01 Engine

01 - Engine
AR01.10-W-2400G Remove/install engine 24.2.11

ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W01.10-1014-09
1 Engine wiring harness 4 Air intake hose with air intake pipe 6 Fuel return pipe
2 Cab-chassis connector plate 5 Fuel feed line 7 Steering oil return flow line
3 Paneling (only for vehicles with code 8 Steering oil pressure line
(F15) MEGASPACE cab)
W01.10-1046-09
Shown on engine 541.9
1 Engine wiring harness 17 Clutch actuator (for vehicles with 21 Compressed air line for AdBlue
9 Coolant manifold (only for vehicles code (GE2) Electronic drive control II metering device (for vehicles with
with code (BA1) Performance- or with code (GE3) Mercedes code (MS4) BlueTec 4 or with code
optimized Voith retarder or with PowerShift) (MS5) BlueTec 5)
code (BA9) Voith secondary 18 Coolant pipe (only for vehicles with 22 Constant throttle compressed air line
retarder R 115) code (BA1) Performance-optimized 23 Compressed air line for engine
10 Coolant pipe (only for vehicles with Voith retarder or with code (BA9) brake
code (BA1) Performance-optimized Voith secondary retarder R 115) 24 Ground cable
Voith retarder or with code (BA9) 19 Coolant pipe (only for vehicles with 25 Electrical line, terminal 30
Voith secondary retarder R 115)
© Daimler AG, 7/2/13, G/03/13, ar01.10-w-2400g, Remove/install engine Page 1 of 9

ENGINES 541.9 in MODEL 930, 932, 933, 934 ENGINES 542.9 in MODEL 930, 932, 934
code (BA1) Performance-optimized 26 Engine mount
11 Compressed-air line Voith retarder or with code (BA9) 27 Transmission oil lines with bracket
12 Exhaust pipe Voith secondary retarder R 115) (only for vehicles with code (N55)
13 Holder with transmission connector 20 Compressor control line (only for Transmission oil cooling)
14 Electrical connector (only for vehicles with code (MZ7)
vehicles with code (GS7) Gear Engageable 1-cylinder compressor
A16 Gear control (GS) control unit (only
control II) or with code (MZ8) Engageable dual
for vehicles with code (GS7) Gear
15 Plunger compressor, without code (MS4) control II)
16 Clutch booster (for vehicles with BlueTec 4 or code (MS5)
X29 Transmission connector
code (GE2) Electronic drive control II BlueTec 5)
or without code (GE3) Mercedes
PowerShift)
Only for vehicles with code (MS4)

BlueTec 4 or with code (MS5) BlueTec 5
30 Connecting piece
31 Coolant line
32 Clamping device
33 AdBlue hose
34 AdBlue line
35 Coolant line
36 Coolant manifold
37 Compressor control line (only for
vehicles with code (MZ7)
Engageable 1-cylinder compressor
or with code (MZ8) Engageable
dual compressor, in combination
with code (MS4) BlueTec 4 or
code (MS5) BlueTec 5)
Y107 SCR tank heater solenoid valve

Arrow Fuse
W01.10-1045-06
Modification notes
14.2.11 Tightening torque - added. Step 25 *BA23.20-N-1006-01A
Tightening torque - added. Step 26 *BA23.20-N-1008-01A
Remove/install
Danger! Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A
scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly
Risk of poisoning caused by swallowing and release the pressure. Do not pour
coolant. coolant into beverage containers.
Wear protective gloves, protective clothing
and safety glasses.
Notes on self-locking nuts and bolts AH00.00-N-0001-01A
1 Switch off ignition
2 Disconnect ground lead from battery AR54.10-W-0003A
3 Detach the trim panel (3) on the cab rear Only in vehicles with code (F15)
wall MEGASPACE cab.
4 Open maintenance flap
5 Remove cover of cab chassis connector Installation: Check seal on cover and
plate (2). replace cover if necessary. The cover should
be closed tightly.
6 Disconnect electrical connectors for electrical
engine wiring harness (1) at cab-chassis
connector plate (2)
7 Unclip electrical engine wiring harness (1)
and place downward
Danger! Risk of injury caused by body parts being Ensure that no one is within tilting range of AS60.80-Z-0001-01A
pinched or crushed as cab is tilted cab as it is being tilted. Always tilt cab all
the way to end position and secure with
safety strut.
8 Tilt cab
Notes on tilting the cab AH60.80-N-0003-01A
9 Clamp off coolant line (31) using clamping Only for vehicles with code (MS4)
device (32) BlueTec 4 or with code (MS5) BlueTec 5.
*000589543700
10 Clamp off coolant line (35) using clamping Only for vehicles with code (MS4)
device (32) BlueTec 4 or with code (MS5) BlueTec 5.
*000589543700
11 Remove radiator Only for vehicles without code (MZ3) AR20.20-W-3865G
Electromagnetic viscous coupling for fan or
without code (MZ5) Electromagnetic fan
drive (Linnig clutch).
Vehicles with code (MZ3) Electromagnetic AR20.20-W-3865GB
viscous coupling for fan.
Only vehicles with code (MZ5) AR20.20-W-3865GA
Electromagnetic fan drive (Linnig clutch)
12 Detach electrical engine wiring harness (1)
at fixture and frame and tie up at engine
13 Remove air intake hose with air intake pipe *BA09.20-N-1001-02C
(4)
*BA09.20-N-1002-02C
14 Disconnect electrical connector for
transmission (X29) on holder with
transmission connector (13)
15 Disconnect electrical connector (14) from Only in case of vehicles with code (GS7)
gear control, control unit (GS) (A16) Gear control II.
16 Detach compressed air line (11) at Installation: Check compressed-air line
compressor and at connecting point on (11) for signs of carbonization.
frame In the event of carbonization, check
compressed-air line (11) up to four circuit
protection valve and replace coked parts if
necessary.
17 Disconnect coolant pipe (10) on coolant Only for vehicles with code (BA1)
manifold (9) and tie up on frame Performance-optimized Voith retarder or with
code (BA9) Voith secondary retarder
R 115.
Catch escaping coolant.
Installation: Check coolant hoses and
clamps; replace if necessary.
18 Detach brackets for compressed-air line (11)
at the engine and at the transmission.
19 Disconnect constant throttle compressed air
line (22) on holder
20 Disconnect engine brake compressed air line
(23) on holder
21.1 Disconnect compressor control line (20) on Vehicles with code (MZ7) Engageable 1-
holder for timing case on the left cylinder compressor or with code (MZ8)
Engageable dual compressor, without code
(MS4) BlueTec 4 or code (MS5) BlueTec 5
21.2 Disconnect compressor control line (37) on Vehicles with code (MZ7) Engageable 1-
holder for timing case on the right cylinder compressor or with code (MZ8)
Engageable dual compressor, in combination
code (MS4) BlueTec 4 or code (MS5)
BlueTec 5
22 Separate compressed air line for AdBlue Only for vehicles with code (MS4)
metering device (21) at bracket on left of BlueTec 4 or with code (MS5) BlueTec 5.
timing case
23 Detach exhaust pipe (12) at engine brake Installation: Clean sealing surfaces and
flap connection check clamp; replace clamp if necessary.
*BA49.10-N-1001-01J
Danger! Risk of poisoning caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A
brake fluid. Risk of injury caused by brake appropriately marked containers. Wear
fluid coming into contact with skin and eyes. protective clothing and eye protection when
handling brake fluid.
24 Disconnect hydraulic-pneumatic power shift Only on vehicles with code (GS3) AR26.60-W-7260-01G
lines (HPS) at engine "Hydraulic" gearshift.
*BA26.60-N-1049-01D
Brake fluid notes AH42.50-P-0001-01A
Notes on hydraulic fluid as per Specification, AH00.40-N-0002-01A
Sheet 345.0
25 Remove propeller shaft on engine power Only for vehicles with code (N52) Rear *BA23.20-N-1006-01A
take-off at the rear and bind to one side engine power take-off, output torque 600
Nm.
26 Remove hydraulic pump on engine power Only for vehicles with code (N53) Rear *BA23.20-N-1008-01A
take-off at the rear and bind to one side engine power take-off, for hydraulic pump.
Do not separate hydraulic lines.
Installation: Install new gasket
27 Disconnect electrical line for terminal 30 (25) *BA15.18-N-1003-01A
on starter and remove on timing case
*BA15.30-N-1002-01C
28 Disconnect ground line (24) at connecting
point for frame
29.1 Disconnect electrical connector on clutch Vehicles without code (GE2) Electronic drive
booster (16) control II or without code (GE3) Mercedes
PowerShift.
29.2 Disconnect electrical connector on clutch Vehicles with code (GE2) Electronic drive
actuator (17) control II or code (GE3) Mercedes
PowerShift
30 Remove compressed-air line on clutch servo Only on vehicles without code (GE2)
unit (16) Electronic drive control II or without code
(GE3) Mercedes PowerShift.
Do not separate hydraulic line.
*BA25.20-N-1003-01J
*BA25.20-N-1010-01J
31.1 Remove clutch booster (16) on transmission Vehicles without code (GE2) Electronic drive
and attach to frame control II or without code (GE3) Mercedes
PowerShift.
*BA25.20-N-1001-01J
Danger! Risk of injury caused by body parts being Always remove ignition key and open bleed AS25.00-Z-0001-01A
trapped or crushed when working on the screw before removing clutch actuator.
pressurized clutch actuator
31.2 Remove clutch actuator (17) on transmission Vehicles with code (GE2) Electronic drive AR25.20-W-3000A
and attach to frame. control II or code (GE3) Mercedes
PowerShift
32 Pull plunger (15) out of release lever of Installation: Clean tappet (15) and check
clutch for damage; replace if necessary.
Lubricate tappet head, tappet cup with long- *BR00.45-Z-1001-06A
life grease.
33 Remove transmission oil lines with bracket Only on vehicles with code (N55)
(27) at oil pan and at timing case and attach Transmission oil cooling.
them to frame
34 Pull retainer (arrow) and disconnect Only for vehicles with code (MS4)
connection piece (30) on SCR tank heater BlueTec 4 or with code (MS5) BlueTec 5.
solenoid valve (Y107) Collect coolant which flows out.
Danger! Risk of burn injuries and scalding when Only pour AdBlue into suitable containers. AS14.40-Z-0001-01A
working at AdBlue lines and the components Wait until the pressure is released before
attached to them. Risk of injury to skin and starting any work on the exhaust
eyes when handling AdBlue. Risk of aftertreatment system.
poisoning caused by swallowing AdBlue
35 Disconnect AdBlue hose (33) with clamping Only for vehicles with code (MS4)
device (32) and disconnect at AdBlue line BlueTec 4 or with code (MS5) BlueTec 5.
(34)
Catch escaping AdBlue and dispose of it.
Do not reuse caught AdBlue since
contaminated AdBlue can lead to damage in
exhaust aftertreatment system.
*000589543700
Installation: Before assembly of AdBlue
hose (33) check for foreign objects,
contamination and damage.
If the AdBlue hose (33) is reused, in the area
in which the hose clamp was seated it must
be shortened by approx. 2 cm. If as a result
the AdBlue hose (33) should be too short, it
must be replaced.
Replace 1-ear clamping device by using a
clamp pliers with side cutting pliers.
Notes on use, material properties and AH14.40-N-0001-01A
handling of AdBlue®
36 Detach coolant line (35) on the coolant Only for vehicles with code (MS4)
manifold (36) BlueTec 4 or with code (MS5) BlueTec 5.
Collect coolant which flows out.
Installation: Install new sealing rings.
37 Disconnect coolant pipe (18) and coolant Only vehicles with code (BA1)
pipe (19) on coolant hose Performance-optimized Voith retarder or with
code (BA9) Voith secondary retarder R 115.
Collect coolant which flows out.
Installation: Check coolant hose and
clamps; replace if necessary.

Danger! Risk of explosion caused by fuel igniting, No fire, sparks, open flames or smoking. AS47.00-Z-0001-01A
risk of poisoning caused by inhaling and Only pour fuels into suitable and
swallowing fuel and risk of injury to eyes appropriately marked containers.
and skin caused by contact with fuel Wear protective clothing when handling fuel.
38 Disconnect fuel feed line (5) and fuel return Collect escaping fuel.
line (6) at connecting points in right
longitudinal frame member and close
Danger! Risk of injury to skin or eyes caused by Depressurize hydraulic system completely AS00.00-Z-0013-01A
hydraulic fluid spraying out under high before starting any work on the system.
pressure. Risk of poisoning caused by Wear protective clothing and safety glasses.
swallowing hydraulic fluid
39 Disconnect steering oil return flow line (7) Catch escaping hydraulic fluid.
and steering oil pressure line (8) at
connections for the power steering fluid
reservoir
40 Remove TDC inspection hole cap at timing *BA01.60-N-1001-01B
case
41 Attach cranking device to timing case *BA01.60-N-1009-01B
*904589046300
42 Remove bolts on left and right engine mount *BA22.10-N-1004-01D
(26)
43 Support transmission with transmission
platform from below
44 Remove engine using engine hoist Vehicles without code (G02) Torque AR01.10-W-2400-01G
converter clutch (WSK)
Transmission 715.500/507/510/513/520/ *BA26.10-N-1001-01C
540
Transmission 715.350/370/380/515/525 *BA26.10-N-1001-01KL
*904589046300
Vehicles with code (G02) Torque converter AR01.10-W-2400-01GA
clutch (WSK)
45 Position engine on engine mounts on jack Secure engine against falling down and
stand and support it under timing case with a tilting.
suitable component lifter
46 Check both engine mounts (26) for wear Installation: Replace engine mount (26)
if necessary.
*BA22.10-N-1006-01D
47 Install in the reverse order
48 Re-teach in transponder keys (also Only after installing a new motor. AR80.57-W-0010C
replacement keys)
49 Check engine oil level with oil dipstick or on Observe engine oil grade set in
display, add oil if necessary* maintenance system or Specifications for
Operating Fluids.
Notes on engine oil AH18.00-N-0101-01B
50 Inspect transmission oil level, adjust to Only on vehicles with code (N55)
correct level if necessary Transmission oil cooling.
Vehicles without code (G02) Torque AR26.00-W-0100A
Vehicles with code (G02) Torque converter AR26.00-W-0100G
clutch (WSK)
Danger! Risk of accident caused by vehicle starting Secure vehicle to prevent it moving off. AS00.00-Z-0005-01A
off by itself when engine is running. Risk of Wear closed and close-fitting work clothes.
injury caused by contusions and burns Do not touch hot or rotating parts.
during starting procedure or when working
near the engine as it is running
51 Start engine and allow to run in idle for 10 s The fuel system is bled automatically. If *BE18.00-N-1001-01D
until the oil pressure has built up, then run engine fails to start or only runs for a brief
the engine at varying speeds period:
Purge fuel system by hand. AP47.00-W-1720-01A

52 Switch off engine and check for leaks Visual inspection.
53 Bleed hydraulic shift Vehicles with code (GS3) "Hydraulic" AR26.60-W-7200A
gearshift and without code (IY2) Hydraulic
fluid as per sheet 345.0.
Vehicles with code (GS3) "Hydraulic" AR26.60-W-7200D
gearshift and with code (IY2) Hydraulic fluid
as per sheet 345.0.
54 Initializing gear control (GS) (A16) control Only for vehicles with code (GS7) Gear AR54.21-W-0009A
unit control II, also in combination with code
(GE2) Electronic drive control II, or with code
(GE3) Mercedes PowerShift, if the clutch
was replaced.
55 Bleed steering system Steering system 765.82 AR46.25-W-3300C
Steering 765.887 AR46.25-W-3300B
56 Enter engine number in FDOK screen 1111 Only after installing a new motor.
Check values for engine oil pressure
Number Designation Engine 541.9,

542.9
BE18.00-N-1001-01D Engine oil pressure at Idling speed bar 0.5
maximum speed bar 2.5
Timing case
Number Designation Engine

541.9. 542.9
BA01.60-N-1001-01B Bolt, end cover of TDC inspection hole to timing Nm 25

case
BA01.60-N-1009-01B Bolt, engine cranking device to timing case Nm 25
Intake manifold, intake manifold preheater
Number Designation Engine Engine

541.9 541.9
except code with code MJ1
MJ1
BA09.20-N-1001-02C Bolt, air intake pipe at bracket Nm 50 60
BA09.20-N-1002-02C Air intake pipe hose clamp Nm 6.0 6.0

542.9 542.9
MJ1
BA09.20-N-1001-02C Bolt, air intake pipe at bracket Nm 50 60
Engine wiring harness

542.9
BA15.18-N-1003-01A Bolt, wiring loom to timing case Nm 25

Starter

541.9, 542.9
BA15.30-N-1002-01C Nut connecting circuit 30 line to starter/ Nm 30

solenoid switch
Engine mounts, engine supports

541.9 542.9
BA22.10-N-1004-01D Bolt, engine carrier to engine mount Front Nm 330 330
at the rear Nm 330 330
BA22.10-N-1006-01D Engine mount on frame Front Nm 150 150
at the rear Nm 150 150
Rear engine power take-off

541.9, 542.9 541.9, 542.9
with code with code
N52 N53
BA23.20-N-1006-01A Nut, propeller shaft to output flange Nm 30 -
BA23.20-N-1008-01A Hydraulic pump on intermediate flange M8 Nm - 30
M10 Nm - 50
M12 Nm - 90
Clutch booster
Number Designation Model

930, 932,
933, 934
BA25.20-N-1001-01J Bolt, clutch booster to transmission housing Nm 50
BA25.20-N-1003-01J Banjo bolt (compressed-air line) on clutch Nm 40

booster
BA25.20-N-1010-01J Union nut (compressed-air line) at clutch Nm 40

booster
Complete manual transmission

Number Designation Trans-
mission
715.500/
507/510/
513/517/
520/527/
540/561/
567/568
BA26.10-N-1001-01C Transmission to flywheel housing Nm 50
Complete manual transmission
Number Designation Transmission Transmissions Transmission

715.350 715.370/380 715.515/525
BA26.10-N-1001-01KL Transmission to engine Nm 50 50 50
Shift mechanism
Number Designation Transmission Transmission

715.500/507/510/ 715.500/507/510
513/520/540 /513/520/540/561
with code GS3 with code GS3
without code and code IY2
IY2
BA26.60-N-1049-01D Hydraulic line to bracket M6 Nm 8 8
M8 Nm 20 20
Exhaust system

541.9, 542.9
BA49.10-N-1001-01J Clamp bolt, exhaust pipe to engine brake valve Nm 50

fitting
000 589 54 37 00 904 589 04 63 00

Clamping device Cranking device

Repair materials
Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11

AR01.20-W-5014G Remove/install cylinder head cover 18.12.09
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Cylinder head cover

2 Cylinder head cover gasket
W01.20-1013-12
Remove/install
1 Open front flap
Danger! Risk of injury caused by body parts being Ensure that no one is within the tilting range AS60.80-Z-0001-01A
pinched or crushed as cab is tilted of the cab as it is being tilted. Always tilt the
cab all the way to the end position and
secure with the safety strut.
2 Tilt cab The front flap must always be opened
when tilting.
3 Remove cylinder head cover (1) Installation: Clean dirt and paint residue
from sealing surfaces.
*BA01.20-N-1001-01C
Crankcase ventilation, cylinder head cover

542.9
BA01.20-N-1001-01C Bolt, cylinder head cover to cylinder head Nm 20
© Daimler AG, 7/2/13, G/03/13, ar01.20-w-5014g, Remove/install cylinder head cover Page 1 of 1
AR01.30-W-5461G Remove/install protective sleeve 13.12.11
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Nozzle holder combination

2 Protective sleeve
3 O-ring
4 Claw-type wrench
W01.30-1037-06
Modification notes
6.7.11 Value modified: Coolant drain plug to radiator *BA20.20-N-1001-01C
Remove/install
and safety glasses.
1 Drain coolant
Notes on coolant AH20.00-N-2080-01A
Drain/fill in coolant Vehicles without code (BA9) Voith AP20.00-W-2080-01A
secondary retarder R 115.
Vehicles with code (BA9) Voith AP20.00-W-2080-01B
*BA01.40-N-1001-01D
*BA20.20-N-1001-01C
*BF20.00-N-1001-01B
2 Remove nozzle holder combination (1) AR07.03-W-6831G
3 Use pronged wrench (4) to unscrew *904589000700
protective sleeve (2)
*BA01.30-N-1001-01D
4 Remove protective sleeve (2) using pliers *442589003700
Installation: Clean sealing surface for
protective sleeve.
5 Take O-ring (3) out of the cylinder head Installation: Clean sealing surface for *BR00.45-Z-1014-06A
cylinder head and install new O-ring with
ATE grease.
Cylinder head

542.9
© Daimler AG, 7/2/13, G/03/13, ar01.30-w-5461g, Remove/install protective sleeve Page 1 of 3

BA01.30-N-1001-01D Protective sleeve on cylinder M12X1 Nm 40
head
M14X1 Nm 45
Cylinder crankcase, timing case cover, end cover

541.9. 542.9
BA01.40-N-1001-01D Coolant drain plug on crankcase M14 1.5 Nm 50
Radiator, coolant hoses

542.9
BA20.20-N-1001-01C Coolant drain plug to radiator Nm 4
Engine cooling system
Number Designation Engine Engine Engine

541.9 541.9 541.9
without code with code BA1 with code BA9
BA1 or BA9
BF20.00-N-1001-01B Coolant Total filling capacity Liters 41.0 53.0 56.0
Anticorrosion/antifreeze agent Liters 20.5 26.5 28.0

down to -37°C

down to -45°C
Specifications for Operating Sheet BB00.40-P-0310-01A BB00.40-P-0310-01A BB00.40-P-0310-01A

Fluids
Sheet BB00.40-P-0325-02A BB00.40-P-0325-02A BB00.40-P-0325-02A

542.9 542.9 542.9
BA1, BA9,
KMKL

down to -37°C

down to -45°C

Fluids
904 589 00 07 00 442 589 00 37 00

Claw-type wrench Pliers
Repair materials
BR00.45-Z-1014-06A ATE grease -

AR01.30-W-5800G Remove/install cylinder head 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Cylinder head gasket

2 Cylinder head
3 Injection line
4 Leak fuel line
5 Tappet rod
6 Rocker arm assembly
7 Valve bridge
8 Cylinder head bolt
9 Constant throttle line
10 Constant throttle line
11 Gasket
12 Exhaust manifold
13 Roll pin
14 Dowel pin
L Shank length
W01.30-1038-06
Modification notes
15.2.08 Reference subdivided and validities added. Operation step 15, 29

Engine 541.9, AR14.10-W-3915GA
Engine 542.9 with code (MS4) BlueTec 4 or
with code (MS5) BlueTec 5
Engine 542.9 without code (MS4) BlueTec 4 AR14.10-W-3915GB
or without code (MS5) BlueTec 5
Removing
and safety glasses.
3 Tilt cab
4 Remove soundproofing on frame at top left
and right
5 Drain partially coolant at radiator AR20.00-W-1142A
6 Remove charge air housing AR09.41-W-8682A
7 Remove clamps of steering oil return line and Only when removing cylinder heads on
steering oil pressure line at brackets left side of engine.
8 Remove leak fuel line (4) at relevant cylinder In addition detach the leak fuel line (4) at
head (2) the cylinder head in front of it and push way
the leak fuel line (4).
9 Remove injection line (3) at respective AR07.15-W-9235G
cylinder head (2)
10 Detach cylinder head cover at respective AR01.20-W-5014G
cylinder head (2)
11 Remove rocker arm assembly (6) at AR05.00-W-5521G
respective cylinder head (2)
12 Take off valve bridges (7).
© Daimler AG, 7/2/13, G/03/13, ar01.30-w-5800g, Remove/install cylinder head Page 1 of 4

13 Pull out tappet rods (5) Turn push rods (5) while pulling out so
that these can release in the roller tappets
and the roller tappets are not pulled out of
the crankcase.
14 Remove constant throttle lines (9, 10) at
relevant cylinder head (2)
15 Remove exhaust manifold (12) at relevant Engine 541.9, AR14.10-W-3915GA
cylinder head series Engine 542.9 with code (MS4) BlueTec 4 or
16 Remove cylinder head bolts (8) and take off Set cylinder head (2) aside so that
cylinder head (2) installed nozzle holder combinations are not
damaged.
17 Remove cylinder head gasket (1)
18 Clean cylinder head (2) When cleaning only scrape cylinder head
sealing surface, do not rub with emery cloth.
19 Close off all bores on crankcase separating
surface using self-made stop plugs
Stop plugs for closing off bores WF58.50-W-0100-04A
Checking
20 Check cylinder head sealing surfaces and AR01.30-W-5800-15A
cylinder head gasket (1)
Height of cylinder head *BE01.30-N-1001-02C
Permissible variation in flatness of lower *BE01.30-N-1002-02C
separating surface in longitudinal direction
If the cylinder head (2) is warped or torn
the cylinder head gasket (1) leaks gas then
it is recommended in the case of a cylinder
head without inductive hardening to install a
new cylinder head with inductive hardening.
In the case of a cylinder head with inductive
hardening, the cylinder head (2) must be
replaced.
If the cylinder head (2) is replaced the cap
and the piston for the constant throttle must
be modified.
Replace O-ring on cap and check seal ring
on piston for wear or damage; replace
piston if necessary.
21 Clean and inspect the separating surfaces of There should be no contamination in
the crankcase and cylinder head (2) bores for engine oil, coolant, push rods (5)
and cylinder head bolts (8) and in the
cylinder liner, otherwise engine damage can
occur.
Only abrade sealant and paint residues
on crankcase separating surface, do not rub
with emery cloth.
22 Check cylinder head bolts (8) If the permissible shank length (L) is *BE01.30-N-1001-01C
exceeded then the cylinder head bolt (8)
concerned must be replaced.
23 Check dowel pins (14) for damage If a dowel pin (14) is damaged, both
centering sleeves or dowel pins (14) must be
pulled out with pliers and replaced using a
new dowel pin (14).
24 Carefully pull stop plug out of all bores in
crankcase
25 Inspect seat of roller tappets in crankcase
Install
26 Fit new cylinder head gasket (1) over dowel Pay attention to installation position of
pin (14) onto crankcase separating surface. cylinder head gasket (1).
27 Place cylinder head (2) over dowel pin (14)
on cylinder head gasket (1)
28 Screw on the cylinder head (2) tightly Oil contact surface, thread and stem of
cylinder head bolts (8) with engine oil.
Pay attention to tightening instruction for AR01.30-W-5800-07B
cylinder head bolts (8).
*BE01.30-N-1001-01C
*BA01.30-N-1002-01D
*422589020900
29 Install exhaust manifold (12) Engine 541.9, AR14.10-W-3915GA
30 Install constant throttle lines (9, 10) at Install new sealing rings.
cylinder head (2)
*BA01.30-N-1003-01D
31 Install push rods (5) Lubricate push rods (5) using engine oil
and ensure they are correctly located in the
push rods
32 Insert valve bridges (7)
33 Install rocker arm assembly (6) AR05.00-W-5521G
34 Install cylinder head cover AR01.20-W-5014G
35 Install leak fuel line (4) Install new sealing rings.
*BA01.30-N-1004-01D
36 Install injection line (3) AR07.15-W-9235G
37 Install charge air housing AR09.41-W-8682A
38 Fit clamps for steering oil return flow line Only for cylinder heads on the left side
and steering oil pressure line to brackets of the engine.
39 Carry out additional test works after engine AR01.10-W-0003A
repair on cylinder head (2) and cylinder
head gasket (1)
40 Check engine oil level using oil dipstick or Observe engine oil grade set in
on display, correct if necessary maintenance system or Specifications for
Operating Fluids.
41 Pour in coolant AR20.00-W-1142A
Danger! Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving by AS00.00-Z-0005-01A
off by itself when engine is running. Risk of itself.
injury caused by contusions and burns Wear closed and snug-fitting work clothes.
during starting procedure or when working Do not touch hot or rotating parts.
42 Start engine and allow to run in idle for 10 s The fuel system is bled automatically. If
until the oil pressure has built up, then allow engine fails to start or only runs for a brief
engine to run at alternating rpm period:

43 Turn off the engine and check the area of Visual inspection.
the installed cylinder head (2) for leaks.
44 Install soundproofing on frame at top left and
right
45 Lower cab
46 Close maintenance flap
Check values for cylinder head bolts

542.9
BE01.30-N-1001-01C Cylinder head bolts Length of shank when new mm 210

M18 2
Permissible shank length mm 212
Check values for cylinder head

541.9, 542.9 541.9, 542.9
without with inductive
inductive hardening at
hardening at cylinder head
cylinder head
BE01.30-N-1001-02C Height of cylinder head New mm 113.85 to 114.15 113.85 to 114.15

after stock removal mm 113,5 -
BE01.30-N-1002-02C Permissible variation of flatness of Wear dimension mm 0.1 0.1

lower separating surface
Cylinder head

542.9
BA01.30-N-1002-01D Cylinder head bolt to Stage 1 Nm 10

crankcase
Stage 2 Nm 50
Stage 3 Nm 100
Stage 4 Nm 200
Stage 5 ° 90
Stage 6 ° 90
See picture -
BA01.30-N-1003-01D Air line of constant throttle to Nm 45

cylinder head
BA01.30-N-1004-01D Leak fuel line to cylinder head Nm 15
422 589 02 09 00
Wrench socket

AR01.40-W-8000G Remove/install timing case cover 25.2.10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODELS 930, 932, 934
W01.40-1117-09
Shown on engine 541.9 without code

(M32) Dual compressor
1 Fuel pipe 8 Electrical line 13 Coolant line

2 Timing case cover with oil separator 9 Sealing ring 14 Fuel pipe
3 Crankcase ventilation hose 10 Locking bush 15 Coolant line
4 Constant throttle line 11 Bracket 16 Fuel pipe
5 Bracket 12 Control line (for code (MZ7) 17 Fuel overflow valve
6 Shaped gasket Engageable 1-cylinder compressor or 19 Bracket with distributor piece
7 Oil pressure line for code (MZ8) Engageable dual
compressor) B16 Camshaft position sensor
Shown on engine 541.9 without code (M32) Dual compressor
18 Hand pressure gun
Arrows separation points
W01.40-1116-01
Modification notes
15.2.08 Work procedure completely revised.
Remove/install
1 Remove turbocharger Only on engine 541.9 and on engine
542.9 with code (MS4) BlueTec 4 or with
code (MS5) BlueTec 5
Engine 541.9 AR09.40-W-6020GA
Engine 542.9 with code (MS4) BLUETEC 4 AR09.40-W-6020GC
or with code (MS5) BLUETEC 5
3 Remove charge air pipe Only for engine 542.9. AR09.41-W-1311G
© Daimler AG, 7/2/13, G/03/13, ar01.40-w-8000g, Remove/install timing case cover Page 1 of 4
ENGINES 541.9 in MODEL 930, 932, 933, 934 ENGINES 542.9 in MODELS 930, 932, 934
and safety glasses.
4 Partially drain coolant at radiator Installation: Pour in coolant. AR20.00-W-1142A
5 Remove coolant lines (13, 15) Collect coolant that flows out
Installation: Replace sealing rings.
*BA01.40-N-1005-01D
*BA13.30-N-1001-01B
6 Disconnect electrical line (8) on camshaft
position sensor (B16) and remove at fuel line
(1)
7 Pull out camshaft position sensor (B16) at Installation: Replace seal ring (9), check
timing case locking bush (10) and replace if necessary.
Press in locking bush (10) and camshaft
position sensor (B16) all the way.
8 Remove fuel line (14) between fuel pump Counterhold threaded connection while
and fuel line (16) detaching fuel line (14).
*BA47.25-N-1002-01B
*BA47.25-N-1008-01B
*BA47.25-N-1011-01B
9 Detach clamp of fuel line (1) at timing case *BA47.25-N-1008-01B
cover with oil separator (2)
Danger! Risk of burn injuries and scalding when Only pour AdBlue into suitable containers. AS14.40-Z-0001-01A
poisoning from swallowing AdBlue
10 Remove AdBlue line on timing case and Only on engine with code (MS4) Bluetec 4 AR14.40-W-2014-01A
compressor or with code (MS5) Bluetec 5.
*000589403700
11 Detach constant throttle line (4) at bracket *BA01.50-N-1001-01A
(5) and between bracket with distributor
piece (19) and constant throttle line on the
right
*BA01.50-N-1002-01A
*BA01.50-N-1003-01A
12 Remove control line (12) between bracket Only for code (MZ7) Engageable 1-
with distribution piece (19) and compressor cylinder compressor or for code (MZ8)
Engageable dual compressor.
13 Remove crankcase ventilation hose (3) at Only on engine with code (542.9 MS4)
timing case cover with oil separator (2) Bluetec 4 or with code (MS5) Bluetec 5.
14 Remove oil pressure line (7) with bracket Only on engine 541.9 or on
(11) at timing case cover with oil separator engine 542.9 with code (MS4) BlueTec 4 or
(2) and cylinder crankcase with code (MS5) BlueTec 5.
Close off bore on crankcase.
*BA01.40-N-1011-01D
15 Remove timing case cover with oil separator Installation:Coat sealant with the hand *BR00.45-Z-1024-01A
(2) pressure gun (18) on the separation points
(arrows), on timing case and on the cylinder
crankcase. Replace profiled gasket (6); pay
attention to installation position.
*000589012500
Observe tightening procedure of timing case AR01.40-W-8000-02A
cover.
*BA01.40-N-1014-01D
541.9. 542.9
BA01.40-N-1005-01D Banjo bolt, coolant line (compressor) to crankcase M14 1.5 Nm 30
BA01.40-N-1011-01D Oil pressure line for exhaust gas turbocharger to M14 1.5 Nm 35
crankcase
BA01.40-N-1014-01D Bolt, timing case cover with oil separator to timing case Nm 25
and crankcase
Constant throttle

542.9
BA01.50-N-1001-01A Transverse line to longitudinal line Nm 35
BA01.50-N-1002-01A Compressed-air line, constant throttle to Nm 30

banjo union

distributor piece
Compressor (compressed air system)

542.9
BA13.30-N-1001-01B Coolant line to compressor Nm 35
Fuel pipes/hoses

541.9. 542.9
BA47.25-N-1002-01B Banjo bolt, fuel line to fuel pump M16 1.5 Nm 50
BA47.25-N-1008-01B Bolt, fixture of fuel line to timing case cover and Nm 25

timing case
BA47.25-N-1011-01B Threaded connection between fuel lines Nm 45
000 589 01 25 00 000 589 40 37 00

Hand pressure gun Clamping device
Repair materials
BR00.45-Z-1024-01A Sealant/Dirko Transparent/Aminosilan A 001 989 29 20
AR01.40-W-8800G Remove/install housing cover at front 30.11.11
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
Shown on vehicle without code (M58)

Higher performance fan
1 Belt pulley/vibration damper

2 Splash ring
3.1 Radial shaft sealing ring (up to engine
end no. 709510)
3.2 Cassette-type sealing ring (as of
engine end no. 709511)
4 Housing cover
5 Seal
6 Dowel pins
7 Oil pan
8 Drift (up to engine end no.
709510)
W01.40-1134-06
Modification notes
2.9.11 Value changed: Screw/bolt, front housing cover to *BA01.40-N-1009-01D

cylinder crankcase.
15.11.11 "Place shim (N 000000 003386) on screws/bolts of Step 11
housing cover (4) if this is not present yet" added.
Removing
1 Remove belt pulley/vibration damper (1) Vehicles without code (ML3) High-speed fan AR03.30-W-1600G
drive with belt drive, vehicles without code
(MZ5) Electromagnetic fan drive (Linnig
coupling), vehicles without code (MZ3)
Electromagnetic viscous fan clutch and
vehicles without code (MO1) Electromagnetic
viscous clutch, Behr
Vehicles with code (ML3) High-speed fan AR03.30-W-1600GA
drive with belt drive but without code (MZ3)
Electromagnetic viscous fan clutch.
Only vehicles with code (MZ5) AR03.30-W-1600GB
Vehicles with code (MZ3) Electromagnetic AR03.30-W-1600GC
viscous fan clutch.
Vehicles with code (MO1) Electromagnetic AR03.30-W-1600GE
viscous fan clutch, Behr
2 Take off slinger (2)
3 Remove oil pan (7) AR01.45-W-7500G
4 Remove cassette-type sealing ring (3.2) Only as of engine end no. 709511 AR03.20-W-3001-02G
Removal and insertion device *457589004300
Front crankshaft seal - altered BT03.20-W-0004-01A
5 Detach housing cover (4)
6 Remove gasket (5)
7 Place the housing cover (4) flat on two Only up to engine end no. 709510.
wood strips and press out radial shaft
sealing ring (3.1) using the drift (8)
Drift *312589131500
Checking
8 Check contact surface of the radial shaft Only up to engine end no. 709510.
sealing ring (3.1) on the crankshaft flange or
on the race
© Daimler AG, 7/2/13, G/03/13, ar01.40-w-8800g, Remove/install housing cover at front Page 1 of 3
If there is galling on the crankshaft flange
or on race:
Fit new race onto crankshaft flange. AR03.20-W-2570G

Clean
9 Clean sealing surfaces
Install
10 Install new gasket (5)
11 Install housing cover (4) Place shim (N 000000 003386) on
screws/bolts of housing cover (4) if this is
not present yet.
Place the housing cover (4) over dowel pins
(6) on the crankcase and push it on.
*BA01.40-N-1009-01D
12 Install oil pan (7) AR01.45-W-7500G
13.1 Install radial shaft sealing ring (3.1) Up to engine end no. 709510 AR03.20-W-3000-01A
Install radial shaft sealing ring (3.1) dry
on the outer surface and coated with engine
oil on the contact surface.
13.2 Install cassette-type sealing ring (3.2) As of engine end no. 709511 AR03.20-W-3001-01G
Install cassette-type sealing ring (3.2) on
the outer surface dry.
14 Fit a slinger (2) Observe installation position. The slinger
(2) must be installed with the flat side
towards belt pulley/vibration damper (1).
15 Install belt pulley/vibration damper (1) Vehicles without code (ML3) High-speed fan AR03.30-W-1600G
Electromagnetic viscous fan clutch and
vehicles without code (MO1) Electromagnetic
viscous clutch, Behr
Electromagnetic viscous fan clutch.
viscous fan clutch.
16 Start engine and perform an engine test run
17 Switch off engine and check the housing Visual inspection.
cover (4), the radial shaft sealing ring (3.1)
or cassette-type sealing ring (3.2) and oil pan
(7) for leaktightness

541.9. 542.9
BA01.40-N-1009-01D Bolt, front housing cover to crankcase M8 10.9 Nm 25
M8 12.9 Nm 40
M10 10.9 Nm 70
312 589 13 15 00 457 589 00 43 00 541 589 02 33 00
Drift Removal and insertion device Removal and insertion device
AR01.40-W-9324G Remove/install/seal cylinder liner 10.10.07
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Crankcase
1.1 Bore
2 Cylinder liner
3 Sealing ring
4 O-ring
5 O-ring
6.1 Extraction device
6.2 Insertion device
7 Oil scraper ring (for code (MS4)
BlueTec 4 or for code (MS5)
BlueTec 5)
Arrows Marking
W01.40-1084-06
Modification notes
1.10.07 Use a commercially available open end wrench, size 24 Step 11

mm, without an extension - added.
Special tool torque wrench handle altered. *001589352100
Removing
1 Remove piston for cylinder concerned When repairing and cleaning, no AR03.10-W-7021G
contamination may enter the crankcase (1),
otherwise engine damage could occur.
2 Make an identification mark (arrows) for the Only if the cylinder liner (2) is used
cylinder liner (2) relative to the crankcase (1) again.
3 Fit on extraction device (6.1) and pull out AR01.40-W-9324-01A
cylinder liner (2)
*541589013300
4 Take off seal (3)
5 Take O-rings (4, 5) out of crankcase (1)
6 Clean cylinder liner (2), cylinder liner support
and bore (1.1) in crankcase (1)
7 Clean grooves for the O-rings (4, 5) in
crankcase (1)
Install
8 Insert new O-rings (4, 5) for bottom cylinder Insert O-rings (4, 5) dry and not twisted.
liner seal into crankcase (1)
9 Insert new seal ring (3) into crankcase (1)
10 Insert cylinder liner (2) into crankcase (1) Grease cylinder liner (2) slightly on the *BR00.45-Z-1014-06A
outside.
Install re-used cylinder liner (2) offset by 90°
relative to old installation position. Observe
identification (arrows).
For vehicles without code (MS4) BlueTec 4 AR03.10-W-7021-02A
or without code (MS5) BlueTec 5, for
installing a new cylinder liner (2), observe
the piston and liner marking (code letters A, B
or C).
Cylinder liner inside Ø *BE01.40-N-1001-03C
11 Fit on insertion device (6.2) and press in Use a commercially available open end AR01.40-W-9324-02A
cylinder liner (2) wrench, size 24 mm, without an extension.
*BA01.40-N-1020-01D
*001589352100
© Daimler AG, 7/2/13, G/03/13, ar01.40-w-9324g, Remove/install/seal cylinder liner Page 1 of 2

*541589013300
12 Measure projection of cylinder liner (2) AR01.40-W-9314G
13 Install pistons For engines with code (MS4) BlueTec 4 AR03.10-W-7021G
or with code (MS5) BlueTec 5 the oil scraper
ring (7) must also be replaced when
installing a new cylinder liner (2).
Check values for cylinder liner

541.9, 542.9
BE01.40-N-1001-03C Cylinder liner inside Ø Code letter A mm 129.990 to

129.995
Code letter B mm 129.995 to

130.005
Code letter C mm 130.005 to

130.010
Crankcase, timing case cover, end cover

541.9, 542.9
BA01.40-N-1020-01D Nut for pressing the cylinder liner into the crankcase Nm 50
001 589 35 21 00 541 589 01 33 00

Torque wrench handle Removal and insertion device
Repair materials

BR00.45-Z-1014-06A ATE grease -
© Daimler AG, 7/2/13, G/03/13, ar01.40-w-9324g, Remove/install/seal cylinder liner Page 2 of 2

AR01.45-W-7500G Remove/install oil pan 12.10.10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W01.45-1016-09
1 Transmission oil lines (only for 3 Strut (only for vehicles with code 7 Gasket
vehicles with code (N55) (N55) Transmission oil cooling and 8 Engine wiring harness
Transmission oil cooling) without code (H03) Air conditioning in 9 Bracket
1.1 Bracket (only for vehicles with code front end or without code (H07) 10 Oil drain screw
(N55) Transmission oil cooling) Automatic air conditioning) 11 Refrigerant compressor (only for
2 Support (only for vehicles with code 4 Oil dipstick guide tube top section vehicles with code (H03) Air
(H03) Air conditioning in front end or 5 Oil filling line conditioning in front end or code
code (H07) Automatic air 6 Oil pan (H07) Automatic air conditioning)
conditioning)
8 Engine wiring harness

12 Carrier
13 Electrical connector
14 Vehicle wiring harness connector
15 Connector for engine wiring harness
16 Fuel heat exchanger
A6 Engine control (MR) control unit

B14 Oil level sensor
G2 ALT
W01.45-1017-11
© Daimler AG, 7/2/13, G/03/13, ar01.45-w-7500g, Remove/install oil pan Page 1 of 8

W01.45-1022-08
6 Oil pan B14 Oil level sensor Arrows separation points

17 Oil dipstick guide tube bottom section
Modification notes
Remove/install
2 Remove alternator (G2) AR15.40-W-5032G
3 Drain engine oil or extract AR18.00-W-3035-02G
*BA01.45-N-1002-01C
For vehicles without code (MB7) *BF18.00-N-1001-01B
Automatic engine oil refilling.
For vehicles with code (MB7) Automatic *BF18.46-N-1001-01A
engine oil refilling.
Notes on oil pan versions AH01.45-W-0002-01A
4 Detach oil dipstick guide tube upper section *BA01.45-N-1006-01C
(4) at fitting
5 Detach oil filler line (5) at oil pan (6)
6.1 Remove strut (3) For vehicles with code (N55)
Transmission oil cooling and without code
(H03) Air conditioning in front end or without
code (H07) Automatic air conditioning.
6.2 Remove support (2) For vehicles with code (H03) Air conditioning
in front end or code (H07) AAC.
*BA83.55-N-1002-01C
7 Remove oil transmission oil lines with Only on vehicles with code (N55)
bracket (1.1) at support (1) and attach on Transmission oil cooling.
frame
Do not disconnect transmission oil lines (1).
8 Remove electrical wiring harness at Only for vehicles with code (H03) Air
refrigerant compressor (11) at oil pan (6) conditioning in front end or code (H07) AAC.
9 Remove refrigerant compressor (11) with Only for vehicles with code (H03) Air
carrier and connected refrigerant lines and conditioning in front end or code (H07) AAC.
attach on frame
Do not separate refrigerant lines.
*BA01.40-N-1012-01D
10 Remove electrical engine wiring harness (8)
on timing case and on bracket (9)
11 Detach bracket (9) from timing case
12 Disconnect electrical connector (13) on oil
level sensor (B14)
13 Disconnect vehicle wiring harness connector
(14) and engine wiring harness connector
(15) at engine control unit (MR) (A6)

14 Remove engine wiring harness (8) at bracket
under engine control (MR) control unit (A6)
and attach to frame
15 Remove engine control (MR) control unit Fuel lines remain connected at the fuel
(A6) with attached fuel heat exchanger (16) heat exchanger (16).
on cylinder crankcase and attach to frame
*BA07.15-N-1010-01B
16 Detach oil pan (6) Installation: In the case of micro-
encapsulated bolts, recut threaded holes in
crankcase, timing case and front housing
cover and clean or blow out.
Install new micro-encapsulated bolts.
Pay attention to tightening procedure of
bolts:
Engine with a thermoplastic or light alloy oil AR01.45-W-7500-01A

pan
Engine with thermoset plastic oil pan AR01.45-W-7500-01B
*BA01.45-N-1001-01C
17 Remove seal (7) Installation: Replace seal (7). AR01.45-W-7500-02G
18 Clean sealing surfaces of oil pan (6) at Installation: Apply the sealant Loctite *BR00.45-Z-1013-01A
timing case, crankcase and front housing 5970 to the connecting point (arrows) to the
cover. timing case and to the front housing cover.
19 Remove oil dipstick guide tube bottom Only when installing a new oil pan (6).
section (17), fittings for oil dipstick guide
tube (4) and oil level sensor (B14) at oil pan
(6)
*BA01.45-N-1003-01C
*BA01.45-N-1004-01C
*BA18.40-N-1003-01D
21 Start engine and allow to run in idle for 10 s
until the oil pressure has built up, then run
the engine at varying speeds
22 Turn off engine and check area of oil pan Visual inspection.
(6) for leaks
23 Check engine oil level with oil dipstick or on Inspect engine oil level after waiting at
display, add oil if necessary* least 5 min. after switching off the engine
Observe engine oil grade set in maintenance
system or Specifications for Operating
Fluids.

