00 00 Powertrain Additional Information

Commercial Vehicle Service Training
Powertrain
Engine mechanical training.
Series 900, 500 and 457
.Additional information
Mercedes Benz DCUK
As at 06-2005
DC 5000
Further ordering or supply of this documentation is not possible
This documentation is intended solely for training use and is not subject to modification.
Printed in Germany
ã 2004 Copyright DaimlerChrysler AG
The work including all parts thereof are protected by copyright. Any exploitation or use requires the prior consent of
DaimlerChrysler AG in writing. This applies, in particular, to duplication, distribution, adaptation, translation,
microfilming and storage and/or processing on electronic systems including databases and online services.
1510 02 - 1st
Edition 12.04 0,15 12 ã 2004 Copyright DaimlerChrysler UK
NM459M Contents (4 day training) 31.10.03
Part Page Title

DAY ONE
Group 00 1 Introduction
Group 1
Group
Group 1
DAY TWO
Group
Group
Group
Group 1
Home
06/02 · Engine Mechanics 459M

Contents 1
NM459M Contents Part 2 (4 day training) 31.10.03
Part Page Title
DAY Three
Group 4
Group
DAY FOUR
Group 1
Assy
Lunch
Assy 1
Group
Final test

Contents 2
NM459M Course Program 31.10.03
Chapter Time Description

Day 1
Group 00 Introduction 10:00 Introduce course program
Introduction of engine ranges Overview of Complete range
Page 0
Page 0
Quick break 11:50
Group 0 12:05
Page 0 Constant throttle
Lunch 12:40
13:40
Group 0
Group 0
Tea
Page 0 Fuel Circuit Theoretical function, (using PPT animation)
Repair and, coding
Home 16:45

Contents 3
NM459M Course Program (continued) 31.10.03

Day 2
Group 0 Feed back 09:00 Questions, comments, observations from previous day
Page 0 0915
Page 0 Fuel circuit series 500 09:45 Theoretical overview, Topographical, and schematic views, and fuel pressures
Page 0 Introduction of series 457 10:30 Theoretical overview, Topographical, and schematic views, and fuel pressures
Coffee 10:50
Page 0 11:10
Page 0 Fuel filter assembly 11:40 Theoretical overview, pre-filters, full-filters and additional filter, servicing and tips
Group 0 Valve gear and Valves 11:55 Service, adjustment, and repair
Lunch 12:40
Group 0 Belt arrange. and Compressor 13:40
Group 0 14:00
Tea 15:00
Page 0 15:20
Home 16:45

Contents 4

Day 3
Feed back 09:00 Questions, comments, observations from previous day
Group 01 Practical on engine
Page 15 Cylinder liner series 500 09:15 500, 457, piston, liner matching procedure
Page 21 Cylinder liner 900 09:45 900 series piston matching procedure, and cylinder / crankcase markings
Page 17 Removal and refitment of liner 10:45 Precautions, inspecting and measuring
Coffee 10:50
Page 25 0il separator 11:10 Theoretical operation service and fault finding
Group 03 Crankshaft sealing methods 11:20 Removal, fitment and repair options
Page 3 Crankshaft axial play 11:25 Checking, setting and adjustment all engines
Page 4 Piston projection 11:35 Checking, fault Identification and changing
Page 7 Connecting rod 11:45 Matching procedure, checking, and repair options
Lunch 12:40
Page 8 Crankshaft 13:40 Inspection, measuring, and repair
Page 10 Pistons and rings 14:40 Inspecting, measuring and mounting
Tea 15:00
Page 21 Crankshaft Tasks 15:20 In book
Home 16:45

Contents 5

Day 4
Feed back 09:00 Questions, comments, observations from previous day
Theory Before engine goes back together
Group 18 Lubrication circuit 09:15 Theory complete tasks to page18
Coffee 10:50
Practical on engine
Rebuild engine 11:10 Rebuild engine to pre-course condition!
Lunch 12:40
Practical on engine Continued
Rebuild engine 13:40 Rebuild engine to pre-course condition!
Group 18 Cooling system 14:40 Theory complete tasks to page16
Tea 15:10
End of course assessment 15:30
Feed back 16:00 Feed back, and end of course critique / critic sheets , and certificates
Home 16:15

Contents 6
71_01 13.05.98 Tex71_01
Engines OM 904/906 LA and OM 501/502 LA 11.05.2000
N01.00-0392-30
05/00 Engine control on the engines Series 900 and 500 in combination with ADM-FR respectively FR
Engines OM 904/906 LA and OM 501/502 LA 1
71_01 13.05.98 Tex71_01
Engine Range 11.05.2000
There are four basic engine groups, or “families:-
1. Petrol engines. Designation M 1-- --. Inline 4, 5, 6,

“V” 6, 8, and 12 cylinders.
2. Light diesel engines. Designation OM 600 series.

Inline 4, 5, 6, and “V” 8.
3. Medium diesel engines. Was OM 300 series, Now

Designation OM 900 series. Inline 4, and six cyl.
4. Heavy diesel engines. Was OM 400 series, Now

Designation OM 500. 900 “V” 6, 8, 10, and “V” 12.
5. And the relatively new OM 457. Inline 6 with

separate cylinder heads.
05/00 Engine control on the engines Series 900 and 500 in combination with ADM-FR respectively FR
Engines OM 904/906 LA and OM 501/502 LA 2
71_01 13.05.98 Tex71_01
Engine OM 457 LA 31.10.2001
Characteristics:
The engine series OM 457 LA is a new development with optimized power and torque characteristics.
The engines are suitable for all operating fields in distribution as well as short-haul and long-haul working.
They are characterized by high economy combined with good fuel consumption and low servicing costs.
With a very low power-to-weight ratio the engine design satisfies market demands for the lowest possible
vehicle weights combined with the highest payload.
Further highlights of the new engine series are their high dependability combined with long service life
with extremely good fuel consumption and at the same time optimal power output.
N01.10-2082-01
Technical highlights of engine series 457:
· High strength, noise-optimized crankcase made of high-alloy gray cast iron.

· Compact design and high operational reliability as a result of integration of oil cooler, unit pumps as well as coolant, fuel and oil galleries in the crankcase.
· Engines in three different power output classes, already comply with the EURO III standard as of start of production.
· Very rigid light alloy oil pan.
· Crankshaft mounted in seven bearings with bolted balancing weights. Bearing points and fillet radii induction case hardened.
· Fit bearing positioned at middle bearing pedestal for vibration reasons.
· Main and conrod bearings designed as free-layer bearings, compression stress side sputtered.
· Crankshaft sealed by means of radial seals with dust lip of non-woven material.
10/01 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Engine OM 457 LA 2
71_01 13.05.98 Tex71_01
· Four-valve technology with 2 inlet valves and 2 exhaust valves at each cylinder.
· MR engine control with engine electronics attached to engine.
· Pump-line-nozzle system with solenoid valve-controlled unit pumps.
· Electronically controlled high pressure injection up to 1800 bar.
· Direct injection with centrally positioned 6-hole injection nozzle.
· Engine brake with exhaust flap and pneumatically operated constant throttle valve. Useful engine speed is higher than rated speed.
· Turbocharging with intercooling.
· Turbobrake as special equipment (SA).
· Engine output possible to rear and to front by means of additional belt drives for ancillaries (SA).
· Operation with bio-diesel (RME) possible.
N01.10-2059-50 N01.10-2060-50
Engine OM 457 LA 3
71_01 13.05.98 Tex71_01
· Camshaft driven by gear drive at the flywheel side

· Gear-driven air compressor with flange-mounted power steering
pump positioned at flywheel side
· Fuel delivery pump driven by camshaft at belt side
· Oil pump in oil pan gear-driven at flywheel side
· Maintenance-free poly V-belt drives for all assemblies
· Planetary drive starter on right side at flywheel
· MR PLD control unit same as series 500, but with additional
fuel cooler
· Inlet valve seat rings made of tribaloy, a high-alloy tungsten steel.
These only need to be equalized when installed.
· Heat protective sleeve same as series 906
· Pistons cooled by oil spray nozzles
· Lubrication of camshaft/unit pumps by additional oil spray nozzles
W01.00-1021-06
You can obtain an overview of the principal technical data from Introductory Manual p. 76 and WIS document SN01.00-W-0001-02C.
Engine OM 457 LA 4
71_01 13.05.98 Tex71_01
Group 01 06.06.2002
Allocation of channels (500 series)
task
A C A
The next component to consider is the cylinder head gasket. Nothing has
C
changed as regards its handling and installation. The Workshop Manual best E
describes the procedures. For diagnosis purposes, however, it is often
B B
necessary to identify the ducts.
Match the holes in the cylinder head gasket to the following terms.
B B
A Push rod ports
B Bolts
D
C Coolant
C
D Oil return
E Oil feed to Rockers
N01.30-2024-12
06/02 PowerSystems · Engine series 500, 900 and 457

Group 01 1
71_01 13.05.98 Tex71_01
Group 01 06.06.2002
Task (900 series) m The next component to consider is the cylinder head gasket. Nothing has changed as regards its
handling and installation. The Workshop Manual best describes the procedures. For diagnosis
purposes, however, it is often necessary to identify the ducts.
Match the holes in the cylinder head gasket to the following terms.
C C C C
B B B B A B
C
C
E
B C B C B C B C B
D A A A A A A A A
A = Push rod ports
B = Bolts
C = Engine coolant
D = Oil Separator Return
E = Oil feed to Rocker shaft
N01.30-2039-05

Group 01 2
71_01 13.05.98 Tex71_01
Assignment of galleries in cylinder head gasket engine series 457 06.06.2002
Exercise (Series 457)
¦ Discuss in your group which drillings of the cylinder head gasket are used
A C A
by the items listed below, and transfer the corresponding letters to the
matching drilling! E
C
B B
B B
A Tappet, oil return flow
B Bolts
C Coolant D
D Oil return flow C
E Oil feed to Rocker shaft
N01.30-2068-12

Group 01 3
71_01 13.05.98 Tex71_01
Cylinder head sealing surfaces 06.06.2002
ExerciseSI01.10-W-0003A m The surface of the contact faces of crankcase / cylinder head is matched to the cylinder head gasket.
When carrying out repairs, particular care should be taken when cleaning the sealing surface.
Use document No. AH01.10-N-0002-01A
Mark the correct statement or statements!
! a The cylinder heads can be cleaned in a bath (chemical high pressure).

