Manual Serie 500 Parte 1

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Operating Instructions
OM 501 LA – OM 502 LA
EU Level III A (EU 97/68/EC)
EPA TIER 3 (US EPA 40 CFR Part 89)
ÊV/t0qvË
5415841681
Order no. 6462 9811 02 Part no. 541 584 16 81 EN Edition A, 01/06
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* Optional equipment Mercedes-Benz vehicles and or suggestions you may have regarding
G Warning about DaimlerChrysler AG can be these Operating Instructions to the
found on the following websites: technical documentation team at the
H Environmental note
www.mercedes-benz.com following address:
! Possible vehicle damage www.daimlerchrysler.com DaimlerChrysler AG, Abt. SVI, HPC: E124,
D-70546 Stuttgart, Germany
i Tip
As at: 01.12.2005
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without the written permission of
Continuation symbol DaimlerChrysler AG.
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page Page reference
-> Term in the glossary of technical

terms
Display Displays in the multi-function

display
Thank you for choosing this Since the scope of delivery varies depend- DaimlerChrysler reserves the right to make
Mercedes-Benz engine. ing on each specific order, the equipment changes to design, equipment and tech-
of your engine may differ from certain nology. You cannot, therefore, base any
Make sure that you read the Operating
descriptions and illustrations in these Op- claims on the data, illustrations or descrip-
Instructions before using the engine for
erating Instructions. These Operating tions in these Operating Instructions.
the first time. This will help you to make
Instructions also describe items of option-
optimum use of the engine and avoid en- Your nearest Mercedes-Benz Service Cen-
al equipment where their operation re-
dangering yourself and others. tre will be happy to assist you further
quires explanation. should you have any more queries.
The Operating Instructions and Mainte-
nance Booklet are an integral part of the
engine. You should therefore always keep
them with the engine and pass them on
to the new owner if you sell it.
Contents
i Please also refer to the index ( page 117) Introduction 3 Safety

Protection of the environment . . . . . 5 Safety precautions . . . . . . . . . . . . . . 38
Operating safety . . . . . . . . . . . . . . . . . 6 Staff qualifications . . . . . . . . . . . . . . 39
Correct use . . . . . . . . . . . . . . . . . . . 7 Conversion parts and
modifications to the engine . . . . . . . 40
1 At a glance
Safety /emergency running
OM 501 LA overview . . . . . . . . . . . . 10 programs . . . . . . . . . . . . . . . . . . . . . . 41
OM 502 LA overview Genuine Mercedes-Benz parts . . . . . 42
(2 turbochargers) . . . . . . . . . . . . . . . 14 4 Operation
OM 502 LA overview
(1 turbocharger) . . . . . . . . . . . . . . . . 18 Starting the engine for the
Location of sensors . . . . . . . . . . . . . 22 first time . . . . . . . . . . . . . . . . . . . . . . 44
Engine number . . . . . . . . . . . . . . . . . 24 Preparation . . . . . . . . . . . . . . . . . . 44
Starting the engine
2 Before commissioning
for the first time . . . . . . . . . . . . . . . 46
General information . . . . . . . . . . . . . 26 Starting the engine . . . . . . . . . . . . 49
Type designation . . . . . . . . . . . . . . 26 Monitoring engine operation . . . . . . 51
Engine data card . . . . . . . . . . . . . . 26 Charge current . . . . . . . . . . . . . . . . 51
Description of the engine . . . . . . . 27 Telligent ® engine system . . . . . . . . 51
Flame-start system* . . . . . . . . . . . 27 Oil pressure . . . . . . . . . . . . . . . . . . 52
Engine brake*/constantly-open Flame-start system* . . . . . . . . . . . 52
throttle valves* . . . . . . . . . . . . . . . 29 Stopping the engine . . . . . . . . . . . . . 53
Telligent® engine system . . . . . . . . 30 Winter operation . . . . . . . . . . . . . . . . 54
Transport and installation . . . . . . . . 34
Contents
Cleaning /protective treatment . . . 56 Engine: oil change and filter 6 Practical advice
Cleaning the engine . . . . . . . . . . . . 56 replacement . . . . . . . . . . . . . . . . . . 73
Cleaning the cooling system . . . . . 57 Adjusting the valve clearance . . . . 76 Malfunctions, causes and
Protective treatment . . . . . . . . . . . 59 Fuel connections . . . . . . . . . . . . . . 80 solutions . . . . . . . . . . . . . . . . . . . . . . . 98
Service products . . . . . . . . . . . . . . . . 60 Heated fuel prefilter with water Jump-starting . . . . . . . . . . . . . . . . . . 106
Diesel fuels . . . . . . . . . . . . . . . . . . 61 separator*: replacing the filter
7 Technical data
FAME fuels . . . . . . . . . . . . . . . . . . . 63 element . . . . . . . . . . . . . . . . . . . . . 81
Engine oils . . . . . . . . . . . . . . . . . . . 65 Replacing the fuel filter Engine data . . . . . . . . . . . . . . . . . . . 108
Coolant . . . . . . . . . . . . . . . . . . . . . 66 element . . . . . . . . . . . . . . . . . . . . . 82 Test values and adjustment
Intake pipe between air cleaner values . . . . . . . . . . . . . . . . . . . . . . . . 113
5 Maintenance
and engine: checking for leaks Tightening torques . . . . . . . . . . . . . 114
Maintenance instructions . . . . . . . . 70 and general condition . . . . . . . . . . 85
8 Glossary
Work schedule overview . . . . . . . . . 71 Poly-V-belt: checking condition . . . 85
Maintenance service . . . . . . . . . . . 71 Engine brake*: checking Index . . . . . . . . . . . . . . . . . . . . . . . . . 117
Additional work . . . . . . . . . . . . . . . 71 condition and adjustment . . . . . . . 89
Additional work with every Engine cooling system: checking
third maintenance service . . . . . . . 71 and correcting the fluid level and the
Work schedules . . . . . . . . . . . . . . . . . 72 antifreeze /corrosion inhibitor . . . . 90
Engine: checking for leaks and Cooling and heating system:
general condition . . . . . . . . . . . . . . 72 checking for leaks and
Lines and hoses on the engine: general condition . . . . . . . . . . . . . . 91
checking for leaks and general Renewing coolant . . . . . . . . . . . . . 94
condition . . . . . . . . . . . . . . . . . . . . 72
Introduction
Protection of the environment
Fuel consumption and engine wear depend

Environmental note H on the operating conditions.
DaimlerChrysler’s declared policy is one of Therefore:
integrated environmental protection. This do not warm up the engine at idle speed
policy starts at the root causes and encom-
switch off the engine during periods in
passes in its management decisions all the
stationary traffic
consequences for the environment which
could arise from production processes or monitor fuel consumption
the products themselves. carry out the specified maintenance
work regularly
The objectives are for the natural resources
which form the basis of our existence on this
planet to be used sparingly and in a manner
which takes the requirements of both nature
and humanity into account.
Operate the engine in an environmentally-
responsible manner and you will help to pro-
tect the environment.
5
Introduction
Operating safety
The operating safety of an engine primarily

depends on its proper installation in the Risk of accident G
system as a whole (e.g. vehicle, machine,
etc.). However, as the operator, you also Engine damage arising from incorrect oper-
have a direct influence on the safe opera- ation could result in an accident.
tion of the engine. Therefore, observe the notes on operating
Some of the requirements for operating the engine in these Operating Instructions.
the engine safely can be met by adhering
to the specified maintenance intervals and
ensuring that the required maintenance Risk of accident G
work is carried out correctly.
Maintenance work that is carried out incor-
However, the safe functioning of the en-
rectly or not at all, and the failure to observe
gine also depends on correct operation,
the specified maintenance intervals, may
which includes, for instance, checking the
reduce the service life of the engine and
engine oil level at regular intervals.
cause engine damage, which could result in
an accident.
Therefore, observe the notes on engine
maintenance in these Operating Instruc-
tions.
6
Introduction
Operating safety
Correct use
Risk of accident G The engine is only designed for installation
Work incorrectly carried out on electronic in accordance with the specifications de-
components and their software could impair fined in the contract.
the functioning of these components. Since The manufacturer of the end product is
the electronic systems are networked, this personally responsible for the complete
might also affect systems that have not system, and in particular for the correct in-
been modified. stallation and compatibility of this engine
For this reason, always have work on, or with the rest of the system.
modifications to, electronic components The engine must not be modified.
carried out at a qualified specialist work- DaimlerChrysler accepts no responsibility
shop. for damage caused as the result of modifi-
DaimlerChrysler recommends that you use cations.
a Mercedes-Benz Service Centre for this Correct use of the engine includes adher-
purpose as it has the necessary specialist ing to these Operating Instructions, ad-
knowledge and tools for the work required. hering to the maintenance intervals and
performing maintenance work correctly in
accordance with these Operating Instruc-
tions.
7
8
At a glance
OM 501 LA overview
OM 502 LA overview (2 turbochargers)
OM 502 LA overview (1 turbocharger) 1
Location of sensors
Engine number
9
At a glance
OM 501 LA overview
10
At a glance
OM 501 LA overview
1 Coolant pump 1
2 Charge pressure pipe from intercooler
(with flame-start system*)
3 Charge pressure pipe to the intercooler
4 Oil filler opening
5 Exhaust gas turbocharger
6 Oil trap crankcase ventilation system
7 Flue pipe (with engine brake throttle
valve*)
8 Oil filter
9 Fuel filter
a Starter motor
b Dipstick
11
At a glance
OM 501 LA overview
12
At a glance
OM 501 LA overview
1 Oil pan 1
2 MR (engine control) unit
3 Flywheel housing
4 Exhaust manifold
5 Fuel pump (with flanged power steering
pump*)
6 Air compressor*
7 Resonator* (only in conjunction with
air compressor)
8 START/STOP buttons
9 Alternator
13
At a glance
OM 502 LA with two turbochargers
14
At a glance
1 Coolant pump 1
5 Turbocharger
7 Flue pipe (with engine brake throttle
valve*)
8 Oil filter
9 Fuel filter
a Starter motor
b Dipstick
15
At a glance
16
At a glance
1 Oil pan 1
3 Flywheel housing
4 Exhaust manifold
5 Fuel pump (with flanged power
steering pump*)
6 Air compressor*
7 Resonator* (only in conjunction
with air compressor)
9 Alternator
17
At a glance
OM 502 LA overview (1 turbocharger)
OM 502 LA with one turbocharger
18
At a glance
1 Coolant pump 1
4 Intake opening (from air cleaner)
5 Exhaust gas turbocharger
8 Oil filter
9 Fuel filter
a Starter motor
b Dipstick
19
At a glance
20
At a glance
1 Oil pan 1
3 Flywheel housing
4 Exhaust manifold
5 Fuel pump (with flanged power
steering pump*)
6 Air compressor*
8 Alternator
21
At a glance
Location of sensors
Example OM 501 LA
22
At a glance
Location of sensors
1 Oil level sensor 1

2 Crankshaft position sensor
(on the flywheel)
3 TDC sensor (on the camshaft sprocket)
4 Fuel temperature sensor
5 Combined charge-air pressure/
temperature sensor
6 Coolant temperature sensor
7 Oil pressure sensor
8 Oil temperature sensor
23
At a glance
Engine number
Location The engine number is also located on the Information on the engine
1 front of the oil filter housing.
The engine number is located on the left- As well as the manufacturer’s specifica-
hand side of the engine, behind the last tions, the following data is listed:
cylinder on the engine block.
Information on the engine
1 Engine model designation

2 Engine number
Location of the engine number on the left- 3 Type approval number
hand side of the fan 4 Engine group
Location of the engine number on the rear
left-hand side
24
Before commissioning
General information
Transport and installation
25
General information
Type designation
OM 501 L A
2
OM Oil engine
(diesel engine)
501 Engine model1
L Intercooler
A Exhaust gas turbo-
charger
1 OM 501: 6 cylinder, OM 502: 8 cylinder
Engine data card Engine data card

