Engine lubrication, engine oil cooling Fo18 [A Danger [Accident hazard resulting rom vehicle secre veide agalnststartng tomove Pages| tering tomove by uefwith engine unintentionally. running. nury hazard resulting from | Wear closed and tight work clothing Pinching and burning whenceaching in |Denotreachintohot or rotating parts uring the starting operation or withthe gine rig. 6 Press and hold down engine stop ® crank the engine for max. 20sRestart pushbutton switch (11, then pres engine [after a pause of apprex. minute to tart pushbutton switch (S10) until engine. [prevent damaging the starter reaches itll presure at carking wpe Cline engine doesnot start when the engine stop pushbutton switch (511)and engine sar pushbutton ste (S10 are pressedsimuteneouly aster reaching ol presure on ol presure clipay, release engine stop button $11) 7 low engine tole fort minute and Bere OON-TOOTOTL observe ol pressure cepay fe Shutoft engine and check for leakage [LI vsal inspection Test values for ol pressure Number Designation Engine 457.960 pera 004-004-011 Engine oll pressure at Idle speed bar] 205 Max. speed bar] =25 Fel oil fitter Number Designation Engine 457.960 fexrezon-ioos0w [Oil filter cover toil iter housing nen] 40 Fe4 oil level, oil pressure sensor Number Designation Engine 457.960, exraaon-ioosor% [Bolt oll pressure temperature sensor wm] 10 10 oll filteril cooler housing 208F620 Engine cooling system [AR20.10-G-1271CH Remove/install coolant pump (3.7.04 MODEL 000.001 with ENGINE 457.960 “Shown wit fan wheel removed 1 bracket 2 Coolantintet fitting 3 Gasket 4 Coolant outlet nipple 5) Coolant thermostat & Coolant pump 7 caster 8 beltpuley coolant pump) caoveaiaees Ey Removal instalation Axdanger Accent hazard esuting from vehide | Secure vehicle against tantng to move Pages| startingtomove by itself with engine [unintentional rinsing. jury hazard resting from | Wear lose and ght work cothing inching and buring when reaching in |Donotreachintohot or rotating parts luring the starting operation orwith the engine running, Adenger Injury hazard Danger ofsevee burmst> [Open colin sytem only at colant Page 26 skinandeyestromhotcotentspewing _|temperatures below 90°C Slowiy open out Coolantistoxicif swallowed over andeleve pressure Do nat beverage containers with coolant. Wear protective gloves, protective clothing and protective gogsies o Notes on coolant alengines Page 168 7 Drain coolant and catch installation: Add ony corosionrost protection agents approved according to oclant regulations to prevent damaging the engine Observe the following: J BB [Coolant regulations [Sheet 310.1 BB00.40-P-0310-01A, BB | Corrosion/frost protection agent [Sheet 325.2 (BB00.40-P-0325-02A ez Remove bracket (1) for Viscous fan Page 215 B Remove fan Page 213 a Loosen alternator Page 179) 5 Remove coolant inlet fiting @)from | LI instalation: Replace gasket) coolant pom (6) fs 8020.10:N-1002010 Wirkahop Manual OM 450LA 209Engine cooling system F620 é Remove coolant outlet tings (@and | [i instalation: Replace gasket. Page 211 coolant thermostat(5) from oolant pump | Observe instalation postion of coolant o thermostat) 7 Remove bee pulley @) rs 8A20.10.N-008010 = Remove coolant pump ( [i nstatation: Clean sealing surfaces on crankcase and on coolant pump (6) Replace gasket fa 8020.10-N-1003-010 a Reinsallin opposite oder 0 [crank the engine and allow toidle |] unt operating vemperatureisreached then shut off engine 1 [check coolant level, correctit necessary Het coolant pump, coolant thermostat Number Designation Engine 487.960 ea201011002010 [Bolt coolantinlet fitting to coolant pump m|50 azoso-11003.010 [Bolt coolant pump to crankcase m|30 fsazoi0%1006010 [Bolt belt pulley to coolant pump m2 210F620 Engine cooling system [AR20.10-G-2460CH Remove/install coolant thermostat (3.7.04 MODEL 000.001 with ENGINE 457.960 1 Coolant thermostat 2 Sealing ring 3 Coolant outlet nipple Ey Removal instalation AXbanger Accident hazard resulting from vehide [Secure vehicle ageinst starting tomove Pages| starting tomoveby sel with engine [unintentionally running. Injury hazard resulting from | Wear dosed and tight work clothing Pinching and burning whenreaching in |Donot reachintohot or rotating parts luring the tating operation orwith the engine ruwig. Banger Danger of severe burnstoskinand yes [Open cooling stem ony at coolant Page 26 rom ot coolant spewing out Coolantis_|emperatures below 90°C Slowly open toxii swallowed cover andreleve presure Do not beverage