rotate fan during this step.

the gap between the radiator shroud and the fan casing

inspect co nd ition o f poiy V-beit, if necessary J,

AP13.22-W-1351A


replace poly V-belt. 5

Swing tensioning pulley back

6

Inspect vibration damper (1), b elt pulleys of If damage or w ear exists i generator (2), o f coolant pum p (3), tensioning device w ith tensioning pulley (4) fo r signs o f damage and fo r concentricity. Replace vibration damper (1).

AR03.30-W-1600B

Replace belt pulleys o f generator (2).

AR15.40-W-5032B

Replace belt pulleys o f coolant pump (3).

AR20.10-W-1271B

Replace tensioning device w ith tensioning pulley (4).

Page 88

installing 7

Fit poly V-belt (6) onto all b elt pulleys (2,3, 5) and vibration damper (1), w ith the exception of tensioning pulley (4)

8

E

Push poly V-belt through the gap

between radiator shroud and fan casing; rotate fan fo r this step.

Use tommy bar (7) and 1/2" extension (8) to swivel tensioning pulley (4) up and hold

9

Fit poly V-belt (6) onto the tensioning pulley (4) and swing tensioning pulley (4) back again. Take o ff tom m y bar (7) w ith

E l Check that poly V-belt (6) is correctly fitted on the belt pulleys (2,3, 5).

extension (8) 10

Install noise encapsulation at side and bottom

A

Dangerl


No person should be in the tiltin g area of the cab when it is being tilted. Always tilt

Page 60

cab as far as th e end position and secure w ith a safety prop. 11

Tilt back cab In direction of travel

AS00.0O-Z-0QO1-O1A

Risk o f injury fro m fin g e rs b e in g pinched or O n ly use ap p ro ved clam p ing devices;

jammed w hen working on springs or sprung bodies which are tensioned

A

D a n ge rl

provide additional shielding for danger area if appropriate. Check special tools fo r damage and m alfunction (visual check); w e ar

protective gloves. Risk o f fingers etc. being jammed or crushed w hen w o rk in g on p arts w hich o re u n d e r tension. W hen releasing or removing parts which are under great tension, the use o f non-approved clamping devices may result in severe injury.

Spring clamps O n n o a ccount use an im pact w ren ch fo r te n sio n in g a n d releasing

operations. Checking clamping devices • The pressing screw must move easily and be undamaged. a

Instructions/precautions O nly use approved clam ping devices for repair w ork on springs,

•

C la m p ing plates m ust n o t be w arped.

Ensure th at the right clamping plates are used w ith the right springs.

sprung bodies, spring actuators and other parts under tension. [ D The coll diameter o f the springs must correspond to the groove in the clamping plate. W ear protective gloves fo r all w ork operations.

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50-954, F2

87

AR13.25-W-3200B

17.1.96

Rem oving and installing p o ly V-belt tensioning device

ENGINE 541.920/921 /922 /9 2 3 19241925/9251927. 542.920/921 /922 /923 Z925/926

1

End cover

2 3

Hexagon socket screw Tensioning device w ith tensioning pulley

4 5 6

B olt Poly V-belt Carrier

W13.2S-0002-06

M o d ifiction notes 6.2.97

Tightening torq ue o f poly V-belt tensioning device to carrier m od ified

Step 2

P a g e 88

E l ES


1

Slacken poly V-belt (5) and take it o ff the tensioning pulley (3)

2

Take o ff end cover (1) and remove hexagon S 3 Poly V -b elt tensioning device to carrier

Page 86

H I Slacken tensioning device.

BA13.25-N-1001-01D

sucket screw (2)

3

Unscrew bolt (4) at tensioning elem ent of

S 3 Tensioning elem ent to tensioning

th e tensioning device (3)

device

4

Take o ff tensioning device (3)

S 3 Belt pulley to tensioning device

5


BA13.25-N-1003-01D

BA13.25-N-1002-01D

S 3 Bett tensioning device Number

BA13.25-N-1001-01D

Designation

Poly V-belt tensioning device to carrier

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

M10

Nm 50

50

M18

Nm 105

105

B A 1 3 .2 S-N -1 0 0 2 -0 1 D

Belt pulle y to te n sio n in g device

Nm 50

50

BA13.25-N-1003-01D

Tensioning element to tensioning device

Nm 35

35


A R 1 3 .3 0 -W - 5 5 1 1A

D is a s s e m b lin g a n d a s s e m b lin g c o m p r e s s o r

7.1 1 .9 6

ENGINE 541.920 /921 /922 /923 /924 /925 /926/927. 542.920 /921 /922 /923 /925 /926

1

Intake pipe

2

Intake m anifold

3 a

Bolt

Resonance tank with hoses

18 19 20 21

5

Bracket

22

6

Bolt

7 8

Bolt

Cover

22.3 Deliveiy valve discs

9

Gasket

22.4 Suction valve disc 23 Compressed a ir pipe

Gasket Cylinder lin er Coolant pipe

Coolant pipe

Cylinder head w ith valve interm ediate p late 22.1 Bolt 22.2 Gasket

10

Crankshaft

11 12 13 14

Conrod Piston Cirdip Piston p in

26 27

Bracket Bolts Bearing bush Bearing flange

IS

Piston ring - groove III (top beveled o il co ntro l ring w ith co il spring)

28 29

O-ring Bearing flange in tim ing case

16 17

Piston ring - groove II (taper-faced ho o k scraper ring)

30 31

Drive gear Bolt

Piston ring - groove 1(taper-faced ho o k scraper ring w ith molybdenum coating)

24

25

Additional Information Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le m od . des. 9 50 -9 54 , F2

89

12 13 14

Piston Circlip Piston p in

18 19 29 30 32

Gasket Cylinder liner Bearing flange in tim ing case Drive gear I S Piston rin g tensioning pliers

E H IE


/ ts Danger!

Risk o f Injury from bruises and jamming w hen tiltin g cap

33 34

S S

B locking device Ring wrench

35 36 37

S

D ia l gage

S S

M easuring bridge Cranking device

A

Pistons setback

No person should be in the tiltin g area o f the cab when it is being tilted. Alw ays tilt

Page 60

cab as far as the end position and secure w ith a safety prop.

1

Tilt cab

®


2

Detach intake pipe (1)

3.1

Remove resonance tank (4)

Page 60

M odel 950,952,953,954

On engine 541.920 - 927

0

Cover of compressor opening on side of

BA01.60-N-1003-01B

tim ing case 0

BA13.30-N-1010-01B

Resonance ta n k to bracket

3.2

Remove resonance tank

On engine 542.920 - 923/925/926

4.1

Remove intake m an ifold (2) at

On engine 541.920 - 927

interm ediate piece 0

A ir intake m an ifold to bracket

BA09.20-N-1001-02C


A

Dangerl


Do no t open the cooling system unless the

scalding from ho t coolant w hich splashes

coolan t tem perature is below 90 °C. Open

out. Risk o f poisoning from sw allow ing

cap slow ly and allow the pressure to

co olant

release. D o n o t p o u r co ola nt In to

Page 96

containers fo r drinks. W ear protective gloves, protective clothes, and eye protection. 5

Drain coolant

@

Notes re coolant

A ll engines

6

Detach coolant pipe (20,21) at compressor cylinder head (22)

[2 Installation: replace seals.

Collect coolant.

AP20.00-W-2080A

Page 96

@ C oolant pipe to compressor 7

Detach compressed air pipe (23) at compressor cylinder head (22)

[2 Installation: tighten compressed air

8

Inspect compressed air pipe (23) between

@ If coking present J

BA13.30-N-1001 -01B

pipe and inspect fo r leaks.

compressor, compressed air drier w ith Integrated pressure regulator and fourcircuit protection valve fo r coking Replace compressed air pipe, pressure regulator or four-circuit protection valve. 9

Detach compressor cylinder head (22)

[2 Installation: replace suction valve disc (22.4) and gasket (18). Pay attention to installation position and roll pins in valve interm ediate plate. @ Cylinder head and cylinder liner to tim ing case

10

Disassemble compressor cylinder head (22) and assemble

BA13.30-N-1005-01B

Page 97

@ @ 0 @

Screw plug (M 2 6 x 1.5)

BA13.30-N-1003-01 B

Screw plug (M 1 4 X 1.5)

BA13.30-N-1004-01 B

Connection (M26 X 1.5)

BA13.30-N-1006-01B

Valve Intermediate plate to compressor cylinder head

BA13.30-N-1007-01B

@

BA13.30-N-1008-01B

Pressure disc valves to valve

interm ediate plate

11

Remove cylinder liner (19)

® Connection (M 36 X2) ED Installation: inspect cylinder liner and

BA13.30-N-1011-01B

piston marking.

BE13.30-N-1003-01B

BE13.30-N-1002-01B

If th e existing cylinder liner is installed, turn cylinder liner through 90°. Use piston ring pliers (32) to compress piston rings (15 to 17) and install cylinder liner. Remove piston ring pliers (32). Cylinder liner height from tim ing case

m

BE13.30-N-1010-01B 541 589 00 37 00

Measure piston setback to contact surface

Page 99

o f cylinder liner

CD If the dim ension fo r piston setback (A)

BE13.30-N-1005-01B

is not achieved, inspect conrod, crankshaft and gasket between tim ing case and cylinder liner.

E n g in es O M 501, O M 502 (m od. des. 5 41.9,542.9), A C T R O S - V e h ic le m od. des. 9 5 0 -9 54 , F2


®

BA13.30-N-1005-01B

Cylinder head and cylinder liner to

tim ing case

SI

12

Take o ff gaske t (18)

13

Cover over opening at crankcase

14

Remove bottom noise encapsulation

15

Attach cranking device (37) fo r engine to

001 589 53 2100

m

541 589 01 2100

m

407 589 00 63 00

O D In sta lla tio n : replace gasket.

m

407 5890063 00

tim ing case

@

Cover o f TDC inspection hole to tim ing

BA01.60-N-1001-01B

case

16

m DO U n til piston pin (14) is accessible.

407 589 00 63 00

SI E Installation: oil piston pin.

541 580 0 0 37 00

o ut piston pin (14) Remove piston (12)


BE13.30-N-1002-01B

Pisto n o u te r 0

BEI 3.3 0 -N -1 0 0 3-01 B

Rotate engine w ith the cranking device (37)

17

18

Use pliers to rem ove circlip (13) a n d pull

O ffset piston ring gaps in turn by 120° and oil piston. 19

R em ove p isto n rin g s (15 to 17)

[2 Inspect p isto n rin g g a p clearance;

if

Page 100

specification n o t achieved, replace piston rings.

20

Remove tim ing case cover

21

Remove fuel/pow er steering pum p unit

22

Remove cover (8) on side o f tim ing case

Piston ring gap clearance

BE13.30-N-1004-01B

IS

000 589 37 37 00

Feeler gage

WHS8.30-Z-1008-12A AR01.40-W-8000A AR46.30-W-0400A

CD Installation: replace gasket (9). @ Cover o f compressor opening on side o f

BA01.60-N-1003-01B

tim in g case 23

24

Rotate engine w ith the cranking device (36)

SI

407 589 00 63 00

□D U n til compressor piston is at TDC.

Page 102

Remove crankshaft (10), conrod (11) and outer bearing flange (27) m

442 589 0003 00

m

442 589 09 63 00

CD Installation: install crankshaft.

Page 103

Piston stroke

BE13.30-N-1001-01B

Crankshaft conrod bearing journal 0

BE13.30-N-1006-01B

C ra n k sh a ft b e a rin g axial play

B E13.30 N 1007 01B

@ Drive gear to compressor w ith special

BA13.30-N-1002-01B

to o l EE3 P o w e r ste e rin g pum p/fuel p u m p to

BA46.30-N -1001-01C

tim in g case

SI

92

442 589 0003 00


25

m

001 589 53 21 00

s

363 589 02 21 00

IS

442 589 0 9 63 00

Inspect bearing bush (26) in outer bearing

Bearing bush inner 0

BE13.30-N-1008-01B

flan g e (27)

H I If w orn J, replace b ea rin g bush

26

Inspect bearing flange (29) in tim in g case

P a g e 10 5

m

730 589 03 15 00

Bearing bush inner 0 ED If w o rn J

BE13.30-N-1008-01B

replace bearing flange

27


28


Page 105

m

730 58903 15 00

sa

000 589 29 33 00

s

000 589 34 33 00

AP20.00-W-2080A

Test data o f compressor Number

Designation

BE13.30-N-1001-01B

Piston stroke

BE13.30-N-1002-01B


BE13.30-N-1003-01B

BE 13.30-N-1004*018

Piston outer 0

Piston ring gap

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

Single-cylinder compressor

mm 48

48

Two-cylinder compressor

mm 38

38

M arking B

mm 100.000-100.010

1Û0.000-100.010

M arking C

mm 100.010-100.020

100.010-100.020

M arking D

mm 100.020-100.030

100.020-100.030

M arking B

mm 99.925-99.935

99.925-99.935

M arking C

mm 99.935-99.945

99.935-99.945

M a r k in g D

mm 9 9 .945-99.955

99.945-99.955

Groove I , D , III

mm 0.20-0.40

0.20-0.40

mm 0.6-1.4

0.6-1 .4

mm 43.959-43.975

43.959-43.975

clearance B E13 .3 0 -N -1 0 0 5 -0 1 B

Piston setback to top

edge o f cylinder liner BE13.30-N-1006-01B


BE13.30-N-1007-01B

Crankshaft bearing play axial

mm 0.050-0.150

0.050-0.150

BE 13.30-N-1008-01B

Bearing bush inner 0

mm 37.980-38.035

37.980-38.035

mm 8 8 .8-89.0

88.8-89.0

mm 83.8-84.0

83.8-84.0

B E 1 3 .3 0 -N -1 0 1 0 -0 1 B

C ylinder liner h eigh t

S in gle -cylind e r

from tim ing case

compressor Two-cylinder compressor

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h ic le m od . des. 9 50-954, F2

93

@ Timing case

Number

BA01.60-N-1001-01B

Designation

Cover o f TDC inspection hole to tim ing

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

Nm 25

25

Nm 50

50

case BA01.60-N-1003-01B

Cover o f compressor opening on side o f t im in g case

@ Intake m anifold, intake m anifold preheater Number

BA09.20-N-1001-02C

Designation


Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925926

Nm 50

50

@ Compressor (compressed air system) Number

Designation

8 A13.30-N-1001*01 B

C oolant pipe to compressor

BA13.30-N-1002-01B

BA13.30-N-1003-01B

B A13.30-N-1004-01B

Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 30

Engine 542.920/ 921/922/923/ 925/926 30

Drive gear to compressor

(direct)

Nm 360

360

w ith special tool

(indirect)

Nm 270

270

Screw plug to compressor cylinder head

M 2 6 X 1 .5

Nm 80

80

Connection fo r coolant p ipe to

M 1 4 X 1 .5

Nm 30

30

Nm 40

40

Nm 80

80

compressor cylinder head BA13.30-N-100S-01B

Cylinder head and cylinder lin er to tim ing case

BA13.30-N-1006-01B

Connection fo r compressed a ir pipe to compressor cylinder head

BA13.30-N-1007-01B

Valve interm ediate plate to compressor cylinder head

Nm 12

12

BA13.30-N-1008-018

Delivery disc valve to valve

Nm 12

12

Nm 25

25

Nm 80

80

M 2 6 X 1.5

interm ediate plate BAI 3.30-N-1U 10-010

Resonance tank to bracket

BA13.30-N-1011-01B

Connection fo r intake air pipe to

M 3 6 X 1 .5

compressor cylinder head

ËÜ3 Pow er steering pum p Number

Designation

Steering 765.889 w ith engine 541, 542

BA46.30-N-1001-01C

Pow er steering pum p/fuel pum p to tim ing case

Nm

60


r

D ia l g a g e

M e a s u rin g b rid g e

D ia l g a g e h o ld e r

In tern al e xtractor

C ra n k in g device

B lo c k in g d e vice

C o m m e r c ia lly a v a ila b le t o o ls (see W o r k s h o p E q u ip m e n t M a n u a l)

Number

Designation

M ake (e.g.)