The engine data card (A4 sheet) forms an
i
integral part of the documents belonging
to the engine and should always be kept The engine data card describes the
with the Maintenance Booklet. It contains scope of delivery from the
details about the engine, including special DaimlerChrysler factory; later changes
equipment. to the scope of delivery are not record-
ed on the data card.
The engine data card must be produced for
the procurement of genuine parts. Always keep the engine data card with
the Maintenance Booklet.
26
General information
Description of the engine The engines produce particularly low emis-

sions. Injection start, injection period and
The OM 501 LA (6-cylinder) and injection quantity are controlled fully elec-
OM 502 LA (8-cylinder) engines are water- tronically.
cooled 4-stroke direct injection diesel en- 2
gines. The control system consists of an engine
control unit mounted on the engine, the
The cylinders are arranged in a V-pattern at MR module, with an integrated heat ex-
an angle of 90°. Each cylinder has two in- changer for cooling through the fuel supply
take valves and two exhaust valves. system, and the application-dependent FR
Each cylinder has a separate fuel-injection (drive control) unit or the ADM adaptation
pump (unit pump) connected by a short module. All these control units are inter-
high-pressure fuel injection line to the mul- connected via the Controller Area Network
ti-hole nozzle located in the centre of the (CAN).
combustion chamber. The unit pumps are
mounted directly on the crankcase and Flame-start system*
Flame-start system
driven by the camshaft. The flame-start system is a cold-start aid
for when ambient temperatures are low. It A flame glow plug is fitted in the charge
The engines are fitted with a turbocharger
reduces the emissions of white smoke pressure pipe of the intercooler. Fuel can
and intercooler as standard. The engines
once the engine has been started. The be ignited at this flame glow plug. The fuel
can be equipped with an engine brake* as
starter motor and battery are also protect- is supplied to the flame glow plug via a so-
an option (throttle valve and constantly-
ed as a result of the shorter start-up time. lenoid valve with a dosing nozzle.
open throttle valves*) as well as with a
flame-start system.
27
General information
The flame-start system is only enabled if

the engine is started within 30 seconds of
the flame-start system indicator lamp go-
ing out.
2
i
If the flame-start system indicator lamp
does not go out after more than 20 sec-
onds, there is a malfunction in the
flame-start system.
i
For operation at low outside temper-
atures, see also the “Diesel fuels”
( page 61) and “Coolant”
Flame-start system indicator lamp
( page 66) sections.
(example)
Following the preglow time, which is de-

pendent on the outside temperature (max-
imum 20 seconds), the flame-start system
is activated and the flame-start indicator
lamp goes out.
Once the engine has been started, the
flame-start system is supplied with fuel by
the fuel pump.
28
General information
Engine brake* /constantly-open The engine brake always remains deacti-

throttle valves* vated at engine speeds of below 900 rpm
to prevent the engine from stalling. The
To increase the braking power, the engines engine brake is also automatically deacti-
can be equipped with an exhaust brake vated if the position sensor is triggered 2
valve on the exhaust gas turbocharger in (e.g. if the accelerator pedal is depressed).
conjunction with constantly-open throttle
valves on the cylinders. i
Whereas exhaust gas backpressure, acting In the emergency running program
through the exhaust brake valves, can be (constant engine speed), the engine
used to increase the braking power, brake can only be activated in overrun
the constantly-open throttle valves cause mode at an increased engine speed.
a reduction of compression in the power The engine brake is automatically deac-
stroke (3rd stroke), leaving compression tivated again once a constant engine
(2nd stroke) practically unaffected. speed has been reached.
Activation of the constantly open throttle
The constantly-open throttle valves are valves
valves in the cylinder head. When open,
they connect the combustion chamber When the engine brake is activated, the
to the exhaust duct, which generates the constantly-open throttle valves are opened
required decompression in the power by compressed air. At the same time, the
stroke. exhaust brake valve on the exhaust gas
turbocharger is closed.
The engine brake is controlled by the drive
control unit ( page 32) or the ADM.
29
General information
Telligent® engine system MR (engine control) unit (mounted on The MR (engine control) unit processes
the engine) data from the drive control unit or the
The engine has a fully electronic control
The MR (engine control) unit is mounted on ADM, indicating for example the position
system, which, in addition to the engine
the right-hand side of the engine. of the position sensor (accelerator pedal),
2 and associated sensors, also comprises: the engine brake* or engine start/stop,
an MR (engine control) unit and etc.
an FR (drive control) unit and/or other
vehicle-specific control units, e.g. ADM
Both are interconnected via a CAN (Con-
troller Area Network) line, on which all the
necessary data/information is exchanged.
The engine control monitors itself as well
as the engine. A safety and emergency run-
ning program is selected automatically,
depending on the malfunctions/system
failures that occur ( page 41).
MR (engine control) unit
30
General information
This data is evaluated along with data from i

the sensors on the engine, such as those
All the information on the control unit
for:
type plate is required to obtain a re-
charge-air pressure and temperature placement engine control unit. 2
coolant temperature
fuel temperature
oil pressure
The data is compared with the maps and
characteristic curves stored in the engine
control unit.
Injection timing, period and volume are
calculated based on these comparisons
and the solenoid valves are actuated to
Control unit type plate
adjust the unit pumps accordingly.
1 Data record
2 Certification no.
3 Engine number
4 Equipment code
31
General information
FR (drive control) unit or ADM (mounted The FR (drive control) unit or the ADM re- If the Telligent ® engine system detects a
on the equipment) ceive data from the: fault, this is stored in the control units as a
operator (position of the position sen- fault code, which can then be read using
The engine can be adapted to meet various
appropriate diagnostic equipment (STAR
2 application-specific requirements by sor, engine start/stop)
DIAGNOSIS or minidiag2).
means of the drive control unit or adapta- engine brake switch*
tion module (ADM). In addition, the electronics warning lamp
other systems (e.g. acceleration skid lights up.
control system)
MR (engine control) unit (e.g. oil pres-
i
sure and coolant temperature) The DaimlerChrysler diagnostic equip-
ment can be connected to the equip-
This data is used to determine the instruc- ment-mounted 14-pin diagnostic sock-
tions for engine control (MR control unit), et or using the EU-compliant service
which are then sent to the engine control connector. This equipment can be used
on the CAN line. to read both the malfunction memory
The FR (drive control) unit or the ADM con- and the stored engine data.
trols various displays, e.g. the electronics
FR (drive control) unit
warning lamp, the engine brake* and the
The FR (drive control) unit or the ADM constantly-open throttle valves*.
stores a range of application-specific data,
such as idling speed, maximum working
speed or speed limitation.
32
General information
Organisational measures All universally applicable, country-specific,

legal and other mandatory regulations for
accident prevention and protection of the
Risk of injury G environment must be observed in addition 2
Before operating the engine, please read
to these Operating Instructions.
these Operating Instructions and other rele-
vant documentation, such as the operating
instructions for the vehicle or the machine
the engine is installed in.
You could otherwise fail to recognise dan-
Diagnostic socket
gers and could injure yourself or others.
The Operating Instructions and Mainte-

nance Booklet must be given to the per-
sonnel responsible for operating or car-
rying out work on the engine, and should
be kept in an easily accessible location
where the engine is used.
These Operating Instructions must be used
to instruct personnel how to handle the en-
EU-compliant service connector
gine. In particular, the notes concerning
safety must be explained. This is especially
important for personnel who only work on
the engine occasionally.
33
Transport
Risk of injury G
2
The engine can break loose and cause injury
to somebody by overturning or falling.
Only lift the engine by the appropriate
lifting points on the engine.
Only use transport equipment that
has been approved for use by
DaimlerChrysler.
Only lift and transport the engine in the
installation position. Observe the maxi-
mum angle of 30° when lifting the en-
gine in or out of the machine or vehicle. Lifting point, flywheel side (OM 501 LA Lifting point, belt side (OM 501 LA shown)
shown)
34
Installation
The engine is only designed for installation
in accordance with the specifications de-
fined in the contract. 2
The manufacturer of the end product is
personally responsible for the complete
system, and in particular for the correct in-
stallation and compatibility of this engine
with the rest of the system.
Observe the “Correct use” ( page 7) and
“Conversion parts and modifications to the
engine” ( page 40) sections.
The “Technical data” section of these
Operating Instructions contains informa-
tion required for the installation of the
engine.
Please consult a Mercedes-Benz Service
Centre if you have any questions.
i
The engine is filled with engine oil at
the factory.
35
36
Safety
Safety precautions
Staff qualifications
Conversion parts and modifications to the engine
Safety/emergency running programs
Genuine Mercedes-Benz parts
37
Safety
Safety precautions
The safety precautions in this section must ! !

be observed to prevent injury to anybody
Note that for electric welding work, The control units must be removed
and damage to the engine, components
the batteries must be disconnected if temperatures of over 80 °C
and cable harness.
and both cables (“+” and “–”) (e.g. in the drying oven) are ex-
! securely connected to each other. pected.
Do not start the engine unless the The connectors for control units Only use suitable test leads
3 batteries are securely connected. must not be disconnected or con- (e.g. DaimlerChrysler connection
nected unless the electrical system set) for taking measurements at
Do not disconnect the batteries
is switched off. connections.
with the engine running.
Incorrect polarity in the control unit Telephones and two-way radios
Do not use a rapid charger to start
power supply (e.g. caused by in- that are not connected to an exteri-
the engine.
correct battery polarity) can cause or aerial can cause malfunctions in
Only perform jump-starting with irreparable damage to the control the vehicle electronics system and
separate batteries. units. thereby jeopardise the operating
Note that the battery terminals safety of the engine.
Tighten the connections on the fuel-
must be removed for rapid battery injection system to the specified
charging. Observe the rapid charger tightening torque.
operating instructions.
38
Safety
Engines may only be operated, maintained
Risk of accident G and repaired by trained personnel instruct-
ed and authorised by the operator.
Maintenance and repair work to the engine
The responsibilities for operation, mainte-
carried out incorrectly can impair both its
nance and repairs must be assigned by the
correct operation and safety, leading to ac-
operator.
cidents and injury. 3
The legal minimum age for carrying out the
Always have work on or modifications to the
work listed above must be observed.
engine carried out at a qualified specialist
workshop which has the necessary special-
ist knowledge and tools for the work re-
quired.
Mercedes-Benz recommends that you use a
Mercedes-Benz Service Centre for this pur-
pose.
39
Safety
Conversion parts and modifications to the engine
The warranty does not cover damage aris-

Risk of accident G ing from tampering with the engine.
Tampering with the engine to modify it can

impair both its correct operation and its
safety, leading to accidents and injury.
3 Always have work on or modifications to the
quired.
Mercedes-Benz recommends that you use a
Mercedes-Benz Service Centre for this pur-
pose.
!
Tampering with the fuel-injection sys-
tem and engine electronics may affect
the performance and emission levels of
the engine. It would no longer be possi-
ble to guarantee compliance with fac-
tory settings or legal environmental
protection conditions.
40
Safety
Safety/ emergency running programs
Safety/emergency running programs
The engine is equipped with an electronic i
control system that monitors both the en- Risk of accident G The DaimlerChrysler diagnostic equip-
gine and itself (self-diagnostic system).
ment can be connected to the equip-
Maintenance and repair work to the engine
If a malfunction is detected, it is immedi- ment-mounted 14-pin diagnostic sock-
carried out incorrectly can impair both its
ately evaluated and one of the following et or using the EU-compliant service
correct operation and safety, leading to ac-
measures is automatically initiated: connector. This equipment can be used
cidents and injury.
to read both the malfunction memory 3
If the engine is running, a malfunction
Always have work on or modifications to the and the stored engine data.
is indicated by the electronic system
warning lamp lighting up.
The fault codes may be shown on a ist knowledge and tools for the work re-
display on vehicles with the Telligent® quired.
engine system (vehicle diagnostics Mercedes-Benz recommends that you use a
system). Mercedes-Benz Service Centre for this pur-
The engine is switched to the appro- pose.
priate back-up function for continued
(but restricted) operation (e.g. con-
stant emergency running speed).
Electronic system warning lamp
41
Safety
Genuine Mercedes-Benz parts
Make sure that the replacement parts are Additional information about recommend-
suitable for your engine. Parts that lead to ed conversion parts and accessories and
an engine/vehicle modification that: permissible technical modifications is
available from any Mercedes-Benz Service
changes the type of machine/vehicle
Centre.
approved in the General Operating
Permit Always quote the engine number and mod-
3 poses a potential risk to road users, or el designation when ordering genuine
parts. You will find the numbers on the en-
causes a deterioration in exhaust gas gine plate ( page 24) and on the engine
emission levels or noise levels data card ( page 26).
will result in the invalidation of the General
Operating Permit (in many countries). The
use of non-approved parts can jeopardise
safety.
Environmental note H
To combine cost-effective repairs with recy-
cling, Mercedes-Benz also offers recondi-
tioned engines and parts. These are of the
same quality and have the same warranty as
new parts.
42
Operation
Starting the engine for the first time
Monitoring engine operation
Stopping the engine
Winter operation
Cleaning /protective treatment
Service products
43
Operation
Preparation Adding coolant