541.9. 542.9
BA01.40-N-1012-01D Bolt, refrigerant compressor carrier/ Nm 150

hydraulic pump/frigoblock to crankcase
Oil pan
Number Designation Engine 541.9 Engine 542.9
BA01.45-N-1001-01C Bolt, oil pan to cylinder crankcase Light alloy Nm 55 55
Duroplastic Stage 1 Nm 10 10
Stage 2 Nm 40 40

Thermo- Nm 55 -
plastic
BA01.45-N-1002-01C Oil drain screw on oil pan Light alloy M20 1.5 Nm 65 65
M22 1.5 Nm 70 70
M26 1.5 Nm 80 80
M26 1.5 Nm 50 50
with valve
Duroplastic M20 1.5 65 65
BA01.45-N-1003-01C Fitting for oil dipstick guide/oil Light alloy M18 Nm 50 50

suction pipe to oil pan
Duroplastic M18 Nm 15 15
Thermo- M18 Nm 15 -
plastic
BA01.45-N-1004-01C Bolt, oil suctioning off tube in oil pan Nm 25 25
BA01.45-N-1006-01C Oil dipstick guide/oil suctioning off Nm 20 20

tube to fitting
Diesel injection system with unit pumps (MR/PLD)

542.9
BA07.15-N-1010-01B Bolt, control unit of engine control Nm 15

(MR) to crankcase
Oil level/oil pressure sensor

542.9
BA18.40-N-1003-01D Oil level sensor on oil pan Nm 50
Refrigerant compressor

930, 932, 933, 934,
950.0, 950.1, 950.2,
950.3, 952.0, 952.1,
952.2, 952.3, 953.1,
953.3, 954.0, 954.1,
954.2
BA83.55-N-1002-01C Support on fixture for refrigerant Nm 50

compressor/frigoblock and alternator
support
Engine lubrication
541.9 without code 541.9 without code
MN9, MY8, without MN9, MY8, with code
code MS4/5 with light MS4/5 with light alloy
alloy oil pan oil pan
BF18.00-N-1001-01B Engine oil Filling capacity with oil filter l 34 34
Specifications for Operating Sheet BB00.40-P-0228-05A BB00.40-P-0228-05A

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

541.9 with code 541.9 with code
MY8, with code MS4/5 MY8, without code
with light alloy oil pan MS4/5 with light alloy
oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet - BB00.40-P-0228-01A
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

MN9 with code MS4/5 MN9, without code
oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet - BB00.40-P-0228-01A
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A

Engine lubrication

codeMS4 /5 with MS4/5 with
thermoplastic oil pan thermoplastic oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

with thermoplastic oil MS4/5 with
pan thermoplastic oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet - BB00.40-P-0228-01A
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

541.9 with code 541.9 without code
codeMS4/5 with MS4/5 with thermoset
thermoset plastic oil plastic oil pan
pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A

Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

MY8 with code MS4/5 MY8, without code
oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet - BB00.40-P-0228-01A
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

MY8, without code MY8, with code MS4/5
MS4/5 with light alloy with light alloy oil
oil pan pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

MS4/5 with with
thermoset plastic oil thermoset plastic oil
pan pan

Fluids

Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Automatic engine oil replenishment
Number Designation Engine 541, 542

with code MB7
BF18.46-N-1001-01A Engine oil Reservoir quantity l 14.0
Specifications for Operating Sheet BB00.40-P-0228-05A
Fluids
Repair materials
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20

AR01.50-W-1000G Remove, install constant throttle 8.10.02
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Cap
2 O-ring
3 Pistons
4 Sealing ring
5 Retainer lock
6 Spring plate
7 Spring
8 Spring guide
9 Valve
10 Spacer
M Setback of valve to cylinder head

separating surface
W01.50-1007-06
3 Pistons
5 Retainer lock
6 Spring plate
7 Spring
11 Pliers
12 Spring disk compressor
13 Magnetic pin
W01.50-0009-06
Remove/install
1 Remove cylinder head AR01.30-W-5800G
2 Measure setback of valve relative to cylinder Clean valve disk and cylinder head *BE01.50-N-1007-01A
head separating surface (M) separating surface (combustion side) of the
cylinder head.
If measurement differs from specification:
Replace cylinder head.

*WE58.40-Z-1002-19A
3 Remove nozzle holder combination AR07.03-W-6831G
4 Remove end cover (1) Installation: replace O-ring (2).
© Daimler AG, 7/2/13, G/03/13, ar01.50-w-1000g, Remove, install constant throttle Page 1 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 ENGINE 542.9 in MODEL 930, 932, 934
5 Remove piston (3) Installation: If the sealing ring is worn or
damaged, the sealing ring and piston must
be replaced.
*442589003700
6 Remove spring (7) Insert a suitable spacer (10, height
approx. 6.0 mm) between valve disk and
mount. Press down the spring plate (6) using
the spring plate compressor (12). Remove
retainer locks (5) with the magnetic pin (13)
and remove the load on the spring plate.
Remove spring plate (6), spring (7) and
spring guide (8).
Installation: Do not confuse the spring
plate (6) with the spring guide (7).
*210589004000
*442589056300
7 Turn cylinder head and pull out valve (9) Installation: Oil valve stem, push in
valve and place spacer (10, height approx.
6.0 mm) below the valve disk.
Test values for constant throttle
Number Designation Engines

541.9, 542.9
BE01.50-N-1007-01A Setback of constant throttle valve mm 4.6...5.4

relative to cylinder head separating
surface
442 589 00 37 00 210 589 00 40 00 442 589 05 63 00

Pliers Magnetic pin Spring plate compressor
Workshop equipment
WE58.40-Z-1002-19A Depth gage
© Daimler AG, 7/2/13, G/03/13, ar01.50-w-1000g, Remove, install constant throttle Page 2 of 2
AR01.60-W-8200GA Remove/install timing case 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934 with CODE (MS4) BlueTec 4
W01.60-1024-09
Shown on engine 541.9 without code

(M32) Dual compressor
1 Resonance reservoir 8 Bracket with distributor piece 13 Seals

2 Timing case 9 Wiring harness mount 14 Exhaust manifold pipe
3 Bracket with transmission and engine 10 Bracket with engine wiring harness 15 Exhaust manifold pipe
wiring harness and ground line
4 Locking bush 11 Bracket with transmission oil lines B15 Crankshaft position sensor
5 O-ring (only for vehicles with code (N55) B16 Camshaft position sensor
6 Screw plug Transmission oil cooling) M1 Starter
7 Radial sealing ring 12 Engine wiring harness
Shown on engine 541.9 with code (MS5) BlueTec 5
2 Timing case
8 Bracket with distributor piece
16 AdBlue injection nozzle
17 AdBlue injection line
18 Compressed-air line
19 Metering device
20 Constant throttle compressed air line
W14.40-1215-12
Modification notes
15.2.08 Work procedure revised.

© Daimler AG, 7/2/13, G/03/13, ar01.60-w-8200ga, Remove/install timing case Page 1 of 5
ENGINES 541.9 in MODEL 930, 932, 933, 934 ENGINES 542.9 in MODEL 930, 932, 934 with CODE (MS4) BlueTec 4 ENGINES 542.9 in MODEL 930, 932, 934 with CODE (MS5) BlueTec 5
Remove/install
1.1 Remove engine Model 930, 932, 933, 934 AR01.10-W-2400G
1.2 Remove engine with transmission Model 934 without code (MP1) Rear cooling AR01.10-W-2401G
system or without code (G02) Torque
Model 934 with code (MP1) Rear cooling AR01.10-W-2401GA
system and with code (G02) Torque
2 Attach engine to commercial vehicle engine- Use an angle bracket.
assembly stand
3 Remove starter (M1) on timing case (2) Installation: Check starter drive pinion in
starter (M1) for wear; replace starter (M1) if
necessary.
*BA15.30-N-1001-01C
4.1 Remove flywheel Vehicles without code (G02) Torque AR03.30-W-8002G
4.2 Remove ring gear carrier with clutch plate Vehicles with code (G02) Torque converter AR03.30-W-8005G
clutch (WSK)
5 Take off oil pan AR01.45-W-7500G
6 Remove exhaust manifold pipes (14, 15) Installation: The stamped in arrow on
the exhaust manifold pipe (14, 15) must point
in the direction of the exhaust collector pipe.
Attach exhaust manifold pipe (14, 15)
unstressed.
*BA14.10-N-1003-01C
*BA14.10-N-1005-01C
*BA14.10-N-1012-01C
7 Remove fuel pump and power steering pump AR47.20-W-5712G
unit
8 Remove resonance tank (1) with hose at
compressor bracket
9 Remove injection line for AdBlue (17) Only for vehicles with code (MS4) AR14.40-W-2001A
BlueTec 4 or with code (MS5) BlueTec 5.
10 Remove exhaust plenum chamber together AR14.10-W-3920-01G
with turbocharger and engine brake flap
fitting
Bolt, intake manifold to compressor *BA09.20-N-1003-02C
cylinder head
Hose clamp intermediate piece to intake *BA09.20-N-1004-02C
manifold and turbocharger
Oil pressure line on exhaust gas *BA09.40-N-1009-01C
turbocharger
Exhaust gas turbocharger oil return line *BA09.40-N-1010-01C
to fitting on timing case
Bolt, oil pressure line to exhaust gas *BA09.40-N-1012-01C
turbocharger bracket
Bolt, exhaust plenum chamber to timing *BA14.10-N-1004-01C
case
Bolt for support/exhaust plenum chamber *BA14.10-N-1009-01C
on timing case
11 Remove timing case cover AR01.40-W-8000G
12 Disconnect compressed air line (18) to Only for vehicles with code (MS4)
metering device (19) at bracket with BlueTec 4 or with code (MS5) BlueTec 5.
distributor piece (8) and remove at timing
case (2)
13 Detach compressed air line of constant *BA01.50-N-1003-01A
throttle (20) at bracket with distributor piece
(8)
14 Remove wiring harness (9) bracket at timing
case (2)
15 Remove bracket with transmission and
engine wiring harness (3) at timing case (2)
16 Remove bracket with engine wiring harness *BA15.18-N-1003-01A
and ground line (10) at timing case (2)
17 Remove fixture together with transmission oil Only on vehicles with code (N55)
lines (11) at timing case (2) Transmission oil cooling.

18 Disconnect electrical engine wiring harness Installation: Replace seal ring (5), check
(12) on crankshaft position sensor (B15) and locking bush (4) and replace if necessary.
pull out crankshaft position sensor (B15) at Press in locking bush (4) and crankshaft
timing case (2) position sensor (B15) all the way.
19 Pull out camshaft position sensor (B16) at Installation: Replace seal ring (5), check
timing case (2) locking bush (4) and replace if necessary.
Press in locking bush (4) and camshaft
position sensor (B16) all the way.
20 Remove lines and detachable parts at timing
case (2)
21 Remove timing case (2) Installation: Position timing case (2) via
dowel pins on crankcase.
*BA01.60-N-1002-01B
22 Remove radial seal (7) in timing case (2) Installation: Check whether a race is AR03.20-W-3063G
mounted on flywheel; install appropriate
radial sealing ring (7) in the timing case (2) if
necessary.
23 Take off attached parts at timing case (2) Only when replacing timing case (2).
Bolt, TDC inspection hole cap to timing *BA01.60-N-1001-01B
case
Bolt, compressor opening end cover on *BA01.60-N-1003-01B
side to timing case
Screw of screw cap (engine power take- *BA01.60-N-1005-01B
off) to timing case
Screw plug for turbocharger oil return *BA01.60-N-1006-01B
flow in the timing case
Turbocharger oil return flow fitting to *BA01.60-N-1007-01B
timing case
24 Take off gaskets (13)
Seals between crankcase and timing case As of engine end no. 349692 BT01.60-W-0001-01A
altered
Constant throttle

542.9

distributor piece
Timing case

541.9, 542.9

case
BA01.60-N-1002-01B Bolt, timing case to crankcase M12 57 Nm 100
M12 105 Nm 100
M12 167 Nm 100
BA01.60-N-1003-01B Bolt, side compressor hole cover to timing case Nm 50
BA01.60-N-1005-01B Bolt, screw cap (engine power take-off) to timing Nm 25

case
BA01.60-N-1006-01B Screw plug, for turbocharger oil return flow in the Nm 80

timing case

BA01.60-N-1007-01B Turbocharger oil return flow fitting to timing case Nm 120

541.9 541.9
MJ1
BA09.20-N-1003-02C Bolt, intake manifold to Nm 50 50

compressor cylinder head
BA09.20-N-1004-02C Hose clamp intermediate piece on Nm 6.0 6.0

intake manifold and turbocharger

542.9 542.9
MJ1


Turbocharger

541.9 542.9
BA09.40-N-1009-01C Oil pressure line to turbocharger M14 1.5 Nm 35 35
BA09.40-N-1010-01C Exhaust gas turbocharger oil return line on fitting M26 1.5 Nm 50 50
on timing case
BA09.40-N-1012-01C Bolt, oil pressure line to exhaust gas turbocharger Nm 25 25

bracket
Exhaust manifold
BA14.10-N-1003-01C Nut, exhaust pipe to exhaust plenum chamber Nm 50 -
BA14.10-N-1004-01C Bolt, exhaust plenum chamber to timing case M16 Nm 150 150
M12 Nm 100 100

M10 Nm 50 50
BA14.10-N-1005-01C Nut, pipe to exhaust manifold Nm 50 50
BA14.10-N-1009-01C Bolt, support/exhaust plenum chamber to timing Nm 40 -

case
BA14.10-N-1012-01C Bolt, exhaust pipe to exhaust manifold Nm 50 50
Engine wiring harness

542.9
BA15.18-N-1003-01A Bolt, wiring loom to timing case Nm 25
Starter

541.9, 542.9
BA15.30-N-1001-01C Nut, starter to timing case Nm 80

AR03.10-W-7311G Remove/install piston rings 3.8.11
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Piston ring (keystone ring)

2 Piston ring (taper-faced ring with
inside angle)
3 Piston ring (bevel-edged ring with
spring expander)
3.1 Coil spring
4 Pistons
5 Pliers
5.1 Knurled screw
A Spread value (piston ring)

Arrow Coil spring end gap
W03.10-1058-06
Modification notes
6.2.06 Measure piston ring end clearance - added. Step 7 AR03.10-W-7311-02G
Removing
1 Remove piston (4) AR03.10-W-7021G
2 Remove combustion residues on piston rings
(1, 2, 3)
3 Clamp connecting rod and piston (4) in a Use protective jaws for clamping.
vise
4 Adjust to max. permissible spread value (B) *BE03.10-N-1002-05D
at pliers (5) knurled screw (5.1)
*000589373700
5 Remove piston rings (1, 2, 3) in the order *000589373700
from top to bottom
Checking
6 Check piston rings (1, 2, 3) for chippings on All piston rings (1, 2, 3) on the respective
the coating piston must be replaced if there is damage.
7 Measure piston ring gap clearance of piston AR03.10-W-7311-02G
rings (1, 2, 3)
*BE03.10-N-1001-05D
Feeler gauge
Install
8 Adjust to max. permissible spread value (B) *BE03.10-N-1002-05D
at pliers (5) knurled screw (5.1)
*000589373700
9 Insert piston ring (3) spring expander (3.1)
into lower groove on piston (4)
10 Install piston ring (3) with pliers (5) The coil spring end gap (arrow) must be
installed offset by about 180° to piston ring
end gap.
*000589373700
11 Install piston rings (1, 2) in the sequence Pay attention to installation position.
from below to above using pliers (5) Marking "TOP" must point toward piston
crown.
*000589373700
12 Check piston rings (1, 2, 3) for chippings on All piston rings (1, 2, 3) on the respective
the coating piston must be replaced if there is damage.
13 Install piston (4) AR03.10-W-7021G
© Daimler AG, 7/2/13, G/03/13, ar03.10-w-7311g, Remove/install piston rings Page 1 of 2

ENGINE 541.9 in MODELS 930, 932, 933, 934 ENGINE 542.9 in MODEL 930, 932, 934
Check values for piston rings
Number Designation Engines Engine

541.9, 542.9 541.9, 542.9
up to engine end no. as of engine end no.
111419 111420
BE03.10-N-1001-05D Piston ring Groove I Keystone When new mm 0.60...0.75 0.45...0.60

gap clearance ring
wear mm 1.0 1.0

limit
Groove II Taper When new mm 0.40...0.55 0.40...0.55

faced compression
ring with
inner chamfer
wear mm 1.0 1.0

limit
Groove III Double When new mm 0.30...0.45 0.40...0.55

beveled oil control
ring with
coil spring
wear mm 0,8 0,8

limit
BE03.10-N-1002-05D Spread value of max. mm 43 43

piston ring
000 589 37 37 00
Pliers
© Daimler AG, 7/2/13, G/03/13, ar03.10-w-7311g, Remove/install piston rings Page 2 of 2

AR03.10-W-7021G Remove/install piston 11.12.08
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Piston
2 Piston pin
3 Circlip
4 Connecting rods
5 Connecting rod bearing cap
6 Connecting rod bolt
7 Connecting rod bearing shells
8 Oil spray nozzle
A Piston projection
L Shank length
W03.10-1049-06
Modification notes
5.3.07 Remove/install oil spray nozzle - added Steps 7 and 23

Assembly sleeve for installation of the piston in the Step 22
cylinder liner - added
Use turning device 904 589 04 63 00 Steps 5 and 22
Step 8 AR03.10-W-7021-04G
Step 8 AR03.10-W-7021-04GA
Step 25 AR03.10-W-7041-01B
Removing
1 Remove cylinder head When repairing and cleaning, no AR01.30-W-5800G
contamination must enter into crankcase,
otherwise engine damage can occur.
2 Remove oil pan AR01.45-W-7500G
3 Remove transmission oil lines on timing case Only on vehicles with code (N55)
Transmission oil cooling.
Do not disconnect transmission oil lines.
4 Take off end cover at timing case
*904589046300
6 Carefully remove deposits on crankcase
separating surface
7 Remove oil spray nozzle (8) AR18.00-W-4000G
8 Remove piston (1) from cylinder liner Vehicles without code (MS4) BlueTec 4 or AR03.10-W-7021-04G
without code (MS5) BlueTec 5
Vehicles with code (MS4) BlueTec 4 or with AR03.10-W-7021-04GA
*422589020900
*904589046300
9 Remove circlips (3)
10 Press out piston pin (2) and take piston (1)
off connecting rod (4)
Checking
11 Remove deposits on piston (1) and assess
piston (1) by means of visual inspection for
reusability
Notes on the assessment of pistons and AH03.10-N-0001-04A
piston rings
© Daimler AG, 7/2/13, G/03/13, ar03.10-w-7021g, Remove/install piston Page 1 of 6

12 Assess connecting rod bearing shells (7) and
crankshaft connecting rod journals by means
of visual inspection for reusability
Notes on assessing wear on connecting rod AH03.10-N-0001-03A
bearings and connecting rod bearing journals
13 Assess honing pattern in the cylinder liner by If honing pattern cannot be assessed
means of visual inspection for reusability clearly:
Measure cylinder bore. AR01.40-W-9202G

Notes for evaluation of a cylinder barrel AH01.40-N-0001-03A
14 Check connecting rod (4) AR03.10-W-6112G
15 Determine connecting rod bearing radial play AR03.20-W-4291-04A
Connecting rod bearing inside dia. for *BE03.10-N-1001-01C
connecting rod bearing shells inserted
Bolt, connecting rod bearing cap to *BE03.10-N-1005-01C
connecting rod
Connecting rod bearing radial play *BE03.10-N-1006-01C
Connecting rod journal dia., connecting rod *BE03.20-N-1004-02C
journal width
*BA03.10-N-1001-01C
*001589532100
16 Measure connecting rod bolts (6) Replace connecting rod bolt (6) *BE03.10-N-1005-01C
concerned if permissible shank length (L) of
connecting rod bolts (6) is exceeded.
Install
17 Match piston (1) to cylinder liner Only for vehicles without code (MS4) AR03.10-W-7021-02A
BlueTec 4 or without code (MS5) BlueTec 5.
Cylinder liner inside dia. *BE01.40-N-1001-03C
18 Install one circlip (3) into piston boss
19 Assemble piston (1) and connecting rod (4) Observe installation position and number
of cylinders on the piston (1) and connecting
rod (4); transfer to a new part if necessary.
Notes on installing pistons and connecting AH03.10-N-2200-02B
rods
20 Lightly lubricate piston pin (2) with engine oil
then lead in piston (1) and connecting rod (4)
by hand
21 Install second circlip (3)
22 Install piston (1) in cylinder liner Vehicles without code (MS4) BlueTec 4 or AR03.10-W-7021-05G
without code (MS5) BlueTec 5
Vehicles with code (MS4) BlueTec 4 or with AR03.10-W-7021-05GA
*BA03.10-N-1001-01C
*422589020900
*541589021400
*904589046300
Notes on installing pistons and connecting AH03.10-N-2200-02B
rods
23 Install oil spray nozzle (8) AR18.00-W-4000G
24 Rotate crankshaft with cranking device and
check for clearance
25 Measure piston projection (A) AR03.10-W-7041-01B
Piston projection at TDC relative to *BE03.10-N-1001-02D
crankcase separating surface
*001589532100
*541589012100
*904589046300
26 Installing oil pan AR01.45-W-7500G
27 Install cylinder head AR01.30-W-5800G
28 Remove turning device for engine at timing
case
29 Install cap at timing case *BA01.60-N-1001-01B
30 Attach transmission oil lines on timing case Only on vehicles with code (N55)
31 Conduct additional testing after engine AR03.10-W-0002A
repairs on piston (1), connecting rod (4) and
cylinder barrel
32 Fill engine oil circuit AR18.00-W-1600G
Check values for cylinder liner

541.9, 542.9
BE01.40-N-1001-03C Cylinder liner inside dia. Code letter A mm 129.990 to

129.995
Code letter B mm 129.995 to

130.005
Code letter C mm 130.005 to

130.010
Test specifications for connecting rod

541.9, 542.9
from engine from engine
end no. 054766 end no. 054766
BE03.10-N-1001-01C Connecting rod bearing inside dia. Default mm 94.064 to 94.110 94.064 to 94.110
for connecting rod bearing shells
inserted
Deviation 0.10 mm 93.964 to 94.010 93.964 to 94.010
Oversize 1.00 mm 93.064 to 93.110 93.064 to 93.110
BE03.10-N-1005-01C Bolt, connecting rod bearing cap to Thread dia. M 16 1.5 16 1.5
connecting rod
Permissible shank mm 74.5 74.5

length
BE03.10-N-1006-01C Connecting rod bearing radial play mm 0.064 to 0.126 0.064 to 0.126
Test specifications for pistons

541.9, 542.9 541.9, 542.9
Standard EURO IV
EUROII from standard
engine end no. Engine
072768,
541.9, 542.9
Engine
EURO V
541.9, 542.9 standard
EURO standard
III
BE03.10-N-1001-02D Piston projection at TDC relative to mm 0.27 to 0.61 0.27 to 0.61

crankcase separating surface
Check values for a crankshaft

EURO standard II EURO standardII
up to engine no. Up to engine no.
098131 098131
BE03.20-N-1004-02C Connecting rod journal Dia. standard mm 93.980...94.000 93.980 - 94.000

dia., connecting rod width mm 37.000...37.100 81.000 - 81.140
journal width
Dia. deviation 0.10 mm 93.880 - 93.900 93.880 - 93.900

width mm 37.000 - 37.100 81.000 - 81.140
Dia. deviation 0.25, mm 93.730 - 93.750 93.730 - 93.750

width mm 37.000 - 37.100 81.000 - 81.140
Dia. deviation 0.50 mm 93.480 - 93.500 93.480 - 93.500

width mm 37.000 - 37.100 81.000 - 81.140
Dia. deviation 0.75 mm 93.230 - 93.250 93.230 - 93.250

width mm 37.000 - 37.100 81.000 - 81.140
Dia. deviation 1.00 mm 92.980 - 93.000 92.980 - 93.000

width mm 37.000 - 37.100 81.000 - 81.140

EURO standardII EURO standard II
As of engine no. as of engine no.
098132 098132
Motor 541.9 Engine 542.9
Norm EURO III EURO standard III
BE03.20-N-1004-02C Connecting rod journal Dia. standard mm 93.980 - 94.000 93.980 - 94.000
dia., connecting rod width mm 37.000 - 37.130 81.000 - 81.140
journal width
Dia. deviation 0.10 mm 93.880 - 93.900 93.880 - 93.900

width mm 37.000 - 37.130 81.000 - 81.140
Dia. deviation 0.25, mm 93.730 - 93.750 93.730 - 93.750

width mm 37.000 - 37.330 81.000 - 81.340
Dia. deviation 0.50 mm 93.480 - 93.500 93.480 - 93.500

width mm 37.000 - 37.330 81.000 - 81.340
Dia. deviation 0.75 mm 93.230 - 93.250 93.230 - 93.250

width mm 37.000 - 37.330 81.000 - 81.340
Dia. deviation 1.00 mm 92.980 - 93.000 92.980 - 93.000

width mm 37.000 - 37.330 81.000 - 81.340

EURO IV standard EURO IV standard
with with
code MS4 code MS4
EURO V standard EURO V standard
with with
code MS5 code MS5

BE03.20-N-1004-02C Connecting rod journal Dia. standard mm 93.980 - 94.000 93.980 - 94.000
dia., connecting rod width mm 37.000 - 37.130 81.000 - 81.140
journal width
Dia. deviation 0.10 mm 93.880 - 93.900 93.880 - 93.900

width mm 37.000 - 37.130 81.000 - 81.140
Dia. deviation 0.25, mm 93.730 - 93.750 93.730 - 93.750

width mm 37.200 - 37.330 81.200 - 81.340
Dia. deviation 0.50 mm 93.480 - 93.500 93.480 - 93.500

width mm 37.200 - 37.330 81.200 - 81.340
Dia. deviation 0.75 mm 93.230 - 93.250 93.230 - 93.250

width mm 37.200 - 37.330 81.200 - 81.340
Dia. deviation 1.00 mm 92.980 - 93.000 92.980 - 93.000

width mm 37.200 - 37.330 81.200 - 81.340
Timing case

541.9. 542.9

case
Connecting rod

542.9
BA03.10-N-1001-01C Bolt, connecting rod bearing Stage 1 Nm 110

cap to connecting rod
Stage 2 ° 90
422 589 02 09 00 001 589 53 21 00 541 589 01 21 00 904 589 04 63 00

Wrench socket Dial indicator Measuring bridge Cranking device

541 589 02 14 00
Assembly sleeve

AR03.20-W-4351G Remove/install crankshaft 23.9.10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Crankshaft
2 Main bearing shell
3 Main bearing shell
4 Thrust plate fitted bearing
5 Main bearing cap
6 Main fitted bearing cap
7 Main bearing cap central bolt
8 Side bolt for main bearing cap
9 Crankshaft sprocket
L Shank length
W03.20-0017-06
W03.20-1099-09
1 Crankshaft 5 Main bearing cap 11 Drift

2 Main bearing shell 6 Main fitted bearing cap
3 Main bearing shell 9 Crankshaft sprocket Arrows Markings
4 Thrust plate fitted bearing 10 Camshaft sprocket
Modification notes
23.6.10 Work procedure changed.
Removing
© Daimler AG, 7/2/13, G/03/13, ar03.20-w-4351g, Remove/install crankshaft Page 1 of 4

1.2 Remove engine with transmission Only model 934 without code (MP1) Rear AR01.10-W-2401G
cooling system or without code (G02) Torque
Only model 934 with transmission 715.5 AR01.10-W-2401GA
with code (MP1) Rear cooling system and
with code (G02) Converter shift clutch (WSK)
2 Remove timing case Engine 541.9, AR01.60-W-8200GA
engine 542.9 with code (MS4) BlueTec 4 or
3 Remove oil pump AR18.10-W-6020G
4 Remove front housing cover AR01.40-W-8800G
5 Remove pistons AR03.10-W-7021G
6 Remove main bearing cap (5) and main fitted Check whether the marking of the main
bearing cap (6) bearing cap (5) is present, if necessary mark
the main bearing cap (5).
7 Remove main bearing shells (3) from main Identify main bearing shells (3) to
bearing caps (5) and from main fitted bearing respective main bearing cap (5) and to main
cap (6) fitted bearing cap (6).
8 Remove fitted bearing thrust plates (4) from
main fitted bearing cap (6)
9 Push fitted bearing thrust plates (4) at fitted
bearing of crankshaft (1) out of crankcase
10 Lift crankshaft (1) out of crankcase using a Screw drifts (11) into crankshaft (1)
lifting cradle and place down to one side at front and rear and secure shackle on it.
Drift *403589026300
11 Remove main bearing shells (2) from Mark main bearing shells (2) relative to
crankcase the crankcase.
12 Clean crankshaft (1) and oil duct in
crankshaft (1)
Check
13 Check grooved pins for fitted bearing thrust If grooved pins are damaged:
plates (4) at main fitted bearing cap (6)
Replace grooved pin at main fitted bearing AR01.40-W-8600-01G
cap.
Protrusion of grooved pin to main bearing *BE01.40-N-1003-02C
cap
14 Check crankshaft (1) by means of visual If there is damage or cracks:
inspection for damage and cracks
Replace crankshaft (1).
15 Clean main bearing shells (2, 3), thrust plates
of fitted bearings (4) and main bearing
journals of crankshaft (1) with a chamois
leather and check by a visual inspection
Information on assessing wear of main AH03.20-N-1000-02A
bearings and main bearing journals
16 Measure concentricity of crankshaft (1) at On engine 541.9, measure at both center AR03.20-W-4351-08G
middle main bearing journal main bearing journals.
On engine 542.9, measure at center main
bearing journal.
*BE03.20-N-1007-02C
Dial gage *001589532100
Dial gauge holder *363589022100
17 Inspect hardness of main and connecting rod AR03.20-W-4351-09G
bearing journals
Hardness of main bearing and connecting *BE03.20-N-1009-02C
rod journals
Hardness tester *000589202100
Notes on hardness test AH00.00-N-0012-01A
18 Determine crankshaft bearing radial play AR03.20-W-4291-02G
Main bearing cap central bolt *BE01.40-N-1002-02C
Main bearing journal dia., main bearing *BE03.20-N-1001-02C
journal width (except main bearings/fitted
bearing journals)
Main bearing journal dia., fitted bearing *BE03.20-N-1002-02C
journal width
Crankshaft main bearing inside dia. when *BE03.20-N-1012-02C
installed
Main bearing radial play *BE03.20-N-1015-02C
Main bearing cap central bolt *BA01.40-N-1013-01D
Main bearing cap side bolt *BA01.40-N-1016-01D
Dial indicator *001589532100

19 Determine connecting rod bearing radial play AR03.20-W-4291-04A
Connecting rod bearing inside dia. for *BE03.10-N-1001-01C
connecting rod bearing shells inserted
Bolt of connecting rod bearing cap to *BE03.10-N-1005-01C
connecting rod
Connecting rod bearing radial play *BE03.10-N-1006-01C
Connecting rod journal dia., connecting rod *BE03.20-N-1004-02C
journal width
*BA03.10-N-1001-01C
20 Determine thickness of fitted bearing thrust AR03.20-W-4351-01G
plate (4) at crankshaft (1)
Main bearing journal dia., fitted bearing *BE03.20-N-1002-02C
journal width
Wall thickness of fitted bearing thrust plates *BE03.20-N-1013-02C
21 Measure central bolts of main bearing cap If permissible shank length (L) is *BE01.40-N-1002-02C
(7) exceeded:
Replace respective central bolt of main

bearing cap (7).
Install
22 Remove any metal abrasion from oil ducts Only if bearing damage has occurred.
and clean the inner components
23 Insert main bearing shells (2) with groove The oil holes of the main bearing shell
into crankcase (2) must match with the oil holes in the
cylinder crankcase, otherwise bearing
damage can occur.
Observe identification of main bearing
shells (2) to crankcase. Lubricate contact
surfaces of main bearing shells (2) with
engine oil.
24 Put crankshaft (1) with shackle onto main Markings (arrows) on crankshaft gear (9)
bearing shells (2) in crankcase and camshaft sprocket (10) must be
positioned opposite each other.
Screw in second drift ( 11) or second bolt
into one of the threaded holes in crankshaft
(1), if necessary, and turn crankshaft (1)
using a suitable lever.
Drift *403589026300
25 Remove drift (11) and shackle from
crankshaft (1)
26 Insert fitted bearing thrust plates (4) between Lubricate fitted bearing thrust plates (4)
crankshaft (1) and crankcase with engine oil. Grooves in fitted bearing
thrust plates (4) must point towards the
crank webs.
27 Insert main bearing shells (3) into main Lubricate contact surfaces of main
bearing cap (5) and main fitted bearing cap bearing shells (3) with engine oil. Observe
(6) identification of the main bearing shells (3) to
respective main bearing cap (5) and to main
fitted bearing cap (6). Retaining lug at main
bearing shell (3) must be inserted into
groove provided for this purpose.
28 Attach fitted bearing thrust plates (4) to main Lubricate fitted bearing thrust plates (4)
fitted bearing cap (6) with engine oil. Grooves in fitted bearing
thrust plates (4) must point towards the
crank webs. The thrust plates of the fitted
bearings (4) are fixed in place by bores in
the grooved pins on the main/fitted bearing
caps (6).
29 Install main bearing cap (5) and main fitted Main bearing cap (5) and main fitted
bearing cap (6) with fitted bearing thrust bearing cap (6) have dowel pins and are
plates (4) marked with numbers and must be installed
according to numbers (e.g. 1x xxx),
beginning at the front, in an ascending order.
30 Lubricate central bolt of main bearing cap (7)
and side bolt of main bearing cap (8) with
engine oil
31 Tighten main bearing cap (5) and main fitted First tighten central bolts of main bearing
bearing cap (6) cap (7) and then tighten side bolts of main
bearing cap (8).
Central bolt for main bearing cap *BA01.40-N-1013-01D
Side bolt for main bearing cap *BA01.40-N-1016-01D
32 Rotate crankshaft (1) by hand and check for
unobstructed movement.
33 Determine crankshaft bearing crankshaft end AR03.20-W-4291-03G
play (1)
Main bearing axial play *BE03.20-N-1006-02C
Dial indicator holder *363589022100
34 Perform additional checking work for engine AR03.20-W-0002A
repair on crankshaft (1)
35 Install pistons AR03.10-W-7021G
36 Install oil pump AR18.10-W-6020G
37 Install front housing cover AR01.40-W-8800G
38 Install timing case Engine 541.9, AR01.60-W-8200GA
engine 542.9 with code (MS4) BlueTec 4 or
39.1 Install engine Model 930, 932, 933, 934 AR01.10-W-2400G
39.2 Install engine with transmission Only model 934 without code (MP1) Rear AR01.10-W-2401G
cooling system or without code (G02) Torque
Only model 934 with transmission 715.5 AR01.10-W-2401GA
with code (MP1) Rear cooling system and
with code (G02) Converter shift clutch (WSK)
Check values for crankcase

542.9
BE01.40-N-1002-02C Main bearing cap central bolt Thread diameter M 18
Length of shank when mm 173

new
BE01.40-N-1003-02C Protrusion of grooved pin to main mm 4.5 to 4.7

bearing cap

541.9, 542.9
from engine from engine
end no. 054766 end no. 054766
BE03.10-N-1001-01C Connecting rod bearing inner Default mm 94.064 to 94.110 94.064 to 94.110
diameter for connecting rod bearing
shells inserted
BE03.10-N-1005-01C Bolt, connecting rod bearing cap to Thread diameter M 16 1.5 16 1.5
connecting rod
Permissible shank mm 74.5 74.5

length
BE03.10-N-1006-01C Connecting rod bearing radial play mm 0.064 to 0.126 0.064 to 0.126

AR03.20-W-4341A Remove/install main bearing of crankshaft 14.2.12
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W03.20-1135-09
1 Carrier (alternator) G2 Generator

2 Carrier (tank heater solenoid valve) M1 Starter
3 Oil pan A6 Engine control MR control unit
4 Oil pump Y107 SCR tank heater solenoid valve
5 Oil suction pipe
6 Oil pressure relief valve
7 Main bearing cap

8 Fitted bearing cap
W03.20-1136-06
Remove/install
© Daimler AG, 7/2/13, G/03/13, ar03.20-w-4341a, Remove/install main bearing of crankshaft Page 1 of 9
Danger! Risk of explosion caused by oxyhydrogen No fire, sparks, open flames or smoking. AS54.10-Z-0001-01A
gas. Risk of poisoning and caustic burns Wear acid-resistant gloves, clothing and
caused by swallowing battery acid. Risk of glasses. Only pour battery acid into suitable
injury caused by burns to skin and eyes and appropriately marked containers.
from battery acid or when handling damaged
lead-acid batteries
2 Disconnect ground line of battery
Notes on battery AH54.10-P-0001-01A
5 Remove bottom noise encapsulation
6 Remove carrier (1) of alternator (G2) AR15.40-W-6232G
7 Remove engine control MR control unit (A6) AR07.15-W-1630G
8 Detach tank heater solenoid valve SCR Only for vehicles with code (MS4)
(Y107) on carrier (2) BlueTec 4 or with code (MS5) BlueTec 5.
Do not disconnect coolant lines and tie up
tank heater solenoid valve SCR (Y107) on
frame.
*BA14.40-N-1012-02A
9 Remove support (2)
10 Remove starter (M1) AR15.30-W-7100G
11 Attach cranking device to timing case Bolt, turning device to timing case *BA01.60-N-1009-01B
Bolt, TDC inspection hole cap to timing *BA01.60-N-1001-01B
case
*904589046300
12 Drain engine oil or extract Installation: Fill with engine oil. AR18.00-W-3035-02G
*BA01.45-N-1002-01C
Without code (MB7) Automatic engine oil *BF18.00-N-1001-01B
refilling
with code (MB7) Automatic engine oil *BF18.46-N-1001-01A
refilling
Engine oil suction unit
Notes on oil pan versions AH01.45-W-0002-01A
13 Remove oil pan (3) AR01.45-W-7500G
14 Remove oil pump (4) with oil suction pipe (5) AR18.10-W-6020G
15 Replace crankshaft main bearing Only a maximum of one main bearing AR03.20-W-4341-04A
cap (7) or main fitted bearing cap (8) may
always be removed so that the crankshaft
does not lower and in the process the front
and rear crankshaft radial sealing ring is
damaged.
Permissible shank length of central bolts of *BE01.40-N-1002-02C
main bearing cap
*541589096300
*904589046300
16 Replace main bearing of fitted bearing cap Only a maximum of one main bearing AR03.20-W-4341-05A
cap (7) or main fitted bearing cap (8) may
always be removed so that the crankshaft
does not lower and in the process the front
and rear crankshaft radial sealing ring is
damaged.
Permissible shank length of central bolts of *BE01.40-N-1002-02C
main bearing cap
Main bearing axial play *BE03.20-N-1006-02C
Remove/install groove pin on main fitted AR01.40-W-8600-01G

bearing cap
Protrusion of grooved pin to main bearing *BE01.40-N-1003-02C
cap
Determine thickness of crankshaft fitted AR03.20-W-4351-01G

bearing thrust washers
Main bearing journal dia. fitted bearing *BE03.20-N-1002-02C
journal width
Fit bearing - thrust washers wall thickness *BE03.20-N-1013-02C
*001589532100
*363589022100
*541589096300
*904589046300
Inspection data of crankcase

