45111495 Engine Repair

Trucks • Drive train Mechanical Engine Components Model Series 457, 500, 900 Advanced Training


As at 09/07

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

Note: The term »employees« does not imply any preference of gender and incorporated male and refers to maler and female employees alike.

Printed in Germany

© 2007 Copyright DaimlerChrysler DaimlerChrysler AG Publisher: Global Training 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.

1511

1284

02

-

3rd Edition

09/07

156

As at 28.09.2007

09/07

Oil Circuit Model Series 500 - Location of Components; Exercise ................................................................................................................................................. 140 Oil Circuit Model Series 500 - Task and Function; Exercise ............................................................................................................................................................ 141 Oil Circuit Model Series 900 - Location of the Components; Exercise ............................................................................................................................................ 142 Oil Circuit Model Series 900 - Task and Function; Exercise ............................................................................................................................................................ 143 Oil Filter Housing, Model Series 900 - Location of Components; Exercise...................................................................................................................................... 145

09/07


09/07


Training Course Description NMXM - MM247

28.09.2007

Course designation

Trucks• Mechanical Engine Components • Model Series 457, 500, 900 • Repair • Advanced Training

Target group

Drive train repair technician

Requirements

The participants have completed the preliminary training and successfully passed the initial test. The relevant knowledge can be acquired in the CBTs "Pump-Line-Nozzle Parts 1 – 2" and "Engine Model Series 500, 900 and 457, Parts 1 – 2" together with the shipped preliminary training.

Level

Run

Method

20% theory, 80% practical work

Duration

4.5 days DCVD

Objectives

The participant can:

Contents

09/07

•

Locate malfunctions in mechanical engine components.

•

Diagnose components and plan and understand necessary repair work using WIS.

•

Mechanical structure of the model series 457, 500, 900 engines

•

Partial disassembly of the engines

•

Fault diagnosis, repair work on the components - mechanical engine components (crank assembly, valve assembly,...), oil circuit, fuel circuit, charge air system and compressor system in the model series 457, 500 and 900 engines.


Agenda for Training Course NMXM - MM247

28.09.2007

Temporal Sequence

Day

Available time

1st day

0:45 h

Training room: Welcome, initial test

1:15 h

Training room: Introduction to the SCR system function, assignment to work groups

4:00 h

Group A

Model series 457 engine: Workshop Display <> Model Series 457

0:30 h

2nd day

4:00 h

Feedback Presentation of modifications/new features on the engines with EURO 4/5, knowledge comparison Model series 457 engine: Workshop Display <> Model Series 457

0:30 h

09/07


Comparison / queries

0:15 h 1:45 h

Group B




Day

Available time

3rd day

0:15 h

Group A

Feedback Knowledge comparison

1:45 h

4:00 h


0:30 h

4th day

5th day



4:00 h



2:30 h

Parts table: Workshop Display <> Miscellaneous

Model series 900 engine: Workshop Display <> Model Series 900 Disassembly

2:30 h

Model series 900 engine: Workshop Display <> Model Series 900 Assembly

Parts table: Workshop Display <> Miscellaneous

1:30 h

09/07

Group B


Training room: Knowledge comparison / queries, final test

Learning Objectives, Training Course NMXM-MM247

28.09.2007

After participating in this training course, you will be able to perform the following on model series 457, 500 and 900:

• Describe the removal and installation of the following components, plan and understand the repair work required for this using WIS, and interpret the necessary measurements: - Unit pump, fuel feed pump, fuel filter - Cylinder head, connecting rods, pistons, cylinder liners, oil spray nozzles - Crankcase ventilation, exhaust manifold, turbocharger - Timing case, flywheel - Roller tappet, camshaft - Main bearings on crankshaft - Oil filter-, oil filter housing oil pan, oil pump with oil intake line - Turbocharger, Turbobrake

09/07


• Describe the disassembly and completion of the following components, plan and understand the repair work required for this using WIS, and interpret the necessary measurements: - Cylinder head with constant throttle - Unit pump

•

Describe the tasks and functions of the following components and systems, and locate malfunctions: - Crankcase ventilation - Fuel circuit in general - Oil circuit in general - Turbobrake

• Use the endoscope for targeted diagnosis

09/07


Exercise of measurement NMXM

Exercise 1

28.09.2007

fixed ed measure or a variable measure? Please tick!  Is it a gange with a fix

Fixed measure Depth gange Outside micrometer Raduis gange Dial gange Hardness analyzer for crankshaft Feeler gange straightedge Tape rule Angle gange Limit plug gange

09/07


Variable measure

 What does the difference in height measure from step (B) to step (A) to step (C)? Please fill in the

Exercise 2

gaps.

Measure step (B):

_____________ _____________ mm

Measure step (C):

_____________ _____________ mm

N58.00-2013-11

09/07


Poor Fuel Quality

Exercise 1

28.09.2007

 In the future, a customer intends to use his vehicles primarily in the Balkans and in the CIS.

He expresses his misgivings due to the poor fuel quality. What do you recommend to your customer? Use the workshop literature (AP47.20-W-0783A, (AP47.20-W-0783A, AN47.20-W-0001A) AN47.20-W-0001A) to help you.  

Exercise 2

 In the CIS and in the Balkans, the sulfur content in fuel is higher than in the EU.

How can you reduce engine wear, and what do you anticipate as regards maintenance intervals? Discuss in your group and explain your opinion, giving consideration to the workshop literature. (AP47.20-W-0783A, (AP47.20-W-0783A, AN47.20-W-0001A) AN47.20-W-0001A)   

09/07


Maintenance Intervals; Exercise

Exercise 1

28.09.2007

 In the future, a customer wants to operate his vehicle with FAME (rape methyl ester [RME]).

What is to be observed? What do you point out to your customer? a

The maintenance intervals are reduced.

b

Approx. 10% higher fuel consumption is to be anticipated.

FAME has harmful effects on seals, and gums up the injection nozzles. Because of this, only EURO 3 engines may be converted. d In the maintenance system, FAME (if available) or alternatively the sulfur content must be set to 0.3 - 0.8%. e The fuel and oil filter must be replaced 1,000 km following conversion. c

Exercise 2

f

Service Information 00.40-N-0008a must be noted.

g

Before standing idle for long periods, the fuel system must be flushed with diesel fuel.

 A customer has discovered that only oil as specified according to sheet 228.3 is available in a new

area of operation instead of the originally used low-friction oil as specified according to sheet 228.5. What do you point out to your customer? a

09/07

The maintenance intervals are reduced.

b

The maintenance system must be switched.

c

The selected MB oil specification can be entered “onboard”.

d

The oil specification can only be switched in the workshop using STAR DIAGNOSIS.

e

Operation with this oil specification is not permissible.


Technical Modifications of Model Series 500 EURO 4/5

28.09.2007

Main changes to the engine Compression ratio Maximum ignition pressure Cylinder liners Cylinder head gasket

• • • •

Cylinder head

•

Constant throttle valve Injection nozzle Cylinder crankcase

• • • • • • • • • •

Timing case Camshaft Camshaft thrust bearing Connecting rods Connecting rod and main bearings

• • • • •

Intake valve and seat rings

Outlet valve

09/07

Increased from a previous 17.75 : 1 to the present 18.50 : 1 Increased from 170 to 180 bar Honed plateau with oil ring at the top end The bead seal has a considerably greater volume of elastomers at the coolant passageways the oil passageways (pressure oil and return flow) the tappet passageways The sealing surface of the water and oil passage ways of the cylinder heads are covered with circular grooves, to take the increased elastomer volumes of the seal. Cylinder head with internal cast reinforcement for improved distribution of the sealant pressure. Intake valve with reinforced plate Intake valve seats in Triballoy O-ring seal at valve shank Seat angle changed to 36 degrees Contoured valve fiber O-ring seal at valve shank Generally with guide sleeve Filter hole, free from leakage oil With new vermicular graphite cast iron (GGV) material on diesel engines with more than 300 kW (408 hp) and on OM 502 diesels with 405 kW (551 hp) and more. Improved timing case sealing Operational reinforcement With thrust collar (as of 05/2006) Surface of large connecting rod laser profiled for better fixing of connecting rod bearing shells Improved connecting rod bearings and main bearings thanks to – improved strength of steel protective shells (material change from C10 to C22) – bronze layer for greater load bearing (less lead) – further improvement to sputter coating


Piston Crankshaft

• •

Oil pump Oil spray nozzle

• •

Vibration damper Exhaust pipe

• •

Turbocharger

• • • • •

Exhaust flap fittings Engine wiring harness Fan box

Modified combustion chamber recess Use of a new crankshaft with increased strength manufactured from manganese-vanadium material (46 MnVS 6BY) Oil pump weight higher delivery rate Next to the piston cooling with the oil splasher pipe, 3 oil spray bore holes have been drilled in the base plate, also for the purpose of cam lubrication. Larger vibration damper Exhaust gas pipe with improved endurance (double steel pipe on standard engine, cast iron version on turbobrake model) Model series 501: Wastegate, 300-350 kW Model series 502: Single-turbocharger version, wastegate, 405-440 (480) kW Unit flap fittings with SCR nozzle Axial fan In-engine fan surround for axial fan (350 kW model)

Main modifications in connection with exhaust gas aftertreatment Engine control unit Retarder coolant connection

• •

Throttle housing SCR tank heater solenoid valve SCR metering unit

• • •

09/07

Engine electronics MR2 with new engine performance mapping (data records) and SCR control functions Design modification for securing the "AdBlue" metering unit. On an engine without a retarder, the retarder connection is still built in but is sealed off. Throttle housing with AdBlue nozzle Additional, engine-mounted valve permitting the "AdBlue" circuit to be heated. Compressed air and AdBlue mixed to form aerosol


Cylinder Head on Model Series 500 - Sealing Surfaces with Countersinks The EURO 4/5 engines are fitted with a modified cylinder head and therefore a new cylinder head gasket with increased elastomer thickness. The following bores in the base of the cylinder head have been provided with countersinks with a depth of 1.0 mm: • Engine oil pressure side (OD) • Engine oil return (OR) • Coolant supply (WZ) • Coolant return (WR)

GT01_30_00023_C11

09/07


Cylinder Head Gasket on Model Series 500 Euro 4/5 On the cylinder head gasket, the elastomer sealing elements at the following bores have been raised by the dimension (X): • Engine oil pressure side (OD) • Engine oil return (OR) • Coolant supply (WZ) • Coolant return (WR) The sealing between the cylinder head and the crankcase is improved because the elastomeric sealing elements are higher. Moreover, a fire shield (arrow) was vulcanized onto the coolant feed hole (WZ). This fire shield (arrow) is an added protection for the elastomeric sealing element in the event of a possible minor gas leak in the cylinder head gasket.

OD OR WR WZ X

Engine oil pressure side Engine oil return Coolant return Coolant feed Dimension W01.30-1062-82

09/07


Cylinder Liners in Model Series 500 - Oil Scraper Ring The cylinder liner (2) has been fitted with an oil scraper ring (3) to prevent carbon buildup. The chrome-molybdenum (CrMo) oil scraper ring (3) has a height of 13.5 mm and a projection of 0.15 mm to the inner diameter of the cylinder barrel in the cylinder liner (2). The oil scraper ring (3) replaces induction hardening in the upper part of the cylinder liner (2). The oil scraper ring's (3) projection reduces carbon deposits on the top land of the piston (area from the piston crown to the first piston ring groove). This reduces wear on the cylinder barrel of the cylinder liner (2).