O rder num ber

WH58.30-Z-1008-12A

Feeler gage

Stiefelmayer D-73734 Esslingen

59

Additional Information En g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le m od. des. 9 5 0 -9 54 , F2

95

AS20.00-Z-0001-01A

Risk o f injury to skin and eyes from scalding from hot coolant w hich splashes out..Risk o f poisoning fro m sw allow ing coolant.

Do not open th e co oling system unless ^

Danger!

th e co olan t tem perature is b elo w 90 °C. Open cap slow ly and a llo w the pressure to release. Do n o t pour co olan t in to containers fo r drinks. W ear protective gloves, protective clothes, and eye protection. Protective measures/rules o f conduct

Possible dangers

-

A llo w cooling system to cool dow n to a co olan t tem perature o f less th an 90 °C.

The cooling system is pressurized w hen th e engine is warm. Risk o f scalding fro m h o t coolant w hich splashes out if th e cooling system is opened suddenly.

-

Risk o f poisoning

-

Open co olan t system cap slowly; open a conventional type of co olan t system cap to the firs t d eten t and o pen a screw-type coolant system cap about 1/2 turn, and a llo w th e pressure to release. W ear protective gloves, protective clothes, and eye protection.

If coolant is sw allowed, the person affected is likely to show signs o f poisoning such as headaches, giddiness and stomach aches, paralysis o f th e respiratory system, unconsciousness, nausea, and convulsions.

-

Do n o t p our coolant into containers fo r drinks.

Risk o f injury

First aid measures •

Pour large q ua ntitie s of cold w ater over th e affected area of skin and cover over w ith sterile bandages.

AH20.00-N-2080-01A

e

Have person affected drink plenty o f w ater to w hich medicinal carbon has been added.

•

Consult a doctor if th e person affected has severe burns or has sw allow ed considerable quantities.


C oolan t com position Passenger car and commercial vehicle engine (normal case): 50 % by volum e w ater and

® A concentration o f anticorrosion/antifreeze agent higher than 55 % by volum e should not be used as th e m axim um antifreeze

50 % by volum e anticorrosion/antifreeze agent. See M B Specifications fo r Service Products fo r d iffe rin g coolant com position fo r commercial vehicle engines.

p ro te ctio n is t h u s reached. A n e ve n h ig h e r c o n c e n tra tio n a g a in

reduces th e antifre eze protection and impairs heat dissipation. W ater

Purposes o f anticorrosion/antifreeze agent e Corrosion and cavitation protectio n fo r all com ponents in the cooling system • a

A n tifree ze protection Increasing boiling' p oin t so th a t th e coolant does not evaporate so rapidly. Ejection o f coolant is avoided at high coolant

U se w a te r w h ic h is clean a n d n o t t o o hard. D rin k in g w a te r

frequently, b ut n o t always, satisfies the requirem ents. The contents o f dissolved substances in the w ater can be of im portance fo r th e occurrence o f corrosion. In cases o f doubt, an a lyze t h e w ater. S e e M B S p ecifica tio ns fo r S e rv ice P rod ucts fo r

fresh w a te r regulations.

temperatures. O peration o f m o nito ring o f coolant A n tifre e z e p rotection

Inspect c o o la n t fo r resistance t o lo w te m p e ra tu re s b e fo re the start

50 % by volum e o f anticorrosion/antifreeze concentration offers antifreeze protection dow n to approx. -37 °C. A higher concentration is only practical at even low er am bient

o f th e cold season o f the year. In countries w ith h ig h am bient tem peratures, inspect the

temperatures.

anticorrosion/antifreeze concentration once a year. The corrosion p rotection in the coolant is reduced during

55 % by volum e o f anticorrosion/antifreeze concentration offers antifreeze protection dow n to approx. -45 °C.

The maxim um perm issible period o f use o f the co olan t is fo r

operation. Such coolants have a severely corrosive effect. passenger car and commercial vehicle engines (norm al case) 3 years. See M B Specifications fo r Service Products fo r th e period o f use fo r d iffe rin g co olan t com position fo r commercial vehicle engines.


® Before pouring fresh coolant into the system, flush the used

Disposing o f coolants Observe legal regulations and local wastewater regulations.

coolant o u t o f the cooling system. Clean cooling system if severe

For workshops located in the Federal Republic o f Germany see: " Umweltschutz-Handbuch fü r Kfz-Reparaturbetriebe "

soiling or oil contam ination exist.

(Environmental protection m anual fo r vehicle repair workshops) Publisher: Verband der Autom obilindustrie e.V. (VDA) D-60625 Frankfurt am Main, Westendstraße 61

A R 13.30-W-5 511-04A

0

Disassembling and assembling compressor cylinder head


Number

Designation

Engine 541.920/ 921/922/923/ 924/925/926/927

Engine 542.920/ 921/922/923/ 925/926

BA13.30-N-1003-01B

Screw plug to compressor cylinder head

M 2 6 X 1 .5

Nm 80

80

BA13.30-N-1004-01B

Connection fo r coolant pipe to compressor cylinder head

M 1 4 X 1 .5

Nm 30

30

BA13.30-N-1006-01B

Connection fo r compressed air pipe

M 2 6 X 1 .5

Nm 80

80

to compressor cylinder head BA13.30-N-1007-01B

Valve interm ediate plate to compressor cylinder head

Nm 12

12

BA13.30-N-1008-01B

Pressure disc valve to valve interm ediate plate

Nm 12

12

BA13.30-N-1011-01B

Connection fo r air intake pipe to compressor cylinder head

Nm 80

80

1

M 3 6X 1 .5

Unscrew connections (1,2,3) and screw plugs (4,5) at cylinder head (6) and take off seals.

Additional Information E n gin es O M 501, O M 502 (m o d. des. 541.9, 542.9), ACTRO S - V e h icle m od . des. 9 50 -9 54 , F2

97

2

Take o ff suction valve disc (7) at cylinder head (6).

3

Unscrew b olt (8) and take o ff valve interm ediate plate (9) and gasket (10).

4

Unscrew nuts (11) and take o ff valve plates (12), delivery valve disc (13) at the valve

W13.30-0017-02

interm ediate p late (9). 5

Fit on valve plates (12) and new delivery valve discs (13).

m

12 13

V alve plates (12) and delivery valve discs (13) should lock in position at the anti-twist lock o f the stud bolts. 6

Tighten nuts (11).

DO

W13.30-0018-01

Pay attention to tig h ten ing torque. 7

Fit on valve interm ediate p late (9) and new gasket (10). Tighten b olt (8).

m Pay attention to installation position relative to roll pins (14). Thicker end should point tow ard cylinder liner. Pay atte ntio n to tightening torque. 8

Fit on new suction valve disc (7) at cylinder head (6).

® Pay attention to installation position fo r suction valve disc.

W 1 3.30-0019-02


9

Tighten connections (1,2,3), screw plugs (4, 5) and new seals at cylinder head (6).

m Pay attention to tightening torques.

W13.30-0020-01

AR13.30-W-5511-06A

M easuring compressor piston setback

Test d a ta o f c o m p re sso r

Num ber

Designation

8E13.30-N-1005-01B

Piston setback relative to to p edge o f cylinder liner

Engine 541.920/ 921/922/923/ 924/925/926/927

0

925/926 0.6-1.4

Com pressor (compressed air system)

Num ber

Designation

BA13.30-N-1005-01B

Cylinder head and cylinder liner to tim ing case

~\

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

Nm 40

40

r

541 589 01 21 00 Measuring bridge

1

mm 0.6-1.4

Engine 542.920/ 921/922/923/

407 589 00 63 00 Cranking device

Use suitable bolts (2) to bolt cylinder lin er (1) tig h t at tim ing case.

m Pay a tte n tio n to tig h te n in g torque.

Gasket between cylinder liner (1) and tim in g case should be installed. Measure piston setback between piston crown and to p edge o f cylinder liner w ithout the gasket fitted.

W13.30-0023-01

E n gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C TR O S - V e h icle m od. des. 9 50 -9 54 , F2


2

Rotate engine a t flywheel w ith the 121 cranking device.

m Position piston (3) to approx. 1 cm before TDC. 3 4

A ttach IS] dial gage (4) w ith a preload in the ISI measuring bridge (5). M o u n t @3 measuring bridge (5) onto the contact surface o f the cylinder lin er and set dial gage scale to “0". Pay attention to m illim eter pointer.

5

M o v e H I m e a s u r in g b r id g e (5) f r o m t h e c o n t a c t s u r fa c e o f t h e c y lin d e r lin e r (1) t o a b o v e t h e c y lin d e r b o re .

m P u ll b a c k t r a c e r p in o n I S d ia l g a g e (4) w h e n m o v in g .

The measurement has to be carried out in the direction o f the piston pin in order to elim inate the piston rock at the piston.

6

Rotate engine at flyw heel w ith the

EZ1cranking device.

ffl Rotate crankshaft (6) until the piston (3) is positioned at TDC. 7

Read o ff 2 1 dial gage (4). The reading o btained is the piston setback dim ension (A). Pay attention to m illim eter pointer. 0 ] If the dimension fo r the piston setback (A) is not achieved, inspect conrod, crankshaft and gasket between tim ing case and cylinder liner. W 13.30-002 5-02

AR13.30-W-5511-01A

Removing and installing compressor piston rings

Test data fo r compressor Number

BE13.30-N-1004-01B

Designation

Piston ring gap

Engine 541.920/ 921/922/923/ 924/925/926/927 Groove I, II, nt

mm 0.20-0.40

Engine 542.920/ 921/922/923/ 925/926 0.20-0.40

clearance

Comm ercially available tools (see W orkshop Equipm ent Manual) Number

Designation

M ake (e.g.)

Order num ber

WH58.30-Z-1008-12A

Feeler gage

Stiefelmayer D-73734 Csslingen

59

100


1

Use the

ISj pliers (4) t o

rem ove p isto n ring s (1, 2, 3) at piston (5) in th e o rd e r fro m to p

to bottom.

2

Measure piston ring gap clearance o f the piston rings (1,2, 3).

m Insert piston rings (1,2,3) in the unw orn area (above to p reversal p o in t o f 1st piston ring) of the cylinder liner (6) and measure gap clearance w ith 10 feeler gage (7).

3

The coil spring (3.1) has to be removed fo r this purpose at the piston ring (3). A fter the measurement, install coil spring (3.1) in the piston ring (3).

m Coil spring gap should be offset 180° to the piston ring gap.

4

Use (S3 pliers (4) to install piston rings (1,2 ,3 ) at the piston (5) in the order from bottom to top. m Before reinstalling and after installing th e piston rings (1,2,3), inspect them visually to determ ine if there is any spailing o f the coating; replace piston rings if necessary. Pay attention to installation position. M arking “TOP" should point to w ard piston crown. Pistonring (1) o f groove I is a taper-faced hook scraper ring w ith molybdenum coating.

Additional Information Engines O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V e h icle m od. des. 9 5 0 -9 5 4 , F2

101

AR13.30-W-5511-02A

V

442 589 00 03 00

Removing compressor crankshaft

J

Ring wrench

1

Fit [Si blocking device (1) over the conrod (2) onto the crankshaft and b olt tight.

m Crankshaft journal should be facing up.

W13.30-0008-01

2

Use I S ring wrench (5) to unscrew b olt (3) at drive gear (4) and take o ut drive gear (4).

3

Detach

4

Press crankshaft (6) together w ith conrod (2) o ut o f the tim ing case and take o ff the outer bearing flange (7).

5

Lift crankshaft (6) and conrod (2) up and out.

6

Take o ff conrod (2) at the crankshaft (6).

IS blocking device (1).

W13.30-0009-01


A R 13.30-W-5 511-03A

Installing compressor crankshaft

Test data fo r compressor D esignation

Num ber

BE13.30-N-1001-01B

Single-cylinder

Piston stroke

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

mm 48

48

mm 38

38

mm 43.959-43.975

43.959-43.975

mm 0.050-0.150

0.050-0.150

compressor Two-cylinder compressor BE13.30-N-1006-01B


BE13.30-N-1007-01B

0

Crankshaft bearing play axial


Num ber

Designation

BA13.30-N-1002-01B

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

Drive gear to compressor

(direct)

Nm 360

360

w ith special tool

(indirect)

Nm 270

270

0 Pow er steering pum p Num ber

Designation

Steering 765.889 w ith engine 541, 542

BA46.30-N-1001-01C

Pow er steering pum p/fuel pum p

Nm

60

to tim in g case

■\

442 589 00 03 00 Ring wrench

1

Dial gage

Dial gage holder

Blocking device

Install conrod (1) over the crankshaft (2).

ffl Oil crankshaft (2) w ith engine oil at the bearing surfaces. 2

Insert crankshaft (2) w ith conrod (1) from above into th e tim ing case (inner bearing flange).

E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le m od. des. 9 50-954, F2


3

Replace O-ring (3) at outer bearing flange (4).

4

Oil bearing flange (4) at fit and O-ring (3).

5

Push crankshaft (2) into the inner bearing flange and position the outer bearing flange (4) at the tim ing case.

4

ffl O il drillings (arrows) in tim ing case and bearing flange (4) should be aligned.

W13.30-0012-01 €

D ra w in b e a rin g fla n g e (4) by evenly tig h te n in g th e b olts (5).

ffl Pay attention to tigh ten ing torque.

'IÄ I ®

»

,

\1 ,' W13.30-0013-01

7

Crankshaft has to be rotated sufficiently until the crankshaft journal w ith conrod (1) is facing up.