542.9
BE01.40-N-1002-02C Main bearing cap central bolt Thread diameter M 18
Length of shank when mm 173

new
BE01.40-N-1003-02C Protrusion of grooved pin to main mm 4.5 to 4.7

bearing cap
Test specifications for crankshaft

EURO standard Ⅱ EURO standardⅡ
up to engine no. Up to engine no.
098131 098131
BE03.20-N-1002-02C Main bearing journal Dia. standard mm 107.980 to 108.000 107.980 to 108.000
dia. fitted bearing width standard mm 42.000 to 42.062 42.000 to 42.062
journal width
Dia. deviation 0.10 mm 107.880 to 107.900 107.880 to 107.900

width standard mm 42.000 to 42.062 42.000 to 42.062
Ø deviation 0.25 mm 107.730 to 107.750 107.730 to 107.750

width deviation 0.50 mm 42.500 to 42.562 42.500 to 42.562



BE03.20-N-1006-02C Main bearing axial play mm 0.150 to 0.351 0.150 to 0.351
BE03.20-N-1013-02C Fit bearing - thrust Default mm 5.375 to 5.425 5.375 to 5.425

washers wall thickness
EURO standardⅡ EURO standard II
As of engine no. as of engine no.
098132 098132
Motor 541.9 Engine 542.9
Norm EURO Ⅱ EURO standard Ⅱ
journal width







EURO IV standard EURO IV standard
with with
code MS4 code MS4
EURO V standard EURO V standard
with with
code MS5 code MS5
journal width






541.9. 542.9
BA01.40-N-1013-01D Central bolt, main bearing cap to crankcase Stage 1 Nm 320
Stage 2 ° 90
BA01.40-N-1016-01D Side bolt, main bearing cap to crankcase Stage 1 Nm 120
Stage 2 ° 90
Oil pan
BA01.45-N-1002-01C Oil drain screw to oil pan Light alloy M20 1.5 Nm 65 65
M22 1.5 Nm 70 70
M26 1.5 Nm 80 80
M26 1.5 Nm 50 50
with valve
Thermoset M20 1.5 65 65

plastic
Timing case

541.9. 542.9

case
Exhaust aftertreatment

541.9 542.9
with code with code
MS4 MS4
or code or code
MS5 MS5
BA14.40-N-1012-02A SCR tank heater solenoid valve on bracket Nm 25 25
Engine lubrication

code MS4/5 with light MS4/5 with light alloy
alloy oil pan oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet - BB00.40-P-0228-01A
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

MN9 with code MS4/5 MN9, without code
oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet - BB00.40-P-0228-01A
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

codeMS4 /5 with MS4/5 with
thermoplastic oil pan thermoplastic oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

with thermoplastic oil MS4/5 with
pan thermoplastic oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet - BB00.40-P-0228-01A
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

541.9 with code 541.9 without code
codeMS4/5 with MS4/5 with thermoset
thermoset plastic oil plastic oil pan
pan
Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

MY8 with code MS4/5 MY8, without code
oil pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet - BB00.40-P-0228-01A
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

MS4/5 with light alloy with light alloy oil
oil pan pan

Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Engine lubrication

MS4/5 with with
thermoset plastic oil thermoset plastic oil
pan pan
Fluids
Sheet BB00.40-P-0228-03A BB00.40-P-0228-03A
Sheet BB00.40-P-0228-01A -
Sheet BB00.40-P-0228-31A BB00.40-P-0228-31A
Sheet BB00.40-P-0228-51A BB00.40-P-0228-51A
See fig. AH01.45-W-0002-01A AH01.45-W-0002-01A
Automatic engine oil replenishment
Number Designation Engine 541, 542

with code MB7
BF18.46-N-1001-01A Engine oil Reservoir quantity l 14,0
Specifications for Operating Sheet BB00.40-P-0228-05A

Fluids
001 589 53 21 00 363 589 02 21 00 541 589 09 63 00 904 589 04 63 00

Dial indicator Dial indicator holder Removal and installation tool Cranking device
AR03.20-W-3063G Replace rear crankshaft radial sealing ring 23.9.10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W03.20-1186-08
1 Pry bar 2 Radial shaft sealing ring 3 Insertion device
Modification notes
22.5.10 Picture changed

Clean timing case in the area of the removed radial shaft Operation step 3
sealing ring (2) and the flywheel flange or ring gear
carrier flange - added.
Install new radial shaft sealing ring (2) using the insertion Step 5 AR03.20-W-3063-01G
device (3) - added
Step 5 AR03.20-W-3063-01GA
Step 5 *457589014300
Removing
1.1 Remove flywheel Vehicles without code (G02) Torque AR03.30-W-8002G
1.2 Remove ring gear carrier with clutch plate Vehicles with code (G02) Torque converter AR03.30-W-8005G
clutch (WSK)
2 Press out radial shaft sealing ring (2) with Cover over crankshaft with a cloth as a
pry bars (1) protection.
Pry bar *003589011600
Clean
3 Clean timing case in the area of the
removed radial shaft sealing ring (2) and the
flywheel flange or ring gear carrier flange.
Checking
4 Check contact surface of radial shaft sealing If there is galling on the flywheel flange
ring (2) on the flywheel flange or ring gear or on the ring gear carrier flange or race:
carrier flange or race on flywheel or ring
gear carrier
Mount new race on the flywheel flange or on
the ring gear carrier flange.
Vehicles without code (G02) Torque AR03.30-W-8350G
clutch (WSK)
Install
5 Install new radial shaft sealing ring (2) with Install radial shaft sealing ring (2) on the
the insertion device (3) outer surface dry and on the inner sealing
lip wet with engine oil.
For a flywheel or a ring gear carrier without AR03.20-W-3063-01G
race.
For a flywheel or a ring gear carrier with AR03.20-W-3063-01GA
race.
A new radial shaft sealing ring (2) with a
larger inside diameter must be installed.
Installer *457589014300
© Daimler AG, 7/2/13, G/03/13, ar03.20-w-3063g, Replace rear crankshaft radial sealing ring Page 1 of 2
6.1 Install flywheel Vehicles without code (G02) Shift clutch AR03.30-W-8002G
converter
6.2 Install ring gear carrier with clutch plate Vehicles with code (G02) Torque converter AR03.30-W-8005G
clutch (WSK)
003 589 01 16 00 457 589 01 43 00

Pry bar Installer
© Daimler AG, 7/2/13, G/03/13, ar03.20-w-3063g, Replace rear crankshaft radial sealing ring Page 2 of 2
AR03.20-W-3001G Replace front cassette-type sealing ring 23.9.10
ENGINES 541.9## ## as of 709511 in MODEL 930, 932, 933, 934
ENGINES 542.9## ## as of 709511 in MODELS 930, 932, 934
W03.20-1193-08
1 Belt pulley/vibration damper 3 Extraction device 4 Insertion device

2 Cassette-type sealing ring
Removing
1 Remove belt pulley/vibration damper (1) Vehicles without code (ML3) High-speed fan AR03.30-W-1600G
Electromagnetic viscous coupling for a fan
and vehicles without code (MO1)
Electromagnetic viscous coupling, Behr
Electromagnetic viscous coupling for a fan.
viscous coupling for a fan.
2 Remove cassette-type sealing ring (2) with AR03.20-W-3001-02G
the extraction device (3)
Install
3 Install new cassette-type sealing ring (2) with AR03.20-W-3001-01G
the insertion device (4)
4 Install belt pulley/vibration damper (1) Vehicles without code (ML3) High-speed fan AR03.30-W-1600G
Electromagnetic viscous coupling for a fan
and vehicles without code (MO1)
Electromagnetic viscous coupling, Behr
Electromagnetic viscous coupling for a fan.
viscous coupling for a fan.
5 Start engine and perform an engine test run
© Daimler AG, 7/2/13, G/03/13, ar03.20-w-3001g, Replace front cassette-type sealing ring Page 1 of 2
ENGINES 541.9## ## as of 709511 in MODEL 930, 932, 933, 934 ENGINES 542.9## ## as of 709511 in MODELS 930, 932, 934
6 Switch off the engine and check the Visual inspection.
cassette-type sealing ring (2) for leaks
457 589 00 43 00
Removal and insertion device
© Daimler AG, 7/2/13, G/03/13, ar03.20-w-3001g, Replace front cassette-type sealing ring Page 2 of 2
ENGINES 541.9## ## as of 709511 in MODEL 930, 932, 933, 934 ENGINES 542.9## ## as of 709511 in MODELS 930, 932, 934
AR03.30-W-8002G Remove, install flywheel 12.12.08
ENGINE 541.9 in MODEL 933
ENGINE 541.9 in MODEL 930, 932, 934 except CODE (G02) Torque converter clutch (WSK)
Shown on engine 541
1 Flywheel
2 Bolt
3 Drifts
4 Dowel pin
B15 Crankshaft position sensor
L Shank length
W03.30-1013-06
Modification notes
8.11.04 Grease ring gear with long-life grease, reset.
Removing
1 Remove clutch For a single-plate clutch AR25.10-W-0050G
For a double-plate clutch AR25.10-W-0050GB
2 Pull crankshaft position sensor (B15) out of
timing case
3 Remove cover of TDC inspection hole at
timing case
*407589006300
5 Lockup flywheel (1) with cranking device *407589006300
6 Remove two opposite bolts (2) on flywheel *422589020900
(1)
7 Screw drifts (3) into freed up threaded holes *403589026300
for removed bolts
8 Unscrew remaining bolts (2) at flywheel (1) *422589020900
9 Remove flywheel (1) over drifts (3) Screw two bolts (M10 1.5) into opposite
threaded holes and pull out flywheel (1).
*403589026300
Checking
10 Measure bolts (2) If permissible shank length (L) is *BE03.30-N-1004-03C
exceeded, replace bolt (2) concerned
11 Check coupling friction surface on flywheel If burned, scored or cracked:
(1)
Rework flywheel (1) or AR03.30-W-8022G
install new flywheel (1).
12 Check ring gear of flywheel (1) for wear If worn:
Replace ring gear of flywheel (1). AR03.30-W-8312G

13 Check flange or race on flywheel (1) for If there is galling on the flange or race:
galling due to radial sealing ring
Install new race on flywheel (1). AR03.30-W-8350G
14 Check locating bearing in flywheel (1) If worn:
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8002g, Remove, install flywheel Page 1 of 3

ENGINE 541.9 in MODEL 933 ENGINE 541.9 in MODEL 930, 932, 934 except CODE (G02) Torque converter clutch (WSK) ENGINE 542.9 in MODEL 930, 932, 934 except CODE (G02) Torque ...
Replace locating bearing in flywheel (1). AR03.30-W-8401G
Install
15 Install flywheel (1) over the drifts (3) Pay attention to installation position of
dowel pin (4).
Remove both bolts (M10 1.5) at flywheel (1).
*403589026300
16 Remove bolts (2) at flywheel (1) Lightly lubricate bolts (2).
Do not tighten down bolts (2).
*422589020900
17 Remove both drifts (3) *403589026300
18 Screw in remaining two bolts (2) on flywheel Lightly lubricate bolts (2).
(1) and tighten all bolts (2)
*BA03.30-N-1001-01F
*422589020900
19 Press in locking bush and crankshaft position Replace O-ring and inspect locking bush;
sensor (B15) as far as the stop. replace if necessary.
20 Install clutch For a single-plate clutch AR25.10-W-0050G
21 Remove cranking device to timing case *407589006300
22 Attach cover of TDC inspection hole at *BA01.60-N-1001-01B
timing case
Check values for flywheel

542.9 without
code G02
BE03.30-N-1004-03C Bolt for flywheel Thread Ø M 16 1.5
Length of shank mm 74.0

when new
Permissible shank mm 75,0

length
Timing case

541.9, 542.9

case
Flywheel, driven plate, vibration damper, starter ring gear

541.9, 542.9
BA03.30-N-1001-01F Bolt, flywheel to crankshaft Stage 1 Nm 210
Stage 2 ° 90

403 589 02 63 00 407 589 00 63 00 422 589 02 09 00
Drift Cranking device Socket

AR03.30-W-8350G Remove/install race on flywheel 31.7.07
1 Race
2 Flywheel
3 Puller
4 Thrust piece
5 Drift
W03.30-0016-06
Modification notes
21.5.07 Measure temperature of the ring gear using a Step 4
temperature measuring instrument - added.
Removing
1 Remove flywheel (2) AR03.30-W-8002G
2 Use puller (3) to pull race (1) off flywheel (2) Insert to detach thrust piece (4) in
flywheel (2).
*000589453300
*312589001500
3 Remove radial sealing ring on timing case AR03.20-W-3063G
Install
Danger! Risk of injury to skin and eyes caused by Wear safety gloves, protective clothing and AS00.00-Z-0002-01A
handling hot or glowing objects. safety glasses, if necessary.
4 Heat up new race (1) Heat race (1) to a temperature of a
maximum of 60°C. Measure temperature
using a temperature measuring instrument.
The race (1) must not have any temper
color; replace race (1) if required.
*403589031500
5 Place race (1) on flywheel (2) The rounded edge of the race (1) must
point outwards.
6 Reposition race (1) using a drift (5) flush to *403589031500
the contact surface of the flywheel (2)
7 Install a new radial sealing ring in timing Install radial sealing ring with a large AR03.20-W-3063G
case inside diameter.
8 Install flywheel (2) AR03.30-W-8002G
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8350g, Remove/install race on flywheel Page 1 of 2

312 589 00 15 00 403 589 03 15 00 000 589 45 33 00
Thrust piece Drift Puller
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8350g, Remove/install race on flywheel Page 2 of 2

AR03.30-W-1600G Remove/install belt pulley/vibration damper 28.7.09
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (ML3) High-speed fan drive with belt drive
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (ML3) High-speed fan drive with belt drive
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (MZ5) Electromagnetic fan drive (Linnig clutch)
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (MZ5) Electromagnetic fan drive (Linnig clutch)
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (MZ3) Electromagnetic viscous coupling for fan
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (MZ3) Electromagnetic viscous coupling for fan
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (MO1) Electromagnetic viscous fan clutch, Behr
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (MO1) Electromagnetic viscous fan clutch, Behr
W03.30-1045-09
1 Radiator 3 Intermediate piece 5 Belt pulley/vibration damper

2 Fan 4 Poly-V belt for alternator 6 Splash ring
7 Drifts
W03.30-1046-02
Remove/install
1 Remove fan (2) AR20.40-W-5614G
Danger! Risk of injury caused by pinching or Use only approved tensioning devices; shield AS00.00-Z-0001-01A
crushing when working on springs or spring off hazard area if necessary.
bodies that are under tension Check special tools for damage and proper
operation (visual inspection).
Wear protective gloves.
2 Release tension on poly-V belt for alternator Installation: Inspect condition of poly-V
(4) and take if off belt pulley of alternator belt of alternator (4), replace if necessary.
Observe poly-V belt routing plan. AR13.22-W-3902-02A
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-1600g, Remove/install belt pulley/vibration damper Page 1 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (ML3) High-speed fan drive with belt drive ENGINE 542.9 in MODEL 930, 932, 934 except CODE (ML3) High-speed fan drive with belt ...
Damage patterns of poly-V belt AP13.22-D-1351-01A
3 Take off end cover at timing case *BA01.60-N-1001-01B
4 Attach cranking device to timing case *407589006300
*BA01.60-N-1009-01B
5 Block engine with rotating device
6 Undo two opposite bolts at belt pulley/ *422589020900
vibration damper (5)
*BA03.30-N-1002-01F
7 Screw in drifts (7) *403589026300
8 Unscrew remaining bolts at belt pulley/ Installation: Check belt pulley/vibration
vibration damper (5) and remove belt pulley/ damper (5) and belt pulleys for remaining
vibration damper (5) via drifts (7) driven parts for damage and smooth running,
if necessary, replace any affected part(s)
*422589020900
*BA03.30-N-1002-01F
9 Take off slinger (6) Installation: Installation position must be
observed. The slinger (6) must be installed
with the flat side towards belt pulley/vibration
damper (5).
Timing case

541.9. 542.9

case

541.9, 542.9
BA03.30-N-1002-01F Bolt, vibration damper to crankshaft Nm 200
403 589 02 63 00 407 589 00 63 00 422 589 02 09 00

Drift Cranking device Wrench socket
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-1600g, Remove/install belt pulley/vibration damper Page 2 of 2
AR03.30-W-1600GC Remove/install belt pulley/vibration damper 12.12.08
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (MZ3) Electromagnetic viscous coupling for fan
ENGINE 542.9 in MODEL 930, 932, 934 with CODE (MZ3) Electromagnetic viscous coupling for fan
W03.30-1029-09
Shown on vehicle with code M58 Higher

output fan
1 Fan box 4 Splash ring 6 Intermediate piece

2 Fan 5 Belt pulley/vibration damper 7 Drifts
3 Poly-V belt for alternator
Remove/install
1 Remove fan (2) Vehicles with Code (M58) Higher AR20.40-W-5614GC
performance fan.
Vehicles without code (M58) Higher AR20.40-W-5614GD
performance fan.
bodies that are under tension Inspect special tools for damage and proper
2 Release tension on the poly-V belt of the Installation: Inspect condition of poly-V
alternator (3) and take if off the belt pulley belt of alternator (3), replace if necessary.
of the alternator
Observe poly-V-belt routing plan. AR13.22-W-3902-02A
Damage patterns of poly V-belt AP13.22-D-1351-01A
*BA01.60-N-1009-01B
*BA03.30-N-1002-01F
7 Screw in drifts (7) *403589026300
8 Unscrew remaining bolts at belt pulley/ Installation: Check the belt pulley/
vibration damper (5) and remove belt pulley/ vibration damper (5) and the belt pulleys for
vibration damper (5) via drifts (7) the remaining driven parts for damage and
smooth running, if necessary, replace any
affected part(s)
*422589020900
*BA03.30-N-1002-01F
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-1600gc, Remove/install belt pulley/vibration damper Page 1 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (MZ3) Electromagnetic viscous coupling for fan ENGINE 542.9 in MODEL 930, 932, 934 with CODE (MZ3) Electromagnetic viscous ...
damper (5).
Timing case

541.9, 542.9

case

457.9 541.9, 542.9
BA03.30-N-1002-01F Bolt, vibration damper to crankshaft Nm 200 200
403 589 02 63 00 407 589 00 63 00 422 589 02 09 00

© Daimler AG, 7/2/13, G/03/13, ar03.30-w-1600gc, Remove/install belt pulley/vibration damper Page 2 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (MZ3) Electromagnetic viscous coupling for fan ENGINE 542.9 in MODEL 930, 932, 934 with CODE (MZ3) Electromagnetic viscous ...
AR03.30-W-1600GB Removing/installing the belt pulley/vibration damper 12.12.08
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (MZ5) Electromagnetic fan drive (Linnig clutch)
ENGINE 542.9 in MODEL 930, 932, 934 with CODE (MZ5) Electromagnetic fan drive (Linnig clutch)
W03.20-1053-09
1 Radiator 4 Intermediate flange 6 Belt pulley/vibration damper

2 Fan wheel 5 Poly-V-belt for alternator 7 Splash ring
3 Electromagnetic fan clutch
8 Drifts
W03.30-1032-02
Modification notes
Remove/install
1 Remove radiator (1) AR20.20-W-3865GA
2 Remove electromagnetic fan clutch (3) AR20.40-W-5616G
3 Detach intermediate flange (4) on belt *BA20.40-N-1008-01C
pulley/vibration damper (6)
bodies that are under load Inspect special tools for damage and proper
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-1600gb, Removing/installing the belt pulley/vibration damper Page 1 of 3
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (MZ5) Electromagnetic fan drive (Linnig clutch) ENGINE 542.9 in MODEL 930, 932, 934 with CODE (MZ5) Electromagnetic fan drive ...
4 Release the tension on the poly-V-belt of the Installation: Inspect condition of poly-V-
of the alternator
Damage patterns for a poly-V-belt AP13.22-D-1351-01A
*BA01.60-N-1009-01B
8 Undo the two opposite bolts at the belt *422589020900
*BA03.30-N-1002-01F
9 Screw in the drifts (8) *403589026300
10 Unscrew the remaining bolts at the belt Installation: Check the belt pulley/
pulley/vibration damper (6) and remove the vibration damper (6) and the belt pulleys for
belt pulley/vibration damper (6) via the drifts the remaining driven parts for damage and
affected part(s)
*422589020900
*BA03.30-N-1002-01F
11 Take off the slinger (7) Installation: Installation position must be
with the flat side to the belt pulley/vibration
damper (6).
Timing case

541.9, 542.9

case

541.9, 542.9
Fan, fan clutch

541.9,
542.9
with
Code
MZ5
BA20.40-N-1008-01C Bolt, intermediate piece to crankshaft Nm 30

vibration damper
403 589 02 63 00 407 589 00 63 00 422 589 02 09 00
AR03.30-W-1600GA Removing/installing the belt pulley/vibration damper 12.12.08
ENGINE 541.9 in MODEL 930, 932, 933, 934
with CODE (ML3) High-speed fan drive with belt drive
except CODE (MZ3) Electromagnetic viscous coupling for fan
ENGINE 542.9 in MODEL 930, 932, 934
with CODE (ML3) High-speed fan drive with belt drive
except CODE (MZ3) Electromagnetic viscous coupling for fan
W03.30-1037-09
1 Radiator 4 Belt pulley fan drive 7 Belt pulley/vibration damper

2 Fan 5 Intermediate piece with freewheel 8 Splash ring
3 Poly-V-belt fan bearing
6 Poly-V-belt for alternator

9 Drifts
W03.30-1030-02
Modification notes
4.6.05 Remove fan (2) - added. Step 1
Remove/install
1 Remove fan (2) AR20.40-W-5614GA
2 Detach fan drive belt pulley (4) at the Block the belt pulley fan drive (4) with
intermediate piece with the freewheel the corresponding tool.
bearing (5)
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-1600ga, Removing/installing the belt pulley/vibration damper Page 1 of 3
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (ML3) High-speed fan drive with belt drive except CODE (MZ3) Electromagnetic viscous coupling for fan ENGINE 542.9 in MODEL 930, ...
*BA20.40-N-1013-01C
3 Detach the intermediate piece with the *BA20.40-N-1011-01C
freewheel bearing (5) at the belt pulley/
4 Release the tension on the poly-V-belt of the Installation: Inspect condition of poly-V-
of the alternator
*BA01.60-N-1009-01B
8 Undo the two opposite bolts at the belt *422589020900
*BA03.30-N-1002-01F
9 Screw in the drifts (9) *403589026300
10 Unscrew the remaining bolts at the belt Installation: Check the belt pulley/
pulley/vibration damper (7) and remove the vibration damper (7) and the belt pulleys for
belt pulley/vibration damper (7) via the drifts the remaining driven parts for damage and
(9) smooth running, if necessary, replace any
affected part(s)
*422589020900
*BA03.30-N-1002-01F
11 Take off the slinger (8) Installation: Installation position must be
with the flat side to the belt pulley/vibration
damper (7).
Timing case

541.9, 542.9

case
Number Designation Engines 541.9,

542.9
Fan, fan clutch

541.9,
542.9
with code
ML3
BA20.40-N-1011-01C Intermediate piece with freewheel bearing Nm 30
to vibration damper
BA20.40-N-1013-01C Bolt, fan drive belt pulley to intermediate Nm 30

piece with freewheel bearing
403 589 02 63 00 407 589 00 63 00 422 589 02 09 00

AR03.30-W-1600GE Remove/install belt pulley/vibration damper 28.7.09
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (MO1) Electromagnetic viscous fan clutch, Behr
ENGINE 542.9 in MODEL 930, 932, 934 with CODE (MO1) Electromagnetic viscous fan clutch, Behr
W03.30-1068-09
1 Radiator 3 Electromagnetic fan clutch 5 Belt pulley/vibration damper

2 Fan wheel 4 Poly-V belt for alternator 6 Splash ring
7 Drifts
W03.30-1046-02
Remove/install
1 Remove radiator (1) AR20.20-W-3865GE
2 Remove electromagnetic fan clutch (3) AR20.40-W-5616GE
bodies that are under tension Check special tools for damage and proper
3 Release tension on poly-V belt of alternator Installation: Check condition of poly-V
(4) and take if off belt pulley of alternator belt of alternator (4), replace if necessary.
Damage patterns of poly-V belt AP13.22-D-1351-01A
*BA01.60-N-1009-01B
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-1600ge, Remove/install belt pulley/vibration damper Page 1 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (MO1) Electromagnetic viscous fan clutch, Behr ENGINE 542.9 in MODEL 930, 932, 934 with CODE (MO1) Electromagnetic viscous fan ...
*BA03.30-N-1002-01F
8 Screw in drifts (7) *403589026300
9 Remove the remaining bolts on the belt *422589020900
*BA03.30-N-1002-01F
10 Remove belt pulley/vibration damper (5) over Installation: Check the belt pulley/
the drifts (7) vibration damper (5) and the belt pulleys for
the remaining driven parts for damage and
affected part(s)
damper (5).
Timing case

541.9. 542.9

case

541.9, 542.9
403 589 02 63 00 407 589 00 63 00 422 589 02 09 00

© Daimler AG, 7/2/13, G/03/13, ar03.30-w-1600ge, Remove/install belt pulley/vibration damper Page 2 of 2
AR03.30-W-8401G Remove/install guide bearing in flywheel 15.6.09
W03.30-1042-09
1 Countersupport 5 Flywheel L Shank length

6 Drift Arrow: Outside edge
2 Internal extractor
7 Bolt
3 Drifts
4 Guide bearing
Modification notes
30.11.05 Repair method has been revised
Remove/install
1 Remove clutch For a single-plate clutch AR25.10-W-0050G
2 Remove cover of TDC inspection hole at *BA01.60-N-1001-01B
timing case
*407589006300
4 Lockup flywheel (5) with cranking device *407589006300
5 Remove two opposite bolts (7) on flywheel Installation: Lightly lubricate bolts (7)
(5) and tighten all bolts (7).
*BA03.30-N-1001-01F
*422589020900
6 Screw drifts (3) into freed up threaded holes *403589026300
for removed bolts
7 Unscrew remaining bolts (7) at flywheel (5) Installation: Lightly oil bolts (7) and
screw them in.
*422589020900
8 Measure bolts (7) If permissible shank length (L) is *BE03.30-N-1004-03C
exceeded, replace bolt (7) concerned
9 Pull out guide bearing (4) using internal *000589273300
extractor (2) and countersupport (1)
*000589343300
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8401g, Remove/install guide bearing in flywheel Page 1 of 3
Installation: Hammer in new guide
bearing (4) using drift (6).
The outer edge (arrow) of guide bearing (4)
must stand flush to the contact surface of
the bolts (7); the guide bearing (4) must not
jut out. Lightly grease the guide bearing (4)
inside.
*403589051500
Long-life grease *BR00.45-Z-1001-06A

542.9 without
code G02
BE03.30-N-1004-03C Bolt, flywheel Thread Ø M 16 1.5

when new
Permissible shank mm 75.0

length
Timing case

541.9, 542.9

case

541.9, 542.9
BA03.30-N-1001-01F Bolt, flywheel to crankshaft Stage 1 Nm 210
Stage 2 ° 90
422 589 02 09 00 403 589 05 15 00 000 589 27 33 00 000 589 34 33 00

Socket Drift Internal puller Counter stay
403 589 02 63 00 407 589 00 63 00
Drift Cranking device
Repair materials

BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11
AR03.30-W-8351G Remove/install race on ring gear carrier 31.7.07
ENGINE 541.9 in MODEL 930, 932, 934 with CODE (G02) Torque converter clutch (WSK)
W03.30-1058-09
1 Ring gear carrier 3 Puller 5 Drift

2 Thrust piece 4 Race
Removing
1 Remove ring gear carrier (1) with clutch AR03.30-W-8005G
plate
2 Use puller (3) to pull race (4) off ring gear Insert to detach thrust piece (2) in ring
carrier (1) gear carrier (1).
*000589453300
*312589001500
3 Remove radial sealing ring on timing case AR03.20-W-3063G
Install
4 Heat up new race (4) Heat race (4) to a temperature of a
maximum of 60°C. Measure temperature
using a temperature measuring instrument.
The race (4) must not have any temper
color; replace race (4) if required.
*403589031500
5 Place race (4) on the ring gear carrier (1) The rounded edge of the race (4) must
point outwards.
6 Reposition race (4) using a drift (5) flush to *403589031500
the contact surface of the ring gear carrier
(1)
7 Install a new radial sealing ring in timing Install radial sealing ring with a large AR03.20-W-3063G
case inside diameter.
8 Install ring gear carrier (1) with clutch plate AR03.30-W-8005G
312 589 00 15 00 403 589 03 15 00 000 589 45 33 00

© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8351g, Remove/install race on ring gear carrier Page 1 of 2
ENGINE 541.9 in MODEL 930, 932, 934 with CODE (G02) Torque converter clutch (WSK) ENGINE 542.9 in MODEL 930, 932, 934 with CODE (G02) Torque converter clutch (WSK)
Thrust piece Drift Puller
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8351g, Remove/install race on ring gear carrier Page 2 of 2
AR03.30-W-8005G Install/remove ring gear carrier with clutch plate 12.12.08
W03.30-1052-09
Shown on engine 541
1 Ring gear carrier 4 Bolts B15 Crankshaft position sensor

2 Clutch plate 5 Drifts L Shank length
3 Washer 6 Dowel pin Arrow A Threaded hole
Removing
1 Remove torque converter clutch AR25.40-W-0100G
2 Pull crankshaft position sensor (B15) out of
timing case
timing case
*904589046300
5 Lockup ring gear carrier (1) using cranking
device
6 Remove two opposing bolts (4) on ring gear *422589020900
carrier (1)
7 Screw drift (5) into threaded holes *403589026300
8 Remove remaining bolts (4) at ring gear
carrier (1)
9 Remove pulley (3), clutch plate (2) and ring Screw in two bolts (M10 1.5 80) in the
gear carrier (1) via the drifts (5) opposite threaded holes (arrows A) and lever
out ring gear carrier (1).
Checking
10 Measure shank length (L) of bolts (4) If permissible shank length (L) is *BE03.30-N-1001-05A
exceeded, replace bolt (4) concerned.
11 Check ring gear on ring gear carrier (1) for If worn:
wear
Replace ring gear on ring gear carrier (1). AR03.30-W-8314G
12 Check flange or race on ring gear carrier (1) If there is galling on the flange or race:
for galling due to radial sealing ring
Replace ring gear carrier (1) or
install new race on ring gear carrier (1). AR03.30-W-8351G
Install
13 Install ring gear carrier (1), clutch plate (2) Pay attention to installation position of
and ring gear carrier (3) via the drifts (5) dowel pin (6).
Remove both bolts (M10 1.5 80) on ring
gear carrier (1)
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8005g, Install/remove ring gear carrier with clutch plate Page 1 of 2
14 Remove bolts (4) on ring gear carrier (1) Lightly lubricate bolts (4).
Do not tighten down bolts (4).
15 Remove both drifts (5)
16 Screw in remaining two bolts (4) on ring Lightly lubricate bolts (4).
gear carrier (1) and tighten all bolts (4)
*BA03.30-N-1004-01F
17 Press in locking bush and crankshaft position
sensor (B15) as far as the stop.
18 Install torque converter clutch AR25.40-W-0100G
19 Remove cranking device to timing case
timing case
Check values for ring gear carrier

542.9
with code G02
BE03.30-N-1001-05A Ring gear carrier bolt Thread Ø M 16 1.5

when new
Permissible shank mm 86.0

length
Timing case

541.9, 542.9

case

541.9, 542.9
BA03.30-N-1004-01F Bolt, ring gear carrier to crankshaft Stage 1 Nm 210
Stage 2 ° 90
403 589 02 63 00 904 589 04 63 00 422 589 02 09 00

© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8005g, Install/remove ring gear carrier with clutch plate Page 2 of 2
AR03.30-W-8314G Remove/install ring gear for ring gear carrier 31.7.07
1 Ring gear
2 Ring gear carrier
A Ring gear inside diameter

B Ring gear carrier diameter for mounting ring gear
W03.30-1059-12
1 Ring gear
2 Ring gear carrier
C Bore
D Core hole bore
W03.30-1060-11
Removing
1 Remove ring gear carrier (2) with clutch AR03.30-W-8005G
plate
2 Heat ring gear (1) and hammer down on ring Underlay ring gear carrier (2).
gear carrier (2) using a suitable drift
Measure
3 Measure ring gear inside diameter (A) and Ring gear inside diameter and overlap *BE03.30-N-1001-04C
flywheel diameter for mounting the ring gear between ring gear and ring gear carrier
(B) and calculate overlap between ring gear
(1) and ring gear carrier (2)
Ring gear carrier diameter for mounting ring *BE03.30-N-1002-05A
gear
If the standard ring gear carrier diameter
for mounting the ring gear (B) or the ring
gear inside diameter (A) and overlap
between ring gear (1) and flywheel (2) are
not reached:
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8314g, Remove/install ring gear for ring gear carrier Page 1 of 2
Replace ring gear carrier (2) or remachine
diameter of ring gear carrier (2) for mounting
ring gear (1) to the deviation and select a
new ring gear (1) with an appropriate
deviation.
Install
4 Heat new ring gear (1) Measure installation temperature of the *BE03.30-N-1001-04C
ring gear using a temperature measuring
instrument.
5 Lay ring gear (1) onto ring gear carrier (2) Allow ring gear (1) to cool for at least 2
up to the contact surface minutes and then set back ring gear (1)
using a brass drift.
6 Attach centerings on ring gear (1) through Use Ø 11,0 mm drill bit.
the bores (C)
7 Drill out core hole bores (D) for thread in the Use a 4.5 mm Ø drill bit.
ring gear (1)
8 Drill out core hole bores (D) for thread in the Use a 8.5 mm Ø drill bit.
ring gear (1)
9 Turn ring gear carrier (2) and chamfer core
hole bores (D) in the ring gear (1)
10 Cut a thread in all core hole bores (D) in the Use a M10 1.5 thread cutter.
ring gear (1)
11 Install ring gear carrier (2) with clutch plate AR03.30-W-8005G
Check values for ring gear carrier

542.9
with code G02
BE03.30-N-1002-05A Ring gear carrier Ø for mounting starter ring Standard mm 432.490 to
gear 432.645
Deviation 0.5 mm 431.990 to

432.145
Check values for starter ring gear

541.9, 542.9
with code G02
BE03.30-N-1001-04C Starter ring gear Inside Ø Standard mm 432.000 to

432.115

431.615
Ring gear carrier - mm 0.375 to 0.645

overlap
Ring gear carrier - mm 0.5

permissible radial runout
Width mm 18.4 to 18.6
Installation temperature °C 200 to 230
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8314g, Remove/install ring gear for ring gear carrier Page 2 of 2
AR03.30-W-8312G Replace ring gear on flywheel 31.7.07
1 Ring gear
2 Flywheel
A Bore for receiving bolt for clutch

pressure plate
B Ring gear inside diameter and
flywheel diameter for mounting ring
gear
W03.30-0014-04
Modification notes
23.5.07 Measure installation temperature of the ring gear using a Step 4
temperature measuring instrument- added.
Removing
1 Remove flywheel (2) AR03.30-W-8002G
2 Heat ring gear (1) and hammer down on Underlay flywheel (2).
flywheel (2) using a suitable drift
Measure
3 Measure ring gear inside diameter and Ring gear inside diameter and overlap *BE03.30-N-1002-04C
flywheel diameter for mounting the ring gear between ring gear and flywheel
(B) and calculate overlap between ring gear
(1) and flywheel (2)
Flywheel diameter for mounting ring gear *BE03.30-N-1005-03C
If the standard flywheel diameter for
mounting the ring gear (1) or the ring gear
inside diameter and overlap between ring
gear (1) and flywheel (2) are not reached:
Replace flywheel (2) or remachine diameter

of flywheel (2) for mounting ring gear (1) to
the deviation and select a new ring gear (1)
with an appropriate deviation.
Install
4 Heat new ring gear (1) Measure installation temperature of the *BE03.30-N-1002-04C
ring gear using a temperature measuring
instrument.
5 Lay ring gear (1) onto flywheel (2) up to the Allow ring gear (1) to cool for at least 2
contact surface minutes and then set back ring gear (1)
using a brass drift.
6 Attach centerings on ring gear (1) through Use Ø 11.0 mm drill bit.
the bores for bolts for clutch pressure plate
(A)
7 Drill out core hole bores for thread in the ring Use a 4.5 mm Ø drill bit.
gear (1)
8 Drill core hole bores for thread in the ring Use a 8.5 mm Ø drill bit.
gear (1)
9 Turn flywheel (2) and chamfer core hole
bores in the ring gear (1)
10 Cut a thread in all core hole bores in the ring Use a M10 1.5 thread cutter.
gear (1)
11 Install flywheel (2) AR03.30-W-8002G
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8312g, Replace ring gear on flywheel Page 1 of 2
542.9 without
code G02
BE03.30-N-1005-03C Flywheel Ø for mounting Standard mm 432.490 to

432.645
Starter ring gear Deviation 0.5 mm 431.990 to

432.145
Check values for starter ring gear

541.9, 542.9
without code
G02
BE03.30-N-1002-04C Starter ring gear Inside Ø Standard mm 432.000 to

432.115

431.615
Flywheel overlap mm 0.375 to 0.645
Flywheel permissible mm 0.5

radial runout
Width mm 18.4 to 18.6
Installation temperature °C 200 to 230
© Daimler AG, 7/2/13, G/03/13, ar03.30-w-8312g, Replace ring gear on flywheel Page 2 of 2
AR05.00-W-5521G Removing/installing rocker arm assembly 14.11.05
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934

2 Bolt
4 Valve bridge
5 Tappet rod
L Shank length
W05.00-1011-06
Remove/install
1 Remove cylinder head cover (1) Installation: Do not install cylinder head AR01.20-W-5014G
cover (1) until valve clearance has been
adjusted.
2 Remove rocker arm assembly (3) Installation: Check rocker arm assembly
for wear and disassemble rocker arm
assembly and replace worn parts if
necessary.
Ensure tappet rods (5) are seated correctly
in the roller tappets. Oil the push rod sockets
with engine oil.
Measure shank lengths (L) of bolts (2); *BE05.30-N-1002-04C
install new bolt if necessary.
*BA05.00-N-1003-01B
3 Take off valve bridges (4). Installation: Check valve bridges (4) for
wear or damage; install new valve bridges if
necessary
5 Set valve clearance
AP05.30-W-0560A
Check values for valve timing

541.9, 542.9
BE05.30-N-1002-04C Bolt, rocker arm bearing Thread M 10

bracket to cylinder head diameter
permissible mm 91
shank
length
Engine timing - general
© Daimler AG, 7/2/13, G/03/13, ar05.00-w-5521g, Removing/installing rocker arm assembly Page 1 of 2
Number Designation ENGINES 541.9,
542.9
BA05.00-N-1003-01B Bolt, rocker arm bearing bracket to Stage 1 Nm 60

cylinder head
Stage 2 ° 90
© Daimler AG, 7/2/13, G/03/13, ar05.00-w-5521g, Removing/installing rocker arm assembly Page 2 of 2
AR05.00-W-2311G Removing/installing roller tappets 31.1.03
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
Shown on engine 541
1 Roller tappet
2 Clamp fixture
W05.20-1007-11
Removing
2 Pull roller tappet (1) with clamping bracket Mark roller tappets (1) to crankcase
(2) out of the crankcase
*541589006300
Checking
3 Check surface on roller tappet (1) through a The roller tappet (1) can be used again
visual inspection for damage and wear if there are minimal score marks or
scratches.
In the case of deep score marks, scratches
or sanding spots: replace relevant roller
tappet (1) and also check camshaft cam
through visual inspection.
Installing
4 Lubricate roller tappet (1) with engine oil
5 Push roller tappet (1) with clamping bracket If used roller tappet (1) are reinstalled
(2) out of the crankcase then observe the markings on them.
Observe groove (arrow) in crankcase and
guide (arrow) on roller tappet (1).
*541589006300
541 589 00 63 00
Clamping bracket
© Daimler AG, 7/2/13, G/03/13, ar05.00-w-2311g, Removing/installing roller tappets Page 1 of 1

AR05.20-W-6292G Remove/install camshaft 28.7.09
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
W05.20-0010-09
1 Roller tappet 3 Camshaft with camshaft sprocket Arrows Markings

2 Push rods 4 Crankshaft sprocket
1 Roller tappet
5 Clamp fixture
Arrow A Groove
Arrow B Guide
W05.20-1023-11
© Daimler AG, 7/2/13, G/03/13, ar05.20-w-6292g, Remove/install camshaft Page 1 of 4

3 Camshaft with camshaft sprocket

6 Guide sleeve
W05.20-1024-11
Remove/install
converter clutch (WSK).
2 Fit the engine with the fastening angle to the
engine assembly stand NFZ
4 Remove timing case Engine 541.9 AR01.60-W-8200GA
Engine 542.9 for vehicles with code (MS4)
Engine 542.9 for vehicles without code AR01.60-W-8200GB
(MS4) BlueTec 4 or without code (MS5)
BlueTec 5
5 Remove oil filter housing AR18.20-W-3471G
6 Remove all MR/PLD unit pumps AR07.15-W-8950G
7 Remove all cylinder heads AR01.30-W-5800G
8 Remove tappet rods (2) When pulling out tappet rods (2), turn
them so that they detach from the roller
tappet (1) and the roller tappet (1) is not
pulled out of the crankcase.
Installation: Oil push rods (2) with
engine oil and ensure they are correctly
located in the roller tappet (1).
9 Use the clamping bracket (5) to pull the Mark roller tappets (1) to crankcase
roller tappet (1) out of the crankcase
Installation: Perform a visual inspection
of the surface of the roller tappet (1) and
check for wear and damage.
The roller tappet (1) can be used again if
there are minimal score marks or scratches.
If scratches, score marks or grinding marks
are deep, the affected roller tappet (1) must
be replaced.
Push in roller tappet (1) wit the clamping
bracket (5), in the process, pay attention to
the groove (arrow A) in the crankcase and
the guide (arrow B) on the roller tappet (1).
*541589006300
10 Fit guide sleeve (6) to the camshaft with the *541589001400
camshaft sprocket (3)
11 Remove camshaft with the camshaft Carefully pull camshaft with camshaft
sprocket (3) sprocket (3) out of the crankcase and in the
process, push back the guide sleeve (6).