! b The oil feed and return flow galleries should be sealed before cleaning.
! c The coolant galleries should be sealed before cleaning.
1 d The sealing surfaces can be cleaned with emery cloth, corundum on the surface is not a problem.
! e The sealing surfaces can be cleaned carefully with a hand scraper.
1 f The sealing surfaces can be cleaned with a rotary wire brush or rotary emery paper.
1 g The sealing surfaces can be cleaned with a sand blaster.
! h The sealing plugs must be removed before assembling.
! i The sealing surface must not suffer any damage as a result of cleaning.

Group 01 4
71_01 13.05.98 Tex71_01
task m Cylinder Head fastening bolts. There are bound to be a few important points here.
Mark the correct statements!
! a Reduced work required for assembly and disassembly.

1 b The tightening sequence does not need to be observed.
1 c The first tightening stage can be skipped because the tightening torque is very low.
! d Tightening torque stages and sequence must be strictly observed.
! e If the tightening torque stages are not adhered to, Can result in stresses (uneven contact force)
1 f The cylinder heads have to be re-tightened after the first service.
task m „Stretch“ bolts or angle tightened bolts are now in wide use.
The advantages are: -
The clamping forces are accurately calculated.
- No need to retighten the bolts after a running in period.
In most cases the bolts maybe reused providing the bolt is not damaged and is within tolerance!
How is this tolerance checked?
Mark the correct statement after discussion in your group and using the work shop media check your
answer.
1 a By the weight of the bolt. As the bolt gets longer it will have a greater mass.
1 b By the tightening torque. Bolts which are out of tolerance will shear.
! c By the length of the bolt, from under the head to the end of the shank.
1 d By the thickness of the bolt. As the bolt stretches its diameter will reduce.
1 e By the number of dot punch marks on the head of the bolt. Each time a bolt is reused must be
indicated by dot punching the head of the bolt. A bolt may be usedup to a maximum of three.times

Group 01 5
71_01 13.05.98 Tex71_01
task m Handling stretch bolts

Apart from the stretch bolt tolerance there are some preconditions to consider before refitting the
bolts.
Number the statements in the correct order.
1 1 The bolts should be cleaned on a wire wheel if there is any evidence of rust, carbon, or any other
debris.
2 2 The bolt length must be measured and compared with the directives in the workshop media.
3 3 The bolt holes should be checked for debris, coolant and oil contamination.
4 4 Lightly lubricate the threads and under the head of the bolt with engine oil, not 85/90 or grease.
5 5 Torque up the bolts adhering to the sequence and stages.
6 6 Mark the bolt heads for position then angle tighten in sequence.
If a bolt is inadvertently over tightened or the sequence is lost during the

tightening of stretch bolts start again form point number 2
Top tip:-
The cylinder head bolts at the engine series 457 are marked with 457.
N01.30-2069-01

Group 01 6
71_01 13.05.98 Tex71_01
Exercises on Cylinder Head Bolts 06.06.2002
Exercise m Complete the table below, paying particular attention to the modified diameter.
Refer to the WIS document AR01.30-W-5800-07C as an aid!
Engine series Bolt diameter Max. shank length

BR 500 M18x2 212 mm
BR 457 M15x2 212 mm
Exercise 1 m Complete the table below!

Refer to the WIS document AR01.30-W-5800-07C as an aid!
Designation Tightening Engine 500 Engine 457

stages
Cylinder head bolt to 1 stage
st
10 10 Nm
crankcase
2 stage
nd
50 50 Nm
3 stage
rd
100 100 Nm
4 stage
th
200 200 Nm
5 stage
th
90 90 tightening angle
6 stage
th
90 90 tightening angle
7 stage
th
- - tightening angle

Group 01 7
71_01 13.05.98 Tex71_01
Cylinder head
OM 904
OM 906

Group 01 8
71_01 13.05.98 Tex71_01
Valve setback engine series 500/457 06.06.2002
Exercise m Use the workshop information (AR0530-W..., AR0530-W... and AR0130-W...)

as an aid for completing the table. Measure a cylinder head!
Specification Actual value
Valve setback relative to

cylinder head contact surface: 0.70 - 1.05 mm
engine series 500
Maximum distance between
both valves: £ 0.2 mm
engine series 500
cylinder head contact surface:
engine series 457
Maximum distance between
both valves:
engine series 457
N01.30-2008-11

Group 01 9
71_01 13.05.98 Tex71_01
Constant throttle Valve seat 500/457 06.06.2002
Exercise Answers and doc number to complete m The corect clearances are critical for theconstant throttle valve seat and piston,
Discuss in your group, and complete the table.
m
- mas
- ma
Maximum and
Specification Minimum values

cylinder head contact surface: 0.00 - 0.00 mm
engine series 500
Min piston height
engine series 500 £ 0.2 mm
cylinder head contact surface:
engine series 457
Min piston height
engine series 457
N01.30-2008-11

Group 01 11
71_01 13.05.98 Tex71_01
Constant throttle Valve seat (Series500) 06.06.2002
Exercise (500 series)
m What is the result of constant-throttle valve seat wear?

What are the repair options?
Discuss in your group, state your answer below
- mas
- ma
- ma
Exercise (500 series)
m Complete the following table regarding piston height
Height Minimum Cap

Cap type Piston height Height
Flat Cap 0.00
Stepped Cap
Repair Cap 0.00
W07.10-0006-06

Group 01 12
71_01 13.05.98 Tex71_01
Fault symptoms constant throttle 06.06.2002
Exercise m When it comes to the subject of the constant throttle we also wish to look more closely at the faults
and their symptoms. The problem on a customer's vehicle is that a valve seat of the constant throttle
is worn.
What are the symptoms, which this fault may cause? Discuss this problem case in your group.
!a Irregular engine running

!b Engine shakes and tends to vibrate
!c Drop in power output
1d Increase in power output
1e No symptoms detectable
!f Engine noises / clattering combustion
Exercise m Which test can you use to pinpoint this fault?
!a Cylinder pressure loss test

!b Mechanical compression test
1c Impact times
!d Test of compression with STAR Diagnosis
!e Smooth idle speed control

Group 01 13
71_01 13.05.98 Tex71_01
Crankshaft sealing engine series 500/457 31.10.2001
Datei: V:\InfoPool_NFZ\Motoren\BR 500\Gruppe03\03.20 Kurbelwelle\TRA KW_Abdichtung BR500 1_D.doc
Exercise 1 m When it comes to the sealing of the crankshaft, different types of seals are available.
Refer to the table below and select the correct repair combination for the circumstances which exist!
Installing and replacing Replacing

radial sealing ring radial sealing ring steel race crankshaft flywheel
Condition with PTFE sealing lip with coil spring
Seal at front leaking.
Radial sealing ring with PTFE sealing lip is
installed, no traces of wear from ring.
!
Seal at front leaking.

installed, traces of wear on sealing surface of
! '!
crankshaft from ring.
Seal at Rear leaking.
Radial sealing ring with coil spring and race is
installed, no wear on race.
!
Seal at rear leaking.

installed, sealing surface at flywheel is damaged.
! !
Crankshaft sealing engine series 500/457 63
71_01 13.05.98 Tex71_0116/03/0516/03/05
Group 05 06.06.2002
Valve clearance AP05.30-W-0560 A AP05.30-W-0560B
„Valve play“ - a familiar subject, and requiring no extra study. Or does it?
² In fact, there are a few things about valve clearance that you do need to know AH 05.30-N-1000BB
Check the correct statements!
8 Valve clearance is measured between the rocker arm and valve bridge.
The valve clearance is measured between the valve bridge and the valve stem.
The valve clearance is set to the specified value, including the test tolerance.
8 The test tolerance serves only to check the valve clearance, and may be +0.2mm to –0.1mm.
8 When checked, the valve clearance at the inlet valve may be +0.30 mm to +0.60 mm.
after setting, the valve clearance at the inlet valve may be +0.30 mm to +0.60 mm
The valve clearance must be adjusted every service.

Group 05 1
71_01 13.05.98 Tex71_0116/03/0516/03/05
Checking / adjusting the valve clearance 06.06.2002
task m Complete the following table with regard to "checking/ setting the valve clearance
m Use the W.I.S. if you need to check your answers
AP05.30-W-0560-01C Checking, adjusting valve clearance
Valve test values
Number Designation Engine Engine

457.944/ 942 541/542
BE05.30-N-1001-01J Valve clearance inlet mm 0.40

exhaust mm 0.60
BE05.30-N-1002-01J Valve clearance test tolerance mm + 0.20 /- 0.10
n General engine control
Number Designation Engine

457.944/ 942
BA05.00-N-1002-01G lock nut at adjusting bolt, Nm 50 Nm

rocker arm

Group 05 2
71_01 13.05.98 Tex71_0116/03/0516/03/05
> Valve adjusting sequence Engines series 457, 904, and 906. 06.06.2002
Method 1
Set inlet and exhaust valves of each cylinder, in
accordance with the injection order.
The cylinder to be adjusted must be positioned at

ignition TDC, and the synchronous cylinder at
valve overlap TDC.
A exhaust valve
E inlet valve
X flywheel side
N05.30-2070-01 A01.00-0001-01
Inlet shown Series OM 457 shown
Engine Crankshaft setting Cylinder / injection sequence
4-cylinder ignition TDC 1 3 4 2

valve overlap 4 2 1 3
6-cylinder ignition TDC 1 5 3 6 2 4
valve overlap 6 2 4 1 5 3

Group 05 3
71_01 13.05.98 Tex71_0116/03/0516/03/05
Method 2
Set inlet and exhaust valves in two crankshaft
settings, according to the table.
First of all set cylinder 6 to overlap TDC. (cylinder

1 to ignition TDC),
then cylinder 1 to overlap TDC (cylinder 6 to
ignition TDC).
A exhaust valve
E inlet valve
X flywheel side
N01.00-0347-01 N01.00-0348-01
Series OM 904 shown Series OM 906 shown
Engine Crankshaft setting Check / Adjust cylinder No.

