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OM 904 LA – OM 906 LA – OM 924 LA – OM 926 LA Operating Instructions

Order no. 6462 9806 02 Part no. 906 584 11 81 EN Edition A 08/03

Thank you for choosing this Mercedes-Benz engine. Please get to know your new MercedesBenz engine first. Make sure you read the Operating Instructions in particular before using the engine for the first time. In this way you can ensure successful and safe use. At the same time you will avoid endangering yourself and others when operating the engine. Items of special equipment are marked with an asterisk *. The equipment in your Mercedes-Benz engine may vary, depending on the version. Mercedes-Benz is constantly updating its engines to the state of

the art. You cannot, therefore, base any claims on the data, illustrations or descriptions in these Operating Instructions. For further information contact a Mercedes-Benz Service Centre. The Operating Instructions and Maintenance Booklet belong with the engine. You should therefore always keep them with the engine and pass them on to the new owner if you sell it. The technical documentation team at DaimlerChrysler AG wishes you every success.

Contents
1 Introduction 5 6 7 8 9 4 Safety 36 37 38 39 40 Cleaning/protective treatment . . . . Cleaning the engine . . . . . . . . . . . . Cleaning the cooling system . . . . . . Protective treatment. . . . . . . . . . . . Service products . . . . . . . . . . . . . . . . Diesel fuels . . . . . . . . . . . . . . . . . . . Engine oils . . . . . . . . . . . . . . . . . . . Coolant . . . . . . . . . . . . . . . . . . . . . . 6 Maintenance 66 67 67 67 67 68 68 55 55 56 58 59 60 62 63

The aim of these Operating Instructions . . . . . . . . . . . . . . . . . . . . . Symbols . . . . . . . . . . . . . . . . . . . . . . . . Protection of the environment . . . . . . Operating safety . . . . . . . . . . . . . . . . . Correct use. . . . . . . . . . . . . . . . . . . . 2 At a glance

Safety precautions. . . . . . . . . . . . . . . Personnel qualifications . . . . . . . . . . Conversion parts and modifications . . . . . . . . . . . . . . . . . . . Safety /emergency running programs . . . . . . . . . . . . . . . . . . . . . . Genuine Mercedes-Benz parts . . . . . 5 Operation

OM 904 LA/OM 924 LA . . . . . . . . . . OM 906 LA/OM 926 LA . . . . . . . . . . Location of sensors . . . . . . . . . . . . . . Engine plate . . . . . . . . . . . . . . . . . . . . 3 Before commissioning

12 16 20 22

General . . . . . . . . . . . . . . . . . . . . . . . . Type designation . . . . . . . . . . . . . . Engine data card. . . . . . . . . . . . . . . Description of the engine . . . . . . . . Flame-start system*. . . . . . . . . . . . Grid heater* . . . . . . . . . . . . . . . . . . Exhaust brake /constantly-open throttle valve*. . . . . . . . . . . . . . . . . Telligent® engine system . . . . . . . . Transport and installation . . . . . . . .

24 24 24 25 26 27 28 29 33

Commissioning. . . . . . . . . . . . . . . . . . Preparation. . . . . . . . . . . . . . . . . . . Starting the engine for the first time . . . . . . . . . . . . . . . . . . . . . . . . Starting the engine . . . . . . . . . . . . . Monitoring engine operation . . . . . . Charge current . . . . . . . . . . . . . . . . Telligent® engine system . . . . . . . . Flame-start system*. . . . . . . . . . . . Grid heater* . . . . . . . . . . . . . . . . . . Stopping the engine. . . . . . . . . . . . . . Winter operation . . . . . . . . . . . . . . . .

42 42 44 47 49 49 50 50 51 52 53

Maintenance instructions . . . . . . . . . Overview of work plans . . . . . . . . . . . Maintenance service . . . . . . . . . . . . Additional work . . . . . . . . . . . . . . . . Additional work during every 3rd maintenance service . . . . . . . . Work plans . . . . . . . . . . . . . . . . . . . . . Engine: Checking for leaks and general condition . . . . . . . . . . . . . . Lines and hoses on the engine: Checking for leaks and general condition . . . . . . . . . . . . . . . . . . . . . Engine: Oil change and filter replacement . . . . . . . . . . . . . . . . . . Adjusting the valve clearance . . . . .

68 69 73

Contents
Fuel prefilter: Cleaning the filter element. . . . . . . . . . . . . . . . . . . . . . Fuel prefilter with heated water separator*: Replacing the filter element. . . . . . . . . . . . . . . . . . . . . . Replacing the fuel filter element. . . Intake pipe between air cleaner and engine: Checking for leaks and general condition . . . . . . . . . . . Poly-V-belt: Checking the condition. . . . . . . . . . . . . . . . . . Engine brake: Checking the condition and setting . . . . . . . . . . . Engine cooling system: Checking and correcting the fluid level and the antifreeze /corrosion inhibitor . . . . . . . . . . . . . . . . . . . . . Cooling and heating system: Checking for leaks and general condition. . . . . . . . . . . . . . . . . . . . . Renewing coolant. . . . . . . . . . . . . . 7 77 Malfunctions, causes and solutions . . . . . . . . . . . . . . . . . . . . . . . 98 Jump-starting . . . . . . . . . . . . . . . . . . 106 8 Technical data Practical advice

78 80

82 83 88

Engine data . . . . . . . . . . . . . . . . . . . . 108 Test values and adjustment values . . . . . . . . . . . . . . . . . . . . . . . . 112 Tightening torques . . . . . . . . . . . . . . 113 9 Glossary and index

Technical terms . . . . . . . . . . . . . . . . 115 Index . . . . . . . . . . . . . . . . . . . . . . . . . 117 90

91 94

Introduction
The aim of these Operating Instructions The aim of these Operating Instructions
These Operating Instructions are intended to assist you in all situations with your new engine. Each section has a list of contents to help you find the information you require quickly: 2 At a glance 5 Operation The engine documentation comprises the following: these Operating Instructions the Maintenance Booklet Specifications for Service Products You may receive additional supplements depending on the equipment.

1

Here you will find all the information you will need when you are operating the engine. 6 Maintenance

This section gives you an overview of the layout of important components in the engine. 3 Before commissioning

This is where you will find more detailed information about maintenance work. 7 Practical advice

This contains the basic information you require for initial operation. If this is your first Mercedes-Benz engine, you should read this section first. 4 Safety

Here you will find practical help for possible problems. 8 Technical data

All the important technical data for the engine is listed here. 9 Glossary and index

This section contains important aspects with regard to safety when handling Mercedes-Benz 900 series engines.

The glossary of technical terms explains the most important technical concepts. The index is intended to help you find information quickly.

5

Introduction
Symbols Symbols

1 You will find the following symbols used in
these Operating Instructions: * This asterisk indicates special equipment. Since not all models have the same standard equipment, the layout of your engine may differ from certain descriptions and illustrations. Warning

Environmental note

H

This symbol means that you have to do something. A number of these symbols one after the other indicates a sequence of actions. page This symbol indicates the page on which you will find further information on the subject. This continuation symbol indicates an interrupted sequence of actions that will be continued on the next page. -> This symbol in the glossary of technical terms means that the term following the arrow is also explained.

An environmental note gives you tips on the protection of the environment.

!
This note draws your attention to possible hazards to your engine.

G

i
This tip contains advice or further information you may find useful.

A warning draws your attention to possible risks of accident and injury to yourself and others. You should therefore always read and observe all warning notices.

6

Introduction Protection of the environment Protection of the environment Environmental note H Fuel consumption and engine wear depend on the operating conditions. 7 . Operate the engine in an environmentallyresponsible manner. This policy starts at the root causes and encompasses in its management decisions all the consequences for the environment which could arise from production processes or the products themselves. and you will help to protect the environment. The objectives are for the natural resources which form the basis of our existence on this planet to be used sparingly and in a manner which takes the requirements of both nature and humanity into account. Therefore you should: not warm up the engine at idle switch off the engine during waiting periods imposed by operations monitor fuel consumption carry out the specified maintenance work regularly 1 DaimlerChrysler's declared policy is one of integrated environmental protection.

safe engine operation also depends on correct servicing. Improper operation of the engine. Faulty maintenance work or failure to carry out maintenance work. exceeding the permitted maximum engine speed in overrun mode or operating the engine with too little oil. Secondly. e. Therefore. etc.g. not changing the oil filter or not observing the correct maintenance interval.g. Engine damage can lead to an increase in the risk of accident. Risk of accident G Risk of accident G Some of the requirements for operating the engine safely can be achieved by adhering to the specified maintenance intervals and ensuring that the required maintenance work is carried out correctly. machine. such as checking the engine oil level at regular intervals. e.g. Engine damage can lead to an increase in the risk of accident.Introduction Operating safety Operating safety 1 The operating safety of an engine firstly depends on its proper installation into the complete system (e. vehicle. as operator or service personnel. observe the notes on operating the engine in these Operating Instructions. 8 . can cause engine damage.). you also have a direct influence on the safe operation of the engine. can cause engine damage. However. Therefore. observe the notes on engine maintenance in these Operating Instructions.

Introduction Operating safety Risk of accident G Work incorrectly carried out on electronic components and its software could impair the functioning of these components. this might also affect systems that have not been modified. The engine must not be modified. Mercedes-Benz recommends that you use a Mercedes-Benz Service Centre for this purpose. adhering to the maintenance intervals and performing maintenance work correctly in accordance with these Operating Instructions. Always have work on or modifications to electronic components carried out at a qualified specialist workshop which has the necessary specialist knowledge and tools to carry out the work required. 1 9 . Since the electronic systems are networked. The manufacturer of the end product is personally responsible for the complete system of the end product. and in particular for the correct installation and compatibility of this engine with the complete system. DaimlerChrysler accepts no responsibility for damage caused as the result of modifications. Correct use The engine is only designed for installation in accordance with the specifications determined in the contract. Correct use of the engine includes adhering to these Operating Instructions.

10 .

At a glance OM 904 LA /OM 924 LA OM 906 LA /OM 926 LA Location of sensors Engine plate 2 11 .

At a glance OM 904 LA/OM 924 LA OM 904 LA /OM 924 LA 2 12 .

At a glance OM 904 LA/OM 924 LA 1 2 3 4 5 6 7 8 9 a b c d Fan Poly-V-belt tensioning pulley Coolant pump Charge pressure pipe (with flame-start system*) from intercooler Charge pressure pipe to intercooler Crankcase ventilation system Heating delivery line* coolant line Oil filler neck Fuel filter Fuel prefilter Dipstick Air compressor (with power-steering pump*) Engine control unit 2 13 .

At a glance OM 904 LA/OM 924 LA 2 14 .

At a glance OM 904 LA/OM 924 LA 1 2 3 4 5 6 7 8 9 a Flywheel housing Charge-air housing Oil filler neck Charge pressure pipe to intercooler Charge pressure pipe (with flame-start system*) from intercooler Exhaust manifold Oil filter Exhaust gas turbocharger Alternator Starter motor 2 15 .

At a glance OM 906 LA/OM 926 LA OM 906 LA /OM 926 LA 2 16 .