Installation: Oil the camshaft with the
camshaft sprocket (3) and camshaft bearing
with engine oil. Carefully push the camshaft
with camshaft sprocket (3) with the guide
sleeve (6) into the crankcase, do not
damage the camshaft bearing. The markings
(arrows) on the camshaft must match those
on the camshaft sprocket (3) and on the
crankshaft gear (4).
Check
12 Perform a visual inspection of the cams of If scratches or scoring are minimal, the
the camshaft with camshaft sprocket (3) and camshaft with camshaft sprocket (3) can be
check for damage and wear reused.
If there are deep scores, scratches or
grinding marks, the camshaft with camshaft
sprocket (3) must be replaced.
13 Check camshaft with camshaft sprocket (3) AR05.20-W-6292-03B
for hardness, smooth operation and cam
elevation
Hardness of cams and journals *BE05.20-N-1006-04C
Camshaft smooth operation deviation *BE05.20-N-1007-04C
Cam elevation - intake and exhaust valve *BE05.20-N-1008-04C
cams
Cam elevation unit pump cams *BE05.20-N-1009-04C
*000589202100
*001589532100
*363589022100
15 Fill the engine oil circuit AR18.00-W-1600G
Check values for camshaft

542.9
BE05.20-N-1006-04C Hardness of cams and journals HRC 58...62
BE05.20-N-1007-04C Camshaft radial runout when Cam base circle mm 0.050

mounted on outside bearing journals
Bearing point mm 0.050
BE05.20-N-1008-04C Cam elevation, valve cams over Inlet mm 8.0 to 8.3

base circle dia.
Outlet mm 8.3 to 8.5
BE05.20-N-1009-04C Cam elevation, unit pump over base mm 17.7 to 18.0

circle dia.
000 589 20 21 00 001 589 53 21 00 363 589 02 21 00 541 589 00 14 00

Hardness tester Dial indicator Dial indicator holder Guide sleeve

541 589 00 63 00
Clamping bracket

AR05.30-W-3731G Check, remove/install valve guides 13.3.08
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Cylinder head
2 Valve guide
3 Drift
4 Cylinder brush
5 Base washer
6 Stepped driver
B Inside diameter
W05.30-1125-06
W05.30-1088-09
1 Cylinder head 9 Bushing A Bore diameter in cylinder head

2 Valve guide 10 Reamer (adjustable) B Inside diameter
7 Reamer 11 Reamer D Distance
8 Drift
Modification notes
18.12.07 Measure valve guides (2) and bores in cylinder head (1) , Step 9 AR05.30-W-3731-09G
modified.
Modified valve stem seal and valve guide, added. Step 12 BT05.30-W-0001-02G
Supercool the valve guides with solid carbon dioxide (dry Steps 13 and 14
ice), added.
Removing
© Daimler AG, 7/2/13, G/03/13, ar05.30-w-3731g, Check, remove/install valve guides Page 1 of 3
2 Remove cylinder head (1) AR01.30-W-5800G
3 Remove valves AR05.30-W-3511G
4 Take out support disks (5)
5 Clean valve guides (2) using a cylinder *000589106800
brush (4)
Checking
6 Check the inside diameter (B) of valve *BE05.30-N-1001-02C
guides (2) using drift (3)
*117589032300
If the side marked "+" of drift (3) can be
inserted in valve guide (2), the related valve
guide (2) must be replaced.
7 Lay cylinder head (1) on a suitable wooden The combustion end of cylinder head (1)
block must face upward.
8 Knock out worn valve guides (2) from the *103589021500
combustion end of cylinder head (1) using
staged drift (6)
9 Measure valve guides (2) and bores in AR05.30-W-3731-09G
cylinder head (1)
*BE05.30-N-1004-02C
*BE05.30-N-1005-02C
Cylinder brush *000589106800
Install
10 Turn the cylinder head (1) and place it on The combustion end of the cylinder head
suitable support blocks (1) must face downward.
11 Ream the valve guide bores (2) in the Only if valve guides (2) at the next
cylinder head (1) to the next oversize using oversize are to be installed.
the corresponding reamer (7)
Note the oversize of the bore diameter in *BE05.30-N-1005-02C
cylinder head (A).
For 0.2 mm oversize use reamer (7) with Ø
15.2 mm H7, and for oversize 0.4 mm use
reamer (7) with Ø 15.4 mm H7. Only turn
reamer (7) clockwise.
12 Allocate new valve guides (2) to the bores Allocate only the modified valve guides
in cylinder head (1), and mark them (2).
Valve stem seal and valve guide modified As of engine end no. 513886 BT05.30-W-0001-02G
Danger! Risk of injury when handling solid carbon Wear heat protective gloves, protective AS00.00-Z-0029-01A
dioxide (dry ice) caused by touching clothing and full eye protection.
extremely cold objects or by inhaling Ensure that the work area is adequately
gaseous carbon dioxide ventilated.
13 Pour solid carbon dioxide (dry ice) into the The valve guides (2) must be completely
cooling box, and insert new valve guides (2) covered by the solid carbon dioxide (dry ice).
using tongs Supercool the valve guides (2) in this way
for about 20 to 30 min.
*346589006300
Danger! Risk of injury when handling solid carbon Wear heat protective gloves, protective AS00.00-Z-0029-01A
dioxide (dry ice) caused by touching clothing and full eye protection.
extremely cold objects or by inhaling Ensure that the work area is adequately
gaseous carbon dioxide ventilated.
14 Take valve guide (2) out of the cooling box Observe the markings on the valve
using the tongs, push sleeve (9) over valve guides (2) and their assignments to the
guide (2) and knock valve guide (2) into bores in cylinder head (1).
cylinder head (1) using drift (8)
The gap (D) from the top edge of valve *BE05.30-N-1007-02C
guide (2) to the contact surface of the valve
spring is specified according to the
installation position of sleeve (9).
Valve guide overlap in cylinder head *BE05.30-N-1002-02C
*541589004300
15 Remove drift (8) and sleeve (9)
16 Ream the bore in valve guide (2) in stages Use an adjustable reamer (10) with Ø 8.4
using adjustable reamer (10), until reamer to 9.0 mm. Only turn reamer (10) clockwise.
(11) can be set at the bore in valve guide
(2)
17 Ream the bore in valve guide (2) to the Only turn reamer (11) clockwise. *BE05.30-N-1001-02C
inside diameter (B) using reamer (11)
*000589105300
brush (4)
19 To test them, lubricate the valve stems with If used valves are being reinstalled, the
engine oil and push the valves into valve markings made on cylinder head (1) and on
guides (2) the valves must be observed.
The valve stems must make smooth contact
all round the inside of the valve guides (2).
20 Insert support disks (5)
21 Install valves AR05.30-W-3511G
22 Install cylinder head (1) AR01.30-W-5800G
23 Install nozzle holder combination AR07.03-W-6831G
Test values for valve guides

542.9
BE05.30-N-1001-02C Inside Ø pressed in Default mm 9.000 to 9.022
Wear limit mm 9.050
BE05.30-N-1002-02C Valve guide overlap in cylinder head mm 0.010 to 0.046
BE05.30-N-1004-02C Outside Ø Default mm 15.028 to 15.046
Oversize 0.2 mm 15.228 to 15.246
Deviation 0.4 mm 15.428 to 15.446
BE05.30-N-1005-02C Bore Ø in cylinder head Default mm 15.000 to 15.018
Oversize 0.2 mm 15.200 to 15.218
Deviation 0.4 mm 15.400 to 15.418
BE05.30-N-1007-02C Distance of top edge of valve guide to Inlet mm 19.65 to 20.95

contact surface of valve spring
Outlet mm 19.65 to 20.95
000 589 10 53 00 000 589 10 68 00 001 589 53 21 00 103 589 02 15 00

Reamer Cylinder brush Dial indicator Stepped driver
117 589 03 23 00 346 589 00 63 00 541 589 00 43 00

Drift Cooling box Drift with bushing
AR05.30-W-3511G Remove/install valves 2.12.09
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
W05.30-1080-08
1 Valve tool 4 Valve spring 6 Seal ring (only for engine with code
2 Conical piece 5 Valve stem seal (MS4) BlueTec 4 or with code (MS5)
3 Valve spring retainer BlueTec 5 up to engine end no.
513885)
7 Valve guide
8 Inlet valves
9 Exhaust valves
10 Dial indicator holder
11 Dial indicator
12 Drift
13 Cylinder brush
W05.30-1112-06
Modification notes
18.12.07 Remove seal ring from valve guide, added. Step 6 AR05.30-W-3510-05G
Removing
3 Measure valve setback to cylinder head Replace cylinder head if necessary. AR05.30-W-4100-01B
separating surface with dial indicator (11)
and dial indicator holder (10)
*BE05.30-N-1001-01C
Dial indicator holder *541589004000
© Daimler AG, 7/2/13, G/03/13, ar05.30-w-3511g, Remove/install valves Page 1 of 3
4 Remove valve springs (4) and valve stem AR05.30-W-3510-02G
seals (5)
Pliers *606589003700
Magnetic pin *210589004000
Valve tool kit *541589006100
5 Mark the intake valves (8) and exhaust
valves (9) and remove from the cylinder
head
6 Remove sealing ring (6) in valve guide (7) Only for vehicles with code (MS4) AR05.30-W-3510-05G
BlueTec 4 or with code (MS5) BlueTec 5 up
to engine end no. 513885.
Hooked wire for removing sealing ring from WF58.50-W-0530-01A
valve guide
brush (13)
Checking
8 Check inside diameter of valve guides (7) *BE05.30-N-1001-02C
using drift (12)
*117589032300
inserted in valve guide (7):
Replace corresponding valve guide (7). AR05.30-W-3731G

9 Check valve seat rings in cylinder head The valve seat ring must not have any
surface damage and must not be burnt;
replace cylinder head if necessary.
10 Check intake valves (8) and exhaust valves The valve stems must have no surface
(9) for additional applicability damage. The grooves in cotters (2) must not
be worn and the chrome layer on valve
stems must not be damaged. The valve
seats must not be scorched. Replace intake
valves (8) and exhaust valves (9) if
necessary.
Install
11 Insert intake valves (8) and exhaust valves Oil valve stems with engine oil.
(9) into cylinder head If used intake valves (8) and exhaust valves
(9) are reinstalled then note markings on
them. Grinding of intake valves (8) and
exhaust valves (9) with grinding paste is not
permissible.
12 Insert valve springs (4) and new valve stem Only install modified valve stem seals (5). AR05.30-W-3510-02G
seals (5)
Sleeve *346589016100
Modified valve stem seal and valve guide As of engine end no. 513886 BT05.30-W-0001-02G
Check values for valves

542.9
BE05.30-N-1001-01C Valve setback to cylinder head mm 0.70 to 1.05

contact surface
Check values for valve guides

542.9
BE05.30-N-1001-02C Inside dia. pressed in Default mm 9.000 to 9.022
Wear limit mm 9.050

000 589 10 68 00 001 589 53 21 00 117 589 03 23 00 210 589 00 40 00
Cylinder brush Dial indicator Drift Magnetic pin
346 589 01 61 00 541 589 00 40 00 541 589 00 61 00 606 589 00 37 00

Sleeve Dial gauge holder Valve tool kit Pliers

AR05.30-W-3510G Replace valve stem seals. 13.3.08
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
W05.30-1080-08
1 Valve tool 4 Valve spring 6 Seal ring (only for engine with code
2 Conical piece 5 Valve stem seal (MS4) BlueTec 4 or with code (MS5)
3 Valve spring retainer BlueTec 5 up to engine end no.
513885)
7 Valve guide
7 Valve guide
8 Cylinder brush
9 Drift
W05.30-1090-02
14 Inlet valves
15 Exhaust valves
W05.30-1069-11
Modification notes
© Daimler AG, 7/2/13, G/03/13, ar05.30-w-3510g, Replace valve stem seals. Page 1 of 3
18.12.07 Remove seal ring from valve guide, added. Step 5 AR05.30-W-3510-05G
Removing
3 Remove valve springs (4) and valve stem AR05.30-W-3510-02G
seals (5)
Pliers *606589003700
4 Mark the intake valves (14) and exhaust
valves (15) and remove from the cylinder
head
5 Remove sealing ring (6) in valve guide (7) Only for vehicles with code (MS4) AR05.30-W-3510-05G
BlueTec 4 or with code (MS5) BlueTec 5 up
to engine end no. 513885.
Hooked wire for removing sealing ring from WF58.50-W-0530-01A
valve guide
6 Clean the valve guides (7) using the cylinder *000589106800
brush (8)
Checking
7 Check intake valves (14) and exhaust valves The valve stems must have no surface
(15) for additional applicability damage. The grooves in the cotters must not
be worn and the chrome layer on the valve
stems must not be damaged. The valve
seats must not be scorched. Replace the
related intake valves (14) and exhaust
valves (15) if necessary.
8 Check the inside diameter of valve guides *BE05.30-N-1001-02C
(7) using drift (9)
*117589032300
inserted in valve guide (7):
Replace corresponding valve guide (7). AR05.30-W-3731G

Install
9 Insert intake valves (14) and exhaust valves Oil valve stems with engine oil. If used
(15) into the cylinder head intake valves (14) and exhaust valves (15)
are reinstalled then note markings on them.
10 Insert valve springs (4) and new valve stem Install: Only the modified valve stem AR05.30-W-3510-02G
seals (5) seals (5).
Sleeve *346589016100
Test values for valve guides

542.9
BE05.30-N-1001-02C Inside Ø pressed in Default mm 9.000 to 9.022
Wear limit mm 9.050
117 589 03 23 00 000 589 10 68 00 210 589 00 40 00 346 589 01 61 00
Drift Cylinder brush Magnetic pin Sleeve
606 589 00 37 00 541 589 00 61 00

Pliers Valve tool kit
AR05.30-W-3512G Replace valve stem seals with cylinder head installed 17.7.08
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934

2 Screw
3 Valve bridge
4 Retaining clamp
5 Screw
6 Conical piece
7 Valve spring retainer
8 Valve spring
9 Valve stem seal
10 Valve guide
L Shank length
W05.30-1041-06
Modification notes
17.7.08 Value modified: Test tolerance for valve clearance *BE05.30-N-1008-01C
Removing
1 Remove all cylinder head covers AR01.20-W-5014G
2 Remove soundproofing from frame on the
upper left and right
timing case
*904589046300
5 Remove clamp (4)
6 Turn engine using cranking device until Observe ignition sequence.
piston on selected cylinder is exactly at
ignition TDC
Firing order AH01.00-N-0100-01B
7 Remove rocker arm assembly (1)
8 Take off valve bridges (3)
9 Remove valve springs (8) and valve stem AR05.30-W-3510-02GA
seals (9)
Pliers *606589003700
Install
10 Replace valve stem seals (9) and install Install modified valve stem seals (9) only. AR05.30-W-3510-02GA
valve springs (8)
Sleeve *346589016100
11 Measure shank length (L) of bolt (5) Renew bolt (5) if the shank length (L) *BE07.03-N-1002-01B
was exceeded.
12 Install retaining clip (4) *BA07.15-N-1003-01B
13 Put on valve bridge (3) Check the valve bridges (3) for wear or
damage, and replace if necessary.
14 Measure shank length (L) of bolts (2) If shank length (L) is exceeded, replace *BE05.30-N-1002-04C
the related bolt (2).
15 Check rocker arm assembly (1) for wear Replace worn components if necessary.
© Daimler AG, 7/2/13, G/03/13, ar05.30-w-3512g, Replace valve stem seals with cylinder head installed Page 1 of 4
16 Install rocker arm assembly (1) Ensure tappet rods are seated correctly
in roller tappets. Oil tappet rocket sockets
with engine oil.
*BA05.00-N-1003-01B
17 Set valve clearance
Check and adjust valve clearance AP05.30-W-0560-01A
Valve clearance *BE05.30-N-1007-01C
Test tolerance for valve clearance *BE05.30-N-1008-01C
*BA05.00-N-1001-01B
*000589109900
18 Replace valve stem seals (9) on remaining Repeat steps 5 to 17, observing the firing
cylinder heads order.
Firing order AH01.00-N-0100-01B
19 Install cylinder head covers Only lower cab after inspecting for leaks. AR01.20-W-5014G
20 Install soundproofing from frame on the
timing case
23 Check the engine oil level on the display or Observe engine oil grade set in
using the oil dipstick, and adjust if necessary maintenance system or Specifications for
Operating Fluids.
until the oil pressure has built up, then allow
engine to run at varying speeds
25 Switch off engine and check for leaks Visual inspection.
Test values for valves

542.9
BE05.30-N-1007-01C Valve clearance Inlet mm 0.40
Outlet mm 0.60
BE05.30-N-1008-01C Test tolerance for valve clearance mm 0.05
Check values for valve timing

541.9, 542.9
BE05.30-N-1002-04C Bolt, rocker arm bearing Thread Ø M 10

bracket to cylinder head
Permissible mm 91
shank
length
Inspection and setting of injection nozzles

542.9
BE07.03-N-1002-01B Bolt of tensioning arm of nozzle holder Permissible mm 91
combination/constant throttle to cylinder shank
head length
Timing case

542.9

case
Engine timing - general

542.9
BA05.00-N-1001-01B Jam nut on rocker arm adjustment Nm 50

screw
BA05.00-N-1003-01B Bolt, rocker arm bearing bracket to Stage 1 Nm 60

cylinder head
Stage 2 ° 90

542.9
BA07.15-N-1003-01B Bolt of tensioning arm of injection Nm 50

nozzle and constant throttle to
cylinder head
606 589 00 37 00 210 589 00 40 00 346 589 01 61 00 541 589 00 61 00

Pliers Magnetic pin Sleeve Valve tool kit
904 589 04 63 00 000 589 10 99 00
Cranking device Tool kit
SM05.30-W-0001A Replace push rods 11.2.11
ENGINE 457.9 in MODEL 375, 940, 942, 943, 944
ENGINE 541.9 in MODEL 930, 932, 933, 934, 950, 952, 953, 954
ENGINE 542.9 in MODEL 930, 932, 934, 950, 952, 954

2 Screw
4 Valve bridge
5 Tappet rods
L Shank length
W05.00-1011-06
Operation no. of operation texts or standard texts and flat rates

Category Op. no. Operation text Time Acc. no. Code
O 027463 OPERATION: REPLACE PUSH RODS (engine 457.9) 2,4h 05 930 61 ST-STANGE
Removing
1 Remove rocker arm assembly (3) Engine 457.9 AR05.00-W-5521D
Engine 541.9 in MODEL 930, 932, 933, 934 AR05.00-W-5521G
Engine 542.9 in model 930, 932, 934
Engine 541.9 in model 950, 952, 953, 954 AR05.00-W-5521B
Engine 542.9 in MODEL 950, 952, 954
2 Remove push rods (5) With regard to return shipment or
scrapping of removed parts, please observe
the information in your warranty system.
Install
3 Insert new push rods (5) Oil push rod sockets with engine oil and
ensure they are correctly located in the roller
tappets.
4 Install rocker arm assembly (3) Engine 457.9 AR05.00-W-5521D
Engine 541.9 in model 930, 932, 933, 934 AR05.00-W-5521G
Engine 542.9 in model 930, 932, 934
Engine 541.9 in model 950, 952, 953, 954 AR05.00-W-5521B
Engine 542.9 in MODEL 950, 952, 954
Parts ordering notes

Part no. Designation Quantity
q601 06 05 12 push rods (engine 457.9) 1
© Daimler AG, 7/2/13, G/03/13, sm05.30-w-0001a, Replace push rods Page 1 of 1

ENGINE 457.9 in MODEL 375, 940, 942, 943, 944 ENGINE 541.9 in MODEL 930, 932, 933, 934, 950, 952, 953, 954 ENGINE 542.9 in MODEL 930, 932, 934, 950, 952, 954
AR07.03-W-6831G Remove/install nozzle holder combination 15.7.02
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Injection line
2 Pressure screw
3 O-ring
4 Pressure pipe connection
5 Retaining clamp
6 Bolt
8 O-ring
9 Sealing sleeve
10 Constant throttle end cover
11 Threaded insert
12 Impact extractor
L Shank length
W07.03-1022-06
1 Injection line
2 Pressure screw
3 O-ring
5 Retaining clamp
6 Bolt
8 O-ring
9 Sealing sleeve
10 Constant throttle end cover
W07.03-1023-06

9 Sealing sleeve
13.1 Assembly tool (mount for sealing sleeve)
13.2 Assembly tool (installation sleeve for nozzle combination head)
W07.03-1024-01
Modification notes
© Daimler AG, 7/2/13, G/03/13, ar07.03-w-6831g, Remove/install nozzle holder combination Page 1 of 3
19.3.04 Work sequence revised, work step Grease sealing sleeve Step 12
at nozzle holder combination omitted
Remove
risk of poisoning caused by inhaling and Pour fuels only into suitable and
swallowing fuel as well as risk of injury to appropriately marked containers.
eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel.
1 Remove cylinder head cover AR01.20-W-5014G
2 Remove injection line (1) AR07.15-W-9235G
3 Unscrew pressure screw (2) and pull out
pressure pipe connection (4)
4 Remove clamp (5)
5 Attach the threaded insert (11) and extractor *355589016300
(12) at the nozzle holder combination (7)
*904589006300
6 Remove nozzle holder combination (7) Do not disassemble nozzle holder
assembly (7)
7.1 Pull off sealing sleeve (9) at nozzle holder Only when reinstalling used nozzle holder
combination (7) combination (7).
7.2 Pull sealing sleeve (9) out of cylinder head Only for a stuck sealing sleeve (9) in the
cylinder head.
*355589016300
*906589026300
8 Clean the combustion residues from the Only when reinstalling used nozzle holder
nozzle holder combination (7) and carry out a combination (7).
visual inspection Clean the contact surface of the sealing
sleeve (9) with a brass brush.
In case of a complaint:
Clean the hole-type nozzle and contact AR07.03-W-6833G

surface of the nozzle holder combination (7)
with ultrasonic nozzle cleaning equipment.
If wear is found:
Always replace the nozzle holder

combination (7).
Install
9 Measure shank length (L) of bolt (6) If max. shank length (L) is exceeded, *BE07.03-N-1002-01B
replace bolt (6)
10 Insert new O-ring (8) at nozzle holder Only when reinstalling used nozzle holder
combination (7) combination (7).
11 Lightly coat O-ring (8) with high-temperature *BR00.45-Z-1051-06A
grease
12 Press new sealing sleeve (9) Only when reinstalling used nozzle holder
onto nozzle holder combination (7) with combination (7).
assembly tool (13.1, 13.2)
*906589036300
13 Fit on new O-ring (3) at pressure pipe Lightly coat O-ring (3) with high- *BR00.45-Z-1051-06A
connection (4) temperature grease and moisten pressure
pipe connections (4) around sealing cone
with engine oil.
14 Install nozzle holder assembly (7) and Note installation position of nozzle holder
position retaining clip (5) assembly (7) in relation to pressure pipe
connection hole
Insert pressure pipe connection (4) into
cylinder head and press in until it engages in
the fuel hole of the nozzle holder
combination (7)
If necessary twist nozzle holder assembly (7)
under retaining clip (5) in cylinder head
15 Tighten retaining clip (5) with bolt (6) *BA07.15-N-1003-01B
16 Tighten pressure pipe connection (4) with *BA07.15-N-1005-01B
pressure screw (2)
17 Install injection line (1) AR07.15-W-9235G
18 Install cylinder head cover AR01.20-W-5014G
Test and adjustment values for injection nozzles

542.9
BE07.03-N-1002-01B Bolt connecting tensioning arm of nozzle Permissible mm 91
holder combination/constant throttle to shank
cylinder head length

542.9
BA07.15-N-1003-01B Bolt connecting tensioning arm of Nm 50

injection nozzle and constant throttle
to cylinder head
BA07.15-N-1005-01B Pressure pipe fitting to cylinder head Nm 40
355 589 01 63 00 904 589 00 63 00 906 589 02 63 00 906 589 03 63 00

Impact extractor Threaded insert Extraction tool Assembly tool
Repair materials
BR00.45-Z-1051-06A Hot bearing grease A 000 989 81 51
AR07.15-W-1630G Remove/install engine control unit (MR) 24.5.02
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934

2 Connector of engine wiring harness
3 Vehicle wiring harness connector
4 Screw
5 Washer
6 Rubber shock absorber
7 Bracket
W07.15-1175-11
Remove/Install
3 Detach fuel heat exchanger (1) at engine The fuel lines remain connected at the AR47.21-W-5621G
control (EC) control unit (A6) fuel heat exchanger (1).
4 Detach connector of vehicle wiring harness For this step push the locking element
(3) at the engine control (EC) control unit toward top and release the connector of the
(A6) vehicle wiring harness (3).
5 Detach connector of engine wiring harness For this step swivel locking clamp toward
(2) at the engine control (EC) control unit bottom and release the connector of the
(A6) engine wiring harness (2).
6 Detach EC/PLN control unit (A6) at Installation: Observe installation position
crankcase of rubber shock absorber (6).
*BA07.15-N-1010-01B
8 Relearn transponder key and also Only if a new engine control (EC) (A6) AR80.57-W-0010C
replacement key control unit is installed.

542.9
BA07.15-N-1010-01B Bolt of engine control (EC) control Nm 15

unit to crankcase
© Daimler AG, 7/2/13, G/03/13, ar07.15-w-1630g, Remove/install engine control unit (MR) Page 1 of 1
AR07.15-W-9235G Remove/install MR/PLD injection lines 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
Shown on engine 542.9 with code (MS5)

BlueTec 5
1 Injection line
3 Pressure screw
W07.15-1460-06
Modification notes
21.5.07 Tighten down rear injection line in the area of the Step 4
compressor using the 17 mm box wrench bit - added.
Removing
Danger! Risk of explosion caused by ignition of No fire, sparks, open flames or smoking. AS47.00-Z-0001-01A
flammable products, risk of poisoning Pour fuels only into suitable and
caused by inhaling fuel vapors or swallowing appropriately marked containers.
fuel as well as risk of injury to skin and Wear protective clothing when handling fuel.
eyes exposed to fuel.
2 Remove injection line (1) The injection line (1) must not be bent
otherwise the coating in the injection line (1)
will detach and this can lead to engine
damage.
*000589070300
Install
3 Tighten the pressure bolt (3) on the pressure *BA07.15-N-1005-01B
pipe connection (2)
4 Install injection line (1) The injection line (1) must not be bent
otherwise the coating in the injection line (1)
will detach and this can lead to engine
damage.
Observe correct installation position.
Tighten down rear injection line (1) in the
area of the compressor using the 17 mm
box wrench bit.
*BA07.15-N-1004-01B
*000589109900
*000589680300
© Daimler AG, 7/2/13, G/03/13, ar07.15-w-9235g, Remove/install MR/PLD injection lines Page 1 of 2
6 Start engine and allow to run for about 10 s The fuel system is bled automatically. If
in neutral then allow engine to run at various engine fails to start or only runs for a brief
different rpm period:

7 Check threaded connections on injection line Check injection line (1) on unit pump
(1) by means of a visual inspection for leaks (under the charge air housing) using a mirror.
If leak exists, replace the relevant injection
line (1).
8 Turn off engine

542.9
BA07.15-N-1004-01B Injection line to pressure pipe Nm 35

connection and unit pump
BA07.15-N-1005-01B Pressure pipe connection to cylinder Nm 40

head
000 589 07 03 00 000 589 10 99 00 000 589 68 03 00

Ring wrench Tool kit Box wrench bit
© Daimler AG, 7/2/13, G/03/13, ar07.15-w-9235g, Remove/install MR/PLD injection lines Page 2 of 2
AR07.15-W-8950G Remove MR/PLD unit pump, install 5.11.02
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
W07.15-1265-09
Shown on ENGINE 542.9
1 Injection line 6 Roller tappet. Y9 Cylinder 4 unit pump

2 Engine wiring harness Y10 Cylinder 5 unit pump
3 Bracket Y6 Cylinder 1 unit pump Y11 Cylinder 6 unit pump
4 Screw Y7 Cylinder 2 unit pump Y12 Unit pump cylinder 7 (engine 542.9)
5 Impact extractor Y8 Cylinder 3 unit pump Y13 Unit pump cylinder 8 (engine 542.9)
Modification notes
22.3.04 When fitting the unit pumps, the camshaft must not be Step 18
rotated
Remove
risk of poisoning caused by inhaling and Pour fuels only into suitable and
swallowing fuel as well as risk of injury to appropriately marked containers.
eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel.
3 Remove charge air pipe Only on engine 542.9. AR09.41-W-1311G
4 Clean crankcase in the area of the relevant Cover over intake openings at cylinder
unit pump heads.
5 Remove injection line (1) for the respective AR07.15-W-9235G
unit pump
6 Separate electrical engine wiring harness (2)
at the relevant unit pump
7 Remove electrical engine wiring harness (2)
at bracket (3).
8 Identify unit pump for the respective cylinder Only when removing several unit pumps
9 Loosen bolts (4) at the relevant unit pump The unit pump is subjected to spring
and unscrew by approx. 4 to 5 mm clamp force and can suddenly spring out of
the crankcase when the bolts (4) are fully
undone and can therefore be damaged.
10 Install extractor (5) at the relevant unit pump *355589016300
11 Pull out relevant unit pump using the A firmly attached unit pump must not be
extractor (5) as far as the heads of the bolts pushed out at solenoid valve and housing
(4) flange, otherwise solenoid valve damage
could occur.
12 Remove extractor (5) *355589016300
© Daimler AG, 7/2/13, G/03/13, ar07.15-w-8950g, Remove MR/PLD unit pump, install Page 1 of 3
13 Unscrew bolts (4) and pull out relevant unit
pump
Check
14 Check roller tappet (6) at unit pump Check surface of roller tappet (6) . The
unit pump can be reused if scoring and
scratching are minimal. If deep scores,
scratches or grinding points are present:
Replace relevant unit pump and also carry

out a visual check of the unit pump cams at
the camshaft.
Install
15 Carefully remove dirt and paint residue from Seal hole in crankcase.
the sealing surface of the crankcase
16 Replacing O-rings at unit pump Only when reinstalling used unit pumps. AR07.15-W-8950-01G
*541589011400
Hot bearing grease *BR00.45-Z-1051-06A
17 Slightly coat unit pump body and the hole in Hot bearing grease *BR00.45-Z-1051-06A
the crankcase with hot bearing grease.
18 Insert unit pump and tighten bolts (4) Do not damage O-rings at unit pump
body.
Carefully press in the unit pump manually
against the spring force whilst screwing in
each bolt (4) by hand.
Then tighten the bolts (4)
*BA07.15-N-1001-01B
19 Install electrical engine wiring harness (2) at
bracket (3) and connect respective unit
pump
20 Install injection line (1) at the relevant unit AR07.15-W-9235G
pump
21 Install charge air pipe Only on engine 542.9. AR09.41-W-1311G
Danger! Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving. AS00.00-Z-0005-01A
off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes.
injury caused by contusions and burns when Do not grasp hot or rotating parts.
working in engine during starting procedure
23 Start engine and bleed fuel system The fuel system is bled automatically.
Allow the engine to run for around 1 minute
if the engine is standing or does not start
Bleed fuel system. AP47.00-W-1720-01A

24 Turn off engine
25 Connect STAR DIAGNOSIS and teach in bar Only when installing new unit pumps.
code of unit pump
Test cable (multiplexer) *WH58.30-Z-1037-13A
Adapter cable for 14-pin diagnostic socket *WH58.30-Z-1039-13A
STAR DIAGNOSIS Compact diagnostic *WH58.30-Z-1049-13A
system for commercial vehicles
jammed and crushed when tilting cab of the cab when being tilted. Always tilt the
26 Lower cab

542.9
BA07.15-N-1001-01B Bolt, MR/PLD unit pump to Nm 65

crankcase
355 589 01 63 00 541 589 01 14 00
Impact extractor Sleeve
Commercially available tools

Number Designation
WH58.30-Z-1037-13A Test cable (multiplexer) 651 100 40 99
WH58.30-Z-1039-13A Adapter cable for 14-pin diagnostic socket 651 101 40 99
WH58.30-Z-1049-13A STAR DIAGNOSIS Compact diagnostic system for commercial vehicles 651 131 10 00
Repair materials

BR00.45-Z-1051-06A Hot bearing grease A 000 989 81 51
AP09.10-W-0980E Replace air filter element 25.11.10
ENGINES 457.9 in MODEL 942, 943, 944.23 with CODE (M49) Tandem air filter
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (M49) Tandem air filter
ENGINES 542.9 in MODEL 930, 932, 934 with CODE (M49) Tandem air filter
ENGINES 542.9 in MODEL 950.0 /1 /2, 952.0 /1 /2 /3, 954.0 /1 /2 with CODE (M49) Tandem air filter
ENGINES 902.9, 906.9, 926.9 in MODEL 950.5 /6, 952.5 /6, 953.6, 954.5 with CODE (M49) Tandem air filter
Model 950.0/1/2, 952.0/1/2/3, 954.0/1/2

Model 930, 932, 934 up to vehicle
identification end no. 871496
N09.10-2022-01 N09.10-2023-01
Model 930, 932, 933, 934 as of vehicle

Model 942, 943, 944.23
Model 950.5/6, 952.5/6, 953.6, 954.5
N09.10-2063-01 N09.10-2064-01
Removing
1 Remove nuts (1) or bolts (5) and remove air Clean air filter cover (2) where
filter cover (2) necessary.
2 Remove air filter elements (3) Remove the top air filter element (3)
first. Clean the air filter housing from inside
to the extent required. Replace air filter
elements (3).
Install
3 Insert new air filter housing (3) Ensure it is correctly seated on the
sealing surfaces.
4 Tighten nuts (4) On model 950.0/1/2, 952.0/1/2/3, 954.0/1/2
and model 930, 932, 934 up to vehicle ident
end no. 871496
*BA09.10-N-1002-01A
5 Install air filter cover (2) Model 950.0/1/2, 952.0/1/2/3, 954.0/1/2 *BA09.10-N-1004-01A
and model 930, 932, 934 up to vehicle
Model 930, 932, 933, 934 as of vehicle *BA09.10-N-1010-01A
identification end no. 871497,
model 942, 943, 944.23
Model 950.5/6, 952.5/6, 953.6, 954.5 *BA09.10-N-1004-01B
6 Confirm replacement of air filter elements
(3) in maintenance booklet
Air filter

541 542 542
in model in model in model
930, 932, 933, 950, 952, 954 930, 932, 934
934, 950, 952,
953, 954
© Daimler AG, 7/2/13, G/03/13, ap09.10-w-0980e, Replace air filter element Page 1 of 2
ENGINES 457.9 in MODEL 942, 943, 944.23 with CODE (M49) Tandem air filter ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (M49) Tandem air filter ENGINES 542.9 in MODEL ...
BA09.10-N-1002-01A Nut, air filter element to air filter housing, Nm 23 23 23
tandem filter
BA09.10-N-1004-01A Nut, air filter cover to air filter housing Nm 5 5 5
BA09.10-N-1010-01A Bolt, air filter housing cover to tandem air Nm 7 - 7

filter
Air filter

457
in model
374, 940, 942,
943, 944, 958
BA09.10-N-1002-01A Nut, air filter element to air filter housing, Nm -

tandem filter
BA09.10-N-1004-01A Nut, air filter cover to air filter housing Nm 5
BA09.10-N-1010-01A Bolt, air filter housing cover to tandem air Nm 7

filter
Air filter

906.9 in model 926.9 in model
950, 952, 953, 950, 952, 953,
954 954
BA09.10-N-1004-01B Bolt, cover to air filter housing Nm 7 7

(tandem air filter)
© Daimler AG, 7/2/13, G/03/13, ap09.10-w-0980e, Replace air filter element Page 2 of 2
ENGINES 457.9 in MODEL 942, 943, 944.23 with CODE (M49) Tandem air filter ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (M49) Tandem air filter ENGINES 542.9 in MODEL ...
AR09.40-W-6021G Remove/install oil return flow line of turbocharger 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934
W09.40-1175-09
1 Turbocharger 5 Oil return line 9 Screw

2 Oil pressure line 6 Fitting
3 Bracket 7 Gasket Arrow A Clearance
4 Lifting eye 8 Screw Arrow B Bead
Remove/install
2 Tilt cab Installation: Only tilt cab back after leak
test has been conducted.
3 Remove clamp for oil pressure line (2) on *BA09.40-N-1012-01C
bracket (3)
4 Detach oil pressure line (2) at turbocharger Seal the holes.
(1)
Installation: Check oil pressure line (2)
for damage, replace oil pressure line (2) for
damage.
Install new seals.
*BA09.40-N-1009-01C
5 Unscrew bolt (8), loosen bolt (9) and turn Only for engine 542.9.
lifting eye (4) to one side
6 Remove oil return line (5) on turbocharger Installation: Replace seal (7). Observe
installation position, the bead (arrow B) on
the seal (7) must point towards the flange of
the oil return line (5).
*BA09.40-N-1003-01C
7 Detach oil return line (5) from fitting (6) of When loosening the oil return line (5),
timing case counterhold the fitting (6). Seal hole.
Pay attention to clearance (arrows A) of
the oil return line (5) in the areas of the
flange and compressor housing of the
turbocharger (1).
*BA09.40-N-1010-01C
© Daimler AG, 7/2/13, G/03/13, ar09.40-w-6021g, Remove/install oil return flow line of turbocharger Page 1 of 2
8 Remove oil return line (5) Installation: Check oil return line (5) for
foreign matter, contamination and damage;
replace if necessary.
10 Start engine and afterwards allow the engine Visual inspection.
to run at alternating rpm. Check oil pressure
line (2) and oil return line (5) for
leaktightness, then switch off engine
Turbocharger

541.9 542.9
BA09.40-N-1003-01C Bolt, oil return flow line to turbocharger Nm 25 25
BA09.40-N-1010-01C Exhaust gas turbocharger oil return line on fitting M26 1.5 Nm 50 50
on timing case

bracket
© Daimler AG, 7/2/13, G/03/13, ar09.40-w-6021g, Remove/install oil return flow line of turbocharger Page 2 of 2
AR09.40-W-6020GA Remove/install turbocharger 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934
W09.40-1179-09
1 Connecting piece 8 Bracket 15 Screening

2 Resonance reservoir 9 Screening 16 Engine brake cylinder
3 Intake manifold 10 Oil return line 17 Compressed-air line
4 Crankcase ventilation hose 11 Compressor 18 Gasket
5 Connecting piece 12 Screw socket
6 Turbocharger 13 Intermediate piece Arrow A Clearance
7 Oil pressure line 14 Engine brake flap connection Arrow B Bead
Modification notes
20.12.07 Work sequence changed.
Remove/install
3 Remove soundproofing from frame on the
4 Detach resonator (2) on intake manifold (3) Installation: Check seal rings on
and on compressor (11) resonator (2) for damage and replace
resonator (2) if necessary.
5 Remove connection piece (1) *BA09.20-N-1002-02C
6 Separate crankcase ventilation hose (4) from
intake manifold (3)
7 Loosen intake manifold (3) with connection *BA09.20-N-1004-02C
piece (5) at turbocharger (6)
8 Detach intake manifold (3) from compressor *BA09.20-N-1003-02C
(11) and lift out
9 Remove compressed-air line (17) on engine
brake cylinder (16)
10 Remove injection line for exhaust Only for vehicles with code (MS4) AR14.40-W-2001A
aftertreatment system BlueTec 4 or with code (MS5) BlueTec 5.
installation: Replace injection line after
each removal.
© Daimler AG, 7/2/13, G/03/13, ar09.40-w-6020ga, Remove/install turbocharger Page 1 of 3

ENGINES 541.9 in MODEL 930, 932, 933, 934
11 Detach exhaust flex pipe from engine brake *BA49.10-N-1001-01J
valve fitting (14)
Assembly notes and installed dimensions for AH49.10-N-0301-01A
exhaust flex pipes
12 Detach exhaust brake flap connection (14) at *BA14.10-N-1002-01C
turbocharger (6)
13 Remove clamp for oil pressure line (7) on *BA09.40-N-1012-01C
bracket (8)
(6)
Installation: Check oil pressure line (7)
for dirt and damage, clean or replace oil
pressure line (7) if necessary.
Before installing the oil pressure line (7), fill
bearing housing of exhaust gas turbocharger
(6) with engine oil through oil inlet hole.
Install new seals.
*BA09.40-N-1009-01C
15 Remove oil return line (10) on screw fitting Counterhold threaded fitting (12) and seal
(12) bore.
Installation: Check oil return line (10) for
dirt and damage and clean or replace oil
return line (10).
Pay attention to clearance (arrows A) of the
oil return line (10) in the areas of the flange
and compressor housing of the turbocharger
(6).
*BA09.40-N-1010-01C
16 Remove turbocharger (6) on exhaust plenum *BA09.40-N-1002-01C
chamber
17 Remove turbocharger (6) together with the Seal openings on turbocharger (6) and
oil return line (10) on exhaust plenum chamber.
18 Pull out intermediate piece (13) on Installation: Replace seal rings on
turbocharger (6) or charge air housing adapter (13).
19 Remove oil return line (10) and bracket (8) Only when replacing the turbocharger (6).
on turbocharger (6)
Installation: Replace seal (18). Observe
observe installation position, the bead (arrow
B) on the seal (18) must point towards the
flange of the oil return line (10).
*BA09.40-N-1003-01C
20 Remove shielding (9) on turbocharger (6) Only when replacing the turbocharger (6).
*BA09.40-N-1008-01C
21 Check all components of air intake, check Clean or replace components if
charging and charge air cooling for foreign necessary.
objects, contamination and damage
to run at alternating rpm. Check engine for

541.9 541.9
MJ1



ENGINES 541.9 in MODEL 930, 932, 933, 934
Turbocharger

541.9
BA09.40-N-1002-01C Nut for turbocharger on exhaust plenum chamber Nm 50
BA09.40-N-1003-01C Bolt, oil return flow line to turbocharger Nm 25
BA09.40-N-1008-01C Bolt for shielding on turbocharger M8 Nm 20
BA09.40-N-1009-01C Oil pressure line to turbocharger M14 1.5 Nm 35
BA09.40-N-1010-01C Exhaust gas turbocharger oil return line on fitting M26 1.5 Nm 50
on timing case
BA09.40-N-1012-01C Bolt, oil pressure line to exhaust gas turbocharger Nm 25

bracket
Exhaust manifold
Number Designation Engine 541.9
BA14.10-N-1002-01C Nut, exhaust pipe engine brake valve fitting to Nm 50

turbocharger
Exhaust system

541.9, 542.9
BA49.10-N-1001-01J Clamp bolt, exhaust pipe to engine brake flap Nm 50

fitting

ENGINES 541.9 in MODEL 930, 932, 933, 934
AR09.40-W-6024G Remove/install oil return flow line for turbocharger 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934
W09.40-1174-09
1 Turbocharger 7 Pressure line (steering) 13 Electrical line

2 Oil pressure line 8 Suction line (steering) 14 Compressed-air line
3 Bracket 9 Compressed-air line 15 Bracket
4 Crankcase ventilation hose 10 Bracket 16 Engine brake cylinder
5 Oil separator 11 Metering device 17 Compressed air interface
6 Bracket 12 AdBlue feed hose
Remove/install
3 Remove soundproofing on frame at upper
left
brake cylinder (16)
5 Remove injection line for exhaust Only for engine 542.9. AR14.40-W-2001A
aftertreatment system
Installation: Replace injection line after
each removal.
6 Detach metering device (11) of exhaust Only for engine 542.9. AR14.40-W-2002A
aftertreatment system
Do not separate AdBlue-feed hose (12) and
electrical line (13) on metering device (11).
7 Detach compressed air line (14) of exhaust Only for engine 542.9.
aftertreatment system at bracket (15) and at
the compressed air interface (17)
8 Remove clamps of pressure line (7) and
suction line (8) from bracket (10) and remove
bracket (10)
9 Detach crankcase ventilation hose (4) from
oil separator (5)
© Daimler AG, 7/2/13, G/03/13, ar09.40-w-6024g, Remove/install oil return flow line for turbocharger Page 1 of 2
10 Detach clamp of oil pressure line (2) from *BA09.40-N-1012-01C
brackets (3, 6)
*BA01.40-N-1019-01D
(1)
*BA09.40-N-1009-01C
12 Detach and remove oil pressure line (2) from Installation: Check oil pressure line (2)
cylinder crankcase for dirt and damage, clean or replace oil
pressure line (2) if necessary.
Install new seals.
*BA01.40-N-1011-01D
to run at alternating rpm. Check oil pressure
line (2) for leaktightness, then switch off
engine
Crankcase, timing case cover, end cover

541.9, 542.9
BA01.40-N-1011-01D Oil pressure line for exhaust gas turbocharger to M14 1.5 Nm 35
crankcase
BA01.40-N-1019-01D Bolt oil pressure line for turbocharger to timing case Nm 25

cover
Turbocharger

541.9 542.9

bracket
© Daimler AG, 7/2/13, G/03/13, ar09.40-w-6024g, Remove/install oil return flow line for turbocharger Page 2 of 2
AR09.41-W-8682A Remove/install charge air housing 3.11.10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W09.41-1046-09

