Engine lubrication, engine oil cooling Fo18 5 [Open shutoff vale @)untirapprox 401 |LT]bo notalow presure gauge to drop of engine ollarepumped rom the oil [below 1.Sbarsin the ol replenishing replenishing canister (nto the oil ducts canister), if necessary pump again and he engine oilextsfee of bubbles |Denot drain oll replenishing canister (3) fom the holes arrows)intherockar arm | completely, because otherwise sr would @ be suckedin 352589 116300 70 Reinstall in opposite oder 1 Fil remaining engine ol nto engine KAP Engine il and fier change Page 185. BS Danger Accent hazard esting fromvehide [Secure vehicle against starting to move Page| starting tomove by itself with engine [unintentional running. Injury hazard resulting fom | Wear dosed and tight work clothing pinching and burning wheneachingin [Do not reachinte hot or rotating pats uring te starting operation or withthe engine running. 2 ranktheengine and alow toiaie | crank the engine with starter formax, | BE18.00-N-1007-01L, osweit approx. minute before attempting to star againto prevent damage tostarer. Domotincreate engine speed along at theo pressure isnot indicated [le i pressure indicator should indicate the ol pressure ater approx. 105 3 shutoff engine and check for leakage | [1 isal inspection 7 heck engine ollevel with olaiptick br AP Engine, oil and filter change Page 185 Test values foroll presure Number [Designation Engine 457960 peiacono0 Engine oll pressure at vdiespeed bar] 05 Maxspeed—_bar|=25 Boititer Number Designation Engine 457960 axrezeivioesaw [Screw pug (lldruifiling) onolfiterhousng WSBx2__Nm|60 352509 11 6300 ee op im, 547 589 02 6300 192F618 Engine lubrication, engine oil cooling [AR18.00-G-4000cH Remove/install oil spray nozzles (piston) (3.7.04 MODEL 000.001 with ENGINE 457.960 1 Oilspray nozzle 2 Banjobolt 1 Ollspray nozzle 2 Banjo bolt 3 Gauge 31 Bcuide 3A 2 3/3] exes Removal, installation 1 Remove ol pan Page 51 2 [Convert turning device [1] only turning devices as of production Page 194 | [date "07/2001" (see stamp) canbe transferred 908 589 04 63 00 3 Install turning/blocking device for engine Page 195 | BA01.60-N-1001-01K 908 589 04 63 00 4 ‘Turn crankshaft with turning/blocking |] altoil spray nozzles(1) can be removed Jdevice until the olspraynozzle(1)is_|with 3crankshaft postions: Oil spray accessible nozzles (1) for eylinders 1/6, 2/5 and Is Unscrew banjo bolt (2) and remove oil [i] installation: The dowel pin (arrow) on spray nozzle (1) the oil spray nozzle (1) should catch inthe ole in the crankcase [=z] BA18.00-N-1001-011, Wirkahop Manual OM 450LA 193Engine lubrication, engine oil cooling F618 457 589.0123 00, Gauge Turing device a Tes é [Check dowel pin (arrow) onoilspray _|LI] event of damage replace ollspray nozzle (1) fordamage nozzle 1) G Install spray nozzle(T)ongauge | @ ifthe ollsplasher pipe bent ool {check ol splasher pipe with guide 3.1). | spray nal (1) damaged replace ol spray nozzle (1) others the pistons arenot sufficient cooled and the piston pin not corey lubricated iz 457589012300 a Reinstall in opposite oder Timing case Number Designation Engine 457360 saarsenviesran [Bolt capen observation hale to timing ave wns engine ubriction, engine oil cooling. general Number Designation Engine 457360 arecersioo1an |Baniobok, ol spray nozzle (piston cooling) 0 wn |a0 crankcase [a03.20-6-1600-04cH (Convert ranking device ‘908 589 04 63 00 ‘ranking device 194Fo18 Engine lubrication, engine oil cooling ® only Z cranking devices (1) which have ‘converted (see production date stamp as of "07/2001"). On older or other cranking devices without this groove (arrow) problems can occur when pivot ble (3)isremoved. 1 this work sequence is illustrated with a] cranking device (1) with groove (arrow), 1 Remove citcip (2) from [¥] cranking device (1). 2 Turnpivot bolt (2) until the Woodruff key (5) is visible in the groove (arrow) 3. Drive pivot bott (3) out of Zlcranking device (1) with brass punch, ‘The gear (falls out ofthe cranking device (1). heck Woodruff key (5) for ‘damage; ifnecessary machine Woodruff key (3) 4 Install gear (ain cranking device (1) and align through hole. Ensure that the groove (arrow) in the |Z] cranking device (1) coincides with the recess in the gear (4), 5. Drive pivot bolt (3) into [cranking device (1) observing the opposite installation pation of he phot bt, Do not damage the groove (arrow) and the Woodruff key (5). 