2 Cylinder liner 3 Oil scraper ring 4 Sealing ring

The outside diameter on the liner collar has been enlarged to improve the fit of the cylinder liner (2) in the cylinder crankcase. The sealing ring (4) between the collar of the cylinder liner (2) and the cylinder crankcase is made of stainless steel (X5CrNi 18-10) and has a l arger outside diameter than the tombac ring used previously. This results in higher abrasion resistance, reduced wear and improved installation reliability for the sealing ring (4). Due to the oil scraper ring (3) in the cylinder liner (2), an assembly tool is required to install the pistons. 09/07


Pistons, Model Series 457/500 - Installation with Oil Scraper Ring Removing the piston from the cylinder liner • Turn the crankshaft until the piston (1) is located approx. 1 cm beneath the oil scraper ring (2). • Insert the piston ring (4) into the cylinder liner (3) and insert a corresponding feeler gauge (5) into the piston ring end gap (arrow). Use only a new keystone ring or a taper-faced ring with internal angle as the piston ring (4). Observe installation position; the "TOP" mark must point downwards in the direction of the piston crown. The feeler gauge (5) prevents compression of the piston ring (4) when pressing out the oil scraper ring (2). • Turn the crankshaft until the piston (1) with the inserted piston ring (4) presses the oil scraper ring (2) out of the cylinder liner (3). Counterhold the cylinder liner (3) if necessary.

W03.10-1045-11

Installing the piston into the cylinder liner • Documentation is currently still in progress. • Lightly lubricate the pistons and piston rings with engine oil. • Turn the end gap of the oil scraper ring such that it points to the short side of the connecting rod big end. • Lightly lubricate assembly sleeve on inside and at collar with engine oil, place it over the piston rings and the pistons and screw together at the knurled screw. The collar of the assembly sleeve must point towards the connecting rod. The handle of the assembly sleeve must point to the short side of the connecting rod big end. • Insert the connecting rod and the piston into the cylinder liner until the collar on the assembly sleeve sits in the cutout of the oil scraper ring and the assembly sleeve lies on the cylinder liner. Turn crankshaft if necessary. • Press the piston into the cylinder liner and take off the assembly sleeve.

•

New piston ring compressor band required: Model series 457: Special tool 457 589 01 14 00 Model series 500: Special tool 541 589 02 14 00

09/07


GT03.10_0018_C81

Technical Modifications of Model Series 457 EURO 4/5

Main changes to the basic engine Compression ratio

•

18.5

Maximum ignition pressure

•

Ignition pressure 180 bar

Turbobrake

•

Expected as of end 2007

Cylinder liners

• • •

With top fitting (as on OM 460 LA) Fine honing pattern Ignition ring

Cylinder head gasket

•

Bead seal with more elastomers at the oil and water passageways

Cylinder head

• •

As per Euro III GG 25 Bead reinforcement as in model series 500

Intake valve and seat rings

• •

Seat angle 30° Contoured fibers

Outlet valve

• •

Seat angle 36° Contoured fibers

09/07


28.09.2007

Cylinder crankcase

• •

As per Euro III GG 25 Firewall-side reinforcement measures

Connecting rods

•

Connecting rod from OM 460 LA to increase crank pin

Piston

• •

AL pistons (Mahle, Alcan, KS) First piston ring 15 mm from piston top edge

Crankshaft

• •

OM 457 LA: Piston ring increase from 90 mm to 94 mm (uniform with OM 460LA). Screwed on counterweights (Atlantis Forge) or, as an alternative, solid forged counterweights.

Oil pump

•

Bigger oil pump, wheel width 43 mm (new), with reinforced cover

Crankcase ventilation

•

Cyclone separator for oil mist separation

Oil spray nozzle

•

Coaxial

Turbocharger

•

New Borg-Warner wastegate turbocharger

09/07


Main modifications via exhaust gas aftertreatment scope Engine control unit

•

Engine electronics MR2 with new engine performance mapping (data records) and SCR control functions

Throttle housing

•

Throttle housing with AdBlue nozzle

SCR tank heater solenoid valve

•

Additional live power valve, allowing heating up of the "AdBlue circuit".

SCR metering unit

•

Urea metering unit, made by Purem

SCR injection

•

Urea nozzle, made by Purem

09/07


Technical Modifications to Model Series 900 EURO 4

28.09.2007

Main changes to the basic engine Basic engine

OM904/ OM906

OM924/ OM926

Compression ratio

• 17.5 : 1

• 17.5 : 1

Maximum ignition pressure

• Increase from 170 to 180 bar

• Increase from 170 to 190 bar

Cylinder head gasket

• Combustion chamber sealing improved • Oil and water channel sealing more heat-resistant

Cylinder head

• Coolant flange for tank heater solenoid valve

• Cast material GGV

• Threaded sleeve for metering unit bracket

• Coolant flange for tank heater solenoid valve • Threaded sleeve for metering unit bracket

Crankcase

• Cast material GGV • Internal cast reinforcement • Omission of upper induction hardening on cylinder barrel

Crankshaft Piston rings

• Modified with larger Fillet radii • Optimized

• Optimized

Piston

• Piston pin diameter increased to 44 mm

Connecting rods

• Piston pin diameter increased to 44 mm • Improved connecting rod material (70MnVs4)

Crankshaft and connecting rod bearing

• Improved material

Camshaft

• Operational reinforcement

• Operational reinforcement

Injection nozzle

• 7-hole

• 9-hole, improved nozzle material

Increase in injection pressure

• 2000 bar

• 2200 bar

09/07


Basic engine

OM904/ OM906

OM924/ OM926

PLD unit pump

• Improved roller tappet mounting

Injection line and pressure pipe connection

• Modified from increased-strength material

Coolant pump

• Threaded fitting for attaching AdBlue heater return

• Threaded fitting for attaching AdBlue heater return

Scope of exhaust aftertreatment

•

Motor electronics MR2, new engine performance maps (data records)

•

AdBlue metering unit with bracket on cylinder head

•

AdBlue nozzle with flanged manifold

•

Valve in the cooling water circuit for controlled heating of the AdBlue lines, the pump module and the AdBlue tank

09/07


Cylinder Head, Model Series 900 EURO 4

28.09.2007

Shown on engine 926.9 At the rear part of the cylinder head the cap (arrow) has been replaced by the coolant flange for the SCR tank heater solenoid valve. On the side of the cylinder head the caps have been partly replaced by threaded sleeves (1). The bracket for the AdBlue metering device is mounted on these threaded sleeves (1). The other holes on the sides of the cylinder head are sealed by screw plugs (2). The cylinder heads in the 924.9 and 926.9 engines have been converted to vermicular graphite cast iron (GGV-40), for greater strength in order to withstand the higher ignition pressure.

1 2

Threaded sleeve Screw plugs

W01.30-1080-75

09/07


Coolant pump, Model Series 900 EURO 4

28.09.2007

A threaded fitting for attaching the AdBlue heater return line is screwed into the coolant pump at the bottom.

W20.10-1041-82

09/07


Engine Oil Change Interval up to 150,000 km (Code MY8)

28.09.2007

In model series 500 engines with code MY8, the oil change interval can be extended up to max. 150,000 km.

Features • Oil centrifuge in the secondary flow oil circuit • Oil filter cover raised • Intermediate cover between oil centrifuge and oil filter element • Oil filter element as in series production • Heat exchanger with 14 plates • Oil filter housing with return duct from the oil centrifuge into the oil sump • Thermoplastic oil pan • Oil quantity for the OM 501 increased by 8 liters

GT18_20_0002_C11

09/07


Operation The oil centrifuge in the secondary engine oil circuit oil filter is mounted on top of the oil filter element (3). The oil centrifuge consists of the following components: • Rotor (4) • Intermediate cover (5) • Threaded cap (6) Part of the engine oil flow is conducted through the oil centrifuge as of an engine oil pressure > 2 bar. Two tangentially attached nozzles are located in the lower section of the rotor (4); the cleaned engine oil from the oil centrifuge flows through them and thus generates the rotation of the rotor (4). The rotor (4) can reach a speed of up to 7,000 rpm. The cleaned engine oil then flows back into the oil pan. When the rotor (4) is rotating, soot particles as well as small metal particles that flow by the oil filter element (3) are separated from the engine oil and collected at the interior walls of the rotor (4) as deposits.

GT18_20_0008_C76

09/07


Technical data: The centrifuge's oil feed pipe contains a valve, which opens at 2.3 ± 0.3 bar. Via this valve, max. 10 l/min unfiltered oil enter the centrifuge. Maintenance note: In the event of maintenance operations, the rotor (4) and the oil filter element (3) have to be replaced. Repair information: • The engine must not be operated without centrifuge (oil pressure). • In the WS control unit, code MY8 is preselected via parameter setting. • In the MR control unit, the oil pan version is preselected via parameter setting.

GT18_00_0005_C01

GT18_00_0007_C11

GT18_00_0008_C01

GT18_00_0009_C01

Valve: 2.3 ± 0.3 bar

09/07


Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Installation

28.09.2007

Due to technical advances, the new cyclone separator will be installed as standard in the crankcase ventilation system of model series 457 engines without Turbobrake as of engine end no. 036 947, on these engines without turbobrake as of engine end no. 011 688, and on model series 500 engines as of engine end no. 265 304. The cyclone separator is maintenance free and need not be replaced again. The cyclone separator should be installed in older engines when maintenance becomes due. You can see if a cyclone separator is already installed by the form of the cover on the crankcase ventilation system.

Note: Installation must be charged to the customers and should be done during regular maintenance. Only the costs for the repair kit will need be paid, as no further maintenance on the crankcase ventilation system will be necessary.

12/06

W01.40-1062-02

1 2 3 4

Cyclone separator, model series 500 Seal Crankcase ventilation system cover, with cyclone separator, model series 500 Crankcase ventilation system cover, previous version, model series 500


W01.40-1070-03

5 6 7

Cyclone separator, model series 457 Seal Crankcase ventilation system cover, with cyclone separator, model series 457

Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Function

28.09.2007

Cyclone separator functional principle The blow-by gases from the crankcase are sent as pre-cleaned crude gases to the cyclone separator insert. The cyclone separator insert is made up of two cyclones. The crude gas enters the cyclone from the side (tangentially). The gas stream is forced into a downwards spiral movement in the entry chamber. This causes the floating oil particles to be pitched towards the wall of the cyclone by the centrifugal forces and then slide down the tapered surfaces of the swirl chamber due to gravity and the downwards movement of the gas. The oil comes out through a hole at the lowest point of the cyclone. As the cyclone tapers towards the bottom, the circumferential speed and centrifugal effect becomes greater so that finer particles can be separated in the lower section. At the lowest point of the cyclone the whirling gas reverses direction and goes back up and the clean gas is guided out through an outlet pipe (take-off tube) at the top. The diameter and tapered form of the take-off tube determine the pressure loss and separation quality of the cyclone. The bypass valve opens up with a high gas flow.

GT01_20_004_C12

12/06


Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Exercise

Exercise

28.09.2007

 Identify the gas stream in the cyclone insert.

Use the description from the "Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Function" chapter and the following guiding questions. •

Where does pure gas enter the cyclone?

•

What path does the gas stream take in the cyclone chamber?

•

Where is the oil separated out from the cyclone chamber?

•

Where does the clean gas emerge from the cyclone chamber?

•

How is the pure gas side sealed from the clean gas side.

GT20_40_0016_C02

09/07


GT20_40_0015_C02

Cylinder Head Fastening, Model Series 457

Exercise 1

28.09.2007

 Complete the following table, paying particular attention to the modified diameter. Use WIS document

AR01.30-W-5800C to help you.

Model series

Bolt dimension

Max. shank length

M18x2

212 mm

Model series 500 Model series 457

Exercise 2

mm

 Complete the following table.