BlueTec 5
1 Charge air pipe (only for engine 7 Tensioning element 13 Charge air hose, black
542.9) 8 Clip
2 Charge air hose, red 9 Leak fuel line Y1 Pneumatic constant throttle solenoid
3 Charge air housing 10 Intermediate piece valve (only for vehicles with code
4 Bolt 11 Sealing ring (GE7) Mercedes
5 Bolt 12 Bracket for the steering oil line PowerShift 2)
6 Gasket

BlueTec 5
1 Charge air pipe (only for engine

542.9)
2 Charge air hose, red
3 Charge air housing
13 Charge air hose, black
14 Electrical connector*
15 Fuel line*
16 Flame starting system*
17 Electrical lines*
19 Screw
B111 Charge air temperature and boost

pressure combination sensor
* Only on vehicles with code (M89) Flame

starting system (FLA)
W09.41-1047-06
Modification notes
15.9.10 Remove pneumatic constant throttle solenoid valve (Y1) Step 12
on charge air housing (3) added.
© Daimler AG, 7/2/13, G/03/13, ar09.41-w-8682a, Remove/install charge air housing Page 1 of 3
Remove/install
safety strut.
3 Remove charge air hose black (13) on Installation: Charge air hose black (13)
charge air housing (3) and charge air hose red (2) must not get
mixed up with each other.
*BA09.41-N-1006-01C
4 Remove charge air hose red (2) on charge Only on engine 541.9.
air housing (3)
Installation: Charge air hose black (13)
and charge air hose red (2) must not get
mixed up with each other.
*BA09.41-N-1006-01C
5 Separate electrical connector (14) and Only for vehicles with code (M89) Flame
electrical lines (17) on the flame starting starting system (FLA)
system (16)
6 Detach fuel line (15) and flame starting Only for vehicles with code (M89) Flame
system (16) from charge air housing (3) starting system (FLA)
Do not disconnect fuel line (15).
Installation: Install new seal
*BA09.30-N-1001-01A
7 Detach mounting plate with hydraulic lines Only on vehicles with code (GS3)
and clamps of hydraulic lines on engine and "Hydraulic" gearshift.
tie up to one side Do not separate hydraulic lines.
8 Disconnect electrical connector (18) on
charge air temperature and boost pressure
combination sensor (B111)
9 Remove bracket for the left front steering oil
line (12) at the lifting eye
10 Detach charge air pipe (1) at charge air Only on engine 542.9.
housing (3)
Installation: On engine with code (MS4)
center the distances between the adapter
(10) to the charge air pipe (1) and to the
turbocharger.
*BA09.41-N-1005-01C
11 Unclip leak fuel lines (9) at the two rear
threaded pins or bolts (5)
12 Remove pneumatic constant throttle solenoid Only on vehicles with code (GE7)
valve (Y1) on charge air housing (3) Mercedes PowerShift 2.
13 Detach charge air housing (3) from the For engine 541.9 up to engine end no.
engine and remove seals (6) 311843 remove both rear threaded bolts.
Installation: Check all threaded pins are
correctly tightened and tighten if necessary.
Pay attention to installation position of seals
(6). Check tensioning elements (7) for wear,
replace bolts (4, 5, 19) if necessary.
Observe installation location of bolts (4, 5,
19).
*BA09.41-N-1001-01C
*BA09.41-N-1002-01C
*BA09.41-N-1003-01C
*BA09.41-N-1008-01C
Mounting of charge air housing on engine - Engine 541.9 as of engine end no. 311844 BT09.41-W-0003-01A
altered Engine 542.9 as of engine end no. 313193
14 Remove intermediate piece (10) Only on engine 541.9 .
Installation: Check seal rings (11) and
replace if necessary.
15 Remove charge air temperature and boost Only when replacing the charge air
pressure combination sensor (B111) housing (3).
Installation: Check sealing ring; replace
charge air temperature and boost pressure
combination sensor (B111) if necessary.
*BA09.41-N-1009-01C
to run at alternating rpm. Check charge air
housing (3), black charge air hose (13) and
red charge air hose (2) for leaktightness,
then switch off engine
Intake manifold preheater

541.9, 542.9
BA09.30-N-1001-01A Bolt, bracket of flame starting system to charge Nm 20

air pipe
Charge air pipe/charge air cooling

541.9 542.9
BA09.41-N-1001-01C Nut, charge air housing to threaded bolt Nm 40 40
BA09.41-N-1002-01C Threaded bolt/bolt on cylinder crankcase Nm 50 50
BA09.41-N-1003-01C Threaded bolt on oil filter housing bracket Nm 50 50
BA09.41-N-1005-01C Bolt, charge air pipe to charge air housing Nm - 25
BA09.41-N-1006-01C Clamp, charge air hose to charge air housing/ Nm 7.5 7.5
charge air pipe and charge air cooler
BA09.41-N-1008-01C Threaded bolt/bolt on oil filter housing Nm 50 50
BA09.41-N-1009-01C Bolt, charge air temperature and charge pressure Nm 10 10

combination sensor to air housing
AR09.41-W-6817A Remove/install charge air cooler 28.7.09
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
W09.41-1058-09
Shown on vehicle with code (H03) A/C in

the front end or code (H07) AAC
1 Charge air cooler mounting bolt

2 Coolant lines 4 Refrigerant lines 6 Charge air cooler
3 Capacitor 5 Bracket 7 Protective grille
Remove/install
1 Remove radiator with charge air cooler (6) Vehicle without code (MZ3) Electromagnetic AR20.20-W-3865G
viscous coupling for fans, without code
coupling) and without code (MO1)
Electromagnetic viscous fan clutch, Behr
Vehicles with code (MZ3) Electromagnetic AR20.20-W-3865GB
Only vehicles with code (MZ5) AR20.20-W-3865GA
2 Remove protective grille (7)
3 Detach coolant lines (2)
4 Remove refrigerant lines (4) on the bracket Only for vehicles with code (H03) Air
(5) and the cooler conditioning in front end or code (H07) AAC.
Installation: The bracket (5) must be
changed when replacing the charge air
cooler (6).
5 Remove condenser (3) Only for vehicles with code (H03) Air
conditioning in front end or code (H07) AAC.
6 Remove charge air cooler mounting bolt (1)
and remove charge air cooler (6)
© Daimler AG, 7/2/13, G/03/13, ar09.41-w-6817a, Remove/install charge air cooler Page 1 of 1
AR13.22-W-0003GA Removing/installing poly-V-belt for alternator 3.3.09
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (M58) Higher output fan
ENGINE 542.9 in MODEL 930, 932, 934 with CODE (M58) Higher output fan
Shown on removed fan
1 Fan
2 Poly-V-belt of alternator
3 Tensioning device
4 Belt pulley (coolant pump)
5 Bracket
6 Fan box
7 Belt pulley on refrigerant compressor
9 Belt pulley (alternator)
W13.22-1021-06
Modification notes
10.10.05 Work procedure completely revised. Steps 1-29
Removing
Danger! Risk of injury caused by being caught or Ensure that no one is within the tilting range AS60.80-Z-0001-01A
pinched as cab is tilted of the cab as it is being tilted. Always tilt the
when tilting.
2 Remove soundproofing on the right side of
the engine
the radiator
4 Detach coolant expansion reservoir from Do not separate coolant lines.
radiator and put to one side
5 Remove red charge air hose
6 Remove fan shroud (6) bracket (5) on the Only vehicles with code (MZ3)
upper right Electromagnetic viscous coupling for fan.
7 Remove tensioning device for poly-V-belt on Only vehicles with code (ML3) high- AR13.25-W-3201G
fan drive speed fan drive with belt drive.
8 Remove soundproofing below the radiator.
9 Swivel tensioning pulley of tensioning device
(3) to the top and hold.
10 Remove alternator (2) poly-V-belt from belt On vehicles with code (H03) Air
pulley/vibration damper (8) and remove from conditioning in front end, additionally on the
belt pulley (4, 9) belt pulley of the refrigerant compressor (7).
11 Pull alternator (2) poly-V-belt over the fan Do not damage the poly-V-belt of the
(1) and take out between fan (1) and fan alternator (2) when removing.
shroud (6) downwards
Checking
© Daimler AG, 7/2/13, G/03/13, ar13.22-w-0003ga, Removing/installing poly-V-belt for alternator Page 1 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (M58) Higher output fan ENGINE 542.9 in MODEL 930, 932, 934 with CODE (M58) Higher output fan
12 Check belt pulleys and tensioning pulley for
damage and smooth operation, replace if
necessary
13 Inspect condition of poly-V-belt of alternator
(2), replace if necessary
Install
14 Pull alternator (2) poly-V-belt over the fan On vehicles with code (H03) Air
(1) and lay on the belt pulley/vibration conditioning in front end, additionally on the
damper (8) and the belt pulley (4, 9) belt pulley of the refrigerant compressor (7).
16 Fit poly-V-belt of alternator (2) onto the Ensure that the poly-V-belt of the
tensioning pulley of the tensioning device (3) alternator (2) is seated correctly.
and swivel back the tensioning device again
17 Install soundproofing below the radiator.
18 Remove tensioning device for poly-V-belt on Only vehicles with code (ML3) high- AR13.25-W-3201G
19 Install fan shroud (6) bracket (5) on the Only vehicles with code (MZ3)
upper right Electromagnetic viscous coupling for fan.
*BA20.40-N-1015-01C
*BA20.40-N-1016-01C
20 Install red charge air hose *BA09.41-N-1006-01C
21 Attach coolant expansion tank on the
radiator
22 Attach soundproofing to the right side of the
radiator
23 Attach soundproofing to right side of the
engine
24 Tilt cab back into driving position
Fan, fan clutch

541.9,
542.9
with code
MZ3/MO1
BA20.40-N-1015-01C Bolt, fan shroud bracket to engine Nm 25
BA20.40-N-1016-01C Bolt, fan shroud to fan shroud bracket Nm 15
© Daimler AG, 7/2/13, G/03/13, ar13.22-w-0003ga, Removing/installing poly-V-belt for alternator Page 2 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (M58) Higher output fan ENGINE 542.9 in MODEL 930, 932, 934 with CODE (M58) Higher output fan
AR13.22-W-0003G Remove/install poly V-belt of alternator 2.2.09
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (M58) Higher output fan
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (M58) Higher output fan
W20.40-1081-09
1 Radiator 5 Charge air hose (red) 9 Belt pulley (alternator)

2 Radiator mounting 6 Belt pulley (coolant pump) 10 Belt pulley on refrigerant compressor
3 Fan 7 Tensioning device
4 Poly-V-belt of generator 8 Belt pulley/vibration damper Arrow: Spacer
Modification notes
10.10.05 Work procedure completely revised. Steps 1-29
Removing
when tilting.
2 Remove trim panel in front of radiator (1)
3 Remove soundproofing from the engine on
the left and right
4 Remove side soundproofing from radiator (1)
on left and right
radiator (1) and put to one side
6 Detach oil dipstcik guide tube and oil filler
pipe at radiator (1)
7 Remove red charge air hose (5)
8 Unscrew bolts at the radiator mounting (2) Fix radiator (1) on right and left with
on right and left and press radiator (1) to the spacers (arrow).
front
9 Remove soundproofing below the radiator
(1).
10 Remove the poly-V-belt tensioning device for Only vehicles with Code (ML3) High- AR13.25-W-3201G
© Daimler AG, 7/2/13, G/03/13, ar13.22-w-0003g, Remove/install poly V-belt of alternator Page 1 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (M58) Higher output fan ENGINE 542.9 in MODEL 930, 932, 934 except CODE (M58) Higher output fan
12 Remove alternator (4) poly-V-belt from belt On vehicles with Code (H03) Air
pulley/vibration damper (8) and remove from conditioning in front end, additionally on the
belt pulley (6, 9) belt pulley of the refrigerant compressor
(10).
13 Swivel back tensioning pulley of tensioning
device (7)
14 Pull poly-V-belt of generator (4) over the fan Do not damage the poly-V-belt of the
(3) and take out between fan (3) and generator (4) when removing.
radiator shroud toward bottom
Checking
15 Check belt pulleys and tensioning pulley for
necessary
16 Inspect condition of poly-V-belt of generator
(4), replace if necessary
Install
17 Pull alternator (4) poly-V-belt over the fan On vehicles with Code (H03) Air
(3) and lay on the belt pulley/vibration conditioning in front end, additionally on the
damper (8) and the belt pulley (6, 9) belt pulley of the refrigerant compressor
(10).
19 Fit poly-V-belt of generator (4) onto the Ensure that the poly-V-belt of the
tensioning pulley of the tensioning device (7) generator (4) is seated correctly.
and swivel back the tensioning device (7)
again
20 Attach poly V-belt tensioning device of fan Only vehicles with Code (ML3) High-
at filter housing speed fan drive with belt drive.
21 Install soundproofing below the radiator (1).
22 Push back radiator (1) and attach to radiator
mounting (2) on right and left
23 Install red charge air hose (5) *BA09.41-N-1006-01C
24 Attach oil dipstcik guide tube and oil filler
pipe at radiator (1)
25 Attach coolant expansion tank onto radiator
(1)
26 Attach soundproofing on the right and left
side of the radiator (1)
27 Attach soundproofing to the engine on the
left and right
28 Install trim panel in front of radiator (1)
29 Tilt cab back into driving position
© Daimler AG, 7/2/13, G/03/13, ar13.22-w-0003g, Remove/install poly V-belt of alternator Page 2 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (M58) Higher output fan ENGINE 542.9 in MODEL 930, 932, 934 except CODE (M58) Higher output fan
AR13.22-W-1302G Remove/install fan poly-V belt 3.3.09
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (ML3) High-speed fan drive with belt drive
ENGINES 542.9 in MODEL 930, 932, 934 with CODE (ML3) High-speed fan drive with belt drive
Shown on vehicle without Code (MZ3) Electromagnetic viscous

clutch for fan
1 Poly-V belt tensioning device for fan

2 Coolant pump belt pulley
3 Belt pulley for fan drive
4 Poly-V belt for fan
5 Fan with viscous fan clutch
6 Charge air hose (red)
W13.22-1014-12
Modification notes
3.3.09 Value modified: Electromagnetic fan clutch on belt pulley Engine 541.9, 542.9 with code MZ3 *BA20.40-N-1017-01C
for fan drive
Removing
when tilting.
the engine
the radiator
5 Remove red charge air hose (6)
6 Swivel tensioner pulley of poly-V belt
tensioning device fan (1) to the top and hold.
7 Remove poly-V belt of fan (4) from the
coolant pump belt pulley (2)
8 Swivel back poly-V belt tensioning device of
fan (1)
9 Remove noise encapsulation below the
radiator.
10.1 Detach fan with viscous fan clutch (5) at the On vehicles without Code (MZ3)
belt pulley fan drive (3) Electromagnetic viscous clutch for fan
10.2 Detach fan with electromagnetic viscous On vehicles with Code (MZ3)
clutch at the belt pulley fan drive (3) Electromagnetic viscous clutch for fan
© Daimler AG, 7/2/13, G/03/13, ar13.22-w-1302g, Remove/install fan poly-V belt Page 1 of 3
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (ML3) High-speed fan drive with belt drive ENGINES 542.9 in MODEL 930, 932, 934 with CODE (ML3) High-speed fan drive with belt drive
11 Remove poly-V belt of fan (4) from the belt Do not damage the poly-V belt of the fan
pulley fan drive (3) (4) when removing.
Checking
12 Check belt pulleys and tensioner pulley for
necessary
13 Inspect condition of poly-V belt of fan (4),
replace if necessary
Install
14 Place poly-V belt fan (4) onto the belt pulley
fan drive (3)
15.1 Install fan with viscous fan clutch (5) at the On vehicles without Code (MZ3)
belt pulley fan drive (3) Electromagnetic viscous clutch for fan
*BA20.40-N-1012-01C
15.2 Install fan with electromagnetic viscous On vehicles with Code (MZ3)
clutch at the belt pulley fan drive (3) Electromagnetic viscous clutch for fan
*BA20.40-N-1017-01C
16 Install noise encapsulation below the
radiator.
17 Swivel tensioner pulley of poly-V belt
tensioning device fan (1) to the top and hold.
18 Place poly-V belt fan (4) onto the coolant Ensure correct seating of poly-V belt of
pump belt pulley (2) and once again swivel fan (4).
back the tensioning device
19 Install red charge air hose (6) *BA09.41-N-1006-01C
20 Attach coolant expansion reservoir on the
radiator
21 Attach soundproofing to the right side of the
radiator
22 Attach soundproofing to right side of the
engine
23 Tilt cab back into driving position The front flap must always be opened
when tilting.

541.9 542.9
Fan, fan clutch

541.9, 541.9,
542.9 542.9
with code with code
ML3 MZ3/MO1
BA20.40-N-1012-01C Bolt, fan with viscous fan clutch to belt Nm 50 -

pulley of fan drive
BA20.40-N-1017-01C Electromagnetic fan clutch on belt pulley Nm 50 30
for fan drive
AR13.25-W-3200G Remove/install poly V-belt tensioning device 3.3.09
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
Shown on vehicle with Code (ML3) High-speed fan drive with

belt drive, with removed fan
1 Poly-V-belt of generator
2 Poly-V-belt tensioning device of high-speed fan drive (only
with Code (ML3) High-speed fan drive with belt drive)
3 Poly-V-belt of fan (only on code (ML3) high-speed fan drive
with belt drive)
4 Cap
5 Hexagon socket head screw
6 Tensioning device for alternator poly-V-belt
7 Bolt
W13.25-1006-11
Modification notes
15.3.05 Remove fan shroud bracket on the upper right - added. Step 6
Remove/install
when tilting.
the engine
the radiator
5 Remove red charge air hose *BA09.41-N-1006-01C
6 Remove fan shroud bracket on the upper Only on vehicles with Code (MZ3)
right Electromagnetic viscous clutch for fan and
with Code (M58) Higher output fan.
*BA20.40-N-1015-01C
*BA20.40-N-1016-01C
7 Slacken poly V-belt of fan (3) and remove it Only on vehicles with code (ML3) high-
from the belt pulley of the coolant pump. speed fan drive with belt drive.
Installation: Inspect condition of poly-V-
belt of fan (3), replace if necessary.
radiator.
9 Relieve the tension on the poly-V-belt for the Installation: Inspect condition of poly-V-
alternator (1) and then remove poly V-belt belt of generator (1), replace if necessary.
from the tensioning pulley on the poly-V-belt
tensioning device (6)
10 Remove cap (4) and unscrew hexagon *BA13.25-N-1001-01D
socket head screw (5)
© Daimler AG, 7/2/13, G/03/13, ar13.25-w-3200g, Remove/install poly V-belt tensioning device Page 1 of 2
11 Unscrew bolt (7) at tensioning element of *BA13.25-N-1003-01D
poly-V-belt tensioning device of generator
(6)
12 Remove poly-V-belt tensioning device of
generator (6) from support

541.9 542.9
Belt tensioning device
Number Designation Engines Engines

541.9, 542.9 541.9, 542.9
without code with Code ML3
ML3
BA13.25-N-1001-01D Bolt connecting poly V-belt tensioning device to M10 Nm 50 50

carrier
M18 Nm 105 105
BA13.25-N-1003-01D Bolt connecting tensioning element to tensioning Nm 35 35

device
Fan, fan clutch

541.9,
542.9
with code
MZ3/MO1
BA20.40-N-1015-01C Bolt connecting fan shroud bracket to Nm 25

engine
BA20.40-N-1016-01C Bolt connecting fan shroud to fan shroud Nm 15

bracket
© Daimler AG, 7/2/13, G/03/13, ar13.25-w-3200g, Remove/install poly V-belt tensioning device Page 2 of 2
AR13.25-W-3201G Removing/installing poly-V-belt tensioning device for high-speed fan drive 2.2.09
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (ML3) High-speed fan drive with belt drive
ENGINE 542.9 in MODEL 930, 932, 934 with CODE (ML3) High-speed fan drive with belt drive
Shown on a removed fan and viscous fan clutch
1 Poly-V-belt tensioning device fan

2 Poly-V-belt fan
3 Belt pulley fan drive
4 Coolant pump belt pulley
W13.25-1009-11
Modification notes
15.3.05 Detach coolant expansion tank on radiator and place Step 4
aside - added.
Removing/installing
when tilting.
the engine
the radiator
4 Remove coolant expansion tank on radiator Do not disconnect coolant lines.
on and place aside
5 Remove red charge air hose *BA09.41-N-1006-01C
Danger! Risk of injury caused by pinching or Only use approved tensioning devices; shield AS00.00-Z-0001-01A
6 Slacken poly-V-belt of fan (2) and take it off Installation: Inspect condition of poly-V-
the belt pulley of the coolant pump (4). belt fan (2), replace if necessary.
7 Detach poly-V-belt tensioning device for fan Installation: Insert dowel pin at the poly-
(1) at filter housing V-belt tensioning device of fan (1) in the
hole of the oil filter housing.
*BA13.25-N-1004-01D
8 Install in reverse order
BA09.41-N-1006-01C Clamp for charge air hose on charge air housing/ Nm 7.5 7.5
© Daimler AG, 7/2/13, G/03/13, ar13.25-w-3201g, Removing/installing poly-V-belt tensioning device for high-speed fan drive Page 1 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (ML3) High-speed fan drive with belt drive ENGINE 542.9 in MODEL 930, 932, 934 with CODE (ML3) High-speed fan drive with belt drive
Belt tensioning device

541.9, 542.9
with Code ML3
BA13.25-N-1004-01D Bolt for poly-V-belt tensioning device on oil filter Nm 45

housing
© Daimler AG, 7/2/13, G/03/13, ar13.25-w-3201g, Removing/installing poly-V-belt tensioning device for high-speed fan drive Page 2 of 2
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (ML3) High-speed fan drive with belt drive ENGINE 542.9 in MODEL 930, 932, 934 with CODE (ML3) High-speed fan drive with belt drive
AR13.30-W-6010GB Remove/install compressor cylinder head 22.3.11
ENGINES 541.9 in MODELS 930, 932, 933, 934 with code (M32) Dual compressor
Compressor lying down
ENGINES 542.9 in MODELS 930, 932, 934 with code (M32) Dual compressor
Compressor lying down
ENGINES 541.9 in MODEL 930, 932, 933, 934 with code (MZ8) Engageable dual compressor
Horizontal compressor
ENGINES 542.9 in MODEL 930, 932, 934 with CODE (MZ8) Engageable dual compressor
Compressor recumbent
1 Cylinder head
2 Valve intermediate plate
3 Coolant return flow line
4 Elbow fitting
6 Hose
7 Coolant feed line
8 Intake valve disk
9 Cylinder liner
10 Gasket
13 Suction line and adapter
14 T-connection
15 Control line (only for code (MZ8)
Engageable dual compressor)
16 Control line (only for code (MZ8)
Engageable dual compressor)
W13.30-1092-06
Vehicles with code (MS4) BlueTec 4 or with code (MS5) BlueTec 5
1 Cylinder head
11 Bracket
12 AdBlue feed line
W14.40-1008-02
Remove/install
3 Partially drain coolant at radiator Installation: Pour in coolant. AR20.00-W-1142A
4 Remove soundproofing on frame above on
the right
© Daimler AG, 7/2/13, G/03/13, ar13.30-w-6010gb, Remove/install compressor cylinder head Page 1 of 5
ENGINES 541.9 in MODELS 930, 932, 933, 934 with code (M32) Dual compressor Compressor lying down ENGINES 542.9 in MODELS 930, 932, 934 with code (M32) Dual compressor Compressor ...
5 Remove suction line and intermediate piece Only on engine 541.9 and engine 542.9
(13) with code (MS4) BlueTec 4 or with code
(MS5) BlueTec 5.
*BA09.20-N-1002-02C
*BA09.20-N-1003-02C
*BA09.20-N-1004-02C
6 Remove hose (6)
7.1 Remove right exhaust manifold pipe Engine 541.9, AR14.10-W-4200G
7.2 Remove right exhaust manifold Engine 542.9 without code (MS4) BlueTec 4 AR14.10-W-3915GB
8 Remove control line (15, 16) at cylinder head Only on vehicles with code (MZ8)
(1) Switchable dual compressor.
*BA13.30-N-1015-01B
9 Detach AdBlue feed line (12) at bracket (11) Only for vehicles with code (MS4)
and at timing case bracket BlueTec 4 or with code (MS5) BlueTec 5.
Do not disconnect AdBlue feed line (12).
*BA14.40-N-1037-02A
and safety glasses.
10 Detach coolant return flow (3) and coolant Collect coolant that flows out
feed line (7) on cylinder head (1)
*BA13.30-N-1001-01B
11 Remove compressed air line (5) at elbow
fitting (4) and T-connection (14)
12 Remove cylinder head (1) Twist the cylinder head (1) together with
the cylinder liner (9). This enables the lower
bolt to be pulled out.
*BA13.30-N-1005-01B
13 Disassemble cylinder head (1) Only when replacing cylinder head (1) or AR13.30-W-5511-04G
valve intermediate plate (2).
Screw plug to compressor cylinder head *BA13.30-N-1003-01B
Fittings for coolant line at compressor *BA13.30-N-1004-01B
cylinder head
Fittings for compressed air line at *BA13.30-N-1006-01B
Bolt, valve intermediate plate at *BA13.30-N-1007-01B
Fittings for intake air line on *BA13.30-N-1011-01B
Screw plug to compressor cylinder head *BA13.30-N-1014-01B
14 Remove intake valve disk (8) and clean Installation: Replace intake valve disk
sealing surfaces (8).
15 Remove soundproofing on frame below
16 Remove cover of TDC inspection hole on *BA01.60-N-1001-01B
timing case
17 Install engine turning device on timing case *BA01.60-N-1009-01B
*407589006300
18 Remove cylinder liner (9) AR13.30-W-7041-02A
Cylinder liner inner dia. *BE13.30-N-1002-01B
Piston outer dia. *BE13.30-N-1003-01B
Cylinder liner height from timing case *BE13.30-N-1010-01B
*541589003700
*407589006300
19 Remove gasket (10) Installation: Replace seal (10).
20 Cover over opening at timing case
Checking
21 Check compressed air line (5) and T- If there is carbonization, it is also
connection (14) for carbonization necessary to check compressed-air line
between compressor, compressed air drier
and four-circuit protection valve and replace
coked parts if necessary.
23 Start engine and carry out engine test run
24 When engine is running, check compressor, Visual inspection
compressed air line (5), coolant return flow
line (3) and coolant feed line (7) for
25 Check control line (15, 16) for leaktightness. Only for code (MZ8) Engageable dual
compressor.
Visual inspection
26 Turn off engine
Inspection data of compressor

541.9, 542.9
with code M32
BE13.30-N-1002-01B Cylinder liner inner dia. Marking B mm 100.000 to

100.010
Marking C mm 100.010 to
100.020
Marking D mm 100.020 to
100.030
BE13.30-N-1003-01B Piston outer dia. Marking B mm 99.925 to 99.935
Marking C mm 99.935 to 99.945
Marking D mm 99.945...99.955
BE13.30-N-1010-01B Cylinder liner height mm 83.8 to 84.0

from timing case
Timing case

541.9. 542.9

case

541.9 541.9
MJ1


542.9 542.9
MJ1



542.9
BA13.30-N-1001-01B Coolant line to compressor Nm 35
BA13.30-N-1003-01B Screw plug on M26 1.5 Nm 80

BA13.30-N-1004-01B Fitting, coolant line on M14 1.5 Nm 35

BA13.30-N-1005-01B Bolt, cylinder head and cylinder liner at Stage 1 Nm 20

timing case
Stage 2 Nm 40
BA13.30-N-1006-01B Fitting, compressed air line to compressor M26 1.5 Nm 80

cylinder head
BA13.30-N-1007-01B Bolt, valve intermediate plate at Nm 12

BA13.30-N-1011-01B Fittings for intake air line on M36 1.5 Nm 80

BA13.30-N-1014-01B Screw plug on M36 1.5 Nm 80

BA13.30-N-1015-01B Banjo bolt, control line to compressor Nm 15
541.9 542.9
with code with code
MS4 MS4
or code or code
MS5 MS5
BA14.40-N-1037-02A AdBlue feed line to compressor Nm 20 20
541 589 00 37 00 407 589 00 63 00

Piston ring compressor pliers Cranking device
AR13.30-W-7043G Remove/install compressor drive wheel 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Box wrench
2 Drive gear
3 Screw
4 Timing case
W13.30-1076-05
Remove/install
2 Attach engine to commercial vehicle engine- Use an angle bracket.
assembly stand
4 Detach cap and install turning device on *BA01.60-N-1001-01B
timing case (4)
*BA01.60-N-1009-01B
*904589046300
6 Loosen bolt (3) in drive gear (2) using box If necessary to loosen the bolt (3),
wrench (1) reposition the box wrench (1) or turn back
the engine using the turning device.
Installation: Using the box wrench (1)
results in a changed indirect tightening
torque on the bolt (3). Torque wrench and
box wrench (1) must be positioned in an
axis.
*BA13.30-N-1002-01B
*442589000300
7 Remove timing case (4) Engine 541.9, AR01.60-W-8200GA
8 Unscrew bolt (3) in drive gear (2) Installation: Only tighten the bolt (3)
after installing the timing case (4).
9 Remove drive gear (2) on the compressor
crankshaft
Timing case

541.9, 542.9
© Daimler AG, 7/2/13, G/03/13, ar13.30-w-7043g, Remove/install compressor drive wheel Page 1 of 2
case

542.9
BA13.30-N-1002-01B Bolt, drive gear at compressor, with special (direct) Nm 360

tool
(indirect) Nm 270
442 589 00 03 00 904 589 04 63 00

Ring wrench Cranking device
© Daimler AG, 7/2/13, G/03/13, ar13.30-w-7043g, Remove/install compressor drive wheel Page 2 of 2
AR13.30-W-7041GA Remove install compressor piston and cylinder liner 8.6.10
ENGINES 541.9 in MODELS 930, 932, 933, 934 with CODE (M32) Dual compressor
ENGINES 542.9 in MODELS 930, 932, 934 with CODE (M32) Dual compressor
1 Compressor cylinder head (horizontal)

2 Compressor cylinder head (upright)
3 Cylinder liner
4 Gasket
5 Piston
6 Piston pin
7 Fuse
8 Connecting rods
W13.30-1048-12
Illustrated on engine 541.9 and vertical

compressor.
3 Cylinder liner
4 Gasket
5 Piston
6 Piston pin
7 Fuse
9.1 Piston ring compressor pliers
9.2 Piston ring compressor band
W13.30-1051-01 W13.30-1050-01
Remove/install
1 Remove cylinder head (1 or 2) Compressor, horizontal. AR13.30-W-6010GB
Compressor, vertical. AR13.30-W-6010GA
2 Remove cylinder liner (3) Installation: If the used cylinder liner (3) AR13.30-W-7041-02A
is reinstalled, observe the mark made and
rotate the cylinder liner (3) through 90°
before installing.
*BE13.30-N-1002-01B
*BE13.30-N-1003-01B
*BE13.30-N-1010-01B
*541589003700
*407589006300
3 Remove gasket (4) Installation: Replace seal (4).
4 Cover over opening at timing case to prevent small parts from falling into
the timing case.
6 Remove TDC inspection hole cap at timing *BA01.60-N-1001-01B
case
7 Attach cranking device to timing case The cranking device must be removed
before starting the engine.
*BA01.60-N-1009-01B
*407589006300
8 Rotate engine using the cranking device Until piston pin (6) is accessible.
*407589006300
© Daimler AG, 7/2/13, G/03/13, ar13.30-w-7041ga, Remove install compressor piston and cylinder liner Page 1 of 2
ENGINES 541.9 in MODELS 930, 932, 933, 934 with CODE (M32) Dual compressor ENGINES 542.9 in MODELS 930, 932, 934 with CODE (M32) Dual compressor
9 Remove fuses (7) with piston ring *541589003700
compressor pliers (9.1) or suitable pliers,
and press piston pin (6) out
10 Remove piston (5) from connecting rod (8)
11 Remove piston rings at piston (5) If necessary, replace piston rings only in AR13.30-W-5511-01A
the event of a piston ring complaint.
*BE13.30-N-1004-01B
*000589373700
Check values for compressor

541.9, 542.9
with code M32
BE13.30-N-1002-01B Cylinder liner inner dia. Marking B mm 100.000 to

100.010
Marking C mm 100.010 to
100.020
Marking D mm 100.020 to
100.030
BE13.30-N-1003-01B Piston outer dia. Marking B mm 99.925 to 99.935
Marking C mm 99.935 to 99.945
Marking D mm 99.945...99.955
BE13.30-N-1004-01B Piston ring gap Grooves I, II, III mm 0.20 to 0.40

clearance
BE13.30-N-1010-01B Cylinder liner height mm 83.8 to 84.0

from timing case
Timing case

541.9. 542.9

case
000 589 37 37 00 541 589 00 37 00 407 589 00 63 00

Pliers Piston ring compressor pliers Cranking device
© Daimler AG, 7/2/13, G/03/13, ar13.30-w-7041ga, Remove install compressor piston and cylinder liner Page 2 of 2
AR13.30-W-7042GA Remove, install compressor crankshaft and connecting rod 8.6.10
ENGINES 541.9 in MODELS 930, 932, 933, 934 with CODE (M32) Dual compressor
ENGINES 542.9 in MODELS 930, 932, 934 with CODE (M32) Dual compressor
1 Piston
2.1 Connecting rod (compressor upright)
2.2 Connecting rod (compressor
recumbent)
3 O-ring
4 Bearing flange
5 Cross plate
6 Remove fuel/power steering pump
unit
7 Crankshaft
8 Bearing flange
9 Drive gear
W13.30-1064-05
Removing
1 Remove both pistons (1) and cylinder liners AR13.30-W-7041GA
for the compressor
3 Remove intake manifold Only on engine with code (542.9 MS4) AR09.20-W-1310G
Bluetec 4 or with code (MS5) Bluetec 5.
4 Remove fuel/power steering pump unit (6) AR47.20-W-5712G
and remove cross washer (5)
5 Remove crankshaft (7) AR13.30-W-5511-02GB
*BA13.30-N-1013-01B
*442589000300
*541589036300
*407589006300
Measure
6 Check connecting rod journal of crankshaft If necessary, fit new crankshaft (7). *BE13.30-N-1006-01B
(7) and measure with an outside micrometer
7 Adjust dial indicator and quick-action probe Adjust dial indicator with approx. 5 mm *BE13.30-N-1008-01B
for internal measurements with the outside preload.
micrometer to inside diameter of the
bushings in the outer bearing flange (4)and
position dial indicator on "0"
*001589532100
8 Measure inside diameter of bushings in the If necessary install new bearing flange *BE13.30-N-1008-01B
outer bearing flange (4) using the quick- (4).
action probe for internal measurements and
dial indicator
9 Adjust dial indicator and quick-action probe Adjust dial indicator with approx. 5 mm *BE13.30-N-1013-01B
for internal measurements with the outside preload.
micrometer to inside diameter of the
bushings in the inner bearing flange (8) and
position dial indicator on "0"
10 Measure inside diameter of bushings in the *BE13.30-N-1013-01B
bearing flange (8) using the quick-action
probe for internal measurements and dial
indicator
If necessary, install new bearing flange
(8).
Remove and install bearing flange for AR13.30-W-5511-07A

compressor.
*730589031500
*000589293300
*000589343300
11 Check teeth and bracing spring in drive gear If necessary install new drive gear (9):
(9) by a visual inspection
Remove and install compressor drive gear. AR13.30-W-7043G
© Daimler AG, 7/2/13, G/03/13, ar13.30-w-7042ga, Remove, install compressor crankshaft and connecting rod Page 1 of 3
Install
12 Install crankshaft (7) AR13.30-W-5511-03GB
Crankshaft bearing clearance-axial *BE13.30-N-1007-01B
*BA13.30-N-1002-01B
*BA13.30-N-1012-01B
*BA13.30-N-1013-01B
*442589000300
*001589532100
*363589022100
*366589002105
*541589036300
Retaining device for installation of dial WF58.50-W-1330-02G
indicator holder at compressor
13 Install fuel/power steering pump unit (6) and AR47.20-W-5712G
remove cross washer (5)
14 Install intake manifold Only on engine with code (542.9 MS4) AR09.20-W-1310G
Bluetec 4 or with code (MS5) Bluetec 5.
15 Install timing case cover AR01.40-W-8000G
16 Install both pistons (1) and cylinder liners of AR13.30-W-7041GA
compressor
Check values for compressor

541.9, 542.9
with code M32
BE13.30-N-1006-01B Crankshaft connecting mm 43.959 to

rod bearing journal dia. 43.975
BE13.30-N-1007-01B Crankshaft bearing Axial mm 0.150 to 0.250

clearance
BE13.30-N-1008-01B Bearing bush/bearing Inside dia. mm 38.000 to 38.039

flange
BE13.30-N-1013-01B Bearing bushes in Inside dia. mm 37.99 to 38.05

timing case

541.9, 542.9
BA13.30-N-1002-01B Bolt, drive gear at compressor, with special (direct) Nm 360

tool
(indirect) Nm 270
BA13.30-N-1012-01B Bolt, bearing flange to timing case Nm 60
BA13.30-N-1013-01B Bolt, blocking device to Nm 40

timing case
442 589 00 03 00 730 589 03 15 00 001 589 53 21 00 363 589 02 21 00
Ring wrench Drift Dial indicator Dial indicator holder
366 589 00 21 05 000 589 29 33 00 000 589 34 33 00 407 589 00 63 00

Extension Internal puller Counter stay Cranking device
541 589 03 63 00
Blocking device
SM13.30-W-0003A Check crankshaft of compressor 8.2.12
ENGINE 541.9 in MODEL 930, 932, 933, 934
W13.30-1198-09
1 Cap 2 Crankshaft 3 Marking
Operation no. of operation texts or standard texts and flat rates

Category Op. no. Operation text Time Acc. no. Code
O 027814 OPERATION: CHECK CRANKSHAFT OF COMPRESSOR 0,4h 13 901 55 KW-LUP
O 027815 OPERATION: REPLACE CRANKSHAFT OF COMPRESSOR 5,4h 13 901 55 KW-LUP
(AFTER CHECK)
Remove
1 Tilt cab
2 Remove cap (1) at side on timing case
Checking
3 Check identification (3) on crankshaft (2) of If the identification is "A5410516" the
compressor correct crankshaft (2) is installed:
Proceed with step 5.

If the identification is "44205" an incorrect
crankshaft (2) is installed. This has to be
replaced:
Proceed with step 4.