At a glance OM 906 LA/OM 926 LA 1 2 3 4 5 6 7 8 9 a b c d e f g Fan Poly-V-belt tensioning pulley Coolant pump Heating forward line* coolant line Charge pressure pipe from intercooler Oil filter Charge pressure pipe to intercooler Oil filler neck Charge-air housing Cylinder head cover Fuel filter Fuel prefilter Engine control unit Air compressor* Dipstick Power-steering pump 2 17 .

At a glance OM 906 LA/OM 926 LA 2 18 .

At a glance OM 906 LA/OM 926 LA 1 2 3 4 5 6 7 8 9 a b Starter motor Flywheel housing Exhaust gas turbocharger Exhaust manifold Charge-air housing Cylinder head cover Oil filler neck Charge pressure pipe to intercooler Charge pressure pipe from intercooler Crankcase ventilation system Alternator 2 19 .

At a glance Location of sensors Location of sensors OM 904 LA/OM 924 LA (comparable to OM 906 LA/ OM 926 LA) 2 20 .

At a glance Location of sensors 1 2 3 4 5 Oil pressure sensor Coolant temperature sensor Fuel temperature sensor TDC sensor (on the camshaft sprocket) Crankshaft position sensor (on the flywheel) 6 Combined charge-air /charge-air pressure sensor 2 21 .

2 Location of engine plate 22 .At a glance Engine plate Engine plate Location The engine plate is located on the righthand side of the engine at the rear underneath the exhaust manifold (arrow).

Before commissioning General Transport and installation 3 23 .

24 . including special equipment features. It contains details about the engine's construction. later changes to the scope of delivery are not included on the data card. Always keep the engine data card with the Maintenance Booklet. 3 Engine data card i The engine data card describes the scope of delivery from the factory from which the engine was shipped. The engine data card must be produced for the procurement of genuine parts.Before commissioning General General Type designation OM 9XX L A OM Oil engine (diesel engine) 9XX L Engine type Intercooler A Exhaust gas turbocharger Engine data card The engine data card (DIN A4 sheet) forms an integral part of the documents belonging to the engine and should always be kept with the Maintenance Booklet.

The cylinders are arranged in-line and have separate fuel-injection pumps (unit pumps) with a short high-pressure fuelinjection line to the multi-hole nozzle located centrally in relation to the combustion chamber. The engine can be optionally equipped with an engine brake* (throttle and constantly-open throttle valves). Thanks to its fully electronic control system for controlling the injection quantity and injection timing via solenoid valves. this is a particularly low-emission engine. Each cylinder has two inlet valves and one exhaust valve. all interconnected via the Controller Area Network (CAN). 3 25 . The unit pumps are mounted directly on the crankcase. The engines are equipped with an exhaust gas turbocharger (sometimes with chargepressure limiting) and intercooler as standard. They are driven by the camshaft roller tappets. an engine control (MR) and an application-related vehicle control unit (FR) or an adaptation module (ADM).Before commissioning General The control system comprises an engineresident control module. Description of the engine The OM 904 LA/ OM 924 LA (4-cylinder) and OM 906 LA /OM 926 LA (6-cylinder) engines are water-cooled four-stroke diesel injection engines.

It reduces the white smoke emission after the engine is started. Fuel can be ignited by a flame glow plug integrated in the charge-air pipe from the intercooler. Flame-start system Flame-start system indicator lamp The flame-start system is primed after a preglow time (maximum 20 seconds) which is dependent on the outside temperature. In addition. The flame-start system is only operational if the engine is started within 30 seconds of the flame-start system indicator lamp going out. the flamestart system is supplied with fuel by the engine's fuel delivery pump. Once the engine has started. it reduces the strain on the starter motor and batteries by shortening the startup time. After this time the flame-start system indicator lamp goes out.Before commissioning General 3 Flame-start system* The flame-start system is a cold-start aid for starting at low outside temperatures. 26 . The fuel is supplied to the flame glow plug via a solenoid valve with a dosing jet.

3 27 . The charge-air is preheated by a heater strip integrated in the charge-air pipe from the intercooler. In addition. it reduces the strain on the starter motor and battery by shortening the startup time.Before commissioning General ! If the flame-start system indicator lamp does not go out after more than 20 seconds there is a malfunction in the flame-start system. The white smoke limit is reduced by a runon heating time of up to 180 seconds after starting the engine. Grid heater* The grid heater is a cold-start aid for starting at low outside temperatures. See also the "Diesel fuels" section ( see page 60) and "Coolant" section ( see page 63) for operation of the engine at low outside temperatures.

At the same time. they form a connection from the combustion chamber to the exhaust port.300 rpm) or at temperatures below 40 °C. When open.Before commissioning General When the engine brake* is applied. the engine can be equipped with an engine brake valve on the exhaust gas turbocharger in conjunction with constantly-open throttle valves on the cylinders. Constantly-open throttle valves on a 4-cylinder engine 3 Exhaust brake/ constantly-open throttle valve* To increase braking power. the engine brake valve on the exhaust gas turbocharger is closed. This opens the valves. The constantly-open throttle valves are not controlled at lower engine speeds (900/ 1. the constantly-open throttle valves are pneumatically pressurised on the 4-cylinder engine and hydraulically pressurised on the 6-cylinder engine. while compression (2nd cycle) is practically unaffected. these limitations must be taken into account under braking conditions. The constantly-open throttle valves are small valves in the cylinder head and located on the side opposite the exhaust valve. 28 . When the power unit is being used. the constantly-open throttle valves cause a pressure reduction in the working cycle (3rd cycle). While the exhaust gas back pressure from the engine brake valve is used to increase the braking power.

The engine brake* is also automatically deactivated if the position sensor is triggered (e. and a drive control unit and/ or other vehicle-specific control units or ADM.Before commissioning General The engine brake* is controlled by the drive control unit ( page 31) or the ADM. in addition to the engine and related sensors. The engine brake* is automatically disabled again once the constant engine speed has been reached. 29 . 3 i In emergency running mode (constant engine speed). The engine brake* is always disabled below 900 rpm to prevent the engine from stalling. also comprises: an engine control unit. the engine brake* can only be activated in overrun mode at a higher engine speed. Both are interconnected via a CAN (Controller Area Network) line which exchanges all the necessary data / information. which.g. Telligent® engine system The engine has a fully electronic control system. if the accelerator pedal is depressed). A safety and emergency running program is selected automatically depending on the malfunctions /failures occurring ( page 39). The engine control monitors itself as well as the engine.

such as those for: charge-air pressure and temperature coolant temperature 3 fuel temperature oil pressure These parameters are compared with the characteristic maps and graphs stored in the engine control unit. The type plate is located on the engine control unit in the upper right-hand corner. etc. This data is evaluated along with data from the sensors on the engine. the engine brake* or engine start/ stop. All the information on the control unit type plate is required to obtain a replacement engine control unit. duration and amount of injection are calculated from the graphs and the unit pumps are controlled accordingly via the solenoid valves.Before commissioning General Engine control unit (engine-resident) The engine control unit is located on the left-hand side of the engine. Start. Engine plate Equipment code 30 . such as the position of the setpoint value sensor (accelerator pedal). 1 2 3 4 Data record Certification no. Control unit type plate i Engine control unit The engine control unit processes data coming from the drive control unit or the ADM.

traction control) engine control unit (e.g. The drive control unit and the ADM control various displays.g.Before commissioning General FR (drive control) unit or ADM (appliance-resident) The engine can be adapted to meet the various application-specific requirements by means of the FR (drive control) unit or adaptation module (ADM). The FR (drive control) unit and the ADM receive data from the operator (position of setpoint value sensor. e.g. 31 . 3 Drive control unit The FR (drive control) unit or the ADM unit stores data for specific applications. the electronics warning lamp. oil pressure and coolant temperature) From this data. the instructions for the MR (engine control) unit are computed and transmitted to it via the CAN line. maximum working speed and speed limitation. engine start/ stop) engine brake switch* other systems (e. the engine brake* and the constantly-open throttle valves*. such as idling speed.

Diagnostic socket Organisational measures Risk of accident and injury G Before operating the engine. The Operating Instructions and Maintenance Booklet must be given to the personnel responsible for operating the engine or carrying out work on the engine. the country-specific legal and all other binding regulations for accident prevention and protection of the environment must be observed. Personnel must be instructed in how to work on the engine using these Operating Instructions. In addition to these Operating Instructions. 14-pin diagnostic socket. this is stored as a fault code in the control units and can be read using the appropriate diagnostic equipment (STAR DIAGNOSIS or Minidiag 2). such as the operating instructions for the vehicle or the machine the engine is installed in. You could otherwise fail to recognise dangers and could injure yourself or others. the electronics warning lamp is The DaimlerChrysler diagnostic testers can be connected to the equipmentresident. 32 . the safety notes must be explained. 3 switched on. i In addition. please read these Operating Instructions and other relevant documentation. Both the malfunction memory and the stored engine data can be read with this equipment. In particular. and should be kept in an easily accessible place where the engine is used. This is especially important for personnel who only work on the engine occasionally.Before commissioning General If the Telligent® engine system detects a fault.

Before commissioning Transport and installation Transport and installation Transport Risk of accident and injury G 3 The engine can tear loose and cause injury to persons by overturning or falling. flywheel end Lifting point. Lifting point. Only use transport equipment which has been approved for use by DaimlerChrysler. timing end 33 . Only lift the engine by the appropriate lifting points on the engine. Only lift and transport the engine in its installation position.

Before commissioning
Transport and installation
Installation The engine is only designed for installation in accordance with the specifications determined in the contract. The manufacturer of the end product is

3 personally responsible for the complete
system of the end product, and in particular for the correct installation and compatibility of this engine with the complete system. Observe the "Correct use" ( page 9) and "Conversion parts and modifications to the engine" ( page 38) sections. These Operating Instructions contain installation data in the "Technical data" section. Should you have any questions, please contact a Mercedes-Benz Service Centre.

i
The engine is filled with engine oil at the factory.

34

Safety
Safety precautions Personnel qualifications Conversion parts and modifications to the engine Safety/emergency running program Genuine Mercedes-Benz parts

4

35

Safety
Safety precautions Safety precautions
Make sure that the following safety precautions are observed to prevent injury to persons as well as damage to the engine, components and cable harness.

!
Note that for electric welding work, the batteries must be disconnected and both connector leads ("+" and "–") securely connected to each other. The control unit connectors must only be removed or inserted when the electrical system has been switched off. Incorrect polarity of the control unit supply voltage (e.g. through incorrect battery polarity) can cause irreparable damage to the control units. Tighten the connections to the fuelinjection system to the specified tightening torque. The control units must be removed if temperatures over 80 °C (e.g. in the drying oven) are expected.

!
Only use suitable test leads (e.g. DaimlerChrysler connection set) for measuring connectors. Telephones and two-way radios which are not connected to an external aerial can cause malfunctions to the vehicle's electronics and could therefore endanger the engine's operating safety.

!
Only start the engine with securely connected batteries.

4

Do not disconnect the batteries with the engine running. Only start the engine with the rotational speed sensor connected. Do not use a rapid charger to start the engine. Only perform jump-starting with separate batteries. Please note that the battery terminals must be removed for rapid battery charging. Observe the rapid charger operating instructions.

