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
Removing and installing exhaust gas turbocharger
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
Technical data engine
O M 501 LA (engine 541.922/ 927)
Page 4
t t ìr - G F
Technical data engine
O M 501 LA (engine 541.923/ 924)
Page5
SS*GF
Technical data engine
O M 501 LA (engine 541.921/925)
Page 6
GF01.00-W-1000-01D
Technical data engine
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
Technical data engine
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
Engine m odel designation
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
4-stroke diesel w ith direct injection
Com bustion method
Exhaust turbocharging and intercooiing
Injection m ethod
Single unit pum p w ith pum p-line-nozzle system (PLD)
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
g/kW h (see diagram)
Technical data engine
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
Engine m odel designation
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
No. o f cylinders/arrangem ent
6 in V arrangem ent
Valves
Operating method
Inlet
2
Exhaust
2
4-stroke diesel w ith direct injection
Com bustion method
Exhaust turbocharging and intercooling
Injection m ethod
Single unit pum p w ith pum p-line-nozzle system (PLD)
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 fu e l consum ption (b)
GF01.00-W -1000-01G P M n b
g/kW h (see diagram)
Technical data engine
Engine 541.921/925
[Ä -G F
Engine o utput Engine torque R ated speed Specific fuel consumption
Additional Information
6
Engine m odel designation
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
Engine torque (M) max.
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
No. o f cylinders/arrangem ent
6 in V arrangement
Valves O perating m ethod
Inlet
2
Exhaust
2
4-stroke diesel w ith direct injection
Com bustion m ethod
Exhaust turbocharging and intercooling
Injection m ethod
Single unit pum p w ith pum p-line-nozzle system (PLD)
Control
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)
g/kW h (see diagram)
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
Technical data engine
O M 502 LA (engine 542.920/926)
Page 8
Technical data engine
O M 502 LA (engine 542.921/925)
Page 9
Technical data engine
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
Additional Information 8
Engine model designation
542.920 (low)
Engine type
O M 502LA. II/2
Engine o utput (P)
kW/HP
390/530
rpm
1800
Engine torque (M) max.
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
No. o f cylinders/arrangem ent
8 in V arrangem ent
Valves
O perating method
Inlet
2
Exhaust
2
4-stroke diesel w ith direct injection
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)
g/kW h (see diagram)
GF01.00-W-1000-011
Technical data engine
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)
Engine m odel designation
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
No. o f cylinders/arrangem ent
8 in V arrangem ent
Valves
Inlet
2
Exhaust
2
4-stroke diesel w ith direct injection
O perating m ethod Com bustion m ethod
Exhaust turbocharging and intercòoling
Injection m ethod
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 consum ption (b)
g/kW h (see diagram)
GF01.00-W-1000-01J
Technical data engine
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
Additional Information 10
Engine m odel designation
542.922 (low) 542.923 (high)
Engine type
O M 502LA. II/3
Engine o utpu t (P)
kW /HP
420/571
rpm
1800
Engine torque (M) max.
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
4-stroke diesel w ith direct injection
Com bustion m ethod
Exhaust turbocharging and intercooling
Injection m ethod
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 fuel consum ption (b)
g/kW h (see diagram)
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
Additional Information 12
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
Additional Information 14
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
Additional Information 16
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.
Additional Information 18
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 .
Additional Information 20
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.
Additional Information 22
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
End cover o f TDC inspection hole to
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
Additional Information 24
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
Additional Information 26
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
Install in th e reverse order
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
Additional Information 28
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
Removing, installing
/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.
Additional Information 30
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
M o d ification notes 6.2.97
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
Additional Information
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
Additional Information 33
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
Risk o f accident as a result o f vehicle
Secure vehicle to prevent It moving off.
Page 20
starting o ff w hen en g in e running. Risk o f
W ear closed and close-fitting w ork clothes.
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
Install in the reverse order
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.
Check engine oil level w ith dipstick
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 oil pressure at
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
Additional Information 34
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
Additional Information 36
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
Remove nozzle holder com bination
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
Additional Information 38
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
Additional Information 40
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
M o d ification notes 6.2.97
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
Additional Information 41
® 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
Install in the reverse order
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
Additional Information 42
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
M o d ifica tio n notes 6.2.97
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
Additional Information 44
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
Install in the reverse order
Z Ü Danger!