8

Fit IS) blocking device (6) over the conrod (1) onto the crankshaft (2) and bolt tight.

9

Fit on drive gear (7) w ith b o lt (8).

10

Tighten b olt (8) w ith I S ring wrench (9).

if®-131 W 13.30 0014 01

ffl Pay attention to tig h ten ing torque. Using the f f l ring wrench (9) results in a m odified tightening torque. Torque wrench and f f l ring wrench (9) should be positioned to each other in a line. 11

Detach f f l blocking device. W13.30-001S-01

12

Use f f l dial gage (10) and f f l dial gage holder (11) to inspect axial play o f crankshaft (2 ).

13

Remove bolts (5) again.

W13.30-0029-01

104


AR13.30-W-5511-05A

Removing and installing bearing bush in outer bearing flange

1

Use a suitable d rift to remove bearing bush from the bearing flange (2).

2

U se I S d r i f t (11 a n d in s e r t (1.11 t o in s t a ll b e a r in g b u s h H I f lu s h in t o t h e h e a r in g f la n g e

( 2).

CD Oil d rillin g (3.1) in b earin g b ush (3) an d in b earin g fla n g e (2) sh o u ld be aligned.

Pay attention to notch (3.2) in the bearing bush (3). Installation position in direction o f compressor crankshaft.

AR13.30-W-5511-07A

Removing, installing bearing flange fo r compressor

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9,542.9), A C TR O S - V e h ic le m od. des. 950 -9 54 , F2

105

1

Assemble S I countersupport (1) and

2

Use

SI internal extractor (2).

S] internal extractor (2) to pull o ut bearing flan g e (3).

m Use a suitable square tim ber to support S

countersupport (1) at tim ing case.

In stallin g:

3

Use

SI d rift (4) and SI insert (4.1) to press In bearing flan g e (3) flush.

m There should be an overlap o f bearing flange (3) to tim in g case.

y \ 4

Oil bearing flange (3) w ith engine oil.

A 1

----------------j § W13.30-0028-01


AR14.10-W-3915B

Removing and installing exhaust manifold

17.1.96

ENGINE 54 1.920 /922 /923 /924 /92S /926 /927 1 2

Exhaust m an ifo ld Exhaust pipe

3 4 5 6 7

Bolts Tensioning sleeves Gaskets N ut B olt

8 9

N ut Exhaust header

W14.10-0002-11

Rem oving, installing Replace all self-locking nuts and bolts

® A

D a n g e r!

R isk o f in jury fro m bruises a n d ja m m in g

N o p erson s h o u ld be in t h e tiltin g area o f

w hen tiltin g cap

th e cab w hen it is being tilted. Alw ays tilt

Page 4


Tilt cab

®


M odels 950,952,953, 954

2


CD A t side righ t or le ft and rear

Disconnect exhaust pipe (2) at exhaust

E 3 Exhaust pipe to exhaust m anifold

Page 4

3

BA14.10-N-1005-01C

m anifold (1) 4

Disconnect exhaust m anifold (1) at the

III Installation: clean sealing surfaces and

cylinder heads

replace gaskets (5). Pay a tte n tio n to installation position o f tensioning sleeve (4).

@ Exhaust m anifold to cylinder head 5

Remove exhaust pipe (2) a t exhaust header

BA14.10-N-1001-01C

ŒI Installation: clean sealing surfaces.

(9)

@ Exhaust pipe to exhaust header 6

BA14.10-N-1003-01C


EÜ3 Exhaust m anifold Num ber

Designation

Engine 541.920/ 921/922/923/ 924/925/926/927

BA14.10-N-1001-01C

Exhaust m anifold to cylinder head

Nm 50

BA14.10-N-1003-01C

Exhaust pipe to exhaust header

Nm

BA14.10-N-1005-01C

Exhaust pipe to exhaust m anifold

Nm 50

50

Additional Information En g in e s O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h ic le m od . des. 9 50-954, F2

3

AS60.80-Z-0001-01A

Injury hazard from pinching and crushing w hen cab Is tilted

W hen tiltin g ensure that no one is present in the tiltin g area o f the cab.

A

Danger!

Always t ilt cab to end position and secure w ith safety brace. Injury hazard A dam aged tiltin g mechanism or im proper handling o f th e tiltin g mechanism can lead to severe injuries w hen tiltin g th e cab.

W hen tiltin g cab: - Protect tiltin g area and particularly tiltin g device against

Rules o f behavior/protective measures

unauthorized access, e.g. by blocking o ff or w ith human

B efore tiltin g cab:

g u a rd .

-

Shut o ff engine. Apply parking brake.

-

Secure vehicle against rolling.

-

O n vehicles w ith m a n u a l transm ission m ove shift lever to

-

A ttach safety cable before tiltin g when so specified in the vehicle operating instructions. Never w ork under cab when partially tilted. Alw ays tilt cab to end position and secure w ith safety brace.

neutral position. On vehicles w ith autom atic transmission move selection lever to position “ N".

AH60.80-N-0003-01A

Notes on tiltin g the cab

Models 673,674,675,676, 677,678, 679,950,952,953,954,957,970,971, 972, 973, 974,975,976

Before tiltin g the cab • Sw itch o ff engine • A p p ly parking brake

e

The refrigerator box must be switched o ff before the cab is tilted.

•

e

The refrigerator box may only be switched on 10 minutes after tiltin g the cab back again.

e

Secure vehicle to stop it rolling aw ay Remove a ll loose objects (e.g. cans, bottles, to o ls, bags etc.)

e

from the cab On vehicles w ith m anual transm ission move sh ift lever to neutral position

e

M o d el 957: release steering column and open fro n t flap

On vehicles w ith a refrigerator box

□ 0 Also refer to the refrigerator box m anufacturer's O perating Instructions and the red inform ation plate on the refrigerator box.

The coupling pin must be inserted correctly. E

A lw ays tilt cab up to its final position.


AR 14.10-W-3915C

R em oving and installing exhaust m anifold

23.1.96

ENGINE 542.920/921 /922 /923 /92S/926

1 2 3 4 5

Exhaust manifold Gaskets Tensioning sleeves Bolts N ut

W14.10-0003-06

El US

Rem oving, installing Replace all self-locking nuts

A

Danger!

Risk o f Injury from bruises and jam m ing


w hen tiltin g cap

the cab w hen it is being tilted. Alw ays tilt

Page 4


T ilt cab N o te s re tiltin g cab

M o d e ls 950, 952, 9 5 3 ,9 5 4

Page 4 2


GOA t side right or left

3

D isc on n e ct exhau st m a n ifo ld (1) at

EE

In sta lla tion : clean sealing surfaces.

turbocharger 3 4

D isc on n e ct exhau st m anifold (1) at the

cylinder heads

EHFlange m anifold to turbocharger Œl In sta lla tion : clean sealing surfaces a n d

BA14.10-N-1006-01C

replace gaskets (2). Pay attention to installation position o f tensioning sleeves (3).

EH Exhaust m anifold to cylinder head 5

BA14.10-N-1001-01C


EE] fcxhaust manifold Num ber

D esignation

Engine 542.920/ 921/922/923/ 925/926

BA14.10-N-1001-01C

Exhaust m anifold to cylinder head

Nm 50

BA14.10-N-1006-01C

Flange m anifold to turbocharger

Nm 50

Additional Information Engines O M 501, O M 502 (m o d. des. 541.9, 542.9), A CTRO S - V e h icle m od. des. 9 50 -9 54 , F2

5

Rem oving and installing exhaust gas p len u m cham ber

AR14.10-W -3920A

8.10.96

ENGINE S41.920/921 /922 /923 /924 /925 /926/927

1

Exhaust pip«

2

Bolts

3

Exhaust plenum cham ber

4

B olt

5

Bolt

6 7

Exhaust pipe B olt

8 9

N ut Support

10

B olt

11

W asher

12

B olt

W14.10-0005-06

ESSI


@ Installation


1

Remove turbocharger

2


[E la t top, at rear, on left and right

3

Remove exhaust pipes (1,6)

CDInstallation: clean sealing surfaces 0 Exhaust pipe to exhaust plenum

AR09.40-W-6020B

BA14.10-N-1003-01C

chamber

4

Remove support (9)

@ Exhaust pipe to exhaust m anifold

BA14.10-N-1005-01C

0 0

Support to exhaust plenum chamber

BA14.10-N-1008-01C

Support/plenum chamber to tim ing

BA14.10-NI-1009-01C

case 5

Take o ff exhaust plenum chamber

0

Exhaust plenum chamber to tim in g case BA 14.10-N-1004-01C

(turbocharger carrier) 6



EH Exhaust m anifold Number

Engine 541.920/

Designation

921/922/923/ 924/925/926/927 BA14.10-N-1003-01C

BA14.10-N-1004-01C

Exhaust pipe to exhaust plenum chamber Exhaust plenum chamber to tim ing case (turbocharger carrier)

Nm 50

M16

Nm 150 Nm 100

BA14.10-N-1005-01C

Exhaust pipe to exhaust m anifold

Nm 50

BA14.10-N-1008-01C

Support to exhaust plenum chamber

Nm 40

Support/exhaust plenum chamber to

Nm 40

BA14.10-N-1009-01C

tim ing case

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9,542.9). ACTRO S - V e h icle m od . des. 9 5 0 -9 54 , F2

7

AR1A.10-W-3925A

18.10.96

Rem oving and installing tra nsverse exhaust pipe

ENGINE 542.920/921 /9 2 2 /9 2 3 /9 2 S /9 2 6 1 2 3 4

Transverse exha ust p ipe Nut N ut B olt

W14.10-0006-06

gum


®

In sta lla tio n

Replace all se lf-lo cking n uts an d b olts

A

Danger!

Risk o f injury from bruises and jam m ing


w hen tiltin g cap

the cab w hen it is being tilted. Always tilt

Page 4


Tilt cab

®


M odel 950,952,953,954

2


Q ] at side rig h t and at rear

3

Detach transverse exhaust pipe (1) at

0

engine brake flap connection

m anifold and flap connection HI Installation: clean sealing surfaces.

Detach transverse exhaust pipe (1) at

0 Flange m anifold to turbocharger HI Installation: clean sealing surfaces.

5

turbocharger

6 S

Page 4

Transverse exhaust pipe to flange

BA14.10-N-1007-01C

BA14.10-N-1006-01C

Install in the reverse order Exhaust m anifold

Num ber

Designation

Engine 5 4 2 .9 2 0 / 9 2 1 /9 2 2 /9 2 3 / 9 2 5 /9 2 6

BA14.10-N-1006-01 C

F la n ge m a n if o ld t o t u rb o ch a rge r

Nm 50

BA14.10-N-1007-01C


Nm 50

m an ifold and flap connection


8

AR14.15-W-581 OB

Repairing en g in e brake fla p connection

14.6.96

ENGINE 541.920/921 Z922/923/924/925/926/927,542.920/921 /922/923/925/926

1

Engine brake flap connection

14

2

Engine brake shaft Bearing bush

B all socket Ball stud

3 4

E n g in e b ra ke flap

15 16 17

5

Bolt

18

B olt

6 7 e

Bracket

19

Bolt

N ut Bush

A

A x ia l p la y o f e n g in e b ra ke shaft

9

Washers

B

Position o f adjusting lever stop w ith engine brake flap

10

B olt

11

Engine brake cylinder

12 13

N ut Circlip

N ut A d ju stin g lever

closed C

Position o f adjusting lever stop w ith engine brake flap opened

B

Disassembling

1


2

Remove engine brake cylinder (11)

3

Take o ff adjusting lever (17)

On engine 541.920 - 927

Page 12

O n e n g in e 542.920-923/925/926

Page 1 3

Release ball socket (14). M ark adjusting lever relative to notch in e n g in e b r a k e s h a f t (2).

4

Take o ff bracket (6)

5

Remove engine brake fla p (4)

6

Remove engine brake shaft (2) and bearing bush (3)

E3

A ssem bling

7

Install bearing bush (3) on bracket side

HI Use a suitable drift.

HI W ith projection (about 3 mm) to inner contact surface. Use a suitable drift.

E n gin es O M 501, O M 502 (m od. des. 5 41 .9,542.9), A C T R O S -V e h ic le m o d .d e s. 9 50 -9 54 , F2


9

1 3 Depth gage

WH58.30-Z-1012-12A

Coat bearing p oin t w ith hot lubricating

BR00.45-Z-1006-06A

paste. 8

Insert engine brake shaft (2) into engine brake flap connection (1)

9

Knock in second bearing bush (3)

Coat bearing p oin t w ith hot lubricating paste.

BR00.45-Z-1006-06A

0 0 Center engine brake shaft (2) to

th ro ttle valve diameter. Projection o f both bearing bushes to inner contact surface should be the same. Use a «riitahle drift. 10

Knock back bearing bushes (3) evenly on both sides until axial play (A) o f engine

BE14.15-N-1002-01A

U ] Use a suitable drift.

brake shaft (2) is achieved B

11

Install engine brake fla p (4)

Feeler gage

WH58.30-Z-1008-12A

E D Pay attention to installation position o f

hole In engine brake flap. B olt heads (5) should p oint tow ard engine w hen engine brake flap closed. Center engine brake flap in engine brake fla p connection (1). 0

12

Measure annular g ap at engine brake flap (4)

T hrottle valve to shaft

BA14.15-N-1003-01A

Engine brake flap must no t be touching engine brake flap connection (1) inclosed E

position (B). E l Feeler gage

WH58.30-Z-1008-12A BA14.15-N-1001-01A

13

Fit on bracket (6)

0 Engine brake bracket to flap connection

14

Install adjusting lever (17)

E Fit adjusting lever onto the splines o f the engine brake shaft (2); pay attention to m a r k in g u ri a d ju s t in g le v e r r e la t iv e to

notch in engine brake shaft (2). Bolt heads (5) should point tow ard engine w hen engine brake flap (4) closed. Adjusting lever stop should be touching bracket (6) w hen engine brake flap (4) fu lly opened and closed.

15

0

A djusting lever to engine brake shaft

BA14.15-N-1002-01A

0

Ball stud to adjusting lever

BA14.15-N-1007-01A

Attach engine brake cylinder (11) to

0

Bearing pin o f engine brake cylinder to

B A14.15-N-1004-01A

b r a c k e t (6)

b ra c k e t [ D Replace nut (7).

16

Set preload o f engine brake cylinder (11) at S Engine brake flap (4) in opened ball socket (14) position (C) 0

Locknut to engine brake cylinder piston

BE14.15-N-1001-01A

BA14.15-N-1005-01A

rod BR00.45-Z-1006-06A

17

Clip in ball socket (14) at ball stud (15) and secure

E Co at ball stud w ith hot lubricating paste.

