Air compressor, belt drives Foo [tone ofthe permisbe values exceeded Replace exhaust gas turbocharger (1) Page 147 e Reinstall in opposite oder Test values for turbocharger Number Designation Engine 457.960 aesaoioorore _[Rotorshaft axa pay m| =o acosaowonroie | Rotorshaft radial play mm|=09 0615895327100 363 580027100, 366565002105 Dalndlatr Ditncatorholer tenon Commercially available tols (se workshop equipment manual) Number [Designation company eg) [Order number fonsesozirize [Feder gouge Boos Gmbi soar esti and Wertstattusristung| Im tippteld a D-46047 Oberhausen [ax0s.40-N-0001-01 | Notes on appraisal of the turbochargerin, the event of blue smoke from the engine (i Engine 457.9, 581.8, 542.3, 902.3, 908.3, 906.9, 926.9 Inthe event of blue smoke from the engine, the following ‘components must be inspected for ol deposit: Turbocharger compressor housing = Intake manifold Intake hose ‘Charge air cooler ‘elf the turbocharger compressor housing or charge air lines are coated witha| asyet tle oil, no damage to the turbocharger is present [i] the normal formation of oil misting in the charge airsystem {does not damage the engine. A certain quantity of ols required te the intake valves, The exuded ol quantity is so minimal that there is no measurable influence on engine oil consumption. completely dry charge air system does not exist. The turbochargers used have an oll-guiding bearing housing with piston rings asa seal forthe rotor shaft to the turbine and compressor housing. The function of thisseal is based on the ‘excess presure in the compressor housing. Atan increased idle speed orn overrun mode, however, a vacuum can occur, which favors il exaping 144F609 Air compressor, belt drives ‘817 ahigh level of oils found in the turbocharger-compressor housing, the charge airlines or in the charge air cooler, afulland careful inspection must be carried out Inspect crankcase ventilation/ol separator for damage and flow. Inspect oil return line for damage and flow. [i ito flow is possible, the oil level in the turbocharger bearing housing increases and ol enters the turbine and compressor housing via the seals. n the case of damage orno flow present, ‘the respective part must be repaired o replaced ‘Check axial play and radial play at rotor shaft f the test values lie outside the tolerance, the turbocharger must be replaced. (HD itis not necessary to replace the second turbocharger along with the first turbocharger if only one turbochargers defective I damage has been caused by a foreign body, both turbochargers, may be damaged. [aR09.40-6-5910-01CH | Check axial play and radial play on rotor shaft Test values for turbocharger Number Designation Engine 457.960 Be09 0-¥-1004018 Rotor shaft axial play im] =0.1 pe09 ao. r0020%8 Rotor shaft radial play =09 (007 589 532300 363 589022100 Commercially available tools (see workshop equipment manual) 366589 0021 05 Number Designation Company(eg) |Ordernumber jweseaozsou-128 — [reeler gauge Boos GmbH Industrie-and Werkstattausrastung Im Lippfela 90 10-4607 Oberhausen 0a Wirkahop Manual OM 450LA 145Air compressor, belt drives ‘Check axial play for rotor shatt 1 Inst ial indicator (3) with [] dial indicator holder (4) 2 Press rotor shaft (1) for exhaust gas turbocharger to stop (arrow A) and hold 3 Setscate for dial indicator (3) to zero 4 Pullrotor shatt (1) for exhaust gas turbocharger to stop (arrow 8) and hold 5 Readoff values [1] the reading is equal tothe axial play forthe rotor shaft). ‘Check radial play for rotor shaft: 5 Press compressor turbine wheel (2) to stop (arrow A) and determine minimum play with Bi teeter gauge (5), 7. Press compressor turbine wheel (2) to opposite side to stop (arrow B) and determine ‘maximum play with Ed feeler gauge (5) Gi] Perform both measurements at same point of compressor housing and on same vane of compressor turbine wheel (2) ‘The difference between the two measuring results is the radial play F609 146F609 