Risk o f accident as a result o f vehicle
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
Check engine oil level w ith electric gage
E
12.2
Check engine oil level w ith dipstick
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 oil pressure at
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
M o d ification notes 6.2.97
Tightening torque fo r oil sump bolts m odified
AR01.45-W-7500-01A
Additional Information 46
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.
Additional Information 48
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
Additional Information 50
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
Additional Information 51
8
Install cylinder head
Page 32
Test data o f cylinder liner Number
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
Additional Information 52
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
-
Additional Information 54
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.
Additional Information 56
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
M odification notes 6.2.97
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
Notes re tiltin g cab
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
Support to fixture o f refrigerant
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
Install in th e reverse order
Æ> Danger!
Risk o f accident as a result o f vehicle
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.
Additional Information 58
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
Check engine oil level w ith electric gage
HI Only if oil level sensor is parameterized. See ACTROS Operating Instructions Part 3
16.2
Check engine oil level w ith dipstick
0 0 If oil level sensor is not parameterized. See ACTROS Operating Instructions Part 4
17
Switch o ff engine and check fo r leaks
Test data o f engine oil pressure Number
Designation
BE18.00-N-1001 -01D
Engine oil pressure at
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
Support to fixture o f refrigerant
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
Additional Information 60
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
Removing, installing
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
Additional Information 61
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
Install in the reverse order
Additional Information 62
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
Removing, installing
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
Additional Information
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
Additional Information
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
Install in the reverse order
26 ^
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 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
Check engine oil level at electric gage
0D O nly if oil level sensor is param eterized. See ACTROS O perating Instructions Part 3
28.2
Check engine oil level w ith dipstick
QD If oil level sensor Is not param eterized. See ACTROS O perating Instructions Part 4
29
Switch o ff engine and check fo r leaks
Test data o f engine oil pressure Num ber
Designation
8E18.00-N-1001-01 D
Engine oil pressure at
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
Crankcase, tim ing case cover, end cover
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
Additional Information 66
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
End cover o f TDC inspection hole to
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
Additional Information 67
Repair products Number
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.
Additional Information 68
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
Additional Information 69
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
Additional Information 70
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
Conrod bearing journal 0
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
Additional Information 72
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
Com m ercially available tools (see W orkshop Equipm ent Manual) Number
Designation
WH 58.30-Z-1001 -12A
Quick calipers fo r internal measurements 0 80 - 100 mm
WH58.30-Z-1013-12A
M icrom eter 7 5 -1 0 0 mm
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.
Additional Information 74
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
M o d ifica tio n notes 6.2.97
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
Additional Information
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
Additional Information 77
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
@ End cover to tim ing case
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
Install cylinder head
Page 32
Test data o f cylinder liner Number
BE01.40-N-1001-03C
Designation
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
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
Additional Information 78
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.
Additional Information 80
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
Install in the reverse order
Additional Information 82
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
Additional Information 84
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
Additional Information
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
Additional Information 87
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
Additional Information
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
Additional Information 89
® 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
Additional Information
^
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
Additional Information 91
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
Additional Information
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
Additional Information 94
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
Conrod bearing journal 0
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
M icrom eter 7 5 -1 0 0 mm
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
Additional Information 96
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
Additional Information 97
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
Additional Information 98
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
End cover TDC inspection hole to tim ing case
Nm 25
Engine 542.920/ 921/922/923/ 925/926 25
Additional Information 100
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
Removing, installing
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
End cover to tim ing case
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
Additional Information 102
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
Install in th e reverse order
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
Shank length when new
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
Flywheel to crankshaft
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
Repair products Number
Designation
O rder num ber
BR00.45-Z-1001-06A
MB lon g life grease
000989 63 51
Additional Information 104
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
Additional Information 105
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
Test data o f fly w h ee l Num ber
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
Additional Information 106
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
Additional Information 4
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
M o d ifica tio n notes 31.1.97
Tightening torque/tightening angle o f flywheel bolts m odified
Step 4
mm
Removing, installing
1
Remove clutch
2
Take o ff cover at tim ing case
@ End cover to 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
Additional Information
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
Install in th e reverse order
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
Shank length when new
mm 74,0
Max. shank length
mm 75,0
Test data o f fly w h ee l Num ber
Designation
Engine 542.920/921/ 922/923/925/926
B E03.30-N-1004-03C
Thread 0
Flywheel bolt
M
16X 1,5
Shank length when new
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
End cover TDC inspection hole to tim ing case
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
Flywheel to crankshaft
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
Repair products Number
Designation
O rdernum ber
B R00.45*Z-1001 -06A
MB lo n g life grease
000989 63 51
Additional Information
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
Additional Information 9
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
Install in the reverse order
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
Additional Information 10
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
Removing, installing
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
Additional Information 12
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
Install in the reverse order
14
Fill engine oil circuit
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
Additional Information 14
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
Additional Information 16
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
Remove nozzle holder com bination
18
Step 3 m odified
Page 18
AR01.30-W-5800B
Page 55
Additional Information
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
Install in the reverse order
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.
