Chassis serial number: 5356587

01-00 Removing and fitting the engine

Assembly
Information! Renew coolant hoses if there is
clear damage to the coolant hoses which were
removed.

Information! Tightening torques for the

engine and information on seals are found in
section 01-00, Engine assembly.

Removal - 9 and 13 litre engines [XPI, PDE, gas]

Tools

Number Designation Illustration Tool board

98 094 Lifting accessory D4

142 033

99 318 Engine support kit D5

142 246

99 470

99 470 Adapter D5
151 442

99 637 Lifting eye D3

316 409

587 308 Ratchet lever hoist N/A

142 730

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 Chassis serial number: 5356587

Number Designation Illustration Tool board

Completing kit for

2 377 964 engine support kit D5
99 318

349 394
Preparatory work
1. Connect SDP3 to the vehicle and unlock the
engine control unit.
The function is accessed by selecting SDP3 >
Checks and adjustments > COO/EMS/LAS >
Immobiliser without enhanced theft protection
(starter keys without transponder)

2. Depressurize the fuel system using SDP3.

3. Depressurise the pneumatic system.

4. Remove the battery cover and detach the

ground cable from the negative terminal.

5. Drain the coolant. See 02-00 Cooling system

assembly > Cooling system > Adjusting –
Draining and filling coolant.

6. Tilt the cab. Refer to 18-65 Cab tilting.

7. Remove the catwalk.

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 Chassis serial number: 5356587

From the left-hand side of the engine

1. Remove the beam between the rear cab
attachments.

1
2

6
3

303 356
4 5 7
1. Beam between rear cab
attachments
2. AC compressor
3. Control unit
4. Hand pump
5. High pressure pump
6. Upper coolant hose to
retarder
7. Oil pipe

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 Chassis serial number: 5356587

2. Disconnect the AC compressor and place it to

one side.
Information! The A/C hoses must not be bent
over 90°

Disconnect the A/C compressor harness-to-

component connector.
Information! Avoid opening the circuit to the
AC system. If the cooling system is opened, it
must be filled with new refrigerant and this may
only be done by authorised personnel.

3. Remove the left-hand cover from the control

unit. Disconnect the third harness-to-component
connector from above.

303 215

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 Chassis serial number: 5356587

4. Detach the fuel pipes 1 of the high pressure

pump and hand pump and detach the
compressed air line 2 from the compressor.

303 216
5. For engines with GAS, Euro 6: Remove the
gas connection on the fuel manifold.

337 533

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 Chassis serial number: 5356587

6. Remove the 5 screws on the hydraulic pump 1. 2

Detach the oil pipes 2 at the clutch housing.

303 217
7. Undo the screws of the gear change linkage; see
picture.

303 218
8. Undo the hose clamp on the upper retarder
coolant hose.

9. Remove the upper screws on the clutch

housing.

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 Chassis serial number: 5356587

From the right-hand side of the engine

1. Undo the exhaust pipe V-clamp. Move the
exhaust pipe out of the way.

1 3

303 219
1. Exhaust pipe
2. Intake manifold
3. Compressor silencer
4. Coolant connection for
expansion tank
5. Charge air cooler hoses
6. EGR cooler hose

2. Detach the hose from the air dryer to the

compressor.
303 211

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 Chassis serial number: 5356587

3. Remove the induction pipe. Cover the air filter

and turbocharger intake manifold.

4. Detach the compressed air pipe for the valve

block.

303 212
5. Detach the coolant hoses from the radiator.

6. Detach the coolant hoses for the expansion

tank.

7. Detach the ribbed hoses for the charge air

cooler and EGR cooler.

8. If the vehicle has an engine heater: Undo the

connection for the engine heater.

From the underside of the vehicle

1. Lift the vehicle.

2. Remove the noise shields.

3. Undo the starter motor cable harness 1, oil

1
dipstick 2 and oil filler hose 3.

2
303 213

4. Detach the ground connection.

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 Chassis serial number: 5356587

5. Disconnect the upper coolant hose of the

retarder cooler.