18

Install engine brake fla p connection (1)

On engine 541.920 - 927

Page 12

On engine 542.920 - 923/925/926

Page 13


Test data o f engine brake Num ber

Designation

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

BE14.15-N-1001-01A

Engine brake cylinder preload

mm 2.5-3.S

2.5-3.5

BE14.15-N-1002-01A

Engine brake shaft axial play

mm 0.4-0.7

0.4-0.7

0

Engine brake

Number

Designation

B A14.15-N-1001-01A

Bracket o f engine brake to fla p connection

Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 35

Engine 542.920/ 921/922/923/ 925/926 35

BA14.15-N-1002-01A

Lever on th rottle valve shaft

Nm 15

15

BA14.15-N-1003-01A

Throttle valve to shaft

Nm 30

30

BA14.15-N-1004-01A

Bearing pin o f engine brake cylinder to

Nm 25

25

bracket BA14.15-N-1005-01A

Locknut to engine brake cylinder piston rod

Nm 20

20

BA14.15-N-1007-01A

Ball stud o f engine brake to lever

Nm 50

50

Commercially available tools (see W orkshop Equipm ent M anual) Number

Designation

M ake (e.g.)

Order number

WH58.30-Z-1008-12A

Feeler gage

Stiefelmayer

59

D-73734 Esslingen WH58.30-Z-1012-12A

Depth gage, range 0 - 200 mm

Stiefelmayer

040 202

D-73734 Esslingen Repair products Num ber

Designation

O rder num ber

BR00.45-Z-1006-06A

Hot lubricating paste

000 989 76 51

Additional Information Engines O M 501, O M 502 (m od. des. 541.9,542.9), A C TR O S - V e h icle m od. des. 9 50 -9 54 , F2

11

AR14.15-W-6302B

R e m o v in g , in s t a llin g e n g in e b r a k e f l a p c o n n e c t io n

14.6.96

ENGINE 541.920/921 Z 92 2 /9 2 3 /9 2 4 /9 2 5 /9 2 6 /9 2 7 1

E n g in e b rake flap co nn ection

2

N ut

3

Exhaust pipe

4

Compressed a ir p ip e

W14.15-0005-06

mi mi


® Installation


^



w hen tiltin g cap

the cab w hen it is being tilted. Alw ays tilt cab as fa r as the end position and secure w ith a safety prop.

Danger!

1

Tilt cab

®


M od el 950.952.953.954

2


| j] o n side left and at rear

3

Detach compressed air pipe (4) at engine

Page 4

Page 4

brake cylinder 4

Detaching exhaust pipe (3) at engine brake

[XIInstallation: clean sealing surfaces.

flap connection (1) 5

Detach engine brake fla p co nn ection (1) at turbocharger

S 3 E x h a u st p ip e fla p co nn ection to

B A 1 4 .1 0 -N -1 0 0 2-01C

turbocharger [ I ] Installation: clean sealing surfaces.

6


@ Exhaust m anifold Number

Designation

Engine 541.920/ 921/922/923/ 924/925/926/927

BA14.10-N-1002-01C

Exhaust pipe fla p connection to

Nm 50

turbocharger


A R 1 4.15-W-6302C

Rem oving, installing en g in e brake fla p connection

18.10.96

ENGINE 542.920 /921 /922 /923/92S/926 1 2 3 4 5 6

Nut Engine brake flap connection Bolt Exhaust pipe Nuts Compressed a ir p ipe

W 1 4 15-0004.06

mini


®

I n s t a lla t io n

R e p la c e a ll s e lf - lo c k in g n u ts a n d b o lts

A

Danger)


No person should be in the tiltin g area of the cab w hen it is being tilted. Always tilt

Page 4


Tilt cab

Page 4

®


M od el 950,952,953,954

2


E

on side left and at rear

3

Detach compressed air pipe (6) at engine brake cylinder

E

Installation: clean sealing surfaces.

4

Detach exhaust pipe (4) at engine brake flap connection (2)

5

Detach transverse exhaust pipe at engine brake flap connection (2)

6

Detach engine brake flap connection (2) at turbocharger

7


0

BA14.10-N-1007-01C

E 0 Flange m anifold to turbocharger E Installation: clean sealing surfaces.

BA14.10-N-1006-01C

Transverse exhaust pipe to flange m anifold and fla p connection Installation: clean sealing surfaces.

Additional Information E n gin es 0 M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50 -9 54 , F2

13

@ Exhaust manifold

Number

Designation

Engine 542.920/ 921/922/923/ 925/926

BA14.10-N-1006-01C

Flange m anifold to turbocharger

Nm 50

BA14.10-N-1007-01C


Nm 50

m anifold and flap connection

Additional information 14

AR1S.40 W 6232A

Rem oving and installing the g enerator support

13.9.96

ENGINE 541.920 /9 2 1 /922 /923 /924 /9 2 S /926 /927, 542.920 /9 2 1 /922 /923 /925/926

1

Generator support

2 3 4

Poly V-belt tensioning device A C compressor support Bracket o f ATFpipes

5

Bolt

6 7

Bolt Bracket o f engine w iring harness

W 1 5 4 0 -0 0 0 3 -0 6

m ill


1

Rem ove g e n e ra to r

A R 1 5.40 W -S0 3 2 B

2

Remove poly V -b elt tensioning device (2)

AR13.25-W-3200B

Detach support o f AC compressor (3) at

3.1

If AC fitted

support (1) @ Support to fixture of AC compressor and generator support 4

Detach bracket o f ATF pipes (4) at support

BA83.55-N-1002-01C

IXI Do not disconnect ATF pipes

(1) Detach bracket o f engine w iring harness

5

(7) and support (1)

BA01.40-N-1010-01D

@ Support generator/poly V-belt tensioning device to crankcase


6

® Crankcase, timing case cover, end cover Engine 541.920/ 921/922/ 923/924/

Designation

Number

925/926/ 927 B A 0 1.40-N -1010-01D

Support of generator/poly V -belt tensioning device to crankcase

Nm

160

Engine 542.920/ 921/922/ 923/925/ 926

160

Additional Information En gin es O M 501. O M 502 (m od. des. 541.9. 542.9). A C T R O S - V e h icle m od. des. 9 50 -954. F2

15

@ AC compressor

Num ber BA83.55-N-1002-01C

Designation Support to fixture o f A C compressor/

M od el 950 Nm 50

M o d el 952

M o d el 953

M o d el 954

50

50

50

frig ob lock and generator support


AR18.00-W-1600B

Filling engine oil circuit

14.fi.96

ENGINE 541.920/921/922 Z923/924/925/926/927,542.920/921 /922 /923/92S/926 1 2 3

Screw p lug (M 3 3 X 2 ) Seal IS] A d ap te r

4 5

I S O il fillin g reservoir W\ Shut-off valve

W18.00-0003-06

Ê3 HU 1

Rem oving, installing R em ove cylinder head covers at first a n d

A R 0 1.20 -W -5 0 1 4B

last cylinder 2


LU on left

3

R em ove screw p lu g (1)

®

4

Attach adapter (3) firm ly to oil filte r

S

Screw p lu g (M 3 3 X 2)

B A 1Q .20-N -1003-01C

352 589 11 63 00

housing (6) (insert)

5

Attach connection hose o f oil fille r reservoir (4) tight to connection fittin g (3)

IS

541 589 02 63 00

SI

352 589 11 63 00

352 589 11 63 00

Filling 6

Pour 5 liters o f approved engine oil Into oil fillin g reservoir and close

IS

7

Crease a pressure o f a b o u t 3 b ar w ith the

LU

S h u t-o ff valve (S) closed.

integral prim ing pump 8

O pen shut-off valve (5) long enough until

GD The pressure in o il fillin g reservoir

about 4 liters o f engine oil has been pum ped from the oil fillin g reservoir (4) into the o il galleries and the engine oil

should not drop below 1.5 ar; re-pump if necessary. Do no t com pletely em pty oil fillin g

flow s out free of bubbles at the rocker

reservoir otherwise air w ill be pum ped in.

arms (arrows)

IS

352 58911 6300

Install in the reverse order 9

Pour in remaining engine oil at fille r neck

Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 5 0 -9 54 , F2

AP18.00-W-0101A


^

Dangerl

Risk o f accident as a result o f vehicle starting o ff w hen engine running. Risk o f

Page 19


W ear closed and close-fitting w ork clothes. injury as a result o f bruizes and burns if you Do n o t grasp hot or rotating parts. insert your hands into engine w hen it is being started o r w hen it is running.

10


@ Crank engine w ith starter fo r no t more

w hen engine Idling

th an 20 Seconds. W ait fo r ab out 2 minutes before m aking repeated attem pt at

BE18.00-N-1001-01D

starting. Do no t rev up engine so long as o il pressure is not indicated.

[Li O il pressure gaae should indicate oil pressure after about 10 seconds.

11.1

Inspect engine oil level at electric gage

I H O nly if oil level sensor is parameterized. See ACTROS O perating Instructions Part 3

11.2

Inspect engine oil level w ith dipstick

12


CD

If oil level sensor Is not parameterized. See ACTROS O perating Instructions Part 4

541 589 02 63 00 A dapter M33

Test data o f engine o il pressure Number

BtlB.0U-N-10Ul-01O

Designation


Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

idle speed

min. bar 0.5

0.5

maxim um speed

min. bar 2.5

2.5

I Oil filte r Number

BA18.20-N-1003*01 C

Designation

Screw plug to oil filte r housing

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

M 1 4 X 1.5

Nm 25

25

M 1 6 X 1.5

Nm 25

25

M 2 4 X 1.5

Nm 25

25

M 33X2

Nm 65

65


ASOO.0O-Z-O005-O1A

Risk o f accident as a result o f vehicle Secure vehicle to prevent it from starting o ff w hen engine is running. Risk o f m oving off. injury as a result o f bruises and burns if you insert your hands Into engine w hen it is



D o not grasp ho t or rotating parts.

Possible dangers Risk o f accident

A

Danger!

Rules o f conduct / Protective measures - As a general rule, carry out w o rk on the running engine only if this is absolutely essential.

from vehicle starting o ff during starting operation (e.g. w hen

Before starting the engine, apply parking brake.

testing compression pressure) as a result o f gear engaged or when engine running and vehicles w ith autom atic transmission as a

On models w ith manual transmission, m ove gearshift lever into Neutral position.

result o f selector lever position "P" or "N " not engaged

On models w ith autom atic transmission, m ove selector lever

(exception: some vehicles d o no t have a selector lever position " P ”).

into position “ P“ or "N " (exception: some vehicles do not have a selector lever position “P”). On models which do not have selector lever position ” P“ ,

Risk o f injury


Severe injuries may be caused by freely rotating parts in the area

unintentionally.

o f the running engine. The heat produced by the engine w hen it is operating can result in severe burns if contact is made w ith individual, unshielded parts.

W e a r closed a n d close-fitting w o rk clothes

Take o ff any jewelry, such as chains, rings etc. If you have long hair, w ear a suitable head cover. Before commencing w ork on the running engine, check to obtain a general picture of the positioning o f parts w hich may be hot. W hen carrying o ut w ork w hen starting the engine or when engine is running, do not touch any hot and rotating parts.

First aid measures in th e event o f bum s • Do not rub the skin areas affected; flush w ith plenty o f cold •

w ater and cover skin w ith sterile bandages. im m ediately consult a physician.

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), ACTRO S - V e h ic le m od . des. 9 50 -9 54 , F2

19

AR18.00-W-4000B

14.6.96

Rem oving and installing oil spray nozzles (pistons)

ENGINE 541.920/921 Z922/923/924/925/926/927,542.920/9211922/923/925/925

W 18.00-0004-09

7 2

O il spray n o zzle B olt

Bum 1 2

3 4

Cranking device US Gage

Removing, installing Remove oil pan A ttach cranking device (3) fo r engine to tim in g case

AR01.45-W-7500B ® Cranking device has to be removed before starting engine

SI 0 Cover o f TDC inspectio hole to tim ing

407 589 00 63 00 BA01.60-N-1001-01B

case 3

Rotate crankshaft until the oil spray nozzle (1) to be removed is accessible

4

Remove oil spray nozzle (1)

CD Installation: the guide at the oil spray nozzle should engage in the hole in the crankcase.

0

BA18.00-N-1001-01C

Oil spray nozzles to

crankcase 5

Inspect oil spray nozzle (1) for dam age

IS CD Bolt oil spray nozzle tig h t to gage (4).

541 589 OO 23 OO

Inspect o il spray pipe w ith guide fo r deform ation, if necessary | adjust oil spray pipe or replace oil spray nozzle 6



20

® Timing case

Num ber

Designation

BA01.60-N-1001-01B

0

Cover o f TDC inspection hole to tim ing case

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/

Nm 25

925/926 25

Engine lubrication, engine o il cooling - general

Num ber

Designation

BA18.00-N-1001-01C

Oil spray nozzles (pistons) to

Nm

Engine 541.920/ 921/922/923/ 924/925/926/927

921/922/923/ 925/926

Engine 542.920/

25

25

crankcase

407 589 00 63 00 Cranking device

Additional Information Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le m od . des. 9 5 0 -9 54 , F2

21

AR18.10-W-5031B

17.1.96

Removing and installing oil pressure relief valve

ENGINE 541.920/921 /922 /923 /924 /92S /926/927, 542.920/921 /922 /923/92S/926 1

O il pressure re lie f valve

2

B o lt

W18.10-0004-11

E3IS) 1


2

Unscrew bolts (2) and take o ff oil pressure

Remove oil sump

AR01.45-W-7500B

relief valve (1)

HI Collect engine oil w hich flow s out. @ Oil pressure relief valve must no t be disassembled. If a problem exists, replace oil pressure relief valve. @ Oil pum p w ith pressure relief valve to crankcase

3

11 Do no t dam age sealing surface.

Clean sealing surface

4


5


BA 18.10-N-1003-01C

Page 17

0 O i l pum p N um ber

BA18.10-N-1003-01C

Designation

O il pum p w ith pressure relief valve to crankcase

Engine 541.920/ 921/922/923/

Nm

924/925/926/927

Engine 542.920/ 921/922/923/ 925/926

25

25


AR18.10-W-6020B

Removing and installing oil pump

17.1.96

ENGINE 541.920 /921 /922 /923 /924 /92S /926 /927. 542.920/92 1 /922 /923 /92S /926 1 2

O il suction p ipe Bolt

3

Bolt

4

Gasket O il pum p Bolt

5 6

M o d ifiction notes 6.2.97

Tightening torque o f bracket to crankcase and oil suction pipe at oil pum p m odified

Steps 2 and 4

Page 23

BA18.10-N-1002-01C

mm


1

Remove oil pressure relief valve

2

Unscrew bolts (2) a t the bracket o f the oil

0

suction pipe (1)

crankcase

Unscrew bolts (6) and take o ff oil pum p (5) together w ith oil suction pipe (1)

GD Collect engine oil which flows out.