Additional Information 20
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
Concentricity o f valve seat to valve stem
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
Com m ercially available tools (see W orkshop Equipm ent Manual) Number
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
Additional Information
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
Additional Information 24
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
Additional Information 25
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
Additional Information
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
Additional Information
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
Removing, installing
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
Additional Information
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
Additional Information 29
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
Additional Information 30
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
Inlet valve seat rings
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
Inlet valve seat rings
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
Valve seat ring overlap in cylinder head
Inlet
m m 0.055-0.090
Exhaust
m m 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
(D) BE05.30-N-1007-03C
Bore 0
Inlet valve seat rings
Standard
in cylinder head (B)
Oversize 0.2
mm 47.500-47.525
Oversize 0.4
m m 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
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
Additional Information 32
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).
Additional Information 34
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
Inlet valve seat rings
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
Valve seat ring overlap in cylinder head
Inlet 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)
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
Additional Information 35
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
Additional Information 36
Test values of valve seat rings
N um ber
Designation
Engine 542.920/921/ 922/923/925/926
BE05.30-N-1001-03C
Inlet valve seat rings
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
Valve seat ring overlap in cylinder head
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
Exhaust valve seat rings in cylinder head (B)
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
Additional Information 38
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.
Additional Information 40
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
Additional Information 41
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)
Concentricity o f valve seat to valve stem
>
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
Additional Information 42
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
D-81309 M ünchen 70
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
Additional Information
® 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
Additional Information 45
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
Additional Information 46
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
Com m ercially available tools (see W orkshop Equipm ent Manual) Number
Designation
WH58.30-Z-1019-05A
Inspection kit for valve seats
M ake (e.g.)
Order number
Hunger
216.93.300
D-81309 M ünchen 70
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
Additional Information 47
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
Additional Information 48
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.
Additional Information 50
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
Additional Information 52
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
Removing, installing
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
Install in the reverse order
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
Loosen handle on manual pump.
2
A ctuate m anual pum p until overflow valve opens audibly.
3
Tighten handle o n manual pump.
Additional Information 54
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
Additional Information 55
;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
Additional Information 56
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
Repair products Number
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. ®
Notes re tiltin g cab
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
Install in the reverse order
PLD control m odule to crankcase.
BA07.15-N-1002-01B
Q ] If a new PLD control m odule is installed
1 58
Additional Information
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.
Additional Information 60
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
Remove noise encapsulation
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
End cover to tim ing case
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
Additional Information 62
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
Additional Information 63
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
End cover o f TDC inspection hole to
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
Additional Information 64
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!
Risk o f accident as a result o f vehicle
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
being started or w hen it is running.
66
Additional Information
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
secure selector lever to prevent it from being operated
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.
Additional Information 68
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
®
Notes re tiltin g 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
Additional Information 69
5
Install in the reverse order
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
Additional Information 70
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
®
Notes re tiltin g cab
M odel 950,952,953, 954
2
Remove noise encapsulation
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
Install in the reverse order
@ 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
Removing, installing
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
A ir intake m anifold to bracket
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
Additional Information
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.