1 2 3 4 5 6 7 8
4-cylinder cyl. 4 valve overlap E/A E A -- -

cyl. 1 valve overlap -- A E A E/A
6-cylinder cyl. 6 valve overlap E/A E A E A --
cyl. 1 valve overlap -- A E A E E/A

Group 05 4
71_01 13.05.98 Tex71_0116/03/0516/03/05
> Flywheel markings (series 500). 06.06.2002
The flywheel is similar to the 500 series with ring

gear for single or double disc clutch or with drive
plate carrier for automatic transmissions or
converter and clutch
units, is fixed to the crankshaft end with 10 bolts.
36 grooves are arranged symmetrically around

the surfaces of the flywheel, with an additional
37 groove.
th
The crank angle position sensor uses this 37 th
groove to detect the position and speed of the

crankshaft.
The TDC-mark for manual TDC location in the

workshop is a blind drill-hole in one of the
grooves.
N03.30-2007-06

Group 05 5
71_01 13.05.98 Tex71_0116/03/0516/03/05
Valve Clearance Adjustment OM 500 series.
Method 1
Adjust inlet and exhaust valves per cylinder,
according to the injection sequence.
The cylinder to be adjusted must be at ignition
TDC, the opposite-running cylinder at valve
overlap TDC.
A exhaust valve
E inlet valve
X flywheel side
N01.00-0200-01 N01.00-0201-01
Engine Crankshaft setting Cylinder / injection sequence
6-cylinder ignition TDC 1 4 2 5 3 6

valve overlap 5 3 6 1 4 2
8-cylinder ignition TDC 1 5 7 2 6 3 4 8
valve overlap 6 3 4 8 1 5 7 2
AH05.30-N-1000-01B ……General Information On Valve Clearance Adjustment

Group 05 6
71_01 13.05.98 Tex71_0116/03/0516/03/05
Method 2
Adjust inlet and exhaust valves in two crankshaft
settings, according to the table.
A exhaust valve
E inlet valve
X flywheel side
N01.00-0200-01 N01.00-0201-01
6-cylinder 8-cylinder
First set 5 cylinder at valve overlap TDC.
th
First set 6 cylinder at valve overlap TDC
th
(1 cylinder in ignition TDC), then set 1 cylinder at overlap

st st
(1 cylinder in ignition TDC), then set 1 cylinder at overlap
st st
TDC (5 cylinder at ignition TDC).

th
TDC (6 cylinder at ignition TDC).
th
1 Engine Crankshaft setting Cylinder / injection sequence

1 2 3 4 5 6 7 8
6-cylinder 5 cyl. valve overlap

th
E/A A E A - E
1 cyl. valve overlap
st
- E A E E/A A
8-cylinder 6 cyl. valve overlap
th
E/A A E E A - A E
1 cyl. valve overlap

st
- E A A E E/A E A

Group 05 7
71_01 13.05.98 Tex71_0116/03/0516/03/05
Valve timing gear
The valve timing gear has changed substantially compared with series 400; there are some points, which should be considered before dismantling the valve gear.
Task AR 01.30- W-5800B m Using the document „ AR0500- W-5521B “, the workshop media and discuss in your group.
Mark the correct statements.
1 a There are no particular precautions.

! b Adjustable valve bridges should be marked for their location and not inter changed.
! c Non adjustable valve bridges may be interchanged.
1 d The push rods can be removed from the tappet without caution.
1 e The push rod should be agitated as they are pulled from the tappet.
! f To gain access to the roller tappet, the cylinder head must be removed.
! g No precaution to be taken when inverting the engine with the push rods removed.
! h Bolts marked 10105 must be replaced by bolts with a MB part No. on the head.
Task SI05.30-W-0001B m Now another point, which must be considered: -

What action should be taken if the “guide pin” is damaged, or broken on an early 500 or 900 series?
Using the document „SI05.30-W-0001B“, the workshop media, Mark the correct statements.
1 i 500 series– renew the cylinder head.

! j 500 series– the pin can be cut flush with the head in-statue, then non-adjustable bridges maybe used
! k It is possible to have adjustable and non-adjustable valve bridges on the same engine.
! l 900 series– renew the cylinder head.
1 m 900 series– the pin can be cut flush with the head in-statue, then non-adjustable bridges maybe used
! n If a guide pin is used, the maximum difference of valve stand back between twin valves is 0.2mm

Group 05 8
71_01 13.05.98 Tex71_0116/03/0516/03/05
Examine valve lift
task m What are the consequences of excessive valve clearance?
!a Incorrect valve clearance

!b Camshaft follower worn / damaged.
1c Worn or damaged rocker arm
1d Worn or damaged push rods
!e Camshaft profile worn / damaged.
!f Valve timing altered.
1g Excessive axial play of camshaft
Task SI05.00-W-0001A m What complaints or types of engine damage require the valve lift to be measured?
! a Metallic noises from the valve area

1 b Rough engine running
1 c Offset of the camshaft / crankshaft
1 d Combustion knocks
! e Tappet wear
! f Bent push rod
! g Worn camshaft lobe
! h Lack of engine power
1 i Worn rocker arm
1 j Broken valve return spring

Group 05 9
71_01 13.05.98 Tex71_0116/03/0516/03/05
Now to group 07 Page 1 06.06.2002
"Notes on the subject!?"

Group 05 10
71_01 13.05.98 Tex71_01
Fuel tests Series 500. 22.01.01
task m So how can we test the fuel system?

Discuss in your group the possible testing points.
m Using the WIS find the document "testing low pressure fuel circuit and print off one main document
for each person
Exercise 1 m Mark the correct positions to check the fuel pressure and fuel quantity test points on the following
diagram.
m Identify and highlight each of the main tests in the text.
Use this legend to assist you

Legend:
I Fuel pressure downstream of fuel filter
II Fuel pressure downstream of fuel pump
III Fuel intake pressure upstream of fuel pump
IV Fuel return flow at fuel tank
V Fuel return flow at nozzle holder combinations
V Low-pressure fuel circuit leak tightness
Exercise 2 m What do the symbol at "G" and "H" represent?
- "G"-- Pressure gauge test, "H"--Return flow quantity test.
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 1
71_01 13.05.98 Tex71_01
Schematic fuel circuit Engine Series 500 22.01.01
N07.15-2043-09
71_01 13.05.98 Tex71_01
Exercise 3 m What pre-test work should be carried out before ANY Fuel pressure tests are carried out?
m List at least six points below!
- Carry out visual inspection of all fuel lines, Screw connections and components.
- Open cap at the fuel tank
- Inspect fuel pre-filter element /renewing
- Inspect fuel filter element / renewing
- if it necessary, parameterise stationary engine speed limit up to 4000 rpm with the D.A.S.
- Rectify and erase any faults
- Bypass any additional filters or fuel heaters i.e. "Racor"filter.
- Fuel temperature < 40 c O
- Fuel must flow bubble free.
71_01 13.05.98 Tex71_01
(Actros) Test sheet for fuel system pressure checks on low-pressure fuel circuit 22.01.01
Dealer: CLAAS “V8”. First registration:

Customer: Registration number:
(2.0 bar up to 092407) (2.65 bar as of 092408) Engine number:
Data Record number:
VIN: Equipment code:
Distance: Tester:
Note Prior to testing the stationary engine speed limit parameter needs setting to4000 rpm, record original setting to be reset on completion of the tests.
Test step Fuel pressure down-stream of fuel filter. Results

I. Idling speed: CLAAS 1100 rpm 4.0 bar bar
Governed speed: CLAAS 1800 rpm 6.5 bar bar
Test step Fuel pressure down-stream of fuel Pump. Results
II. Idling speed: CLAAS 1100 rpm 4.0 bar bar
Governed speed: CLAAS 1800 rpm 7.0 bar bar
Test step Fuel intake pressure up stream of fuel pump. Results
III. Idling speed: CLAAS 1100 rpm -0.20 bar
bar
Governed speed: CLAAS 1800 -0.30 bar
Test step Fuel return flow quantity at fuel tank. Results
IV. Idling speed: CLAAS 1100 rpm 0.9 l/min Lt/min
Governed speed: CLAAS 1800 1.15 l/min Lt/min
Test step Fuel return flow quantity at injector leak off connections. Results
V. Idling speed: moist with fuel Quantity
Governed speed: Max only drips of fuel Quantity
Test step Low-pressure fuel circuit leak tightness. Results
VI. Test pressure 5.5 bar/ test time 5 minuets:
bar/min
Tolerance NO pressure drop
71_01 13.05.98 Tex71_01
Usefull adaptor parts for test equipment. 14.12.1998
Notes m
N 915 039 01 22 05 16mm single depth banjo bolt with M12 x 1.5 threaded fitting
N 915 040 01 22 06 16mm double depth banjo bolt with M12 x 1.5mm threaded fitting
N 915 047 01 22 03 16mm double depth banjo bolt
N 0000 0000 1070 seal ring16mm
A001 990 98 71 M12 x 1.5 90 degree angle fitting
N 0076 0301 4106 Copper sealing washer 14mm
N 0076 0301 2106 Copper sealing washer 12mm
A 01599764 82 Clear plastic pipe
Opening bridge
Opening bridge retaining nut
71_01 13.05.98 Tex71_01
*INFO! Fuel pre-screener with heated water trap, code K81 12.05.2000
So that premature soiling of the series fuel filter