36

Mercedes-Benz recommends that you use a Mercedes-Benz Service Centre for this purpose. Always have work on or modifications to the engine carried out at a qualified specialist workshop which has the necessary specialist knowledge and tools to carry out the work required. Maintenance and repair work on the engine may only be carried out by personnel who have undergone the appropriate training. G Maintenance and repair work to the engine incorrectly performed can cause engine damage and may lead to personal injury as a consequence. maintenance and repairs must be determined by the operator. The legal minimum age for carrying out the work listed above must be observed. Responsibility for operation. maintained and repaired by trained personnel instructed and authorised by the operator.Safety Personnel qualifications Personnel qualifications Risk of accident and injury Engines may only be operated. 4 37 .

Safety Conversion parts and modifications Conversion parts and modifications Risk of accident G ! Tampering with the fuel-injection system and engine electronics can affect the engine's performance and emissions characteristics. 38 . Always have work on or modifications to the engine carried out at a qualified specialist workshop which has the necessary specialist knowledge and tools to carry out the work required. Tampering with the engine with the intention to produce modifications to it can impair both its correct operation and its safety. leading to personal injury as a consequence. 4 The warranty does not cover damage arising from tampering with the engine. Compliance with the factory settings and legal environmental protection conditions can then no longer be guaranteed. Mercedes-Benz recommends that you use a Mercedes-Benz Service Centre for this purpose.

Risk of accident G Incorrectly performed maintenance and repair work on the engine can impair both its correct operation and safety. connected to the 14-pin diagnostic socket (equipment-resident). Always have work on or modifications to the engine carried out at a qualified specialist workshop which has the necessary specialist knowledge and tools to carry out the work required. The fault codes may be shown on a display which is part of the Telligent® engine system (vehicle diagnostic system). 4 Electronic system warning lamp i The fault codes can be read from the DaimlerChrysler diagnostic testers (STAR DIAGNOSIS or Minidiag 2 tester). As soon as the electronic control system has detected and assessed a malfunction. the electronic system warning lamp lights up. Mercedes-Benz recommends that you use a Mercedes-Benz Service Centre for this purpose. The engine switches to the appropriate back-up function for continued (but restricted) operation (e. indicating a malfunction. 39 . one of the following measures is automatically implemented: When the engine is in operation. constant emergency running speed).g. leading to accidents and personal injury as a consequence.Safety Safety /emergency running programs Safety/emergency running programs The engine is equipped with an electronic control system which monitors both the engine and itself (self-diagnostic system).

or Additional information about recommended conversion parts and accessories and permissible technical modifications is available from any Mercedes-Benz Service Centre. You will find the numbers on the engine ( page 22) and on the engine data card ( page 24). 4 cause a deterioration in exhaust gas emission levels or noise levels. The use of non-approved parts can impair safety. 40 . These are of the same quality and have the same warranty as new parts.Safety Genuine Mercedes-Benz parts Genuine Mercedes-Benz parts Make sure that the replacement parts are suitable for your vehicle. Always quote the engine plate and type designation when ordering genuine parts. Environmental note H To combine cost-effective repairs with recycling. Mercedes-Benz also offers reconditioned engines and parts. will result in the invalidation of the General Operating Permit (in many countries). Parts which lead to a vehicle modification.g.: a change in the type of vehicle approved in the General Operating Permit which could pose a threat to road users. e.

Operation Commissioning Monitoring engine operation Stopping the engine Winter operation Cleaning/protective treatment Service products 5 41 .

This eliminates the need for special initial operation oils and the oil change otherwise required.5 of the Mercedes-Benz Specifications for Service Products are used.5 of the Mercedes-Benz Service Product Guidelines. 5 Check the oil level and add engine oil if necessary via the filler neck (arrow) up to the maximum mark on the dipstick ( see page 71). The extended maintenance intervals can be observed if engine oils in accordance with Sheet 228. enabling the first oil change to take place at the usual oil change intervals for normal operation. These high-quality engine oils assist the running-in process. the engine is filled with engine oil in accordance with Sheet 228. Oil filler neck Topping up with coolant Coolant composition ( see page 63) Filling the cooling system ( see page 94).Operation Commissioning Commissioning Preparation When it leaves the factory. 42 .

Operation
Commissioning
Refuelling Use summer or winter fuel depending on the season. See also "Diesel fuels" ( page 60). Checking the batteries Risk of burning

G

Risk of explosion

G

!
Make sure that utmost cleanliness is observed while refuelling and that no water is allowed to enter the tank. Bleeding the fuel system The fuel system is bled when the engine is started after refuelling if the fuel system was previously allowed to run dry. Continuous bleeding takes place automatically in the filter.

The acid contained in batteries burns skin and eyes on contact. Do not allow acid to come into contact with your skin, eyes or clothing. Wear suitable protective clothing, as battery acid can burn through normal clothing. In addition, protective gloves and safety goggles should be worn. Rinse acid splashes off immediately with clean water and consult a doctor if necessary.

Gases escaping from batteries can explode and injure people. Therefore, do not allow fire, naked flames, smoking or the creation of sparks in the vicinity of batteries.

Only use batteries which are completely filled and have been perfectly maintained. Grease the battery terminals with acidproof grease (terminal grease).

5

i
The cable cross-sections are dependent on the distance between the battery and the starter motor.

i
To ensure that the fuel system can be bled, the battery must have enough charge when the engine is started.

43

Operation
Commissioning

Starting the engine for the first time Carry out the work listed under "Preparation for commissioning" ( page 42) before operating the engine for the first time. Switch on the operating current. Start the engine with the setpoint value sensor at idling position (e.g. accelerator pedal), for instance by operating the starter switch on the equipment or Start button 2 on the engine, ( see page 47).

i
As a safety feature, the Telligent® engine system is equipped with a function that only allows the engine to be started with the transmission in neutral.

Risk of burns

G

5

The engine becomes very hot while it is running and remains so for some time after it has stopped. It will cause burns if you touch it. Start-Stop buttons Before starting any work on the engine, allow all engine parts to cool down or else wear suitable gloves and items of clothing to protect yourself against hot engine components.

1 Stop button 2 Start button

44

Operation
Commissioning

Risk of injury

G

Risk of scalding

G

Risk of poisoning

G

There is a danger of limbs being caught, entrapped, crushed or torn off by rotating engine parts. Therefore you should: Keep a safe distance between yourself and rotating engine parts, including when the engine is being started. Wait until all engine parts have come to a standstill before carrying out any work on the engine. Wear work clothing which is fastened and close-fitting. Wear a hair net if necessary. Remove jewellery such as watches and necklaces.

The cooling system is pressurised. Hot coolant can spray out when the cooling system is opened and scald your skin and eyes. Only open the cooling system at coolant temperatures below 90 °C. Unscrew the sealing cap slowly and release any excess pressure completely before opening the cap fully. Wear suitable protective gloves, protective clothing and safety goggles when handling coolant.

There is a risk of poisoning if coolant is swallowed. Never swallow coolant. Never put coolant into container normally used for beverages. Store coolant out of the reach of children.

To check the coolant level: Leave the engine running at moderate speeds for approximately 5 minutes. If the coolant temperature is below 50 °C, check the coolant level again and add coolant if necessary.

5

45

all heating system valves must be opened while the cooling system is being topped up. and tighten if necessary. Check the engine oil level approximately 5 minutes after stopping the engine and add oil up to the maximum mark on the dipstick if necessary. Check the securing bolts on the exhaust manifold. Otherwise there might be too little coolant in the cooling system after filling. Check the engine for leaks.Operation Commissioning ! If a heating system is connected to the cooling system. starter motor and air compressor for firm seating. Top up with coolant if necessary. Check for firm seating of mountings on the engine. 5 46 . hose clamps and pipe connections on the engine as well as the oil feed and return lines on the exhaust gas turbocharger for leaks and firm seating. Check the hose fittings. coolant pump. Only close the heating system valves once the engine has been running for a brief period. engine mountings.

Place wheel chocks in front of or behind the wheels. knocking people down or trapping them. 47 . Insert the key into the ignition and turn it to the driving position. 5 i Starting the engine for the first time ( see page 44). Shift the transmission into neutral. Shift the transmission into neutral. Before starting the engine: Prevent the vehicle from rolling away by applying the parking brake and. by placing chocks under the wheels. Carry out special measures before starting the engine when it has been stopped for a long period. a vehicle might accidentally be set in motion when the engine is started. if necessary. using an electric preheating device) Starting procedure In the case of vehicle engines.g. At outside temperatures below –30 °C we recommend preheating the coolant (e.Operation Commissioning Starting the engine Risk of injury i G If not properly secured. see the "Cleaning/protective treatment" section ( page 55). secure the vehicle to prevent it from rolling away accidentally: Apply the parking brake. The following indicator and warning lamps light up: 1 Charge current indicator lamp 2 Electronic system warning lamp 3 Flame-start system indicator lamp or grid heater Start the engine within 30 seconds of the flame-start indicator lamp going out.

flame-start system not in operation) to approximately 20 seconds (maximum preglow time) depending on the outside temperature. 48 . break off the starting procedure after a maximum of 20 seconds.Operation Commissioning ! Keep the engine running at idling speed until an oil pressure reading is displayed. The preglow time lasts for approximately 30 seconds and depends on the temperature of the coolant and the charge air. there are malfunctions. the indicator lamp lights up and then goes out once the preglow time has finished. i 5 Start-Stop buttons If necessary. If the indicator lamp for the fl ame-start system does not go out after approxi mately 20 s econds. i The grid heater is controlled by the drive control unit or the ADM control unit. do not place the cold engine under a full load immediately after starting. Determine the cause. 1 Stop button 2 Start button using the starter switch on the equipment using Start button 2 on the engine. The charge current indicator lamp and electronic system warning lamp must go out after the engine has started. Monitor the oil pressure gauge immediately after starting the engine. ( see page 49) and ( page 50). If no oil pressure is displayed after approximately 10 seconds. and then repeat after approximately 1 minute. During the preglow time. there is a fault. If they remain on. see the "Oil pressure" section ( page 51). At extremely cold temperatures. s ee the "Telligent® engine s ystem" section ( page 50). i The indicator lamp for the flame-start system lights up for approximately 2 seconds (function check. switch off the engine.

Do not run the engine without a poly-Vbelt since the alternator and coolant pump will not be driven. 49 . torn). This will result in engine damage. ! The poly-V-belt contact surfaces must not be damaged (e. oily or glazed. 5 Charge current indicator lamp If the indicator lamp does not go out or lights up when the engine is running.g.Operation Monitoring engine operation Monitoring engine operation Charge current The charge current indicator lamp must go out after the engine has been started. stop the engine and check the poly-V-belt.

( see page 31). Flame-start system* 5 Electronic system warning lamp Flame-start system indicator lamp There is a fault in the flame-start system. the flame-start system indicator lamp lights up when the engine is running the flame-start system indicator lamp does not go out after more than approximately 20 seconds when the engine is started 50 . Even temporary faults are stored. The fault codes may be shown on a display which is part of the Telligent ® engine system (vehicle diagnostic system). If the electronic system warning lamp lights up while the engine is running. there is a fault in the Telligent® engine system. Each fault is stored in the system with a special fault code. read or determine the fault code. if: If the warning lamp does not go out or lights up while the engine is running. Fault codes can be read using DaimlerChrysler diagnostic equipment (STAR DIAGNOSIS or Minidiag 2-Tester).Operation Monitoring engine operation Telligent® engine system The electronic system warning lamp must go out after the engine has been started.