6. Drain the retarder cooler by undoing the coolant

plug.

303 214
7. Detach the electrical cables and the compressed
air lines at the upper rear edge of the gearbox.
Mark the electrical cables to make fitting easier.

303 220
8. If the chassis is long: Undo the propeller shaft
mounting at the joint.

IMPORTANT!

Mark the position of the propeller shaft before

removal. Secure the universal joint using cable
ties as illustrated so that it is not detached from
the propeller shaft.

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 Chassis serial number: 5356587

9. Undo the 4 screws at the front of the propeller

shaft and then use an M12 screw as a puller.

10. Detach the propeller shaft at the rear and lower

the propeller shaft.

11. Detach the compressed air lines for the clutch

servo.

IMPORTANT!

Hold the union when the compressed air line is

unscrewed. Otherwise there is a risk of
damaging the clutch servo.
Do not disconnect the clutch fluid pipes.

303 221

12. Undo the clutch servo.

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 Chassis serial number: 5356587

13. Fit engine supports 99 318 Engine support kit

or 2 377 964 Completing kit for engine support
kit 99 318 and the adapters 99 470 Adapter to
support the engine.
Before the engine supports can be fitted, 2
screws must be removed from the oil sump as
illustrated.

303 222
14. Remove the gearbox; see 05-00 Gearbox
assembly.

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 Chassis serial number: 5356587

Removing the engine

1.
IMPORTANT! o
max 30

300 424
The lifting eyes are designed to manage a
maximum inclination angle of 30° when lifting
an engine with the gearbox removed.

IMPORTANT!

The lifting eyes on the engine are not designed

to lift the whole vehicle and therefore must not
be used for this purpose. All three lifting eyes
must be used when lifting the engine.

Lower the vehicle.

2. Undo the bolts at the engine brackets - 3 bolts

on each side of the engine.

303 223

3. Fit the lifting eyes on the flywheel housing

studs.
Lifting eyes can be ordered as spare parts, part
number 99 637 Lifting eye.
Hook 587 308 Ratchet lever hoist into the
lifting eye at the front edge of the engine. Hook
98 094 Lifting accessory into the 2 lifting eyes
at the rear of the engine.
303 224

Lift out the engine.

Fitting - 9 and 13 litre engines [XPI, PDE, gas]

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 Chassis serial number: 5356587

Tools

Number Designation Illustration Tool board

98 094 Lifting accessory D4

142 033
99 318 Engine support kit D5

142 246
99 470

99 470 Adapter D5

151 442 D3
99 637 Lifting eye

316 409

587 308 Ratchet lever hoist N/A

142 730

Completing kit for

2 377 964 engine support kit D5
99 318
349 394

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 Chassis serial number: 5356587

Preparatory work
1. Transfer the following to the new engine:
• Fan
• Front pulley studs
• Bracket 1 for retarder coolant pipe 1

• Coolant pipe 2 for coolant pump

• Flywheel housing studs

303 225
• Pressure plate

303 226
2. Remove the tensioning pulley where the AC
compressor will sit on the new engine.

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 Chassis serial number: 5356587

Lift the engine

1.
IMPORTANT! o
max 30

300 424
The lifting eyes are designed to manage a
maximum inclination angle of 30° when lifting
an engine with the gearbox removed.

IMPORTANT!

The lifting eyes on the engine are not designed

to lift the whole vehicle and therefore must not
be used for this purpose. All three lifting eyes
must be used when lifting the engine.

Fit 99 637 Lifting eye to the flywheel housing

studs.
Hook 587 308 Ratchet lever hoist into the
lifting eye at the front edge of the engine. Hook
98 094 Lifting accessory into the 2 lifting eyes
at the rear of the engine.
Lower the engine so that it is resting on the
engine insulators and 99 318 Engine support
kitor 2 377 964 Completing kit for engine
support kit 99 318and 99 470 Adapter.
2 screws must be removed from the oil sump
before the engine supports can be fitted.

2. Install the bolts at the engine brackets - 3 bolts

on each side of the engine.
Do not tighten the bolts until the gearbox has
been installed in the gearbox beam.