3

Page 22

0

Bracket o f oil pump suction pipe to

O il pum p w ith pressure relief valve to

BA18.10-N-1003-01C

crankcase 4

unscrew bolts (3) and take o il oil suction

E

Replace gasket (4).

0

Suction pipe to oil pum p

pipe (1) at oil pum p (5)

5

Clean sealing surfaces at oil pum p (5), oil

BA18.10-N-1001-01C

@ Do not damage sealing surfaces.

suction pipe (1) and crankcase 6


7


Page 17

® O il pump Number

D e sig n a tio n

BA18.10-N-1Q01-Q1C BA18.10-N-1002-01C

E n g in e 541.920/

E n g in e 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

Suction pipe to oil pump

Nm

35

35

Bracket o f oil pum p suction pipe

Nm

35

35

Nm

25

25

to crankcase BA18.10-N-1003-01C

O il pum p w ith pressure relief valve to crankcase

Engines O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S -V e h ic le m o d . des. 9 50 -9 54 , F2


A R 1 8 .1 0 -W - 6 0 3 0 A

3 0 .1 0 .9 6

D is a s s e m b lin g a n d a s s e m b lin g o il p u m p

ENGINE 541.920/921 Z922/925/9241925/926/927.542.920/921 /922/923/925/926

W18.10-0007-09

1 2

Bolts Cover

3 4

Driven o il pum p gear Driving o il pum p g ear

5

O il p um p housing

6

Drive gear

7 8

SI D ial gage holder

A

0

Disassem bling

1

Remove oil pum p

2

M esure axial play o f oil pum p gears (3,4)

S I D ial gage

A m o u n t by which drive g ea r stands back relative to drive shaft

Page 23 BE18.10-N-1002-01A Q ] Fit dial gage (7) and dial gage holder (8) w ith preload onto oil pump housing (5). Position tracer pin on shaft o f oil pump gear and move shaft up and down. Check reading on gage. If the specification is exceeded I replace or repair oil pump

3

Take o ff cover (2)

4

Take driven gear (3) out o f oil pump

IS

001 58953 2100

m

363 589 02 2100

DO Do not damage sealing surface

housing (5) 5

Use a suitable d rift to press driving gear (4) o u t o f drive gear (6)

0

Assem bling

6

Insert driving gear (4) into oil pump housing (5)

7

Insert driven gear (3) into oil pum p housing (5)

24


8

Inspect backlash o f oil pum p gears

9

A ttach cover (2) tig h t

10

Heat drive gear (6) and press o nto drive shaft

11

Backlash o f o il pum p gears

BE18.10-N-1003-01A

El Feeler gage

WH58.30-Z-1008-12A

0 Cover to o il pump ED H eat drive gear to about 80 °C; pay

BA18.10-N-1004-01C BE18.10-N-1004-01A

a tte n tio n to am ount by which it stands back. □ rive gear should rotate easily.

Install oil pum p

Page 23

Test data o f o il pump Num ber

Designation

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

BE18.10-N-1002-01A

A xial play o f oil pum p gear - oil pum p housing

mm 0.050-0.128

0.050-0.128

BE18.10-N-1003-01A

Backlash o f oil pum p gears

mm 0.312-0.476

0.312-0.476

DE10.10-N-1004-01A

A m o u n t b y w h ic h d rive sh a ft stan d s back to

m m 0.5

0.5

Engine 541.920/ 921/922/923/ 924/925/926/927

Engine 542.920/ 921/922/923/ 925/926

25

25

drive gear

@

O il p u m p

Num ber

Designation

BA18.10-N-1004-01C

Cover to oil pum p

Nm

Com m ercially availab le to o ls (see W orkshop Equipm ent M anual) Num ber

Designation

M ake (e.g.)

O rder num ber

WHS8.30-Z-1008-12A

Feeler gage

Stlefelmayer D-73734 Esslingen

59

Additional Information En g in e s O M 501, O M 502 (m od. des. 541 .9 ,54 2 .9 ), A C T R O S - V e h ic le m od . des. 9 5 0 -9 5 4 , F2

25

AR18.20-W-3471B

14.6.96

Removing and installing oil filter housing

ENGINE 541.920/921 /922 /923/924/925/926Z927, 542.920/921 /922 /923/92S/926

J 2

14

O il filte r housing Bracket

Fuel pipes B olt

B o lt

15 17

B o lt C o olan t hose

18 19 20 21

3

O il filte r cap Seal O il filte r elem ent

9 10

Gasket B o lt

23

11

C o o la n t connection Seal

B65 Coolant tem perature sensor

12 13

Fuel filte r housing

B11

3 4 5 6 7

22


1

Remove charge a ir housing

2.1

Rem ove ch arge a ir pip e

3

Slacken poly V -b elt and take o ff at co olan t pum p b elt pulley Danger!

B olt Engine w iring harness Seals Seal Brocket B olt

312 OHpressure sensor

gemu

A

B olt

O il tem perature sensor

AR09.41-W-8681B O n e n g in e 542.920 - 923/925/926

A R 0 9 .4 1 -W -1 3 1 1 B

AR13.22-W-1202B



scalding from h o t coolant w hich splashes

co olan t tem perature is b e lo w 90 °C. O pen


cap slow ly and a llo w the pressure to release. D o not pour co olan t into

Page 29

c o n ta in e rs fo r drinks.

W ear protective gloves, p rotective clothes, and eye protection. 4

Drain coolant

C ollect coolant.

®

Notes re coolant

A ll engines

5

Detach coolant connection (11)

0

AP20.00-W-2080A

Page 30

C o o la n t pipe to co olan t pum p

BA2Q.10-N-1003-01D

[ D Inspect seals (12), replace if necessary.

26


6

Detach coolant hose (5) at oil filte r housing (1)

0 Bracket o f fuel pipe to oil filte r housing 0 O il filte r cap to oil filte r housing EDThe engine oil flows back into the oil

7

Detach bracket (22) o f fuel pipes

8

Unscrew oil filte r cap (6) together w ith oil filte r elem ent (8)

9

Detach fuel filte r (13) at bottom o f oil filter

0

housing (1)

CDD o no t separate fuel pipes (14) 0 Bracket o f fuel pipe to oil filte r housing EDD o n o t separate fuel pipe IUTo o il pressure sensor (B12), oil

BA47.25-N-1009-01B BA18.20-N-1001-01C

pan w h en the oil filte r elem ent is removed.

10

Detach fuel pipe (14) at oil filte r housing (1)

11

Detach engine w iring harness (19)

Fuel filte r housing to oil filter housing

BA47.20-N-1001-02C

BA47.25-N-1009-01B

tem perature sensor (B11) and coolant tem perature sensor (B65) 12

Unclip engine w iring harness (19) at oil filte r housing (1)

13

Puli out oil filte r cap (6)

ED

Collect engine oil which drips out o f oil filte r elem ent (8).

Ell Installation: inspect seal (7), replace if necessary. 14

Inspect oil filte r elem ent (8) fo r signs of

If dam aged or d irt is present, replace oil

damage and dirt

filte r elem ent.

15

Detach oil filte r housing (1) at crankcase

16

Take o ff gasket (9) and clean sealing

CDC o llect engine oil which flows out. LL!Installation: replace gasket.

AP18.00-W-0101A

BA18.20-N-1002-01C

surfaces 17

Inspect oil-w ater heat exchanger fo r external damage

CDIf dam age present

18


EDInstallation: when replacing oil filte r

J,

replace oll-w ater heat exchanger.

Page 31

housing j, install existing oil-w ater heat exchanger.

Page 31

Install existing screw plugs, coolan t tem perature sensor (B65), oi I pressu re sensor (B12) and oil tem perature sensor (B11). Replace seals.

0 0 0 0

O il tem perature sensor

BA15.60-N-1001-01A

C o olan t tem perature sensor

BA15.60-N-1002-01A

Screw plugs

BA18.20-N-1003-01C

O il pressure sensor

BA18.40-N-1001-01D

19


Page 17

ÆDanger!

Risk o f accident as a result of vehicle Secure vehicle to prevent it starting off. starting o ff w hen engine running. Risk of W ear closed and close-fitting w ork clothes. Injury as a result o f bruizes and burns if you Do n o t grasp hot or rotating parts.

Page 19

insert your hands into engine w hen it is being started or w hen it is running.

Additional Information E ngines O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h icle m od. des. 9 5 0 -9 5 4 , F2

27

20


® Crank engine w ith starter fo r not more

w hen engine idling.

th an 20 seconds. W ait about 2 minutes

BE18.00-N-1001-01D

before m aking a further attem pt at starting. Do not rev up engine so long as oil pressure is n o t indicated. L D The oil pressure gage should indicate o il pressure afte r ab out 10 seconds.

21.1

C D o n ly if oil level sensor is param eterized.

inspect engine oil level ax electric gage

See ACTROS O perating Instructions Part 3 21.2

Inspect engine oil level w ith dipstick

22


G O If oil level sensor is not parameterized. See ACTROS Operating Instructions Part 4

Test data o f engine o il pressure Num ber

D esignation

BE18.00-N-1001-01D


Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

idle speed

min. bar 0.5

0.5

m axim um speed

min. bar 2.5

2.5

ËÜÜ Fuel filte r N um ber

Designation

BA47.20-N-1001-02C

Fuel filte r housing to o il filte r housing

Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 25

Engine 542.920/ 921/922/923/925 /926 25

@ Tem perature sensor N um ber

Designation

Engine 541.920/

E ngine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

BA15.60-N-1001-01A

O il tem perature sensor to o il filte r housing M 1 4 X 1.5

Nm 30

30

B A 15 .S 0 -N -1 00 2-01 A

C o o la n t te m p e ra tu re se n so r to oil filter

Nm

30

M 1 4 X 1.5

30

housing

ÉÜ3 O il filte r Num ber

D esignation

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

BA18.20-N-1001-01C

O il filte r cap to o il filte r housing

Nm 40

40

BA18.20-N-1002-01C

O il filter, o il-w ater heat exchanger

Nm 50

50

M 1 4 X 1 .5

Nm 25

25

M 1 6 X 1 .5

Nm 25

25

housing to crankcase BA18.20-N-1003-01C

Screw plug to oil filte r housing

M 2 4 X 1 .5

Nm 25

25

M 33X2

Nm 65

65


0

Oil level, oil pressure sensor

Num ber

Designation

BA18.40-N-1001-01D

O il pressure sensor to oil filte r

Nm

Engine 541.920/ 921/922/923/ 924/925/926/927

Engine 542.920/ 921/922/923/

40

40

925/926

housing

EÜ3 Coolant pump, coolant therm ostat Num ber

Designation

BA20.10-N-1003-01D

Engine 541.920/ 921/922/923/ 924/925/926/927 M8

C oolant pipe to coolant pump

Nm 25

Engine 542.920/ 921/922/923/ 925/926 25

@ Fuel pipes/hoses Num ber

Designation

BA47.25-N-1009-01B

AS20.00-Z-0001-01A

Bracket o f fuel pipe to oil filte r housing

Engine 541.920/

Engine 542.920/

921/922/923/ 924/925/926/927

921/922/923/ 925/926

Nm 25

25


Do not open the cooling system unless A

scalding from hot coolant w hich splashes out..Risk o f poisoning from sw allowing

the coolant tem perature is below 90 °C. Open cap slow ly and allo w the

coolant.

Danger!

pressure to release. D o not pour coolant into containers fo r drinks. W ear protective gloves, protective clothes, and eye protection.

Possible dangers Risk o f injury

Protective measures/rules o f conduct - A llo w cooling system to cool dow n to a coolant temperature o f less than 90 “C.

The cooling system is pressurized when the engine is warm. Risk o f scalding from hot coolant w hich splashes o ut if the cooling system is opened suddenly.

-

Risk o f poisoning

-

If coolant is sw allow ed, the person affected is likely to show signs o f poisoning such as headaches, giddiness and stomach aches, paralysis o f the respiratory system, unconsciousness, nausea, and convulsions.

Open coolant system cap slowly; open a conventional type of coolant system cap to the first detent and open a screw-type coolant system cap a b o u t '/ 2 turn, and allo w the pressure to release. W ear protective gloves, protective clothes, and eye protection. Do not pour coolant into containers fo r drinks.

First aid measures •

Pour large quantities o f cold w ater over the affected area of

•

skin and cover over w ith sterile bandages. Have person affected drink plenty o f water to which m edicinal carbon has been added.

•

Consult a doctor if the person affected has severe burns or has swallowed considerable quantities.

Additional Information Engines O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h icle m od. des. 9 50 -9 54 , F2

29

AH20.00-N-2080-01A


Coolant com position Passenger car and commercial vehicle engine (normal case):

A concentration o f anticorrosion/antifreeze agent higher than

50 % by volum e w ater and 50 % by volum e anticorrosion/antifreeze agent.

55 % by volum e should not be used as th e m axim um antifreeze protection is thus reached. A n even h ig h er concentration again

See M B Specifications fo r Service Products fo r d ifferin g coolant composition fo r commercial vehicle engines.

reduces th e antifreeze protection and im pairs heat dissipation.

Purposes o f anticorrosion/antifreeze agent

W ater Use w ater which is clean and n o t to o hard. D rinking water

•

Corrosion and cavitation protection fo r all com ponents in the cooling system

•

Antifreeze protection

frequently, but not always, satisfies the requirements. The contents o f dissolved substances in th e w ater can be of im portance fo r the occurrence o f corrosion. In cases o f doubt,

Increasing b oiling p oin t so th at the coolant does not evaporate

analyze th e water. See MB Specifications fo r Service Products fo r

so rapidly. Ejection o f coolant is avoided at high coolant temperatures.

fresh w ater regulations.

•

O peration o f m onitoring o f coolant Antifreeze protection

Inspect coolant fo r resistance to low tem peratures before the start

50 % by volum e o f anticorrosion/antifreeze concentration offers antifreeze protection dow n to approx. -3 7 °C.

o f the cold season o f the year. In countries w ith high am bient tem peratures, inspect the

A higher concentration is only practical at even low er am bient

anticorrosion/antifreeze concentration once a year.

temperatures.

The corrosion protection in the coolant is reduced during

55 % by volum e o f anticorrosion/antifreeze concentration offers antifreeze protection dow n to approx. -4 5 °C.

operation. Such coolants have a severely corrosive effect. The maxim um permissible period o f use o f th e coolant is fo r passenger car and commercial vehicle engines (normal case) 3 years. See MB S p ecifications fo r Service P ro d u c ts fo r th e p eriod o f use fo r diffe rin g coolant com position fo r comm ercial vehicle engines. Disposing o f coolants

(§> Before p o u rin g fresh c o o la n t into th e system, flu sh th e used

O b se rve legal regu la tio ns a n d lo ca l w a ste w a te r regulations.

coolant out o f th e cooling system. Clean cooling system if severe soiling or oil contam ination exist.