5 bar at idling speed If the pressure falls below these values.Operation Monitoring engine operation Have the flame-start system checked at a specialist workshop. stop the engine and determine the cause. if: the engine is not started within 30 seconds of the flame-start system indicator lamp going out the engine is started while the flame-start system indicator lamp is still lit the charge current indicator lamp does not go out when the engine is running the engine reaches a temperature at which the flame-start system is no longer needed 5 51 . Oil pressure Grid heater* ! There is a fault with the grid heater if the indicator lamp flashes.5 bar at rated speed 0. i The flame-start system switches off automatically. ! Once the operating temperature has been reached. the engine oil pressure must not fall below: 2. DaimlerChrysler recommends that you visit a Mercedes-Benz Service Centre for this purpose as it has the necessary specialist knowledge and tools to carry out the work required.

Press Stop button 1 on the engine or on the equipment-resident stopping facility. allow the engine to idle without load for one or two minutes. ! Stop the engine immediately if you observe any of the following signs: oil pressure drops or fluctuates considerably power and speed drop while the position sensor (accelerator pedal position sensor) stays in the same position large amounts of exhaust smoke are emitted from the exhaust coolant and oil temperature increase very quickly 5 Start-Stop buttons 1 Stop button 2 Start button unusual noises suddenly occur in the engine or exhaust gas turbocharger 52 .Operation Stopping the engine Stopping the engine After driving at full power output or at a high coolant temperature.

Avoid fire. protective clothing and safety goggles when handling coolant. naked flames. Store coolant out of the reach of children. 5 53 . There is an increased risk of fire when handling fuels as they are highly flammable. Hot coolant can spray out when the cooling system is opened and scald your skin and eyes. select an engine oil that is compatible with the SAE class and the ambient temperatures expected during the period of use ( see page 62). Engine oil When changing the engine oil. There is a risk of poisoning if coolant is swallowed. Never swallow coolant. Wear suitable protective gloves.Operation Winter operation Winter operation The following notes should be observed at the start of the cold season: Fuel Risk of fire Coolant Risk of poisoning Risk of scalding G G G The cooling system is pressurised. Unscrew the sealing cap slowly and release any excess pressure completely before opening the cap fully. Never put coolant into container normally used for beverages. Check the coolant's antifreeze protection in good time and increase the antifreeze/ corrosion inhibitor concentration if necessary ( see page 63). Use cold-resistant diesel fuel ( see page 60). and sparks and refrain from smoking when handling fuels. Only open the cooling system at coolant temperatures below 90 °C.

5 Careful maintenance and low power consumption will help maintain the full battery charge. Rinse acid splashes off immediately with clean water and consult a doctor if necessary. do not allow fire. Do not allow acid to come into contact with your skin. Ensure good ventilation when recharging. at -10 °C it is only about 60% of normal capacity. protective gloves and safety goggles should be worn. naked flames. and the creation of sparks and do not smoke in the vicinity of batteries. as battery acid can burn through normal clothing. G The acid contained in batteries burns skin and eyes on contact.Operation Winter operation Batteries Have the batteries serviced and recharged more frequently during the cold months of the year. In addition. eyes or clothing. for example. Starting capacity is greatly reduced in cold weather. Therefore. 54 . store the batteries in a heated place if possible. Wear suitable protective clothing. Risk of acid burns Risk of explosion G Gases escaping from batteries can explode and injure people. If the engine is not used for a long period of time.

Observe the instructions for using care and cleaning products. ventilation or bleed ducts.Operation Cleaning/protective treatment Cleaning/protective treatment Cleaning the engine Risk of fire and injury Risk of poisoning G ! Make sure that water does not enter the intake. Never use fuels for cleaning. Be careful to protect the belt drive against preservative agents. Only clean the engine in a washing area designed for this purpose. Fuels are highly flammable and can injure your health. Information about suitable cleaning and preservative agents is available from any Mercedes-Benz Service Centre. they can cause fires or skin irritation and poisoning. Dispose of empty packaging and used cleaning materials in an environmentally-responsible manner. If they are used as cleaning agents. Always keep care and cleaning agent containers closed and out of the reach of children. 5 55 . G Care and cleaning agents can be toxic and lead to severe poisoning if swallowed. i Environmental note H Observe the regulations for environmental protection. Protect the engine after cleaning. Never store care or cleaning products in foodstuff containers such as bottles so as to avoid confusion with foodstuffs.

To avoid damage. do not aim the water jet directly at: electrical components connectors seals or hoses Information about suitable cleaning and preservative agents is available from any Mercedes-Benz Service Centre. Cleaning the cooling system Risk of scalding Environmental note G H ! Maintain the minimum distance between the high-pressure cleaner nozzle and the object to be cleaned: approximately 70 cm for roundspray jets Collect used coolant. 5 approximately 30 cm for 25° flatspray jets and concentrated-power jets Keep the water jet constantly moving while cleaning. Hot coolant can spray out when the cooling system is opened and scald your skin and eyes. protective clothing and safety goggles when handling coolant. 56 . Only open the cooling system at coolant temperatures below 90 °C. Unscrew the sealing cap slowly and release any excess pressure completely before opening the cap fully. insects. etc.Operation Cleaning/protective treatment High-pressure cleaners Observe the manufacturer's operating instructions. Wear suitable protective gloves. ! Only apply moderate pressure when cleaning since the radiator fins could otherwise be damaged. Blow out any foreign objects (dust. cleaning solutions and detergents and dispose of them in accordance with current local regulations and in an environmentally-responsible manner.) from the radiator fins using compressed air or remove by spraying water on the rear side of the radiator (against the direction of the cooling air flow). The cooling system is pressurised.

Store coolant out of the reach of children. Immediately afterwards. fill the cooling system with clean water. warm up the engine.Operation Cleaning/protective treatment Drain off coolant when the engine is cold ( page 95). Never put coolant into container normally used for beverages. Fill the cooling system with new coolant ( page 96) and follow the instructions in the "Coolant" section ( page 63). Then repeat the procedure a second time. G There is a risk of poisoning if coolant is swallowed. If a heater is attached to the cooling system. Warm up the engine at moderate engine speed up to approximately 80 °C (coolant thermostat starts to open) and allow to run for approximately 5 minutes longer. Never swallow coolant. "P3 Croni" (50 g cleaning agent per litre of water).g. and drain off the water after 5 more minutes. e. Switch off the engine and allow to cool to approximately 50 °C. Drain off the cleaning solution completely. open the regulating valves fully. Risk of poisoning Degreasing Fill the cooling system with a 5% solution of water and a mild alkaline cleaner. 5 57 .

It is essential that the engine be protected from direct contact with water (rain/spray water). Protective treatment The special protection required will depend on the length of time the engine is to be out of use as well as the climate of the place where the engine is to be located or stored. After cleaning the engine. If this is not possible. 5 58 . store it in a dry.Operation Cleaning/protective treatment Information is available from any Mercedes-Benz Service Centre. If the engine is to be out of use for less than 12 months and the above conditions are met. special protective treatment measures are required. well-ventilated place as far as possible. If the engine is to be out of use for more than 12 months and there are exceptional storage and transport conditions. We strongly recommend asking for information. the intervals for carrying out regular protective measures must be halved. no corrosion-protection measures need to be taken.

Do not allow service products to come into contact with your skin. 59 . Observe the prevailing regulations when handling service products and storing and disposing of them. Risk of fire G Environmental note H 5 There is an increased risk of fire when handling fuels and lubricants as they are highly flammable.Operation Service products Service products Risk of poisoning/injury Special lubricant additives are not necessary. These are listed in the MercedesBenz Specifications for Service Products. eyes or clothing. The warranty entitlement may be restricted if special lubricant additives are used. avoid inhaling vapours. Always wear appropriate protective clothing and a breathing mask when handling service products. Keep service products out of the reach of children. Avoid fire. in an environmentallyresponsible manner. rinse off thoroughly with clean water and consult a doctor if necessary. the filter. naked flames. i Information is available from any Mercedes-Benz Service Centre. Consult a doctor immediately if a service product is swallowed. only brands that have been tested and approved by DaimlerChrysler should be used. Observe the legal requirements. Service products could otherwise endanger people and the environment. and sparks and refrain from smoking when handling service products. If possible. e. For this reason.g. Clean affected areas of skin with soap and water. G Service products can cause injury or poisoning if they come into contact with skin or are swallowed. Greases and lubricants must be compatible with engine components. If service products do come into contact with your eyes. Dispose of service products as well as parts which come into contact with service products.

5 60 . They ensure reliable operation down to approximately –20 °C. If diesel fuels with a sulphur content above 0. you must consult a Mercedes-Benz Service Centre to have the exact operating procedures (e. maintenance intervals) explained. To prevent operating problems (e. etc. diesel fuel with improved cold flow properties is available on the market in the winter months. Grades such as marine diesel fuel. Fuel additives are not necessary. Diesel fuels in extremely cold weather At low outside temperatures. are not permitted. as a result of blocked filters). carry out an oil change at shorter intervals. heating oils. The warranty entitlement may be restricted if fuel additives are used. This can lead to fuel system malfunctions. paraffin separation may affect the flow characteristics of diesel fuel.3% by weight are used. special cold-resistant winter-grade diesel fuels are sold.g. Diesel fuels Only use commercially available vehicle diesel fuels (EN 590). Deviations may be possible in the transition between the cold and the warm seasons. filter the fuel when filling the tank. and in other countries.Operation Service products The 900 series engines are suitable for use with FAME fuels in accordance with DIN E 51606. Therefore. Filling the vehicle's fuel tank from drums or canisters may introduce impurities into the fuel system. If you do so. Winter-grade diesel fuel can normally be used without risk of malfunctioning at the outside temperatures expected in the country of sale.g. Observe the information provided in the Maintenance Booklet. In Germany.

depending on the outside temperatures. Risk of fire and explosion ! If petrol is added. you must avoid fire. there is a risk of serious engine damage. naked flames and sparks and refrain from smoking when handling these service products. never add petrol to diesel fuel. Therefore. Comply with the manufacturer's recommendations. 5 61 . Malfunctions caused by paraffin separation can only be remedied by warming up the entire fuel system. The addition of 5% by volume of kerosene improves the coldresistance of diesel fuel by approximately 1 °C. as the fuel's cold-flow properties could deteriorate. Therefore. Do not add additives to especially coldresistant winter diesel fuels.Operation Service products If summer diesel fuel or winter diesel fuel with less resistance to low temperatures is used. only add a specific quantity of flow improver or kerosene. before paraffin separation affects the diesel's flow properties. Add the flow-improver additive to the diesel fuel in good time. depending on outside temperatures. Do not exceed the maximum mixing ratio of 50% kerosene. Flow improvers The effectiveness of flow improvers cannot be guaranteed with all fuels. Observe the relevant safety regulations. For this reason. Kerosene Add as little as possible. never add petrol to diesel fuel. G Adding petrol reduces the flash point for the diesel fuel and increases the risk of fire and explosion. Information about approved flow improvers is available from any Mercedes-Benz Service Centre.