can be avoided, an additional filter can be fitted
under S.A. K81.
The filter is fitted in line between the fuel tank (1)
and the fuel supply pump (5) and so protects the
main filter from excess debris.
Free water in the fuel is trapped in the lower part
of the filter housing and must be drained
regularly.
W47.20-1011-05
Field of application: -
It is highly recommended that in countries with a high possibility of refuelling using contaminated fuel through dirt and or high water content the additional filter
K81 is installed.
Vehicles, which are operated in Eastern Europe or with fuel from these regions to be refuelled, should be mandatory equipped with this additional filter.
71_01 13.05.98 Tex71_01
Customer benefits:
· Extended durability of the fuel injection system / injection components.
· Long maintenance interval despite heavy operations.
· Higher economy due to less mail functions of the vehicle.
W47.20-1006-11
71_01 13.05.98 Tex71_01
14.12.1998
71_01 13.05.98 Tex71_01
Real fuel circuit engine series 457 23.02.2005
Exercise 1 m Enter the missing designations in the list for the real fuel circuit, using WIS document
Note: Component designation
I Hand priming pump

II Fuel cooler
III Fuel pump
IV Fuel filter
V Unit pump
VI Injection nozzle
VII Pressure holding valve
VIII Overflow line
1 from fuel tank through hand priming pump

to fuel cooler
2 to fuel pump
3 to fuel filter
4 to unit pumps
5 from unit pumps
6 to injection nozzles
7 Leak fuel line
8 from pressure holding valve to fuel pump
9 Fuel filter drain line
(when replacing filter)
10 to fuel tank
A Suction line
B Return flow line
C Low pressure line
D High pressure line
N07.00-2083-09
Fuel Circuit Engine Series 457 89
71_01 13.05.98 Tex71_01
Symbolic Fuel System Engine Series 457 31.10.2001
Exercise 2 m With the aid of the WIS document SN47.00-W-0003-02A enter the direction of flow of the fuel!
N07.00-2082-09
71_01 13.05.98 Tex71_01
Legend for Schematic fuel circuit Series 457. m Mark the fuel circuit test points.
1.1 Fuel strainer (800 mm) Fuel circuit

1.2 Air admission valve (-0.04 to +0.4 bar) .. Fuel feed/suction side
2 Fuel prefilter (RED 300 mm) with fuel priming pump (CAT 500 mm) .. Fuel feed/pressure side
3.1 Assembly valve in fuel feed (Opened by fuel line coupling) .. Fuel high pressure side (injection line) downstream of PLD unit pumps
3.2 Assembly valve in fuel return flow(Opened by fuel line coupling) .. Fuel return flow downstream of unit pump
4. Fuel heat exchanger .. Fuel scavenging quantity (fuel bypass)
5. Fuel pump .. Fuel return flow/leak fuel
5.1 Pressure relief valve (7.0 bar) - - - Fuel passages in crankcase
5.2 Check valve (0.2 bar) ----- Fuel lines
6. Fuel filter (3 mm)
6.1 Fuel filter drain valve
6.2 Continuous ventilation in fuel filter (0.7 mm)
7. Nozzle holder combination
8. PLD unit pumps (Y6 to Y13)
10. Overflow valve (2.0 bar)
10.1 Continuious ventilation 0.7mm (in overflow valve)
12 Restrictor (0.5 mm) in flame starting system fuel line
B10 Fuel temperature sensor

R3 Flame glow plug
Y5 Flame starting system solenoid valve
G Pressure gage test
H Fuel return flow test
71_01 13.05.98 Tex71_01
14.12.1998
71_01 13.05.98 Tex71_01
Engine tests 10.10.2001
Exercise 1 m Is it possible to test the engine using the star diagnosis?

I think some of you may have seen one or more of these tests before!
But, which test is used for which particular problem?
A number of important engine tests are listed,
m Discuss in the group the possible complaints, and problems which can be detected and checked with
these tests
m Carry out all engine tests, and
m Assign the fault or problems to the tests on the relevant pages:-
23/05 PowerSystems · Engine series 500, 900 and 457 Chapter 02

Engine tests MR (PLD) 1
71_01 13.05.98 Tex71_01
Engine tests
Getting started.
Ignition off, plug minidiag into diagnostic

socket.
____________Minidiag 2_____________
Ignition on, then select No. 2 ecu search
routine.
Press OK
1 minidiag2 info
- " pipes 2 ecu search routine
- No
F2 darker F3 lighter
- wh off

71_01 13.05.98 Tex71_01
Engine tests
Getting started.
Now select No. 1, KWP2000

Press OK ____________Minidiag 2_____________
ecu detection
- " pipes 1 KWP2000

2 J1587
-
3. free running
-
?
- No
- wh off

71_01 13.05.98 Tex71_01
Engine tests
Getting started.
Wait for minidiag to end search!!!!

____________Minidiag 2_____________
KW 168 / 2 searching
- " pipes 1 PLD text

2 ADM text
-
?
-
- No
- wh off

71_01 13.05.98 Tex71_01
Engine tests
Getting started.
Automatically changes to this screen

____________Minidiag 2_____________
Select 1 PLD
Then press OK
ecu list
- PLD , Pump Litung Doser
1 PLD
- PLD , Pump injector-Line Injector 2 ADM
?
- PLD Only calculates the quantity of fuel and
- Point of injection
- ADM, Adaption Module
- ADM, Purpose; to adapt customers vehicles or
- machine to control the Mercedes-Benz engine,
- Can operate with analog or digital input/outputs

71_01 13.05.98 Tex71_01
Engine tests
Getting started.
This is the main menue for the PLD system
For the engine tests select 3 routines

____________Minidiag 2_____________
Then press OK
PLD functioning
- Add over view of menue 1 diagnosis

2 set parameters
-
3 routines
?
- 4 password routines
5 system info
- No
- wh off

71_01 13.05.98 Tex71_01
Engine tests
Selecting the engine tests

____________Minidiag 2_____________
Then press OK
PLD functioning
- Add over view of menue 1 diagnosis

2 set parameters
-
3 routines
?
- 4 password routines
5 system info
- No
- wh off

71_01 13.05.98 Tex71_01
Engine tests
Carrying out the engine tests

____________Minidiag 2_____________
Then press OK
PLD routine list
- Add over view of menue
- 1 voltmeter
2 cylinder cutoff
- 3 compression check
?
4 idle speed balance
5 impact delay time
- The engine idle speed must be between 500 6 pump-line-nozzel ch
- to 850 rpm to carry out the idle speed balance
- Jaguar remove cab module fuse F52
- Lexion remove cab module fuse F4 and or F16
- Adjust perameter group 3 perameter number 1
- From 1002 to 550 rpm (change back after test)

71_01 13.05.98 Tex71_01
Engine tests
Carrying out the engine tests
1 voltmeter
____________Minidiag 2_____________
What a waste of time:- NEXT!!!
PLD routine list

- Add over view of menue
- 1 voltmeter
? 2 cylinder cutoff
5 impact delay time
6 pump-line-nozzel ch
- The engine idle speed must be between 500
- to 850 rpm to carry out the idle speed balance
- Jaguar remove cab module fuse F35
- Lexion remove cab module fuse F4 and or F16

71_01 13.05.98 Tex71_01
Engine tests
2 cylinder cutoff
How would this test equate to an engine with

the "in line type injection pump?
____________Minidiag 2_____________
State your answer below:-
- "Cracking off" the Injector pipes PLD routine list
- 1 voltmeter
2 cylinder cutoff
How would you recognise a fault in a particular 5 impact delay time
cylinder? 6 pump-line-nozzel ch
- No change in the engine note or running
- when a cylinder is switched off

71_01 13.05.98 Tex71_01
3 compression check
A better name for this test is a

"cylinder compression comparison":- ____________Minidiag 2_____________
How does the D.A.S. know the compression in
the cylinder? PLD routine list
The MR control unit recognises the load on
the piston from the crankshaft speed whilst
cranking. 1 voltmeter
2 cylinder cutoff
State the advantages, -and disadvantages of
this test below. 3 compression check
- Good for fast diagnosis of individual cylinders 5 impact delay time
- Picks the best cylinder and calls it 100%
- If compression is equally poor at all cylinders
- No fault can be found ! < 75% indicates a fault

State the correct compression figures for this
engine:-
____29___bar. To ___20___bar.
Maximum difference ____4____bar.

71_01 13.05.98 Tex71_01
Engine tests
This test is similar to the "test of compression,

except, the fact that this time the engine is
running.
____________Minidiag 2_____________
Explain below the % value!
PLD routine list
- The fuel compensation value at idle speed.
1 voltmeter
- To maintain even piston speeds at engine idle. 2 cylinder cutoff
3 compression check
- 4 idle speed balance
5 impact delay time
How would you recognise a fault in a particular 6 pump-line-nozzel ch
cylinder?
State the Maximum value
- A higher than average piston speed will result in
- the fuel being backed off on that cylinder,
- Conversely if the piston speed is low, the fuel
- quantity is increased.A value > 4% ind. a fault.

71_01 13.05.98 Tex71_01
Engine tests
5 impact delay time
Read Impact times, what does this mean?