When it leaves the factory, the engine is Coolant composition ( see page 66).
filled with an engine oil complying with Filling the cooling system
Sheet 228.5 of the Mercedes-Benz Specifi- ( see page 94).
cations for Service Products.
These high-quality engine oils assist the
running-in process, enabling the first oil
change to take place in accordance with
4 the specified oil change intervals for nor-
mal operation. This eliminates the need for
special initial operation oils and the oil
change otherwise required.
The extended maintenance intervals can
only be observed if engine oils complying
with Sheet 228.5 of the Mercedes-Benz
Specifications for Service Products are Check the oil level and, if necessary,
used. add engine oil via filler opening 1 up
to the maximum mark on the dipstick
( see page 74).
44
Operation
Refuelling i
Use summer or winter fuel depending on Bleed the heated fuel prefilter with wa- Risk of explosion G
the season. See also “Diesel fuels” ter separator* mounted on the vehicle
Gases leaking from batteries may explode
( page 61). or machine with the integrated hand
and therefore cause injury.
pump.
! Fire, naked flames, smoking and sparks are
When refuelling do not allow water to Checking the batteries therefore not permitted in the vicinity of the
enter the tank, contaminating the fuel. batteries.
Bleeding the fuel system Risk of injury G Only use batteries that have been correctly 4
If the fuel system is run dry, the system will filled and maintained. Grease the battery
The acid contained in batteries burns skin
be bled the next time the engine is started terminals with acid-proof grease (battery
and eyes on contact.
after refuelling. Automatic continuous terminal grease).
Do not allow acid to come into contact
bleeding takes place in the filter. with your skin, eyes or clothing. i
i Wear suitable protective clothing, as The cable cross-sections are depend-
The battery must be sufficiently battery acid can burn through normal ent on the distance between the bat-
clothing. In addition, protective gloves tery and the starter motor.
charged during the starting procedure
and safety goggles should be worn.
to ensure that the fuel system can be
bled. Rinse acid splashes off immediately with
clean water and consult a doctor if nec-
essary.
45
Operation
Starting the engine for the first time i

Carry out the work listed under “Prepara- For additional safety, the Telligent® en-
tion” ( page 44) before operating the engine system is equipped with a function
gine for the first time. that only allows the engine to be start-
ed with the transmission in neutral.
Switch on the operating current.
Start the engine with the position sen-
sor (e.g. accelerator pedal) in the idling Risk of injury G
position, e.g. by pressing START button
4 1 on the engine ( see page 49). The engine becomes very hot while it is run-
ning and remains so for some time after it
has stopped. It will cause burns if touched.
Before starting any work on the engine, al-
low all engine parts to cool down or else
Start/stop buttons wear suitable gloves and items of clothing to
protect yourself against hot engine compo-
1 START button nents.
2 STOP button
46
Operation
Risk of injury G Risk of injury G Risk of poisoning G

There is a danger of limbs being caught, en- The cooling system is pressurised. Hot cool- There is a risk of poisoning if coolant is swal-
trapped, crushed or torn off by rotating en- ant can escape under pressure when the lowed.
gine parts. Therefore you should: cooling system is opened and scald your Never swallow coolant.
Keep a safe distance between yourself skin and eyes.
Never store coolant in containers nor-
and rotating engine parts, including Only open the cooling system at coolant mally used for drinks.
when the engine is being started. temperatures below 90 °C.
Wait until all engine parts have stopped
Store coolant out of the reach of chil- 4
Unscrew the cap slowly and release any dren.
moving before carrying out any work on excess pressure completely before
the engine. opening the cap fully.
To check the coolant level:
Wear work clothing which is fastened Wear suitable protective gloves, protec- Run the engine at moderate speeds for
and close-fitting. Wear a hair net if tive clothing and safety goggles when about 5 minutes.
necessary. Remove jewellery such as handling coolant.
watches and necklaces. If the coolant temperature is below
50 °C, check the coolant level again
and add coolant if necessary.
47
Operation
i Check the engine oil level approximate-

ly 5 minutes after stopping the engine
If a heating system is connected to the
and add oil up to the maximum mark on
cooling system, all heating system
the dipstick if necessary.
valves must be opened while the cool-
ing system is being topped up. Check brackets secured to the engine
for firm seating.
Otherwise, there might be too little
coolant in the cooling system after it is Check the securing bolts on the ex-
filled. haust manifold, engine mountings,
coolant pump, starter motor and air
4
Only close the heating system valves once compressor for tightness.
the engine has been running for a brief pe-
riod and, where applicable, the coolant has
been topped up.
Check the engine for leaks.
Check the hose fittings, hose clamps
and pipe connections on the engine as
well as the oil feed and return lines on
the exhaust gas turbocharger for leaks
and firm seating, and retighten if nec-
essary.
48
Operation
Starting the engine i

At outside temperatures of below
Risk of accident and injury G –30 °C, Mercedes-Benz recommends
preheating the coolant (e.g. using an
If not properly secured, a vehicle might acci- electrical preheating device)
dentally be set in motion when the engine is
started, knocking somebody down or trap- Starting procedure
ping them. Before starting the engine:
For vehicle engines, always secure the ve-
Prevent the vehicle from rolling away hicle against pulling away inadvertently:
by applying the parking brake and, if
4
necessary, by placing chocks under the Apply the parking brake.
wheels. Shift the transmission into neutral.
Shift the transmission into neutral. Insert the key into the ignition lock and
turn it to the drive position.
The following indicator lamps /warning 1 Charge current indicator lamp
i
lamps light up: 2 Electronic system warning lamp
Starting the engine for the first time 3 Flame-start system*
( see page 46).
Observe the special measures to be
carried out before the engine is started
after it has been switched off for a long
period, see the “Cleaning/protective
treatment” section ( page 56).
49
Operation
To start the engine using the START button If the vehicle is equipped with a flame-start i
on the machine or on the engine: system*:
Depending on the outside temperature,
Wait until the flame-start system* indi- the flame-start system* indicator lamp
cator lamp goes out. lights up:
Start the engine within 30 seconds us- from approximately 2 seconds
ing the START button on the machine (function check, flame-start system
or engine. not in operation)
! to approximately 20 seconds
4 Keep the engine running at idling speed (maximum preglow time)
until an oil pressure reading is dis- If the flame-start system* indicator
played (do not rev the engine). If no oil lamp does not go out after 20 seconds,
pressure is displayed after approxi- there is a malfunction.
mately 10 seconds, switch off the en- Do not place the cold engine under full
gine. Determine the cause load immediately.
( page 52).
If necessary, interrupt the starting pro-
Start/stop buttons
cedure after a maximum of 20 seconds,
1 START button and then repeat after approximately
2 STOP button 1 minute.
On the engine: press START button 1 The charge current indicator lamp and
on the engine. electronic system warning lamp must
go out after the engine has started. If
Monitor the oil pressure gauge immedi-
they remain lit, this indicates that there
ately after starting the engine.
is a malfunction; ( see page 51) and
( page 51).
50
Operation
Charge current !
The charge current indicator lamp must go Make sure that the poly-V-belt contact
out after the engine has started. surfaces are not damaged (e.g. torn),
oily or glazed as this could cause the
poly-V-belt to slip.
Do not run the engine without a poly-V-
belt. The alternator and coolant pump
would not be driven, which would result
in engine damage. 4
Electronic system warning lamp
Telligent ® engine system Fault codes can be read using
The electronic system warning lamp must DaimlerChrysler diagnostic equipment
Charge current indicator lamp go out after the engine has started. (STAR DIAGNOSIS or minidiag2 tester)
If the warning lamp does not go out or if it ( see page 32). If the electronic system
If the indicator lamp does not go out or if it warning lamp lights up while the engine is
lights up while the engine is running, there
lights up when the engine is running, stop running, read or determine the fault code.
is a malfunction in the Telligent ® engine
the engine and check the poly-V-belt.
system.
Each malfunction is stored in the system
with its own fault code. Temporary faults
are also stored.
51
Operation
Oil pressure i
! The flame-start system is automatically
deactivated if:
After the engine has reached normal
operating temperature, the engine oil the engine is not started within
pressure must not fall below: 30 seconds of the flame-start sys-
tem indicator lamp going out
2.5 bar at rated speed
the engine is started when the
0.5 bar at idling speed
flame-start indicator lamp is lit
4 If the oil pressure falls below these val-
the charge current indicator lamp
ues, stop the engine and trace the
does not go out while the engine is
cause.
running
the engine reaches a temperature
Flame-start system*
at which the flame-start system is
There is a malfunction in the flame-start Flame-start system indicator lamp no longer required
system if: (example)
the flame-start system indicator lamp

lights up while the engine is running
the indicator lamp does not go out
within 20 seconds of the engine being
started
52
Operation
Stopping the engine
Stopping the engine
Run the engine at idling speed for one Press STOP button 2 on the engine or
or two minutes without load after oper- on the machine-mounted engine shut-
ation at full power or a high coolant down facility.
temperature.
!
Stop the engine immediately if any of
the following occur:
significant drops or fluctuations in
oil pressure
4
falling power output and engine
speed with the position sensor
(accelerator pedal) in the same
position
large amounts of exhaust smoke
emitted from the exhaust
significant increases in coolant and
oil temperature
Start/ stop buttons sudden, unusual noises from the

engine or exhaust gas turbocharger
1 START button
2 STOP button
53
Operation
Winter operation
The following points should be observed at Jump-starting Coolant

the start of the cold season:
Fuel
Risk of explosion G Risk of injury G
The use of liquid or gaseous jump-starting The cooling system is pressurised. Hot cool-
Risk of fire G equipment can cause explosions. This may ant can escape under pressure when the
result in severe injuries. cooling system is opened and scald your
Fuel is highly flammable. For this reason, Do not use liquid or gaseous jump- skin and eyes.
avoid fire and naked flames and refrain from starting equipment, such as ether or Only open the cooling system at coolant
4 smoking when handling fuel. Startpilot to start the engine. temperatures below 90 °C.
Unscrew the cap slowly and release any
Use cold-resistant diesel fuel Engine oil excess pressure completely before
( see page 61). opening the cap fully.
When changing the engine oil, select an
engine oil that is compatible with the SAE Wear suitable protective gloves, protec-
classification and the ambient tempera- tive clothing and safety goggles when
tures expected during the period of use handling coolant.
( see page 65).
54
Operation
Winter operation
Batteries
Risk of poisoning G Have the batteries serviced and recharged Risk of explosion G
more frequently during the cold months of
There is a risk of poisoning if coolant is swal- Gases leaking from batteries may explode
the year.
lowed. and therefore cause injury.
Never swallow coolant. Fire, naked flames, smoking and sparks are
Risk of injury G therefore not permitted in the vicinity of the
Never store coolant in containers nor-
mally used for drinks. batteries.
The acid contained in batteries burns skin
Store coolant out of the reach of chil- and eyes on contact. 4
dren. Careful maintenance and low power con-
Do not allow acid to come into contact sumption will help to maintain the full bat-
with your skin, eyes or clothing.
Check the antifreeze protection properties tery charge. Starting capacity is greatly
Wear suitable protective clothing, as reduced in cold weather; at –10 °C, for ex-
of the coolant in good time and increase
battery acid can burn through normal ample, it is only around 60% of normal ca-
the antifreeze /corrosion inhibitor concen- clothing. In addition, protective gloves
tration if necessary ( see page 66). pacity. If the engine is not used for a long
and safety goggles should be worn.
period of time, store the batteries in a
Rinse acid splashes off immediately with heated place if possible. Ensure good ven-
clean water and consult a doctor if nec- tilation when recharging.
essary.
55
Operation
Cleaning/protective treatment
Cleaning the engine !