naked flames and sparks and refrain from smoking when handling these service products. then the diesel fuel. only use engine oil brands approved by MercedesBenz. i The use of non-approved engine oil brands can restrict the warranty entitlement. Engine oil SAE classes Engine oils are specially tested for suitability in our engines. 62 . Observe the information provided in the Maintenance Booklet. 5 For this reason. These are listed in the MercedesBenz Specifications for Service Products. only mix kerosene with diesel fuel in the fuel tank. Add the kerosene first. you must avoid fire. Risk of fire and explosion Engine oils G Adding kerosene reduces the flash point of the diesel fuel and increases the risk of fire and explosion.Operation Service products For safety reasons. Run the engine for a while to ensure that the additive reaches all parts of the fuel system. Therefore. Observe the relevant safety regulations.

the engine oil change is entered in the Maintenance Booklet along with the engine oil brand. If the water is not of sufficient quality. i Information is available from any Mercedes-Benz Service Centre. Never put coolant into container normally used for beverages. Only use engine oils of the same grade and SAE class when topping up. even if antifreeze properties are not necessary. the properties of the engine oil are impaired and the engine oil and filter changes must therefore be carried out at shorter intervals. The coolant must remain in the cooling system all year round to ensure anti-corrosion protection and to increase the boiling point. Information is available from any Mercedes-Benz Service Centre. it must be treated. The coolant is a mixture of water and antifreeze/corrosion inhibitor. grade and SAE class. since the level of corrosion protection gradually decreases. 63 . Never swallow coolant. 5 i If engine oil of a lower grade is used to top up. i Renew the coolant every three years. After maintenance work. The coolant water must satisfy certain requirements which are not always fulfilled by drinking water.Operation Service products If engine oils of a different grade are used. There is a risk of poisoning if coolant is swallowed. Store coolant out of the reach of children. Water Coolant Risk of poisoning G Water without additives is not permitted as a coolant. Select the SAE class of engine oil in accordance with the outside temperatures. the oil change intervals will alter.

We recommend that you ask the relevant water authority for advice on the disposal of coolant. 5 ! If the concentration is too low.g. ! In this case. When topping up (after coolant loss). Information is available from any Mercedes-Benz Service Centre. When disposing of used coolants. Antifreeze/corrosion inhibitor % by vol. 64 . –37 °C approximately –45 °C 45 maximum 55 Disposal Environmental note H 50 50 The coolants mentioned are biodegradable substances. Due to the complex tasks which a modern coolant must perform. MB corrosion inhibitor A 000 98913 2510 by DaimlerChrysler AG or an approved additive from another manufacturer). use an approved coolant additive without antifreeze properties in accordance with Sheet 312. Above this concentration. antifreeze protection deteriorates and heat dissipation is less effective. there is a risk of engine damage as a result of corrosion/cavitation. make sure that the antifreeze/corrosion inhibitor concentration is 50% by volume (this ensures antifreeze protection down to –37 °C).0 of the Mercedes-Benz Specifications for Service Products (e. the coolant must be renewed every year.Operation Service products Antifreeze/corrosion inhibitor To prevent damage to the cooling system: Only use approved antifreeze/corrosion inhibitor. when no antifreeze/ corrosion inhibitor is available and/or no antifreeze protection is required (in tropical regions). observe the legal requirements and waste water regulations in the country concerned. In exceptional cases. improper "recycling" consisting simply of a mechanical pre-cleaning must be emphatically rejected. Do not use an antifreeze/corrosion inhibitor concentration of over 55% by volume (maximum antifreeze protection). Coolant mixing ratio: Antifreeze protection down to Water % by vol.

Maintenance Maintenance instructions Overview of work plans Work plans 6 65 .

please observe the instructions on servicing the engine given in these Operating Instructions. Have the work which is carried out confirmed in the Maintenance Booklet.g. Faulty maintenance work or failure to carry out maintenance work. For this reason. please make sure that you read the relevant sections of the technical documentation concerned with servicing and repairs. 66 .Maintenance Maintenance instructions Maintenance instructions This section describes all maintenance work which concerns the engine. can cause engine damage. e. This proof of regular maintenance is always required for any warranty claims. Risk of accident Risk of accident The scope of maintenance and frequency of maintenance work depend on the different operating conditions and are listed in the Maintenance Booklet.5 of the Mercedes-Benz Specifications for Service Products must be changed if more than 12 months elapse before the engine is operated for the first time. not changing the oil filter or not observing the correct maintenance interval. Also observe the maintenance regulations for special accessories.. 6 i All maintenance intervals and maintenance work refer to genuine MercedesBenz parts and accessories specifically approved for the engine by DaimlerChrysler. Engine damage can lead to an increased risk of accident. for example: Operating Instructions and workshop information You should also familiarise yourself first with the legal requirements. for example: work safety and accident prevention regulations You could otherwise fail to recognise dangers and could injure yourself or others. ! The engine oil filled at the factory in accordance with Sheet 228. G G Before any maintenance work or repairs are carried out.

Maintenance Overview of work plans Overview of work plans Maintenance service Engine: Oil change and filter replacement Checking and correcting the fluid level If more fluid is lost than can be accounted for by normal consumption. 6 67 . 5th. i Renewal interval depends on the coolant additive used (see Mercedes-Benz Specifications for Service Products). trace the cause and rectify. Poly-V-belt: Check condition Checking for leaks and general condition Check for points of abrasion and incorrect positioning: Engine Lines and hoses on the engine Intake pipe between air cleaner and engine Cooling and heating system i The valve clearance must be adjusted during the first maintenance service and then during the 3rd. 7th maintenance services and so on. Engine cooling system: Check and correct fluid level and antifreeze / corrosion inhibitor concentration Additional work Check and adjust valve clearance Additional work during every 3rd maintenance service Fuel prefilter: Clean filter element Fuel filter: Replace filter Fuel prefilter with water separator: Replace filter element Engine brake*: Check condition and setting Renew coolant i Change the engine oil and replace the oil filter at least once a year.

Lines and hoses on the engine: Checking for leaks and general condition Make a visual inspection of lines and hoses. Wear a hair net if necessary. Sealing points which are slightly damp are harmless. It may cause burns if you touch it.Maintenance Work plans Work plans Engine: Checking for leaks and general condition Visual inspection of the engine for signs of leakage. G 6 The engine is very hot when it is running and also for some time after it has been switched off. Wait until all engine parts have come to a standstill before carrying out any work on the engine. entrapped. Therefore you should: Keep a safe distance between yourself and rotating engine parts. Before starting any work on the engine. allow all engine parts to cool down or else wear suitable gloves and items of clothing to protect yourself against hot engine components. Remove jewellery such as watches and necklaces. ! Remedy more significant leaks involving constant oil loss immediately. crushed or torn off by rotating engine parts. 68 . Also make a listening check for: leaks check for undamaged condition chafe-free routing and correct mounting Risk of burns Risk of injury G There is a danger of limbs being caught. Wear work clothing which is fastened and close-fitting. including when the engine is being started.

Allow oil to drain from the filter housing. Never wipe the filter housing out. Risk of scalding G Hot engine oil spraying out can scald your skin and eyes.Maintenance Work plans Engine: Oil change and filter replacement i Only change engine oil when the engine is at normal operating temperature. ! Make sure that no foreign objects enter the filter housing. Oil filter cap 6 Remove the oil filter cap using the socket spanner insert (WAF 36). Wear suitable protective gloves. Unscrew cap 1 and oil filter element 3 and remove element 3 from the cap by pressing the lower edge on the sides. protective clothing and eye protection. 69 .

Maintenance Work plans Screw the cap on the oil filter housing and tighten it Tightening torque: 25 Nm. pull out the dipstick and insert the scavenging device sealed with an O-ring into the guide pipe. Insert new filter element in the cap and clip it into place by pressing on it. 70 . Extracting and draining the engine oil Extraction: Extract the engine oil through the dipstick guide pipe. To do this. 6 Cap with oil filter element Dipstick guide pipe 1 Cap 2 Sealing ring 3 Oil filter element Replace the sealing ring on cap 2. ! Observe the operating instructions for the engine oil scavenging device.

Unscrew the drain plug carefully and allow the oil to drain out.5 – 60 Nm M26 x 1. Oil filler neck 6 Oil drain plug 71 . Environmental note H Dispose of engine oil and filters in accordance with the regulations in force at the place of use of the engine.5 – 85 Nm Add new engine oil into the engine via the oil filler neck up to the maximum mark on the dipstick. Renewing: Screw the drain plug back in with a new sealing ring and tighten.Maintenance Work plans Draining: Place a suitable collecting receptacle under the drain plug on the underside of the oil sump. Tightening torque: M20 x 1.

switch off the engine and establish the cause. If no oil pressure is displayed after approximately 10 seconds. 6 Stop the engine. Check the filter and drain plug for leaks.Maintenance Work plans Start the engine with the setpoint value sensor in the idling position. 72 . Monitor the oil pressure gauge. Top up oil to the maximum mark on the dipstick if necessary. Check the oil level after approximately 5 minutes. ! Keep the engine running at idling speed until an oil pressure reading is displayed.

even if it was only operated for a brief period). a vehicle might accidentally be set in motion.40 mm = 0. Shift the transmission into neutral. by placing chocks under the wheels. Clean very dirty cylinder head covers before removing.60 mm Risk of injury Adjusting the valve clearance G If not properly secured.Maintenance Work plans Special tools Rotation device: 904 589 04 63 00 Valve clearance: Inlet valves Exhaust valve = 0. i Adjust the valve clearance when the engine is cold (at least 30 minutes after the engine was stopped. Always secure the vehicle against rolling away by applying the parking brake and. Only turn the engine over using the rotation device provided for this purpose. Layout of cylinders and valves 6 = inlet valve = exhaust valve X = flywheel end 73 . knocking people down or trapping them and otherwise causing an accident and injuring you or others. if necessary.

Unscrew Allen bolt 3 from the cylinder head cover together with sealing washers 4. 6 1 2 3 4 5 6 Charge-air manifold Cylinder head cover Allen bolt Sealing washer Cover seal Engine breather hose Check the gasket between the cylinder head cover and charge-air manifold 1 and replace if necessary.Maintenance Work plans Removing and fitting the cylinder head cover Removing: Remove engine breather hose 6 from the cylinder head cover. 74 . Remove cylinder head cover 2. Flywheel housing inspection hole Fit rotation device (904 589 04 63 00) on the flywheel housing inspection hole. Position the cylinder head cover. Always replace the gasket between the cylinder head cover and the cylinder head. Fitting: Clean the cylinder head and the cylinder head cover sealing surfaces. Fit Allen bolts 3 with new sealing washers 4 and tighten Tightening torque: 30 Nm.

1 cylinder to overlap TDC (no. 4 or 6 cylinder is at overlap TDC (no. Use the rotation device to turn the crankshaft until no. 6 75 . 1 cylinder at ignition TDC).Maintenance Work plans Adjusting the valve clearance Engine OM 904/ 924 LA OM 906/ 926 LA Crankshaft position 1 4th cylinder valve overlap 1st cylinder valve overlap 6th cylinder valve overlap 1st cylinder valve overlap I/ E – I/ E – 2 I E I E Cylinder/ valves to be adjusted 3 E I E I 4 I /E I E 5 6 E I I/ E I – inlet valve E – exhaust valve Adjust all valve clearances in 2 crankshaft positions. Check the valves in accordance with the above table and adjust. Then turn no. 4 or 6 cylinder at ignition TDC).