For workshops located in the Federal Republic o f Germany see: "Um weltschutz-Handbuch fo r Kfz-Reparaturbetriebe" (Environm ental protection m anual fo r vehicle repair workshops) Publisher: Verband der A u to m obilin d ustrie e.V. (VDA) D-60625 Frankfurt am M ain, W estendstraBe 61


AR18.30-W-6840B

Removing and installing the oil/water heat exchanger

17.10.96

ENGINE 541.920/921/922/923/924/925/926/927, 542.920/921 /922/923/92S/926 1 2 3

O il-w ater heat exchanger Gaskets B o lt

W18.30-0002-11

mm


1

Remove oil filte r housing

2

Remove oil-w ater heat exchanger (1)

P a g e 26 GD O il-w ater heat exchanger should be replaced if external damage exists and if m aterial abrasion present in engine oil. E

Installation: clean sealing surfaces and

replace gaskets (2). ® Oi)-water heat exchanger to oil filte r

B A18.30-N-1001 -01D

housing 3


® O il cooling system Num ber

D e sign a tio n

BA18.30-N-1001-01 D

O il-w ater heat e x ch ange r to oil filter h o u sin g

Nm

E n g in e 541.920/

E n g in e 542.920/

921/922/923/ 924/925/926/927

921/922/923/

25

25

925/926

Additional Information E n g in e s O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S -V e h ic le m od. des. 9 50 -9 54 , F2

31

A R 2 0 .0 0 -W - 1 0 1 0 A

1 1 .1 2 .9 6

C h e c k in g c o o lin g s y s te m f o r le a k s

ENGINE 541.920/921 /922 Z923/924 /92S/925/927,542.920/921 /922 /923/92S/926 1 2 3

Cap Expansion reservoir [ i l A d a p te r

A

121 Tester

W20.00-0003-11

Checking Danger!



scalding from ho t co olan t which splashes out. Risk o f poisoning from sw allowing

coolant tem perature is b elo w 90 °C. Open cap slowly and allow the pressure to

coolant

P a g e 29

release. Do not pour coolan t into containers fo r drinks. W ear protective cloves, protective clothes, and eye protection.

1

®

2

Open cap (1) at expansion reservoir (2)

HI Release pressure and then unscrew cap.

Notes re coolant

A ll engines

P a g e 30

Set heater switches to maximum heating capacity

3


4

Attach adapter (3) and tester (4) to

Q] Adjust coolant level to correct level, if necessary.

AP20.00-W-2010A

m

001 589 83 21 00

m

655 589 00 63 00

expansion reservoir (2)

5

Fill cooling system at tester (4) with

HI Test pressure a bo ut 1.0bar gage

compressed air

If there is a leak in cooling system, a pressure drop is visible at gage, if necessary j inspect cooling and heating hoses, coolant pipes and connection points fo r condition and loss of coolant. Inspect hose clips fo r condition and correct installation.

6

Detach adapter (3) and tester (4) at expansion reservoir

7

Rectify leak in cooling system

SI I I Release pressure. E Retighten or replace hose clips.

655 589 00 63 00

Replace gaskets, cooling and heating hoses. 8

Screw cap (1) tig h t o nto expansion

ODAdjust coolant to correct level

AP20.00-W-2010A

reservoir (2)

32


Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h icle m od. des. 9 5 0 -9 5 4 , F2

33

AR20.00 W 1030B

Rem oving g rease and scale in coolin g system

10.11.96

ENGINE 541.920 /921 /922 /923 /924 /92S /926 /927. 542.920 /921 /922 /923 /92S /926

Removing grease Æ

Danger!

Risk o f injury to skin and eyes from scalding from ho t coolant w hich splashes out. Risk o f poisoning from swallowing coolant

Do not open th e cooling system unless the coolan t tem perature is below 90 °C. Open

Page 29

cap slow ly and allow the pressure to release. Do not pour coolant into containers fo r drinks. W ear protective gloves, protective clothes, and eye protection.

1

Drain coolant com pletely and collect

®

Notes re coolant

A ll engines

2

Fill cooling system w ith a 5 % solution of m ildly alkaline cleaner and fresh water

P3 Croni M ixin g ratio: 50 g cleaner to 1 liter water

BR00.45-Z-1011-04A

G risiron 7220

BR00.45-Z-1012-04A

A

3

Danger!

AP20.00-W-2080A

page 30


Secure vehicle to prevent it moving off.

starting o ff w hen engine running. Risk o f

W ear closed close-fitting w ork clothes.

injury as a result o f bruises and burns if you insert your hands into engine w hen it is being started or w hen it is running.

Do not touch ho t or rotating parts.

Warm up engine speed to a coolant

[ D If necessary, the radiator can be

tem perature o f approx. 80 °C at moderate

covered over.

Page 19

revs and m aintain this co olan t temperature fo r about 5 minutes 4

Switch o ff e n g in e e n d a llo w coolant

tem perature to cool dow n to about 50 °C 5

6

Drain solution com pletely from cooling system

H I Dispose o f solution in accordance w ith environm ental regulations.

Flush cooling system tw ice w ith fresh

Q ] Dispose o f water in accordance w ith

water; run the engine each tim e fo r about 5 minutes

environm ental regulations.

Removing scale 7

Fill cooling system w ith a 10 % solution o f water and citric, tartaric or oxalic acid

C D Before removing scale, always remove

grease in cooling system even if there is no visible sign o f oiling. Chrom ic acid o r products containing chrom e must no t be used in order to avoid p ollution o f th e wastewater. LD it is best to use citric acid. M ixin g ratio: 100 g citric acid to 1 liter water. C D Chemicals fo r preparing solutions can

also be obtained from the chemical trade. Com m ercially available products composed o f the acids m entioned, can also be used fo r rem oving scale and rust. 8

Warm up engine to ab out 80 °C at m oderate revs and hold at this tem perature fo r about 10 minutes

9

34

Switch o ff engine and a llo w to cool down to about 50 °C


Drain solution completely

10

[XI Dispose o f solution in accordance w ith environmental regulations.

Rinse cooling system at least 3 times w ith

11

fresh w ater; run engine each tim e fo r S m inutes

IX

Dispose o f water in accordance w ith environmental regulations.

Fill cooling system w ith specified coolant

12

AP20.00-W-2080A

and inspect fo r leaks Repair products D e sig n a tio n

Num ber

O rd e r n u m b e r

BR00.45-Z-1011-04A

P3 Croni

Henkel

BR00.45-Z-1012-04A

Grisiron7220

Hoechst

Additional Information Engines O M 501, O M 502 (m od. des. 541.9,542.9), A C T R O S - V e h ic le m od . des. 950-954, F2

35

AR20.10-W -1271B

Rem oving and installing angina coolant pum p

14.6.96

ENGINE 541.920/921 /922 /923 /924 /92S /926 /927,542.920 /921 /922 /923 /925 /926

1

Poly V-balt

2

M 8 X 12 b o lt

3 4

Belt p u lle y M 8 X 6 0 b o lt

5

Coolant thermostat

6

C o olan t pum p

7

Gasket

8 9

C o olan t p ip e (retarder) M 1 0 X 9 0 b o lt

10

M 1 0 X 5 0 b o lt

11 12 13

Gasket Gasket c o o la n t p ipe

14

Bolt

6

C o olan t pum p

15 16 17 18

Fan drive Support Bolt Bolt

W20.10-0011-06

g ill


1

Rem ove noise encapsulation

2

Remove coolant therm ostat (5)

3

Slacken belt pulley (3)

[T! at rig h t a n d b otto m

Page 43 Q ] Counterhold belt pulley E § Belt pulley to coolant pump

4

Slacken poly V-belt (1) and take o ff

BA20.10-N-1002-01D AR13.22-W-1202B

5

Remove belt pulley (3)

6.1

Detach fan drive (15) and support (16) and rotate

@ On engine S42.922/923

BA20.40-N-1004-01C

6.2

Detach support (16) at coolant pum p (6)

@ On engine 542.922/923

BA20.40-N-1005-01C

36


Detach coolant pipe (8) at coolant pum p (6) W ith retarder

7.1

8

E

Installation: replace gasket (7)

0

C oolant pipe to co olan t pum p

Detach coolant pipe (13) a t co olan t pum p

E

Collect coolant w hich flow s o u t

(6)

E


0

Coolant pipe to coolant pum p

E


0

Coolant pum p to crankcase

Remove coolant pump (6) and take o ff

9

BA2 0.10-N-1005-01D

BA20.10-N-1005-01D

gasket (11)

10

BA20.10-N-1001-01D

Clean sealing surfaces on crankcase and coolant pum p (6)

11


12


AP20.00-W-2080A

EÜ3 C oolan t pum p, coolant therm ostat Num ber

D esignation

Engine 541.920/

Engine 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

BA20.10-N-1001-01D

C o o la n t p u m p t o c ra n k c a s e

Nm

25

25

BA20.10-N-1002-01D

B e lt p u lle y t o c o o la n t p u m p

Nm

25

25

BA20.10-N-1005-01D

C o o la n t p ip e ( in le t c o n n e c t io n ) t o c o o la n t p u m p

Nm

50

50

M10

0 Fan, fan clutch N um ber

D esignation

Engine 542.922/ 923

BA20.40-N-1004-01C

Fan drive to support

Nm

30

8A20.40-N-1005-01C

Support to coolant pump

Nm

30

Additional Information E n g in es O M 501, O M 502 (m o d . des. 541.9, 542.9), AC T R O S - V e h ic le m o d . des. 9 50-954, F2

37

AR20.10-W-1401B

Disassembling, assembling coolant pump

4.9.96

ENGINE 541.920 /921 /922 /923 /924 /92S /926 /927, 542.920 /921 /922 /923 /92S /926

1

Flange

2

Circlip

3

B earing w ith shaft

4

C o olan t pum p housing

5

Cassette-type seal

6

Im peller

7

I S Puller

8

® Thrust piece

5 6

Cassette-type seal Im peller

9

I S D rift

A

Gap betw een Im peller a n d coolant pum p housing

B

Clearance between coolant pum p housing and flange

W 20.10-0008-06

W20.10-0009-06

□

Disassembling

1

Remove coolant pump

2

Pull flange (1) o ff bearing shaft (3)

3

38

Page 36 IS

000 589 65 33 00

IS

321 589 00 63 00

Remove circlip (2)


Use a suitable d rift to press bearing shaft

4

B

Fixed workshop press 6 5 1

WE58.40-Z-1001-12A

(3) o u t o f im peller (6) and coolant pump housing (4) 5

Remove cassette-type seal (5)

0

Assem bling

6

O il outer race o f bearing (3) w ith engine oil ® Press In bearing only at outer race and press into the coolant pum p housing (4) w ith a suitable d rift

B 7

Fixed workshop press 6 5 1

WE58.40-Z-1001-12A

Install cird ip (2)

8

Heat flan g e (1) and press onto bearing

Q] H eat flange to about 80 °C.

shaft (3)

® Counterhold at bearing shaft w hen pressing on.

BE20.10-N-1002-01C

Measure dimension (B) clearance between coolant pump housing (4) and flange (contact surface o f belt pulley).

B 9

10

11

Fixed w orkshop press 6 5 1

WE58.40-Z-1001-12A

Fit on new cassette-type seal (5) over the

m

bearing shaft (3) and press in as far as coolant pum p housing (4) w ith the d rift

® Inspect seat of cassette-type seal on shaft and in coolant pump housing

Press im peller (6) onto bearing shaft (3)

® Counterhold at bearing shaft when pressing on

352 589 0815 00

Measure size o f gap (A) between im peller and coolant pum p housing (4)

BE20.10-N-1001-01C

B

WH58.30-Z-1008-12A

Feeler gage

Rotate coolant pum p at flange (1) and check to ensure it runs freely

12

Page 36

Install coolant pump

Test and setting data o f coolant pum p Designation

Num ber

BE20.10-N-1001-01C

G ap bew een im peller and coolant pum p housing (A)

BE20.10-N-1002-01C

000 589 65 33 00

Engine 542.920/921/ 922/923/925/926

mm 0,6-1,0 Fig. see

Clearance between coolant pump housing and flange (B)

Engine 541.920/921/ 922/923/924/925/926/ 927

0,6-1,0

AR20.10-W-1401-01A mm 100

Fig. see

AR20.10-W-1401-01 A 100

AR20.10-W-1401-01A

AR20.10-W-1401-01A

321 589 00 63 00

P u ller

Thrust piece

Additional Information E n gin es O M 501, O M 502 (m o d. des. 541.9, 542.9), A C T R O S - V e h icle m od . des. 9 50 -9 54 , F2

39


Designation

M ake (e.g.)

O rd er num ber

WH58.30-Z-1008-12A

Feeler gage

Stiefelmayer

59

D-73734 Esslingen W orkshop equipm ent/M B testers (see W orkshop Equipm ent M anual) WE58.40-Z-1001-12A

Fixed workshop press 6 5 1 , e.g, M atra-W erke GmbH, D-60314 Frankfurt/M ain


AR20.1O-W-2455A

19.7.95

Totting coolant thermostat

ENGINE 904.905/906/907/908/909/910/911/921 /922,906.910/911/920/921 Z922/923 ENGINE 541.920 /921 /922 /923 /924 /925 /926 /927. 542.920 /921 /922 /923 /92S1926 ENGINE 906.940/941 1 1/1 1/2

C oolant therm ostat M a in valve Bypass valve

W20.10-OOOS-04

Shown on engine 906.920- 923 1

Coolant therm ostat

1/1

M ain valve

W 20.KM 001-01

SI

Testing

1


On engine 904.905 - 907/909- 911/921/922

AR20.10-W-2460A

and 906.910/911/920- 923/940/941 On engine 904.908 In model S68,870

2

A 3

4

On engine 541.920 - 927 On engine 542.920 - 923/925/926

Page 43

Risk o f injury to skin and eyes through handling ho t or glow in g objects

W ear safety gloves, protective clothes and if necessary, eye protection.

Page 42

Use a suitable source o f heat to heat the water. Stir w ater so th a t the water

® On no account use a w elding torch or

Suspend coolant therm ostat (1) w ith a wire in a vessel filled w ith water Danger!

tem perature is th e same at all points.

soldering iron fo r heating the coolant therm ostat (1).