Use WIS document AR01.30-W-5800C to help you.

Designation Cylinder head bolt to crankcase

09/07

Tightening stages

Model series 500 engine

1st stage

10

Nm

2nd stage

50

Nm

3rd stage

100

Nm

4th stage

200

Nm

5th stage

90

Angular degree

6th stage

90

Angular degree

7th stage

-

Angular degree


Model series 457 engine

Exercise 3

 Install cylinder head gasket, tighten cylinder head bolts -

Identify the correct statements. a b

The tightening pattern must be observed precisely. The first tightening stage can be skipped, because the torque is very low.

c

The cylinder head gasket can only be used once.

d

If the tightening torque is not applied in stages, strain may occur (uneven clamping force).

e

The bolts' tightening pattern does not necessarily have to be observed.

f

The cylinder heads must be retightened following the first service.

Note: In model series 457, the cylinder head bolts are identified with the imprint 457.

N01.30-2069-01

09/07


Exercise 4

 Handling the stretch-shank bolts.

Before the bolt is used, points other than the bolt tolerance must be noted.       

09/07

The bolts must be cleaned with a wire brush, as they should be free of rust, carbon and dirt. The bolt length must be compared with the data in the workshop literature. (From the lower side of the bolt head to the end of the bolt). The bolt holes must be free of dirt, coolant and oil. The bolts should be oiled lightly on the threads and beneath the head with engine oil, but not with 85/90 oil or grease. The bolts are tightened according to the tightening pattern and in stages. Identify the cylinder heads which have already been tightened. If a bolt has unintentionally been tightened excessively, loosen all bolts and measure for elongation.


Cylinder Head Fastening, Model Series 500; Exercise

28.09.2007

Exercise 1 

The cylinder head is tightened in 6 stages. Use the workshop literature (AR01.30-W-*****) and enter the values.

1. stage

Nm

2. stage

Nm

3. stage

Nm

4. stage

Nm

5. stage

°

6. stage

°

W01.30-0010-06

09/07


Exercise 2

 Install cylinder head gasket and tighten cylinder head bolts -

Identify the correct statements. a b c d e f

Exercise 3

The tightening pattern must be observed precisely. The first tightening stage can be skipped, because the torque is very low. The cylinder head gasket can only be used once. If the tightening torque is not applied in stages, strain may occur (uneven clamping force). The bolts tightening pattern does not necessarily have to be observed. The cylinder heads must be retightened following the first service.

 Handling the stretch-shank bolts.

Besides the bolt tolerance, other points must be observed before using stretch-shank bolts.        

09/07

The bolts must be cleaned with a rotating brush, as they must be free of rust, carbon and dirt. The bolt length must be compared with the data in the workshop literature. (From the lower side of the bolt head to the end of the bolt). Following removal, stretch-shank bolts may only be reused 3 times. The bolt holes must be free of dirt, coolant and oil. Engine oil is applied to the bolts at the threads and underneath the bolt head, however W85/90 must not be used to oil or grease the bolts. The bolts are tightened according to the tightening pattern and in stages. Identify the cylinder heads which have already been tightened. If a bolt has unintentionally been tightened excessively, loosen all bolts and measure for elongation.


Cylinder Head Gasket, Model Series 457 - Assignment of Ducts; Exercise

28.09.2007

Exercise 

In your group, discuss which bores through the cylinder head gasket are used for the purposes listed below, and transfer the corresponding letters to the relevant bore.

A B C D E

Coolant Bolts Pressure oil Oil return Tappet, oil return

N01.30-2068-12

09/07



28.09.2007

Exercise 

In your group, discuss which bores through the cylinder head gasket are used for the purposes listed below, and transfer the corresponding letters to the matching bore.

A B C D E

Coolant Bolts Pressure oil Oil return Tappet, oil return N01.30-2024-12

09/07



28.09.2007

 Which bores through the cylinder head gasket are used for the purposes listed below?

Exercise

Transfer the corresponding letters to the corresponding bore. Discuss in your group.

A = Coolant B = Pressure oil C = Push rods D = Cylinder head bolts E = Return oil N01.30-2039-05

09/07


Cylinder Head Gasket, Model Series 457 / 500, Evaluation

28.09.2007

W01.30-1039-71

Check cylinder head gasket (1) at combustion chamber.

Check cylinder head gasket (1) at the sealing rings.

Sealing surface (BA) at combustion chamber bore: The cylinder head gasket (1) was gas-tight.

A damaged sealing ring (elastomer) (C) in the engine oil bore or coolant bore is the result of a cylinder head gasket (1) which is not gas-tight.

Sealing surface (BB) at combustion chamber bore: The cylinder head gasket (1) was not gas-tight.

09/07

W01.30-1040-71


In the case of a leaky cylinder head gasket, the cylinder head and crankcase sealing surface must also be examined.

Cylinder Head Gasket, Model Series 500 - New Feature, Bead Seal

28.09.2007

Excerpt from WIS: BT01.30-W-0005-01A "Modified cylinder head gasket" ENGINE 541.9, 542.9 As of engine end no. 265.000, the cylinder head gasket has been modified to provide a better seal for the combustion chamber and coolant circuit at the cylinder head/crankcase contact surface. The cylinder head gasket has been improved with a bead (D) to seal the combustion chamber and the sealing element on the coolant feed (E) has been reinforced. Only the modified cylinder head gasket may be installed during repairs.

W01.30-1052-11

09/07


Cylinder Head, Model Series 457 / 500, Check

28.09.2007

Excerpt from WIS: AR01.30-W-5800-15A AR01.30-W-5800-15A

Check cylinder head for cracks (arrows) in area of cylinder head bolt bores and contact surfaces. Visible cracks always occur in combination with pitting around the cylinder head bolt bores, most often on the exhaust side only. The cylinder head must be replaced if there are cracks in it.

W01.30-1041-81

Check contact surfaces around the cylinder head bolt bores for pitting (arrow). If pitting has occurred, the height (H) of the cylinder head must be measured following stock removal . If too much stock is removed and the measurement falls below minimum, the cylinder head must be replaced. The cylinder head bolts must always be replaced. Lubricate cylinder head bolt at the collar surface, the thread and the stem using engine oil.

W01.30-1042-81

09/07


Visually inspect cylinder head sealing surface for flatness. Note: In the case of an induction hardened cylinder heads, do not check over the hardened parts (material projection). Place a straightedge over both coolant bores (WR, WZ) on the cylinder head sealing surface. Check flatness within the sealing area (X) of the cylinder head gasket only. If a gap forms under the straightedge due to pitting (arrow) of the cylinder head gasket (beaded or crimped) on the cylinder head sealing surface, the cylinder head sealing surface must be face-ground or the cylinder head exchanged. When face-grinding, the following notes have to be observed: - Material removal on the cylinder head must not fall below the permissible overall cylinder head height, "minimum height". - Only face-grind the cylinder head sealing surface through face grinding. - The surface quality of the cylinder head sealing surface must be maintained. (see WIS, AR01.30-W-7162B / AR01.30-W-7162C) W01.30-1053-81

09/07


Cylinder Head, Model Series 457 and 500 EURO 4/ 5, Coolant Loss

Damage profile • Cracks between the lower apex of the core hole bore and the sealing surface to the cylinder crankcase • Occurs on exhaust side only • Occurs on EURO 4/5 engines only Cause • Alternating cold/hot temperature stress produces tension in the cylinder head that leads to cracks forming at the shortest point between the core hole bore and the sealing surface Remedy • As of October 2007, the sheet metal core hole cover on the exhaust side will be replaced by a solid core hole cover. Important information for service • If a customer with a EURO 4/5 vehicle complains of coolant loss, always check the area between the core hole bore and the sealing surface for cracks. • The cracks may sometimes be very fine. • If cracks are found, replace the affected cylinder head.

09/07


GT01_30_0030_C81

Cylinder Head Model Series 900 - Sealing Surface Assessment

28.09.2007

Excerpt from WIS: AR01.30-W-5800-15B AR01.30-W-5800-15B

Check flatness of the cylinder head sealing surface via visual inspection. In the area of the lines, place a straightedge over the coolant bores (W) on the cylinder head sealing surface. Check flatness within the sealing area (X) of the cylinder head gasket only. If a gap forms under the straightedge on the cylinder head sealing surface, the cylinder head sealing surface must be face-ground or the cylinder head exchanged. When face-grinding, the following notes have to be observed:

- Only carry out face-grinding if an impermissible deviation in - flatness is measured in the longitudinal direction. - Material removal on the cylinder head must not fall below the permissible - overall cylinder head height, "minimum height". - Only face-grind the cylinder head sealing surface via face grinding. - The surface quality of the cylinder head sealing surface must be maintained. W01.30-1043-81

09/07


Cylinder Head, Model Series 500, New Feature, Inductively-hardened Sealing Surface

28.09.2007

Excerpt from WIS: BT01.30-W-0004-01A, AR01.30-W-5800-15A ENGINE 541.9, 542.9 As of engine end no. 263.000, the cylinder heads have been modified. The cylinder head sealing surface has been inductively hardened at four points (arrows). This inductive hardening is visible by a slight increase in height at the four points (arrows). This increases the contact pressure on the cylinder head gasket. Repair information: Cylinder head sealing surfaces with the four inductively hardened points (arrows) may only be visually checked for flatness in the sections where there are no raised areas due to inductive hardening. The cylinder head generally has to be exchanged if there is any distortion to the cylinder head or wear to the cylinder head sealing surface caused by the beaded cylinder head gasket, otherwise a seal between the cylinder head and crankcase cannot be ensured. The cylinder head sealing surface may not be reworked (ground).

W01.30-1044-81

09/07


The modified cylinder heads can be recognized by a production ID (C). The ID is located near the outlet duct and can also be read with an installed cylinder head and exhaust manifold.

Production ID (C) example: Meaning of ID 541 - 54 part no. A 541 010 54 20 10.03.03 manufacture date 10.03.2003 ID number "5" (arrow) The new, inductively-hardened cylinder heads are identified with the ID number "5" (arrow) or higher.

W01.30-1051-81

NOTES:

09/07


Cylinder Liners, Model Series 457/500; Exercise

28.09.2007

Assignment of cylinder liner and piston  The piston and the cylinder liners are identified with letters. These provide information on the

Exercise 1

installation tolerance. Complete the table. Use WIS document AR03.10-G-7021-02CH.

Bushing Pistons

A

B

C

BA BC W03.10-0029-02

09/07


Remove/install cylinder liner Complete the following tasks with the aid of the overview WIS AR01.00-Z-9457OB.  Operations for removing cylinder liners.

Exercise 2

Complete the table. Use the workshop literature.

09/07

a

Identify cylinder liner to the crankcase.

b

Identify cylinder liner with cylinder number.

c

Use a steel hammer to knock the cylinder liner out of the crankcase from below.

d

It is not necessary to identify the position of the cylinder liner, as it has been manufactured to maximum tolerance.

e

Use the extraction device to remove the cylinder liner.

f

When using the extraction device, it must be ensured that the installed oil spray nozzles are not damaged.

g

On installation, offset cylinder liners 90° clockwise.


Exercise 3

 On installation of the cylinder liner, certain points must be observed.

Discuss this in your group. Complete the table. Use the workshop literature. Important actions: Exchange

Cleaning

Install dry

Coat with engine oil

Coat with ATE grease

Measure for....

Tombac ring contact surface on liner collar and crankcase Grooves in the crankcase for Viton oval ring grooves Viton oval rings Tombac ring Sealing surface of the Viton oval rings on the cylinder liner Cylinder bore following installation of cylinder liner Cylinder liner collar following installation of cylinder liner

Exercise 4

 How can you check whether the Viton oval rings are correctly seated in their groove after pressing in

the cylinder liner?  