6 Attach circip (2) to [8 cranking device (1). 7 Ollmoving parts of 1 cranking device (1). groove (arrow) under the crclip (2) can be [aR03.30.w-1600-038 [Attach crankingiblocking device for engine, detach el Timing case Number Designation Engines Engines '900:3,902.9, | 924.9,926.9 904.3, 906.9, xorsonoo201a —_inspectionholeclosure covert ——_-Nm|25 as timing case Fel Timing case Number Designation Engine 4579 exorson-iooronm —— [Bolt,inspection hole cover totiming _ Nm|25 Wirkahop Manual OM 450LA 195Engine lubrication, engine oil cooling F618 908 589 04 63 00 Shown on engine 908 +s TT 1 Remove noise encapsulation below the timing case. fl 2 Remove cover (1) attiming case. ~ 3 use suitable bolts (4) to bolt cranking device (2) tight at timing case. ® The cranking device (2) must be dismantied before the engine is started, otherwise tmay damage the flywheel or the timing case. i] the cranking device (2) can also be used to insert the pin (3) to lock the engine. 4 Removein the reverse order | 196F618 Engine lubrication, engine oil cooling [AR18.10-G-5031CH Remove/install oll pressure relief valve (3.7.04 MODEL 000.001 with ENGINE 457.960 1 Bolt 2 cp 3 Ollpressure relief valve eSBs Removal, installation 1 Remove ol pan Page 51 2 Unscrew bolts (1) and remove protective |) Do not disassemble oll pressure relief cap (2) together with ollpressurerelief | valve (3) nthe event of complaint replace valve (3) oil pressure relief valve (2). 1 catch engine oil running out in suitable vessel ba BA18.10-N-1001.01N A [Clean sealing surface a Reinstall in opposite order 5 Fillengine oil circuit Page 191 Fl oi! pump Number Designation Engine 457.960, exreron-100r0wN [Bolt oil pump with pressure relief valve to Nem] 35 crankcase Workshop Manual OM LA 197n, engine oil cooling Fo18 198F618 Engine lubrication, engine oil cooling [AR18.10-G-6020CH Remove/install oll pump (3.7.04 MODEL 000.001 with ENGINE 457.960 1 oltsuction ive 5 2 ase 4 Otsu rtevvae L—-] i (un f Ee [Removal instalation 7 Remove oipan Paget 5 Remove ol pene eet valve) Page 197 5 Remove mount forall scion pipe) rom fronase ns Remove olson ips (rom pump |(insalaions inal newseal@) @ 8 save08-100301N fi Tenove apap Giron cankene | sate0ars00200N é clear elng sutceonol pump (ono cen pipe and on cankcae 7 Reisalln oppo order ot pump Number esgnaton Tagine 7380 axienieerow [Bol ollpumptowenkeae was tansewieeroin [Bot intake manifold tool pune wmf Wirkahop Manual OM 450LA 199n, engine oil cooling Fo18 200F618 Engine lubrication, engine oil cooling [aR18.20-G-3471CH Remove/instal ol filter housing (3.7.04 MODEL 000.001 with ENGINE 457.960 1 ofter housing 2 otitercover 3 Seaingring 4 Oifiterelement 5 Screw pg 14x15) & —Coolanthose 7 Coolantintet fitting 2 Gasket 9 Oivwaterheatexchanger 10 Gasket 11 Grankease breather ine 12 Airintake hose 13° Engine wring bamess 8110 Oilcombination sensor (temperature pressure) aes Removal instalation A Danger 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, A danger 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 charge ar pipe Page 149) 5 Remove crankcase breatherlineW1/and _|[H] Check sir intake hose (12) and howe Page 141 ir inake hose (12) to exhaust gas clamps fr damage, replace necessary turbocharger a Remove exhaust manifold with engine Page 174 brake lp fitings and exhaust gos turbocharger ‘Wwokop anual OM EOLA 201Engine lubrication, engine oil cooling F618 s Unscrew oil filter cover (2) with ol filter ]LL] When screwing out the engine oil element 2) returns to the ol pan from the ol iter housing [=] BA18.20-N-1006-01N é Detach engine wiring harness (13) from coolantiniet fing) 7 Remove altemator 1 not kink or damage poly-V-bet Page 179 otherwise the engine can be damaged by Poly-V-belts tearing of CL only take poly-V-belt for fan and alternator off of belt pulley, donot remove 8 Remove coolant inlet fitting (7) rom installation: Replace sealing ring (8) coolant pump [=] BA20.10-N-1002-010 ls Disconnect engine wiring harness (13) from cil combination sensor (8110) 10 Pull out