Replace
4 Replace crankshaft (2) of compressor With regard to return shipment or AR13.30-W-7042G
scrapping of removed parts, please observe
the information in your warranty system.
Install
5 Attach end cover (1) *BA01.60-N-1003-01B
6 Lower cab
Timing case

541.9. 542.9
© Daimler AG, 7/2/13, G/03/13, sm13.30-w-0003a, Check crankshaft of compressor Page 1 of 2

ENGINE 541.9 in MODEL 930, 932, 933, 934
BA01.60-N-1003-01B Bolt, side compressor hole cover to timing case Nm 50
Parts ordering notes
Part no. Designation Quantity

QAP 602 14 05 Parts kit 1
© Daimler AG, 7/2/13, G/03/13, sm13.30-w-0003a, Check crankshaft of compressor Page 2 of 2

ENGINE 541.9 in MODEL 930, 932, 933, 934
AR14.10-W-4200G Remove/install exhaust manifold pipe 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934
1 Exhaust manifold
2 Exhaust manifold pipe (left)
3 Exhaust manifold pipe (right)
4 Exhaust manifold (left)
5 Exhaust manifold (right)
W14.10-1039-06
Remove/install
and right
4 Remove exhaust manifold pipe (2 or 3) Installation: The stamped-in arrow on
the exhaust manifold pipe (2 or 3) must point
towards the exhaust plenum chamber (1).
Install exhaust manifold pipe (2 or 3) free of
tension at the exhaust manifold (4 or 5) and
exhaust plenum chamber (1).
Engine 541.9 only. *BA14.10-N-1003-01C
*BA14.10-N-1005-01C
*BA14.10-N-1012-01C
to run at alternating rpm. Check exhaust
manifold pipe (2 or 3) for leaktightness, then
switch off engine
Exhaust manifold
© Daimler AG, 7/2/13, G/03/13, ar14.10-w-4200g, Remove/install exhaust manifold pipe Page 1 of 2
BA14.10-N-1003-01C Nut, exhaust pipe to exhaust plenum chamber Nm 50 -
BA14.10-N-1012-01C Bolt, exhaust pipe to exhaust manifold Nm 50 50
© Daimler AG, 7/2/13, G/03/13, ar14.10-w-4200g, Remove/install exhaust manifold pipe Page 2 of 2
AR14.10-W-3915GA Remove/install exhaust manifold 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934

BlueTec 5
1 Exhaust manifold
2 Exhaust manifold pipe
3 Roll pin
W14.10-1038-06
Modification notes
27.10.05 Document revised completely.
Remove/install
and right
4 Remove exhaust manifold (1) on exhaust Installation: Observe installation position
manifold pipe (2) and on cylinder heads of roll pins (3), large bore points towards the
exhaust manifold (1).
*BA14.10-N-1001-01C
*BA14.10-N-1005-01C
5 Take off gaskets Installation: Replace seals. Observe
installation position of gaskets, the lugs must
be fixed in position in the free threaded
holes in the cylinder heads.
to run at alternating rpm. Check exhaust
manifold (1) for leaktightness, then switch off
engine
Exhaust manifold
© Daimler AG, 7/2/13, G/03/13, ar14.10-w-3915ga, Remove/install exhaust manifold Page 1 of 2

BA14.10-N-1001-01C Bolt, exhaust manifold to cylinder head Nm 50 50
© Daimler AG, 7/2/13, G/03/13, ar14.10-w-3915ga, Remove/install exhaust manifold Page 2 of 2

AR14.10-W-3920G Remove/install exhaust plenum chamber 25.3.08
ENGINES 541.9 in MODEL 930, 932, 933, 934

2 Exhaust manifold
3 Screening
4 Screening
6 Bracket
7 Steering suction line
8 Steering pressure line
W14.10-1037-06
Remove, Install
1 Remove turbocharger AR09.40-W-6020GA
2 Remove exhaust manifold pipes (1 and 5) AR14.10-W-4200G
3 Detach the steering suction line (7) and Do not separate steering suction line (7)
steering pressure line (8) at the bracket (6) and steering pressure line (8).
4 Detach bracket (6) at exhaust plenum
chamber (2)
5 Remove exhaust plenum chamber (2) *BA14.10-N-1004-01C
*BA14.10-N-1009-01C
6 Remove shielding (3 and 4) at exhaust Only when replacing the exhaust
plenum chamber (2) collector (2).
*BA14.10-N-1010-01C
Exhaust manifold
BA14.10-N-1004-01C Bolt, exhaust plenum chamber to timing case M16 Nm 150
M12 Nm 100
M10 Nm 50
BA14.10-N-1009-01C Bolt, support/exhaust plenum chamber to timing Nm 40

case
BA14.10-N-1010-01C Bolt of shield to exhaust plenum chamber Nm 20
© Daimler AG, 7/2/13, G/03/13, ar14.10-w-3920g, Remove/install exhaust plenum chamber Page 1 of 1
ENGINES 541.9 in MODEL 930, 932, 933, 934
AR14.15-W-6302GA Remove/install engine brake valve fitting 22.3.11
ENGINES 541.9 in MODEL 930, 932, 933, 934
2 Engine brake cylinder
3 Engine brake valve fitting
4 Exhaust flex pipe
W14.15-1011-11
Only for vehicles with code (MS4) BlueTec 4 or with code

(MS5) BlueTec 5
3 Engine brake valve fitting

5 AdBlue injection line
6 AdBlue injection nozzle
W14.40-1165-11
Modification notes
20.12.07 Assembly notes and installed dimension for exhaust flex Operation step 6
pipe added.
Remove/install
left
brake cylinder (2)
5 Remove injection line for AdBlue (5) Only for vehicles with code (MS4) AR14.40-W-2001A
BlueTec 4 or with code (MS5) BlueTec 5.
Installation: Replace injection line for
AdBlue (5) after each removal.
6 Detach exhaust flex pipe (4) from engine
brake valve fitting (3)
© Daimler AG, 7/2/13, G/03/13, ar14.15-w-6302ga, Remove/install engine brake valve fitting Page 1 of 3
ENGINES 541.9 in MODEL 930, 932, 933, 934
*BA49.10-N-1001-01J
exhaust flex pipes
7 Remove engine brake valve fitting (3) on *BA14.10-N-1002-01C
turbocharger
8 Remove shielding on engine brake valve Only when replacing engine brake valve
fitting (3) fitting (3).
*BA14.10-N-1011-01C
Danger! Risk of burn injuries and scalding when Pour AdBlue into suitable containers only. AS14.40-Z-0001-01A
poisoning caused by swallowing AdBlue
9 Remove AdBlue injection nozzle (6) on Only on vehicles with code (MS4)
engine brake valve fitting (3) BlueTec 4 or with code (MS5) BlueTec 5 if
the engine brake valve fitting (3) is replaced.
Installation: Check contact surface on
engine brake valve fitting (3) for foreign
objects and dirt. Check AdBlue injection
nozzle (6) for dirt and damage, replace if
necessary.
*BA14.40-N-1002-02A
to run at alternating rpm. Check engine
brake valve fitting (3) and exhaust flex pipe
(4) for leaktightness, then switch off engine
12 Check function of engine brake
Exhaust manifold
BA14.10-N-1002-01C Nut, exhaust pipe engine brake valve fitting to Nm 50

turbocharger
BA14.10-N-1011-01C Bolt, shielding to exhaust pipe engine brake valve Nm 20

fitting

541.9
with code
MS4
or code
MS5
BA14.40-N-1002-02A Injection nozzle on engine brake valve fitting/ Nm 10

exhaust pipe
Exhaust system

541.9, 542.9
ENGINES 541.9 in MODEL 930, 932, 933, 934
BA49.10-N-1001-01J Clamp bolt, exhaust pipe to engine brake valve Nm 50
fitting
ENGINES 541.9 in MODEL 930, 932, 933, 934
AR14.15-W-5816G Remove/install engine brake cylinder for engine brake flap 9.3.10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934

BlueTec 5
2 Engine brake cylinder
3 Bracket
4 Ball socket
5 Ball stud
6 Fuse
W14.15-1113-06
Removing
2 Tilt cab
left
brake cylinder (2)
5 Remove securing device (6) and ball socket
(4) on ball stud (5)
6 Remove engine brake cylinder (2) on
bracket (3)
Install
7 Check ball socket (4) and ball stud (5) for *BA14.15-N-1007-01A
wear; replace if necessary
8 Fit engine brake cylinder (2) onto bracket *BA14.15-N-1004-01A
(3)
9 Adjust engine brake cylinder (2) on engine AR14.15-W-5816-01A
brake flap
Engine brake cylinder - preload *BE14.15-N-1001-01A
*BA14.15-N-1005-01A
10 Coat ball stud (5) with paste *BR00.45-Z-1005-06A
11 Clip in ball socket (4) of engine brake
cylinder (2) with preload at ball stud (5) and
install retainer (6)
Danger! Risk of injury caused by moving parts that No parts of the body or limbs should be AS00.00-Z-0009-01A
can pinch, crush or, in extreme cases, even within the operating range of the mechanism
sever extremities when moving components.
12 Check engine brake flap adjustment AR14.15-W-5815-01A
13 Attach compressed air line (1) on engine
brake cylinder (2)
14 Install soundproofing at left upper frame
© Daimler AG, 7/2/13, G/03/13, ar14.15-w-5816g, Remove/install engine brake cylinder for engine brake flap Page 1 of 2
15 Lower cab
17 Check function of engine brake
Check values for engine brake

542.9
BE14.15-N-1001-01A Engine brake cylinder - preload mm 2.5 to 3.5
Engine brake

542.9
BA14.15-N-1004-01A Nut, engine brake cylinder to bearing pin Nm 25
BA14.15-N-1005-01A Locknut to engine brake cylinder piston rod Nm 20
BA14.15-N-1007-01A Ball stud to lever Nm 50
Repair materials
BR00.45-Z-1005-06A Paste, hot lubrication 1 kg, DB supply specification 6879.20 A 000 989 76 51
© Daimler AG, 7/2/13, G/03/13, ar14.15-w-5816g, Remove/install engine brake cylinder for engine brake flap Page 2 of 2
AR15.30-W-7300C Disassembling/assembling the alternator 9.3.10
ENGINES 457.9 in MODEL 374, 375, 940, 942, 943, 944, 958
with Mitsubishi starter
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W15.30-1055-09
1 Choke housing 12 Pin 23 Sealing ring

2 Circlip 13 Release lever bearing 24 Screw
3 Stop ring 14 Cover 25 Dynamo body
4 Starter drive pinion 15 Thrust bearing 26 Carbon brushes (plus)
5 Spring 16 Seal boot 27 Carbon brush (minus)
6 Bolts 17 Solenoid switch 28 Electrical line
7 Series relay 18 Gasket 29 Carbon brush holder
8 Sealing ring 19 Cover 30 Springs
9 Bearing 20 Ball 31 Sealing ring
10 Epicyclic gear system with 21 Armature 32 Cover
overrunning clutch 21.1 Commutator 33 Bolts
11 Release lever 22 Bearing
W15.30-1056-09
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7300c, Disassembling/assembling the alternator Page 1 of 6

ENGINES 457.9 in MODEL 374, 375, 940, 942, 943, 944, 958 with Mitsubishi starter ENGINES 541.9 in MODEL 930, 932, 933, 934 with Mitsubishi starter ENGINES 542.9 in MODEL 930, 932, ...
1 Choke housing 22 Bearing M1 Starter
7 Series relay 25 Dynamo body
10 Epicyclic gear system with 26 Carbon brush (plus) Arrow A Marking
overrunning clutch 27 Carbon brush (minus) Arrow B Groove
17 Solenoid switch 29 Carbon brush holder Arrow C Instancing
19 Cover 30 Spring Arrow D Casting lugs
20 Ball 31 Sealing ring
21 Armature 32 Cover
21.1 Commutator 34 Vernier caliper
W15.30-1058-08
1 Choke housing 12 Pin 18 Gasket

10 Epicyclic gear system with 13 Release lever bearing
overrunning clutch 14 Cover Arrow E Surface
11 Release lever 15 Thrust bearing Arrow F Rounding
Disassemble/assemble
1 Remove starter (M1) Engine 457.9 AR15.30-W-7100C
Engine 541.9, 542.9 AR15.30-W-7100G
Installation: Before installing the starter
(M1), carry out a function test on a starter
testing stand if necessary.
2 Clean starter (M1)
3 Clamp the starter (M1) on the choke housing Use protective jaws.
(1) in a vise in a horizontal position
4 Detach the electrical line (28) from the Engine 457.9 *BA15.30-N-1008-01K
solenoid switch (17)
Engines 541.9, 542.9 *BA15.30-N-1009-01C
5 Detach electrical lines of the series relay (7) Engine 457.9 *BA15.30-N-1006-01K
on the solenoid switch (17)
Engine 457.9 *BA15.30-N-1007-01K
Engines 541.9, 542.9 *BA15.30-N-1007-01C
Engines 541.9, 542.9 *BA15.30-N-1008-01C
6 Detach series relay (7) at choke housing (1) Installation: Replace bolts.
Engine 457.9 *BA15.30-N-1009-01K
Engines 541.9, 542.9 *BA15.30-N-1010-01C
7 Unscrew bolts (6) on solenoid switch (17) Installation: Recut the thread of the
bolts (6) in order to remove all the remains
of the old quick-action adhesive. Apply quick-
action adhesive to the thread of the bolts (6).
Press the solenoid switch (17) into the choke
housing (1) while tightening.
Engine 457.9 *BA15.30-N-1005-01K
Engines 541.9, 542.9 *BA15.30-N-1006-01C
Quick-action adhesive *BR00.45-Z-1001-02A

8 Remove solenoid switch (17) Installation: Recut the thread for the
bolts (6) in order to remove all the remains
of the old quick-action adhesive while
reinstalling the removed solenoid switch (17).
Check the seal boot (16) on the solenoid
switch (17), replace if necessary. Thread in
the solenoid switch (17) on the release lever
(11). If necessary, pull out the starter drive
pinion (4) by hand.
9 Remove starter drive pinion (4) AR15.30-W-7302-01C
*541589076300
Engine 457.9 *BA15.30-N-1012-01K
Engines 541.9, 542.9 *BA15.30-N-1013-01C
Install starter drive pinion (4) AR15.30-W-7302-02C
*000589883300
*126589003400
*541589076300
Engine 457.9 *BA15.30-N-1012-01K
Engines 541.9, 542.9 *BA15.30-N-1013-01C
Molykote BR 2 plus grease *BR00.45-Z-1081-06A
10 Clamp the choke housing (1) in a vise in a Use protective jaws.
vertical position
11 Check the marking (arrow A) on the cover Mark (arrow A) if necessary.
(32) and dynamo body (25)
12 Unscrew bolts (33) on cover (32) Engine 457.9 *BA15.30-N-1011-01K
Engines 541.9, 542.9 *BA15.30-N-1012-01C
13 Remove bolts (24) Engine 457.9 *BA15.30-N-1010-01K
Engines 541.9, 542.9 *BA15.30-N-1011-01C
14 Remove cover (32) and seal ring (31) Loosen the cover (32) by hammering
gently with a plastic hammer if necessary.
Installation: Clean the groove (arrow B)
in the cover (32). Insert a new seal ring (31)
in the dynamo body (25). Pay attention to
the marking (arrow A) on the cover (32) to
the dynamo body (25).
15 Push the springs (30) to the side with Installation: Push the springs (30) to the
needle nose pliers and pull out the carbon side with needle nose pliers and insert the
brushes (26, 27) from the carbon brush carbon brushes (26, 27) into the guide of the
holder (29) carbon brush holder (29). Position the
springs (30) on the carbon brushes (26, 27).
16 Remove the carbon brush holder (29) with Installation: Pay attention to the
the carbon brushes (27) installation position of the carbon brush
holder (29) with respect to the cover (32).
17 Measure the length of the carbon brushes If the length is less than the minimum *BE15.30-N-1001-01B
(26, 27) with a vernier caliper (34) length, install new carbon brushes (26) with
dynamo body (25) and new carbon brushes
(27) with carbon brush holder (29).
18 Detach the dynamo body (25) and remove Installation: Place the new seal ring (23)
the seal ring (23) in the choke housing (1) or in the dynamo
body (25). Install dynamo body (25).
Pay attention to the installation position of
the electrical line (28). This must be routed
between the casting lugs (arrows D) on the
choke housing (1).
19 Lift out armature (21) Pay attention to the ball (20) in the
armature shaft or in the mount of the
epicyclic gear system with overrunning clutch
(10).
Installation: Place the ball (20) with
grease in the middle in the mount of the
(10) and insert the armature (21).
20 Check the commutator (21.1) for score In case of slight scoring, rub the *BE15.30-N-1002-01B
marks and measure the outside diameter of commutator (21.1) gently with an emery
the commutator (21.1) with a vernier caliper cloth and clean the gaps. In case of heavy
(34) scoring or if the length is less than the
minimum length, install a new starter (M1).
21 Check the bearing (22) on the armature (21) In case of a complaint:
Install a new bearing (22) on the armature AR15.30-W-7305-01C

(21).

22 Remove cap (19) Installation: Pay attention to the
installation position of the cover (19), the
instancing (arrow C) on the cover (19) must
point towards the armature (21).
23 Pull out thrust bearing (15) The thrust bearing (15) consists of two
parts.
24 Remove gasket (18) Installation: Replace seal (18). Pay
attention to the installation position of the
seal (18), the collar must be seated in the
choke housing (1).
25 Remove cover (14) Installation: Pay attention to the
installation position of the cover (14), the
surface (arrow E) must point towards the
(10) and the recess towards the release
lever bearing (13).
26 Take out the epicyclic gear system with The pin (12) in the release lever (11) can
overrunning clutch (10) along with the fall out.
release lever (11)
Installation: Grease the planetary gear
in the epicyclic gear system with overrunning
clutch (10).
27 Remove the release lever (11) on the Installation: Grease both the guide pins
epicyclic gear system with overrunning clutch on the release lever (11) and guide notch on
(10) the epicyclic gear system with overrunning
clutch (10).
The pin (12) in the release lever (11) and the
release lever bearing (13) must be installed.
The release lever bearing (13) must point
upwards. Attach the release lever (11) on
the guide notch on the epicyclic gear system
with overrunning clutch (10). The rounding
(arrow F) on the release lever (11) must
point downwards.
28 Remove the bearing (9) and seal ring (8) in Installation: Install new bearing (9) and AR15.30-W-7305-02C
the choke housing (1) seal ring (8).
*673589011500
*730589081500
*739589011500
29 Clean and remove dirt, grease and carbon
brush dust from all parts
30 Assemble in the reverse order
Test and setting values for starter

457.9 541.9, 542.9
BE15.30-N-1001-01B Minimum length of carbon brushes mm 12.0 12.0
BE15.30-N-1002-01B Commutator outside diameter, minimum mm 38,1 38,1

dimensions
Starter

457.9
BA15.30-N-1005-01K Bolt connecting solenoid switch to choke Nm 6.5

housing

BA15.30-N-1006-01K Nut connecting line to solenoid switch M12 Nm 26
terminal B
BA15.30-N-1007-01K Nut connecting line to solenoid switch M6 Nm 3.5

terminal Sf

terminal M
BA15.30-N-1009-01K Bolt connecting front-end relay to choke Nm 6.5

housing
BA15.30-N-1010-01K Bolt connecting cover and field winding Nm 12

housing to choke housing
BA15.30-N-1011-01K Bolt connecting carbon brush holder to Nm 4

cover
BA15.30-N-1012-01K Bolt, holding device to choke housing Nm 6.5
Starter

541.9, 542.9
BA15.30-N-1006-01C Bolt connecting solenoid switch to choke Nm 6.5

housing
BA15.30-N-1007-01C Nut connecting line to solenoid switch Nm 26

terminal B
BA15.30-N-1008-01C Nut connecting line to solenoid switch Nm 3.5

terminal Sf

terminal M
BA15.30-N-1010-01C Bolt connecting front-end relay to choke Nm 6.5

housing
BA15.30-N-1011-01C Bolt connecting cover and field winding Nm 12

BA15.30-N-1012-01C Bolt connecting carbon brush holder to Nm 4

cover
BA15.30-N-1013-01C Bolt, holding device to choke housing Nm 6.5
673 589 01 15 00 730 589 08 15 00 739 589 01 15 00 000 589 88 33 00

Drift Drift Drift Two-armed puller

126 589 00 34 00 541 589 07 63 00
Puller arms Holding device
Repair materials
BR00.45-Z-1001-02A Thread locking adhesive, Loctite 241 A 002 989 94 71
BR00.45-Z-1081-06A Molykote BR 2 plus grease Liqui Moly GmbH
Jerg-Wieland-Strasse 4
D-89081 Ulm-Lehr, Germany
www.liqui-moly.de

AR15.30-W-7100G Remove/install starter 15.2.12
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Electric cable circuit 30

2 Electric cable circuit 50
M1 Starter
W15.30-1016-12
Modification notes
11.3.05 Document revised completely.
Remove/install
Danger! Risk of explosion caused by escaping No fire, sparks, open flames or smoking. AS54.10-Z-0001-01A
oxyhydrogen gas. Risk of injury caused by Wear acid-resistant gloves and clothing and
caustic burns to eyes, skin and mucous safety glasses with side guards.
membranes from battery electrolyte (contains Do not place any conductive objects on the
diluted sulfuric acid) or metal spatter due to battery and avoid any short circuit from
short circuit. Risk of burn injuries caused battery positive to ground.
by short circuit. Risk of poisoning caused Only fill liquid battery electrolyte (diluted
by swallowing battery electrolyte (contains sulfuric acid) into suitable and appropriately
diluted sulfuric acid) or absorption of lead marked containers.
over the skin or orifices
2 Disconnect ground lead from battery
3 Remove soundproofing on frame below
4 Remove electrical line for circuit 30 (1) and *BA15.30-N-1002-01C
electrical line for circuit 50 (2) on starter
(M1)
*BA15.30-N-1004-01C
5 Remove starter (M1) on timing case *BA15.30-N-1001-01C
6 Inspect starter pinion and starter (M1) for Replace starter (M1) if necessary.
wear
7 Inspect ring gear of flywheel for wear If necessary:
Replace ring gear of flywheel AR03.30-W-8312G

9 Synchronize tachograph
10 Reset clock
11 code radio
Starter

541.9, 542.9
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7100g, Remove/install starter Page 1 of 2

BA15.30-N-1001-01C Nut, starter to timing case Nm 80
BA15.30-N-1002-01C Nut, line for circuit 30 to starter/solenoid Nm 30

switch
BA15.30-N-1004-01C Nut, line for clamping device 50 to Nm 2.5

front-end relay
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7100g, Remove/install starter Page 2 of 2

AR15.30-W-7305C Remove/install bearing in starter 23.10.07
ENGINES 457.9 in MODEL 374, 375, 940, 942, 943, 944, 958
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Choke housing
2 Armature
3 Commutator
4 Bearing
5 Ball
6 Cover
Arrow A Instancing
W15.30-1039-06
W15.30-1048-08
1 Choke housing 10 Epicyclic gear system with 13 Pin

7 Gasket overrunning clutch
8 Thrust bearing 11 Release lever Arrow B Surface
9 Cover 12 Release lever bearing Arrow C Rounding
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7305c, Remove/install bearing in starter Page 1 of 3

1 Choke housing
14 Bearing
15 Sealing ring
W15.30-1049-11
Removing
1 Remove starter Engine 457.9 AR15.30-W-7100C
Engine 541.9, 542.9 AR15.30-W-7100G
2 Clean starter
3 Remove solenoid switch AR15.30-W-7301C
4 Remove starter drive pinion AR15.30-W-7302C
5 Clamp the choke housing (1) in a vise in a Use protective jaws.
vertical position
6 Remove cover, carbon brushes and dynamo AR15.30-W-7304C
body
7 Lift out armature (2) Pay attention to the ball (5) in the
armature shaft or in the mount of the
(10) in the process.
8 Remove cap (6)
9 Pull out thrust bearing (8) The thrust bearing (8) consists of two
parts.
10 Remove gasket (7)
11 Remove cover (9)
12 Take out the epicyclic gear system with The pin (13) in the release lever (11) can
overrunning clutch (10) along with the fall out.
release lever (11)
13 Remove the release lever (11) on the
(10)
14 Remove choke housing (1)
16 Remove bearing (4) on armature (2) Use pulling device and separator. AR15.30-W-7305-01C
17 Remove seal ring (15) and bearing (14) in AR15.30-W-7305-02C
the choke housing (1)
*673589011500
Install
18 Install new seal ring (15) and new bearing AR15.30-W-7305-02C
(14) in the choke housing (1)
*730589081500
*739589011500
19 Press new bearing (4) on to the armature AR15.30-W-7305-01C
(2)
20 Attach the release lever (11) in the guide Grease both the guide pins on the
notch on the epicyclic gear system with release lever (11) and the guide on the
overrunning clutch (10). epicyclic gear system with overrunning clutch
(10).
The pin (13) in the release lever (11) and the
release lever bearing (12) must be installed.
The release lever bearing (12) must point
upwards. The rounding
(arrow C) on the release lever (11) must
point downwards.
21 Insert the epicyclic gear system with Grease epicyclic gear system with
overrunning clutch (10) together with the overrunning clutch (10).
release lever (11) into the choke housing (1)
22 Install cover (9) Pay attention to the installation position
of the cover (9), the surface (arrow B) must
point towards the epicyclic gear system with
overrunning clutch (10) and the recess
towards the release lever bearing (12).
23 Install new gasket (7) Pay attention to the installation position of
the seal (7), the collar must be seated in the
choke housing (1).
24 Press in the thrust bearing (8) The thrust bearing (8) consists of two
parts.
25 Place cover (6) Pay attention to the installation position
of the cover (6), the instancing (arrow A) on
the cover (6) must point towards the
armature (2).
26 Place the ball (5) of the armature shaft in Fix the ball (5) with grease in the middle
the middle in the mount of the epicyclic gear in the epicyclic gear system with overrunning
system with overrunning clutch (10). clutch (10).
27 Insert armature (2)
28 Install dynamo body, carbon brushes and AR15.30-W-7304C
cover
29 Remove choke housing (1) from the vise
30 Install starter drive pinion AR15.30-W-7302C
31 Install solenoid switch AR15.30-W-7301C
32 Install starter Engine 457.9 AR15.30-W-7100C
Engine 541.9, 542.9 AR15.30-W-7100G
673 589 01 15 00 730 589 08 15 00 739 589 01 15 00

Drift Drift Drift
Repair materials

www.liqui-moly.de

AR15.30-W-7302C Remove/install starter drive pinion 23.10.07
ENGINES 457.9 in MODEL 374, 375, 940, 942, 943, 944, 958
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
Removing
1 Remove starter Engine 457.9 AR15.30-W-7100C
Engine 541.9, 542.9 AR15.30-W-7100G
2 Clean starter
3 Clamp starter in a vise in a horizontal Use protective jaws.
position
4 Remove solenoid switch AR15.30-W-7301C
5 Remove starter drive pinion AR15.30-W-7302-01C
Engine 457.9 *BA15.30-N-1012-01K
Engines 541.9, 542.9 *BA15.30-N-1013-01C
*541589076300
Install
7 Install starter drive pinion AR15.30-W-7302-02C
Engine 457.9 *BA15.30-N-1012-01K
Engines 541.9, 542.9 *BA15.30-N-1013-01C
*000589883300
*126589003400
*541589076300
8 Install solenoid switch AR15.30-W-7301C
9 Remove choke housing from the vise
10 Carry out a function test on a starter testing
stand if necessary
11 Install starter Engine 457.9 AR15.30-W-7100C
Engine 541.9, 542.9 AR15.30-W-7100G
Starter

457.9
BA15.30-N-1012-01K Bolt, holding device to choke housing Nm 6.5
Starter

541.9, 542.9
BA15.30-N-1013-01C Bolt, holding device to choke housing Nm 6.5
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7302c, Remove/install starter drive pinion Page 1 of 2
000 589 88 33 00 126 589 00 34 00 541 589 07 63 00
Two-armed puller Puller arms Holding device
Repair materials
www.liqui-moly.de
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7302c, Remove/install starter drive pinion Page 2 of 2
AR15.30-W-7303G Remove/install series relay 23.10.07
ENGINES 457.9 in MODEL 374, 375, 940, 942, 943, 944, 958
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Series relay
2 Electrical line
3 Electrical line
4 Solenoid switch
M1 Starter
W15.30-1033-06
Remove/install
Engine 541.9, 542.9 AR15.30-W-7100G
3 Detach electrical lines (2, 3) from solenoid Engine 457.9 *BA15.30-N-1006-01K
switch (4)
Engine 457.9 *BA15.30-N-1007-01K
Engines 541.9, 542.9 *BA15.30-N-1007-01C
Engines 541.9, 542.9 *BA15.30-N-1008-01C
4 Detach series relay (1) at the choke housing Installation: Replace bolts.
Engine 457.9 *BA15.30-N-1009-01K
Engines 541.9, 542.9 *BA15.30-N-1010-01C
Starter

457.9

terminal B

terminal Sf
BA15.30-N-1009-01K Bolt connecting front-end relay to choke Nm 6.5

housing
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7303g, Remove/install series relay Page 1 of 2

Starter

541.9, 542.9

terminal B

terminal Sf
BA15.30-N-1010-01C Bolt connecting front-end relay to choke Nm 6.5

housing
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7303g, Remove/install series relay Page 2 of 2

AR15.30-W-7301C Remove/install solenoid switch 9.3.10
ENGINES 457.9 in MODEL 374, 375, 940, 942, 943, 944, 958
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W15.30-1031-09
1 Solenoid switch 4 Electrical line M1 Starter

2 Screw 5 Electrical line
3 Starter drive pinion 6 Electrical line
1 Solenoid switch
7 Release lever
8 Seal boot
W15.30-1032-04
Remove/install
Engine 541.9, 542.9 AR15.30-W-7100G
3 Clamp starter (M1) located in a vise Use protective jaws.
4 Detach electrical line (6) from solenoid switch Engine 457.9 *BA15.30-N-1008-01K
(1)
Engines 541.9, 542.9 *BA15.30-N-1009-01C
5 Detach electrical lines (4, 5) from solenoid Engine 457.9:
switch (1)
*BA15.30-N-1006-01K
*BA15.30-N-1007-01K
Engine 541.9, 542.9
*BA15.30-N-1007-01C
*BA15.30-N-1008-01C
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7301c, Remove/install solenoid switch Page 1 of 2

6 Remove bolts (2) Installation: Recut thread on the bolts
(2) in order to remove all the remains of the
old adhesive. Coat thread on the bolts (2)
with adhesive. Press in the solenoid switch
(1) when bolting securely in the housing.
Engine 457.9 *BA15.30-N-1005-01K
Engines 541.9, 542.9 *BA15.30-N-1006-01C
Adhesive *BR00.45-Z-1001-02A
7 Remove solenoid switch (1) Installation: When installing the solenoid
switch (1) which has been removed recut the
thread for the bolts (2) in order to remove all
the remains of the old adhesive. Check seal
boot (8) on solenoid switch (1), replace if
necessary. Thread in the solenoid switch (1)
on the release lever (7), if necessary pull out
the starter drive pinion (3) by hand.
Starter

457.9
BA15.30-N-1005-01K Bolt connecting solenoid switch to choke Nm 6.5

housing

terminal B

terminal Sf

terminal M
Starter

541.9, 542.9
BA15.30-N-1006-01C Bolt connecting solenoid switch to choke Nm 6.5

housing

terminal B

terminal Sf

terminal M
Repair materials
BR00.45-Z-1001-02A Thread locking adhesive, Loctite 241 A 002 989 94 71
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7301c, Remove/install solenoid switch Page 2 of 2

AR15.30-W-7304C Remove/install carbon brush 15.1.10
ENGINES 457.9 in MODEL 374, 375, 940, 942, 943, 944, 958
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W15.30-1040-09
1 Solenoid switch 7 Carbon brush (plus) 13 Electrical line

2 Cover 8 Carbon brush (minus)
3 Screw 9 Spring M1 Starter
4 Screw 10 Sealing ring
5 Dynamo body 11 Commutator Arrow A Marking
6 Carbon brush holder 12 Vernier caliper Arrow B Casting lugs
2 Cover
11 Commutator
12 Vernier caliper
14 Armature
15 Bearing
16 Ball
17 Epicyclic gear system with overrunning clutch
Arrow C Groove
W15.30-1047-12
Removing
Engine 541.9, 542.9 AR15.30-W-7100G
© Daimler AG, 7/2/13, G/03/13, ar15.30-w-7304c, Remove/install carbon brush Page 1 of 3
3 Clamp starter (M1) in a vise in a vertical Use protective jaws.
position
4 Check the marking (arrow A) on the cover Mark (arrow A) if necessary.
(2) and dynamo body (5)
5 Unscrew bolts (4) on the cover (2)
6 Remove bolts (3)
7 Take off cover (2) Loosen the cover (2) by hammering
gently with a plastic hammer if necessary.
8 Clean the groove (arrow C) in the cover (2)
9 Push the springs (9) to the side with needle
nose pliers and pull out the carbon brushes
(7, 8) from the carbon brush holder (6)
10 Remove the carbon brush holder (6) with the
carbon brushes (8)
11 Measure the length of the carbon brushes (7, If the length is less than the minimum *BE15.30-N-1001-01B
8) with a vernier caliper (12) length, a new carbon brush holder (6) with
carbon brushes (7, 8) and dynamo body (5)
must be installed.
12 Detach electrical line (13) from solenoid
switch (1)
13 Detach the dynamo body (5) and remove
seal rings (10)
14 Check the commutator (11) for score marks In case of slight scoring, rub the *BE15.30-N-1002-01B
and measure the outside diameter of the commutator (11) gently with an emery cloth
commutator (11) with a vernier caliper (12) and clean the gaps.
In case of heavy scoring and if the length is
less than the minimum length, install a new
starter (M1).
15 Check bearing (15) at the armature (14) for Remove the armature (14) before AR15.30-W-7305-01C
damage, install new if necessary installing a new bearing (15). Pay attention
to the ball (16) in the armature shaft or in
the mount of the epicyclic gear system with
overrunning clutch (17) while removing the
armature (14).
brush dust from all removed parts
Install
17 Place the ball (16) of the armature shaft in Only if the armature (14) has been
the middle in the mount of the epicyclic gear removed.
system with overrunning clutch (17). Fix the ball (16) with grease in the epicyclic
gear system with overrunning clutch (17).
18 Insert armature (14) Only if the armature (14) has been
removed.
19 Place the new lower seal ring (10) in the
choke housing or in the dynamo body (5).
20 Install dynamo body (5). Play attention to the installation position
of the electrical line (13). This must be
routed between the casting lugs (arrows B)
on the choke housing .
21 Place the carbon brush holder (6) with the Pay attention to the installation position
carbon brushes (8) of the carbon brush holder (6) with respect
to the cover (2).
22 Push the springs (9) to the side with needle The carbon brushes (8) must lie against
nose pliers and install the carbon brushes (8) the commutator (11).
in the guide in the carbon brush holder (6)
23 Push the springs (9) to the side with needle The carbon brushes (7) must lie against
nose pliers and install the carbon brushes (7) the commutator (11).
in the guide in the carbon brush holder (6)
24 Insert a new upper seal ring (10) in the
dynamo body (5).
25 Install cap (2) Pay attention to the marking (arrow A) on
the cover (2) to the dynamo body (5).
26 Tighten bolts (4) on the cover (2) for the Engine 457.9 *BA15.30-N-1011-01K
carbon brush holder (6)
Engine 541.9, 542.9 *BA15.30-N-1012-01C
27 Tighten screws (3) Engine 457.9 *BA15.30-N-1010-01K
Engine 541.9, 542.9 *BA15.30-N-1011-01C
28 Tighten electrical line (13) at the solenoid Engine 457.9 *BA15.30-N-1008-01K
switch (1)
Engine 541.9, 542.9 *BA15.30-N-1009-01C
29 Remove starter (M1) from the vise
30 Carry out a function test on a starter testing
stand if necessary
31 Install starter (M1) Engine 457.9 AR15.30-W-7100C
Engine 541.9, 542.9 AR15.30-W-7100G
Test and setting values for starter

457.9 541.9, 542.9
BE15.30-N-1001-01B Minimum length of carbon brushes mm 12,0 12,0
BE15.30-N-1002-01B Commutator outside diameter, minimum mm 38,1 38,1

dimensions
Starter

457.9

terminal M
BA15.30-N-1010-01K Bolt connecting cover and field winding Nm 12

BA15.30-N-1011-01K Bolt connecting carbon brush holder to Nm 4

cover
Starter

541.9, 542.9

terminal M
BA15.30-N-1011-01C Bolt connecting cover and field winding Nm 12

BA15.30-N-1012-01C Bolt connecting carbon brush holder to Nm 4

cover
Repair materials
www.liqui-moly.de

AR15.40-W-5033G Disassemble, assemble alternator 12.9.11
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W15.40-1064-09
1 Alternator cover 6 Screw 11 Drive bearing

2 Governor 7 Belt pulley 12 Drive bearing-retainer plate
3 Screw 8 Nut 13 Rotor
4 Alternator housing 9 Drive bearing housing 14 Centrifugal separator
5 Fitting ring 10 Spacer washer 15 Slip ring bearing
Modification notes
31.8.11 Information on self-locking bolts and nuts, added. AH00.00-N-0001-01A
Disassemble/assemble
1 Remove alternator AR15.40-W-5032G
2 Take off belt pulley (7) Counterhold rotor shaft with socket
wrench and unscrew nut (8)
*BA15.40-N-1002-01C
3 Mark drive bearing housing (9) to stator Installation: Attach markings congruently
frame (4) to one another
4 Detach alternator cover (1) at alternator *BA15.40-N-1006-01C
housing (4)
*BA15.40-N-1014-01C
5 Detach governor (2) at alternator housing (4) *BA15.40-N-1007-01C
6 Detach drive bearing housing (9) from *BA15.40-N-1005-01C
alternator housing (4)
7 Pull drive bearing housing (9) with the rotor To do so, loosen drive bearing housing
(13) out of the alternator housing (4) (9) with light blows of a rubber hammer from
the alternator housing (4).
8 Detach drive bearing housing (9) from the *BA15.40-N-1008-01C
drive bearing-retainer plate (12) by
unscrewing the bolts (6)
9 Remove rotor (13) with the drive bearing (11) To do so, slacken the rotor (13) with light
and slip ring bearing (15) out of the drive blows of a rubber hammer from the
bearing housing (9) alternator housing (9).
10 Check diameter of slip rings on the rotor If the slip rings are below the minimum *BE15.40-N-1002-02B
shaft value:
Replace alternator.
11 Check length of carbon brushes on regulator If the carbon brushes are below the AR15.40-W-5033-02A
minimum value:
Replace the regulator

© Daimler AG, 7/2/13, G/03/13, ar15.40-w-5033g, Disassemble, assemble alternator Page 1 of 2
*BE15.40-N-1001-02B
12 Remove fitting ring (5) Ensure fitting ring (5) is correctly seated.
13 Detach drive bearing (11) and slip ring Installation: Replace centrifugal AR15.40-W-5033-01A
bearing (15) from rotor (13) separator (14).
*000589883300
*126589003400
14 Assemble in the reverse order
Check values for regulator

541.9, 542.9 as
of end no.
177214
BE15.40-N-1001-02B Length of carbon brushes mm 5.0
BE15.40-N-1002-02B Diameter of slip ring mm 14,4
Alternator

541.9, 542.9
as of end no.
177214
BA15.40-N-1002-01C Nut, belt pulley to alternator M16 1.5 Nm 90
BA15.40-N-1005-01C Bolt, drive bearing housing to alternator Nm 5

housing
BA15.40-N-1006-01C Bolt, cover to alternator housing Nm 4
BA15.40-N-1007-01C Bolt, regulator to alternator housing M4 13 Nm 2
M4 19 Nm 3
BA15.40-N-1008-01C Drive bearing housing on drive bearing Nm 2

retainer plate
BA15.40-N-1014-01C Nut, cover to terminal B1+ and B2+ for Nm 15

alternator
000 589 88 33 00 126 589 00 34 00

Two-armed puller Puller arms
© Daimler AG, 7/2/13, G/03/13, ar15.40-w-5033g, Disassemble, assemble alternator Page 2 of 2

AR15.40-W-5032G Remove/install alternator 12.9.11
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W15.40-1068-09
1 Connector 4 Ground cable 7 Coolant line

2 Electrical line 5 Poly-V belt
3 Carrier 6 Belt pulley G2 Alternator
3.1 Socket
Modification notes
Remove/install
1 Disconnect ground line of battery AR54.10-W-0003A
3 Release tension on poly-V belt (5) of Installation: Inspect condition of poly-V
alternator (G2) and remove belt pulley (6) belt (5), replace if necessary.
Damage profiles for poly-V belt. AP13.22-D-1351-01A
4 Disconnect ground line (4) on alternator (G2) *BA15.40-N-1009-01C
5 Remove cable tie and disconnect electrical *BA15.40-N-1013-01C
line (2) on alternator (G2)
6 Remove cable ties, unlock plug (1) with Installation: In addition secure safety
retaining bracket and pull out of alternator clamp with a cable tie.
(G2)
7 Detach alternator (G2) on carrier (3) and Press coolant line (7) to cooler.
remove downwards.
Installation: Check alternator (G2) belt
pulley (6) for damage and concentricity;:
Replace belt pulley (6). Also counterhold

alternator shaft using a socket wrench.
*BA15.40-N-1002-01C
Turn back bush (3.1) in carrier (3) and insert
alternator (G2).
*BA15.40-N-1001-01C
© Daimler AG, 7/2/13, G/03/13, ar15.40-w-5032g, Remove/install alternator Page 1 of 2

Alternator

541.9, 542.9
as of end no.
177214
BA15.40-N-1001-01C Bolt/nut connecting alternator to carrier M10 Nm 50
M12 Nm 80
BA15.40-N-1009-01C Bolt, ground line to alternator Nm 12
BA15.40-N-1013-01C Nut, electrical line to alternator terminal B2+ Nm 30
© Daimler AG, 7/2/13, G/03/13, ar15.40-w-5032g, Remove/install alternator Page 2 of 2

AR15.40-W-5760G Remove/install regulator for alternator 14.2.12
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
W15.40-1070-08
1 Connector 5 Circuit B2+ nut 8 Governor

2 Electrical line 6 Bolt
3 Cover 7 Bolt G2 alternator
4 Circuit B1+ nut
Modification notes
16.6.11 Value modified: Nut, cover to terminal B1+ and B2+ for *BA15.40-N-1014-01C
alternator
Remove/install
Danger! Risk of explosion caused by escaping No fire, sparks, open flames or smoking. AS54.10-Z-0001-01A
oxyhydrogen gas. Risk of injury caused by Wear acid-resistant gloves and clothing and
caustic burns to eyes, skin and mucous safety glasses with side guards.
membranes from battery electrolyte (contains Do not place any conductive objects on the
diluted sulfuric acid) or metal spatter due to battery and avoid any short circuit from
short circuit. Risk of burn injuries caused battery positive to ground.
by short circuit. Risk of poisoning caused Only fill liquid battery electrolyte (diluted
by swallowing battery electrolyte (contains sulfuric acid) into suitable and appropriately
diluted sulfuric acid) or absorption of lead marked containers.
over the skin or orifices
2 Disconnect ground line of battery
3 Remove bottom soundproofing
4 Remove cable tie and disconnect electrical *BA15.40-N-1013-01C
line (2) on alternator (G2)
5 Remove cable tie, unlock plug (1) with circlip Installation: In addition secure safety
and pull out at alternator (G2) clamp with a cable tie.
6 Remove bolt (6), circuit B1+ (4) nut and *BA15.40-N-1006-01C
circuit B2+ (5) nut as well as cover (3) on
alternator (G2)
*BA15.40-N-1014-01C
7 Unscrew bolts (7) and remove regulator (8) Installation: Check both slip rings in the
alternator (G2) for score marks, if necessary:
Replace alternator (G2). AR15.40-W-5032G

Check length of carbon brushes of the AR15.40-W-5033-02A
regulator (8), replace regulator (8) if
necessary.
*BE15.40-N-1001-02B
*BA15.40-N-1007-01C
9 Synchronize tachograph
10 Reset clock
11 Code radio
© Daimler AG, 7/2/13, G/03/13, ar15.40-w-5760g, Remove/install regulator for alternator Page 1 of 2
Check values for regulator

541.9, 542.9 as
of end no.
177214
BE15.40-N-1001-02B Length of carbon brushes mm 5.0
Alternator

541.9, 542.9
as of end no.
177214
BA15.40-N-1006-01C Bolt, cover to alternator housing Nm 4
BA15.40-N-1007-01C Bolt, regulator to alternator housing M4 13 Nm 2
M4 19 Nm 3
BA15.40-N-1013-01C Nut, electrical line to alternator terminal B2+ Nm 30
BA15.40-N-1014-01C Nut, cover to terminal B1+ and B2+ for Nm 15

alternator
© Daimler AG, 7/2/13, G/03/13, ar15.40-w-5760g, Remove/install regulator for alternator Page 2 of 2
AR15.40-W-5710G Remove/install alternator belt pulley 12.9.11
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Poly-V belt
2 Belt pulley
G2 Alternator
W15.40-1074-11
Modification notes
Remove/install
2 Release tension on poly-V belt (1) and Installation: Inspect condition of poly-V
remove on belt pulley (2) for alternator (G2) belt (1), replace if necessary.
Damage profiles for poly-V belt. AP13.22-D-1351-01A
3 Remove nut at the belt pulley (2); remove Also counterhold alternator shaft using a
belt pulley (2) on alternator (G2) socket wrench.
*BA15.40-N-1002-01C
Alternator

541.9, 542.9
as of end no.
177214
© Daimler AG, 7/2/13, G/03/13, ar15.40-w-5710g, Remove/install alternator belt pulley Page 1 of 1
AR15.40-W-6232G Remove/install alternator support 12.10.10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Alternator support
2 Bracket
3 Engine wiring harness
4 Poly-V belt tensioning device
G2 Generator
W15.40-1046-06
5 Support for A/C compressor (only for code (H03) A/C in

front end)
6 Bracket
W15.40-1047-11
Remove/install
2 Remove support for A/C compressor (5) on Only on vehicles with code (H03) air
alternator carrier (1) conditioning in front end.
*BA83.55-N-1002-01C
3 Remove bracket (6) with transmission oil Do not separate transmission oil lines.
lines on alternator carrier (1)
4 Remove engine wiring harness (3) on
alternator carrier (1)
5 Remove bracket (2) for engine wiring *BA01.40-N-1010-01D
harness (3) and alternator carrier (1)
6 Remove poly-V belt tensioning device (4) Only when alternator carrier (1) is AR13.25-W-3200G
replaced.
© Daimler AG, 7/2/13, G/03/13, ar15.40-w-6232g, Remove/install alternator support Page 1 of 2

541.9. 542.9
BA01.40-N-1010-01D Bolt for ALT/poly-V belt tensioning device support to Nm 160

crankcase
Refrigerant compressor

930, 932, 933, 934,
950.0, 950.1, 950.2,
950.3, 952.0, 952.1,
952.2, 952.3, 953.1,
953.3, 954.0, 954.1,
954.2
BA83.55-N-1002-01C Support on fixture for refrigerant Nm 50

compressor/frigoblock and alternator
support
© Daimler AG, 7/2/13, G/03/13, ar15.40-w-6232g, Remove/install alternator support Page 2 of 2

AR18.00-W-4000G Remove/install oil spray nozzles (pistons) 31.7.07
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Oil spray nozzle
W18.00-1023-06
Modification notes
10.6.07 Unfasten/fasten clamps for transmission oil lines on Steps 2 and 12

timing case - added.
Turning device altered. Step 4 *904589046300
Oil spray nozzles for piston crown cooling altered - Step 8 BT18.00-W-0001-01G
added.
Removing
2 Unfasten clamps for transmission oil lines on Only on vehicles with code (N55)
timing case Transmission oil cooling.
3 Take off end cover at timing case
*904589046300
5 Rotate crankshaft with turning device until
the oil spray nozzle to be removed (1) is
accessible.
6 Unscrew banjo bolt and remove oil spray
nozzle (1)
Checking
7 Check oil splasher pipe and dowel pin on oil The oil spray nozzle (1) must not be
spray nozzle (1) by means of a visual damaged and the oil splasher pipe must not
inspection be bent or clogged. The piston crown will not
be adequately cooled from below otherwise.
This can lead to heat damage on the piston
or a piston jamming.
Install
8 Install oil spray nozzle (1) and screw tight The dowel pin at the oil spray nozzle (1)
with banjo bolt must engage in the hole in the crankcase.
*BA18.00-N-1001-01C
Oil spray nozzles for piston crown cooling As of engine end no. 447672. BT18.00-W-0001-01G
altered
9 Turn crankshaft with turning device until
other oil spray nozzles (1) can be installed
11 Install cap at timing case *BA01.60-N-1001-01B
12 Fasten clamps for transmission oil lines on Only on vehicles with code (N55)
timing case Transmission oil cooling.
13 Installing oil pan AR01.45-W-7500G
© Daimler AG, 7/2/13, G/03/13, ar18.00-w-4000g, Remove/install oil spray nozzles (pistons) Page 1 of 2
Timing case

541.9, 542.9

case
Engine lubrication, engine oil cooling general

542.9
BA18.00-N-1001-01C Bolt, oil-spray nozzle at crankcase Nm 25
904 589 04 63 00
Cranking device
© Daimler AG, 7/2/13, G/03/13, ar18.00-w-4000g, Remove/install oil spray nozzles (pistons) Page 2 of 2
AR18.10-W-6030G Disassembling/assembling the oil pump 11.11.04
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Cover
2 Driven oil pump gear
3 Driving oil pump gear
4 Oil pump housing
5 Drive gear
6 Remover
7 Block
8 Drift
9 Depth gauge
A Setback of drive gear to drive shaft
W18.10-1017-06
Measuring
1 Remove oil pump AR18.10-W-6020G
2 Measure axial play of driven oil pump gear AR18.10-W-6030-01G
(2) and driving oil pump gear (3)
*BE18.10-N-1002-01A
*001589532100
*363589022100
3 Remove cover (1) Do not damage the sealing surface.
4 Measure gear backlash of driven oil pump AR18.10-W-6030-02G
gear (2) and driving oil pump gear (3)
*BE18.10-N-1003-01A
*BA18.10-N-1004-01C
*WH58.30-Z-1004-12A
Disassembling
5 Remove driven oil pump gear (2) from oil
pump housing (4)
6 Lead fitting drift (8) through the bearing bore
on the removed driven oil pump gear (2) into
the oil pump housing (4) and place drive
wheel (5) in place
7 Place fitting block (7) on the other side of The drift (8) and block (7) must be at
the drive wheel (5) the same height otherwise the drive wheel
(5) will be damaged.
8 Press out the driving oil pump gear (3) from Heat up the drive wheel (5) if necessary.
the drive wheel (5) using a fitting pressing-
out drift (6)
*WH58.30-Z-1002-28A
9 Check driven oil pump gear(2), driving oil Replace oil pump if necessary.
pump gear(3), inside area of the oil pump
housing (4) and cover (1) for wear
Assembling
10 Insert driving oil pump gear (3) into the oil
pump housing (4)
11 Press the drive wheel (5) onto the axle shaft Measure setback of the drive wheel (5) *BE18.10-N-1004-01A
for the driving oil pump gear(3) until the to the axle shaft (A) with a depth gage.
setback of the drive wheel (5) to the axle
shaft (A) is achieved
*WE58.40-Z-1002-19A
12 Insert driven oil pump gear (2) into the oil
pump housing (4)
© Daimler AG, 7/2/13, G/03/13, ar18.10-w-6030g, Disassembling/assembling the oil pump Page 1 of 2
13 Measure gear backlash of driven oil pump AR18.10-W-6030-02G
gear (2) and driving oil pump gear (3)
*BE18.10-N-1003-01A
*BA18.10-N-1004-01C
*WH58.30-Z-1004-12A
14 Screw cover (1) tight *BA18.10-N-1004-01C
Checking
15 Check whether the driven oil pump gear (2)
and the driving oil pump gear (3) can be
turned by turning the drive wheel (5)
16 Install oil pump AR18.10-W-6020G
Inspection data of oil pump
Number Designation Engine 541.9.