Air intake, supercharging [AR09.40-G-6020CH Remove/install exhaust gas turbocharger 5.7.04 MODEL 000.001 with ENGINE 457.960 1 exhaust gas turbocharger 2° Grhaustmaniond 3 mut 4 Gasket ees Removal instalation 7 termove exhaustmaifol @) wth engine |Linstallation: Replace sal @ Page 71 brake lp tings and exhast gas turbocharger (1) 2 Temove engine brake fap fing om Page 175 exhaust gas turbocharge) 5 Terove exhaust gus turbocharger (from |) Plgholeson exaust gas turbocharger exhaustmaifla 2) with caps otherwise drt can damage te exhaust ges trbochrger El ntataion: Replace nus (2) fs 2A09.40.1-100401N a Reinstall opposite order BB rubocharger Number Designation Engine 57960 ssoszonroacow [Nut for turbocharger on exhaust manifold wm] s0 Wirkahop Manual OM 450LA 147Air intake, supercharging Fo09 148F609 Air intake, supercharging [AR09.41-G-1311CH Remove/install charge air pipe 5.7.04 MODEL 000.001 with ENGINE 457.960 1 clamp 2 Oring 3 Charge airpipe 4 Chargeair hose 5 Exhaust gas turbocharger ess) Removal, installation 1 Remove charge air hose (4) 4] check charge air hose (4) and hose clamps for condition, replace if necessary [=] BA09.41-N-1001-01L 2 Remove clamp (1) from charge air pipe (3). | Plug holes on exhaust gas turbocharger and exhaust gas turbocharger (5) (1) with caps, otherwise drt can damage the exhaust gas turbocharger (1). (i) installation: Replace O-ring (2) 3 Remove charge ar pipe (3) with bracket a Reinstall in opposite order Fed charge ar pipe/charge air cooler Number Designation Engine 457.960 eaceat-n-1001- 010 [ciamp, charge air hose to charge air en]75 housing/charge air pipe and charge air cooler Wirkahop Manual OM 450LA 149Air intake, supercharging Fo09 150F609 Air compressor, belt drives [AR09.41-G-2003CH Remove/install charge air pressure, charge air temperature sensor 5.7.04 MODEL 000.001 with ENGINE 457.960 1 Connector for engine wiring harness 8111 Charge air combination sensor (temperature and pressure) eSBs Removal, installation 1 Unlock engine wiring harness connector (1) from charge air combination sensor (8111) and pul off 2 Remove charge air combination sensor __| Li] installation: Check O-ring on charge air ein) [combination sensor (8111) for damage, if necessary install new charge air Jcombination sensor (8111). [=] BA09.41-N-1004-01L a Reinstall in opposite order {el charge air pipe/charge air cooler Number Designation Engine 457.960 eonar.n-r00801 Bolt, charge ar pressure, charge air temperature Nm] 10 sensor to charge air manifold Wirkahop Manual OM 450LA 151Air compressor, belt drives Foo 152F609 Air intake, supercharging [AR09.41-G-8681CH Remove/install charge air manifold 5.7.04 MODEL 000.001 with ENGINE 457.960 Bole Gasket Connector Intake manifold Gasket Start/stop button 111 Charge aircombination sensor (temperature and p Charge air manifold ressure) Corer ess) Removal, installation Remove intake manifold (5) from charge _ |i] Replace seal (6) air manifolds (1) fs ea09.41-4- 1002011 5 Remove starstop button Oy with bracket 5 Unlock connector (tom charge air combinationsenor(@11) and pl of a Unscrew bots @andremove charge air | (A intlation: ean sealing surace, manifota() replace seals) fs 2n09.41-4-003011 5 Reina opposite order 15 charge i ppeharge ir cooler Number Designation Fogine 57960 exconiasonaait [Bolt charge arppe to charge ar menial neo exonarwsonseit [Bot charge armenfoldto glinder head 1m 30 Wirkahop Manual OM 450LA 153Air intake, supercharging Fo09 154F613, Air compressor, belt drives [AR13.22-G-0003CH Remove/install alternator poly-V-belt 5.7.04 MODEL 000.001 with ENGINE 457.960 ‘Shown with fan wheel removed 1 Poly. v:bele fan) 2. Tensioning device (alternator poly-V-belt) 3 Poly-Vbelt (alternator) fe Removal Avvanser jury hazard from pinching when working | Use only approved tensioning devs. get onsprngs and spring bodies under estan | necesay sel hazardov areas pdcitonaly check pei tol for damage ane proper function visual nsec Wear protective gloves. 