09/07


Cylinder liner projection

The principle of measuring the cylinder liner projection has not changed in comparison with model series 400. Measuring the cylinder liner projection on the engine is very important and also very simple.

Exercise 5

 Look up the values in the workshop literature and enter them in the table below.

When you have installed the liners, choose one cylinder liner and carry out the measurement. Document the result in the table. Specified value

Actual value --

Tightening torque for fastening plate Cylinder liner projection Maximum difference between the 4 measurements

Exercise 6

 Incorrect liner projection may cause various symptoms.

Assign possible symptoms to the liner projection status. Symptoms: Compression gases in the coolant

Status

Coolant in the engine oil

Liner projection > normal Liner projection < normal Difference between the 4 measurements > normal

09/07


External coolant loss

Engine oil in the coolant

Fuel in the engine oil

Exercise 7

 Assume the liner projection is incorrect. Which repair options are available?

Discuss this in your group and use the workshop literature.

Exercise 8

a

Staged Tombac rings are available.

b

Tombac rings are only available with one dimension. If necessary, use a second Tombac ring to correct the projection.

c

Only 1 Tombac ring may be installed.

d

A repair stage of 0.5 mm exists.

e

The cylinder liner shoulder must be adapted.

f

The cylinder liner collar must not be reworked.

 How can the lower cylinder liner O-rings be checked for leaks?

Which symptoms exist if leaks are present? Check:  Symptoms: 

09/07


Cylinder Liners, Model Series 900; Exercise

28.09.2007

Cylinder barrels and cylinder liners Cylinder liners can be used in the event of repair. To do this, the crankcase is drilled open.

N01.40-2032-11

09/07


W01.40-1016-12

Exercise 1 

On an engine, the cylinder barrels have been measured for wear. Assuming the basic dimension, the following measurement results were determined and transferred to the table. Use the workshop literature (AR01.40-W-9202A). Evaluate the results.

Meas uring point

Measurement Out-ofresults roundness

A

B

I

0.09

0.11

II

0.04

0.04

Cylinder wear

W01.40-0034-06

Exercise 2

 Can the engine still be used?

 

09/07


Crankcase marking following machining

Exercise 3 

On a reconditioned engine, cylinder liners have been inserted. The crankcase sealing surface was also reworked by 0.6 mm. Indicate the identification used to document machining on the signing surface in field 6 (AR01.40-W-9273-01A).



W01.40-0036-12

09/07


Exercise 4

 What must be noted with regard to the pistons after machining the crankcase sealing surface?

The piston crown must be reworked. A thicker cylinder head gasket is required.  Install a repair piston with a lower compression level.  

09/07


Cylinder Barrel, Model Series 457/ 500/ 900 - Assessment; Exercise

28.09.2007

Excerpt from WIS: AH01.40-N-0001-03A

W01.40-1044-81

Matt gray surface, honing pattern visible, dry cylinder barrel, without oil residues, without shining areas or reflecting areas of smoothness. There should not be any burn marks or streaks on the cylinder barrels or liners. Individual, slight drawing scores are non-critical. The honing pattern is more or less clearly recognizable over the cylinder barrel. At the reversal point of the piston ring, the honing pattern may be partially eroded.

W01.40-1042-74

With engines 904.9, 906.9 only The stripe profile (arrows) in the upper area of the cylinder barrel arises due to induction hardening on production of the crankcase, and is to be regarded as the normal condition. The longer the engine's operating time, the less visible the stripe pattern becomes.

The cylinder liner or the crankcase can be reused.

09/07


Exercise 1 

Different types of damage to the cylinder barrel. How would you decide?

W01.40-1051-81

W01.40-1052-81

The following applies if carbon is present in the top land area:

09/07

The following applies if individual, continuous scratches or score marks are present:



Clean the top land area and reuse the cylinder liner or the crankcase.



The cylinder liner or the cylinder liner must be exchanged even if minor scratches or score marks are present.



Replace the cylinder liner or the crankcase.



The cylinder liner or the crankcase can be reused if slight scratches or score marks are present.



Additionally remove the piston and assess the piston rings.



It is sufficient to remove scratches using abrasive paper.


Exercise 2 


W01.40-1053-81

W01.40-1055-81

The following applies if ring shaped depressions are present at the upper and lower piston ring reversal point with visible color shadings (arrow), but the honing pattern can still be recognized:

The following applies in the case of pressure sheen marks and smoothness, e.g. individual, bare areas (arrow) in the cylinder barrel or allround indentations at the upper and lower piston ring reversal point:



The cylinder liner or the crankcase can be reused.





The cylinder liner or the crankcase must be exchanged.





09/07


The crankcase can be reused if the engine reveals no in-engine complaints, e.g. noises or increased engine oil consumption. The cylinder liner must be replaced.

The cause may be poor engine oil quality (oil viscosity).

Exercise 3 


W01.40-1035-81

W01.40-1041-81

The following applies in the case of imperceptible dry friction marks or deposits (arrow) on the cylinder barrel running downwards from the 2nd or 3rd piston ring: Caused by soot particles and fuel washings of the engine oil film.  Caused by damaged piston rings 



09/07

The cylinder liner is unusable and must be replaced. The piston should also be replaced.


The following applies if the honing pattern is only barely or not visible or there is a perceptible wear step at the upper reversal point of the first piston ring (arrow): The cylinder liner is unusable and must be replaced.  If the model series 900 engine reveals no inengine complaints, e.g. noises or increased engine oil consumption, the crankcase can be reused.  If the model series 900 engine reveals inengine complaints, e.g. noises or increased engine oil consumption, the crankcase can be reworked. 

Exercise 4 


W01.40-1036-81

If the cylinder barrel is perceptibly roughened along its entire length or material deposits and perceptible traces of scoring are found on the cylinder barrel and on the piston skirt, the following applies: The cylinder liner is unusable and must be replaced.  The crankcase is unusable and must be replaced or machined. Additionally check the pistons and piston rings, replace if necessary.  The cylinder liner is unusable and must be machined. Additionally check the pistons and piston rings, replace if necessary. 

09/07


Plateau Honing

28.09.2007

Advantages: • Reduction in oil consumption • Better limp-home capabilities • Improvement in running-in characteristics • Reduction in friction power loss Process: The plateau structure is generated in three work phases: pre-honing, intermediate honing (basic structure honing), and the overlaid plateau honing. In the first work phase, or pre-honing, pre-honing , fluctuations in quality from fine boring are level leveled out. A consistent quality must be stipulated for basic structure honing. In the second work phase, an addi add itional macro form from improvement of the cylinder barrel is achieved, generating the basi basic structure C. In the third work phase, also known as plateau honing, the surface peaks of basic structure C are worn away in a few seconds and the small plateaus, bearing structure A0 with a low peak-to-valley height and high percentage contact area, are formed. The material wear depends on pre-machining and generally amounts to 0.04 to 0.1 mm. GT01_10_0013_C11

09/07


Constant Throttle - Fault Symptoms; Exercise

Exercise 1

28.09.2007

 We would also like to deal in greater detail with faults and symptoms related to the constant throttle.

In a customer's vehicle, a constant throttle valve seat is worn. What symptoms may this fault cause? Discuss this problem case in your group. a b c d e f

Exercise 2

Engine runs rough The engine shakes and tends to vibrate Power loss Output increase No symptoms noticeable Engine noise / knocking combustion

 Which test can be used to locate this fault? a

Cylinder pressure loss test Mechanical compression test c Impact times d Compression test with STAR DIAGNOSIS e Smooth idle speed control b

09/07


Nozzle Protection Sleeve, Model Series 457/500; Exercise

28.09.2007

The injection nozzle holder assembly (1) is inserted into a nozzle protection sleeve (2). This principle is used in model series 300, 457, 500 and 900. The special tool for removal is identical for model series 500 and 900.

Exercise 

Which operation step must be observed when the protective sleeve of an engine is to be removed and subsequently reinstalled? For help, refer to WIS documents AR01.30-W-5461* and AR07.03-W-6831*.

a b c d e f

The constant throttle must be removed. The fuel circuit must be drained. The cylinder head must be removed. The coolant must be drained. Following installation of the nozzle protection sleeve a pressure test must be conducted to check for leaks. The O-ring must always be replaced and coated with acid-free ATE grease.

W01.30-0012-06

09/07


Heat Protection Sleeve - Locations

28.09.2007

The nozzle holder assemblies for OM 906LA engines and engine model series 457 have been equipped with a heat protection sleeve since the start of production. In the meantime, it is also used in engine model series 500. The collar of the heat protection sleeve also acts as a sealing surface. In order to ensure perfect sealing, the heat protection sleeve must be replaced every time the nozzle holder assembly is removed, just as with the sealing rings that were used previously. A nozzle protection sleeve with a larger inside diameter and an M14x1 (previously M12x1) external thread are necessary if heat protection sleeves are used. This is the reason why a modified cylinder head is needed.

Example view: Model series 457 N01.10-2078-12

09/07


Heat Protection Sleeve - Special Tool

906 589 02 63 00

28.09.2007

906 589 02 63 01

906 589 00 63 00

To enable extraction of the heat protection sleeve even when the rocker arms are installed, special tool 906 589 02 63 00 has been extended. Extension 906 589 02 63 01 was temporarily available for retrofitting old extraction tools which had already been delivered. This extension is no longer available today. The injection nozzle heat protection sleeve has since been modified. The modified heat protection sleeve is shorter than the previous one. Only the modified (shorter) heat protection sleeve may be installed during repairs. To avoid damage, a new assembly tool, part no. 906 589 03 63 00, must be used for installation. The new assembly tool consists of the previous mounting bushing and a new assembly sleeve (black plastic); it replaces the previous assembly tool, part No. 906 589 00 63 00. The previous press-on sleeve (white plastic) must be destroyed. The new assembly sleeve can also be used on all engines. The new press-on sleeve, part no. 906 589 03 63 01 (black plastic), can also be ordered as a separate part and used in conjunction with the female bushing of the current assembly tool.

09/07


Heat Protection Sleeve, Model Series 457/ 500/ 900 - Modifications

Model:

28.09.2007

ENGINE 457 in model 375.4, 944 ENGINE 541 in model 930, 932, 933, 934, 950.0/1/2/3, 952. 0/1/2/3, 953.1/3, 954. 0/1/2 ENGINE 542 in model 930, 932, 934, 950.0/1/2/3, 952. 0/1/2/3, 954. 0/1/2 ENGINE 906 in model 970, 972, 974, 975, 976 ENGINE 906 in model 375.3, 940, 950.5/6, 952.5/6, 953.6, 954.5, 957 ENGINE 926 in model 950.5/6, 952.5/6, 953.6, 954.5, 957

Information

SI07.03-W-0001B

The sealing sleeve on the injection nozzle in the above engines has been modified. The modified sealing sleeve has been decreased from 19.4 mm to 17.4 mm. Only the modified (shorter) sealing sleeve may be installed in engines 906 and 926. For engines 457, 541 and 542, the modified (shorter) or previous (longer) sealing sleeves may be installed in the event of repairs. To avoid damage, a new assembly tool, part no. 906 589 03 63 00, must be used for installation.