It must be possible to pull the feeler gauge through with only light resistance. Slacken counternut 2 to adjust the valve clearance. Adjust the valve clearance by turning adjustment screw 1. Tightening torque: 25 Nm. Concluding work Refit the cylinder head cover ( see page 74). 76 . Remove the rotation device from the flywheel housing inspection hole.Maintenance Work plans Checking and adjusting the valve clearance Measure the valve clearance between the rocker arm and valve stem (exhaust valve) or valve bridge (inlet valve) with a feeler gauge (arrow). Retighten the counternut. 6 1 Adjustment screw 2 Counternut Check the valve clearance again and readjust if necessary.

Insert the filter element in the cap and screw the cap onto the filter housing. naked flames and sparks and refrain from smoking when handling fuels. Tightening torque: 25 Nm.Maintenance Work plans Fuel prefilter: Cleaning the filter element Risk of fire G Environmental note H There is an increased risk of fire when handling fuels as they are highly flammable. Avoid fire. 6 Clean cap 1 and filter element 2. Open the tank cap to remove excess pressure in the fuel tank. Clean the outside of the fuel prefilter and cover any hoses /lines under the prefilter. Fuel prefilter Check sealing ring 3 for the cap and replace if necessary. Replace the filter element if it is very dirty or damaged. Unscrew cap 1 and pull it out of the filter housing together with filter element 2. 1 Cap 2 Filter element 3 Sealing ring 77 . Dispose of used filter elements and fuel residue in accordance with current local regulations.

Refit in the reverse order.Maintenance Work plans Fuel prefilter with heated water separator*: Replacing the filter element Risk of fire G Environmental note H There is an increased risk of fire when handling fuels as they are highly flammable. Open the drain valve and loosen the vent screw. Remove the separator vessel from the filter element and clean or replace as necessary. Fuel prefilter with heated water separator* 1 2 3 4 Hand pump Filter housing Water separator (heated) Water drain valve 78 . Collect the fuel/ water mixture from the filter element in a suitable receptacle. Dispose of used filter elements and fuel residue in accordance with current local regulations. Avoid fire. Remove the heater connector. 6 Unscrew the filter element. Use new sealing rings when fitting. naked flames and sparks and refrain from smoking when handling fuels.

The fuel system bleeds automatically. i Leave the engine running for approximately 1 minute. 6 79 . Start the engine and bleed the fuel system. Check the pre-filter for leaks. Then close the vent screw. Close the drain valve and fill the prefilter using the fuel hand pump.Maintenance Work plans ! Screw the filter element onto the filter head tightly by hand.

naked flames and the creation of sparks refrain from smoking when handling fuels.Maintenance Work plans Replacing the fuel filter element Risk of fire G There is an increased risk of fire when handling fuels as they are highly flammable. 1 Cap 2 Filter housing 1 Cap 2 Sealing ring 3 Filter element 4 Dirt trap 5 Filter housing 80 . Allow fuel to flow out. Avoid fire. 6 Fuel filter Pull cap 1 and filter element slightly out of filter housing 2. Open the tank cap to prevent excess pressure in the fuel tank. Unscrew fuel filter cap 1 with the socket spanner insert (WAF 36).

The fuel system bleeds automatically. i If the level of the diesel fuel in the tank is higher than the level of the engine. Check the fuel filter for leaks with the engine running. i To ensure the fuel system can be bled. Insert dirt trap 4 into filter housing 5. Replace sealing ring 2. the battery must have enough charge when the engine is started. Clip new filter element 3 into cap 1.Maintenance Work plans Remove the cap and filter element. i Leave the engine running for approximately 1 minute. Pull dirt trap 4 out of the filter housing by the tabs. Clean cap 1 and dirt trap 4. Tightening torque: 25 Nm. Lightly grease sealing ring 2 and the filter element seals. observe the correct installation position. since the fuel system must fill up with fuel first. Unclip filter element 3 by pressing the lower edge of the filter element on the sides. Start the engine and bleed the fuel system. do not empty dirt trap 4 into the filter housing. the feed line must be closed when replacing the filter. ! Neither dirt nor water should enter the filter housing. 6 81 . Screw on cap and filter element and tighten. The diesel fuel could flow out.

6 82 . intake pipe and connection hoses for damage and leaks. Check the hose clamps. flanged joints and intake manifold for firm seating.Maintenance Work plans Intake pipe between air cleaner and engine: Checking for leaks and general condition Check the rubber sleeves.

Maintenance Work plans Poly-V-belt: Checking the condition Risk of injury i Replace the poly-V-belt if one of the damage patterns shown on the next page is detected. G Faulty poly-V-belts may tear and parts or all of the belt may be thrown off. thereby causing injury to persons. For information on installing and removing the poly-V-belt ( see page 86). 83 . Always observe the specified maintenance intervals for poly-V-belts. Check the poly-V-belt for damage in sections. replace the polyV-belt concerned immediately. rotate the engine and poly-V-belt a little at a time Flywheel housing inspection hole 6 rotate further using the rotation device until the chalk mark is reached again. Special tools Rotation device: 904 589 04 63 00 Fit the rotation device to the flywheel housing inspection hole. If damage is detected. Make a chalk mark on the poly-V-belt. Remove the rotation device.

Maintenance Work plans 6 84 .

Maintenance Work plans Damage patterns 1 Condition as new (as reference: trapezoidal ribs) 2 One-sided wear: wedge-shaped ribs 3 Cord visible in the base of the ribs 4 Ribs split 5 Transverse cracks in several ribs 6 Rubber lumps in the base of the belt 7 Deposits of dirt or stones 8 Rib detached from the base of the belt 9 Cord torn out to the side a Outer cord frayed b Transverse cracks on the back of the belt c Transverse cracks in several ribs 6 85 .

except for the tensioning pulley (see illustrations for poly-V-belt routing). replace parts if necessary. Check that the tensioning device and belt pulley are in perfect condition (e. G The tensioning device is spring-tensioned. Keep your fingers out of the area between the belt pulley and the poly-V-belt when fitting or dismantling the poly-Vbelt. Remove the spanner and check for correct seating of the poly-V-belt on the belt pulley. tensioning pulley and deflection pulleys as well as wear on belt pulleys). Make sure that the tool is handled correctly. insert the poly-V-belt and swing back the tensioning pulley. 1 Tensioning pulley 2 Spanner Attach spanner 2 with the 17 mm socket to the hexagon bolt of tensioning pulley 1.g. Lay the poly-V-belt (new) on all belt pulleys. 6 Spanner with extension in the tensioning device Wear work gloves when working on the tensioner. there is a risk of injury from hands or fingers being crushed or trapped in pretensioned parts. 86 .Maintenance Work plans Removing and installing the poly-V-belt Risk of injury Swing back the tensioning device. Swing the tensioning pulley upwards using the lever. check for worn bearings on the tensioning device. When it is loosened or tightened. Swing the tensioning pulley upwards and remove the poly-V-belt.

Maintenance Work plans Routing of the poly-V-belt (engine without refrigerant compressor) Routing of the poly-V-belt (engine with refrigerant compressor) 6 1 2 3 4 Alternator Coolant pump Tensioning pulley Crankshaft 1 2 3 4 5 6 Alternator Coolant pump Tensioning pulley Refrigerant compressor Deflection and guide pulley Crankshaft 87 .

Maintenance Work plans Checking the condition Remove the wire circlip from the ball cup on the engine cylinder. Push the ball cup back onto the ball neck. Check the firm seating of the throttle valve lever on the throttle valve shaft. and the throttle valve shaft for wear. Check the engine brake cylinder. Tighten screws if necessary. Force the ball cup off the ball neck of throttle valve lever 1. Fit the wire circlip. ball neck and ball cup. Engine brake: Checking the condition and setting 6 Throttle valve lever in rest position Throttle valve lever in working position Grease the ball cup with the grease specified. 1 Throttle valve lever 2 Retainer 1 Throttle valve lever 2 Retainer 88 .

the pre-tension of the engine brake cylinder return spring is then sufficient. illustration on the left-hand side). Check the position of the throttle valve shaft: the notches must be horizontal when the engine brake is in the rest position ( page 88. When the engine brake cylinder (with the cylinder retracted) is in the rest position. the throttle valve lever must also lie against the bracket. illustration on the righthand side). 6 89 .Maintenance Work plans Checking the adjustment i Throttle valve lever 1 must lie against bracket 2 in the operating position (cylinder extended) when the engine brake is operated. The notches must be vertical in the working position ( page 88.

Wear suitable protective gloves. The correct concentration of 50% by volume antifreeze /corrosion inhibitor in the coolant is indicated when there is antifreeze protection down to –37 °C. ! Only use service products approved by DaimlerChrysler. Unscrew the sealing cap slowly and release any excess pressure completely before opening the cap fully. Never put coolant into containers normally used for beverages. Only open the cooling system at coolant temperatures below 90 °C. G There is a risk of poisoning if coolant is swallowed. Relieve excess pressure. Check the antifreeze/ corrosion inhibitor before correcting the coolant level. The cooling system is pressurised. correct the mixing ratio.Maintenance Work plans Engine cooling system: Checking and correcting the fluid level and the antifreeze/ corrosion inhibitor Risk of scalding Risk of poisoning G i Only check and correct the coolant level when the coolant temperature is below 50 °C. Open the engine cooling system radiator cap slowly. Check the antifreeze / corrosion inhibitor using testing device. Hot coolant can spray out when the cooling system is opened and scald your skin and eyes. ( see page 63). Store coolant out of the reach of children. If less antifreeze protection is displayed. 6 90 . Only use prepared coolant with 50% by volume antifreeze/corrosion inhibitor for topping up. Never swallow coolant. protective clothing and safety goggles when handling coolant.

6 91 . Cooling and heating system: Checking for leaks and general condition The "Engine cooling system: Checking and correcting the fluid level and antifreeze / corrosion inhibitor" work item must have already been carried out. Check the radiator for external dirt. Check the coolant level. ! If damage /faults are found. heat dissipation and antifreeze protection deteriorate. The cooling system is correctly filled if the coolant reaches the mark in the filler neck. there is a risk of engine damage as a result of corrosion/cavitation in the cooling system. Check that all lines and hoses are undamaged. repair the radiator or replace it. The fins must not be dirty. ! Avoid concentrations of more than 55% by volume antifreeze /corrosion inhibitor. otherwise maximum antifreeze protection down to –45 °C will not be achieved.Maintenance Work plans ! If the concentration is too low. that they are routed to avoid chafing and that they are secured in accordance with the regulations. Carry out a visual inspection of the radiator for leaks and undamaged condition. If the concentration is higher.

92 . Store coolant out of the reach of children. Remove the coolant expansion tank cap. Pressure tester special tool 6 Wear suitable protective gloves. Never swallow coolant. On heating systems: Open the regulating valves and shutoff valves. The cooling system is pressurised. Only open the cooling system at coolant temperatures below 90 °C. protective clothing and safety goggles when handling coolant. Never put coolant into containers normally used for beverages. Unscrew the sealing cap slowly and release any excess pressure completely before opening the cap fully. Fit the testing equipment. Hot coolant can spray out when the cooling system is opened and scald your skin and eyes.Maintenance Work plans Special tool: Pressure tester 001 589 83 21 00 Risk of scalding Risk of poisoning G G There is a risk of poisoning if coolant is swallowed.