What is impacting what?
____________Minidiag 2_____________
Explain
- Term below the term
relates Impact
to, the time time.
taken from the PLD routine list
- control unit energising the solenoid valve

1 voltmeter
- to the recognition of the solenoid valve 2 cylinder cutoff
3 compression check
- impacting the valve seat. 4 idle speed balance
5 impact delay time
How would you recognise a fault in a particular 6 pump-line-nozzel ch
cylinder?
State the Maximum value below:-
- Maximum value = 1600 Micro sec.
- 12V system = 3200 ish Micro sec

71_01 13.05.98 Tex71_01
Engine tests
Concider an engine which has covered a

million km, or 5000 hours work, and a unit
pump fails, only one unit pump needs to be
____________Minidiag 2_____________
changed.
The new unit pump must deliver the same
PLD routine list
quantity of fuel at the same point of injection
as the remaining unit pumps!
1 voltmeter
To compensate for the new unit pump we 2 cylinder cutoff
have a coding which can be programmed in to 3 compression check
the PLD control unit, under the sub menu 6
pump-line-nozzel ch
5 impact delay time
For the engine tests select No.6, 6 pump-line-nozzel ch
pump-line-nozzel ch
Then press OK
-.
-
How would you recognise a fault in a particular
-
cylinder?

71_01 13.05.98 Tex71_01
Engine tests
____________Minidiag 2_____________
Press OK PLD routine 6
Pump line nozzel change

(press OK to contonue)
-.

71_01 13.05.98 Tex71_01
Engine tests
____________Minidiag 2_____________
Press OK PLD routine 6
Read injection code of new

injection pump
Press OK to continue
Press << to escape
-.

71_01 13.05.98 Tex71_01
Engine tests
____________Minidiag 2_____________
Select cylinder, PLD routine 6

Cylinders are numbered from the front ,
in the case of “V” engines front right-
1. Inj. Pump code cylinder 1
hand bank
Pick a cylinder 4. Inj. Pump code cylinder 4
Cylinder 2 for example 5. Inj. Pump code cylinder 5
-.

71_01 13.05.98 Tex71_01
Engine tests
DO NOT change the numbers on the

training vehicle unless you Know the unit
____________Minidiag 2_____________
pump number!!
PLD routine 6
X_XXX_XXX_XX_XXXXX
____________________________________________
Please enter the injection
pump code like described
in example below:
5--063--868—26--0027
-.

71_01 13.05.98 Tex71_01
Exercise m To sum to up:-

m Assign the fault or problems to the tests.
Engine test Use, possible complaint and problems
Test for mechanical wear of faulty single cylinder (gas seal).

Test of compression In the case of irregular engine running.
Pin pointing a faulty cylinder (gas seal or injection) in the
Single cylinder shutoff case of irregular engine running
Unit pump, injector, if irregular engine running
Smooth running control: correction value mechanical wear or faulty single cylinder (gas seal).
Uneven running, or misfire pump, r
Test of Impact times
Poor engine start and very irregular engine running after
Testing rpm sensors for incorrect polarity repairs to engine speed and position sensors
Uneven engine running condition under load due to
Test of single cylinder comparison “Uneven unit pumps (new mixed with old).
Actuate from the MR control unit, out-puts the "proportioning
Test of proportioning solenoid valves solenoid valves" and check their operation.
Supplementary electrical tests in the case of component-
Voltmeter relevant fault code.

71_01 13.05.98 Tex71_01
Exercise m Carry out the necessary test at the vehicle. Enter the results on the table.
Single cylinder switch off Test of compression
Cylinder 1 Cylinder 1 %
Smooth running control Read Impact time:
Cylinder 1 % Cylinder 1 us.


71_01 13.05.98 Tex71_01
Group 18 23.02.05
Task (Series 500) m Assign the respective number to the components in the layout!
Use the existing workshop literature.
1 Oil suction pipe / Gauze strainer

2 Check valve
3 Oil pressure relieve valve
4 Heat exchanger
8
5 Oil pump
2
6 Main oil gallery ( unfiltered)
7 Oil spray nozzle
3
8 Check valve for priming the lubrication 5
system 6 4
7 1
9 Main oil gallery (filtered)
N18.00-2011-50

Group 18 1
71_01 13.05.98 Tex71_01
Task (Series 500) m Assign the respective number to the components in the layout!
The following components are integrated in the

7 6 10 1
die-cast aluminium housing of this attached unit:
1 Full flow filter

2 Filter drain valve
3 Filter bypass valve (2,7 bar)
4 Oil temperature sensor
5 Oil pressure sensor
6 Heat exchanger (flat pipes)
7 coolant temperature sensor
4
8 Connector for bypass filter (outlet)
9 Connector for bypass filter (inlet)
10 Riser pipe
11 Connector for priming the lubrication system
5 3 9
2 8 11
N18.20-2020-05

Group 18 2
71_01 13.05.98 Tex71_01
Oil circuit engine series 457
task 1 6
Assign the respective number to the

components in the layout! 9
Use the existing workshop literature. 5
1 Oil sump 11
2 Intake pipe with sieve filter
8
3 Oil pump
4 Main lube oil gallery (unfiltered) 13
5 Oil cooler (oil-water heat exchanger)
6 Oil filter
7 Oil spray nozzle for cooling pistons 7
4
8 Oil spray nozzle for camshaft
9 Oil gallery for valve gear
10 Turbocharger return flow line 10
11 Turbocharger feed line
12 Main lube oil gallery (filtered)
13 Oil feed check valve
14 Oil Pressure relief valve 2
3
14 12
N18.00-2011-50

Group 18 3
71_01 13.05.98 Tex71_01
Task (Series 457) Latest doc m Assign the respective number to the components in the layout!
The following components are integrated in the

9
die-cast aluminium housing of this attached unit:
1 Full flow filter

2 Filter drain valve
3 Filter bypass valve (2,7 bar)
4 Oil pressure /Oil temperature sensor 11
5 Oil feed check valve

1
6 Heat exchanger (flat pipes) 3
6
7 Connector for bypass filter (outlet)
8 Connector for bypass filter (inlet)
9 Riser pipe 2
10 Connector for priming the lubrication system

11 Auto refill solenoid (S.A.)
5 7 8 10
N18.20-2020-05

Group 18 4
71_01 13.05.98 Tex71_01
Oil circuit engine series 900 06.06.2002
task m Assign the respective numbers to the components to in the layout!

1 Oil suction pipe
3
2 Oil pressure relieve valve
3 Heat exchanger
4 Oil pump
5 Main oil gallery
6 Oil spray nozzle
1
5
6
N18.00-2011-50

Group 18 5
71_01 13.05.98 Tex71_01
Oil filter housing (Series 900)
task
m To enable a clean oil change an emptying valve 2

is fitted to the filter housing. The task is
similar to the fuel filter-emptying valve.
5
However the location and its function differs.
Identify the following components.
1 oil combi-sensor 3
2 bypass valve
3 service drain valve 4
4 check valve 1
5 riser pipe
N18.20-2013-01 N18.20-2021-03

Group 18 6
71_01 13.05.98 Tex71_01
Oil pressure test
task m The low-pressure warning may illuminate, what instruction should be given to the driver?
m How does the technician verify the fact that the engine is suffering from low-pressure?
1 a Drive the vehicle slowly, the oil pressure is of no importance, oil flow is the critical factor.
X b Don't run the engine, with the ignition on check “actual values” - oil pressure,
with the engine not-running the approximate value should be 0 bar!
1 c The engine must be run at maximum speed, the oil warning will eventually go out!
1 d The oil pressure sensor must be changed, then run the engine and re-check.
! e A calibrated gauge must be fitted then run the engine.
Maximum and minimum oil pressure
Task (insert document No.) m Using the workshop media state the minimum oil pressure
1 f 0.3 bar at idle speed.

X g 0.5 bar at idle speed.
X h 2.5 bar at rated speed.
1 i 3.0 bar at rated speed.
1 j 5.0 bar at rated speed.
X k Maximum oil pressure is governed by the pressure relief valve and is 6.5 bar

Group 18 7
71_01 13.05.98 Tex71_01
Task (insert document No.) m Hardened bearings are fitted to all high performance engines, these hardened surface are
thousandths of a millimetre thick. To help protect the bearing surface the lubrication circuit must be
primed before initial start up.
m Below is a selection of different components. After replacement of which components, is priming of
the lubrication system required with the special device?
1 a Cylinder head gasket

1 b Pump unit
1 c Compressor
1 d Injector
! e Crankshaft
! f Connecting rod
1 g Turbo charger
1 h Oil filter
! i Oil filter housing
1 j Oil pressure switch
! k Heat exchanger
1 l Oil pan
1 m Oil pump
1 n Oil spray nozzles
Task (insert document No.) m When priming the lubrication system, the pressure should be?
1a 0 - 2 bar
!b 2 - 4 bar
1c 5 - 10 bar
Xd The oil pressure must not fall below 1.5 bar

Group 18 8
71_01 13.05.98 Tex71_01
task m Priming of the lubrication system has to be maintained till...
1 a air bubbles expelling at the oil

filter.
1 b air bubbles expelling at the pipe of

the dip stick.
1 c the oil expels bubble free at oil

filler neck.
1 d the entire contents of one vessel has

been flushed through the engine.
1 e 5 litres of engine oil has been flushed

through the engine.
! f the oil expels bubble free at the

rocker arms.
1 Connector plug (M33x2)

2 Seal ring
3 Adapter
4 Oil container for priming
5 Shutoff valve
W18.00-0001-06
Note: When priming the lubrication system with the container, up to15 litres of engine oil will be needed.

Group 18 9
71_01 13.05.98 Tex71_01
m You are now familiar to the priming procedure

of the lubrication circuit,
task
m Mark the position of the “priming point on the

graphic opposite with an Arrow
W18.00-0001-06
Note: When priming the lubrication system with the container, up to15 litres of engine oil will be needed.