Note: In future, only the modified (shorter) sealing sleeve will be used in series production. GT07_03_0021_C72

09/07


GT07_03_0022_C72

Nozzle Holder Assembly and Protective Sleeve - Sealing; Exercise

Exercise

28.09.2007

 Use the illustration to identify the "upper" and "lower" seals of the nozzle holder assembly (DHK) and

the protective sleeve. Use the table provided to note the possible effects of defective seals. Defective seal: Effect / symptom

DHK O-ring to cylinder head

Protective sleeve O-ring to cylinder head

DHK to protective sleeve

Protective sleeve to cylinder head

Coolant in the combustion chamber Coolant in the fuel tank Fuel in the oil Coolant loss, increased pressure in the system Fuel return is under increased pressure

W07.03-1006-01

09/07


Oil Pan Torque Specifications, Model Series 500

28.09.2007

W01.45-0003-09

09/07


Exercise

 Use the workshop literature to determine the tightening torques for the parts listed

in the table. AR01.45-W-7500b

Components: Oil pan to crankcase (6)

Nm Light alloy Plastic

Stage 1 Stage 2

Oil drain screw to oil pan (10)

Light alloy

M20x1.5 M26x1.5

Plastic

without metal bus h with metal bush

Oil dipstick guide tube fitting (2) to oil pan (4)

Light alloy Plastic

Oil dipstick guide tube bolt (2) to oil pan Cable duct bolt (12) to oil pan (4) Oil level sensor (B14) to oil pan (4)

Light alloy Plastic

without metal bus h with metal bush

09/07


Oil Pan, Model Series 900 - Tightening Torques

28.09.2007

Exercise 

Use the workshop literature (AR01.45-W-7500...) to determine the tightening torques for the parts listed in the table.

Components:

Nm

Oil pan to crankcase (3) Oil drain screw to oil pan (6)

M20x1.5 M26x1.5

Engine oil level sensor B14 to oil pan (4) W01.45-0005-06

09/07


Clean Main Oil Duct; Exercise

28.09.2007

W01.40-1021-06

Exercise

 Name cases of damage in which it is necessary to clean the oil ducts.



Note: The operations are described in WIS documents AR01.40-W-8501A and AR01.40-W-8501B. 09/07


W01.40-1018-06

Connecting Rod, Model Series 457

Exercise 1

28.09.2007

 The large connecting rod eye is identified with a number.

Discuss its meaning in your group. 

Assignment of connecting rod to cylinder.



Assignment of connecting rod to crankshaft.



Connecting rods are manufactured only as complete sets and must only be used as such in the engine. 

The connecting rod is precisely balanced; the numbers indicate the weight of the connecting rod. 

The side with the number must be installed in the direction of the camshaft. Particular care must be taken not to damage the oil spray nozzle when installing the connecting rod. 

The connecting rod and its bearing shell are assembled in pairs and must not be exchanged with others.

W03.10-1005-06

09/07


Exercise 2

 Discuss the possible option for repairing the connecting rod in your group. Use the workshop

literature to help you. Indicate your answers in the table. Status:

Rework connecting rod

Exchange connecting rod

Connecting rod with blue color due to bearing damage The connecting rod bush is damaged Large connecting rod eye is worn The cracked surface is damaged (model series 500) The toothed surface is damaged (model series 457) The connecting rod is bent

Exercise 3

 The removal/installation of a piston is familiar to all.

Important criteria have to be observed in this case. Indicate your answers in the table. Criteria:

True

Install the connecting rod in the piston so that the direction arrow on the piston crown points forwards and the longer side of the obliquely split connecting rod is on the left side. The cutout on the piston for the oil spray nozzle must point inwards to the center of the e ngine. Prior to installation, oil the piston and offset the piston ring end gaps in sequence by 120°. A tensioning strap must always be used when compressing the piston rings. Turn the piston slightly when inserting so that the oil spray nozzle is not damaged on installation of the connecting rod. The lug on the connecting rod bearing shell must sit in the groove of the connecting rod bearing cap or the connecting rod. The connecting rod and connecting rod bearing cap must lie precisely on the crankshaft crank pin and are pressed on by hand while screwing in the connecting rod bolts.

09/07


False

Connecting Rod, Model Series 500; Exercise

28.09.2007

 The large connecting rod eye is identified with a 4-digit number.

Exercise 1

Discuss its meaning in your group. 

Assignment of connecting rod to cylinder.



Assignment of connecting rod to crankshaft.



Connecting rods are manufactured only as complete sets and must only be used completely in the engine.



The connecting rod is precisely balanced; the numbers indicate the weight of the connecting rod.



The side with the number must be installed in the direction of the oil spray nozzle. Particular attention must be paid to the fact that the oil spray nozzle is not damaged on installation of the connecting rod.



The connecting rod and its bearing shell are assembled in pairs and must not be exchanged with others.

N03.10-2026-01

09/07


Exercise 2

 Discuss the possible option for repairing the connecting rod in your group, with the support of the

workshop literature. Indicate your answers in the table. Status:

Rework connecting rod

Exchange connecting rod

Connecting rod with blue color due to bearing damage The connecting rod bush is damaged Large connecting rod eye is worn The cracked surface is damaged The connecting rod is bent

Exercise 3

 The removal/installation of a piston is familiar to all.

Important criteria have to be observed in this case. Indicate your answers in the table. Criteria:

True

Install the connecting rod in the piston so that the longer side of the obliquely split connecting rod corresponds to the cutout for the oil spray nozzle on the piston. The cutout on the piston for the oil spray nozzle must point inwards to the center of the e ngine. Prior to installation, oil the piston and offset the piston ring end gaps in sequence by 120°. A tensioning strap must always be used when compressing the piston rings. Turn the piston slightly when inserting so that the oil spray nozzle is not damaged on installation of the connecting rod. The lug on the connecting rod bearing shell must sit in the groove of the connecting rod bearing cap or the connecting rod. The connecting rod and connecting rod bearing cap must lie precisely on the crankshaft crank pin and are pressed on by hand while screwing in the connecting rod bolts.

09/07


False

Repair Flywheel, Model Series 457/ 500

Exercise

28.09.2007

 When the clutch is exchanged, the flywheel must be checked.

Discuss your procedure in your group and enter your results in the table.

Status

Rework flywheel

Exchange flywheel

Starter ring gear - 0.5

Exchange ring gear

Wear on the ring gear

Scorch marks, scoring and cracks on the surface of the flywheel Scoring/cracks are deeper than the max. permissible amount of stock removal Outer flywheel diameter smaller than standard

Attention:

09/07

Important: On removal and installation of the flywheel and the pressure plate, it must be ensured that the signal grooves for the inductive sensor are not damaged, as the engine will otherwise no longer starts. The location of the signal grooves on the flywheels for model series 457 and model series 500 are different. If interchanged, the engine does not start.


Crankshaft End Play; Exercise

28.09.2007

 The crankshaft end play can only be checked when the crankshaft is fully installed.

Exercise

Determine the permissible, maximum end play values and then carry out a measurement on the engine. Assess the result.

Permissible, maximum value Crankshaft end play, mm

W03.20-0037-01

09/07


Actual value

Crankshaft - Measure Journals and Bearings, Model Series 500

28.09.2007

Exercise 1 

Measure one crankshaft journal and the relevant main bearing. Enter the values in the table below and evaluate the results. Use the workshop literature (AR03.20-W-4355....)

W03.20-0030-09

Main bearing journal ∅ A Bearing No.

Specified value

Measurement 1

Main bearing inner ∅ H in installed condition Measurement 2 (90°)

Specified value

1 2 3 4 09/07


Measurement 1

Measurement 2

Measurement 3

Exercise 2

 Measure one connecting rod journal and the relevant connecting rod bearing. Enter the values in the

table below and evaluate the results. Use the workshop literature AR03.10-W-6111-06B.

W03.10-0020-01

Connecting rod bearing inner diameter in installed condition

Connecting rod journal ∅ Bearing No.

Specified value

Measurement 1 A

Measurement 2 B

Specified value

1 2 3 4 5 6

09/07

W03.10-0017-01


Measurement 1 A

Measurement 2 B

Measurement 3 C

Crankshaft Seal, Model Series 500; Exercise

Exercise

28.09.2007

 Various seal variants are available for the crankshaft seal.

Use the table below and select the correct repair combination for the given conditions.

Installation and replacement Radial sealing ring with small inside diameter

Status

Radial sealing ring with large inside diameter

Front seal leaky. Radial sealing ring without race is installed, no galling on the crankshaft. Front seal leaky. Radial sealing ring without race is installed, sealing surface on the crankshaft is run in. Front seal leaky. Radial sealing ring and race are installed, no wear on the race. Rear seal leaky. Radial sealing ring without race is installed, sealing surface on the flywheel is damaged

09/07


Exchange Steel race

Crankshaft

Flywheel

Front Crankshaft Seal, Model Series 457/500 - Replace Radial Sealing Ring

28.09.2007

The "Replace front crankshaft radial sealing ring" repair procedure has changed. Due to use of the extraction device and installer, the crankshaft radial sealing ring can be replaced without removing the housing cover. Information: AR03.20-W-3000B: AR03.20-W-3000G: AR03.20-W-3000D:

Model series 500 in MODEL 950, 952, 953, 954 Model series 500 in MODEL 930, 932, 933, 934 Model series 457.9 in MODEL 375.4, 944

541 589 02 33 00

09/07


Removing the front crankshaft radial sealing ring

W03.20-1048-11

W03.20-1050-11

W03.20-1051-11

W03.20-1048-11

W03.20-1049-11

Installing the front crankshaft radial sealing ring

W03.20-1047-11

09/07


Piston Projection, Model Series 457/500

28.09.2007

 The correct piston projection is very important.

Exercise 1

In which of the situations listed below would you measure the piston projection? Discuss the answers in your group.           

Engine does not run smoothly Replace and seal cylinder liner O-rings After planing the crankcase After planing the cylinder head Engine overrevving damage Compression loss Water loss in the area of the cylinder head gasket Mechanical problem in the valve assembly, e.g. valve breakage Performance problems Mechanical foreign objects in the combustion chamber Suspected water ingestion damage

N03.10-2018-01

Exercise 2

 From the workshop literature (AR03.10-W-7041-xxx), determine the specified piston projection values

and also measure these on one cylinder in the engine. Specified value

09/07

Measurement

Piston projection, model series 500 (in mm)

____________

Piston projection, model series 457 (in mm)

____________


Remove and Install Camshaft, Model Series 500; Exercise

W05.20-0011-01

Exercise 1

09/07

28.09.2007

W05.20-0009-01

 Check the correct statements. a

Before removing, mark the installation location of the adjustable valve bridges.

b

Turn the push rods when pulling out, so that they work loose in the roller tappet (AR05.20-W-6292B).

c

If the engine is turned on the assembly stand following removal of the cylinder head and push rods, the roller tappets must be removed beforehand.

d

To remove and install the roller tappets (with special tool, see AR05.20-W-6292B), the push rods and the cylinder head must be removed.

e

The roller tappets must be oiled on installation. The guide wedge on the roller tappet must be inserted into the guide groove in the crankcase.


Exercise 2

 Special tools are required to remove and install the roller tappets and the camshaft. in your group and

with the aid of the workshop literature (AR05.20-W-6292B), clarify which special tool is used for this.  Roller tappet:  Camshaft:

Exercise 3

 On installation of the camshaft, attention must be paid to the correct installation position with regard

to the timing. Describe this with the aid of the workshop literature (AR05.20-W-6292B).  

09/07


Valve Setback, Model Series 457/500; Exercise

28.09.2007

 Use the workshop information (AR05.30-W-… ) to complete the table.

Exercise

Measure a cylinder head.