Measure w ater tem perature

[XI The rate a t which the w ater is heated

BE20.10-N-1001-02A

up should not be more than 1° to 2 °C/min. from about 8 °C below the start o f opening o f the co o la n t therm ostat. Pay a tte n tio n to

standard or tropical version o f coolant therm ostat (1). BE20.10-N-1001-02B 5.1

Heat w ater to the fu ll opening

[XI Except engine 906.920- 923

BE20.10-N-1003-02A

tem perature o f th e bypass valve (1/2) BE20.10-N-1003-02B

6

Heat w ater to the fu ll opening

[XI The main valve (1/1) must be fu lly open

tem perature o f the m ain valve (1/1) and measure stroke

after 6 to 8 minutes. If the test values are no t achieved J,

En g in es O M 501, O M 502 (m od. des. 541.9,542.9), ACTRO S - V e h ic le m od. des. 9 50 -9 54 , F2

BE20.10-N-1002-02A


BE20.10-N-1002-02B

7

Install coolant therm ostat (1)

Replace coolant therm ostat (1).

BE20.10-N-1002-02A

On engine 904.905 - 907/909- 911/921/922

AR20.10-W-2460A

and 906.910/911/920- 923/940/941 On engine 904.908 in model 668,670 On engine 541.920-927

P ag e 43

On engine 542.920 - 923/925/926 Test data o f coolant therm ostat Number

Engines 904.904/905/ 906/907/908/909/910/

Designation

911/915/916/917/921/ 922/923/926/932, 906.910/911/915/916/ 919/9229/932/933 BE20.10-N-1001-02A

C oolant therm ostat - start o f opening

BE20.10-N-1002-02A

C oolant therm ostat - main valve fu lly open at

°C 83±2 °C 95

tem perature and m in. stroke (A) BE20.10-N-1003-02A

mm 8

C oolant therm ostat - bypass valve closed at

°C 92

Test data o f coolant therm ostat Number

Designation

BE20.10-N-1001-02B

Coolant therm ostat - start o f opening

BE20.10-N-1002-02B

Coolant therm ostat - main valve

Engines 541.920/

Engines 542.920/

921/922/923/ 924/925/926/927

921/922/923/925

“C 83 + 2

83 ± 2

fu lly open at °C 95

95

Stroke in mm & 8 BE20.10-N-1003-02B

A500.00-Z-0002-01A

Coolant therm ostat - bypass valve closed at

Risk o f injury to skin and eyes from handling hot or glow ing objects

Injury hazard Contact w ith hot or glow in g objects w itho ut suitable protective

/926

£8

•c 92

92

W ear heat resistant gloves, protective

Æ Danger!

clothing and protective goggles if necessary Protective measures/rules o f behavior - W ear protective clothing, protective goggles and heat

clothing can cause severe burns to skin and eyes.

resistant gloves.

W h e n g lo w in g objects m a ke contact w ith w a te r h o t w ate r v a p o r

T ra n sp o rt h o t o r g lo w in g objects o n ly w ith the aids p rovid ed

and droplets are produced w hich can lead to severe bum s to skin and eyes.

fo r such purposes. -

If ho t or g low in g objects come into contact w ith unprotected skin

Avoid form ation of sparks and contact w ith combustible materials w hen handling glow in g objects.

or eyes severe, possibly p e rm a n e n t d a m a g e can result.

First-aid measures DO Contact between glow in g objects and com bustible m aterials poses a fire hazard.

e

Rinse affected areas o f skin w ith large quantities o f cold water and cover w ith sterile dressings.

•

Consult physician immediately.


AR20.10-W-2460B

Rem oving a n d eng in e installing co o la n t therm ostat

14.6.06

ENGINE 541.920/921 Z922/923/924/925/926/927,542.920/921 /922 /923 /92S /926 1 2 3 4 5 6 7 8 3

Coolant fitting Bolt Bracket fo r plate-type air cleaner Bolt Charge a ir hose (red) Seals Coolant therm ostat C oolant pum p c o o lan t hose

W 2 0 .10-0010-06

usmi


â \ Danger!

Risk o f injury from bruises and jamming w hen tiltin g cap

No person should be in the tilting area of the cab w hen it is being tilted. Always tilt cab as far as the end position and secure

Page 4

w ith a safety prop. 1

Tilt cab

®


M odel 950, 952,953,954

2

Rem ove noise encapsulations

IT] side right

3

Remove red charge air hose (5)

Page 4

ÜÜ inspect condition o f charge air hose and hose clips, replace if necessary DO Installation: charge air hoses must no t be mixed up. @ Red charge air hose is temperatureresistant and must be installed between charge air pip e and intercooler

0


BA09.41-N-1006-01C

housing/charge air pipe and intercooler 4.1

Rem ove p late-type air cleaner

If p late-type air cleaner fitted

5.1

Bracket (3) fo r plate-type air cleaner

If plate-type air cleaner fitted 0

Front bracket to suspension eye or

BA09.00-N-1001-01A

c u u ld iil fitting

^

Danger!



scalding from ho t coolant which splashes

coolant tem perature is below 90 °C. Open


cap slow ly and allow the pressure to release. Do no t pour coolant into

Page 29

containers fo r drinks. W ear protective gloves, protective clothes, and eye protection.

E n gin es O M 501, O M 502 (m od. des. 5 41 .9,542.9), ACTRO S - V e h icle m od. des. 9 5 0 -9 54 , F2


6

Drain coolant

(XI Collect coolant.

®

Notes re coolant

A ll engines

7

Remove coolant fittin g (1)

AP20.00-W-2080A

Page 30

[X] Collect coolant which flow s out. ® C o olan t pipe to coolant pum p

8


BA20.10-N-1003-01D

CD Installation: replace seals (6). P ay a tte n tio n t o installation p osition o f

coolant thermostat; the vent openings (arrows) must always face up 9

Test coolant therm ostat (7)

10


11


Page 41

AP20.00-W-2080A

@ A ir intake, turbocharging, general Num ber

BA09.00-N-1001-01A

Designation

Front bracket to liftin g eye or coolant fitting

Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 25

Engine 542.920/ 921/922/923/ 925/926 25

® Charge a ir pipe/intercooler N um ber

Designation

BA09.41-N-1006-01C


Engine 541.920/ 921/922/923/ 924/925/926/927 Nm 7,5

Engine 542.920/ 921/922/923/ 925/926 7,5

h o u sin g/ ch arge pip e a n d intercooler

® C o olan t pum p, coolant therm ostat N um ber

BA20.10-N-1003-010

Designation

Coolant pipe to coolant pump

M8

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

Nm 25

25


A R 2 0 .2 0 -W -3 8 6 5 B

R e m o v in g a n d in s t a llin g r a d ia t o r

1 7 .1.96

ENGINE 541.920 /921 /922 /923 /924 /92S /926 /927, 542.920 /921 /922 /923 /92S /926

W20.20-0002-09

1

Heat exchanger (air conditioning)

11

Dipstick guid e tube

2 3 4

Bracket w ith heating pipes

O il fille r pipe Coolant hose

Radiator with intercooier and coolant expansion reservoir

12 13 14

Plug connector Coolant hose

15 16

R adiator m ounting

Charge a ir hose (red)

Clip (refrigerant pipes) Bracket (refrigerant pipes) Clips (refrigerant pipes) Protective grille

Coolant hose (vent)

5 6 7 6 9

Selector rod

18 19 20

10

Coolant hose (coolant pum p)

21

4 15 16 17

Radiator w ith interco oler an d coolant expansion reservoir Bolt Radiator m ounting Viscous fan

A

Clearances betw een rad iator shroud an d viscous fan

Charge air hose (black)

Gear oil pipes Bolt

W20.20-0003-02

S I EH


Additional Information E n g in es O M 501, O M 502 (m od. des. 541.9,542.9), A C TR O S - V e h icle m o d . des. 9 5 0 -9 5 4 , F2

45

A Danger!


Do no t open th e cooling system unless the

scalding from hot coolant w hich splashes

co olan t tem perature is below 90 °C. Open

out. Risk o f poisoning from sw allow ing

cap slow ly and allow the pressure to

co olant

release. D o n o t p o u r co o la n t into

Page 29

containers fo r drinks. W e ar protective gloves, protective clothes, and eye protection. ®

Notes re coolant

© Installation


1

Drain coolant

2

Open maintenance flap

3.1

Remove bracket (19) at bottom left of

Page 30

A ll engines

OD Collect coolant.

AP20.00-W-2080A

If A /C fitted

intercooler 4.1

Detach clips (20) at both coolant pipes

If A/C fitted

QD Do no t disconnect coolant pipes. 5.1

Remove heat exchanger (1) at intercooler

If A/C fitted

Q] Tie up heat exchanger at cab m ounting. Do no t disconnect coolant pipes. 6

Remove protective grille (1) at Intercooler

7

Detach gear o il pipes (14) at bottom o f radiator (4)

i n Collect gear o il w hich flow s out. Seal

A Danger)


No person should be in the tiltin g area o f th e cab w hen it is being tilted. Alw ays tilt cab as fa r as th e end position and secure w ith a safety prop.

Page 4

8

Tilt cab

®


M o d el 673 - 679,950,952,953,954

Page 4

9.1

Detach air cleaner housing above engine

If plate-type air cleaner

10

Remove noise encapsulation at side and

openings w ith plugs.

below 11.1

Detach selector rod (9) at relay lever, push

Q] If MPS transmission

to g e th e r a n d tie u p at cab

12

Unplug connector (5) o f coolant gage at coolant expansion reservoir (4)

13

R em ove ch arge a ir hoses (7, 8)

Q D Inspect co n d itio n o f ch arge air hoses

and hose clips, replace if necessary.

EEInstallation: Charge air hoses must not be mixed up. @ Red charge air hose (7) is temperatureresistant and always has to be installed betw een charge air pipe and intercooler (4). BA09.41-N-1006-01C 14

Detach coolant hoses (3,6,10,13)

[Li Collect coolant which flow s out. Inspect c o n d itio n o f c o o la n t hoses a n d h o se clips,

replace if necessary. 15

Remove bracket, oil fille r pipe (12) and dipstick guide tu b e (11) and tie up at engine

16

Unscrew bolts (15) at radiator m ounting (16)

46

Q] Inspect radiator m ounting (16) fo r wear, replace if necessary.


17

Lift radiator together w ith intercooler and coolant expansion reservoir (4) up and out

S3 Attach tackle to intercooler to side left and right. @ Do not damage radiator and intercooler, coolant expansion reservoir and heat exchanger o f air cond ition ing (1).

S3 Installation: After inserting the radiator, center radiator to viscous fan until the same clearance exists on all sides betw een radiator shroud and the viscous fan. IS


19

Inspect coolant level and adjust to correct

AP20.00-W-2010A

level 20

inspect cooling system fo r leaks

21

Inspect gear oil level

A P 2 0 .0 0 -W -2 0 5 0 A

S3 Top up o il to lower edge o f oil filler

AP26.00-W-2601A

opening 0

Charge air pipe/intercooler

N um ber

D esignation

BA09.41-N-1006-01C

Charge air hose to charge air housing/

Engine 541.920/ 921/922/923/

Engine 542.920/ 921/922/923/

924/925/926/927

925/926

Nm 7.5

7.5


Additional Information En gin es O M 501, O M 502 (mod. des. 541.9, 542.9), A C T R O S - V e h ic le m od . des. 9 50 -9 54 , F2

47

Fan, fan clutch Num ber

Engine 541.920/

Designation

921/922/923/

Engine 542.920/

924/925/926/927

921/925/926

BA20.40-N-1001-01C

Viscous fan clutch to interm ediate piece

Nm

50

50

BA20.40-N-1002-01C

Fan to viscous fan clutch

Nm

30

30

Additional Information E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h icle m od. des. 9 50-954, F2

49

AR20.40-W-5614B

17.12.96

Removing and installing fan

ENGINE 542.922/923

W20.40-0002-09

1

Viscous fan clutch

7

2 3 4

Fan B o lt

8 9 10

Fan drive Bolt Support Bolt

11

Bolt

5 6

Interm ediate piece B o lt B o lt

s a is i


A



w h e n tilting cep

the cab w h e n it is b e in g tilted. A lw a y s tilt

Danger!

Page 4


T ilt cab

®


M odel 950,952,953,954

2


CD bottom and side right

3

Take off cover (T D C insp ection hole) at

0

Page 4

BA 01.60-N -1Q 01-01B

En d co ver t o tim in g case

tim ing case

EDUse a suitable tool to block flyw heel at

4

Block engine at flyw heel

5

Detach viscous fan clutch (1) together w ith

□ 0 Installation : viscous fan clutch and fan

fan (2) and interm ediate piece (4) at fan

should be stored upright fo r at least 1 hour

drive (7) and take d o w n and out

before installing

ring gear

6

Detach fan drive (7) at support (9)

7

Detach fan d rive (7) at v ib ra tio n d am p e r

8

Detach interm ediate piece (5) and viscous fan clutch (1)

50

0 0 0 0

Fan drive to interm ediate piece

BA20.40-N-1006-01C


BA20.40-N-1004-01C

Fan drive to v ib ra tio n d a m p e r

B A 2 0 .4 0-N -1 0 0 3 -0 1 C

Viscous fan clutch to interm ediate

BA20.40-N-1001-01C

piece


9

Detach viscous fan clutch (1) at fa n (2)

® Fan to viscous fan dutch

BA20.40-N-1002-01C

10

Detach support (9) at coolant pum p

0

BA20.40-N-1005-01C

11

Install in th« reverse order

Support to coolant pum p

® Timing case Number

Designation

BA01.60-N-1001-018

End cover o f TDC inspection hole to tim ing case

Engine 542.920/ 921/922/923/ 925/926 Nm 25

@ Fan, fan clutch Number

Designation

BA20.40-N-1001-01C

Viscous fan clutch to interm ediate piece

Nm

50

Engine 542.922/ 923

BA20.40-N-1002-01C

Fan to viscous fan clutch

Nm

30

BA20.40-N-1003-01C

Fan drive to vibration dam per

Nm

30

BA20.40-N-1004-01C


Nm

30

BA20.40-N-1005-01C

Support to coolant pump

Nm

30

BA20.40-N-1006-01C

Fan drive to interm ediate piece

Nm

50

Additional Information E n gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h ic le m od. des. 9 50 -9 54 , F2

51

AR23.20-W-9440A

Disassembling and assembling rear engine output

20.3.96

ENGINE 541.920/921 /922 /923/924/925/926/927.542.920/921 /922/923/92S/926 with CODE (N51) Rear engine output output torque 392 Nm with CODE (NS2) Rear engine output, output torque 600 Nm 1

O il spray nozzle

2 3 4

Nut G ear O-ring

5 6

Bearing housing R oller bearing

7

Shaft

8 9

Spacer tube B allb e arin g

10

R oller bearing

11

Race

12

Shim

13 14

O-ring Bearing cap

15

Radial scat

16

Spring lock washer

17

B olt

18 19 20

Cover plate O utp ut flange N ut

W23.20-0001-06

2 3

N ut Gear

21 22

5 7 14

Bearing housing Shaft w ith bearing Bearing cap

23 24 25

17

Bolt

26

20

N ut

IS) Puller IS Internal extractor IS Countersupport US H o t a ir blow er IS Retaining wrench IS Box wrench


0 A

Disassembling Danger!


