Freightliner Business Class M2 Workshop Manual (EN)

BUSINESS CLASS M2 WORKSHOP MANUAL Models: M2 100 M2 106 M2 106V M2 112 M2 112V STI-457, S18 (9/10P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

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Foreword The purpose of this manual is to assist the service technician when the vehicle is serviced. Major drivetrain component service information is not included in this manual, but is located in each manufacturer’s service manual. Instructions and procedures are those recommended by Freightliner Trucks or the component manufacturer. Maintenance schedules and additional service information are included in the Business Class ® M2 Maintenance Manual . IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing.

Freightliner Trucks reserves the right to discontinue models, and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice. Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.com for more information, or contact Daimler Trucks North America LLC at the address below. Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them.

To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials. NOTICE: Parts Replacement Considerations Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage. © 2002–2010 Daimler Trucks North America LLC All rights reserved.

No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North America LLC is a Daimler company. Daimler Trucks North America LLC Service Systems and Documentation (CVI-SSD) P.O. Box 3849 Portland, OR 97208-3849

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Introduction Descriptions of Service Publications Daimler Trucks North America LLC distributes the following major service publications in paper and electronic (via ServicePro ® ) formats. Workshop/Service Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, trans- missions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, specifications, and troubleshooting.

Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems. They have information such as lubrication procedures and tables, fluid replacement procedures, fluid capacities, specifica- tions, and procedures for adjustments and for checking the tightness of fasten- ers. Maintenance manuals do not contain detailed repair or service information. Driver’s/Operator’s Manual Driver’s/operator’s manuals contain information needed to enhance the driver’s understanding of how to operate and care for the vehicle and its components.

Each manual contains a chapter that covers pretrip and post-trip inspections, and daily, weekly, and monthly maintenance of vehicle components. Driver’s/ operator’s manuals do not contain detailed repair or service information. Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve- ments, and related information. Some service bulletins are updates to informa- tion in the workshop/service manual. These bulletins take precedence over workshop/service manual information, until the latter is updated; at that time, the bulletin is usually canceled. The service bulletins manual is available only to dealers.

When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject. IMPORTANT: Before using a particular service bulletin, check the current service bulletin validity list to be sure the bulletin is valid. Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures. Web-based repair, service, and parts documentation can be accessed using the following applications on the AccessFreightliner.com website.

ServicePro ServicePro ® provides Web-based access to the most up-to-date versions of the publications listed above. In addition, the Service Solutions feature provides di- agnostic assistance with Symptoms Search, by connecting to a large knowledge base gathered from technicians and service personnel. Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data. PartsPro PartsPro ® is an electronic parts catalog system, showing the specified vehicle’s build record.

EZWiring EZWiring makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be ac- cessed from within PartsPro. Business Class M2 Workshop Manual, Supplement 17, March 2010 I – 1

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Introduction Descriptions of Service Publications Warranty-related service information available on the AccessFreightliner.com website includes the following documentation. Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice. These campaigns pertain to matters of vehicle safety. All recall campaigns are distributed to dealers; customers receive notices that apply to their vehicles. Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or replacement of parts.

All field service campaigns are distributed to dealers; cus- tomers receive notices that apply to their vehicles. I – 2 Business Class M2 Workshop Manual, Supplement 17, March 2010

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