3. Remove the lifting chains.

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 Chassis serial number: 5356587

From the underside of the vehicle

1. Lift the vehicle.

2. Fit the gearbox, see 05-00 Gearbox assembly.

3. Screw the lower screws onto the clutch housing.

4. Fit the gearbox beam bolts. There are 3 screws

on each side.

5. Remove the engine supports and adapters. Fit

the oil sump bolts.

303 222
6. Fit the clutch servo and clutch servo air hose;
see picture.

303 221

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 Chassis serial number: 5356587

7. Fit the electrical cables and compressed air lines

to the upper rear edge of the gearbox.

303 220
8. Fit the coolant hose for the retarder.

9. Fit the propeller shaft. Start at the front without

tightening the bolts. The holes for the guide
pins must correspond.
Fit the bracket for the support bearing.
Fit the rear propeller shaft.
Tighten all propeller shaft bolts.

10. Information! All the contact surfaces must be

1
clean and dry.

Fit the oil dipstick 1, oil filler hose 2, starter

motor cable harness 3 and ground lead.

2
303 213

11. Fit the noise shields.

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 Chassis serial number: 5356587

Right side of engine

1. Tighten the bolts at the right-hand engine
bracket.

1 3

303 219
1. Exhaust pipe
2. Intake manifold
3. Compressor silencer
4. Coolant connection for
expansion tank
5. Charge air cooler hoses
6. EGR cooler hose

2. If the vehicle has an engine heater: Fit the

engine heater.

3. Attach the ribbed hoses for the charge air cooler

and EGR cooler.

4. Fit the coolant connections for the expansion

tank.

5. Attach the coolant hoses to the radiator.

6. Fit the compressor silencer.

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 Chassis serial number: 5356587

7. Fit the hose from the air dryer to the

compressor.

303 211
8. Fit the intake manifold.

9. Fit the exhaust pipe.

323 452

IMPORTANT!

Retighten the V-clamps once the engine has

reached normal operating temperature.

10. Fit the compressed air pipe to the valve block. 303 212

From the left-hand side of the engine

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1
2

6
3

303 356
4 5 7
1. Beam between rear cab 4. Hand pump
attachments 5. High pressure pump
2. AC compressor 6. Upper coolant hose to retarder
3. Control unit 7. Oil pipe
1. Tighten the bolts at the left-hand engine
bracket.

2. Fit the 6 upper bolts of the clutch housing.

3. Fit the upper coolant hose to the retarder.

4. Screw the 3 bolts onto the gear change linkage.

303 218

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 Chassis serial number: 5356587

5. Fit the power steering hydraulic pump 1. 2

Attach the oil pipes 2 at the clutch housing.

303 217
6. Attach the fuel pipes 1 of the high pressure
pump and hand pump and attach the
compressed air line 2 to the compressor.

2
303 216

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 Chassis serial number: 5356587

7. For engines with GAS, Euro 6: Fit the gas

connection to the fuel manifold.

337 533
8. Bleed the fuel system.

9. Fit the harness-to-component connector on the

control unit.
Fit the cover on the control unit.

303 215

10. Fit the A/C compressor and the A/C compressor

harness-to-component connector and hoses.

11. Fit the beam between the rear cab attachments.

12. Fit the catwalk.

13. Tilt the cab back. Refer to 18-65 Cab tilting.

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 Chassis serial number: 5356587

14. Fill with coolant. See 02-00 Cooling system

assembly > Cooling system > Adjusting –
Draining and filling coolant.

15. Fit the battery ground lead and battery cover.

SDP3 procedure after engine renewal

1. Start SDP3 and follow the instructions.
Adjust any parameters under SDP3 > Checks
and adjustments.

2. Lock the engine control unit to the vehicle.

The function can be accessed in SDP3 >
Checks and adjustments > Functions >
Calibration > Theft protection > Locking and
unlocking control units.
Check that the fuel valve is unlocked.
Look to see if there are any fault codes. Rectify
the fault codes.
Clear inactive fault codes.

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