Risk of fire and injury G Make sure that water does not enter
Risk of poisoning G Fuels are highly flammable and can consti-
the intake, ventilation or bleed ducts.
tute a health hazard. If they are used as Protect the engine after cleaning. Be
Care and cleaning agents can be toxic and careful to protect the belt drive from
cleaning agents, they can cause burns or
lead to severe poisoning if swallowed. exposure to preservative agents.
skin irritation and poisoning.
Always keep care and cleaning agent
Never use fuels for cleaning.
containers closed and out of the reach
of children.
i
4 Information about suitable cleaning
Never store care or cleaning products in
containers for comestibles such as bot- Environmental note H and preservative agents is available
tles so as to avoid confusion.
from any Mercedes-Benz Service Cen-
Observe the regulations for environmental tre.
Observe the instructions for using care protection.
and cleaning products.
Only clean the engine in a washing area de-
signed for this purpose. Dispose of empty
packaging and used cleaning materials in an
environmentally-responsible manner.
56
Operation
High-pressure cleaners Cleaning the cooling system

Observe the manufacturer’s operating in- Risk of injury G
structions. Environmental note H The cooling system is pressurised. Hot cool-
! ant can escape under pressure when the
Collect used coolant, cleaning solutions and
Maintain the minimum distance be- cooling system is opened and scald your
detergents and dispose of them in an envi-
tween the high-pressure cleaner nozzle skin and eyes.
ronmentally responsible manner in accord-
and the object to be cleaned: ance with relevant local regulations. Only open the cooling system at coolant
temperatures below 90 °C.
approximately 70 cm for round-
spray jets Blow out any foreign objects (dust, in- Unscrew the cap slowly and release any 4
sects, etc.) from the radiator fins using excess pressure completely before
approximately 30 cm for 25° flat- opening the cap fully.
compressed air or remove them by
spray jets and concentrated power Wear suitable protective gloves, protec-
spraying water from the rear side of the
jets tive clothing and safety goggles when
radiator (against the direction of the
Keep the water jet moving constantly cooling air flow). handling coolant.
while cleaning. To avoid damage, do
not aim the water jet directly at: !
electrical components Only apply moderate pressure when
cleaning since the radiator fins could
connectors otherwise be damaged.
seals or
hoses
57
Operation
Degreasing
Risk of poisoning G Fill the cooling system with a 5% solu-
tion of water and a mild alkaline clean-
There is a risk of poisoning if coolant is swal-
er, e.g. “P3 Croni” (50 g cleaning agent
lowed.
per litre of water).
Never swallow coolant.
Warm the engine up to approximately
Never store coolant in containers nor- 80 °C (coolant thermostat starts to
mally used for drinks. open) at a moderate engine speed and
Store coolant out of the reach of chil- allow it to run for approximately 5 min-
4 dren. utes longer.
Switch off the engine and allow it to
Drain off coolant when the engine is
cool to approximately 50 °C.
cold ( page 94).
Drain off the cleaning solution com-
If a heater is connected to the cooling
pletely.
system, open the regulating valves
fully. Immediately afterwards, fill the cooling
system with clean water, warm up the
engine, and drain off the water after
5 more minutes. Then repeat the pro-
cedure a second time.
Fill the cooling system with new cool-
ant ( page 95) and observe the notes
in the “Coolant” section ( page 66).
58
Operation
Protective treatment i
The special protection required will de- Information is available from any
pend on the length of time the engine is to Mercedes-Benz Service Centre. Con-
be out of use as well as the prevailing am- sultation is strongly recommended.
bient conditions in the place where the en-
gine is to be located or stored.
After cleaning the engine, store it in as dry
and well-ventilated an area as possible.
If this is not possible, the intervals for car- 4
rying out regular protective measures
must be halved.
It is essential that the engine be protected
from direct contact with water (rain/spray
water).
No anti-corrosion measures are required if
the engine is to be out of use for less than
12 months and the above storage condi-
tions are observed.
Special protective treatment measures are
required if the engine is to be out of use for
more than 12 months or there are ex-
ceptional storage and transport condi-
tions.
59
Operation
Service products
Special lubricant additives are not neces-

If service products do come into contact
Risk of poisoning sary. The use of special lubricant additives
and injury G with your eyes, rinse them thoroughly
with clean water and consult a doctor if may limit your warranty entitlement.
Service products can cause injury or poison- necessary.
i
ing if they come into contact with skin or are Consult a doctor immediately if a serv-
Information about service products is
swallowed. ice product is swallowed.
available from any Mercedes-Benz
Observe the relevant regulations when han- Keep service products out of the reach Service Centre.
dling, storing and disposing of service prod- of children.
4 ucts. Service products could otherwise
endanger people and the environment. Environmental note H
Risk of fire G
Always wear appropriate protective
clothing and a breathing mask when Dispose of service products and parts that
There is an increased risk of fire when han-
handling service products. Avoid inhal- come into contact with service products,
dling fuels and lubricants as they are highly
ing vapours where possible. e.g. filters, in an environmentally-responsi-
flammable.
ble manner.
Do not allow service products to come
Avoid fire, naked flames and sparks, and re-
into contact with your skin, eyes or Observe legal requirements.
frain from smoking when handling service
clothing. Clean affected areas of skin
with soap and water. products.
Greases and lubricants must be com-

patible with engine components. For
this reason, only brands that have been
tested and approved by DaimlerChrysler
must be used. These are listed in the
Mercedes-Benz Specifications for Service
Products.
60
Operation
Service products
Diesel fuels Diesel fuels in extremely cold weather If summer diesel fuel or less cold-resistant
winter diesel fuel is used, only add a specif-
Only use commercially available diesel At low outside temperatures, paraffin sep-
ic quantity of flow improver or kerosene
fuels (EN 590). The use of other fuels aration may affect the flow characteristics
suitable for the outside temperatures.
is subject to official approval from of diesel fuel.
DaimlerChrysler. To prevent operating problems (e.g. as a
Fuel additives are not necessary. The use result of blocked filters), diesel fuels with Risk of explosion G
of fuel additives may limit your warranty improved cold flow properties are available
Adding petrol reduces the flash point for the
entitlement. on the market in the winter months. Devia-
diesel fuel and increases the risk of fire and
tions are possible in individual countries
If diesel fuels with a sulphur content of explosion. 4
and in the transition between the cold and
more than 0.3% by weight are used, the en- warm seasons. In Germany, special cold- For this reason, do not mix petrol with
gine oil must be changed at shorter inter- resistant winter-grade diesel fuels are the diesel fuel under any circumstances.
vals. Observe the information in the available that ensure reliable operation For this reason, you must avoid fire, na-
Maintenance Booklet. down to approximately –20 °C. Winter- ked flames and sparks, and refrain from
Filling the vehicle’s fuel tank from drums or grade diesel fuel can normally be used smoking when handling these service
canisters may introduce impurities into the without risk of malfunctions at the outside products.
fuel system. This can lead to fuel system temperatures to be expected in the coun- Observe the relevant safety regulations.
malfunctions. The fuel must therefore be try of sale.
filtered when filling the tank.
The fuel must not be mixed with water un-
der any circumstances.
61
Operation
Service products
! Kerosene
There is a risk of serious engine dam- Add only as much as is required for the Risk of explosion G
age if petrol is mixed with diesel. prevailing outside temperatures. The addi-
Adding kerosene reduces the flash point of
tion of 5% by volume of kerosene improves
For this reason, do not mix petrol the fuel, increasing the risk of fire and explo-
the cold-resistance of diesel fuel by ap-
with the diesel fuel under any circum- sion.
proximately 1 °C. Do not exceed the max-
stances. For this reason, avoid fire and naked
imum mixing ratio of 50% kerosene.
flames and refrain from smoking when
Mix the additive with the diesel fuel in good ! handling these service products.
time, before the flow properties of the die-
4 There is a risk of engine damage if ker- Only mix kerosene with diesel in the fuel
sel are affected by paraffin separation. osene is permanently mixed with die- tank.
Malfunctions caused by paraffin separa- sel. First add the kerosene and then the die-
tion can only be remedied by warming up
It is therefore not permissible to mix sel fuel.
the entire fuel system.
kerosene with diesel on a permanent Observe the relevant safety regulations.
Do not mix additives with special cold- basis.
resistant winter diesel fuels as the cold-
flow properties of the fuel could deterio- Run the engine for a while to ensure that
rate. the additive reaches all parts of the fuel
Flow improvers system.
The effectiveness of flow improvers cannot
be guaranteed with all fuels. Observe the
manufacturer’s recommendations. Infor-
mation about approved flow improvers is
available from any Mercedes-Benz Service
Centre.
62
Operation
Service products
FAME fuels ! !
The OM 501 LA and OM 502 LA engines The fuel filter and engine oil filter Only use FAME fuels complying
are suitable for operation with FAME fuel must be replaced approximately with EN 14214. Special additives
(bio-diesel fuel) complying with EN 14214. 200 operating hours following con- are not permitted. The use of fuels
version to FAME fuel. that do not comply with the
The following effects arise from operation EN 14214 standard or the addition
with FAME fuel: The oil and fuel filter must be re-
placed with every engine oil of special additives may lead to
slight increase in fuel consumption change. malfunctions or damage to the en-
gine.
slightly reduced engine power output FAME fuels reduce the service life
FAME fuels attack painted surfaces. 4
of a conventional fuel filter.
increased white smoke development Immediately rinse off the FAME
after a cold engine start The engine oil change and filter re-
fuel with water before it has time
placement intervals are significant-
Before operation with any FAME fuel, a to react with the paintwork. Use
ly reduced. The engine oil change
Mercedes-Benz Service Centre must be only engine oils complying with
and filter replacement must be car-
consulted to clarify the precise proce- Mercedes-Benz Specifications for
ried out at least once a year.
dures for use (e.g. maintenance intervals). Service Products sheet number
228.5 or 228.3.
Observe the following points for operation
with FAME fuel:
63
Operation
Service products
! !
FAME fuels may cause components Based on negative experiences, Environmental note H
in the fuel system to stick if the en- DaimlerChrysler does not accept
the use of pure vegetable oils as an If you operate your vehicle using bio-diesel
gine is left switched off for long pe-
alternative to diesel or FAME fuels. fuel, please consult your disposal firm as to
riods. For this reason, always use
The use of pure vegetable oils can whether the engine oil must be collected
up the amount of FAME fuel remain-
lead to engine damage arising from separately. Not all manufacturers of rere-
ing in the fuel tank and refuel with
coking and oil sludge forming as fined products (lubricants manufactured
conventional diesel fuel before the
well as deposits in combustion from used engine oils) are able to process
engine is switched off for long peri-
4 chambers. engine oil contaminated with bio-diesel fuel.
ods. Run the engine for at least one
hour before the vehicle is parked Observe the special notes and national reg-
up. ulations on the disposal of engine oils. Infor-
The quality of hoses adjacent to the mation is available from any qualified spe-
engine, and connected either to the cialist workshop or Mercedes-Benz Service
vehicle or machine, must satisfy the Centre.
requirements of FAME fuels.
64
Operation
Service products
Mercedes-Benz does not accept warranty FAME fuels (bio-diesel fuels) at low Engine oils are specially tested for their
claims for damage if: temperatures suitability for use in our engines. For this
reason, only use engine oil brands ap-
the cause of the damage is in any FAME fuels are reliable down to outside
proved by Mercedes-Benz. These are listed
way connected to the use of a FAME temperatures of approximately –20 °C in
in the Mercedes-Benz Specifications for
fuel that does not comply with the accordance with EN 14214.
Service Products. Observe the information
EN 14214 standard
Flow improvers in the Maintenance Booklet.
the regulations of sheet number 135 of
i
the Mercedes-Benz Specifications for The addition of flow improvers or kerosene
Service Products concerning operation has no effect on the cold stability of FAME The use of non-approved engine oil
brands may limit your warranty entitle- 4
with FAME fuels have not been ob- fuels.
served ment.
Engine oils
malfunctions or consequential damage
(e.g. paint damage) arise from the han-
dling of or operation with FAME fuels
SAE engine oil classes
65
Operation
Service products
The oil change intervals will change if en- Coolant !