Specified value

Actual value

Valve setback to cylinder head contact surface:

1

Cylinder head

2

Intake valve

3

Exhaust valve

4

Dial indicator holder

5

Dial indicator

B

Valve setback to cylinder head contact surface

W05.30-1085-06

09/07


Valve Setback, Model Series 900 - Check; Exercise

Exercise

28.09.2007

 Use the workshop information (AR05.30-W-4511A, AR05.30-W-4100-01A and AR01.30-W-7162A) to

complete the table. Measure the cylinder head.

Specified value

Actual value

Valve setback to cylinder head contact surface: Maximum difference between both valves:

W05.30-0022-01

09/07


W05.30-0058-05

Notes

09/07

28.09.2007


Model Series 457 Fuel Circuit - Symbolic; Exercise

Exercise

28.09.2007

 Follow the fuel flow and mark it with arrows.

N07.00-2082-09

09/07


Legend 1 1.1 1.2 2 2.1 3.1 3.2 4 5 5.1 6 6.1 6.2 7 8

Fuel tank Fuel strainer (800 m) Air admission valve Manual fuel feed pump Fuel prefilter "Racor" (special equipment) Plug-on valve on the fuel filler neck (locked in open position) Plug-on valve in the fuel return line (locked in open position) Fuel heat exchanger Fuel pump Pressure relief valve (7.0...8.0 bar) Fuel filter (KF 1.5 µm) Fuel filter emptying valve Permanent relief bore Nozzle holder combination PLN unit pumps (Y6 to Y11)

09/07

10 Overflow valve (2.0 bar) 10.1 Throttle in the overflow valve 12 Throttle in the flame starting system fuel line R3 Flame glow plug Y5 Flame starting system solenoid valve A Fuel feed line/intake vacuum-side B Fuel feed line/pressure side C Fuel flushing volume (fuel bypass) D Fuel return line after unit pump/leak fuel E Fuel high pressure side (injection line) after PLN unit pumps


Fuel Circuit, Model Series 457 - Requirements; Exercise

Exercise

28.09.2007

 Let us examine the following requirements on the fuel circuit.

Assign the individual requirements to the corresponding components. Use the fuel circuit diagram to help you.

Components required

Set requirements No fuel must escape from the engine circuit during engine removal or installation. The unit pump head must be cooled by fuel. A high quantity of fuel must therefore be circulated. A defined system pressure must therefore establish itself in the system. The circuit must constantly ventilate itself independently during normal operation. The circuit must be limited to a maximum pressure in the event of a fault. The fuel feed must not run dry when the engine is stopped. When replacing the fuel filter, the fuel must flow out of the fuel filter housing after screwing on the cover (which requires lifting the filter insert).

09/07


Notes

09/07

28.09.2007


Model Series 500 Symbolic Fuel Circuit; Exercise

28.09.2007

GT05_15_0005_C81

09/07


Exercise

1 1.1 2 3.1 3.2 4. 5. 5.1 6. 6.1 6.2 7. 8. 9. 10.


10.1 11.1 11.2 12

Fuel tank Fuel strainer (800 μm) Fuel prefilter (KVF 300 μm) with manual fuel feed pump Plug-on valve on the fuel filler neck (locked in open position) Plug-on valve in the fuel return line (locked in open position) Fuel heat exchanger Fuel pump (KFP) Pressure relief valve (9.0 to 12.0 bar) Fuel filter (KF 1.5 μm) Fuel filter emptying valve Permanent ventilation in KF (0.7 mm) Nozzle holder combination PLN unit pumps (Y6 to Y13) Banjo union with permanent ventilation (0.7 mm) Overflow valve (up to engine no. 092407 2.0 bar, as of engine no. 092408 2.65 bar) Throttle (3.1 mm) in overflow valve Fuel filler neck connector (in frame) Fuel return line connector (in frame) Throttle (0.5 mm) in the fuel line flame starting system

B10 R3 Y5 G H

Fuel temperature sensor Flame glow plug Flame starting system solenoid valve Pressure gauge test Fuel return volume test

09/07

Fuel circuit A Fuel feed line/suction side B Fuel feed line/pressure side C Fuel high pressure side (injection line) after PLN unit pumps D Fuel return line after unit pump E Fuel flushing volume (fuel bypass) F Fuel return line/leak fuel --Fuel ducts in crankcase ----- Fuel lines


Notes

09/07

28.09.2007


Model Series 900 Fuel Circuit - Symbolic (from Engine 040488); Exercise

28.09.2007

W07.15-1063-09

09/07


Exercise


1 1.1 1.2 2 2.1 2.2 3.1 5 8 8.1 10 12 12.1 14.1 15.1 17 17.1 18.1 18.2

Fuel delivery pump (KFP) Pressure limiting valve in fuel delivery pump (9.2 bar) Check valve in fuel delivery pump (0.2 bar) Fuel filter (KF) Fuel discharge valve Constant vent in fuel filter Bypass from fuel feed passage to fuel return passage Nozzle holder combination Overflow valve (4.5 bar) Constant vent (0.5 mm) PLD unit pump (Y6 to Y11) Fuel prefilter (KVF) Check valve in fuel prefilter Assembly valve in fuel feed (opened by pressure) Assembly valve in fuel return flow (opened by pressure) Fuel tank Air admission valve Restrictor (0.5 mm) in flame starting fuel line Throttle (threaded throttle) in the flame starting fuel line

B10 R3 Y5

Fuel temperature sensor Flame starter glow plugs Solenoid valve

09/07

A B CC D E

Fuel circuit Fuel feed (suction/vacuum side) Fuel return (leak fuel) Fuel feed (pressure side) Fuel high pressure side (downstream of PLD unit pumps) Fuel return (fuel filter drain)

-------------

Fuel passages in crankcase Fuel lines


Fuel Circuit, Model Series 900 - Requirements; Exercise

Exercise

28.09.2007

 Let us examine the following requirements on the fuel circuit.

Assign the individual requirements to the corresponding components. Use the fuel circuit diagram to help you.

Components required

Set requirements No fuel must escape from the engine circuit during engine removal or installation. The unit pump head must be cooled by fuel. A high quantity of fuel must therefore be circulated. A defined system pressure must therefore establish itself in the system. The circuit must constantly ventilate itself independently during normal operation. The circuit must be limited to a maximum pressure in the event of a fault. The fuel feed must not run dry when the engine is stopped. When replacing the fuel filter, the fuel must flow out of the fuel filter housing after screwing on the cover (which requires lifting the filter insert). The fuel may only reach the fuel feed pump after being prefiltered.

09/07


Notes

09/07

28.09.2007


Fuel Pressure Test Points, Model Series 500; Exercise

28.09.2007

W07.15-1080-09

09/07


Components 1 Fuel tank 1.1 Fuel strainer (800my) 2 Fuel prefilter (KVF 300my) with manual fuel feed pump 3.1 Plug-on valve on the fuel filler neck (locked in open position) 3.2 Plug-on valve in the fuel return line (locked in open position) 4 Fuel heat exchanger 5 Fuel pump (KFP) 5.1 Pressure relief valve (9.0 -12.0 bar) 6 Fuel filter (KF 1.5 my) 6.1 Fuel filter emptying valve 6.2 Permanent ventilation in KF (0.7 mm) 7 Nozzle holder combination 8 PLN unit pumps (Y6 to Y13) 9 Banjo union with permanent ventilation (0.7 mm) (located on fuel filter in EURO 4/5 vehicles) 10 Overflow valve (up to engine no. 092407 2.0 bar, as of engine no. 092408 2.65 bar) 10.1 Throttle (3.1 mm) in overflow valve 11.1 Fuel filler neck connector (in frame) 11.2 Fuel return line connector (in frame) 12 Throttle (0.5 mm) in the fuel line flame starting system

09/07

B10 Fuel temperature sensor R3 Flame glow plug Y5 Flame starting system solenoid valve Fuel circuit A Fuel feed line/suction side B Fuel feed line/pressure side C Fuel high pressure side (injection line) after PLN unit pumps D Fuel return line after unit pump E Fuel flushing volume (fuel bypass) F Fuel return line/leak fuel Test points, test data G Pressure gauge test H Fuel return volume test

-------

Fuel channels in ZKG Fuel lines


Exercise Test point

 At which test points are the following tests made? Match the items.

Fuel test System pressure in low pressure circulation after filter Fuel return volume to fuel tank Low pressure fuel circuit leaktightness Fuel suction pressure of the fuel pump Air bubble formation in the intake line Fuel return volume (leak oil quantity) nozzle holder assembly with pressure pipe connection

09/07


Notes

09/07

28.09.2007


Fuel Pressure Test Points, Model Series 900; Exercise

28.09.2007

W07.15-1015-09

09/07


Fuel circuit diagram 1 Fuel feed pump (KFP) 1. Pressure limiting valve in fuel delivery pump (9.2 bar) 1.2 Check valve in the fuel feed pump (0.2 bar) 2 Fuel filter (KF) 2.1 Fuel filter emptying valve 2.2 Permanent ventilation in KF 3.1 Bypass from fuel feed duct to return duct 5 Nozzle holder combination 8 Overflow valve (4.5 bar) 8.1 Permanent purging (0.5 mm) 10 PLN unit pumps (Y6 to Y11) 12 Fuel prefilter (KVF) 12.1 Check valve in KVF 14.1 Plug-on valve on the fuel filler neck (locked in open position) 15.1 Plug-on valve in the fuel return line (locked in open position) 17 Fuel tank 17.1 Air admission valve 18.1 Throttle (18.1 mm) in the flame starting fuel line 18.2 Throttle (threaded throttle) in the flame starting fuel line

09/07

B10 Fuel temperature sensor R3 Flame start glow plug Y5 Solenoid valve

Fuel circuit A Fuel feed line (intake vacuum-side) B Fuel return (leak fuel) C Fuel feed line (pressure side) D Fuel high pressure side (after PLN unit pumps) E Fuel return (fuel filter emptying)

Test points, test data G Pressure gauge test H Fuel return volume test


Exercise

Test point

 At which test points are the following tests made? Match the items.

Fuel test System pressure in the low pressure circuit Unit pump flushing volume Fuel suction pressure before the fuel pump Fuel return volume to fuel tank Fuel return volume (leak oil quantity) nozzle holder assembly with pressure pipe connection Low pressure fuel circuit leaktightness Fuel filter return amount and nozzle holder assembly with pressure pipe connection Air bubble formation in the intake line

09/07


Fuel Circuit, Model Series 500 - Symptoms; Exercise

Exercise 1

28.09.2007

 Let us deal with the symptoms and effects in the event of complaints in the fuel circuit.

You have the following situation: A pressure pipe connection is broken on an engine. Which symptoms may occur in such a case of damage. Discuss this problem case in your group and note your solutions.    

Exercise 2

 Which fuel test would you use to locate this problem? If you would carry out several tests, please

specify the sequence and explain this.    

09/07


Exercise 3

 Here is another problem case you might encounter every day:

A lot of turns of the crankshaft are needed in the morning before the engine starts up. You think that the problem is located in the fuel circuit. Which tests would you carry out and in what sequence? Discuss this problem case in your group and note your suggestions.    

Exercise 4

 Which possible causes for this complaint can you check with the test options you listed above?

    

09/07


Fuel Filter Housing, Model Series 500/ 457; Exercise

28.09.2007

Exercise 1 Several components are shown in the fuel filter housing in the graphic representation of the "symbolic fuel circuit". In the illustration, mark the following components with 1 for fuel filter drain valve and 2 for permanent ventilation.

N07.15-2044-01

09/07


Unit Pump Magnet - Sealing; Exercise

28.09.2007

In the event of an external leak at the unit pumps' magnet (4), the sealing elements (2) may be replaced. Use the video sequence "Seal the unit pump magnet" and the workshop information document AR07.15-W-8960 to complete the exercises.