542.9
BE18.10-N-1002-01A End play of oil pump gear - oil pump housing mm 0.050...0.128
BE18.10-N-1003-01A Backlash of oil pump gears mm 0.312...0.476
BE18.10-N-1004-01A Setback of drive shaft to drive gear mm 0.5
Oil pump
Number Designation Engines 541.9.

542.9
BA18.10-N-1004-01C Bolt for cover on oil pump Nm 25
001 589 53 21 00 363 589 02 21 00

Dial indicator Dial indicator holder

Number Designation
WH58.30-Z-1004-12A Feeler gauge
WH58.30-Z-1002-28A Heating plate
Workshop equipment
WE58.40-Z-1002-19A Depth gage
© Daimler AG, 7/2/13, G/03/13, ar18.10-w-6030g, Disassembling/assembling the oil pump Page 2 of 2
AR18.10-W-6020G Removing/installing the oil pump 21.2.03
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODELS 930, 932, 934
Shown on ENGINE 542.9
1 Bracket
2 Bracket
3 Oil inlet pipe
4 Transmission oil pump
W18.10-1016-11
Removing/installing
2 Remove both brackets (1, 2) for oil suction Installation: Release both brackets
pipe (3) on crankcase (1, 2) on oil suction pipe (3) as required,
align and tighten up again.
*BA18.10-N-1002-01C
*BA18.10-N-1005-01C
3 Remove oil suction pipe (3) on the oil pump Installation: Install new gasket
(4)
*BA18.10-N-1001-01C
4 Remove oil pressure relief valve (5) on the Collect engine oil which flows out.
oil pump (4)
*BA18.10-N-1003-01C
5 Remove oil pump (4) from crankcase Collect engine oil which flows out.
*BA18.10-N-1003-01C
Checking
6 Check oil pump (4) for wear Also disassemble the oil pump (4), only
in the case of the complaint that the engine
oil pressure is too low:
Disassembling and assembling the oil pump AR18.10-W-6030G

(4).
7 Check oil pressure relief valve (5) for chips, Do not disassemble oil pressure relief
foreign matter, piston for easy movement valve (5). In the event of complaint replace
and the spring tension of the spring oil pressure relief valve (5).
8 Clean sealing surfaces with a lint free rag
Oil pump

542.9
BA18.10-N-1001-01C Bolt for intake manifold on oil pump Nm 25
BA18.10-N-1002-01C Bolt for bracket of oil pump suction pipe on M8 Nm 25

crankcase
M12 Nm 80
© Daimler AG, 7/2/13, G/03/13, ar18.10-w-6020g, Removing/installing the oil pump Page 1 of 2
ENGINE 541.9 in MODELS 930, 932, 933, 934 ENGINE 542.9 in MODELS 930, 932, 934
BA18.10-N-1003-01C Bolt for oil pump and pressure relief valve on Nm 35
crankcase
BA18.10-N-1005-01C Bolt for bracket on oil pump suction pipe Nm 35
© Daimler AG, 7/2/13, G/03/13, ar18.10-w-6020g, Removing/installing the oil pump Page 2 of 2
ENGINE 541.9 in MODELS 930, 932, 933, 934 ENGINE 542.9 in MODELS 930, 932, 934
AR18.10-W-5031G Removing/installing the oil pressure relief valve 31.1.03
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
W18.10-1015-11
Removing/installing
2 Remove oil pressure relief valve (1) Collect engine oil which flows out.
Do not disassemble oil pressure relief valve
(1). In the event of complaint replace oil
pressure relief valve (1).
*BA18.10-N-1003-01C
3 Clean sealing surfaces with a lint free rag
4 Check oil pressure relief valve (1) for chips, Do not disassemble oil pressure relief
foreign matter, piston for easy movement valve (1). In the event of complaint replace
and the spring tension of the spring oil pressure relief valve (1).
Oil pump

542.9
BA18.10-N-1003-01C Bolt for oil pump and pressure relief valve on Nm 35

crankcase
© Daimler AG, 7/2/13, G/03/13, ar18.10-w-5031g, Removing/installing the oil pressure relief valve Page 1 of 1
AR18.20-W-3471G Remove/install oil filter housing 19.12.11
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W18.20-1030-09
1 Oil filter housing 5 Bracket 11 Fuel lines

2 Threaded pin (only on engine 541.9 6 Oil filter cover 12 Fuel pipe
up to engine end no. 311843 and 7 Sealing ring
engine 542.9 up to engine end no. 8 Oil filter element B11 Engine oil temperature sensor
313192) 9 Gasket B12 Oil pressure sensor
3 Engine wiring harness 10 Fuel filter B65 Coolant temperature sensor
4 Coolant hose
1 Oil filter housing
Arrow: Screw
W18.20-1031-11
Modification notes

Dimensions of assembly pins changed. Step 17 WF58.50-W-1820-01A
Remove/install
and safety glasses.
© Daimler AG, 7/2/13, G/03/13, ar18.20-w-3471g, Remove/install oil filter housing Page 1 of 5
3 Remove poly-V belt tensioning device for Only for code (ML3) High-speed fan drive AR13.25-W-3201G
high-speed fan drive with belt drive.
4 Slacken alternator poly-V belt and take it off Installation: Check alternator poly-V belt
the belt pulley for condition, replace if necessary.
Damage profiles for a poly-V belt AP13.22-D-1351-01A
5 Remove coolant thermostat AR20.10-W-2460G
6 Remove coolant hose (4) at oil filter housing Collect coolant that flows out
(1)
7 Unscrew oil filter cab (6) together with oil While removing the engine oil runs from
filter element (8) the oil filter housing (1) back into the oil pan.
*BA18.20-N-1001-01C
8 Disconnect engine wiring harness (3) on oil
pressure sensor (B12), engine oil
temperature sensor (B11) and coolant
temperature sensor (B65)
9 Remove fan shroud bracket on the upper left Only on vehicles with code (M58) Fan of
higher output and with code (MZ3)
Electromagnetic viscous coupling for fan.
*BA20.40-N-1015-01C
*BA20.40-N-1016-01C
10 Detach electrical engine wiring harness (3)
at oil filter housing (1)
11 Remove threaded bolt (2) on oil filter Only on engine 541.9 up to engine end
housing (1) no. 311843 and on engine 542.9 up to
engine end no. 313192
*BA09.41-N-1008-01C
12 Detach bracket (5) of fuel lines (11) at oil *BA47.25-N-1009-01B
filter housing (1)
13 Detach bracket (5) of fuel lines (11) at *BA47.25-N-1010-01B
cylinder crankcase
14 Remove fuel line (12) below on oil filter Do not disconnect fuel line (12).
housing (1)
*BA47.25-N-1009-01B
15 Remove fuel filter (10) on oil filter housing Do not disconnect fuel lines (11).
(1)
*BA47.20-N-1001-02C
16 Pull out oil filter cap (6) together with oil Installation: Replace seal (7). Inspect oil
filter element (8) filter element (8) for damage and
contamination, replace oil filter element (8) if
necessary.
17 Unscrew bolts at oil filter housing (1) First remove the two bolts (arrows) and
in their places screw in the two fabricated
assembly pins. Afterwards remove the
remaining bolts.
Installation: Observe bolt plan for oil AR18.20-W-3471-01A
filter housing (1).
First screw in all bolts except for those in
whose places the assembly pins are screwed
in. After that remove the two fabricated
assembly pins and pull out of oil filter
housing (1) using the magnetic pin.
Afterwards screw in the remaining two bolts
(arrows) and tighten all the bolts.
*210589004000
*BA18.20-N-1002-01C
Assembly pins for installation of oil filter WF58.50-W-1820-01A
housing
18 Detach oil filter housing (1) at crankcase Remove oil filter housing (1) via both
screwed in assembly pins. Collect coolant
and engine oil which flows out.
19 Remove gasket (9) Installation: Clean sealing surfaces.
Install a new gasket (9) via both screwed in
assembly pins.
20 Inspect oil-water heat exchanger for external In case of damage:
damage
Replace oil-water heat exchanger. AR18.30-W-6840G
21 Remove detachable parts at oil filter housing Only when replacing oil filter housing (1).
(1)
Installation: Replace sealing rings and
gasket.
Engine oil temperature sensor (B11) *BA15.60-N-1005-01A
Coolant temperature sensor (B65) *BA15.60-N-1006-01A
Oil pressure sensor (B12) *BA18.40-N-1001-01D
Cap screws *BA18.20-N-1003-01C
Coolant fitting *BA18.20-N-1006-01C
*001589650900
23 Fillling the engine oil circuit AR18.00-W-1600G
25 Turn off the engine and check area of oil Visual inspection.
filter housing (1) for leaks
26 Check engine oil level at display; correct if Inspect engine oil level after waiting at
necessary least 5 min. after switching off the engine
Observe engine oil grade set in maintenance
system or Specifications for Operating
Fluids.

541.9 542.9
BA09.41-N-1008-01C Threaded bolt/bolt on oil filter housing Nm 50 50
Temperature sensor

542.9
BA15.60-N-1005-01A Engine oil temperature sensor on oil filter M14 1.5 Nm 30

housing
BA15.60-N-1006-01A Coolant temperature sensor on oil filter M14 1.5 Nm 30

housing
Oil filter

541.9, 542.9 541.9, 542.9
except code with code MY8
MY8
BA18.20-N-1001-01C Oil filter cover to oil filter housing Nm 40 40
BA18.20-N-1002-01C Bolt, oil filter, oil-water heat Nm 50 50

exchanger housing to crankcase
BA18.20-N-1003-01C Screw plug to oil filter housing M14 1.5 Nm 25 -
M16 1.5 Nm 25 -
M24 1.5 Nm 40 40
M33 2 Nm 75 75
BA18.20-N-1006-01C Coolant fitting to oil filter/oil-water Nm 6 6

heat exchanger housing
Oil level/oil pressure sensor

541.9, 542.9
BA18.40-N-1001-01D Oil pressure sensor to oil filter Nm 40

housing
Fan, fan clutch

541.9,
542.9
with code
MZ3/MO1
Fuel filter
BA47.20-N-1001-02C Fuel filter housing to oil filter housing Nm 50 50
Fuel pipes/hoses

541.9, 542.9
BA47.25-N-1009-01B Bolt, bracket of fuel line to oil filter housing Nm 25
BA47.25-N-1010-01B Bolt, fuel line bracket to cylinder crankcase Nm 25
001 589 65 09 00 210 589 00 40 00
Wrench socket Magnetic pin
AR18.30-W-6840G Removing/installing the oil-water heat exchanger 21.2.03
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Oil/water heat exchanger

2 Seal
W18.30-1002-11
Removing/installing
1 Remove oil filter housing (3) AR18.20-W-3471G
2 Remove oil/water heat exchanger (1) Replace oil/water heat exchanger (1) in
the event of outer damage and abrasion
material in engine oil.
*BA18.30-N-1001-01D
3 Remove seals (2) and clean sealing surfaces Installation: Replace seals (2)..
Oil cooling system
Number Designation Engine 541.9.

542.9
BA18.30-N-1001-01D Bolt for oil-water heat exchanger on oil filter Nm 25

housing
© Daimler AG, 7/2/13, G/03/13, ar18.30-w-6840g, Removing/installing the oil-water heat exchanger Page 1 of 1
AR20.00-W-1142A Drain/fill in coolant 13.12.11
ENGINES 541.9 in MODEL 930, 932, 933, 934, 950, 952, 953, 954
ENGINES 542.9 in MODELS 930, 932, 934, 950, 952, 954
Illustrated on model 930
1 Cap
W20.00-1006-11
2 Drain screw
3 Drain pipes
4 Drain screw
W20.00-1008-01 W20.00-1007-01
5 Retarder coolant hoses

(only on vehicles with code (BA9)
Voith secondary retarder R 115)
6 Drain screw
Performance-optimized Voith retarder)
7 Heat exchanger
Performance-optimized Voith retarder)
W20.00-1005-01 W43.30-1210-01
Modification notes
6.7.11 Value modified: Coolant drain plug to radiator *BA20.20-N-1001-01C
Drain
and safety glasses.
2 Unscrew cap (1).
3 Set temperature selection wheel for the
heater to the max. heat output and switch on
ignition
4 Drain coolant at radiator To do this place drain hose on the drain
fitting (3) and loosen drain screw (2). Collect
coolant in clean container.
© Daimler AG, 7/2/13, G/03/13, ar20.00-w-1142a, Drain/fill in coolant Page 1 of 3
ENGINES 541.9 in MODEL 930, 932, 933, 934, 950, 952, 953, 954 ENGINES 542.9 in MODELS 930, 932, 934, 950, 952, 954
5 Drain coolant at crankcase Remove drain screw (4). Collect coolant
in clean container.
6 Remove both coolant hoses (5) on the Only on vehicles with code (BA9) Voith
retarder secondary retarder R 115.
Collect coolant in clean container.
7 Remove drain screw (6) on heat exchanger Only on models fitted with code (BA1)
(7) Performance-optimized Voith retarder.
Collect coolant in clean container.
Filling
9 Attach both coolant hoses (5) to the retarder Only on vehicles with code (BA9) Voith
Check coolant hoses and hose clamps for
damage; replace if necessary.
10 Tighten drain screw (6) on heat exchanger Only on models fitted with code (BA1)
(7) Performance-optimized Voith retarder.
*BA43.30-N-1015-01E
Slightly grease new sealing ring. *BR00.45-Z-1062-06A
11 Tighten drain plug (4) on cylinder crankcase Replace sealing ring.
*BA01.40-N-1001-01D
12 Tighten drain screw (2) on cooler and *BA20.20-N-1001-01C
remove drain hose
13 Check coolant for soiling In the case of strong soiling the coolant
must generally be replaced; if necessary.:
Remove grease and scale in the cooling

system
Model 930, 932, 933, 934 AR20.00-W-1030G
Model 950, 952, 953, 954 AR20.00-W-1030B
14 Check coolant with antifreeze tester In the case of low antifreeze protection,
replace the anti-frost protection part or
replace the coolant.
*BF20.00-N-1001-01B
15 Pour in coolant
16 Start engine and bleed cooling and heating Run engine for about 5 minutes at
system varying rotational speeds.
Top off coolant constantly to the bottom
edge of the filler neck.
17 Turn off engine
18 Screw down cap (1)
19 Inspect cooling system for leaks Visual inspection

541.9. 542.9
BA01.40-N-1001-01D Coolant drain plug to crankcase M14 1.5 Nm 50
Radiator, coolant hoses

541.9, 542.9
BA20.20-N-1001-01C Coolant drain plug to radiator Nm 4

Retarder
Number Designation Models

374, 375, 930,
932, 933, 934,
940, 942, 943,
944, 950, 952,
953, 954, 958
with Code BA1
BA43.30-N-1015-01E Coolant drain plug to heat exchanger Nm 25

541.9 541.9 541.9
BA1 or BA9

down to -37°C

down to -45°C

Fluids

542.9 542.9 542.9
BA1, BA9,
KMKL

down to -37°C

down to -45°C

Fluids
Repair materials
BR00.45-Z-1062-06A Lubricating grease, Olista Longtime, DB supply specification 6804.60 A 001 989 36 51 10
AR20.00-W-1030G Remove grease and scale in the cooling system 14.12.10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
Remove grease
and safety glasses.
1 Drain coolant completely
Replace coolant AP20.00-W-2080A
2 Fill cooling system with a 5% cleaning Mixing ratio:
solution of a mildly alkaline cleaner and 50 g of cleaner to 1 l of water.
fresh water
Cleaner for engine and cooling system *BR00.45-Z-1009-04A
3 Crank engine and let it run at a medium The radiator can be covered over at the
rotational speed until the coolant temperature front if necessary.
reaches approx. 80°C; hold coolant
temperature at this level for about 5 minutes
4 Switch off engine and allow coolant
temperature to cool down to approx. 50°C
5 Drain cleaning solution completely from the Dispose of cleaning solution in an
cooling system environmentally acceptable manner.
6 Flush cooling system 2 times with fresh Drain out water fully after every flushing
water; run the engine with each flushing and dispose of in an environmentally
filling for about 5 minutes for this purpose acceptable manner.
Remove scale
7 Fill cooling system with a 10% cleaning Before removing scale, always remove
solution of water and citric, tartaric or oxalic grease in the cooling system even if there is
acid no visible sign of oiling.
Chromic acid or products containing chrome
must not be used because of the risk of
contaminating wastewater.
It is preferable to use citric acid.
Mixing ratio:
100 g of citric acid to 1 l of fresh water.
Chemicals for preparing the cleaning
solutions can be obtained from the chemical
trade.
Commercially available products which
contain the aforementioned acids may also
be used for removing scale and rust.
8 Crank engine and let it run at a medium The radiator can be covered over at the
rotational speed until it reaches approx. 80°C; front if necessary.
hold it at this level for about 10 minutes
9 Switch off engine and allow to cool down to
approx. 50°C
10 Fully drain off cleaning solution Dispose of cleaning solution in an
environmentally acceptable manner.
11 Flush cooling system at least 3 times with Drain out water fully after every flushing
fresh water; run engine with each flushing and dispose of in an environmentally
filling for 5 minutes for this purpose acceptable manner.
12 Pour in coolant
Replace coolant AP20.00-W-2080A
Repair materials

BR00.45-Z-1009-04A Cleaner for engine and cooling system -
© Daimler AG, 7/2/13, G/03/13, ar20.00-w-1030g, Remove grease and scale in the cooling system Page 1 of 1
AR20.10-W-1401G Disassemble/assemble coolant pump 21.10.11
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
1 Flange
2 Retaining ring
3 Bearing shaft
4 Coolant pump housing
5 Cassette-type seal
6 Impeller
7 Thrust piece
W20.10-1019-06
5 Cassette-type seal
6 Impeller
9 Drift
A Gap between impeller and coolant

pump housing
B Distance between coolant pump
housing and flange
W20.10-0009-06
Disassemble
1 Remove coolant pump AR20.10-W-1271G
2 Press flange (1) off the bearing shaft (3)
using a thrust piece (7)
Put something under the flange (1).
Stationary workshop press 65 t Workshop press
gotis://G_58.2_01.0
*321589006300
3 Remove circlip (2)
4 Use a suitable drift to press bearing shaft
(3) out of the impeller (6) and the coolant
pump housing (4)
gotis://G_58.2_01.0
© Daimler AG, 7/2/13, G/03/13, ar20.10-w-1401g, Disassemble/assemble coolant pump Page 1 of 2
5 Remove cassette-type seal (5)
Assemble
6 Oil new bearing shaft (3) at bearing outer
race with engine oil and press into the
coolant pump housing (4) using a suitable
drift
Only place drift on bearing outer race.
gotis://G_58.2_01.0
7 Install circlip (2).
8 Press flange (1) onto bearing shaft (3) Observe distance between coolant pump *BE20.10-N-1002-01C
housing and flange (B).
gotis://G_58.2_01.0
9 Fit new cassette-type seal (5) onto the Check seating of the cassette-type seal
bearing shaft (3) and press in as far as the (5) on the bearing shaft (3) and in coolant
coolant pump housing (4) with the drift (9) pump housing (4).
Service Information: Special tool modification SI58.20-W-0004B
*352589081500
10 Press impeller (6) onto bearing shaft (3) Observe gap between impeller and *BE20.10-N-1001-01C
coolant pump housing (A).
Feeler gauge
gotis://G_58.2_01.0
11 Check bearing shaft (3) for ease of
movement
12 Check flange (1) and impeller (6) for Visual inspection.
unobstructed movement
13 Install coolant pump AR20.10-W-1271G
Test and adjustment values for coolant pump

541.9, 542.9 541.9, 542.9
except code with code ML3
ML3
BE20.10-N-1001-01C Gap between impeller and coolant mm 0.6 to 1.0 0.6 to 1.0
pump housing (A)
BE20.10-N-1002-01C Distance between coolant pump mm 100 160.6

housing and flange (B)
321 589 00 63 00 352 589 08 15 00

Thrust piece Drift
© Daimler AG, 7/2/13, G/03/13, ar20.10-w-1401g, Disassemble/assemble coolant pump Page 2 of 2

AR20.10-W-1271G Remove/install coolant pump 3.3.09
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Poly-V belt
2 Belt pulley
3 Coolant thermostat
4 Seal (only for code (BA1)
Performance-optimized Voith retarder
or for code (BA9) Voith secondary
retarder R115)
5 Coolant line (only for code (BA1)
Performance-optimized Voith retarder
or for code (BA9) Voith secondary
retarder R115)
6 Gasket
7 Coolant pump
8 Gasket
9 Coolant line
10 Charge air pipe (only for engine
542.9)
W20.10-1015-06
7 Coolant pump
10 Charge air pipe (only for engine 542.9)
12 Bracket
13 Wiring harness
14 Electrical wiring harness (only for code (MZ3)
Electromagnetic viscous coupling for fan or for code (MZ5)
Electromagnetic fan drive (Linnig clutch))
15 Holder (only for code (MZ3) Electromagnetic viscous
coupling for fan or for code (MZ5) Electromagnetic fan
drive (Linnig clutch))
16 Support (only for code (MZ3) Electromagnetic viscous
coupling for fan or for code (MZ5) Electromagnetic fan
drive (Linnig clutch))
S10 Start engine button (only for engine 541.9 up to end no.
393023, engine 542.9 up to end no. 393525)
S10.1 Start engine button/ Stop engine button (only for engine
541.9 up to end no. 393024, engine 542.9 up to end no.
393526)
S11 Stop engine button (only for engine 541.9 up to end no.
393023, engine 542.9 up to end no. 393525)
W20.10-1049-12
Modification notes
15.3.05 Remove fan shroud bracket on the upper right - added. Step 8
Remove/install
2 Remove charge air housing (11) AR09.41-W-8682A
3 Remove charge air pipe (10) Only for engine 542.9. AR09.41-W-1311G
© Daimler AG, 7/2/13, G/03/13, ar20.10-w-1271g, Remove/install coolant pump Page 1 of 3

and safety glasses.
4 Remove coolant thermostat (3) AR20.10-W-2460G
5.1 Bind up Start engine button (S10) and Stop Engine 541.9. up to end no. 393023
engine button (S11) on the coolant pump (7) , engine 542.9 up to end no. 393525
and bind to one side
Do not separate electrical connection.
5.2 Bind up Stop engine button (S10.1) on the Engine 541.9. as of end no. 393024
coolant pump (7) and bind to one side , engine 542.9 as of end no. 393526
Do not separate electrical connection.
6 Remove holder (12) with electrical wiring *BA09.00-N-1001-01A
harness (13) on the coolant pump (7)
7 Remove poly-V belt tensioning device for Only on vehicles with code (ML3) high- AR13.25-W-3201G
high-speed fan drive speed fan drive with belt drive.
8 Remove fan shroud bracket on the upper Only on vehicles with code (M58) Higher
right output fan.
*BA20.40-N-1015-01C
*BA20.40-N-1016-01C
9 Loosen bolts of belt pulley (2) *BA20.10-N-1002-01D
10 Slacken poly-V belt (1) on alternator and Installation: Inspect condition of poly-V
remove on belt pulley (2) of the coolant belt of alternator (1); replace if necessary.
pump (7)
Damage profiles for poly-V belt AP13.22-D-1351-01A
11 Take off belt pulley (2)
12 Disconnect electrical wiring harness (14) Only for vehicles with code (MZ3)
with code (MZ5) Electromagnetic fan drive
(Linnig clutch).
13 Detach support (15) at charge air cooler (16) Only for vehicles with code (MZ3)
(Linnig clutch).
*BA20.40-N-1010-01C
14 Remove bracket (15) on the coolant pump Only for vehicles with code (MZ3)
(7) Electromagnetic viscous coupling for fan or
(Linnig clutch).
15 Remove coolant line (5) and seal (4) on the Only on vehicles with code (BA9)
coolant pump (7) Performance-optimized Voith retarder or with
code (BA1) Voith secondary retarder R115.
*BA20.10-N-1005-01D
16 Remove coolant line (9) and seal (8) on the *BA20.10-N-1005-01D
coolant pump (7)
17 Remove coolant pump (7) and gasket (6) *BA20.10-N-1001-01D
Air intake, air charging, general

542.9
BA09.00-N-1001-01A Bolt, front bracket to lifting eye or coolant Nm 25

connection
Coolant pump, coolant thermostat

541.9, 542.9 541.9, 542.9
without code with Code ML3
ML3

BA20.10-N-1001-01D Bolt, coolant pump to crankcase Nm 25 25
BA20.10-N-1002-01D Bolt, pulley to coolant pump Nm 25 30
BA20.10-N-1005-01D Bolt coolant line (inlet connection) to coolant M10 Nm 50 50

pump
Fan, fan clutch

541.9, 541.9,
542.9 with 542.9
code MZ5 with code
MZ3/MO1
BA20.40-N-1010-01C Bolt, support of electromagnetic fan clutch Nm 50 50

to coolant pump
BA20.40-N-1015-01C Bolt, fan shroud bracket to engine Nm - 25
BA20.40-N-1016-01C Bolt, fan shroud to fan shroud bracket Nm - 15

AR20.10-W-2460G Removing/installing the coolant thermostat 3.3.09
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Coolant line
2 Charge air hose (red)
3 Sealing ring
4 Coolant thermostat
5 Coolant pump
6 Coolant hose
W20.10-1014-06
Modification notes
17.3.05 Remove upper bracket for fan shroud on coolant line (1) - Step 8
added.
Remove/install
when tilting.
the engine
the radiator
6 Remove red charge air hose (2) *BA09.41-N-1006-01C
Risk of poisoning from swallowing coolant. and release the pressure. Do not pour
coolant into beverage containers.
and safety glasses.
7 Drain coolant partially Only drain coolant at radiator AR20.00-W-1142A
8 Remove upper fan shroud bracket on Only vehicles with code (M58) Higher
coolant line (1) output fan and code (MZ3) Electromagnetic
*BA20.40-N-1015-01C
*BA20.40-N-1016-01C
9 Detach coolant line (1) at coolant pump (5) Installation: Install new sealing rings (3).
*BA20.10-N-1003-01D
10 Remove both coolant thermostats (4) Installation: Observe installation position
of both coolant thermostats (4) (arrows).
© Daimler AG, 7/2/13, G/03/13, ar20.10-w-2460g, Removing/installing the coolant thermostat Page 1 of 2
Coolant pump, coolant thermostat
Number Designation Engines Engines

541.9, 542.9 541.9, 542.9
without code with code ML3
ML3
BA20.10-N-1003-01D Bolt, coolant line to coolant pump M8 Nm 25 25
Fan, fan clutch

541.9,
542.9
with code
MZ3/MO1
© Daimler AG, 7/2/13, G/03/13, ar20.10-w-2460g, Removing/installing the coolant thermostat Page 2 of 2
AR20.20-W-3865GE Remove/install radiator 7.12.11
ENGINE 541.9 in MODEL 930, 932, 933, 934 with CODE (MO1) Electromagnetic viscous fan clutch, Behr
ENGINE 542.9 in MODEL 930, 932, 934 with CODE (MO1) Electromagnetic viscous fan clutch, Behr
W20.20-1061-09
1 Heater pipe 9 Coolant hose 16.2 Transmission oil lines

2 Coolant hoses (heater) 10 Charge air housing 17 Radiator mounting
3 Coolant expansion reservoir 11 Coolant pipe 18 Charge air cooler
4 Coolant hose (from engine) 12 Fan with viscous fan clutch 19 Protective grille
5 Coolant hose (to coolant pump) 13 Oil dipstick guide tube 20 Capacitor
6 Radiator 14 Oil filler pipe 21 Trim
7 Coolant hose 15 Coolant hose
8 Electrical connector 16 Connecting points B6 Coolant level switch
16.1 Transmission oil hoses
Shown on vehicle with code (H03) Air

conditioning in front end
26 Low pressure refrigerant line

27 High pressure refrigerant line
28 Connecting point
29 Connecting point
30 Connecting point
31 Connecting point
W20.20-1031-01 W83.55-1023-01
Modification notes
7.12.11 Value modified: Hose to transmission oil cooling line *BA26.55-N-1007-01A
Value modified: Hose to transmission oil cooling line *BA26.55-N-1004-01KL
Remove/install
2 Detach trim panel on cab rear wall Only in vehicles with code (F15)
MEGASPACE cab.
3 Remove soundproofing below the radiator (6)
and safety glasses.
© Daimler AG, 7/2/13, G/03/13, ar20.20-w-3865ge, Remove/install radiator Page 1 of 4

4 Drain coolant Only drain coolant at radiator. AR20.00-W-1142A
6 Remove middle trim panel (21) over the
bumper
7 Discharge air conditioning system Only for vehicles with code (H03) Air AR83.30-W-1760A
conditioning in front end or with code (H07)
AAC.
8 Remove coolant hoses (2) to heater heat
exchanger
9.1 Remove sensor unit with hydraulic lines on Vehicles with code (GS3) "Hydraulic" AR26.60-W-0012-01G
cab gearshift
*BA26.60-N-1025-01D
*BA26.60-N-1026-01D
*BA26.60-N-1030-01D
9.2 Tilt cab Vehicles without code (GS3) "Hydraulic"
gearshift.
10 Remove soundproofing on the left and right
side of the engine
side of radiator (6)
12 Remove charge air housing (10) AR09.41-W-8682A
14 Disconnect electrical connector (8) on
coolant level switch (B6)
15 Remove all coolant hoses (4, 5, 7, 9, 15) on
the cooler side
16 Detach coolant expansion reservoir (3) on
radiator (6)
17 Detach oil dipstick guide tube (13) and oil
filler pipe (14) at radiator (6) and tie up at
engine
18 Disconnect low pressure refrigerant line (26) Only for vehicles with code (H03) Air
and high pressure refrigerant line (27) at conditioning in front end or with code (H07)
connecting points (30, 31) AAC.
When undoing union nut, counterhold on
fitting hexagon.
Installation : Replace sealing rings.
*BA83.30-N-1009-01B
19 Unscrew bolts at the radiator mounting (17)
on right and left
20 Remove coolant pipe (11) on coolant Installation: Replace sealing rings. AR20.10-W-2460G
thermostat
21 Detach low-pressure refrigerant line (26) and Only for vehicles with code (H03) Air
high-pressure refrigerant line (27) from conditioning in front end or with code (H07)
connecting points (28, 29) AAC.
When undoing union nut, counterhold on
fitting hexagon.
Installation : Replace sealing rings.
*BA83.30-N-1009-01B
22 Disconnect transmission oil hoses (16.1) Only on vehicles with code (N55)
from transmission oil lines (16.2) at Transmission oil cooling.
connecting points (16)
Disconnect transmission oil hoses (16.1)
at the connecting points (16) only. If
transmission oil hoses (16.1) are removed at
the oil cooler, the oil cooler can be
damaged.
Collect feathering-out transmission oil
and seal lines with plug.
Vehicles with code (GS7) Gear control *BA26.55-N-1007-01A
"hydraulic" or code (GS3) Gear control II:
Vehicles with code (GE3) Mercedes *BA26.55-N-1004-01KL
PowerShift or code (GE7) Mercedes
PowerShift 2
23 Connect transmission oil hoses (16.1) below Only on vehicles with code (N55)
at the radiator (6) Transmission oil cooling.
24 Attach removal and installation tools onto AR20.20-W-3865-08G
radiator (6)
25 Remove radiator (6) with charge air cooler Installation: When installing the radiator
(18) upwards (6), ensure that the protective grille (19) is
not tilted at the vehicle frame.
27 Check/correct transmission oil level Only on vehicles with code (N55)
Observe oil grade set in maintenance system
or Specifications for Operating Fluids.
Vehicles without code (G02) Torque AR26.00-W-0100A
clutch (WSK)
Transmission oil cooling, oil pump
Number Designation Transmission Transmission Transmission

715.320/321 715.500/507/ 715.570/576
510/513/517/
520/527/540/
561/567/568
BA26.55-N-1007-01A Hose to transmission oil cooling line Nm 60 60 60
Transmission oil cooling, oil pump
Number Designation Transmission Transmissions Transmission

715.350 715.370/380 715.515/525
BA26.55-N-1004-01KL Hose to transmission oil cooling line Nm 60 60 60
Shift mechanism
Number Designation Transmission Transmission Transmission

715.320 with 715.500/507/510/ 715.500/507/510
code GS3 513/520/540 /513/520/540/561
with code GS3 with code GS3
without code and code IY2
IY2
BA26.60-N-1025-01D Nut and bolt, shift control unit to center Nm 30 30 30

tunnel
BA26.60-N-1026-01D Bolt, HPS line bracket to center tunnel Nm 20 20 20
BA26.60-N-1030-01D Clamp bolt for gearshift lever Nm 20 20 20
Shift mechanism
Number Designation Transmission

715.570
with code GS3
and code IY2
BA26.60-N-1025-01D Nut and bolt, shift control unit to center Nm 30

tunnel

BA26.60-N-1026-01D Bolt, HPS line bracket to center tunnel Nm 20
BA26.60-N-1030-01D Clamp bolt for gearshift lever Nm 20
Air conditioning

930, 932,
933, 934
with code
H01, H03,
H07, H09
BA83.30-N-1009-01B Union nut, refrigerant lines sz. 19 Nm 16
WAF 27 Nm 30
WAF 32 Nm 40

AR20.30-W-4392C Remove/install coolant level switch 24.5.06
ENGINE 541.9 in MODEL 933, 953
ENGINE 541.9, 542.9 in MODEL 930, 932, 934, 950, 952, 954
Illustrated on model 930
1 Expansion reservoir
2 Wiring harness connector
B6 Coolant level switch

Arrows Retaining clamp
W20.30-1014-06
Modification notes
25.4.06 Work procedure completely revised Operation steps 1 to 8
Remove/install
2 Open maintenance flap Only on model 930, 932, 933, 934.
safety strut.
3 Tilt cab
4 Disconnect wiring harness (2) connector plug
5 Unclip wiring harness on expansion reservoir
(1)
6 Unlock coolant level switch (B6) at retaining
clamps (arrows) and remove coolant level
switch (B6) from expansion reservoir (1)
8 Read out fault memory in drive control FR STAR DIAGNOSIS diagnosis system *WH58.30-Z-1049-13A
(FMR) control unit using STAR DIAGNOSIS;
delete faults if necessary
Number Designation
WH58.30-Z-1049-13A STAR DIAGNOSIS Compact diagnostic system for commercial vehicles 651 131 10 00
© Daimler AG, 7/2/13, G/03/13, ar20.30-w-4392c, Remove/install coolant level switch Page 1 of 1
ENGINE 541.9 in MODEL 933, 953 ENGINE 541.9, 542.9 in MODEL 930, 932, 934, 950, 952, 954
AR20.40-W-5614G Remove/install fan 28.7.09
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (ML3) High-speed fan drive with belt drive
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (ML3) High-speed fan drive with belt drive
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (MZ5) Electromagnetic fan drive (Linnig clutch)
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (MZ5) Electromagnetic fan drive (Linnig clutch)
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (MZ3) Electromagnetic viscous coupling for fan
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (MZ3) Electromagnetic viscous coupling for fan
ENGINE 541.9 in MODEL 930, 932, 933, 934 except CODE (MO1) Electromagnetic viscous fan clutch, Behr
ENGINE 542.9 in MODEL 930, 932, 934 except CODE (MO1) Electromagnetic viscous fan clutch, Behr
W20.40-1049-09
1 Charge air cooler 6 Fan wheel 11 Charge air pipe

2 Coolant expansion reservoir 7 Intermediate piece 12 Oil filler pipe
3 Radiator 8 Oil dipstick guide tube 13 Radiator mounting
4 Coolant hose 9 Belt pulley/vibration damper
5 Viscous fan clutch 10 Coolant line Arrow Spacer
Remove/install
the way to the end position and secure with
safety strut.
1 Tilt cab The maintenance flap must always be
open when tilting.
radiator (3).
and safety glasses.
3 Drain coolant partially Only drain coolant at radiator. AR20.00-W-1142A
4 Remove trim panel in front of radiator (3)
side of the engine
side of the radiator (3)
7 Detach oil dipstick guide tube (8) and oil
filler pipe (12) from radiator (3)
9 Remove charge air pipe (11) Only for engine 542.9. AR09.41-W-1311G
© Daimler AG, 7/2/13, G/03/13, ar20.40-w-5614g, Remove/install fan Page 1 of 2

10 Detach coolant expansion reservoir (2) at Do not separate coolant lines.
radiator (3) and place to the side
11 Remove coolant hose (4)
12 Detach coolant line (10) at coolant Installation: Replace sealing rings. AR20.10-W-2460G
thermostat
13 Unscrew bolts at the radiator mounting (13) Fix radiator (3) on right and left in place
on right and left and press radiator (3) to the (arrow).
front
14 Detach fan wheel (6) with viscous fan clutch *BA20.40-N-1001-01C
(5) at intermediate piece (7)
15 Detach intermediate piece (7) from the belt At the same time press the radiator (3)
pulley/vibration damper (9) and remove at top to the front.
upwards
*BA20.40-N-1008-01C
16 Take out fan wheel (6) with viscous fan
clutch (5) upwards
17 Detach viscous fan clutch (5) at fan wheel Only if the viscous fan clutch (5) or the
(6) fan wheel (6) are replaced.
*BA20.40-N-1002-01C
Fan, fan clutch

541.9,
542.9
without
code
ML1,
ML3,
MZ5,
MZ3, MO1
BA20.40-N-1001-01C Bolt, viscous fan clutch to adapter Nm 50
BA20.40-N-1002-01C Bolt, fan to viscous fan clutch Nm 30
BA20.40-N-1008-01C Bolt, intermediate piece to crankshaft Nm 30

vibration damper
© Daimler AG, 7/2/13, G/03/13, ar20.40-w-5614g, Remove/install fan Page 2 of 2

AR23.20-W-9440G Disassemble/assemble rear engine power take-off 29.7.10
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (N53) Rear engine output for hydraulic pump
ENGINES 542.9 in MODEL 930, 932, 934 with CODE (N53) Rear engine output for hydraulic pump
W23.20-1014-09
1 Bearing housing 5 Distance sleeve 8 Shim

2 Roller bearing 6 Ball bearing 9 Spacer ring
3 Bearing inner race 7 Drive shaft 10 Flange cover
4 Distance sleeve
Disassemble
1 Remove rear engine power take-off AR23.20-W-9430G
2 Remove bearing in rear engine power take- Use workshop press. AR23.20-W-9440-02G
off
*321589006300
Assemble
3 Install bearing in rear engine power take-off Use workshop press. AR23.20-W-9440-02G
*321589006300
*BR00.45-Z-1069-02A
4 Determine thickness of shim (8) on rear AR23.20-W-9440-04G
engine power take-off
*BE23.20-N-1001-01A
5 Install rear engine power take-off AR23.20-W-9430G
Check values for the rear engine output