oil filter cover (2) and oil filter | [i] installation: Check sealing ring (3), element) replace if necessary " [check whether oll fiiter element (4)is_ |i] if damaged or soiled replace ol filter, damaged or soiled element 1 BAP Replace ol fiter element Page 187 2 Unscrew screw plug (5) and drain [catch cootant running out, remaining coolant from oliwater heat exchanger [=} BA18.20-N-1007-01N B Remove oil filter housing (1) from [EI catch coolant and engine oil running | BAT8.20-N-1004-01N crankcase out When replacing ol fiter housing (1) transfer following parts to new oi fiter rousing (1: ‘ oivwater heat exchanger (9) Remove, install olwater heat exchanger Page 205 it combination sensor (8110) Remove install ol pressure i Page 207 temperature sensor 9 Screw plug (ol circuit filling) with new |BA18.20-N-1005-01N seating ings BS Lock botts on oil cooler housing with | 8A18.20-N-1007-01N new sealing rings 14 Drain remaining engine ol from ol fiter housing (1) and catch 15 Drain remaining engine oil from oil/water |] For this purpose, press oll retention heat exchanger 9) and catch valve into oil;water heat exchanger. 16 Remove gasket (10) and clean sealing [i] installation: Replace gasket. surface 7 Check oil/water heat exchanger (9)for _| [iin the event of damage: outer damage 1 202Fo18 Engine lubrication, engine oil cooling Replace olwaterheat exchanger @) Page 205; 8 Teinsallin opposite order Ti nstaaiintake hose (12) to exhaust Jaasturbocharger fist after filing engine lero 3 il engine ol crit Page 191 20 check engine ollevel with ail dipstick KAP Engine oll and filter change Page 185 ar [rank the engine andalow toidie_Donotincrease engine speed as longs oil pesure isnotindeated to prevent damaging the engine [Rime cit pressureinicatorshould | Be1800:-1001-01L indicate the ol pressure ater approx. 10s fe Shutoff engine and checkforeakage | visal inspection Test value for oil pressure Number Designation Engine 457360 aeizconiooron [engine ollpessureat vdlespeed bar] 05 Maxspeed_bar|=25 oatiter Number Designation Engine 457.960 axrezeivroesaw [Bolt olfiterol cooler housing vo crankcase wn] 50 aaveacivioosaw [Screw plug (llerculfiling) onollfiterhousing MSBX2_Nm|80 aavezeiroesam [Oi fitercoveroilfiter housing | aavezoiiooraw |Lockbots toll coolerhousing Maxis _Nm|20 axis _nm[z0 axis _nm|zo aoxis _nm|ao coolant pump, coolant thermostat Number [Designation Engine 457360 asorenioenar0 [Bolt coolantinit iting to coolant pump un |50 Wirkahop Manual OM 450LA 203n, engine oil cooling Fo18 204Fo18 Engine lubrication, engine oil cooling [AR18.30-G-6840CH | Remove/instal ll water heat exchanger 3.7.08 MODEL 000.001 with ENGINE 457.960 1 oitwaterheat exchanger 2 Gasket 1 es Removal instalation 7 Remove oifiterhousing Page 201 P Remove owaterheatexchanger(®) | [A] Replace olf water heat exchanger (in the event of outer damage and engine abrasion in engine ol 2 8a18.30.2-1001.01° 5 Remove gasket @) [Tinstatation: Clean seating surfaces and replace gasket. Donotuse emery paper for cleaning a Reinsallin opposite order oicooter Number Designation Engine 457.960 pxreacivioovaw [Bott ollwaterheat exchanger toil cooler nas housing Wirkahop Manual OM 450LA 205n, engine oil cooling Fo18 206Fo18 Engine lubrication, engine oil cooling [AR18.40-6-4133CH | Remove/intal ol pressure, oll temperature sensor 797.08 MODEL 000.001 with ENGINE 457.960 1 agine wining hamessconmectar 2 Oiftercover 2 S E So a : Whey Zee SO (temperature, pressure) i >} fo I 8 6 as / Va A 5 le 510 Engine startpushbutton switch 511 Engine stop pushbutton stch es Removal instalation 5 Unscrew ol fier cover) from oi iter | Engine ol returns tothe oll pan by housing unscrewing the oi fiter covers 2), [1 nsttation: Check sealing rng onl iter cover, replace necessary 3 8A18.20:N-100601N 5 Unlock engine wring harness connector (1) rom oil combination sensor (8110) nd pulloft 3 Remove oll combinationsersor(8110) | Catch engine il running out [i instatation: Check Oxng oni combination sensor (110) for damage, replace cil combination sensor (6110) necessary fa BA18.40-N-100401K a Reinsallin opposite oder i} Test 5 heck engine ollevel with olaiptick AP Engine oil and fiter change Page 185. 207 Workshop Manual OM LA