gine oils of a different quality grade are
Coolant is a mixture of water and anti- The effectiveness of the coolant's anti-
used. Information is available from any
freeze/corrosion inhibitor. To protect corrosion protection decreases over
Mercedes-Benz Service Centre. Select the
against corrosion and raise the boiling time.
SAE engine oil class in accordance with the
point, coolant must remain in the cooling You should therefore replace the cool-
outside temperature.
system all year round. ant, depending on the antifreeze/
When maintenance work is carried out,
corrosion inhibitor used, every 3 or
confirmation of the engine oil change is en-
tered in the Maintenance Booklet along Risk of poisoning G 5 years (see Mercedes-Benz Specifica-
tions for Service Products).
4 with the engine oil brand, its grade and its
There is a risk of poisoning if coolant is swal-
SAE class.
lowed. Water
i Never swallow coolant. Water without additives is not permitted as
The properties of the engine oil deteri- Never store coolant in containers nor- a coolant, even if antifreeze properties are
orate if a lower grade is used to top up mally used for drinks. not necessary.
the engine oil level; the engine oil Store coolant out of the reach of chil- The coolant water must satisfy certain re-
change and filter replacement must dren. quirements which are not always fulfilled
therefore be carried out at shorter in- by drinking water.
tervals.
If the water is not of sufficient quality, it
Only use engine oils of the same quality must be treated.
grade and SAE class when topping up.
i
Information is available from any
Mercedes-Benz Service Centre.
66
Operation
Service products
Antifreeze/corrosion inhibitor Coolant mixing ratio: Disposal

Observe the following to prevent damage
Antifreeze pro- –37 approx.
to the cooling system:
tection down –45 Environmental note H
Only use an approved corrosion to °C
The coolants described are biodegradable
inhibitor/antifreeze. Information is Water % by vol. 50 45 substances. Observe the legal requirements
available from any Mercedes-Benz
Corrosion 50 max. 55 and waste water regulations in the country
Service Centre.
inhibitor/anti- concerned when disposing of used coolants.
When topping up (after a loss of cool- freeze % by vol. We recommend that you consult the rele-
ant), a corrosion inhibitor /antifreeze
vant local water authority for advice on the
4
concentration of 50% by volume must In exceptional cases, when no antifreeze / disposal of coolant.
be ensured (antifreeze protection down corrosion inhibitor is available and/or no
to –37 °C). Due to the complex tasks that a modern
antifreeze protection is required (in tropi-
coolant must perform, improper “recycling”
! cal zones), use an approved coolant addi-
consisting simply of mechanical pre-clean-
tive without antifreeze properties (see
If the concentration is too low, there ing must be categorically rejected.
Mercedes-Benz Specifications for Service
is a risk of engine damage as a conse-
Products).
quence of corrosion/cavitation.
!
Do not use an antifreeze/corrosion in- In this case, the coolant must be re-
hibitor concentration of more than 55% newed every year.
by volume (maximum antifreeze pro-
tection). Above this concentration, an- Information is available from any
tifreeze protection deteriorates and Mercedes-Benz Service Centre.
heat dissipation is less effective.
67
68
Maintenance
Maintenance instructions
Work schedule overview
Work schedules
69
Maintenance
Maintenance instructions
This section describes all maintenance The scope of maintenance and frequency
work to be carried out on the engine. Risk of accident G of maintenance work depend on the differ-
ent operating conditions and are listed in
Maintenance work that is carried out incor- the Maintenance Booklet.
Risk of injury G rectly or not at all, e.g. not changing the oil
Have work that is carried out confirmed
filter or not observing maintenance inter-
Before having maintenance or repair work with an entry in the Maintenance Booklet.
vals, can cause engine damage. Engine dam-
carried out, please make sure that you read This proof of regular maintenance is al-
age can lead to an increased risk of an acci-
the relevant sections of the technical docu- ways required for any warranty claims.
dent.
mentation relating to maintenance and re-
Please also observe the maintenance in-
pair measures, e.g.: Therefore, observe the notes on engine
structions for special accessories.
maintenance in these Operating Instruc-
Operating Instructions and workshop in-
tions. !
5 formation.
You should also familiarise yourself first with Change the engine oil filled at the fac-
the legal requirements, such as: i tory, which complies with Sheet 228.5
All maintenance intervals and main- of the Mercedes-Benz Specifications
health and safety as well as accident
prevention regulations. tenance work refer to genuine for Service Products, if more than
Mercedes-Benz parts and accessories 24 months have elapsed before the en-
You could otherwise fail to recognise dan- gine is operated for the first time.
that have been expressly approved
gers and could injure yourself or others.
for the engine by DaimlerChrysler.
70
Maintenance
Maintenance service Checking and correcting fluid level Additional work with every
Engine: If more fluid is lost than can be accounted for third maintenance service
Oil change and filter replacement by normal consumption, trace the cause and Fuel filter:
rectify it Replace filter
i Engine cooling system: Fuel prefilter with water separator:
For operation with diesel fuel: Check and correct fluid level and Replace filter element
Change the engine oil and replace the antifreeze/corrosion inhibitor concen-
oil filter at least every two years. tration i
If operated with FAME fuel (bio-diesel If operated with FAME fuel:
Additional work
fuel): Replace the fuel filter together with
Valve clearance:
Change the engine oil and replace the engine oil change and filter replace-
Check and adjust
oil filter at least once every year. ment. 5
i
Poly-V-belt: The valve clearance must be adjusted Engine brake*:
Check condition during the first maintenance service and Check condition and setting
then during the 3rd, 5th, 7th mainte- Coolant:
Checking for leaks and general condition nance services and so on. Renew
Check for points of abrasion and incorrect
i
positioning.
Renewal interval depends on the coolant
Engine: additive used (see Mercedes-Benz Speci-
Lines and hoses on the engine fications for Service Products).
Intake pipe between the air cleaner and
engine
Cooling and heating system
71
Maintenance
Work schedules
Engine: checking for leaks and Lines and hoses on the engine:
general condition checking for leaks and general Risk of injury G
Visual inspection of the engine for condition
There is a danger of limbs being caught, en-
signs of leakage. Visual and aural check for leaks from trapped, crushed or torn off by rotating en-
lines and hoses. Also check that all
Sealing points which are slightly damp can gine parts. Therefore you should:
lines and hoses are undamaged, routed
be ignored. Keep a safe distance between yourself
in such a way that there will be no chaf-
and rotating engine parts, including
! ing and secured correctly.
when the engine is being started.
More significant leaks involving con-
Wait until all engine parts have stopped
stant oil loss must be rectified immedi- Risk of injury G moving before carrying out any work on
ately. the engine.
5 The engine becomes very hot while it is run-
Wear work clothing which is fastened
ning and remains so for some time after it
and close-fitting. Wear a hair net if nec-
has stopped. It will cause burns upon con- essary. Remove jewellery such as
tact. watches and necklaces.
Before starting any work on the engine,
allow all engine parts to cool down or
wear suitable gloves and items of cloth-
ing to protect yourself against hot en-
gine components.
72
Maintenance
Work schedules
Engine: oil change and filter Oil filter replacement

replacement
i
Only change the engine oil when the
engine is at normal operating tempera-
ture.
Risk of injury G
Hot engine oil escaping under pressure can
scald your skin and eyes. 5
Wear suitable protective gloves, protective
clothing and safety goggles.
Oil filter
Oil filter on the engine 1 Cap
!
Unscrew oil filter cap 1 using the use 2 Sealing ring
Make sure that no foreign objects enter
of the socket spanner insert (WAF 36). 3 Oil filter element
the filter housing. Never wipe the filter
housing out because lint or dirt can en- Allow the oil to drain from the filter Unscrew oil filter cap 1 with oil filter
ter the oil circuit. housing. element 3 and unclip oil filter element
3 from the cap by pressing on the
sides of the bottom edge.
73
Maintenance
Work schedules
Replace sealing ring 2 on oil filter

cap 1 with a new one. The sealing ring
must be lightly greased.
Insert new oil filter element 3 into oil
filter cap 1 and press until it clips into
place.
Screw on cap 1 with the oil filter ele-
ment and tighten.
Tightening torque: 40 Nm.
Siphoning and draining engine oil

5
To siphon:
! 1 Dipstick 1 Oil drain plug

Observe the operating instructions for 2 Dipstick guide pipe
the engine oil extractor unit.
To drain:
Siphon off the engine oil through the
Place a suitable collecting receptacle
dipstick guide pipe.
under drain plug 1 on the underside of
To do this, pull out oil dipstick 1 and the oil sump.
insert an extractor unit sealed with an
Unscrew drain plug 1 carefully and al-
O-ring into dipstick guide pipe 2.
low the oil to drain out.
74
Maintenance
Work schedules
!
Environmental note H Keep the engine running at idling speed
until an oil pressure reading is dis-
Dispose of engine oil and filters in accord-
played. If no oil pressure is displayed
ance with the regulations in force where the
after approximately 10 seconds, switch
engine is operated.
off the engine. Determine the cause.
Screw the oil drain plug back in with a Check the oil filter and drain plug for
new sealing ring and tighten. leaks.
Stop the engine. Check the oil level af-
Adding engine oil ter approximately 5 minutes. Top up
the oil to the maximum mark on the 5
Add new engine oil to the engine via the dipstick if necessary.
oil filler opening 1 up to the maximum
mark on the oil dipstick. 1 Oil filler opening
Start the engine and run it at idling
speed (with the position sensor in the
idling position) and monitor the oil
pressure gauge.
75
Maintenance
Work schedules
Adjusting the valve clearance Special tools

Turning tool 904 589 04 63 00 Risk of accident G
Valve adjustment tool 422 589 00 11 00
If not properly secured, a vehicle might acci-
dentally be set in motion, knocking some-
Valve clearance:
body down or trapping them or causing an
accident and injuring you or others.
Intake valves = 0.40 mm
Always prevent the vehicle from rolling
Exhaust valve = 0.60 mm
away by applying the parking brake and,
if necessary, by placing chocks under
i the wheels.
Adjust the valve clearance when the Shift the transmission into neutral.
5 engine is cold (at least 30 minutes after Only turn the engine over using the rota-
stopping the engine, even if it was only tion device provided for this purpose.
operated for a brief period).
Clean very dirty cylinder head covers
Layout of cylinders and valves before removal.
= intake valve
= exhaust valve
= flywheel end
X
76
Maintenance
Work schedules
Removing and fitting the cylinder head Concluding work

covers After adjusting the valves:
Undo hexagon bolts 2 on cylinder Refit the cylinder head cover
head cover 1. ( see page 77).
Remove cylinder head cover 1. Remove the turning tool from the fly-
To refit, follow the instructions for remov- wheel housing inspection hole.
ing in the reverse order. Seal the inspection hole with the cap.
i
Valve clearance adjustment
OM 501 LA: page 78.
5
Valve clearance adjustment
Flywheel inspection hole OM 502 LA: page 79.
Unscrew the cap from the inspection
hole in the flywheel housing.
Fit turning tool 904 589 04 63 00 to
the flywheel housing inspection hole.
Cylinder head cover mounting
77
Maintenance
Work schedules
Valve clearance adjustment OM 501 LA
Engine Crankshaft position Cylinder/valves to be adjusted