Additional Information 74
AR09.40-W-6020B
Removing and installing exhaust gas turbocharger
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
Removing, installing
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
Additional Information 75
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
Install in the reverse order
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
Crankcase, tim ing case cover, end cover
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
O il delivery pipe to turbocharger
Nm 25
BA09.40-N-1002-01C
Turbocharger to exhaust plenum chamber
Nm 50
BA09.40-N-1003-01C
O il return flo w pipe to turbocharger
Nm 25
BA09.40-N-1004-01C
Insulation above turbocharger
Nm 50
Additional Information 76
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
Rem oving, installing
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
Remove engine brake flap connection (14)
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
Additional Information 77
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
O il return flo w pipe to turbocharger
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
O il delivery pipe to turbocharger
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
Insulation above turbocharger
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
Install in the reverse order
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
Crankcase, tim ing case cover, end cover
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
Additional Information 78
0
Turbocharger
Number
D esignation
Engine 542.920/ 921/922/923/ 925/926
BA09.40-N-1001-01C
O il delivery pipe to turbocharger
Nm 25
BA09.40-N-1003-01C
Oil return flo w pipe to turbocharger
Nm 25
BA09.40-N-1004-01C
Insulation above turbocharger
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
Charge air hose to charge air
Nm 7.5
Engine 542.920/ 921/922/923/ 925/926
housing/charge air pipe and intercooler
Additional Information 80
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
Additional Information 82
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
M o d ification notes 6.2.97
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
Removing, installing
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
®
Notes re tiltin g 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
Charge air hose to charge air
housing/charge air pipe and intercooler 3.2
Remove charge air hose (12)
On engine 542.920-923/925/926
0
Charge air hose to charge air
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
Install in the reverse order
@ 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
Additional Information 84
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
charge air pipe and 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 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
M odification notes 6.2.97
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
Additional Information
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
Risk o f injury from bruises and jam m ing w hen tiltin g cap
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
Rem oving, installing
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
Install In the reverse order
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
Additional Information 88
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
Rem oving, installing
/ 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
®
Notes re tiltin g 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
Additional Information 90
A
Dangerl
Risk o f injury to skin and eyes from
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
Additional Information 91
®
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)
Cylinder liner inner 0
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
Additional Information
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
Install in the reverse order
28
Inspect coolant level
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
Cylinder liner inner 0
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
Crankshaft conrod bearing journal 0
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
A ir intake m anifold to bracket
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
Additional Information 94
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.
Instructions re coolant
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.
Additional Information 96
® 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
Compressor (compressed air system)
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
Additional Information 98
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
Additional Information 99
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
Additional Information
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
Additional Information 102
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
Crankshaft conrod bearing journal 0
BE13.30-N-1007-01B
0
Crankshaft bearing play axial
Compressor (compressed air system)
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
Additional Information 103
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
Additional Information
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
Additional Information 106
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
cab as far as th e end position and secure w ith a safety prop. 1
Tilt cab
®
Notes re tiltin g cab
M odels 950,952,953, 954
2
Remove noise encapsulation
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
Install in the reverse order
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.
Additional Information 4
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
No person should be in the tiltin g area o f
w hen tiltin g cap
the cab w hen it is being tilted. Alw ays tilt
Page 4
cab as far as the end position and secure w ith a safety prop. 1
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
Remove noise encapsulation
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
Install In the reverse order
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
Rem oving, installing
@ Installation
Replace all self-locking nuts and bolts
1
Remove turbocharger
2
Remove noise encapsulation
[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
Install in the reverse order
Additional Information 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
Rem oving, installing
®
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
No person should be in the tiltin g area o f
w hen tiltin g cap
the cab w hen it is being tilted. Always tilt
Page 4
cab as far as the end position and secure w ith a safety prop. 1
Tilt cab
®
Notes re tiltin g cab
M odel 950,952,953,954
2
Remove noise encapsulation
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
Transverse exhaust pipe to flange
Nm 50
m an ifold and flap connection
Additional Information
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
Remove engine brake flap connection (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
Additional Information
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
Additional Information 10
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
Removing, installing
® Installation
Replace all self-locking nuts and bolts
^
Risk o f injury from bruises and jamming
No person should be in the tiltin g area o f
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
®
Notes re tiltin g cab
M od el 950.952.953.954
2
Remove noise encapsulation
| 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
Install in the reverse order
@ 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
Additional Information 12
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
Removing, installing
®
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)
Risk o f injury from bruises and jam m ing w hen tiltin g cap
No person should be in the tiltin g area of the cab w hen it is being tilted. Always tilt
Page 4
cab as far as th e end position and secure w ith a safety prop. 1
Tilt cab
Page 4
®
Notes re tiltin g cab
M od el 950,952,953,954
2
Remove noise encapsulation
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
Install in the reverse order
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
Transverse exhaust pipe to flange
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
Removing, installing
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
Install in the reverse order
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
Additional Information 16
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
Remove noise encapsulation
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
Additional Information 17
^
Dangerl
Risk o f accident as a result o f vehicle starting o ff w hen engine running. Risk o f
Page 19
Secure vehicle to prevent it starting off.