containers with coolant. Wear protective gloves, protective clothing and protective gogsies o Notes on coolant alengines Page 168 7 Brain coolant and catch [ instalaion: Add only corosonirort protection agents approved according to oclant regulations to prevent damaging the engine Observe the following J BB |Coolant regulations [Sheet 310.1. (BB00.40-7-0310-018 BB | Corrosion/frost protection agent [Sheet 325.2 BB00.40-7-0325-02A B Remove coolant ouletippie trom |B BA20,10'100%-010 coolant pump B Remove coolant thermontat() together instalation: Replace sealing ings(@),_ | BROOAS -10TB 5A wth seling ings 2). areae and postion on coolant thermostat . observe instalation poston af sealing rings (2). Observe instalation postion of coolant thermostat (the blow holes (arrows should point upward a Reinstall in opposite oder Wirkahop Manual OM 450LA atEngine cooling system F620 [crank the engine and allow to idle [4] Until operating temperature isreached, then shutoff engine 6 [Check coolant level, correctit necessary el coolant pump, coolant thermostat Number Designation Engine 457.960, Bol, coolant outlet nipple with coolant thermostat on coolant pump ‘nen]25 Repair agent Number Designation Order number enooas-2- 1018064 ATE grease 22F620 Engine cooling system [AR20.40-G-5614CH Remove/install fan 9.7.04 MODEL 000.001 with ENGINE 457.960 1 Fanve! 2 Pobyvbel (fan) 3 betepuey on) 4 Vicouston clutch ees Removal instalation Avvanser Injury hazard fom pinching when working [se only approved terloning devices, Page st onsorings and spring bodies under tension [shed hacardous area adiionaly necessary Check special tol for damage and proper function visual nspection Wear protective gloves. 1 Remove poy V-belt (2) [remove pty vbel 2) ony partially Page 157 El instatition: Observe elt route and damage pattem fr poly-Vbets 2). it necessary replace pay V-ble nthe event of weer t Poy V-belt route Paget WAP | Damage pattern for poly-V-belt Page 92 Bi Temovevioustan latch @)from ett [Lock up le pulley) with pulley) corresponding tel fs 2a20.40.- 1003018 P Termove fan wheel iy wthvicousfan|LETenaue that fan wheel (with vious eluteh tan dutch (are always stored in vertical peor a Remove vioustan catch (@)from fan |i] ony if vacousfancuch ofan wheel (1) whee! (1)isto be replaced Ci] installation: if viscous fan clutch (4) mustbe replaced, store viscous fan clutch (4) in vertical position min. 1h before installation [=] BA20.40-N-1001-01M Wirkahop Manual OM 450LA 213Engine cooling system F620 5 Reinstall in opposite order fel Fan, fan clutch Number Designation Engine 457.960 eazoaon-ioorowm [Bolt fan on viscous fan clutch nen] 30 sazoaon-ioosowm | Nut viscous fan clutch to wm] 50 belt pulley fan drive 24F620 Engine cooling system [AR20.40-G-5640CH Remove/install bracket for viscous fan 9.7.04 MODEL 000.001 with ENGINE 457.960 1 Bracket (fan drive) 2 Bertpulley fan) 3° Belt pulley (alternator) aes Removal instalation Avdanger Injury hazard fom pinching when working | Use only approved tensioning 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 Remove en Page 213 2 Teleaseerson on poy-V-beltandremove | instalation: Observe betroute and Page 155 rom ele puley 3) eamoge pattern fr poly-V-bels, if necessary replace poy bel 1 Poty-veteroure Page 91 KAP Damage patter for poly-V-belt Page 92 3 Remove bracket (1) for fan drive TE check bet pulley) forcondiion, replace if necesay [i instatation: Observe various bot Ienaths fs 8420.40:N-1008.01M a Reinstall in opposite oder el Fan, fan clutch Number Designation 20a0.n-1008.01m Fan drive bracket to crankcase Wirkahop Manual OM 450LA 25Engine cooling system F620 216roa? Fuel system [AR47.20-6-1070CH | Remove/install main fuel iter 296.08 MODEL 000.001 with ENGINE 457.960 1 Main fue fier 2 bracketing eye 3 Fuelline from feak fuel ine) 4 Fueling (to fuel tank) : 1 ‘5 Fuelline (frm fuel pump) 5 6 Fuellie to unit pumps) in| nla a 2 ‘ i ess Removal, instalation ES Danger Accident hazard resulting fromvehice | Secure vehicle againststarting tomove Pages) starting tomoveby sel with engine [unintentionally running Injury hazard resulting from | Wear tightly fitting work dothes Pinchingand buming when reaching in| Denotreachnte hot or rotating parts luring the tating operation or withthe engine running A dangert Fuel vapors present an explosion hazard. | Fir, open ights and smoking prohibited. Page 27 Fuelvaporsareoxiewhen inhaled while Avoid sparks handing open fuel. Conactwth ful can_|Fil and tre ful onyin containers cause eye and skin injury intended and marked fo this purpose. Wear protective dothing when handling uel 7 Remove fuellines (4) frommain uel | instalation: Replace sealing ings. iter) 2 847 25.N-1003-01L B Remove fuelines(5,6)frommain uel | instalation: Replace sealing ngs tern) 3 8447 25:N-00401L B Temove main fel iter) from is BAA 20.N-1005-02K bracketing eye 2) fa 8447 20-N-1006-02K a Reinstall in opposite order, 5 [crank the engine and bleed fuelsstem, ET Altow engine vo run for approx. allow engine ticle min Fuel system bleeds by self é ShucoFt engine and check fuel lines (3,45, [LH visual inspection. 