Group 18 10
71_01 13.05.98 Tex71_01
1 a air bubbles expelling at the oil

filter.
1 b air bubbles expelling at the pipe of

the dip stick.
1 c the oil expels bubble free at oil

filler neck.
1 d the entire contents of one vessel has

been flushed through the engine.
1 e 3 litres of engine oil has been flushed

through the engine.
! f the oil expels bubble free at the

rocker arms.
1 Connector plug
2 Seal ring
3 Adapter
4 Oil container for priming
5 Shutoff valve
6 Heat exchanger
W18.00-0001-06

Group 18 11
71_01 13.05.98 Tex71_01
Oil spray nozzle
m Although the oil spray nozzle for series 500 is

shown the principal is the same for all engine
series
W18.00-0004-09
Task Ar18.00-W-4000B m State the task of the oil spray nozzles
Discuss this question in the team and mark the correct answers!
!a Oil from the spray nozzles is used to lubricate the piston pin.
Xb Oil from the spray nozzles is also used to lubricate the roller tappets.
!c The oil spray nozzle fills the oil gallery in the piston and cools the piston ring zone and piston crown.
Xd Oil from the spray nozzles is used to lubricate the pump unit.
Xe Due to piston cooling, exhaust gas emissions are reduced.
!f The oil spray nozzles have to be checked for correct alignment with the special tool.
Xg If the nozzle is damaged, or bent, the nozzle assembly must be renewed.
!h The camshaft is lubricated via an additional spray nozzle. (457)

Group 18 12
71_01 13.05.98 Tex71_01
Oil spray nozzle engine series 457
In contrast to the familiar engine series 500, two oil spray nozzles are installed
for each cylinder on the redesigned engine series 457. One of these (the one on
the right looking in direction of travel) cools the piston in the same way as
before, while the second one (on the left looking in direction of travel) is
positioned separately and performs the task of lubricating the camshaft.
Note:
It is no longer permissible to straighten the oil spray nozzles.
The oil spray pipe is brazed, and straightening can result in initial damage.
Exercise 2
m What are the consequences of an oil spray nozzle, which is damaged or

incorrectly set?
Discuss this problem case in your group!
1 a None
1 b High oil consumption
! c Pistons are not cooled
! d "Piston seizure"
1 e Engine becomes hot
1 f Oil dilution
N01.10-2081-12

Group 18 13
71_01 13.05.98 Tex71_01
Exercise 2 m When removing a conrod, you have inadvertently knocked the spray pipe of the oil spray nozzle.
You then carried out an inspection, which reveals that the spray pipe has been considerably
misshapen. What is the procedure you then adopt?
A a The nozzle must on any account be replaced!

b b The nozzle pipe must be straightened!
Task (AR018.00-W-00010-1A). Swarf ingress.

m An engine suffers from engine damage, as a result metallic debris is passed into the lubrication
system, the crankcase is still serviceable.
m What must be done before the engine is rebuilt?
Mark the correct statement.
X l The oil filter must be thoroughly cleaned.

X m All chippings must be thoroughly cleaned from all oil galleries and channels.
X n The oil pump must be cleaned out and if damaged renewed.
X o The oil pressure relief valve must be cleaned and if the seat is area damaged, renewed.
! p The oil check valve must be cleaned, inspected and renewed if necessary.
! q The oil / water heat exchanger must be renewed.
X r The under skirt oil spray nozzles must be removed, cleaned, and inspected.
X s If misaligned or damaged the nozzle must be replaced.

Group 18 14
71_01 13.05.98 Tex71_01
Cleaning Main Oil Channels 06.06.2002
W01.40-1021-06 W01.40-1018-06
Task m Name cases of damage with those a cleaning of the oil channels are necessary.
- Aaa
Notes: The work is described in the WIS documents AR01.40-W-8501A and AR01.40-W-8501B.

Group 18 15
71_01 13.05.98 Tex71_01
06.06.2002

Group 18 16
71_01 13.05.98 Tex71_01
Group 20 23.02.05
task m Determine the approved coolant agents /-additives and mixture ratio.
Percentage /ratio - 50% / -37°C

Coolant agent - Anti corrosion and anti freeze agent
MB-sheet-No. - 312.0;- 325.0 /1;- 325.2;- 325.3,;- 325.0;- 325.2;- 325.3
task m Determine the maximum value in per cent, which can be used for a mixture ratio of anti corrosion/
anti freeze and cooling water?
- 55% max./ -45°C
task m Why should the maximum value not be exceeded?
- A higher anti freeze percentage decreases the anti freeze protection and the heat
- dissipation declines.

Group 20 1
71_01 13.05.98 Tex71_01
Coolant
task m The coolant should be changed on regular intervals, because the chemical additives / substances
deteriorates.
m How often should the coolant be changed?
1a Only when a repair was performed, for example, a damaged coolant hose was replaced.
1b Once a year
1c Every 2 years
!d Every 3 years
1e Every 5 years
task m After the repair has been finished and the coolant replaced, are there any additional jobs to do
(Actros, and Atego Heavy)? (see GF00.20-W-3005A)
- Resetting of the service system

Group 20 2
71_01 13.05.98 Tex71_01
Degreasing and decalcifying of the cooling system
task m Use the workshop literature and tick the correct statements!
!a The cooling system has to be degreased in case of oil traces.

1b The cooling system has to decalcified first and then degreased.
!c The cooling system has to degreased first and then decalcified.
!d The mixture ratio has an influence on calcifying of the cooling system.
Xe If the correct ratio of corrosion inhibitor is permanently used there will be no need to decalcify.
1f When radiator has been replaced, cooling system has to be decalcified.
Description Part number Mixing ratio

Mild alkaline cleaner A 001 985 21 71 (500g) 50g : 1 litre clean water
Citric acid A 000 989 10 25 (500g) 100g : 1 litre clean water
Corrosion inhibitor (NOT to be used in 900 or 500) A 000 989 20 22 1:100

Group 20 3
71_01 13.05.98 Tex71_01
task m Use the workshop literature to complete the following sentences with the team. Use the listed key
words at the bottom of the page.
When degreasing, fill the cooling system with a 5 per cent solution of a mild alkaline cleaner and freshwater. Start and run the engine
at mean speed till temperature has reached 80°C and maintain this temperature for approx 5 min . Switch off the engine and have
the coolant temperature drop to approx. 50°C . Drain the entire solution of the cooling system and refill the system
2 times and run the engine each time for 5 min .
When decalcifying, fill the cooling system with a 10 per cent solution of citric acid and freshwater. Start and run the engine at
mean speed till temperature has reached 80°C, maintain this temperature for approx. 10 minutes. Switch off the engine and have the coolant
temperature drop to approx. 50°C. Drain the entire solution of the cooling system and refill the system 3 x with freshwater and
have the engine run each time for 5 min.
Note: The coolant and the chemicals for the cooling system must correspond with approved MB-specification.
entire refill freshwater 50°C 5 minutes

5 per cent mild alkaline cleaner citric acid mean speed
5 minutes 80°C 2 times 10 per cent entire

Group 20 4
71_01 13.05.98 Tex71_01
Coolant circuit
task m Everybody knows the „short“ and „full“ coolant circuits of a vehicle.
Why do we distinguish these two circuits?
Which component of the cooling system is responsible of the coolant circulation in the respective
circuits?
- Thermostat
task m Define the correct terms to the different descriptions of coolant circulation:
The "short coolant circuit", The "transition period, and the "full coolant circuit".
- Full coolant circuit At engine operating temperature, the coolant has to be cooled by the air stream. Thereby flows the
coolant through the radiator, but only, when the thermostat is fully open. The coolant is maintained at a
constant temperature.
- Transition period In this period, the engine has not reached the operating temperature, the thermostat commences to open
up and therefore the radiator already cools little of the coolant. This period last only for a short time.
- Short coolant circuit When the engine is cold, the coolant in the block has to be warmed up first. Therefore the coolant is not
admitted to the radiator, but only as long as the thermostat is in closed position. The coolant circulates in
the engine block; hence the engine warms up faster, but more importantly more evenly.

Group 20 5
71_01 13.05.98 Tex71_01
task m The 3 layouts show the coolant flow in relation to the operating position of the thermostats.
Define the term to each layout, use the terms from the last task.
N20.10-2015-01 N20.10-2016-01 N20.10-2017-01
- Short coolant circuit - Transition period - Full coolant circuit
B To radiator
C To engine
D From engine coolant pump

Group 20 6
71_01 13.05.98 Tex71_01
Thermostat
task m What are the consequences when thermostats are not installed? Use the layouts of the different
operating positions of the thermostats. Discuss the statements with the team. Tick the correct
answers.
1a The direction of coolant flow in the engine is restricted.

1b It takes too long to warm up the engine.
!c The viscous fan is not efficient till the radiator is hot.
!d The engine overheats.
1e The pressure in the cooling system is lower, because the by-pass valve is not installed.
1f The pressure in the cooling system is higher, because the by-pass valve is not installed.

Group 20 7
71_01 13.05.98 Tex71_01
task
On the layout, right hand side, the location of the

thermostats is shown.
What do the arrows indicate?
Make the correct decision.
1 a Code of the manufacturer.

1 b Vents to be located at the lowest
position of the housing.
! c Identification for installation position.
1 d „Lugs“ originated from production
process.
! e Vents to be located at the highest
position of the housing.
1 f Vents to be located at horizontal position
of the housing.
W20.10-0010-06

Group 20 8
71_01 13.05.98 Tex71_01
Group 20
Coolant pump seal SI 20.00-L-KW-00-30X
The coolant pump seal consists of two plates, one

ceramic the other a carbon ring.
This sealing method has a number of advantages

over “lip” type seals.
1. Not attacked by the corrosion inhibitor / anti-

freeze mixture.
2. Not affected by great temperature change.
3. Very hard wearing.
The design requires a certain amount of leakage

in the sealing gap between the ceramic and
carbon rings to act as a lubricant and reduce
wear.
Some of this may create evidence of staining at

the outlet of the coolant pump.
W20.10-0010-06

Group 20 9
71_01 13.05.98 Tex71_01
Cooling Systems.
Coolant Pump Seal.
task Coolant Pump Seal.