Example: Code 70 = 0. The cooling system opening pressure can be seen on the code on the cap or pressure relief valve.7 bar pressure. i A pressure relief valve is integrated in the testing equipment so that a pressure of 1. 6 93 .2 bar cannot be exceeded.Maintenance Work plans Connect the compressed-air hose with the tyre inflator connection to the valve and build up a test pressure equal to the cooling system opening pressure.

Only open the cooling system at coolant temperatures below 90 °C. There is a risk of poisoning if coolant is swallowed. Never swallow coolant. protective clothing and safety goggles when handling coolant. Hot coolant can spray out when the cooling system is opened and scald your skin and eyes.Maintenance Work plans Renewing coolant Risk of poisoning Risk of scalding G i Before renewing the coolant. Store coolant out of the reach of children. 94 . Never put coolant into containers normally used for beverages. ! Only use antifreeze/ corrosion inhibitor approved by Mercedes-Benz ( see page 59). Unscrew the sealing cap slowly and release any excess pressure completely before opening the cap fully. check the cooling and heating system for leaks and condition. G The cooling system is pressurised. 6 Wear suitable protective gloves. Have the coolant renewal confirmed in the Maintenance Booklet.

Wear suitable protective gloves. Let off excess pressure and remove the radiator cap. Open the engine cooling system radiator cap slowly. Coolant drain plug 6 Place the drain hose on the coolant drain plug on the engine (arrow). Only carry out work on the cooling system at coolant temperatures below 50 °C. Loosen the drain plug (1 to 2 turns) The coolant flows out. etc.Maintenance Work plans Draining coolant Risk of scalding i G There are additional drain plugs on the radiator. On heating systems: Open the heating temperature selector (regulating valve). 95 . i First cover the lines. Hot coolant will scald your skin and eyes. protective clothing and safety goggles when handling coolant. beneath the drain plugs and place a receptacle suitable for the volume of coolant.

Retighten the coolant drain plug on the engine.Maintenance Work plans Adding coolant Start the engine and allow it to run at different speeds for approximately 1 minute. Switch off the engine and close the cooling system again. 6 Fit additional drain plugs (without hose connections) with new seals and screw tight. Clear blocked drain openings from deposits. Add coolant in the specified ratio until it reaches the lower edge of the filler neck. Environmental note H Dispose of used coolant in accordance with prevailing local regulations ( see page 64). see the vehicle manufacturer's operating instructions. 96 . Pull off the drain hose. i For further information.

causes and solutions Jump-starting 7 97 .Practical advice Malfunctions.

Risk of accident and injury G Incorrect maintenance and repair work to the engine can cause engine damage and may cause personal injury as a consequence. it is important that malfunctions are remedied in good time.Practical advice Malfunctions. Always have work on or modifications to the engine carried out at a qualified technical workshop which has the necessary specialist knowledge and tools to carry out the work required. causes and solutions Besides careful operation and maintenance of the engine. DaimlerChrysler recommends that you visit a Mercedes-Benz Service Centre for this purpose as it has the necessary specialist knowledge and tools to carry out the work required. In particular. Further information on the measures listed under "Solution" can be found in the "Maintenance" or "Tests and other work for remedying problems" section. work relevant to safety or on safety-related systems must be carried out at a qualified specialist workshop. causes and solutions Malfunctions. Maintenance and repair work on the engine may only be carried out by personnel who have undergone the appropriate training. 7 98 . Always have faults that you cannot remedy yourself rectified at a qualified specialist workshop. You can rectify certain faults yourself ( page 99). Mercedes-Benz recommends that you use a Mercedes-Benz Service Centre for this purpose.

pre-cleaner or screen in the fuel tank blocked Fuel system or filter leaking Fuel not resistant to cold Solution Charge the battery Tighten the cable on the terminal. solder on a new terminal.Practical advice Malfunctions. Have it checked by specialists Refuel Clean or replace the filter element ( page 80) Clean and bleed the system Seal Clean the pre-filter ( Replace fuel filter Use winter fuel ( Outside temperature too low page 60) Observe measures for winter operation ( page 53) page 78) 7 99 .Fuel tank empty diately Fuel filter blocked Fuel line. If necessary. causes and solutions General troubleshooting Malfunction Starter pinion does not turn or turns too slowly Cause Battery is not sufficiently charged Connecting cable to the starter motor is loose Starter motor solenoid switch malfunction Engine does not start or stops again imme.

have pressure tested at a qualified specialist workshop 100 .Practical advice Malfunctions. short circuit in cabling or in Stop button. causes and solutions Malfunction Engine starts badly Cause Fuel temperature too high or sensor malfunction Engine control unit malfunction Solution Replace fuel temperature sensor. engine control unit malfunction 7 Leakages or pressure too low in the lowpressure fuel circuit or fuel delivery pump drive defective Test for leaks (visual inspection). have pressure tested at a qualified specialist workshop Consult a qualified specialist workshop Consult a qualified specialist workshop Leakages or pressure too low in the lowpressure fuel circuit Engine stops unexpectedly Engine control unit malfunction (total failure) Electrical system interrupted. consult a qualified specialist workshop Test for leaks (visual inspection). consult a qualified specialist workshop Read engine control unit malfunction memory.

replace if necessary. replace i f necess ar y. consult a qualified specialist workshop 7 Coolant temperature too high 101 . consult a qualified specialist workshop Check tem perature sens or. consult a qualified specialist workshop Check temperature sensor. causes and solutions Malfunction Engine in emergency running mode: Constant speed 1. check fan speed cut-in point. consult a qualified specialist workshop Remove each sensor.300 rpm Engine surges. vibrates or runs irregularly Cause Engine control unit or drive control unit malfunction Crankshaft position sensor or TDC sensor (camshaft angle sensor) polarity reversed Solution Read malfunction memory in control units. replace if necessary.Practical advice Malfunctions. replace if necessary. cons ult a qual ified specialist wor ks hop Charge-air temperature too high or temperature sensor malfunction Fuel temperature too low Check temperature sensor. check fan speed cut-in point. sensor polarity is reversed if engine runs better (emergency running engine speed) – reverse polarity Consult a qualified special ist w orkshop Poor engine output (lack of power) Charge-air pressure sensor malfunction Check with DaimlerChrysler diagnostic tester.

Practical advice Malfunctions. consult a qualified specialist workshop Tractive force interruption Loose contacts in the electrical supply Leakages or pressure too low in the lowpressure fuel circuit Poor engine braking power Drive control unit malfunction 7 Constantly-open throttle valve* defective Engine brake flap* defective 102 . consult a qualified specialist workshop Check battery terminal clamps and connector on engine control unit for firm seating and corrosion Test for leaks (visual inspection). consult a qualified specialist workshop Carry out a function/visual inspection. leaking) Engine control or drive control module malfunction Solution Carry out function or visual inspection Carry out visual inspection for leaks. consult a qualified specialist workshop Check control. have pressure tested at a qualified specialist workshop Read drive control unit malfunction memory. consult a qualified specialist workshop Read control unit malfunction memory. causes and solutions Malfunction Poor engine output (lack of power) Cause Engine brake valve* defective Fault in the fuel system (blocked.

radiator very dirty on outside Thermostat malfunction see Replacing the poly-V-belt ( page 86) Consult a qualified specialist workshop Clean or remove limescale Check. causes and solutions Malfunction Fuel consumption too high Cause Fuel temperature too high or sensor malfunction Turbocharger leaking on pressure (delivery) side Connection points (unit pump – line and injectors) defective or leaking Solution Replace fuel temperature sensor. replace if necessary. consult a qualified specialist workshop Consult a qualified specialist workshop Replace sensor Top up.Practical advice Malfunctions. consult a qualified specialist workshop 7 103 . consult a qualified specialist workshop Carry out a test for leaks. consult a qualified specialist workshop Set pumps using STAR DIAGNOSIS or Minidiag 2. bleed ( page 96) Engine cut-off too early (maximum revs cannot be reached) Engine gets too hot (according to coolant temperature gauge) Drive control unit or ADM control unit defective or incorrectly programmed Coolant temperature sensor malfunction Insufficient coolant or cooling system not fully bled Poly-V-belt damaged Fan does not switch on correctly Radiator dirty on inside or choked with limescale.

engine oil entering combustion chamber 104 . have it checked at a qualified specialist workshop Engine emits black smoke Charge-air sensor. air cleaner dirty 7 Exhaust fumes are blue Constantly-open throttle valve defective Oil level in the engine too high. consult a qualified specialist workshop Consult a qualified specialist workshop Correct oil level. replace tensioning pulley if necessary Replace the poly-V-belt ( page 86) Check.Practical advice Malfunctions. consult a qualified specialist workshop Consult a qualified specialist workshop Carry out visual inspection. causes and solutions Malfunction Charge current indicator lamp does not light up while the vehicle is stationary Charge current indicator lamp lights up when the engine is running Cause Bulb malfunction or supply line broken Poly-V-belt too slack Poly-V-belt torn Alternator or regulator malfunction Solution Replace bulb or repair break Check belt tension. coolant sensor or fuel temperature sensor defective Injector defective Exhaust gas turbocharger or charge-air pipe defective. consult a qualified specialist workshop Check with DaimlerChrysler diagnostic tester.

causes and solutions Malfunction Exhaust fumes are white Cause Cylinder head or cylinder head gasket leaking. foreign object in the compressor or turbine.Practical advice Malfunctions. coolant entering the combustion chamber Combustion malfunction Damage to bearings Leakage in intake pipe and exhaust pipe causes whistling noise Turbine or compressor wheel scrapes on the housing. seized bearing in rotating parts Solution Locate damaged cylinder using pressure loss test. consult a qualified specialist workshop Consult a qualified specialist workshop Consult a qualified specialist workshop Remedy leakage. replace seals if necessary Have the exhaust gas turbocharger replaced at a qualified specialist workshop Engine "knocks" Knocking noise from the bearings Abnormal noises 7 105 .

Remove the jump leads in the reverse order. it must have thawed out before jump-starting. Wear suitable protective clothing. Otherwise a battery could be irreparably damaged. naked flames and sparks and refrain from smoking in the vicinity of batteries. There is a risk of short circuit. Therefore. Start the engine ( see page 47) and allow to run for a short while. eyes or clothing. G Gases escaping from batteries can explode and injure people. and also wear protective gloves and safety goggles. The acid contained in batteries burns skin and eyes on contact. ! Make sure that the donor battery and the starter battery have the same nominal voltage. A discharged battery can freeze at about –10 °C.Practical advice Jump-starting Jump-starting If the battery is discharged. Only use insulated jump leads (cable cross section approximately 70 mm 2) and insulated terminal clamps. There is a risk of short circuit. 7 106 . Avoid contact of acid with your skin. the maximum on-board voltage of 28 V must not be exceeded (as this would cause electronic damage to the control part). Risk of burning Risk of explosion G ! When jump-starting the engine. Do not place any metal parts on the batteries. avoid fire. Rinse acid splashes off immediately with clean water and consult a doctor if necessary. as battery acid can burn through normal clothing. the engine can be started using jump leads and a donor battery. Connect the positive terminals first and then the negative battery terminals.