Example: Unit pump, model series 500/model series 457

12/06


N07.02-2031-03

Exercise 1

 Which components must be replaced?



Exercise 2

Exercise 3

 Indicate the torque specifications for the bolts (6).

Model series 500, model series 457:

Model series 900:









 What requires particular attention when sealing an external leakage at the unit pump magnet?

Mark the correct answer with an "X". The valve plate (1.1) must not be twisted.  Ensure scrupulous cleanliness.  The original, mutual installation position of certain components must be marked. 

12/06


Install Unit Pump, Model Serie 500; Exercise

Exercise 1

28.09.2007

 Before reinstalling a unit pump, please clarify the precise process and the required conditions in

advance. Which precautionary measures must be implemented? Refer to the corresponding workshop literature (AR07.15-W...) and mark the correct information.

09/07

a

Turn the crankshaft with rotary device until pump cam point towards the unit pump.

b

Only replace the O-ring when it is damaged.

c

The pump can only be installed when the cam is located in the base circle.

d

Before installing the unit pump, replace O-rings using special tool.

e

The O-rings must be coated with assembly grease before installing the unit pump.

f

To insert the unit pump into the crankcase, use of assembly pins for guidance is vital.

g

Press unit pump into the crankcase by hand counter to spring force, insert mounting bolts and draw unit pump into the seat with these.

h

Tighten the mounting bolts to the prescribed torque.

i

The lines at the solenoid valve must be connected according to the defined specifications.

j

After replacing a unit pump, unit pump classification must be carried out.

k

After moving a used unit pump (for diagnostic purposes), unit pump classification must be carried out.


Exercise 2

 Which color do sealing ring (2) and sealing ring (3) have when located properly?

What must additionally be noted when installing the sealing rings?

 Upper seal ring:  Lower seal ring:  Assembly notes:

W07.15-1107-01

09/07


Install Unit Pump, Model Series 900; Exercise

Exercise 1

28.09.2007

 Before reinstalling a unit pump, please clarify the precise process and the required conditions in

advance. Which precautionary measures must be implemented? Refer to the corresponding workshop literature (AR07.15-W...) and mark the correct information.

09/07

l

Turn the crankshaft with rotary device until pump cam point towards the unit pump.

m

Only replace the O-ring when it is damaged.

n

The pump can only be installed when the cam is located in the base circle.

o

Before installing the unit pump, replace O-rings using the protective sleeve (special tool).

p

The O-rings must be coated with assembly grease before installing the unit pump.

q

To insert the unit pump into the crankcase, use assembly pins to guide the unit pump.

r

Pull the unit pump into its seat with the mounting bolts and tighten them.

s

Press the unit pump by hand against the spring load into the crankcase. The gap should be approx. 4 mm.

t

Press in the unit pump by hand as far as possible. Close up the remaining distance using the bolts by turning slowly. Then tighten to the prescribed torque.

u

The lines at the solenoid valve must be connected according to the defined specifications.

v

After replacing a unit pump, unit pump classification must be carried out.

w

After moving a used unit pump (for diagnostic purposes), unit pump classification must be carried out.


Exercise 2

 Which color do sealing ring (2) and sealing ring (3) have when located properly?

What must additionally be noted when installing the sealing rings?

 Upper seal ring:  Lower seal ring:  Assembly notes:

W07.15-1107-01

09/07


Unit Pump Classification

28.09.2007

The unit pumps in model series 900 and 457 are coded at the time of manufacture. The coding is used to compensate for manufacturing tolerances in the unit pump. The code of each individual pump is recorded when it is installed in the engine on the assembly line and stored in the MR control unit. To ensure smooth running of the engine, the engine control system uses the codes to assign proportioned fuel to the individual unit pumps (i.e. to set injection times). If unit pumps are replaced or relocated for diagnostic purposes, the unit pumps for each cylinder need to be reassigned (classed).

Entering the wrong code may cause the engine to run rough and can damage the engine.

AXOR Unit pump replacement Cylinders Cylinder 1

X-XXX-XXX-XX-XXXXX

2

Cylinder 2

X-XXX-XXX-XX-XXXXX

3

Cylinder 3

X-XXX-XXX-XX-XXXXX

4

Cylinder 4

X-XXX-XXX-XX-XXXXX

5

Cylinder 5

X-XXX-XXX-XX-XXXXX

6

Cylinder 6

X-XXX-XXX-XX-XXXXX

Note: The user must read off the unit pump number on the unit pump and enter it for the corresponding unit pumps that are replaced. To enter, press F3.

09/07

Code

1

cylinder. Only enter the number of

Note: The smooth idle control must be reset after coding the unit pumps.

MR


The code is given as a 14-digit number (C) on the unit pump's model plate. The code is entered into the engine control system using the "Replace unit pump" menu in DAS.

A MB number B Certification number C Unit pump number D Barcode E, G, H Manufacturer information F Manufacturer barcode N07.02-2028-01

09/07


Turbocharger, Model Series 457 - Mechanical Check; Exercise

28.09.2007

Exercise 

Complete the table using the workshop information (AR09.40-W-.......). Measure a turbocharger.

W09.40-1042-02

W09.40-1043-02

Specified value Rotor shaft axial play: Radial play on rotor shaft

09/07


Actual value

Turbobrake - Location of Components

28.09.2007

1 Turbocharger 2 Vacuum cell 3 Turbobrake A6 MR/PLD control unit B104 Turbine speed sensor Y87 Electric-pneumatic converter (EPW) OM 457 LA view

09/07


W09.40-1061-06

Turbobrake - Components and Function

28.09.2007

N14.15-2067-50

09/07


The Turbobrake has replaced the engine brake flap; it is designed as an axially sliding guide vane (4) within the turbocharger. As soon as a stronger engine braking effect is required, the guide vane (4) is pushed into the annular duct of the turbine entrance, thus reducing the flow cross-section of the annular duct, as well as the flow angle of the exhaust gas on the turbine. This accelerates the exhaust gas and thus leads to an increase in the turbine's rpm, which increases the boost pressure. The built-up boost pressure also increases the engine braking effect, i.e. the increased compression corresponds to an increase in the braking work. The guide vane is slid by the working cylinder (1). It is actuated by the FR, similar to the engine brake flap. Driver requests are transmitted via the engine control/permanent brake control operating lever. The constant throttle is also actuated at a coolant temperature > 60°C.

09/07

OM 457 LA view

1 2 3 4

Working cylinder Positioning cam Housing Guide vane


W09.40-1066-09

5 Positioner 6 Array 7 Turbine scroll

8 Vacuum cell 9 Vent element 10 Rotary valve

The turbine rpm is forwarded by the turbine speed sensor (B 104) in the turbocharger to the engine control (MR) control unit (A6) and limited to 90,000 rpm to prevent the turbocharger from being damaged by overspeeds. The engine control (MR) control unit actuates the electropneumatic pressure converter (Y87) that operates the rotary valve's (4) vacuum cell (2) to limit and control the braking torque. Just as with a wastegate valve, the exhaust gas is sent past the turbine wheel via a bypass. This limits the boost pressure and turbine rpm. The Turbobrake responds within a period of 1 to 10 s, depending on the engine's initial speed and initial load condition. Thanks to the constant throttle, a high braking power is present almost spontaneously after activation. The driver feels this as a smooth start to braking up to the maximum braking power by the Turbobrake.

OM 457 LA view

2 4 5 6

09/07

Vacuum cell Rotary valve Bypass tube Turbine wheel


W09.40-1062-06

7 Rotary valve housing A6 MR control unit B104 Turbine speed sensor Y87 EPW valve

Turbobrake - Comparison with other Brake Systems

28.09.2007

Turbobrake, comparison with engine brake flap

A Engine brake flap, constant throttle and retarder B Turbobrake and constant throttle C Engine brake flap and constant throttle W09.40-1067-75

Advantages of the Turbobrake: • 50% more braking power in comparison with the standard engine brake (brake valve and constant throttle) at an engine speed of 2500 rpm • Lower weight (weight saving of approx. 85 kg in comparison with a hydraulic retarder) • Cooling system relief in comparison with a hydraulic retarder • Constant braking power, as independent of the coolant temperature • Maintenance-free system 09/07


Turbobrake - Location, Design and Function of the Guide Vane

28.09.2007

Location: The guide vane (1) is located in the array (2) and can be moved axially.

Operation: The extended guide vane (1) reduces the flow cross section of the annular port and changes the flow angle of the exhaust gases onto the turbine in order to increase turbine performance.

Configuration OM 457 LA

1 Guide vane 2 Array

09/07


W09.40-1065-09

3 Turbocharger

A Guide vane retracted B Guide vane extended

Turbobrake - Location, Design and Function of the Vent Element

28.09.2007

Design: The vent element (1) consists of the rotary valve (4), which is supported by rotatable bearings in the turbocharger housing and is connected to the pressure capsule (2).

Location: The vent element (1) is located at the turbocharger (3) in the entry area of the turbine scroll.

Operation: The vent element (1) regulates the exhaust gas mass flow in the turbine and if required, guides this flow through the cross-sections in the rotary valve (4) in the exhaust air pipe.

1 Vent element 2 Pressure capsule 3 Turbocharger 4 Rotary valve OM 457 LA view

09/07


W09.40-1063-06

Turbobrake - Turbine Speed Sensor, Location and Function

28.09.2007

Location: The turbine speed sensor (B104) is bolted into the turbocharger (1) housing. Operation: The turbine shaft rotates past the turbine speed sensor (B104) and induces a voltage signal. This is recorded by the turbine speed sensor (B104) and forwarded to the MR/PLD control unit.

1 Turbocharger B104 Turbine speed sensor OM 457 LA view

09/07


W07.04-1024-03

Turbobrake - Electric-pneumatic Converter (EPW), Location, Structure and Function

28.09.2007

Location: In the OM 457 LA, the electric-pneumatic converter (EPW) (Y87) is bolted onto the crankcase beneath the turbocharger on the right-hand side of the engine.

Exercise: The electrical-pneumatic converter (EPW) (Y87) is actuated by the MR/PLD control unit and regulates the opening ratio of the blow-off element.

Y87 Electric-pneumatic converter (EPW) OM 457 LA view

09/07


W07.17-1002-03

Design and function:

1 2 3 4 5 6 7 8 9

Blow-off element control line Compressed air supply line Aluminum housing Exhaust air line Electrical connector Valve Pressure sensor Control electronics Proportional solenoid W07.17-1003-12

According to the modulated input signal (value specified by the MR/PLD control unit), the electric-pneumatic converter (EPW) (Y87) outputs a pressure in the blow-off element's control line (1). The regulating electronics (8) compares the specified value with the pressure in the blow-off element control line (1). The pressure in the blow-off element's control line (1) is measured by the pressure sensor (7). One of the regulated quantities generated by the regulating electronics (8) actuates the valve (6) for admitting and removing air with the proportional magnets (9) till the required pressure in the blow-off element control line (1) is set.

09/07


Turbobrake - Engine Brake Request

28.09.2007

3-stage selector lever in the A XOR Switch position 1: Switch position 2:

The constant throttle is engaged and 50% of the maximum Turbobrake braking power are set. The blow-off facility is used to regulate the Turbobrake's brake force. Constant throttle and 100% Turbobrake braking power. The rotary valve closes. In both cases, the guide vane is always extended fully.

6-stage selector lever in the A XOR The individual brake stages equate to 20%, 40%, 60%, 80% and 100% of the maximum braking power. The sl iding sleeve is always extended fully. The individual output stages are achieved via the rotary valve.

Cruise control Even in cruise control braking mode, the guide vane is always extended fully. The required braking power is set continuously via the rotary valve.