1 2 3 4 5 6
OM 501 LA 5th cylinder valve overlap I /E E I E — I
6-cylinder 1st cylinder valve overlap — I E I I/E E
I – intake valve Checking and adjusting the valve clear- Measure the valve clearance between
E – exhaust valve ance the rocker arm and valve bridge using a
feeler gauge (arrow). It must be possi-
Adjust all valve clearances in 2 crankshaft ble to pull the feeler gauge through
positions. with only light resistance.
5
Use the turning tool to turn the crank- Loosen counternut 2 to permit ad-
shaft until the 5th cylinder is at overlap justment of the valve clearance. Adjust
TDC (1st cylinder in ignition TDC). Then the valve clearance by turning adjust-
move the 1st cylinder to overlap TDC ment screw 1.
(5th cylinder in ignition TDC).
Retighten the counternut; tightening
Check and adjust the valves in accord- torque 50 Nm.
ance with the table above.
Check the valve clearance again and
readjust if necessary.
1 Adjustment screw
2 Counternut
78
Maintenance
Work schedules
Valve clearance adjustment OM 502 LA
Engine Crankshaft position Cylinder/valves to be adjusted

1 2 3 4 5 6 7 8
OM 502 LA 6th cylinder valve overlap I/E E I I E — E I
8-cylinder 1st cylinder valve overlap — I E E I I/E I E
I – intake valve Checking and adjusting the valve clear- Measure the valve clearance between
E – exhaust valve ance the rocker arm and valve bridge using a
feeler gauge (arrow). It must be possi-
Adjust all valve clearances in 2 crankshaft ble to pull the feeler gauge through
positions. with only light resistance.
5
Use the turning tool to turn the crank- Loosen counternut 2 to permit ad-
shaft until the 6th cylinder is at overlap justment of the valve clearance. Adjust
TDC (1st cylinder in ignition TDC). Then the valve clearance by turning adjust-
move the 1st cylinder to overlap TDC ment screw 1.
(6th cylinder in ignition TDC).
Retighten the counternut; tightening
Check and adjust the valves in accord- torque 50 Nm.
ance with the table above.
Check the valve clearance again and
readjust if necessary.
1 Adjustment screw
2 Counternut
79
Maintenance
Work schedules
Fuel connections
80
Maintenance
Work schedules
Low-pressure fuel circuit Heated fuel prefilter with water

1 From the fuel tank separator*: replacing the filter
2 To the fuel pump element
3 To the fuel filter
4 To the unit pumps Risk of fire G
5 Return line to the fuel tank
6 Return line to the unit pumps There is an increased risk of fire when han-
dling fuels as they are highly flammable.
Avoid fire, naked flames and sparks, and re-
frain from smoking when handling fuels.
5
Dispose of used filter elements, seals and Heated fuel prefilter with water separator*
fuel residue in accordance with relevant lo-
1 Fuel hand pump
cal regulations.
2 Filter housing
3 Water separator
4 Water drain valve
81
Maintenance
Work schedules
Open water drain valve 4 and the i Replacing the fuel filter element
bleed screw. Collect the fuel/water
Run the engine for approximately
mixture from the filter element in a
container.
1 minute. The fuel system bleeds auto- Risk of fire G
matically. If the engine stalls or does
Unscrew filter housing 2. not start, bleed the fuel system manu- There is an increased risk of fire when han-
Unscrew water separator 3 from filter ally. dling fuels as they are highly flammable.
housing 2 and clean or replace as Avoid fire, naked flames and sparks, and re-
necessary. Start the engine, check the prefilter for frain from smoking when handling fuels.
leaks.
Refit in the reverse order. Use new
seals.
5 !
Screw filter housing 2 onto the filter Dispose of used filter elements, seals and
head tightly by hand. fuel residue in accordance with relevant lo-
cal regulations.
Close the drain valve and fill the prefil-
ter using fuel hand pump 1. Then
close the bleed screw.
Start the engine and bleed the fuel sys-
tem.
82
Maintenance
Work schedules
i Open the tank cap to prevent excess

pressure in the fuel tank.
The fuel prefilter is fitted on the ma-
chine or vehicle. Unscrew fuel filter cap 1 using the
socket spanner insert (WAF 36).
Observe the operating and mainte-
nance instructions in the machine / Pull cap 1 with the filter element out
vehicle operating instructions for the of filter housing 3 slightly. Allow the
fuel prefilter. fuel to flow out.
Remove the cap and filter element. Un-
clip the filter element by pressing the
sides of the lower edge of the filter ele-
ment.
5
!
Make sure that no foreign objects
enter the filter housing. Fuel filter element
Never wipe the filter housing out. 1 Cap

2 Sealing ring
The ingress of water must be pre- 3 Filter element
vented.
Replace sealing ring 2 with a new one
(grease lightly).
Clip new filter element 3 into cap 1.
Replacing the fuel filter element
1 Cap
83
Maintenance
Work schedules
Screw on cap 1 with filter element 3 i

and tighten.
To bleed the system manually, the ma-
chine or vehicle must be equipped with
Bleed the fuel system ( page 45) a hand pump, e.g. on a fuel prefilter.
Start the engine and bleed the fuel sys-
tem. Start the engine, check the fuel filter
for leaks.
!
Run the engine for approximately Environmental note H
1 minute. The fuel system bleeds auto-
matically. If the diesel fuel level (fuel tank) is above
5 If the engine stalls or does not start, engine height, the feed line must be closed
bleed the fuel system manually. when the filter is replaced. Diesel fuel could
otherwise flow out.
Check the fuel filter for leaks with the
engine running.
84
Maintenance
Work schedules
Intake pipe between air cleaner and Poly-V-belt: checking condition Check the poly-V-belt for damage sec-
engine: checking for leaks and tion by section; to do this, turn the en-
gine or poly-V-belt gradually using the
general condition Risk of injury G turning tool until the chalk mark is
Check the rubber sleeves, intake pipes reached again.
and connection hoses for damage and Faulty poly-V-belts may tear and parts or all
leaks. of the belt may be thrown off, thereby caus- !
ing injury to others. Replace the poly-V-belt if one of the
Check the hose clamps, flanged joints
and intake manifold for firm seating. Always observe the specified mainte- damage patterns shown on the next
nance intervals for poly-V-belts. page is detected. For information on fit-
If damage is detected, replace the poly- ting and removing the poly-V-belt
V-belt concerned immediately. ( see page 87).
5
Special tools Remove the turning tool.
Turning tool: 904 589 04 63 00 Screw the cap back into the inspection
hole in the flywheel housing.
Fit the turning tool to the flywheel Tightening torque: 25 Nm.
housing inspection hole.
Make a chalk mark on the poly-V-belt.
85
Maintenance
Work schedules
Damage patterns
86
Maintenance
Work schedules
1 Condition as new (as reference: trape- Removing and fitting the poly-V-belt
zoidal ribs) Risk of injury G
2 One-sided wear: wedge-shaped ribs
3 Cord visible at the base of the ribs The tensioning device is spring-tensioned.
4 Ribs split When it is loosened or tightened, there is a
5 Transverse cracks in several ribs risk of injury from crushing or entrapment in
6 Rubber nodules at the base of the belt pretensioned parts.
7 Deposits of dirt or stones For this reason, always carry out work
8 Rib detached from the base of the belt on the tensioning device with extreme
9 Cord torn out at the side care.
a Outer cord frayed
b Transverse cracks on the back of the Make sure that the tool is handled cor-
rectly.
belt 5
c Transverse cracks in several ribs
Fit the clamping handle with 1/2" ex-
tension into the tensioning device.
Clamping handle with extension in the ten- Swing the tensioning pulley down and
sioning device remove the poly-V-belt.
Swing back the tensioning device.
87
Maintenance
Work schedules
Check that both the tensioning device

and the belt pulley are in perfect condi-
tion (e.g. check for worn bearings on
the tensioning device, tensioning pul-
ley and guide pulleys as well as for
wear on belt pulleys); replace parts if
necessary.
Lay the poly-V-belt (new) on all belt pul-
leys, except for the tensioning pulley
(see illustrations for poly-V-belt rout-
ing).
5 Swing the tensioning pulley down using
the lever, lay the poly-V-belt on the ten-
sioning pulley and swing the tensioning
pulley back. Poly-V-belt routing without refrigerant com- Poly-V-belt routing with refrigerant com-
pressor OM 501 LA/ OM 502 LA pressor OM 501 LA/ OM 502 LA
Remove the clamping handle and
check for correct seating of the poly-V- 1 Coolant pump pulley 1 Coolant pump pulley
belt on the belt pulleys. 2 Crankshaft pulley 2 Crankshaft pulley
3 Tensioning pulley (tensioning device) 3 Tensioning pulley (tensioning device)
4 Alternator 4 Refrigerant compressor pulley
5 Alternator
88
Maintenance
Work schedules
Engine brake*: checking condition Remove the wire circlip from the en-
and adjustment gine brake cylinder ball socket.
Prise off the ball socket from throttle
Checking condition valve lever 2 ball neck.
Check the engine brake cylinder, ball
neck and ball socket as well as the
throttle valve shaft for wear.
Check the throttle valve lever on the
throttle valve shaft for firm seating and
retighten the clamping screws if neces-
sary.
5
Lubricate the ball socket with the spec-
ified grease.
Press the ball socket back onto the ball Throttle valve lever in active position
neck, fit the wire circlip. 1 Retainer
2 Throttle valve lever
Throttle valve lever in inactive position
1 Retainer
2 Throttle valve lever
89
Maintenance
Work schedules
Checking adjustment Engine cooling system: checking

and correcting the fluid level and the Risk of poisoning G
i
antifreeze/corrosion inhibitor
When the engine brake is applied, There is a risk of poisoning if coolant is swal-
throttle valve lever 2 must make con- lowed.
tact with retainer 1 when the throttle Risk of injury G
Never swallow coolant.
valve lever is in its active position (cyl-
inder extended). The cooling system is pressurised. Hot cool- Never store coolant in containers nor-
ant can escape under pressure when the mally used for drinks.
The throttle valve lever must also make cooling system is opened and scald your Store coolant out of the reach of chil-
contact with the retainer when the en- skin and eyes. dren.
gine brake cylinder is in its inactive po-
Only open the cooling system at coolant
sition (cylinder retracted); if this is the
5 temperatures below 90 °C.
case the return spring pretension of the !
engine brake cylinder is adequate. Unscrew the sealing cap slowly and re-
lease any excess pressure completely Only use service products approved by
Check the position of the throttle valve before opening the cap fully. DaimlerChrysler (see specification for
shaft: when the engine brake is inac- Wear suitable protective gloves, protec- service products).
tive, the slot ( page 89, illustration on tive clothing and safety goggles when
left) must be vertical. When the engine handling coolant.
brake is in the active position, the slot
( page 89, illustration on right) must
be horizontal.
90
Maintenance
Work schedules
i ! Cooling and heating system:

Only check and correct the coolant lev- If the concentration is too low, there is checking for leaks and general
el when the coolant temperature is a risk of engine damage as a result of condition
below 50 °C. Check the antifreeze / corrosion/cavitation in the cooling
i
corrosion inhibitor concentration be- system.
The “Engine cooling system: checking
fore correcting the coolant level. Only
and correcting the fluid level and
use a prepared coolant with an anti- i antifreeze /corrosion inhibitor” opera-
freeze/corrosion inhibitor concentra-
Avoid antifreeze/corrosion inhibitor tion must have already been carried
tion of 50% by volume for topping up.
concentrations of more than 55% by out.
volume, otherwise maximum antifreeze
Open the engine cooling system cap
protection down to –45 °C will not be Carry out a visual inspection of the ra-
slowly, relieving the excess pressure. 5
achieved. Heat dissipation and anti- diator for leaks and damage.
Check the antifreeze/corrosion in- freeze protection deteriorate at higher
hibitor concentration using a testing concentrations. !
device. The specified antifreeze/ corro- If damage /faults are detected, repair
sion inhibitor concentration of 50% by Check the coolant level. the radiator or replace it.
volume is present if antifreeze protec- The cooling system is correctly filled if
tion is ensured down to –37 °C. If less the coolant reaches the mark in the fill- Check the radiator for external dirt.
antifreeze protection is displayed, cor- er neck. The fins must not be dirty.
rect the mixing ratio.
91
Maintenance
Work schedules
Check the radiators, coolant pump, en-

gine oil radiator and engine cap for Risk of injury G Risk of poisoning G
leaks.
The cooling system is pressurised. Hot cool- There is a risk of poisoning if coolant is swal-
Check that all cooling and heating sys-
ant can escape under pressure when the lowed.
tem lines and hoses are undamaged,
cooling system is opened and scald your Never swallow coolant.
that they are routed in such a way that
skin and eyes.
chafing is avoided and that they are se- Never store coolant in containers nor-
cured in accordance with regulations. Only open the cooling system at coolant mally used for drinks.
temperatures below 90 °C.
Store coolant out of the reach of chil-
Unscrew the cap slowly and release any dren.
excess pressure completely before
opening the cap fully.
5
Wear suitable protective gloves, protec-
tive clothing and safety goggles when
handling coolant.
92
Maintenance
Work schedules
Remove the coolant expansion tank

cap.
Fit the pressure tester.
Connect the compressed-air hose with
tyre inflator connection to the valve
and build up a test pressure equal to
the cooling system opening pressure.
i
The cooling system opening pressure
can be determined from the code on
the cap or pressure relief valve. 5
Example: code 70 = 0.7 bar overpres-
sure.
Pressure tester special tool
The cooling system pressure tester has
i a built-in pressure relief valve so that
Special tool: a pressure of 1.2 bar cannot be ex-
ceeded.
Pressure tester 001 589 83 21 00
On heating systems: open the regulat-

ing valves and shut-off valves.
93
Maintenance
Work schedules
Renewing coolant Draining coolant

Risk of poisoning G
Risk of injury G There is a risk of poisoning if coolant is swal-
lowed.
The cooling system is pressurised. Hot cool-
ant can escape under pressure when the Never swallow coolant.
cooling system is opened and scald your Never store coolant in containers nor-
skin and eyes. mally used for drinks.
Only open the cooling system at coolant Store coolant out of the reach of chil-
temperatures below 90 °C. dren.
Unscrew the cap slowly and release any
5 excess pressure completely before !
opening the cap fully. Only use antifreeze /corrosion inhibitor
Wear suitable protective gloves, protec- approved by Mercedes-Benz, (see
tive clothing and safety goggles when specifications for service products).
handling coolant. Coolant drain plug
i Open the engine cooling system cap
Before renewing the coolant, check the slowly, relieving the excess pressure,
cooling and heating system for leaks and remove it.
and condition. Have the coolant renew- On heating systems: open the heating
al confirmed in the Maintenance Book- temperature selectors (regulating
let. valves).
94
Maintenance
Work schedules
Connect the drain hose to the coolant Clear blocked drainage openings of de- i
drainage connection on the radiator posits.
Observe any further information in the
and drain the coolant. Fit a new seal to the coolant drain plug operating instructions from the ma-
Unscrew coolant drain plug 1 from on the engine and retighten. chine /vehicle manufacturer.
the engine block and collect the cool- Fit additional drain plugs (without hose
ant in a suitable receptacle. connections) with new seals and screw
i them in tight.
First cover the lines, etc., under the
Adding coolant
drain plugs and place a suitable recep-
tacle underneath, large enough to col- Start the engine and run it at varying
lect the amount of coolant in the en- speeds for approximately 1 minute.
gine. 5
Add coolant of the specified composi-
tion until it reaches the lower edge of
the filler neck.
Switch off the engine and seal the cool-
Dispose of used coolant in accordance with ing system again.
prevailing local regulations
( see page 67).
95
96
Practical advice
Malfunctions, causes and solutions
Jump-starting
97
Practical advice
While careful operation and maintenance

of the engine are essential, it is also impor- Risk of accident G
tant that malfunctions be remedied in
good time. You will find further information Maintenance and repair work to the engine
on the measures described under “Solu- carried out incorrectly can cause engine
tion” in the “Maintenance” or “Tests and damage. Engine damage can lead to an in-
other work for remedying problems” sec- creased risk of accidents.
tions. Maintenance and repair work on the engine
You can rectify certain faults yourself may only be carried out by personnel who
( page 99). have undergone the appropriate training.
Have faults that you cannot remedy your- Always have work on or modifications to the
self rectified at a qualified specialist work- engine carried out at a qualified specialist
shop. workshop which has the necessary special-
6 DaimlerChrysler recommends that you use quired.
a Mercedes-Benz Service Centre for this
purpose as it has the necessary specialist Mercedes-Benz recommends that you use a
knowledge and tools for the work required. Mercedes-Benz Service Centre for this pur-
In particular, work relevant to safety or on pose.
safety-related systems must be carried out
at a qualified specialist workshop.
98
Practical advice
General troubleshooting
Malfunction Cause Solution

Starter pinion does not turn or turns too Battery is not sufficiently charged Charge the battery
slowly Connecting cable to the starter motor is Tighten the cable on the terminal. If
loose necessary, solder on a new terminal
Starter motor solenoid switch malfunction Have it checked at a qualified special-
or starter motor malfunction ist workshop
Engine does not start or stalls again Fuel tank empty Refuel
immediately Fuel filter blocked Replace the filter element ( page 82)
Water separator, prefilter or fuel filter Clean/replace
blocked
Fuel system or filter leaking Replace the seals
6
Fuel not resistant to cold Clean the prefilter ( page 81),
Replace the fuel filter
Use winter fuel ( page 61)
99
Practical advice

Engine does not start or stalls again imme- Incorrect engine oil viscosity Alter the engine oil viscosity to the con-
diately ditions of use
Engine starts poorly MR (engine control) unit malfunction Read out the MR (engine control) unit,
have it checked at a qualified specialist
workshop
Leaks or insufficient pressure in the low- Check for leaks (visual check); have
pressure fuel circuit the pressure tested at a qualified spe-
cialist workshop
Engine stops inadvertently MR (engine control) unit malfunction Have it checked at a qualified special-
(total failure) ist workshop
Power supply to the MR/ADM control Have it checked at a qualified special-
units interrupted or short circuit in wiring ist workshop
6
Leaks or insufficient pressure in the low- Check for leaks (visual check); have
pressure fuel circuit or a fuel delivery the pressure tested at a qualified spe-
pump drive malfunction cialist workshop
100
Practical advice

Engine in emergency running mode Data flow interruption MR/ADM control Read out the malfunction memory of
units the control units and have them
checked at a qualified specialist work-
shop
Engine surges, vibrates or runs irregularly Crankshaft position sensor or camshaft Visit a qualified specialist workshop
position sensor faulty or no signal
Malfunction in the fuel system Read out the fault code, have it
checked at a qualified specialist work-
shop
Poor engine output (lack of power) Air cleaner dirty or blocked Replace the air cleaner element
Charge-air temperature too high due to Clean the outsides of the charge-air
dirty charge-air cooler or radiator cooler and radiator
6
Coolant temperature too high Check temperature sensor and replace
if necessary, check fan speed; visit a
qualified specialist workshop
Fault in the fuel system (blocked, leaking) Visual check for leaks; visit a qualified
specialist workshop
101
Practical advice

Poor engine output (lack of power) Charge-air system not tight, hose clamp on Check for tightness at a qualified spe-
charge-air hose loose or faulty cialist workshop
Charge-air pressure sensor malfunction Check with diagnostic equipment and
replace if necessary; visit a qualified
specialist workshop
Engine brake flap* is faulty or stuck Function test or visual check
Interruption in tractive power Increased voltage drop to MR/ADM con- Check the battery terminal clamps and
trol unit (loose contact) the connectors on the MR/ADM con-
trol unit for firm seating and corrosion
Poor engine braking power Engine brake flap* malfunction or fault in Function test/visual check; visit a
the control qualified specialist workshop
Fuel consumption too high Connection points (unit pump – line and Check for tightness at a qualified spe-
6
injectors) leaking cialist workshop
Misfiring Have the engine checked at a qualified
specialist workshop
102
Practical advice

Engine cuts-off too early (maximum engine FR or ADM control unit defective or incor- Visit a qualified specialist workshop
speed cannot be reached) rectly programmed
Engine gets too hot (according to coolant Not enough coolant in the cooling system Top up, bleed ( page 95)
temperature gauge) Coolant temperature sensor or display Replace sensor or display
faulty
Poly-V-belt damaged See “Replacing the poly-V-belt”
( page 87)
Fan does not switch on correctly Visit a qualified specialist workshop
Radiator dirty on inside or choked with Clean or remove limescale
limescale; radiator very dirty on outside
Thermostat malfunction Check, replace if necessary; visit a
qualified specialist workshop 6
103
Practical advice

Charge current indicator lamp does not Bulb defective or supply line interruption Replace bulb or repair interruption
light up while the engine is not running
Charge current indicator lamp lights up Poly-V-belt too slack Check belt tensioner for proper opera-
when the engine is running tion
Poly-V-belt torn Replace the poly-V-belt ( page 87)
Alternator or regulator malfunction Check; visit a qualified specialist work-
shop
Engine emits black smoke Air cleaner dirty or blocked Replace the air cleaner element
Engine brake faulty Visit a qualified specialist workshop
Turbocharger faulty Visual check; visit a qualified specialist
workshop
6 Misfiring, injector faulty Visit a qualified specialist workshop
104
Practical advice

Exhaust fumes are blue Oil level in the engine too high; crankcase Correct the oil level, have the crank-
ventilation system faulty, engine oil enter- case ventilation system checked at a
ing combustion chamber qualified specialist workshop
Exhaust fumes are white Coolant entering combustion chamber Locate damaged cylinder using pres-
sure loss test; visit a qualified special-
ist workshop
Engine “knocks” Misfiring Visit a qualified specialist workshop
Knocking noise from the bearings Bearing damage Visit a qualified specialist workshop
Abnormal noises Leaks in intake pipe and exhaust pipe Repair leaks, replace seals if necessary
causes whistling noise
Turbine or compressor wheel is scraping Have the exhaust gas turbocharger
the housing; foreign objects in the com- checked at a qualified specialist work-
6
pressor or turbine; seized bearing in rotat- shop
ing parts
Valve clearance too great Check the valve clearance, adjust if
necessary
105
Practical advice
Jump-starting
If the battery is discharged, the engine can !

be started using jump leads and a donor Risk of explosion G When jump-starting the engine, the
battery.
maximum on-board voltage of 28 V
Gases leaking from batteries may explode
must not be exceeded (as this would
and therefore cause injury.
Risk of injury G cause electronic damage to the control
Fire, naked flames, smoking and sparks are unit).
The acid contained in batteries burns skin therefore not permitted in the vicinity of the
and eyes on contact. batteries. Connect the positive terminals first and
Do not allow acid to come into contact then the negative terminals of the bat-
with your skin, eyes or clothing. ! tery.
Wear suitable protective clothing, as Make sure that the batteries have the Start the engine ( see page 49) and
battery acid can burn through normal same nominal voltage. A battery could run it for a short while.
clothing. In addition, protective gloves otherwise be irreparably damaged.
and safety goggles should be worn. Remove the jump leads in the reverse
6 Do not place any metal objects on the order.
Rinse acid splashes off immediately with
batteries. There is a risk of short cir-
clean water and consult a doctor if nec-
essary.
cuit.
Only use insulated jump leads (cable
cross section approximately 70 mm 2)
and insulated terminal clamps. There is
a risk of short circuit.
A discharged battery can freeze at
about –10 °C; it must have thawed out
before jump-starting.
106
Technical data
Engine data
Test values and adjustment values
Tightening torques
107
Technical data
Engine data
Dimensions
(standard version, other versions on re-
quest)
OM 501 LA
A = Engine length 1,160 mm
B = Engine width 1,020 mm
C = Engine height 1,130 mm
OM 501 LA OM 501 LA
108
Technical data
Engine data
OM 502 LA
(2 turbochargers)
OM 502 LA (2 turbochargers) OM 502 LA (2 turbochargers)
109
Technical data
Engine data
OM 502 LA
(1 turbocharger)
OM 502 LA (1 turbocharger) OM 502 LA (1 turbocharger)
110
Technical data
Engine data
Weights
OM 501 LA OM 502 LA (2 turbochargers) OM 502 LA (1 turbocharger)