Technical data Engine data Test values and adjustment values Tightening torques 8 107 .

other versions on request) OM 904 LA OM 924 LA A = Engine length B = Engine width C = Engine height 830 mm .645 mm 925 mm OM 906 LA OM 926 LA A = Engine length B = Engine width C = Engine height 1.645 mm 940 mm Illustrated: OM 904/ 924 LA Illustrated: OM 904/924 LA 8 108 .078 mm .Technical data Engine data Engine data Dimensions in mm: (Standard version.

Technical data Engine data Weights OM 904 LA OM 924 LA Engine. dry Engine. wet General data Type Type of cooling system Combustion principle Number of cylinders OM 904 LA/ OM 924 LA: OM 906 LA/ OM 926 LA: Cylinder bore OM 904 LA/ OM 906 LA OM 924 LA/ OM 926 LA Piston stroke OM 904 LA/ OM 906 LA OM 924 LA/ OM 926 LA In-line engine with exhaust gas turbocharger and intercooler Forced circulation cooling 4-stroke diesel direct injection 4 6 102 mm 106 mm 130 mm 136 mm 395 kg 420 kg OM 906 LA OM 926 LA 530 kg 573 kg 8 109 .

29 l 8 110 .Technical data Engine data General data continued Displacement OM 904 LA/ OM 924 LA: OM 906 LA/ OM 926 LA: Direction of rotation of engine viewed from flywheel Type of starting Coolant capacity of engine without intercooler OM 904 LA/ OM 924 LA: OM 906 LA/ OM 926 LA: Engine oil capacity including oil filter OM 904 LA/ OM 924 LA: OM 906 LA/ OM 926 LA: 4. 24 l.200 cm 3 Anti-clockwise Electric 8.800 cm 3 6.370 cm3 /7. 13 l. 16 l min.250 cm3 /4. max.5 l min.5 l 12. max.

–20 °C 24 V 4.0 kW 8 111 . 450 A max. battery and alternator (standard) Starter motor Voltage Output Battery (not in scope of delivery) Voltage Cold test current in accordance with DIN 72311 Cold start ability without jump-starting and 75% battery charge down to Alternator Voltage Current rating 28 V 80 A 24 V max.Technical data Engine data Data: Starter motor.

4 mm 0.6 mm ≥ 0.5 bar ≥ 2.Technical data Test values and adjustment values Test values and adjustment values Engine oil pressure (min) at idling speed at rated speed Valve clearance Inlet valve Exhaust valve 0.5 bar 8 112 .

other lubricants require significantly different tightening torques. Designation Engine block Cylinder head cover to cylinder head bolt Oil sump bolt to cylinder crankcase Poly-V-belt tensioning device to cylinder crankcase / to hydraulic pump retainer/to support Fuel /injection system Injection line to unit pump pressure pipe connection Banjo bolts for fuel lines Cap to fuel filter housing Starter motor/alternator Starter motor to timing case Alternator support to cylinder crankcase 50 100 35 40 25 30 25 50 Nm 8 113 .Technical data Tightening torques Tightening torques i All threads on mechanical parts and related contact surfaces must be clean and smooth and lubricated with engine oil.

5 thread M26 x 1.Technical data Tightening torques Designation Alternator to support Alternator to retainer Oil circuit Oil drain plug in oil sump M20 x 1.5 thread Alternator retainer to oil filter Oil filter housing to cylinder crankcase Oil filter housing support to cylinder crankcase Oil filter cap to oil filter housing Pressure sensor to oil filter housing Valve adjustment Counternut on rocker arm set screw Cooling circuit Coolant line with thermostat valve to coolant pump Coolant pump to cylinder crankcase Belt pulley to coolant pump hub Nm 50 65 65 85 40 25 25 25 25 25 25 25 25 8 114 .

such as the alternator. It can be used to preheat the charge air using fuel combustion. It can be used to preheat the charge air using a heater coil. Works by closing the exhaust pipe. engine torque request via accelerator pedal position. The FR is permanently installed in the driver's cab. FR (Drive control) control unit. Control unit Part of the electronic system which controls the engine or transmission functions.Technical terms ADM Control module as interface between the engine and the vehicle electronics. 9 115 . When the engine brake is operated. Emergency running program Special program in the Telligent® engine system which allows limited engine operation if electronic components have failed. e. for example. Engine plate Number specified by the manufacturer and marked on the cylinder head to clearly identify each engine. the constantly-open throttle valve causes a reduction in the cylinder pressure during the working stroke. It controls vehicle-relevant functions and switches on the engine control via CAN bus commands. coolant pump or refrigerant compressor. Engine oil viscosity Measurement of the internal friction (viscosity) of an oil at a defined temperature. or the lower the temperature the oil can withstand without becoming too thick. Grid heater This is a cold-start aid for the engine. This reduction of potential malfunction sources improves reliability and maintenance friendliness. At the same time the number of components required is lower. The drive control is a monitored electronic system and is connected to the engine control via the CAN bus. Flame-start system This is a cold-start aid for the engine. FAME fuels (Fatty Acid Methyl Ester) FAME fuels are bio-diesel fuels based on fatty acid methyl esters.g. Belt drive Drive connection from the engine to the engine assemblies. Exhaust brake also throttle valve brake. CAN (Controller Area Network) Serial data transfer system which networks the vehicle's electronic systems and allows an organised mutual data exchange. The viscosity is better the higher the temperature the oil can withstand without becoming too thin. Constantly-open throttle valve Valve fitted in the cylinder head in conjunction with throttle valve brake or Turbobrake*.

g. e.Technical terms Minidiag 2 DaimlerChrysler AG electronic diagnostic tool for reading faults and parameters on commercial vehicles. Telligent ® engine system Mercedes-Benz electronic engine control. Tightening torque (Nm) Product of force and lever arm length with which bolted connections.g. engine speed and others) into electrical values for use in the engine control unit. term for the upper position of the piston in the cylinder. Controls fuel injection period and quantity depending on the current operating conditions and driver's requests. such as the engine idling speed and exchanges data with the drive control. (Nm = Newton metres) 9 STAR DIAGNOSIS DaimlerChrysler AG electronic diagnostic system 116 . It controls the engine functions. are tightened. OM Engine name. oil temperature. cylinder head bolts. Sensor Electronic component which converts certain parameters (e. TDC Top dead centre. abbreviation for oil engine = diesel engine. Engine control is a monitored electronic system which forms part of the Telligent® engine system. MR (Engine control) control unit.

. . . . . . . . . . . . 7 Exhaust brake. . . . . . . Cleaning . . . 51 9 117 . . . . . . . . . . . . . . . . . . . . . . . . 64 B Battery . . . . Fuel additives . . . . . . . . . . . . . . . . . . . . . . . . . . 111 C Charge current . . . . . . . . . . 64 Drive control unit. . . . . . . Renewing . . . . . . . . . . . . . . Oil change and filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling the tank . . 31 Adjusting the valve clearance . . . . Prefilter. . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . Engine Checking for leaks and general condition . . . . . . . . . . . . . . . . . . . 60 Sulphur content . . . . 22 Environmental note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . Constantly-open throttle valve. . . . . . . . . Cylinder head cover Removing and fitting . . . . . . . Conversion parts and modifications . . . . . 43. . . . . . . . . . Degreasing . . . . 26 61 53 43 80 77 60 80 68 55 69 47 52 89 88 G Genuine Mercedes-Benz parts . . . . . . 108 Disposal of service products . . . . 70 Engine plate . . . . . . . . .Index A Adaptation module . . . . . . . . . . Engine brake Checking the adjustment . . . . . . . . . . . . . . . . . . . . 60 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . draining . . . Commissioning . . . . . . . . . . . . 108 Engine data card . . . . . . . Flow improvers . . . . . . . 29 Engine control unit . 31 E Emergency running program . . . . . . . . . . . . 32 Diagnostic testers . . . 30 Engine data . . . . . . . . . . . . . . . . . . . . . . Checking the condition. . . . . . . . . . . . . . . . . . . . . . . . . 40 Grid heater . . . . . . . . . . . . . . . . 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant level. . . 106. . . . . . . . . . . . . . . . . . . . . . . . Cooling system Cleaning . Stopping . . . . . 49 42 28 38 64 94 90 56 57 74 D Diagnostic socket . . . . . . . . . . . Fuel system Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F Flame-start system . . . . . . . Filter element . . 111 Antifreeze/corrosion inhibitor . . . 73. . 32 Diesel fuels In extremely cold weather. . . 24 Engine oil Extracting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Mixing ratio. . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . 76 W Warning lamp . . . 32. . . . . . . . . . . . . . . . . . . . . 51 Operating safety . . . . . . . . . . 12 P Personnel . . . . . . . . . . 56 I Indicator lamp . . . . . . 113 Transport and installation. . . . . . . . . . . . . . . . . . . . . . . 50 Test values and adjustment values . . . . . . . . . . . 87 Tensioning pulley . . . . . 67 9 118 . . . . . . . . . . . . . . . . . . . . . . . 47 Warranty entitlement . . . . . . . . 59 Water . . . . . 75 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Safety precautions . . . . . . . . . . . . . . . 32. . . . . . . . . . . 61 L Location of sensors . . . . . . . . . . . . . 32 Poly-V-belt Checking the condition. . . . . . . . . . 36 Service products . . . . . . . .Index H High-pressure cleaners . . . . 66 Maintenance intervals . 83 Removing and installing . . 42 Maintenance service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Weights . . . . . . . . . . . . . . . . . . 20 M Maintenance instructions . . . . . . . . . . . . . . . . . . 38 Protective treatment . . . . . 86 Routing . . . . . 44 T Telligent® engine system . . . . . . . . . . . . . . . . . . . . . . . . . 86 Protection of the environment . . . . . . . . . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 S Safety and emergency running program . . . . . . . . . . . . . . . . . . 8 Overview OM 904 LA/OM 924 LA . . . . . . . . . . . . . . . . . . 73 Adjustment . . . . . . . . . . . . . . . . . . 109 Winter operation . . . . . . . . . . . . . . 47 Intake pipe Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V Valve clearance . . . . . . . . . . . . . . 53 Work plans . 111 Starting the engine for the first time . . . . . . . . 82 J Jump-starting . . . . . . . . . . 106 K Kerosene. . . . . . . . . . . . . . . 112 Adjusting . . . . . . . 33 Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Special lubricant additives . . . . . . . . . . . . 67 O Oil pressure . . . . 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Tightening torques . . . . . . 59 Starter motor .

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Germany As at: 25. translated or otherwise reproduced.Contact Mercedes-Benz will be happy to answer any queries you may have: Mercedes-Benz Contact Telephone: 00800 1 777 7777 International: +49 69 95 30 72 77 Internet Further information about Mercedes-Benz and DaimlerChrysler can be found on the following websites: www. without written permission. .05.com Editorial office You are welcome to forward any queries or suggestions you may have regarding these Operating Instructions to the technical documentation team at the following address: DaimlerChrysler AG. 70546 Stuttgart. HPC: R822. in whole or in part.2003 Title illustration number N00.01-2194-31 Not to be reprinted.com www.daimlerchrysler.mercedes-benz.

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