7 Remove polyV-bel() Page 157 P vt tensioning ply for tesioning ovic(@) downward and hol 3 nermove paly-bet(@) from bet pulls 3 Pvorback tensioning pale fortersoning evi) Gi Press fan wheel toward rontandvemove Do not damage pol\-belt() when pobv.belt() renoving a rest é check ber pulleys and versioning poles fordamageandsmoothnes, pace necessary. 7 check poly. v-bet for condition, replace it necesary AP | Damage pattern for poly-V-belt Page 92 @ Installation 8 Preston whee toward rontand postion | (ll observe beltroute of poly W-be Page 91 poisbelt(3 onbett pale 5 Pivot tensioning ply for tensloning device) downward and hol ovshop wana ow EA 155Air compressor, belt drives Fo13 70 Postion poh-v-bele@)entensioning | Ensue thatpoly-vbels@) seated pulley oftensioning device 2and pivot feorect back tensioning device @) " Install poly-V-belt (1) Page 157 156F613, Air compressor, belt drives [aR13.22-G-1302CH Remove/install poly-V-belt fan 5.7.04 MODEL 000.001 with ENGINE 457.960 ‘Shown with fan wheel removed 1 bestpulley 2 Poly-vibelt 3 Tensioning device Removal AS Danger! Injury hazard from pinching when working | Use only approved tensioning devices, Jon springs and spring bodies under tension |shield hazardous area additionally it necessary. [Check special tools for damage and proper function (visual inspection)Wear protective gloves 1® Notes on self-locking nuts and bolts |All models Page 59 | 7 Pivot tensioning pulley for tensioning device (3) downward and hold 2 Remove poly-V-belt (2) from belt pulley 3 Pivot back tensioning pulley of tensioning device (3) a Remove viscous fan clutch with fan wheel |[TTarrest belt pulley (1) with trom belt pulley (1) corresponding tool 5 Press fan wheel toward front and remove |[4] Do not damage poly-V-belt (2) when poly-V-bel (2) removing ] Test 6 [check belt pulleys and tensioning pulleys for damage and smoothness, replace if necessary, 7 [check poly-V-belt (2) for good condition |i if necessary replace poly-V-belt (2) AP [Damage pattern for poly-V-belt Page 92 Gs installation 8 Press fan wheel toward front and position |[1] | Observe belt route of poly-V-belt poly-¥-bet (2) on belt pulley Workshop Manual OM LA 157Air compressor, belt drives Fo13 Poiy- V-belt route Page 91 9 Install viscous fan clutch with fan wheel on |[LJArrest belt pulley (1) with ete pulley (1) corresponding tool fe BA20.40-N-1003-01M 10 Pivot tensioning pulley for tensioning device (3) downward and hold n Position poly-V-belt (2) on tensioning [i] Ensure that poly-V-belts (2) isseated pulley for tensioning device(3)and pivot _|correctly back tensioning device (3) fel Fan, fan clutch Number Designation Engine 457.960 eazoaon-ioosanm [Bolt viscous fan clutch to nen] 50 belt pulley fan drive 158Fo13 Air compressor, belt drives [AR13.25-G-3200CH | Remove/instal poy-V-belt tensioning device 77.08 MODEL 000.001 with ENGINE 457.960 “Shown wit fan wheel removed 1 poly. vbeteatemator) 2 Tensioning pulley 3 pol 4 Tensioning device (alternatorpob-V belt) a inn awa 17 \ 2 j aes Removal instalation Avdanger Injury hazard fom pinching when working [se only approved terloning devices, Page 91 Jon springs and spring bodies under tension [shield hazardous area adlittonalyif neces heck special tool for damage and proper function visual inspection) Wear protective gloves. 7 Release tension on polyWVibel(i)and | instalation: Observe poly-v-belt route: [remove from tensioning pulley (2) 1 Poty-vbeltroute Page 91 Bl Unscrew bol) from tensioning device (@) [BB BA1325N-1002.010 5 Remove tensioning device) [iinstaation: ist insert pinon back of tensioning device (a) into mounting hoes ey Test a heck poty.v-bet (For condition, replace necessary AP | Damage pattern for poly-V-belt Page 92 5 Reinstall in opposite order 5 eeitensioning device Number Designation Engine 457.960 axnaswtoenaro [Bolt pol-v-beletensoning device vo wn] 50 angina cre ‘Wwokop anual OM EOLA 159