6) forleakage et iter Number ation Engine 457.960 ener aowiooreax [Bolt fuel fiter to bracket wim [25 Workshop Manual OM LA 27Fuel system fel Fuel fitter Number Designation Engine 457.960, Bolt, mount fuel filter /frontlifting eyes to im] 100 crankcase el Fuel linesihoses Number Designation Engine 457.960, axe. a5.n-1002- 010 Banjo bol, ful line! leak fuel line to banjo bolt New] 15 exer as.n-1006-01. Banjo bot, fuel ine to fue fiter housing nm] 50 F647 218F647 Fuel system [aRa7.20-G-5710CH Remove/install fuel pump 29.6.04 MODEL 000.001 with ENGINE 457.960 1 Fuelpresue line 2 Fuelintake tne 3 Seningrings 4 Gasket 5 Fuel pump casei ees Removal instalation Aanser Explosion heard rom igniting, Fuels [Fire open ight and anokng prohibited, foxiciben taken orally inhale. nary | avoid sparks page27 hazard rom skin and eye contact with ue Filan store fel oly in containers Intended and marked fortis purpose Wear protective dothing when handling uel 5 Remove MAUPLDcontolunit. Page 133 P Fel presureline (1) [Tintin Replace sealing rings) fs 8447 25.4-100801L 5 Termove fuel inate ine @ [instar Replace seating rings @) fs nar 25.007 010 a Remove fue pump) Tinton: Replace gone = ea47.204-100202k 5 Reinstall opposite order rect fier Murer Designation Engine 457960 anaonionex [ok fuel pumpto wn] as crankcase uel inesthases Murer Designation Engine 457960 per 25-1007 01. Banjo bok, fuel intake ine on fuel pump nem] 50 Workshop Manual OM LA 219Fuel system F647 fel Fuel linesshoses Number Designation Engine 457.960 Banjo bot, fuel pressure ine to fuel pump ‘ve 50 20F647 Fuel system [aR47.20-G-5821CH Remove/install bearing for fuel pump drive 29.6.04 MODEL 000.001 with ENGINE 457.960 1 rie whee 2 Grae 3 Sewing a crap & lowepunch TaN ei Removal 1 Femovecnshat pocket cover oi Remove fel pump @) Page 219 fi Remove dive gear rom bean) q Remove cr fi Remove crip) é Temove bearing () om aankas with 5750900500 rt punch 6) eB stalaon r sal cin) e Ts bering @) om cankave wh ai [LL] Un bewing make contac wh puns aig) jw 157588001500 9 Install circlip (2) © isallarive wheel Don beng @ | Ta 201100802 TH tale pu Page 219 @ Isl arian pecker Page 45 ue er Number Deigation Engin #57960 sarzowowaex [Bot fel pun dive gear beng wa f30 ors Oma maFuel system Foa7 57 589 00 1500 22F647 Fuel system [AR47.21-G-5621CH 296.04 Remove/install fuel heat exchanger MODEL 000.001 with ENGINE 457.960 Fuel heat exchanger Fuel line Fuel line Manual fuel feed pump AG MRYPLO control unit es Removal instalation BS banger Injury hazard for skinandeyeswhen | Wear protective gloves, protecive doting Page 80 handling hot or slowing subecs and protective gogsies [EX Danger [cident hazard resuting from vehide [Secure vehicle ageinststaring tomove Pages) starting tomove by itself with engine [unintentional running. Injury hazard resulting from | Wear dosed and tight work clothing Pincing and burning whenreaching in |Donot reachintohot or rotating parts uring the starting operation or withthe engine ruwig. A danger Explosion hazard rom igniting. Fuels |Fre, open lightsandsmoking prohibited toxcwhen taken oral or inhaled. Injury [Avoid sparks Page 27 hazard rom skin and eye contact with ue Filan store fel oly in containers intended and marked fo this purpose. Wear protective dothing when handling uel 7 Remove feline @) from fuetheat | tnstataion: Replce sealing ngs. Jexchanger(®) 2 0447 25.n-1009.01L B Remove fuelline@) together with manva |i stallion: Replace sealing ngs. ft fed pump (6) from fuel heat exchanger) 3 0A47.25.n-1004-016 3 Remove fuelheatexchanger(1)from LL] donot dassemble uel heat exchanger MRIPLD contol unt(A8) oo. fs 8207. 15.0-1001.01F a Reinstall in opposite oder 5 [rank the engine and bieedfuelsstem, [LI Allow engine trun for approx 1 allow engine tide min Ful system bleeds by tse é shutoff engine and check fuelines@,3) | visal inspection for leakage Wirkahop Manual OM 450LA 23