Daimler Chrysler Nm5m Engine Mechanics Series 500

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NM5M • Engine Mechanics Series 500

As at 04/03

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This document is intended solely for use in training and is not subject to regular updating.

Printed in Germany Note:

 2001 Copyright DaimlerChrysler AG The term »employees« does not imply any preference
of gender and incorporated male and refers to maler
Publisher: Global Training and female employees alike.
This document with all its sections is protected under the laws of copyright. Its use for any purpose whatsoever
requires the prior written consent of DaimlerChrysler AG. This applies in particular to its reproduction, distribution,
modification, translation, recording on microfilm or storage and/or processing in electronic systems, including
databases and on-line services.

1510 2995 02 - 1st edition 09.99

nd
2 edition modified 04.03 140
 Contents 26.04.2003

Page Title
1 Description of Training Code NM5M - MM 226
2 Concept of EURO 3 of series 500 and series 900
4 Cylinder heads engine series 500 Euro 2/Euro 3
5 Cylinder head engine series 500
8 Cylinder liners Euro 2, Euro 3
10 Oil pan engine series 500
12 Pistons engine series 500: Euro 2 and Euro 3
13 Valve gear engine series 500: modifications
14 Valve seat rings engine series 500
15 Fuel prefilter with heated water separator, code K81
17 Modified charge air combination sensor
18 Exhaust plenum chamber Engine Series 500
19 Dual pipes to the turbocharger engine series 500
20 Modified MR characteristic curve - Engine protection function
21 Fan drive and fan systems
24 Electromagnetic fan drive (Linnig clutch) ENGINE 541, 542 with CODE MZ5
28 Assignment of galleries in cylinder head gasket engine series 500
29 Cylinder head sealing surfaces
30 Attachment of cylinder head engine series 500

10/01 NM5M • Engine Mechanics Series 500

Contents I 1
 Page Title
33 Sealing of nozzle holder combination / protective sleeve
34 Nozzle protective sleeve engine series 500
35 Cylinder liners engine series 500
40 Crankshaft engine series 500
43 Crankshaft bearing and crankshaft assembly
46 Crankshaft - Gaging journals and bearings engine series 500
48 Removing, installing camshaft engine series 500
50 Piston projection engine series 500
51 Valve setback engine series 500
52 Sealing of unit pump solenoid engine series 500
53 Installing charge air manifold engine series 500
55 Turbocharger
56 Compressor engine series 500
57 Oil spray nozzle engine series 500
59 Oil pan engine series 500
61 Connecting rod engine series 500
63 Crankshaft sealing engine series 500
64 Repairing flywheel
65 Checking valve lift engine series 500
66 Valve bridges engine series 500
67 Valve clearance
68 Crankcase ventilation system engine series 500

10/01 NM5M • Engine Mechanics Series 500

Contents I 2
 Page Title
70 Real fuel circuit engine series 500
71 Fuel circuit in crankcase - Functions
72 Fuel filter housing engine series 500
73 Symbolical fuel circuit Engine Series 500
75 Fuel pressure test Engine Series 500
77 Possible symptoms at fuel circuit of engine series 500
80 Replacing fuel filter and fuel prefilter
82 Poor fuel quality
83 Service intervals
84 Removing unit pumps
85 Installing unit pump engine series 500
87 Classification of unit pumps
89 Engine tests
91 Charge pressure
93 Inspecting charge air cooler and charge air hoses for leaks
94 Testing charge pressure
96 Analysis of charge pressure tolerance band
100 Inspecting compressor for oil discharge
102 Fault symptoms constant throttle
103 Components oil circuit Engine Series 500
104 Oil cooler- oil filter case Engine Series 500
105 Priming of the lubrication system BR 500

10/01 NM5M • Engine Mechanics Series 500

Contents I 3
 Page Title
107 Engine Oil circuit Series 500
108 Cleaning Main Oil Channels
109 ACTROS oil level sensing
110 Coolant circuit engine series 500
111 3-chamber expansion reservoir
112 Thermostat in coolant circuit
115 Installation of thermostat engine series 500
116 Inspecting cooling system for leaks
118 Degreasing, descaling cooling system
119 Coolants
121 Fan drives and fan systems
122 Features of viscous fan clutch and electromagnetic fan clutch
123 Operating stages of Linnig fan clutch
124 Electromagnetic fan control (Linnig) ENGINE 541, 542 with CODE MZ5
127 Entry test to NM5M

10/01 NM5M • Engine Mechanics Series 500

Contents I 4
 Description of Training Code NM5M - MM 226 26.10.2001

Target group: Mechanics

Requirements: The participant has taken part in the Basic Training "Electrical and Electronic Systems - Diagnosis - NEB1".
He has worked through the CBT Programs "Pump-line-nozzle (PLD) Part 1+2" or has available equivalent
knowledge.
He has successfully worked through the preliminary training sent out in advance.
Development stage: 2
Split between practical/theoretical: 70% / 30%
Duration/Location: 2 days, Esslingen-Brühl, mobile
Objectives of course: The participant is able to:
− pinpoint faults of mechanical engine components.
− determine condition of engine components and plan and understand the repair procedures required
using WIS.
− state and describe the extent and contents of the modifications and new features of series 500.