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
Start engine and observe oil pressure gage
@ 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
Switch o ff engine and check fo r leaks
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 oil pressure at
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
Additional Information 18
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
W ear closed and close-fitting w ork clothes.
being started or w hen it is running.
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
secure selector lever to prevent it from being operated
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
Install in the reverse order
Additional Information
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
Rem oving, installing
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
Install in the reverse order
5
Fill engine oil circuit
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
Additional Information 22
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
Rem oving, installing
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
Install in the reverse order
7
Fill engine oil circuit
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
Additional Information 23
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
Additional Information
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
Removing, installing
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
Risk o f injury to skin and eyes from
Do not open the cooling system unless the
scalding from h o t coolant w hich splashes
co olan t tem perature is b e lo w 90 °C. O pen
out. Risk o f poisoning from sw allow ing coolant
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
Additional Information
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
Install In the reverse order
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
Fill engine oil circuit
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
Start engine and observe oil pressure gage
® 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
Switch o ff engine and check fo r leaks
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 oil pressure at
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
Additional Information 28
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
Risk o f injury to skin and eyes from
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
Instructions re coolant
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
Additional Information 30
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
Removing, installing
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
Install in the reverse order
® 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!
Risk o f injury to skin and eyes from
Do not open the cooling system unless the
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
Inspect coolant level
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
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
Risk o f accident as a result o f vehicle
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
Additional Information
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
Removing, installing
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
Additional Information
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
Installation: replace gasket (12)
0
Coolant pipe to coolant pum p
E
Installation: replace gasket (11)
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
Install in th e reverse order
12
Inspect coolant level
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)
Additional Information
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
Com m ercially available tools (see W orkshop Equipm ent Manual) Number
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
Additional Information 40
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
Remove coolant therm ostat (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
Additional Information 41
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.
Additional Information 42
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
Rem oving, installing
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
®
Notes re tiltin g 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
Charge air hose to charge air
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!
Risk o f injury to skin and eyes from
Do not open the cooling system unless the
scalding from ho t coolant which splashes
coolant tem perature is below 90 °C. Open
out. Risk o f poisoning from sw allow ing coolant
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
Additional Information 43
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
Remove coolant therm ostat (7)
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
Install in the reverse order
11
Inspect coolant level
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
Charge air hose to charge air
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
Additional Information 44
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
Removing, installing
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!
Risk o f injury to skin and eyes from
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
Replace all self-locking nuts and bolts
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)
Risk o f injury from bruises and jam m ing when tiltin g cap
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
®
Notes re tiltin g 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.
Additional Information
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
Install In the reverse order
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
charge air pipe and intercooler
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
Removing, installing
A
Risk o f injury from bruises and jamming
No person should be in the tiltin g area o f
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
cab as far as th e end position and secure w ith a safety prop. 1
T ilt cab
®
Notes re tiltin g cab
M odel 950,952,953,954
2
Remove noise encapsulation
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
Fan drive to support
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
Additional Information
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
Fan drive to support
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
Additional Information 52
0 A
Disassembling Danger!
Risk o f injury from bruises and jam m ing when tiltin g cap
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
Additional Information
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!
Risk o f injury from bruises and jam m ing w hen tiltin g cap
BA23.20-N-1003-01A
Counterhold input flange (19) w ith
BA23.20-N-1002-01A
Input gear to shaft
AR01.40-W-8000A
No person should be in the tiltin g area o f
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
Additional Information
35.1
Check engine oil level at electric gage
Li] Only if oil level sensor is parameterized. See ACTROS Operating Instructions Part 3
35.2
Check engine oil level w ith dipstick
36
Switch o ff engine and check fo r leaks
0
Q] If oil level sensor is not param eterized. See ACTROS Operating Instructions Part 4
Crankcase, tim ing case cover, end cover
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.
Additional Information 56
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
Loosen handle on manual pump.
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
Additional Information
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