542.9 with code
N53
BE23.20-N-1001-01A Preload value on rear engine power take- mm 0.10...0.20

off
© Daimler AG, 7/2/13, G/03/13, ar23.20-w-9440g, Disassemble/assemble rear engine power take-off Page 1 of 2
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (N53) Rear engine output for hydraulic pump ENGINES 542.9 in MODEL 930, 932, 934 with CODE (N53) Rear engine output for hydraulic ...
321 589 00 63 00
Thrust piece
Repair materials
BR00.45-Z-1069-02A Loctite 640 Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 München
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
© Daimler AG, 7/2/13, G/03/13, ar23.20-w-9440g, Disassemble/assemble rear engine power take-off Page 2 of 2
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (N53) Rear engine output for hydraulic pump ENGINES 542.9 in MODEL 930, 932, 934 with CODE (N53) Rear engine output for hydraulic ...
AR23.20-W-9441GA Remove, install radial shaft sealing ring on rear engine power take-off 29.7.10
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (N52) Rear engine power take-off, output torque 600 Nm
ENGINES 542.9 in MODEL 930, 932, 934 with CODE (N52) Rear engine power take-off, output torque 600 Nm
W23.20-1091-09

BlueTec 4
1 Bearing housing 5 Nut 9 Shim

2 Flange cover 6 Screw 10 O-ring
3 Cover panel 7 Drive shaft 11 Radial shaft sealing ring
4 Output flange 8 Race
Removing
2 Tilt cab
3 Remove soundproofing on frame at top left,
right and rear
4 Take off cranking device at timing case and *BA01.60-N-1009-01B
attach end cover
*904589046300
6 Remove propeller shaft from output flange
(4) and pivot to side
7 Unscrew nut (5) from drive shaft (7)
8 Remove output flange (4) and cover panel
(3)
9 Remove flange cover (2) from bearing Collect engine oil that flows out.
housing (1)
10 Remove O-ring (10) from flange cover (2)
11 Remove shim (9) from flange cover (2)
12 Remove radial shaft sealing ring (11) from
flange cover (2)
Checking
13 Check race (8) on radial shaft sealing ring If necessary, replace race (8):
(11) on drive shaft (7) for galling
Disassemble/assemble rear engine power AR23.20-W-9440GA
take-off
Install
© Daimler AG, 7/2/13, G/03/13, ar23.20-w-9441ga, Remove, install radial shaft sealing ring on rear engine power take-off Page 1 of 3
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (N52) Rear engine power take-off, output torque 600 Nm ENGINES 542.9 in MODEL 930, 932, 934 with CODE (N52) Rear engine power ...
14 Install new radial shaft sealing ring (11) on
flange cover (2) with suitable punch.
15 Insert shim (9) into flange cover (2)
16 Insert new O-ring (10) into flange cover (2). Coat O-ring (10) with engine oil.
17 Install flange cover (2) on bearing housing Observe hole pattern for flange cover (2)
(1) in relation to flange of bearing housing (1).
18 Coat new bolts (6) at first five threads with *BR00.45-Z-1069-02A
thread locking compound
19 Tighten new bolts (6) to pretension value Observe tightening procedure for flange AR23.20-W-9440-05GA
test. cover (2) on rear engine power take-off.
*BA23.20-N-1007-01A
20 Check pretension value on rear engine AR23.20-W-9440-06GA
power take-off.
*BE23.20-N-1001-01A
21 Tighten bolts (6) Observe tightening procedure for flange AR23.20-W-9440-05GA
cover (2) on rear engine power take-off.
*BA23.20-N-1001-01A
22 Push cover panel (3) onto drive shaft (7)
23 Install output flange (4)
24 Tighten new nut (5) and secure *BA23.20-N-1003-01A
25 Fit propeller shaft to drive flange (7) Replace nuts and bolts.
*BA23.20-N-1006-01A
attach end cover
Operating Fluids.
29 Switch off the engine and check around unit Visual inspection.
pumps for leaktightness
30 Install soundproofing on frame at top left,
right and rear
31 Lower cab

542.9 with code
N52
BE23.20-N-1001-01A Preload value on rear engine power take- mm 0.10 to 0.30

off
Timing case

541.9. 542.9

case

541.9, 542.9
with code
N52
BA23.20-N-1001-01A Bolt, bearing housing and flange cover to Nm 30

timing case
BA23.20-N-1003-01A Nut, output flange to drive shaft M24 1.5 Nm 300
BA23.20-N-1006-01A Nut, propeller shaft to output flange Nm 30

timing case for pretension checking
904 589 04 63 00
Cranking device
Repair materials
Arabellastrasse 17
81925 München
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
AR23.20-W-9430GA Remove/install rear engine power take-off 29.7.10
ENGINES 541.9 in MODEL 930, 932, 933, 934 with CODE (N52) Rear engine power take-off, output torque 600 Nm
ENGINES 542.9 in MODEL 930, 932, 934 with CODE (N52) Rear engine power take-off, output torque 600 Nm
W23.20-1023-09

BlueTec 4
1 Bearing housing 7 Drive shaft 12 Box wrench

2 Flange cover 8 Turbocharger 13 Adapter
3 Cover panel 9 Drive gear
4 Output flange 10 Oil spray nozzle 14 Torque wrench
5 Nut 11 Nut
6 Screw Arrow Bore
1 Bearing housing
2 Flange cover
7 Drive shaft
15 O-ring
16 Roller bearing
17 Distance sleeve
18 Race
19 Ball bearing
20 Roller bearing
21 Race
22 Shim
23 O-ring
24 Radial shaft sealing ring
W23.20-1086-06
Removing
© Daimler AG, 7/2/13, G/03/13, ar23.20-w-9430ga, Remove/install rear engine power take-off Page 1 of 5
2 Tilt cab
3 Remove soundproofing on frame at top left,
right and rear
5 Remove charge air pipe Engine 542.9 only. AR09.41-W-1311G
6 Remove turbocharger (8) Only engine 541.9 or engine 542.9 with
code (MS4) BlueTec 4 or with code (MS5)
BlueTec 5
Engine 541.9 AR09.40-W-6020GA
Engine 542.9 with code (MS4) BlueTec 4 or AR09.40-W-6020GC
7.1 Remove exhaust collector Engine 541.9 AR14.10-W-3920G
Engine 542.9 with code (MS4) BlueTec 4 or AR14.10-W-3920GA
7.2 Remove intake manifold Engine 542.9 without code (MS4) BlueTec 4 AR09.20-W-1310G
attach end cover
*904589046300
11 Remove propeller shaft from output flange
(4) and pivot to side
12 Unscrew nut (5) from drive shaft (7)
13 Remove output flange (4) and cover panel
(3)
14 Remove bearing housing (1) AR23.20-W-9430-01GA
Box wrench *402589030300
Adapter *402589030302
Pulling device *652589003300
Torque wrench *000589109901
15 Unscrew oil spray nozzle (10) from cylinder
crankcase
Checking
16 Check hole (arrow) on oil spray nozzle (10) If applicable, clean oil spray nozzle (10).
for leakage
Install
17 Tighten oil spray nozzle (10) on cylinder Replace sealing ring.
crankcase
*BA01.40-N-1006-01D
18 Block engine with rotating device Only if turning device is not locked up.
19 Install bearing housing (1) AR23.20-W-9430-02GA
*BA01.60-N-1002-01B
*BA23.20-N-1004-01A
Box wrench *402589030300
Adapter *402589030302
Pulling device *652589003300
Torque wrench *000589109901
20 Coat new bolts (6) at first five threads with *BR00.45-Z-1069-02A
thread locking compound
21 Tighten new bolts (6) to pretension value Observe tightening procedure for flange AR23.20-W-9440-05GA
test cover (2) on rear engine power take-off.
*BA23.20-N-1007-01A
22 Check pretension value at rear engine AR23.20-W-9440-06GA
power take-off.
*BE23.20-N-1001-01A
23 Tighten flange cover (2) with bolts (6) Observe tightening procedure for flange AR23.20-W-9440-05GA
cover (2) on rear engine power take-off.
*BA23.20-N-1001-01A
24 Push cover panel (3) onto drive shaft (7)
25 Install output flange (4) with new nut (5) and *BA23.20-N-1003-01A
secure nut (5)
26 Attach propeller shaft to output flange (4) Replace nuts and bolts.
*BA23.20-N-1006-01A
attach end cover
28 Install timing case cover AR01.40-W-8000G
29.1 Install exhaust manifold Engine 541.9 AR14.10-W-3920G
Engine 542.9 with code (MS4) BlueTec 4 or AR14.10-W-3920GA
29.2 Install intake manifold Engine 542.9 without code (MS4) BlueTec 4 AR09.20-W-1310G
30 Install turbocharger (8) Only engine 541.9 or engine 542.9 with
code (MS4) BlueTec 4 or with code (MS5)
BlueTec 5
Engine 541.9 AR09.40-W-6020GA
Engine 542.9 AR09.40-W-6020GC
31 Install charge air pipe Engine 542.9 only. AR09.41-W-1311G
Operating Fluids.
34 Pour in coolant AR20.00-W-1142A
35 Start engine and allow to run in idle for 10 s The fuel system is bled automatically. If
until the oil pressure has built up, then run engine fails to start or only runs for a brief
the engine at varying speeds period:

36 Switch off the engine and check around unit Visual inspection.
pumps for leaktightness
37 Install soundproofing on frame at top left,
right and rear
38 Lower cab

542.9 with code
N52
BE23.20-N-1001-01A Preload value on rear engine power take- mm 0.10 to 0.30

off

541.9. 542.9
BA01.40-N-1006-01D Oil nozzle for oil supply (power take-off) to crankcase M18 1.5 Nm 80
Timing case

541.9. 542.9

case
BA01.60-N-1002-01B Bolt, timing case to crankcase M12 57 Nm 100
M12 105 Nm 100
M12 167 Nm 100

541.9, 542.9
with code
N52

timing case
BA23.20-N-1003-01A Nut, output flange to drive shaft M24 1.5 Nm 300
BA23.20-N-1004-01A Nut (double hexagon), drive gear to drive M33 1.5 Nm 500 (+50)
shaft
BA23.20-N-1006-01A Nut, propeller shaft to output flange Nm 30

timing case for pretension checking
402 589 03 03 00 402 589 03 03 02 652 589 00 33 00 541 589 01 43 00

Ring wrench Adapter Pulling device Removal and insertion device
904 589 04 63 00 000 589 10 99 01

Cranking device Torque wrench
Repair materials

Arabellastrasse 17
81925 München
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
AR47.10-W-4100B Remove/install fuel tank 20.3.12
MODEL 374, 375, 930, 932, 933, 934, 940, 942, 943, 944, 950.5 /6, 952.5 /6, 953.6, 954.5, 957, 958
Shown on model 944 with auxiliary

heating
1 Fuel line (return flow)

2 Fuel line (feed)
3 Fuel line (auxiliary heater)
4 Vent line
5 Securing clamp
6 Connector
7 Fuel tank
8 Tensioning straps
B22 Fuel fill level sensor
W47.10-1005-06
Modification notes
20.3.12 Value changed: nut, tensioning strap to LH additional fuel Model 958.2/4 *BA47.10-N-1002-01C
tank Model 958.0
Remove/install
2 Disconnect electrical connectors for side
marker lamps
3 Remove side paneling
4 Open the cap.
5 Drain off fuel from fuel tank (7) Collect fuel in a suitable safety
container.
6.1 Disconnect plug (6) on fuel fill level sensor For model 374, 375.3/4, 930, 932, 933, 934,
(B22) 940, 942, 943, 944, 950.5/6, 952.5/6, 953.6,
954.5, 957, 958
6.2 Remove both electrical lines on fuel fill level On model 375.1
sensor (B22)
7 Remove securing clamp (5) Only for model 374, 375.3/4, 930, 932, 933,
934, 940, 942, 943, 944, 950.5/6, 952.5/6,
953.6, 954.5, 957
8 Detach fuel lines (1, 2) as well as the vent Mark fuel lines (1, 2) and catch escaping
line (4) fuel in a suitable safety container.
Installation: Observe identification of fuel
lines (1, 2).
9 Disconnect fuel line (3) Only on vehicles with auxiliary heater.
10 Unscrew nuts on the tensioning straps (8) Installation: Ensure that chafe protection
straps are correctly positioned at the fuel
tank brackets and at the tensioning straps
(8).
*BA47.10-N-1001-01C
*BA47.10-N-1002-01C
11 Fold up tensioning straps (8) and remove
fuel tank (7) from the fuel tank consoles
12 Remove fuel fill level sensor (B22) Only if fuel tank (7) is replaced.
Model 958 AR47.10-W-7000A
Model 374, 375, 940, 942, 943, 944, 950.5/6, AR47.10-W-7000B
952.5/6, 953.6, 954.5, 957
© Daimler AG, 7/2/13, G/03/13, ar47.10-w-4100b, Remove/install fuel tank Page 1 of 2
MODEL 374, 375, 930, 932, 933, 934, 940, 942, 943, 944, 950.5 /6, 952.5 /6, 953.6, 954.5, 957, 958
Model 930, 932, 933, 934 AR47.10-W-7000C
Fuel tank
Number Designation Model Model Model

374.5/6, 375.1, 970, 930, 932,
375.3/4, 972, 974, 933, 934
975, 976
940, 942, 943,
944, 950, 952,
953, 954, 957
BA47.10-N-1001-01C Nut, tensioning strap on fuel tank on Nm 45 33 45

the right
BA47.10-N-1002-01C Nut, tensioning strap on the Nm 33 - 33

additional fuel tank on the left
Fuel tank
Number Designation Model Model

958.2/4 958.0
BA47.10-N-1001-01C Nut, tensioning strap on fuel tank on Nm 20 20

the right
BA47.10-N-1002-01C Nut, tensioning strap on the Nm 33 -

additional fuel tank on the left
© Daimler AG, 7/2/13, G/03/13, ar47.10-w-4100b, Remove/install fuel tank Page 2 of 2

MODEL 374, 375, 930, 932, 933, 934, 940, 942, 943, 944, 950.5 /6, 952.5 /6, 953.6, 954.5, 957, 958
AR47.10-W-7000C Remove/install fuel level sensor 17.6.09
MODEL 930, 932, 933, 934, 950.0 /1 /2 /3, 952.0 /1 /2 /3, 953.1 /3, 954.0 /1 /2
1 Fuel line (return flow)

2 Fuel line (feed)
3 Vent line
4 Securing clamp
6 Fuel line (auxiliary heater)
W47.10-1036-11
7 Measuring lever
W47.10-1035-06
Modification notes
3.4.09 Work procedure completely revised
Remove/install
2 Disconnect electrical connector (5) on fuel fill
level sensor (B22)
3 Remove securing clamp (4)
4 Remove fuel lines (1, 2) as well as the vent Mark fuel lines (1, 2) and catch escaping
line (3) from fuel fill level sensor (B22) fuel in a suitable safety container.
Installation: Observe identification of fuel
lines (1, 2).
5 Remove fuel line (6) Only on vehicles with auxiliary heater.
6 Unlock fuel fill level sensor (B22) and pull out To unlock, turn the fuel fill level sensor
of the fuel tank (B22) counterclockwise.
© Daimler AG, 7/2/13, G/03/13, ar47.10-w-7000c, Remove/install fuel level sensor Page 1 of 2
MODEL 930, 932, 933, 934, 950.0 /1 /2 /3, 952.0 /1 /2 /3, 953.1 /3, 954.0 /1 /2
Pull out fuel fill level sensor (B22)
upwards very carefully. Otherwise, the
measuring lever (7) consisting of thin wire
and the measuring electronics connected
can be damaged..
Installation: Replace sealing ring and
carefully install fuel fill level sensor (B22) in
the fuel tank.
Fuel fill level sensor modified Only applies to model 930, 932, 933, 934 BT47.10-W-0008-01A
© Daimler AG, 7/2/13, G/03/13, ar47.10-w-7000c, Remove/install fuel level sensor Page 2 of 2
MODEL 930, 932, 933, 934, 950.0 /1 /2 /3, 952.0 /1 /2 /3, 953.1 /3, 954.0 /1 /2
AR47.20-W-5510G Remove/install fuel filter 8.3.06
ENGINE 541.9 in MODELS 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934
1 Fuel filter housing

2 Cover
4 Fuel line (from fuel tank)
5 Fuel line (only with code (M89) Flame starting system (FLA))
6 Fuel line (to fuel duct unit pump)
7 Fuel line (to the fuel tank)
8 Leak fuel line
W47.20-1016-11
Modification notes
26.1.06 Mark banjo bolt, fuel line to flame starting system for Step 8
removal - added.
Remove/install
and skin caused by contact with fuel. Wear protective clothing when handling fuel.
1 Open end cover at fuel tank
2 Open front flap
Danger! Risk of injury caused by being caught or Ensure that no one is within tilting range of AS60.80-Z-0001-01A
pinched as cab is tilted cab as it is being tilted. Always tilt cab all
safety strut.
3 Tilt cab Installation: Tilt the cab back only after
the leak test has been conducted
4 Remove soundproofing on frame at the
upper left
5 Unscrew cap (2) with fuel filter insert and Installation: Replace sealing ring in cap
remove (2).
*BA47.20-N-1002-02C
6 Remove leak fuel line (8) at banjo bolt for Collect escaping fuel.
fuel line (7)
*BA47.25-N-1006-01B
7 Detach fuel line (7) at fuel filter housing (1) Collect escaping fuel.

*BA47.25-N-1003-01B
8 Remove fuel line (5) at banjo bolt for fuel Only for code (M89) Flame starting
line (6) system (FLA).
Collect escaping fuel. Mark banjo bolt for
fuel line (5) to flame starting system; this
banjo bolt has a small diameter and must not
be confused with the banjo bolt for leak fuel
line (8).
*BA47.25-N-1007-01B
9 Detach fuel line (6) at fuel filter housing (1) Collect escaping fuel.
*BA47.25-N-1003-01B
© Daimler AG, 7/2/13, G/03/13, ar47.20-w-5510g, Remove/install fuel filter Page 1 of 2

10 Remove fuel line (4) at bracket and at fuel Collect escaping fuel.
filter housing (1)
*BA47.25-N-1003-01B
11 Remove fuel filter housing (1) at oil filter *BA47.20-N-1001-02C
housing (3)
during starting procedure or when working Do not grasp hot or rotating parts.
near the running engine
13 Start the engine, bleed fuel system and The fuel system is bled automatically. If
perform engine test run the engine fails to start or only runs for a
brief period:

14 Turn off the engine and check area of fuel Visual inspection.
filter housing (1) for leaks
Fuel filter
BA47.20-N-1001-02C Fuel filter housing to oil filter housing Nm 50 50
BA47.20-N-1002-02C Cap to fuel filter housing Nm 25 25

541.9, 542.9
BA47.25-N-1003-01B Banjo screw, fuel line to fuel filter housing M16 1.5 Nm 50
BA47.25-N-1006-01B Banjo bolt, leak fuel line to banjo bolt for fuel M8 1 Nm 15
filter housing
BA47.25-N-1007-01B Banjo bolt, fuel line (flame starting system) to M8 1 Nm 15

banjo bolt and valve
© Daimler AG, 7/2/13, G/03/13, ar47.20-w-5510g, Remove/install fuel filter Page 2 of 2

AR47.20-W-5712G Remove/install fuel, power steering pump unit 21.2.12
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934
W46.30-1006-09
1 Fitting (only for engine 541.9) 4.1 Oil suction line 7 Fuel pressure line
2 Elbow fitting (only for engine 541.9) (only for engine 541.9) 8 Sealing ring
3.1 Oil pressure line 4.2 Oil suction line 9 Cross plate
(only for engine 541.9) (only for engine 542.9) 10 Bracket (only on engine 541.9)
3.2 Oil pressure line 5 Fuel intake line 11 Bracket (only on engine 542.9)
(only for engine 542.9) 6 Power steering/fuel pump unit
Modification notes
Remove/install
safety strut.
1 Tilt cab
2 Remove fuel intake line (5) and fuel pressure Collect escaping fuel.
line (7) to the power steering unit, fuel pump
device (6)
*BA47.25-N-1002-01B
3.1 Remove oil pressure line (3.1) and oil suction With engine 541.9
line (4.1) on bracket (10)
Steering 765.8 *BA46.30-N-1008-01C
Steering ZF 8098 *BA46.30-N-1007-01R
3.2 Remove bracket (11) for oil pressure line With engine 542.9
(3.2) and oil suction line (4.2) on intake
manifold
Steering 765.8 *BA46.30-N-1008-01C
Steering ZF 8098 *BA46.30-N-1007-01R
line (4.1) at the power steering unit, fuel
pump device (6)
© Daimler AG, 7/2/13, G/03/13, ar47.20-w-5712g, Remove/install fuel, power steering pump unit Page 1 of 4
Counter connection (1) and elbow fitting
(2) when unscrewing; collect escaping
hydraulic oil.
Installation: Counter connection (1) and
elbow fitting (2) when tightening.
Steering 765.8 *BA46.30-N-1003-01C
Steering 765.8 *BA46.30-N-1006-01C
Steering ZF 8098 *BA46.30-N-1004-01R
Steering ZF 8098 *BA46.30-N-1002-01R
line (4.2) at the power steering unit, fuel
pump device (6)
Catch escaping hydraulic fluid.
Installation: Install new sealing rings.
Steering 765.8 *BA46.30-N-1003-01C
Steering 765.8 *BA46.30-N-1006-01C
Steering ZF 8098 *BA46.30-N-1004-01R
Steering ZF 8098 *BA46.30-N-1002-01R
5 Detach power steering/fuel pump unit (6) Installation: Replace seal (8). Turn shaft
from timing case of the power steering unit, fuel pump unit (6)
until the guide of the cross plate (9) is
vertical.
Steering 765.8 *BA46.30-N-1001-01C
Steering ZF 8098 *BA46.30-N-1006-01R
6 Remove cross plate (9). Installation: Place cross coupling (9) *BR00.45-Z-1051-06A
onto the compressor crankshaft and secure
with grease against slipping.
If the compressor crankshaft is not level:
Attach cranking device to timing case,

turn engine with the cranking device until
compressor crankshaft is not standing level
and remove cranking device on the
timing case again.
*BA01.60-N-1001-01B
*BA01.60-N-1009-01B
Turning device *904589046300
7 Reconfigure fitting (1) and elbow fitting (2) to Only for engine 541.9 and when
the new power steering unit, fuel pump unit replacing the power steering unit, fuel pump
(6) unit (6).
Install new seals.
Steering *BA46.30-N-1002-01C
Steering *BA46.30-N-1005-01C
Steering ZF 8098 *BA46.30-N-1005-01R
Steering ZF 8098 *BA46.30-N-1003-01R
9 Bleed fuel system AP47.00-W-1720-01A
10 Check hydraulic oil level in steering system Steering system 765.82 AR46.25-W-3300C
and bleed steering
Steering 765.887 AR46.25-W-3300B
Steering ZF 8098 AR46.25-W-3001A
Timing case

541.9. 542.9
BA01.60-N-1001-01B Screw/bolt, cap of TDC inspection hole to timing Nm 25

case
BA01.60-N-1009-01B Screw/bolt, engine cranking device to timing case Nm 25
Power steering pump
Number Designation Steering
765.8
with engine
541.9, 542.9
BA46.30-N-1001-01C Power steering pump/fuel pump at timing Nm 60

case
BA46.30-N-1002-01C Elbow fitting, suction line to power steering Nm 80

pump
BA46.30-N-1003-01C Suction line to elbow fitting / power Nm 100

steering pump
BA46.30-N-1005-01C Connection of pressure line to power Nm 40

steering pump
BA46.30-N-1006-01C Pressure line to connection / power Nm 80

steering pump
BA46.30-N-1008-01C Lines on air intake pipe Nm 25
Power steering pump
Number Designation Steering

ZF 8098
BA46.30-N-1002-01R Pressure line to connection - power steering Nm 80

pump
BA46.30-N-1003-01R Connection of pressure line to power steering Nm 40

pump
BA46.30-N-1004-01R Suction line to elbow fitting - power steering Nm 100

pump
BA46.30-N-1005-01R Elbow fitting, suction line to power steering pump Nm 80
BA46.30-N-1006-01R Power steering pump/fuel pump at timing case Nm 60
BA46.30-N-1007-01R Lines on air intake pipe Nm 25
Fuel pipes/hoses

541.9. 542.9
BA47.25-N-1002-01B Banjo bolt, fuel line to fuel pump M16 1.5 Nm 50
904 589 04 63 00
Cranking device
Repair materials

BR00.45-Z-1051-06A High-temperature grease A 000 989 81 51
AR47.21-W-5621G Remove/install fuel heat exchanger 18.1.10
ENGINE 541.9 in MODEL 930, 932, 933, 934
ENGINE 542.9 in MODEL 930, 932, 934

2 Fuel pipe
3 Check valve and fuel line
W47.21-1005-11
Remove/Install
Danger! Risk of explosion if ignition takes place, No fire, sparks, naked flames or smoking. AS47.00-Z-0001-01A
risk of poisoning caused by inhaling fuel Pour fuels only into suitable and
vapors or swallowing fuel, as well as risk of appropriately marked containers.
injury to skin and eyes exposed to fuel. Wear protective clothing when handling fuel.
2 Remove fuel lines (2), check valve and fuel *BA47.25-N-1001-01B
line (3) at fuel heat exchanger (1)
3 Remove fuel heat exchanger (1) at engine The fuel heat exchanger must not be
control (MR) control module (A6) disassembled.
*BA07.15-N-1009-01B
5 Bleed fuel system
AP47.00-W-1720-01A

542.9
BA07.15-N-1009-01B Bolt of fuel heat exchanger to MR/ NM 8

PLD control module
Fuel pipes/hoses

542.9
BA47.25-N-1001-01B Banjo bolt of fuel line/check valve to fuel heat M16 1.5 NM 50
exchanger
© Daimler AG, 7/2/13, G/03/13, ar47.21-w-5621g, Remove/install fuel heat exchanger Page 1 of 1
GF47.00-W-0002MP Fuel supply, function 18.2.03
ENGINES 541.9 in MODELS 930, 932, 933, 934
ENGINES 542.9 in MODELS 930, 932, 934
W47.00-1011-79
1 Fuel tank A6 Engine control (MR) control unit A Suction or vacuum side fuel feed line
2 Manual fuel feed pump Y6 Cylinder 1 unit pump B Fuel feed line, pressure side
2.1 Fuel prefilter Y7 Cylinder 2 unit pump C Fuel high-pressure line
4 Fuel heat exchanger Y8 Cylinder 3 unit pump D Fuel return line
5 Fuel pump Y9 Cylinder 4 unit pump
6 Fuel filter Y10 Cylinder 5 unit pump
7 Nozzle holder combination Y11 Cylinder 6 unit pump
9 Overflow valve
General information
The fuel supply ensures that the fuel required for combustion is
available under all operating conditions in the sufficient quantity, at
the correct time and with the required pressure.
Fuel to the individual cylinders is supplied through the Pump Line
Nozzle System (PLD System), which is provided with fuel by the
fuel low pressure circuit.
Fuel low pressure circuit Pump Line Nozzle system (PLD system)
The fuel low pressure circuit ensures that the fuel is cleaned and The fuel provided by the fuel low pressure circuit through the
is provided to the unit pumps of the PLD System in the sufficient pump-line-nozzle system is injected into the cylinders in the
quantity and with the required pressure. adequate quantity, at the correct time and with the correct
It basically consists of the following components: pressure.
Fuel tank(1) The pump-line-nozzle system consist of the cylinder 1 to 6 unit
Manual fuel feed pump (2) pumps (Y6 to Y11) for engine 541.9 or the cylinder 1 to 8 unit
Fuel prefilter (2.1) pumps (Y6 to Y13) for engine 542.9, the pressure pipe connection,
Fuel heat exchanger (4) the injection nozzles in the nozzle holder combinations (7) and the
high pressure fuel lines (C), over which the individual unit pumps
Fuel pump (5)
are connected with the respective injection nozzles.
Fuel filter (6)
The excess fuel delivered during the fuel high pressure delivery
Suction or vacuum side fuel feed line (A)
goes back to the fuel low pressure circuit via the fuel return lines
Pressure side fuel feed line (B) (D).
Fuel return lines (D)
Fuel low pressure circuit - function GF47.00-W-3011MP

Fuel high pressure delivery function GF47.00-W-3012MP
© Daimler AG, 7/2/13, G/03/13, gf47.00-w-0002mp, Fuel supply, function Page 1 of 1

ENGINES 541.9 in MODELS 930, 932, 933, 934 ENGINES 542.9 in MODELS 930, 932, 934
AR49.10-W-4801GA Remove/install muffler 7.7.10
ENGINES 457.9 in MODEL 942, 943
with CODE (K68) Vertical exhaust muffler(s) behind cab
except CODE (MS4) BlueTec 4
ENGINES 541.9 in MODEL 930, 932, 933
ENGINES 541.9 in MODEL 930, 932, 933
ENGINES 906.9 in MODEL 950, 952, 953 with CODE (K68) Vertical exhaust muffler(s) behind cab
ENGINES 926.9 in MODEL 950, 952, 953
ENGINES 926.9 in MODEL 950, 952, 953
Shown on engine 541.9 in model 932.3
1 Exhaust pipe with exhaust flex pipe

2 Bracket
3 Tensioning strap
4 Muffler
5 Bolt (only on model 930, 932, 933)
6 Shield
7 Clamp (only on model 930, 932, 933)
8 Line (only on model 930, 932, 933)
9 Connection fitting (only on model 930,
932, 933, 942, 943)
10 Engine hoist
W49.10-1045-06
Remove/install
1 Tilt cab Only on model 942, 943.
Installation: Only tilt cab back after leak
2 Detach guard plate (6) Engine 457.9 *BA49.10-N-1009-01K
Engine 541.9, 542.9 *BA49.10-N-1008-01J
Engine 906.9, 926.9 *BA49.10-N-1006-01O
3 Release clamp with heat shield at exhaust Only on model 942, 943.
pipe with exhaust flex pipe (1) and at the
bracket
© Daimler AG, 7/2/13, G/03/13, ar49.10-w-4801ga, Remove/install muffler Page 1 of 3

ENGINES 457.9 in MODEL 942, 943 with CODE (K68) Vertical exhaust muffler(s) behind cab except CODE (MS4) BlueTec 4 ENGINES 457.9 in MODEL 942, 943 with CODE (K68) Vertical ...
Installation: Align clamp with heat shield
with the fender.
*BA49.10-N-1005-01K
4.1 Release clamp at muffler (4) and the Model 942, 943, 950, 952, 953
exhaust pipe with exhaust flex pipe (1) at
the muffler (4)
Engine 457.9 *BA49.10-N-1001-01K
Engine 906.9, 926.9 *BA49.10-N-1001-01O
4.2 Release clamp (7) and push backwards at Model 930, 932, 933
the exhaust pipe with exhaust flex pipe (1)
Installation: Loosen bolt (5) on bracket
(2). Align exhaust pipe with exhaust flex pipe
(1) with the exhaust pipe of the muffler (4)
and tighten bolt (5).
*BA49.10-N-1002-01J
5 Detach line (8) at muffler (4) Only on model 930, 932, 933
Counterhold the connection fitting (9) when
loosening the line (8).
Installation: Tighten line (8) at
connection fitting (9) without stress.
*BA49.10-N-1007-01J
6 Mount the engine hoist (10) on the brackets
on the muffler (4) and lift the muffler (4)
slightly
7 Loosen lower tensioning strap (3) and Engine 457.9 *BA49.10-N-1007-01K
detach the upper tensioning strap (3)
Engine 541.9, 542.9 *BA49.10-N-1006-01J
Engine 906.9, 926.9 *BA49.10-N-1005-01O
8 Lift out muffler (4) with the engine hoist (10)
9 Unscrew nut on connection fitting (9) and Only on model 942, 943 if the muffler (4)
remove check ball is replaced.
Installation: Counterhold connection
fitting (9) at the muffler (4) when tightening
the nut.
*BA49.10-N-1008-01K
11 Start the engine and check the exhaust
system for leaktightness, then turn off the
engine
Exhaust system

457.9
BA49.10-N-1001-01K Bolt connecting clamps to front muffler, exhaust Nm 50

pipe, muffler and exhaust flex pipe
BA49.10-N-1005-01K Bolt connecting clamps to bracket Nm 50
BA49.10-N-1007-01K Nut, muffler tensioning strap to holder M12 Nm 35
BA49.10-N-1008-01K Union nut, compressed air line to muffler Nm 100
BA49.10-N-1009-01K Bolt, protective plate to muffler M8 Nm 25
Exhaust system

541.9, 542.9

BA49.10-N-1002-01J Clamp bolt, exhaust pipe to muffler Nm 50
BA49.10-N-1006-01J Nut, muffler tensioning strap to holder M12 Nm 35
BA49.10-N-1007-01J Union nut, compressed air line to muffler Nm 100
BA49.10-N-1008-01J Bolt, protective plate to muffler Nm 25
Exhaust system

900.9, 902.9,
904.9, 906.9,
924.9, 925.9,
926.9
BA49.10-N-1001-01O Bolt, clamp to exhaust pipe, muffler and exhaust Nm 50

flex pipe
BA49.10-N-1005-01O Nut, muffler tensioning strap to holder M12 Nm 35
BA49.10-N-1006-01O Bolt, protective plate to muffler M8 Nm 25

AR49.10-W-8000A Remove/install exhaust flex pipe 22.3.11
ENGINES 457.9, 541.9, 542.9, 900.9, 902.9, 924.9, 925.9, 926.9 with CODE (K68) Vertical exhaust muffler(s) behind cab
ENGINES 457.9, 541.9, 542.9, 900.9, 902.9, 924.9, 925.9, 926.9 with CODE (KJ6) Vertical exhaust muffler, centrally behind
cab
W49.10-1065-08
Shown on model 932 with injection

nozzle on exhaust flex pipe
1 Exhaust flex pipe (early type with 2 Exhaust flex pipe (new type without 3 Injection nozzle (amble)
rubber covering) rubber covering) 4 Flange
Removing
safety strut.
2 Tilt cab
3 Remove injection nozzle (3) from exhaust Only for vehicles with an injection nozzle
flex pipe (1) (3) on the exhaust flex pipe (1).
4 Remove exhaust flex pipe (1)
5 Remove flange (4) of older exhaust flex pipe
(1)
Install
6 Check the new exhaust flex pipe (2) for Damage can only occur during transport
damage or during other handling.
The lamella on the new exhaust flex pipe
(2) should be checked in particular.
One should always install an undamaged
exhaust flex pipe (2).
7 Install flange (4) onto new exhaust flex pipe The flange (4) must be firmly fitted and
(2) fitted flush to the exhaust flex pipe (2)
before it is fitted.
Engine 457.9 *BA49.10-N-1014-01K
Engine 541.9, 542.9 *BA49.10-N-1013-01J
Engine 900.9, 902.9, 924.9, 926.9 *BA49.10-N-1001-01O
8 Install new exhaust flex pipe (2) Replace gaskets.
Fit exhaust flex pipe (2) free of tension
since otherwise it can tear due to vibration.
Engine 457.9 *BA49.10-N-1013-01K
Engine 457.9 *BA49.10-N-1015-01K
Engine 541.9, 542.9 *BA49.10-N-1012-01J
© Daimler AG, 7/2/13, G/03/13, ar49.10-w-8000a, Remove/install exhaust flex pipe Page 1 of 3
ENGINES 457.9, 541.9, 542.9, 900.9, 902.9, 924.9, 925.9, 926.9 with CODE (K68) Vertical exhaust muffler(s) behind cab ENGINES 457.9, 541.9, 542.9, 900.9, 902.9, 924.9, 925.9, 926.9 with ...
Engine 541.9, 542.9 *BA49.10-N-1014-01J
Engine 900.9, 902.9, 924.9, 926.9 *BA49.10-N-1001-01O
Engine 900.9, 902.9, 924.9, 926.9 *BA49.10-N-1002-01O
9 Install new injection nozzle (3) onto exhaust Only for vehicles with an injection nozzle
flex pipe (2) with new seal (3) on the exhaust flex pipe (2).
*BA14.40-N-1002-02A
10 Start engine, and check exhaust system for Visual inspection.
leaks with engine running
11 Turn off engine
safety strut.
12 Lower cab

541.9 542.9
with code with code
MS4 MS4
or code or code
MS5 MS5
BA14.40-N-1002-02A Injection nozzle on engine brake valve fitting/ Nm 10 10

exhaust pipe
Exhaust system

457.9
BA49.10-N-1013-01K Bolt, exhaust pipe V ribbon clip to engine brake Nm 12

valve fitting
BA49.10-N-1014-01K Bolt, flange flat band clip to exhaust pipe Nm 25
BA49.10-N-1015-01K Bolt, exhaust pipe flat band clip to inlet pipe Nm 12

exhaust gas trap
Exhaust system

541.9, 542.9
BA49.10-N-1012-01J Bolt, exhaust pipe V ribbon clip to engine brake Nm 12

valve fitting
BA49.10-N-1013-01J Bolt, flange flat band clip to exhaust pipe Nm 25
BA49.10-N-1014-01J Bolt, exhaust pipe flat band clip to inlet pipe Nm 12

exhaust gas trap
Exhaust system

900.9, 902.9,
904.9, 906.9,
924.9, 925.9,
926.9
BA49.10-N-1001-01O Bolt, clamp to exhaust pipe, muffler and exhaust Nm 50

flex pipe
BA49.10-N-1002-01O Bolt, exhaust pipe clamp to engine brake flap Nm 15

fitting/exhaust connection
AR49.10-W-5530G Remove/install exhaust pipe 15.1.08
ENGINES 541.9 in MODEL 930, 932, 933, 934 except CODE (K68) Vertical exhaust muffler(s) behind cab
ENGINES 542.9 in MODEL 930, 932, 934 except CODE (K68) Vertical exhaust muffler(s) behind cab
ENGINES 541.9 in MODEL 930, 932, 933
ENGINES 541.9 in MODEL 930, 932, 933
Shown on engine 541.9 in model 934 with

code (MS4) BlueTec 4 without Code
(K68) Vertical muffler(s)behind cab
1 Engine brake flap connection

2 Clip
3 Exhaust pipe with exhaust flex pipe
4 Clip
5 Muffler
W49.10-1044-06
Remove/install
3 Remove soundproofing on frame at upper Only on vehicles with code (K68) Vertical
left muffler(s) behind cab
4.1 Release clamp (4) at exhaust pipe (5) Vehicles without code (K68) Vertical
muffler(s) behind cab
*BA49.10-N-1002-01J
4.2 Release clamp at muffler in a vertical Vehicles with code (K68) Vertical muffler(s)
position and push backwards at exhaust pipe behind cab
with exhaust flex pipe (3)
*BA49.10-N-1002-01J
5 Unscrew bolt at muffler bracket in a vertical Only on vehicles with code (K68) Vertical
position muffler(s) behind cab
6 Release clamp (2) and detach exhaust pipe *BA49.10-N-1001-01J
with exhaust flex pipe (3) at engine brake
valve fitting (1)
7 Twist exhaust pipe with exhaust flex pipe (3) Installation: Check exhaust pipe with
and pull out at the muffler (5) exhaust flex pipe (3) for damage, replace if
required.
© Daimler AG, 7/2/13, G/03/13, ar49.10-w-5530g, Remove/install exhaust pipe Page 1 of 2

ENGINES 541.9 in MODEL 930, 932, 933, 934 except CODE (K68) Vertical exhaust muffler(s) behind cab ENGINES 542.9 in MODEL 930, 932, 934 except CODE (K68) Vertical exhaust muffler(s) ...
exhaust flex pipes
9 Start the engine and check the exhaust
system for leaktightness, then turn off the
engine
Exhaust system

541.9, 542.9
BA49.10-N-1001-01J Clamp bolt, exhaust pipe to engine brake flap Nm 50

fitting
BA49.10-N-1002-01J Clamp bolt, exhaust pipe to muffler Nm 50
© Daimler AG, 7/2/13, G/03/13, ar49.10-w-5530g, Remove/install exhaust pipe Page 2 of 2

ENGINES 541.9 in MODEL 930, 932, 933, 934 except CODE (K68) Vertical exhaust muffler(s) behind cab ENGINES 542.9 in MODEL 930, 932, 934 except CODE (K68) Vertical exhaust muffler(s) ...

01 Engine

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What are the main components of the engine exhaust system being removed and installed?

What are the main components of the engine exhaust system being removed and installed?

What safety precautions need to be taken when working on the engine exhaust system?

What safety precautions need to be taken when working on the engine exhaust system?

01 - Engine

AR01.10-W-2400G Remove/install engine 24.2.11

Shown on engine 541.9

© Daimler AG, 7/2/13, G/03/13, ar01.10-w-2400g, Remove/install engine Page 1 of 9

Only for vehicles with code (MS4)

Y107 SCR tank heater solenoid valve

© Daimler AG, 7/2/13, G/03/13, ar01.10-w-2400g, Remove/install engine Page 4 of 9

Purge fuel system by hand. AP47.00-W-1720-01A

Number Designation Engine 541.9,

BE18.00-N-1001-01D Engine oil pressure at Idling speed bar 0.5

maximum speed bar 2.5

Number Designation Engine

BA01.60-N-1001-01B Bolt, end cover of TDC inspection hole to timing Nm 25

BA01.60-N-1009-01B Bolt, engine cranking device to timing case Nm 25

Intake manifold, intake manifold preheater

Number Designation Engine Engine

BA09.20-N-1001-02C Bolt, air intake pipe at bracket Nm 50 60

BA09.20-N-1002-02C Air intake pipe hose clamp Nm 6.0 6.0

Intake manifold, intake manifold preheater

Number Designation Engine Engine

BA09.20-N-1001-02C Bolt, air intake pipe at bracket Nm 50 60

BA09.20-N-1002-02C Air intake pipe hose clamp Nm 6.0 6.0

Engine wiring harness

Number Designation Engine 541.9,

BA15.18-N-1003-01A Bolt, wiring loom to timing case Nm 25

© Daimler AG, 7/2/13, G/03/13, ar01.10-w-2400g, Remove/install engine Page 6 of 9

Number Designation Engine

BA15.30-N-1002-01C Nut connecting circuit 30 line to starter/ Nm 30

Engine mounts, engine supports

Number Designation Engine Engine

BA22.10-N-1004-01D Bolt, engine carrier to engine mount Front Nm 330 330

at the rear Nm 330 330

BA22.10-N-1006-01D Engine mount on frame Front Nm 150 150

at the rear Nm 150 150

Rear engine power take-off

Number Designation Engine Engine

BA23.20-N-1006-01A Nut, propeller shaft to output flange Nm 30 -

BA23.20-N-1008-01A Hydraulic pump on intermediate flange M8 Nm - 30

Number Designation Model

BA25.20-N-1001-01J Bolt, clutch booster to transmission housing Nm 50

BA25.20-N-1003-01J Banjo bolt (compressed-air line) on clutch Nm 40

BA25.20-N-1010-01J Union nut (compressed-air line) at clutch Nm 40

Complete manual transmission

BA26.10-N-1001-01C Transmission to flywheel housing Nm 50

Complete manual transmission

Number Designation Transmission Transmissions Transmission

BA26.10-N-1001-01KL Transmission to engine Nm 50 50 50

Number Designation Transmission Transmission

BA26.60-N-1049-01D Hydraulic line to bracket M6 Nm 8 8

Number Designation Engine

BA49.10-N-1001-01J Clamp bolt, exhaust pipe to engine brake valve Nm 50

000 589 54 37 00 904 589 04 63 00

© Daimler AG, 7/2/13, G/03/13, ar01.10-w-2400g, Remove/install engine Page 8 of 9

© Daimler AG, 7/2/13, G/03/13, ar01.10-w-2400g, Remove/install engine Page 9 of 9

1 Cylinder head cover