Evidence of staining at the outlet of the coolant pump may cause some confusion as to whether the
coolant pump is serviceable.
What action should be taken?

Determine the sequence below:-
1 X a Check the water pump bearings for wear.

3 ! b Check cooling system with pressure test.
2 1 c Visually check coolant pump for leaks.
4 ! d Eliminate coolant stain/trace.
5 ! e If the coolant pump shows no evidence of leaks clean and monitor.
Lime scale and rust particles interfering with the However the debris will eventually be ground to dust, and the sealing surfaces will stabilise after a short
sealing surfaces may cause a slight leakage from period of operation
time to time. If coolant pump is leaking: - Seal, recondition or renew.

Group 20 10
71_01 13.05.98 Tex71_01
Cooling system leak checking
task m The coolant circuit can be checked like any other system. Determine, the correct statements
concerning cooling system leak checking. Use the workshop literature.
!a The pressure tester should be mounted in place of the filler cap.

1b Pressure cap located at the right side.
1c Pressure cap located at the rear.
1d 0,5 bar
1e The cap pressure rating should not to be exceeded.
!f The test pressure is approx. 1.0 bar with the ATEGO and AXOR.
1g The test pressure amounts to approx. 1.2 bar with the ACTROS
1h The test duration is approx. 5 to 10 minutes.
Xi The heater regulator should be set to maximum.
task m What other Components / systems can be checked or tested using the coolant pressure test?
m Discuss the statements with the team and tick the correct answers.
! f Retarder cooling system leaking

! g Leakage at the clamps of the system
1 h Internal leakage on the coolant circuit
! i Cylinder head gasket
! j O-Rings of the cylinder liner
! k Leakage at the Tombac-seal ring
! l Leakage at the protection sleeve of the injector

Group 20 11
71_01 13.05.98 Tex71_01

Group 20 12
PE07.15-W-2002-60DA Legend of wiring diagram of engine
control(MR)
Item Designation Coordinate
A3 FR/FMR control module 7M

A4 Flame starting system control unit 10m
A6 MR/PLD control module 4A
15A
28A
40A
51A
61A
A7 Base module 4M
B10 Fuel temperature sensor 47M
B14 Oil level sensor 30M
B15 Crankshaft angle position sensor 49M
B16 Cylinder TDC sensor 50M
B65 Coolant temperature sensor 44M
B110 Oil combination sensor (temperature, pressure) 32M
B111 Charge air combination sensor (temperature, pressure) 38M
F30-A7 MR/PLD fuse, tml.15 (base module) 4L
M1 Starter 17M
S1 Drive switch 13M
S10 Engine start pushbutton switch 19M
S11 Engine stop pushbutton switch 21M
X2.2 Connection, cab to chassis 4G
5G
6G
7G
11G
14G
X8 Circuit 30 terminal block, battery rack 3M
X13 Diagnostic socket 11M
Y6 Cylinder 1 unit pump 52M
Y49 Constant throttle solenoid valve 23M
Y70 Fan stage 1 solenoid valve 25M
(50) CAN interface 6C
(63) Diagnosis 11C
42C
(167) Fuel temperature 47C
(171) Coolant temperature 44C
(175) Crankshaft angle and TDC recognition 48C
(176) Crankshaft angle position 49C
(177) Charge air pressure 37C
(178) Boost air temperature 46C
(185) Proportioning valves power output stages 22C
(186) Unit pumps power output stages 52C
(207) Engine start 19C
(208) Engine stop 21C
(209) Engine start/engine stop 20C
(232) Oil pressure 32C
(233) Oil level 30C
Copyright DaimlerChrysler AG 29.03.2005 CD-Ausgabe G/09/04 . This WIS print-out will not be recorded by Modification services. Page 1
(234) Oil temperature 45C
(235) TDC cylinder 1 50C
(266) Signal acquisition and evaluation 30C
(267) Temperature sensor signal acquisition and evaluation 43C
(273) Voltage supply 1C
(279) Starter actuation 18C
(285) Control logic 4B
15B
28B
39B
51B
61B
(312) Cables twisted 5E
5I
8I
48G
52G
58G
(350) optionally depending on version 16H
PE07.15-W-2002-60C Legend of wiring diagram of engine
control(MR)
Item Designation Coordinate
A3 FR/FMR control module 7M

A6 MR/PLD control module 6A
17A
29A
40A
51A
62A
A7 Base module 5M
B10 Fuel temperature sensor 45M
B11 Oil temperature sensor 42M
B12 Oil pressure sensor 37M
B14 Oil level sensor 26M
B15 Crankshaft angle position sensor 47M
B16 Cylinder TDC sensor 48M
B65 Coolant temperature sensor 40M
B111 Charge air combination sensor (temperature, pressure) 35M
F30-A7 MR/PLD fuse, tml.15 (base module) 4L
M1 Starter 15M
S1 Drive switch 12M
S10 Engine start pushbutton switch 17M
S11 Engine stop pushbutton switch 19M
X2.2 Connection, cab to chassis 4G
6G
7G
8G
9G
12G
X13 Diagnostic socket 9M
Y6 Cylinder 1 unit pump 50H
50M
58H
55H
60H
58M
61H
(21) Atmospheric pressure sensor 39C
(50) CAN interface 6C
(63) Diagnosis 9C
(167) Fuel temperature 45C
(171) Coolant temperature 40C
(175) Crankshaft angle and TDC recognition 47C
(176) Crankshaft angle position 47C
(177) Charge air pressure 35C
(178) Boost air temperature 43C
(185) Proportioning valves power output stages 21C
(186) Unit pumps power output stages 51C
(209) Engine start/engine stop 17C
(232) Oil pressure 37C
(233) Oil level 27C
(234) Oil temperature 42C
(235) TDC cylinder 1 48C
(266) Signal acquisition and evaluation 26C
(267) Temperature sensor signal acquisition and evaluation 40C
(273) Voltage supply 2C
(279) Starter actuation 15C
(285) Control logic 6B
17B
29B
40B
51B
62B
(309) V6 engine 49L
(310) V8 engine 49H
(312) Cables twisted 5E
5H
46F
50F
50I
57F
57I
(350) optionally depending on version 13H
(430) Fan speed detection 11C
Copyright DaimlerChrysler AG 20.03.2003 CD-Ausgabe G/04/01 Will not be recorded by Modification services Page 1
LEGEND ADM (Version 4)
A 501 Instrument cluster 30 L
A 501 e1 Oil level warning lamp. (0.2A max) 28 L
A 501 e2 Oil pressure warning lamp. (0.2A max) 28 L
A 501 e3 Coolant temperature warning lamp. (0.2A max) 29 L
A 501 e4 ADM - FR/ MR Fault lamp (0.2A max) 30 L
A 501 h1 Warning buzzer. (0.2A max) 30 L

A 501 k1 Oil level relay (0.2A max) 28 L
A 501 k2 Oil pressure relay (0.2A max) 28 L
A 501 k3 Coolant over temp. relay (0.2A max) 29 L
A 501 k4 ADM - FR/ MR Fault relay (0.2A max) 30 L
A 501 p1 Oil pressure gauge 32 L

A 501 p2 Coolant temperature gauge. 31 L
A 501 p3 Engine rev counter. 32 L
B 501 Foot throttle actuator (FFG) 35 L
E 501 Charge warning lamp alternator 1. 16 L

E 502 Charge warning lamp alternator 2. 22 L
E 503 Lamp 1. Kickdown. (max 0.2A). 63 L
E 504 Lamp 2. Idle position (max 0.2A). 63 L
E 505 Lamp 3. (max 0.2A). 64 L
E 506 Lamp 4. (max 0.2A). 65 L
F 501 Fuse Kl 30 ADM (u509). 7E

F 502 Fuse Kl 15 (diagnosis socket). 75 G
F 503 Fuse Kl 30 (diagnosis socket). 76 G
G1 Alternator. 9L
G2 Battery (12/24V) 7L
G3 Alternator 2. 14 L
J3 Kl 31 central ground point. __G

J16 Kl 15 ignition supply diagnosis socket (unfused). __G
J18 Kl 30 battery supply diagnosis socket unfused). 18 G
J28.1 Kl D+ alternator 2 (charging signal). 20 G
J501 Kl 50 start signal. 4 G+
J502 Kl W engine speed via alternator. 9 G+
Page 1
LEGEND ADM (Version 4) 2
K 501 Relay 1 alternator 1. 18 L
K 502 Relay 1 alternator 2. 20 L
K 503 Retarder relay (out put) 0.5A. 23 L
K 504 Engine brake relay (out put) 1.2 A. 25 L
K 505 Kickdown relay (max 0.2A). 56 L
K 506 Idle relay 2 (max 0.2A). 58 L
K 507 Relay 3 (max 0.2A). 59 L
K 508 Relay 4 (max 0.2A). 61 L
K 509 Engine brake Relay out put (max 1.2A). 69 L
N501 ADM Control unit. __ A
S501 Ignition switch 3L

S502 Neutral switch. 41 L
Up to three working speeds programable.