Engine, 885 kg 1,125 kg 1,125 kg
without fluids
Engine, with fluids 935 kg 1,180 kg 1,180 kg
General data
OM 501 LA OM 502 LA
Type V-engine with exhaust gas turbocharger and intercooler
Type of cooling system Forced circulation cooling
Combustion principle 4-stroke diesel direct injection
Number of cylinders 6 8
Cylinder bore 130 mm
Piston stroke 150 mm
Displacement 11,946 cm 3
15,927 cm3 7
Direction of rotation of engine when looking at flywheel side of Anti-clockwise
engine
Starter Electric
Coolant capacity of engine without intercooler 16.5 l 20 l
Engine oil capacity including oil filter minimum 28 litres; minimum 30 litres;
maximum 34 litres maximum 38 litres
111
Technical data
Engine data
Data: Starter motor, battery and

alternator (standard)
Starter motor
Voltage 12 /24 V
Output 6.2 kW
Battery (not in scope of delivery)
Voltage 12 /24 V
Cold test current in accordance with DIN 72311 maximum 700 A
Cold start ability without jump-starting and 75% battery charge down to maximum –20 °C
Alternator
Voltage 28 V
Current rating 35 /80 A
112
Technical data
Engine oil pressure (minimum)
at idling speed ≥ 0.5 bar

at rated speed ≥ 2.5 bar
Valve clearance
Intake valve 0.4 mm

Exhaust valve 0.6 mm
113
Technical data
Tightening torques
i
All threads on mechanical parts and re-
lated contact surfaces must be clean,
smooth and lubricated with engine oil;
other lubricants require significantly
different tightening torques.
All tightening torques are specified in
Nm and apply for the OM 501 LA and
for the OM 502 LA.
Engine block Nm
Bolt securing cylinder head cover to the cylinder head 20
Bolt securing light-alloy oil sump to the crankcase 55
Bolt securing alternator/tensioning pulley support to the crankcase 160
Bolt securing tensioning pulley to the support
7
Thread M 10 50
Thread M 18 105
114
Technical data
Tightening torques
Fuel/injection system Nm
Injection line to the unit pump pressure pipe connection 35
Banjo bolts for fuel lines
Thread M 16x1.5 50
Thread M 8x1 15
Cap to the fuel filter housing 25
Starter motor/alternator Nm
Starter motor to the timing case 80
Alternator support to the cylinder crankcase 160
115
Technical data
Tightening torques
Oil circuit Nm
Oil drain plug to the light-alloy oil sump
Thread M 20x1.5 60
Thread M 26x1.5 80
Oil filter/oil radiator to cylinder crankcase 50
Oil filter cap to the oil filter housing 40
Screw securing cap to the oil separator 6
Cooling circuit Nm
Coolant line with thermostat valve to the coolant pump 25
Coolant pump to the cylinder crankcase 30
Belt pulley to the coolant pump hub 25
7 Valve adjustment Nm
Counternut to the rocker arm adjustment screw 50
116
Index
A D F
Adaptation module . . . . . . . . . . . . . . 32 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . 61 FAME
Adjusting the valve clearance . . . . . 76 Diesel fuels Fuels . . . . . . . . . . . . . . . . . . . . . . . . 63
OM 501 LA . . . . . . . . . . . . . . . . . . . . 78 In extremely cold weather . . . . . . . . 61 Flow improvers . . . . . . . . . . . . . . 61, 62
OM 502 LA . . . . . . . . . . . . . . . . . . . . 79 Sulphur content . . . . . . . . . . . . . . . . 61 FR (drive control) unit . . . . . . . . . . . . 32
ADM . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Dimensions . . . . . . . . . . . . . . . . . . . 108 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Antifreeze/corrosion inhibitor . . . . 67 Disposal of service products . . . . . . 67 Refuelling . . . . . . . . . . . . . . . . . . . . . 45
Fuel additives . . . . . . . . . . . . . . . . . . 61
B E Fuel system
Battery . . . . . . . . . . . . . . . . 45, 106, 112 Emergency running program . . . . . . 29 Bleeding . . . . . . . . . . . . . . . . . . . . . . 45
Bio-diesel . . . . . . . . . . . . . . . . . . . . . . 63 Engine Fuels
Checking for leaks Diesel . . . . . . . . . . . . . . . . . . . . . . . . 61
C and general condition . . . . . . . . . . . 72 FAME . . . . . . . . . . . . . . . . . . . . . . . . 63
Charge current . . . . . . . . . . . . . . . . . 51 Cleaning . . . . . . . . . . . . . . . . . . . . . . 56
Conversion parts Oil change and filter replacement . . 73 G
and modifications . . . . . . . . . . . . . . . 40 Starting . . . . . . . . . . . . . . . . . . . . . . 49 Genuine Mercedes-Benz parts . . . . . 42
Coolant . . . . . . . . . . . . . . . . . . . . . . . . 66 Stopping . . . . . . . . . . . . . . . . . . . . . . 53
Mixing ratio . . . . . . . . . . . . . . . . . . . 67 Engine brake . . . . . . . . . . . . . . . . . . . 29 H
Renew . . . . . . . . . . . . . . . . . . . . . . . 94 Checking condition and High-pressure cleaners . . . . . . . . . . 57
Coolant level . . . . . . . . . . . . . . . . . . . 91 adjustment . . . . . . . . . . . . . . . . . . . . 89
Cooling system I
Engine data . . . . . . . . . . . . . . . . . . . 108
Cleaning . . . . . . . . . . . . . . . . . . . . . . 57 Installation . . . . . . . . . . . . . . . . . . . . . 35
Engine data card . . . . . . . . . . . . . . . . 26
Degreasing . . . . . . . . . . . . . . . . . . . . 59 Intake pipe
Engine oil
Checking for leaks . . . . . . . . . . . . . . 85
Cylinder head cover SAE classifications . . . . . . . . . . . . . . 65 8
Removing and fitting . . . . . . . . . . . . 77 Siphoning, draining . . . . . . . . . . . . . 74 J
Engine plate . . . . . . . . . . . . . . . . . . . . 24 Jump-starting . . . . . . . . . . . . . . . 38, 106
Environmental note . . . . . . . . . . . . . . 5
117
Index
K P T
Kerosene . . . . . . . . . . . . . . . . . . . 61, 62 Personnel . . . . . . . . . . . . . . . . . . . . . . 33 Telligent® engine system . . . . . . 32, 51
Poly-V-belt Test values and adjustment
L Checking condition . . . . . . . . . . . . . 85 values . . . . . . . . . . . . . . . . . . . . . . . . 113
Location of sensors . . . . . . . . . . . . . 22 Removing and fitting . . . . . . . . . . . . 87 Tightening torques . . . . . . . . . . . . . 114
Routing . . . . . . . . . . . . . . . . . . . . . . . 88 Transport . . . . . . . . . . . . . . . . . . . . . . 34
M
Protection of the Transport and installation . . . . . . . . 34
Maintenance instructions . . . . . . . . 70
environment . . . . . . . . . . . . . . 5, 33, 40 Troubleshooting . . . . . . . . . . . . . . . . 98
Maintenance intervals . . . . . . . . . . . 44
Protective treatment . . . . . . . . . . . . 59 Cause . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance service . . . . . . . . . . . . . 71
General . . . . . . . . . . . . . . . . . . . . . . . 99
MR (engine control) unit . . . . . . . . . . 30 R Solution . . . . . . . . . . . . . . . . . . . . . . 99
Renewal interval Type designation . . . . . . . . . . . . . . . . 26
O
Engine oil . . . . . . . . . . . . . . . . . . . . . 71
Oil filter replacement . . . . . . . . . . . . 73
Oil filter . . . . . . . . . . . . . . . . . . . . . . 71 W
Oil pressure . . . . . . . . . . . . . . . . . . . . 52
Replacing the fuel filter element . . . 82 Warranty entitlement . . . . . . . . . . . . 60
Operating safety . . . . . . . . . . . . . . . . . 6
Water . . . . . . . . . . . . . . . . . . . . . . . . . 66
Overview S Winter operation . . . . . . . . . . . . . . . . 54
OM 501 LA . . . . . . . . . . . . . . . . . . . . 10 Safety and emergency running Work schedules . . . . . . . . . . . . . . . . . 78
OM 502 LA (1 turbocharger) . . . . . . 18 program . . . . . . . . . . . . . . . . . . . . . . . 29
OM 502 LA (2 turbochargers) . . . . . 14 Safety precautions . . . . . . . . . . . . . . 38
Service products . . . . . . . . . . . . . 60, 67
Special lubricant additives . . . . . . . . 60
8 Starter motor . . . . . . . . . . . . . . . . . . 112
Starting the engine for the
first time . . . . . . . . . . . . . . . . . . . 44, 46
Starting using a donor battery . . . 106
118

Manual Serie 500 Parte 1

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Continuation symbol for a warning

page Page reference

-> Term in the glossary of technical

Display Displays in the multi-function

i Please also refer to the index ( page 117) Introduction 3 Safety

Fuel consumption and engine wear depend

The operating safety of an engine primarily

OM 502 LA with two turbochargers

OM 502 LA with one turbocharger

1 Oil level sensor 1

Information on the engine

1 Engine model designation

1 OM 501: 6 cylinder, OM 502: 8 cylinder

Engine data card Engine data card

Description of the engine The engines produce particularly low emis-

The flame-start system is only enabled if

Following the preglow time, which is de-

Engine brake* /constantly-open The engine brake always remains deacti-

MR (engine control) unit

This data is evaluated along with data from i

Organisational measures All universally applicable, country-specific,

The Operating Instructions and Mainte-

The safety precautions in this section must ! !

The warranty does not cover damage aris-

Tampering with the engine to modify it can

Electronic system warning lamp

Preparation Adding coolant

Starting the engine for the first time i

Risk of injury G Risk of injury G Risk of poisoning G

i Check the engine oil level approximate-

Starting the engine i

the flame-start system indicator lamp

Start/ stop buttons sudden, unusual noises from the

The following points should be observed at Jump-starting Coolant

Cleaning the engine !

High-pressure cleaners Cleaning the cooling system

Special lubricant additives are not neces-

Greases and lubricants must be com-

SAE engine oil classes

The oil change intervals will change if en- Coolant !

Antifreeze/corrosion inhibitor Coolant mixing ratio: Disposal

Engine: oil change and filter Oil filter replacement

Replace sealing ring 2 on oil filter

Siphoning and draining engine oil

! 1 Dipstick 1 Oil drain plug

Adjusting the valve clearance Special tools

Removing and fitting the cylinder head Concluding work

Cylinder head cover mounting

Valve clearance adjustment OM 501 LA

Engine Crankshaft position Cylinder/valves to be adjusted

Valve clearance adjustment OM 502 LA

Engine Crankshaft position Cylinder/valves to be adjusted

Low-pressure fuel circuit Heated fuel prefilter with water

i Open the tank cap to prevent excess

Never wipe the filter housing out. 1 Cap

Screw on cap 1 with filter element 3 i

Check that both the tensioning device

Throttle valve lever in inactive position

Checking adjustment Engine cooling system: checking

i ! Cooling and heating system:

Check the radiators, coolant pump, en-

Remove the coolant expansion tank