Contents: − Initial test

− Info part in the case of engine series 500
− Training the mechanical design of engine series 500 including practical fault diagnosis
and repair work on mechanical engine components as well as on the fuel system
(two work stations: "Engine" and "Vehicle")

10/01 NM5M • Engine Mechanics Series 500

Description of Training Code NM5M - MM 226 1
 Concept of EURO 3 of series 500 and series 900 26.10.2001

General

DaimlerChrysler is represented worldwide with a very large range of cars and 10.1999 10.2000 10.2001 10.2005
commercial vehicles, and engines, and has committed itself to environmental
protection as a global corporate objective. That is why the aim of the EURO 2
company is always to implement environmentally-relevant legislation and
EURO 3
regulations at the earliest possible date in order to be able to offer customers EURO 3 ...
low-emission vehicles and engines in advance of the statutory date of
... möglicher
implementation. Subventionsbeginn

In advance of EURO 3 emission regulations vehicles fitted with engine ... gültig für Typprüfung
OM 501 LA were offered as optional equipment, initially from 10/99, in the
two power stages of 313 hp/394 hp, in a restricted vehicle program, which Verfügbarkeit der
Baureihe 900
already comply with the limits which come into effect from 10/2001. Mercedes-Benz
EURO3-Motoren
... alle Neuzulassungen
Baureihe 500
als SA

With effect from 01/2000 practically all engines for the ACTROS and ATEGO EURO 4
are available in EURO 3. ECONIC as of approx. 04/2000. EURO 4 ...

... frühestmöglicher
Subventionsbeginn

.PPT

10/01 NM5M • Engine Mechanics Series 500

Concept of EURO 3 of series 500 and series 900 2
Modifications

Engine 541, 542 with essential modifications at the vehicle side:

∗ Improved cooling module, the system area and block depth are enlarged at the charge air cooler and radiator
∗ Inlet air flow
∗ Exhaust system
∗ Noise encapsulation
∗ Cab mounting of M, L and LH cab

Code MS3:
∗ Conversion of nozzle holder combinations from 8- to 6-hole nozzles
∗ Increase in compression ratio from (ε) 17.25:1 to (ε) 17.5:1
∗ Telligent engine management with extended functions
∗ Modified unit pumps
∗ Camshaft with optimized cam shape for unit pumps
∗ Optimized inlet valve seat rings and inlet valves

Engine 904, 906 with essential modifications at vehicle side:

∗ Improved cooling module, charge air cooler and radiator enlarged

Code MS3:
∗ Conversion of nozzle holder combinations from 8- to 6-hole nozzles
∗ Increase in compression ratio from (ε) 17.4:1 to (ε) 18.0:1 as a result of modified piston recess shape
∗ Telligent engine control with enlarged functions
∗ Rated engine speed reduced from 2300 rpm to 2200 rpm
∗ Optimized mechanical oil separator

10/01 NM5M • Engine Mechanics Series 500

Concept of EURO 3 of series 500 and series 900 3
Daimler Chrysler Nm5m Engine Mechanics Series 500
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Cylinder heads engine series 500 Euro 2/Euro 3 26.10.2001

Old version of cylinder head, as at 04/99 N01.30-2065-11 Cylinder head in Euro 3 version N01.30-2064-11

The deck surfaces of the previous Euro 2 version were milled.
Since 2000, as part of the "Euro 3" package of measures, the deck surfaces
of the cylinder heads are turned to defined surface finish.
This modification has been implemented as of 06/2000 also for all V8 and
for the 315 kW V6 engines conforming to Euro 2, as of January 2001 also
for all other V6 engines.
The new cylinder heads must be faced only by surface grinding down to a
minimum head height of 113.5 mm. The surface finish (peak-to-valley height
and waviness) must be maintained in all cases.
Refer also to Work Instruction AR 01.30-W-7162B (06/04/2000).

10/01 NM5M • Engine Mechanics Series 500

Cylinder heads engine series 500 Euro 2/Euro 3 4
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