No person should be in the tilting area of the cab w hen it is being tilted. Always tilt

Page 4

cab as fa r as the end position and secure with a safety prop.

1

Tilt cab

®

Notes re tilting cab

Models 950,952, 953, 954

Page 4 2

Detach propeller shaft

3

Detach right and rear noise encapsulation

4

Remove tim ing case cover

5

Slacken nut (2) fo r gear (3) w ith box

AR01.40-W-8000A

Q] Counterhold output flange (19).

wrench (26)

6

Unscrew nut (20)

H

402 589 03 03 00

m

460 589 01 31 00

E Counterhold flange (19) w ith retaining wrench (25).

m 7

460 589 01 3100

Take o ff output flange (19) and cover plate (18)

8

Remove bearing cap (14)

9

Take o ff O-ring (13) and shim (12)

10

Tighten nut (20) w ith p uller (21)

E Collect engine oil w hich flows out. @ Place protective padding below the bolt o f the puller.

m 11

745 589 00 33 00

Use puller (21) to pull o u t shaft (7) and bearings (6,9,10) and at the same tim e unscrew nut (2)

12

Take input gear (3) out o f th e tim in g case

13

Take spacer tube (8) out o f th e bearing housing (5)

14

Use internal extractor (22) and counter

® Place protective pads below the

support (23) to pull bearing housing (3) o u t

co un tersup po rt (23)

o f the tim ing case

15

HI

000 589 35 33 00

m

000 589 68 33 00

Take o ff O-ring (4) at bearing housing (5)

Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h ic le m o d . des. 9 50 -9 54 , F2


53

16

Page 56

Remove bearings (6,9,10) at the shaft (7) and install

001 58919 33 00

SI 0

17

Assem bling Check th at oil nozzle (1) in the crankcase is

0

O il nozzle to crankcase

E

Replace O-ring

BA01.40-N-1006-01D

tig h tly located 18 19

20

Fit O-ring (4) over the bearing housing (5) Insert bearing housing (5) in the tim ing

G O Machined face pointing tow ard tim ing

case

case cover. Fix bearing housing in place w ith bolts.

Heat tim ing case w ith ho t air b low er and knock bearing housing (5) into the tim ing case

21

Insert spacer sleeve (8) into the bearing housing (5)

22

Insert shaft (7) w ith bearings (6,9,10) into the bearing housing (5)

23

E

Pay attention to locking lug.

E

W hen Inserting the shaft, fit the input

gear (3) over th e splines and screw in the new nut (2) o nto the thread o f the shaft.

Insert radial seal (15) and O-ring (13) into the bearing cap (14) Fit on shim (12)

24

Install bearing cap (14)

E

25

M easure distance betw een bearing cap (14) and bearing bush (5)

S

Tighten bolts (17) diagonally to 10 Nm.

Specification=0.10 mm to 0.20 mm. If the distance is greater, install a thinner

shim (12); if th e distance is less, install thicker shim. 26

Tighten bearing cap (14)

27

Fit cover plate (18) o nto the shaft (7)

28

Install input flange (19)

@ Bearing housing to tim ing case

BA23.20-N-1001-01A

E D Replace n u t (20) and secure.

Counterhold inp u t flange. m

460 5 8 9 0 1 3 1 0 0

@ O utput flan g e to shaft 29

Use box wrench (26) to tighten nut (2) at th e gear (3) and secure

E

retaining wrench (25). m

460 589 01 3100

GH

402 589 03 03 00

0

30

Install tim ing case cover

31

Fit on propeller shaft

32

Install noise encapsulation

/ h Danger!


BA23.20-N-1003-01A

Counterhold input flange (19) w ith

BA23.20-N-1002-01A

Input gear to shaft

AR01.40-W-8000A


Page 4

the cab when it is being tilted. Alw ays tilt cab'as far as the end position and secure w ith a safety prop.

33

T ilt cab In direction o f travel

34

Start angina

@ Crank engine w ith starter fo r no t more than 20 seconds. W ait about 2 minutes before making a repeat attem pt at starting.

54


35.1


Li] Only if oil level sensor is parameterized. See ACTROS Operating Instructions Part 3

35.2


36


0

Q] If oil level sensor is not param eterized. See ACTROS Operating Instructions Part 4


N um ber

Designation

BA01.40-N-1006-01D

O il nozzle fo r oil supply (PTO) to crankcase

M 18X 1.5

Nm

Engine 541.920/ 921/922/

Engine 542.920/

923/924/

923/925/

925/926/ 927

926

80

80

921/922/

@ Rear engine outpout N um ber

Designation

Engine 541.920/ 921/922/923/

921/922/923/

Engine 542.920/

924/925/926/927

925/926

BA23.20-N-1001-01A

Bearing housing to timing case

Nm 25

25

BA23.20-N-1002-01A

Input gear to shaft

Nm 300

300

BA23.20-N-1003-01A

O utp ut flange to shaft

Nm 300

300

0 0 0 5 89 6 8 33 00 In tern al e x tra cto r

r

\^

001 589 19 33 00

J

Puller

Additional Information En gin es O M 501, O M 502 (m od. des. 541.9, 542.9), A CTRO S - V e h icle m od . des. 9 50-954, F2

55

AR23.20-W-9440-02A

Removing and installing bearings in rear engine output

001 589 19 33 00 Puller

1

Press th e bearings (4, 5) and bearing race (3) at the output end o ff the shaft ( 1) .

DD Screw nut (2) flush onto th e shaft (1) as a p rotection fo r th e thread. 2

Use puller (7) to pull bearing inner race (6) fo r the inp u t end roller b ea ring o ff the shaft (1).

W23.20-0002-01

3

Heat inn er race (6.1) fo r rear bearing on a heating plate to ab o u t 80° C and fit it onto the shaft (1) at th e input end.

4

Heat first half o f sp lit inner race (5.1) o f angu lar-co ntact ball b ea rin g (S) to

ab out 80° C and fit onto the shaft (1) at o u tp u t side. 5

Fit ball b earing (5) o n to th e bearing

inner race (5.1). Heat second half o f the split inner race (5.2) o f th e angular-contact ball bearing to about 80° C, fit it onto the shaft (1) and press it fu lly on.


Heat inner race (4.1) - at o utput side o f roller bearing to about 80° C, fit onto the shaft (1) and press into final position. Fit roller bearing (4) onto the bearing inner race (4.1).

9

Heat race (3) fo r the shaft seal to

a b o ut 80° C and fit it onto the shaft (1). 10

O il b o th b e arin gs (4, 5).

11

Press inp u t end roller bearing (6) out o f the bearing flange (8).

12

Insert roller bearing (6) into the bearing flange (8). Oil roller bearing (6).

W23.20-0008-01

Additional Information I B P 1

E n g in es O M 501, O M 502 (m od. des. 541.9, 542.9), A C TR O S - V e h icle m o d . des. 9 50 -9 54 , F2

57

0

BA46.30-N-1003-01C

S uction line o n elbow /pow er steering

pum p 0

B A46.30-N-1006-01C

Pressure line o n conn ection

piece/pow er steering pum p

6

Detach p o w er steering pum p/fuel pum p

HI Installation:

unit (1) fro m tim in g case

tu rn p o w e r steering pum p/fuel pu m p unit

Replace O -ring (2) and

shaft un til th e g u id e o f th e cross-type disc (3) is up right.

BA46.30-N-1001-01C

0 P o w e r steering pum p/fuel pu m p on tim ing case 7

Rem ove cross-type disc (3)

E

Installation: Tu rn en gin e w ith tu rn in g

device un til the cross-type disc g u id e on the com pressor crankshaft is horizontal, pu t on cross-type disc and secure w ith grease to preven t it fro m slipping. If po w er steering pum p/fuel p u m p unit (1)

8

E

Installation: Replace sealing rings (4,7).

0

Suction line elb o w on po w er steering

is replaced, reb uild co nn ectio n piece (5) and e lb o w (10)

B A46.30-N-1002-01C

pu m p 0

BA46.30-N-1005-01C

Pressure lin e con n ectio n piece on

p o w e r steering pum p 9

Install in reverse o rder

10

Bleed fu e l system

11

Replenish hydraulic flu id in steering system

P a g e 61

AR46.25-W-3300A

and bleed system

0

Tim ing case

N um ber

Designation

BA01.60-N-1001-01B

End cover, TDC inspection hole on

Engines 541.920/

Engines 542.920/

921/922/923/

921/922/923/

924/925/926/927

925/926

Nm 25

25

tim ing case

0

P o w e r steering pum p

Num ber

S te e rin g 765.869

D e sig n a tio n

w ith engine 541, 542 BA46.30-N-1001-01C

Power steering pum p/fuel pum p on tim ing case

Nm

60

BA46.30-N-1002-01C

Suction line elb o w on pow er

Nm

80

steering pump BA46.30-N-1003-01C

Suction line on elbow /pow er steering pum p

Nm

100

BA46.30-N-1005-01C

Pressure line connection piece on pow er steering pump

Nm

80

BA46.30-N-1006-01C

Pressure line on connection

Nm

80

piece/power steering pump

Additional Information E n g in e s O M 501, O M 502 (m od. des. 541.9,542.9), A CTRO S - V e h icle m od. des. 9 50 -9 54 , F2

59

AP47.00-W-1720-01A

Bleeding air in fuel system

1


2

Actuate manual pum p until ove rflow valve opens audibly.

3

Tighten handle o n manual pump.

Additional Information Engines O M 501, O M 502 (m od. des. 541.9, 542.9), A C T R O S -V e h ic le m od. des. 9 5 0 -9 54 , F2

61

AR47.20-W -5712A

R em oving and installing fuel p um p/pow er steering pum p unit

8.10.96

ENGINE 541.920/921 /922 /923 /924 /92S /926/927, 542.920 /921 /922 /923 /92S/926

EH HD

R em oving, installing Rem ove fu e l pu m p/po w e r steering pum p

Page 58

unit, install


62

AR46.30-W-0400A

8.10.96

Removing and installing p o w er steering/fuel pump unit

STEERING 76S.889 w ith E N G IN E S41.920/921 Z922/923 /924 /92S/926/927, S42.920 /921 /922 /923 /9 2S/92 6 1

P o w e r steering p u m p /fu e l p u m p u n it

2

O -rin g

3

Cross-type disc

4

Se aling rin g

5

C o n n e c tio n p iece

6

S te e rin g lin e (pressure)

7

S e a lin g rin g

8

Pressure ring

9

Nut

10

E lb o w

11

S te e rin g lin e (suction)

12

B anjo b o lt

13

S e a lin g ring

14

F u e l lin e (suction)

15

Fue l lin e (pressure)

16

B anjo b o lt

17

B o lt

mum A D an g er!

R e m o v in g , installin g Risk o f in ju ry d ue to being tra p p e d or

N ob o d y should be w ith in th e tiltin g ran ge '

crush ed w h en tiltin g th e cab.

o f th e cab w h ile tiltin g . A lw a y s t ilt th e cab

Page 4

up to its fin a l p osition an d secure w ith a safety support. 1

T ilt cab

® 2

N otes o n tiltin g cab

M o d els 9 5 0 ,9 5 2 ,95 3 ,9 5 4

R em ove en g in e en capsulation

CDb e lo w

3

A tta c h tu rn in g device fo r en g in e to tim in g

@ The tu rn in g device m ust be rem oved

case

/ h D an g er!

Page 4

b efore sta rting th e engine. is

407 589 0 0 6 3 00

@ End cover on tim in g case

BA01.60-N-1001-01B

R isk o f e x p lo sio n d u e to ig n itio n , risk o f

Fire, sparks, naked flam e an d sm o kin g

p o is o n in g fro m in h a lin g an d sw allo w in g

fo rb id d e n .

fu e l as w e ll as risk o f in ju ry d ue to fu el

O nly p o u r fu els in to su itable, a p p ro p ria te ly

Page 60

co m in g in to co ntact w ith th e skin an d eyes. m arked containers. W ear p rotective clo th in g w h e n ha n d lin g fuel. 4

5

R em ove fu e l lines (14,15) on p ow er

HI C o lle ct fu el w h ich runs out.

ste erin g p um p/fu el pum p u n it (1)

In stallation : Replace sealing ring s (13).

D e tach steering lines (6,11) fro m p ow er

0 Fuel lin e on fu el pum p Q] Steady conn ectio n piece (5) a n d e lb o w

ste erin g p u m p /fu el pum p un it(1 )

(10) w h e n loosening and co lle ct any h y d ra u lic flu id w h ich runs o ut.

[3 In stallation : Steady c o n n e ctio n piece (5) an d e lb o w (10) w h en tig h te n in g

58

BA47.25-N-1002-01B

AR20.40-W-5614A

29.10.96

Rem oving and installing fan

ENGINE 541.920/921 /9 2 2 /9 2 3 /9 2 4 /9 2 S/9 2 6 /9 2 7 ,542.920/921 Z925/926

W20.40-0001-06

Em u

R em o vin g , in stallin g

Æ D anger)

Risk o f in ju ry fro m bruises an d ja m m in g

No person should be in th e tiltin g area o f

w h e n tiltin g cap

th e cab w h e n it is b ein g tilte d . A lw a y s tilt

Page 4

cab as fa r as th e end p o sitio n an d secure w ith a safety prop. 1

T ilt cab

®

N otes re tiltin g cab

M o d e l 9 5 0 ,9 5 2 ,9 5 3 ,9 5 4

2

Rem ove noise en cap su lation

H I b o tto m

3

Take o ff cover a t tim in g case

0

End cover a t tim in g case

4

B lock en g in e a t fly w h e e l

H

Use a su itab le to o l to b lo ck fly w h e e l at

Page 4

BA01.60-N-1001-01B

ring g ear 5

D etach viscous fa n clutch (1) to g e th e r w ith

[ U In sta llation : viscous fa n clutch an d fa n

fa n (2) a t in te rm e d ia te piece an d ta ke

should be stored u p rig h t fo r a t least 1 ho u r

d o w n and o u t

b efore installin g 0

BA20.40-N-1001-01C

Viscous fa n clutch to in term e diate

piece 6

D etach viscous fa n clu tch (1) a t fa n (2)

7

Install in th e reverse o rd er

0

0

BA20.40-N-1002-01C

Fan to viscous fa n clutch

T im ing case

N um ber

D é sig n atio n

En g in e 541.920/

E ng ine 542.920/

921/922/923/

921/922/923/

924/925/926/927 BA01.60-N-1001-01B

End cover o f TDC in sp e ctio n h o le to

Nm 25

tim in g case

48

From the library of Barrington Diesel Club

925/926 25

Om501 Om502 Workshop Manual Abby

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