S503 Working speed control "0" switch 44 L
S505 Climate control Switch 43 L
S507 Switch ADR speed Increase "+". 46 l
S508 Switch ADR speed decrease "--". 47 l
S509 Special function 0 switch Input wired to positive (anti gas accel- 48 L
-erator pedal lock) &ABS signal from conventional ABS ECU.
S510 Special function 1 switch Input wired to ground (anti gas accel-- 51 L
-erator pedal lock) &ABS signal from conventional ABS ECU.
S511 Engine brake switch (input). 49 L
S512 Rear axle switch. (n/a) 50 L

S513 Engine bay door switch (bus). 67 L
S521 Door open switch (bus). 68 L
Page 2.
LEGEND ADM (Version 4) 3 (Foot notes)
U501 Valid for actual value 2. (PWM output signal). 26 K
U502 Valid for hand throttle signal. (Input). 52 K
U503 Valid for vehicle speed signal. (C3 from tacho). 39 K
U504 Valid for actual value for foot throttle actuator (output). 53 K
U505 Valid for analogue input 1. (Vacant). 54 K
U506 Valid for connection relay 1-4 (kickdown, Idle, and two vacant). 56 F
U507 Valid for connection lamp 1-4 (kickdown, Idle, and two vacant). 62 F
U508 Valid for engine CAN-Bus. 71 J
U509 Connections Must be fitted. __ A
U510 Pins can be connected for additional monitoring equipment. 29 A
U511*** *Kl 15 to ADM and MR 32 B
Contact must be made at the same time(on/off)
Emergency stop, switch Kl 15 at ADM and MR by a "ground
held" relay.
U512 1. MBRA1 engine brake output.(Constant throttle [KDR] or 25 A
constant throttle with Brake flap [BK]). 69 A
2.MBRA2 brake flap (BK) (In combination with MBRA 1 constant
throttle (KDR).
U 518 Twisted wires 71 E
U 519 Valid for customer specific relays (terminals Kl D+ G1 and G2). 17 J
V 501 Blocking diode alternator 1 (60V,1A) zB. Typ 4060 11 L

V 502 Blocking diode alternator 2 (60V,1A) zB. Typ 4060 15 L
W 501 Main Ground point. 6G
X 501 Diagnosis socket (k line). 74 L
Page 3.
22 04 ADM FR 01 R Wyllie
04.01 ADM FR 02 R Wyllie
ADM FR (version 4)
Plug 1 15 Pins.
Pin Input/ Mandatory/ Designation Signal Monit Description Param
numb Output Optional. type ored eterNo
1 Input Mandatory Kl 30 -- -- Supply voltage.
2 Output Optional. P OEL A -- Signal for conventional oil pressure gauge.
3 Output Optional. LA ADM A -- Warning lamp ADM-FR and MR.
4 Output Optional. RET A A YES Retarder deactivation via foot throttle.
5 Input Mandatory Kl 31 -- -- Ground terminal.
6 Output Optional. MBRA 1 A YES Output to engine brake 1.
7 Output Optional. T MOT A -- Signal for conventional temperature gauge.
8 Output Optional. FFG 2+ -- -- Accelerator pedal 2, (supply).
9 Output Optional. BUZZER A -- Serious fault warning buzzer.
10 Output Optional. IWA 2 A -- Actual value output 2, Hz, speed, PWM, load
11 Output Optional. FFG1 -- -- Accelerator pedal 1, (supply).
12 Output Optional. LA T MOT A -- Coolant over temperature warning lamp.
13 Output Optional. LA OEL ST A -- Impermissibly low oil level warning lamp.
14 Output Optional. LA P OEL A -- Low oil pressure at current engine rpm.
15 Input Mandatory Kl 15 DE -- Terminal 15 Input.
Page 1
ADM FR (version 4)
Plug II 18 Pins.
Pin Input/ Mandatory/ Designation Signal Monit Description Param
numb Output Optional. type ored eter
No
1 Input Mandatory C3 (B7) IE Speed input from tachograph.
2 Input MBRE DE Engine brake input, (for MBRA1 and MBRA2 Y
outputs).
3 Input Mandatory Kl W IE Plausibility of engine speed, (from engine
speed sensors).
4 Input KLIMA IE 1 Working speed increase.
2 To reflect a change over between ADR and
Driving mode.
5 Input Mandatory Kl 50 IE Input for engine start signal, from start
switch (must also go to MR).
6 Input ADR + DE 1 ADR mode-"working speed increase".
2 Driving mode-"Idle speed increase".
7 Input ADR 0 DE 1 Activating selected limits.
2 To reflect a change over between ADR and
Driving mode.
8 Input DSF1 DE "Special Function", In put wired to GROUND,
with programmable function-"Anti-Gas"
accelerator pedal lock for conventional ABS
control units
9 Input Mandatory NE DE Neutral position from transmission. (Start
Inhibitor).
10 Output N_MOT A Output for Kl W (conventional RPM counter).
11 Output HA DE Rear axle - VACANT.

12 Input DSF0 DE "Special Function", In put wired to POSITIVE
with programmable function-"Anti-Gas"
accelerator pedal lock for conventional ABS
control units
13 Input Mandatory FFG1 IE YES PWM signal from accelerator pedal "Branch
1"
14 Input ADR1 DE Kl 15signal to activateADR1 mode.
15 Input FFG2 IE PWM signal from accelerator pedal "Branch
2"
16 Input ADR2 DE Kl 31signal to activateADR2 mode.
17 Input HFG IE Specified speed (from hand throttle sensor
PWM signal).
18 Input ADR -- DE 1 ADR mode-"working speed decrease".
2 Driving mode-"Idle speed decrease".
Page 2
ADM FR (version 4)
Plug III 12 Pins.
Pin Input/ Mandatory/ Designation Signal Monit Description Pera-
numb Output Optional. type ored meter
No
1 VACANT
2 VACANT
3 VACANT
4 Input AE 1 Analogue Input
5 Input MKLE Engine cover. (bus). Kl 31 switched
6 Input TROE Door open.(bus). Kl 15 switched.
7 Output REL4 Output Relay 4 (via Kl 15)
10 Output REL1 Output Relay 1 (Kick down).
11 Output IWA1 Actual value FFG Output1 (Auto
transmission)
12 Output MBRA2 Engine brake output (1.2A)
Page 3
ADM FR (version 4)
Plug IV 9 Pins.
Pin Input/ Mandatory/ Designation Description Param
numb Output Optional. eterNo
1 Bi Optional CAN-HH CAN- High speed, High signal.
2 VACANT
3 Bi Optional CAN-HL CAN- High speed, Low signal.
4 Mandatory if HF-GND CAN Ground (shielding).
using pins 1&3
5 Bi Optional Diagnosis.
6 Mandatory HF-GND CAN Ground (shielding).
7 Bi Mandatory CAN-LH CAN- Low speed, high signal.
8 VACANT
9 Bi Mandatory CAN-LL CAN- Low speed, Low signal.
Page 4
ADM FR (version 4)
Plug 1 15 Pins.
Pin Input/ Mandatory/ Designation Description Param
numb Output Optional. eterNo
Page 4

00 00 Powertrain Additional Information

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

00 00 Powertrain Additional Information

Uploaded by

Copyright:

Available Formats

Commercial Vehicle Service Training

Part Page Title

06/02 · Engine Mechanics 459M

Part Page Title

06/02 · Engine Mechanics 459M

Chapter Time Description

06/02 · Engine Mechanics 459M

Chapter Time Description

06/02 · Engine Mechanics 459M

Chapter Time Description

06/02 · Engine Mechanics 459M

Chapter Time Description

06/02 · Engine Mechanics 459M

Engines OM 904/906 LA and OM 501/502 LA 11.05.2000

Engine Range 11.05.2000

There are four basic engine groups, or “families:-

1. Petrol engines. Designation M 1-- --. Inline 4, 5, 6,

2. Light diesel engines. Designation OM 600 series.

3. Medium diesel engines. Was OM 300 series, Now

4. Heavy diesel engines. Was OM 400 series, Now

5. And the relatively new OM 457. Inline 6 with

Engine OM 457 LA 31.10.2001

Technical highlights of engine series 457:

· High strength, noise-optimized crankcase made of high-alloy gray cast iron.

· Camshaft driven by gear drive at the flywheel side

Allocation of channels (500 series)

06/02 PowerSystems · Engine series 500, 900 and 457

06/02 PowerSystems · Engine series 500, 900 and 457

Assignment of galleries in cylinder head gasket engine series 457 06.06.2002

Exercise (Series 457)

06/02 PowerSystems · Engine series 500, 900 and 457

Cylinder head sealing surfaces 06.06.2002

! a The cylinder heads can be cleaned in a bath (chemical high pressure).

06/02 PowerSystems · Engine series 500, 900 and 457

! a Reduced work required for assembly and disassembly.

06/02 PowerSystems · Engine series 500, 900 and 457

task m Handling stretch bolts

If a bolt is inadvertently over tightened or the sequence is lost during the

06/02 PowerSystems · Engine series 500, 900 and 457

Exercises on Cylinder Head Bolts 06.06.2002

Engine series Bolt diameter Max. shank length

Exercise 1 m Complete the table below!

Designation Tightening Engine 500 Engine 457

06/02 PowerSystems · Engine series 500, 900 and 457

06/02 PowerSystems · Engine series 500, 900 and 457

Valve setback engine series 500/457 06.06.2002

Exercise m Use the workshop information (AR0530-W..., AR0530-W... and AR0130-W...)

Specification Actual value

Valve setback relative to

06/02 PowerSystems · Engine series 500, 900 and 457

Constant throttle Valve seat 500/457 06.06.2002

Valve setback relative to

06/02 PowerSystems · Engine series 500, 900 and 457

Constant throttle Valve seat (Series500) 06.06.2002

Exercise (500 series)

m What is the result of constant-throttle valve seat wear?

Exercise (500 series)

m Complete the following table regarding piston height

Height Minimum Cap

Flat Cap 0.00

Repair Cap 0.00

06/02 PowerSystems · Engine series 500, 900 and 457

Fault symptoms constant throttle 06.06.2002