Brake stages for Freightliner, USA Switch position 1 Switch position 2 Switch position 3

Constant throttle only, the Turbobrake is not actuated Constant throttle and 50% Turbobrake braking power Constant throttle and 100 % Turbobrake

Remark: If certain transmissions (e.g. Allison) are used, the braking power or the braking torque may have to be reduced.

09/07


Turbobrake - Troubleshooting, Functions for Operation

28.09.2007

Guide vane actuation: Discernible from the outside via movement of the clamp, which is actuated via the pneumatic working cylinder. Control takes place via an electropneumatic 3/2-way valve. In MB vehicles, this is actuated by the drive control (FR) system. Actuation may also be done manually using STAR DIAGNOSIS. In the OM 460 (Freightliner), the clamp is actuated by the engine control (MR) system via proportioning valve 6. Rotary valve actuation: Discernible from the outside via rotation of the rotary valve, which is actuated via linkage by the vacuum cell. The vacuum cell is actuated pneumatically by the EPW valve. The EPW valve is controlled by the MR via proportioning valve 1. Manual actuation may also take place via STAR DIAGNOSIS. On starting the engine, the rotary valve must move and assume its closed position. Constant throttle valve actuation: Not discernible from the outside, the constant throttle valve is actuated hydraulically via an electrohydraulic 3/2-way valve seated on the oil filter housing. The 3/2-way valve is controlled by the MR via proportioning valve 2. Manual actuation may also take place via STAR DIAGNOSIS. To check the function of the valve, the engine can first be briefly revved up in neutral. On engagement of the constant throttle, the rpm drop must be significantly greater than on non-actuation. The constant throttle valve causes slight hissing. If in doubt, pressure buildup in the control line can be checked using a pressure gauge or an oil line banjo bolt can be opened slightly (Attention: Danger of major oil escape). The constant throttle only functions if the coolant temperature exceeds 60°C. Turbocharger speed sensing: Turbocharger speed sensing protects the turbine from excessive speeds in braking mode. Rpm control is carried out by the MR via the blow-off facility's control system.

Note: If proportioning valves are manually engaged using STAR Diagnosis, it is vital to switch the ignition off completely following the test, as the engine otherwise remains in test mode.

09/07


Turbobrake - Troubleshooting

28.09.2007

General visual inspections for proper operation with the vehicle stationary

Function of the constant throttle valves Prerequisite: Vehicle engine is at operating temperature. Constant throttle valve actuation: Switch on brake stage 1, run up engine speed and allow to decrease rapidly. The rpm drop must be significantly faster than without a constant throttle. A conspicuous noise can also be heard in the exhaust system. Function of the Turbobrake Prerequisite: Actuation of blow-off facility: Actuation of guide vane:

Vehicle engine is at operating temperature. Switch on the ignition and switch on brake stage 2. Tilt cab. Start engine using start button. On starting the engine, the piston rod of the vacuum cell must discernibly extend. On switching off the engine, the piston rod of the vacuum cell must retract completely. Switch on brake stage 1 or 2 and run up engine speed using start button. The engine begins to surge. The yoke of the guide vane must turn over completely.

General function checks during vehicle operation Charger speed check At full load (fueled) n > 1,500 rpm: In max. Turbobrake braking mode n > 2.000 rpm:

Charger speed > 90000 rpm, max. 110000 rpm Charger speed > 85000 rpm to max. 90000 rpm

Control pressure check Line pressure at actuating cylinder: Specified: > 8 bar Line pressure at EPW valve: Specified: > 5 bar in idle and at full load (Note: Future engines will also be influenced by the rotary valve in fueled mode.)

09/07


Troubleshooting table Complaints / malfunctions Turbobrake inoperative

Clamp for guide vane does not operate.

Blow-off facility linkage does not function.

09/07

Possible causes Current fault code in FR, MR or other systems. Clutch status "closed" not recognized. Parameter incorrectly set in FR or MR. Solenoid valve has no electrical actuation. Clamp, actuation cam or guide vane sluggish or mechanically blocked. Actuating cylinder sluggish or mechanically blocked. No or insufficient compressed air at the actuating cylinder. No or insufficient compressed air to the solenoid valve. EPW valve has no electrical actuation.

Remedy / measures Read out and rectify fault Teach-in clutch. Check and correct parameter. Check parameterization in the FR. Unhook actuating cylinder and check clamp for mechanical freedom of movement. Check actuating cylinder function. Check compressed air supply from the solenoid valve to the actuating cylinder. Check/measure compressed air supply to the solenoid valve. Check circuit 4 reservoir pressure. Control line for PWM signal has discontinuity (PWM signal 0 is permissible). Check parameterization in the MR. Rotary valve sluggish or mechanically blocked. Unhook actuating cylinder and rotary valve for mechanical freedom of movement. Note: Vacuum cell linkage under tension. No or insufficient compressed air at the vacuum cell. Check hose line from the EPW valve to the vacuum cell for constriction and leaks. Check vacuum cell for leaks Pressure measurements in the hose line: Specified pressures: 5 bar in idle, min. 2 bar in engine braking mode. No or insufficient compressed air to the EPW valve. Check/measure compressed air supply to the EPW valve. Check circuit 4 reservoir pressure. EPW valve without function Exchange EPW valve.


Complaints / malfunctions Braking power inadequate

Possible causes Engine is operated at excessively low speeds. Insufficient compressed air at the vacuum cell.

No or insufficient compressed air to the EPW valve. EPW valve malfunction Constant throttle valves do not open, 3/2-way valve has no electrical actuation Constant throttle valves do not open, insufficient oil pressure.

09/07


Remedy / measures Driver note, engine speeds > 2000 rpm if possible Check hose line from the EPW valve to the vacuum cell for constriction and leaks. Check vacuum cell for leaks Pressure measurements in the hose line: Specified pressures: 5 bar in idle, min. 2 bar in engine braking mode. Check/measure compressed air supply to the EPW valve. Check circuit 4 reservoir pressure. Exchange EPW valve. Check parameterization in the MR. Coolant temperature must be > 60°C. Check/measure oil pressure to the constant throttle valves

Turbobrake - Troubleshooting; Exercise

A3 A4 A6 A11 A22

Drive control (FR) control unit Flame starting system (FLA) control unit Engine control (MR) control unit Brake control (BS) control unit Parameterizable special module (PSM) control unit

B1 B11 B17 B104

Foot throttle actuator Engine oil temperature sensor Vehicle speed sensor Turbine speed sensor

P3 P4

Modular tachograph (MTCO) Instrument

S1 S2

Drive switch Engine control/permanent brake operating lever

Y1 Y49 Y87

Engine brake 1 solenoid valve Constant throttle solenoid valve Electrical-pneumatic converter (EPW)

28.09.2007

View of the AXOR

09/07


GT05_00_0025_C82

Exercise

 Place the right control unit code in the boxes below.

Which control unit controls the guide vane? Which component detects the turbine speed? Which component adjusts the pneumatic pressure in the pressure capsule for the purpose of rotary valve control? Which control unit controls the rotary valve?

09/07


Charge Air Manifold, Model Series 457 - Installation; Exercise

28.09.2007

Exercise 1 

Which parts must be replaced prior to installation of the charge air manifold? Name the components and use WIS document AR09.41-W-8681D to help you.



W09.41-1013-06

09/07


Exercise 2

Exercise 3

 Indicate the tightening torques for the following bolts.

Bolt, charge air pipe to charge air manifold:



Bolt (2), charge air manifold to cylinder head:



 Different hoses are used between the charge air housing and the charge air cooler.

Which of the following statements are correct? a

The side on which the red and black hoses are fitted is irrelevant. The red charge air hose must be installed between the turbocharger charge air pipe and the charge air cooler. c Correct installation is very important, because only the red hose is heat-resistant. d The black hose is resistant to vacuum. e The black hose is flame-resistant. b

09/07


Charge Air Manifold, Model Series 500 - Installation; Exercise

28.09.2007

Exercise 1 

Which parts must be replaced prior to installation of the charge air manifold? Name the components. Use the workshop literature AR09.41-W-8681B.

   

W09.41-1006-09

09/07


Exercise 2

Exercise 3

 Indicate the tightening torques for the following threaded studs.

Threaded stud (9) to crankcase:



Threaded stud (10) to oil filter housing bracket:



 Different hoses are used between the charge air housing and the charge air cooler.

Which of the following statements are correct? a

The side on which the red and black hoses are fitted is irrelevant. The red charge air hose must be installed between the charge air pipe and the charge air cooler. c Correct installation is very important, because only the red hose is heat-resistant. d The black hose is resistant to vacuum. e The black hose is flame-resistant. b

09/07


Oil Circuit, Model Series 457; Exercise

Exercise

28.09.2007

 Get to understand the oil circuit using the graphic below and assign the components listed in the

legend to the oil circuit.

8 11

1 Oil sump 2 Intake tube with fine-mesh filter 3 Oil pump 4 Main lubricating oil duct (unfiltered) 5 Oil cooler (oil/water heat exchanger) 6 Oil filter 7 Oil spray nozzle for piston cooling 8 Oil spray nozzle for camshaft 9 Oil spray nozzle for valve gear 10 Turbocharger return line 11 Turbocharger feed line 12 Main lubricating oil duct (filtered) N18.00-2071-50

12/06


Oil Circuit Model Series 457 - Task and Function; Exercise

28.09.2007

 Various valves with very different tasks and functions are included in the oil circuit.

Exercise

Enter the appropriate valve in the table below. Use WIS function description GF18.00-W....

The....................

Tasks and functions The ...... is located underneath the oil pump and serves to limit the maximum oil pressure. If the maximum oil pressure is exceeded, the ........ opens up and lets the engine oil flow directly from the oil pump back into the oil pan. The ....... is located in the oil filter housing underneath the oil filter insert and opens when the oil filter cover is removed. This ensures a clean oil filter change with little environmental pollution since the amount of oil remaining in the filter element at the time of disposal is reduced. The ........ is installed in the filter dome housing unit (riser) and seals an opening in the filter element disk in the oil filter element. The ........ is normally closed. If the oil filter element is clogged, the pressure increase in the oil filter housing causes the ......... to open. This ensures that the engine remains lubricated, although the engine oil that flows through the filter ........ is not filtered.

12/06


Oil Circuit Model Series 500 - Location of Components; Exercise

28.09.2007

Exercise 

Match the numbers to the components in the graphic. Discuss their function in your group. Use the available workshop literature.

1 2 3 4 5 6 7 8

Oil intake tube Oil check valve Oil pressure relief valve Oil cooler Oil pump Main oil duct Oil spray nozzle Oil check valve for oil circuit filling

N18.00-2011-50

09/07



28.09.2007


Exercise

Enter the appropriate valve in the table below. Use WIS function description GF18.00-W-0001B.

The....................

Tasks and functions The ..... is located in the right rear of the crankcase and ensures that the engine oil does not return to the oil pan when the engine is stopped . As a result, the oil ducts are always filled with engine oil. This ensures optimal lubrication of the components from the moment the engine is started again. The ...... is located underneath the oil pump and serves to limit the maximum oil pressure. If the maximum oil pressure is exceeded, the ........ opens up and lets the engine oil flow directly from the oil pump back into the oil pan. The ....... is located in the oil filter housing underneath the oil filter insert and opens when the oil filter cover is removed. This ensures a clean oil filter change with little environmental pollution since the amount of oil remaining in the filter element at the time of disposal is reduced. The ....... is located at the bottom of the oil filter housing and is closed with a screw plug (M33x2). When the engine is being assembled or during repair operations, the ........ allows the engine oil circuit to be filled with engine oil before the engine is started. The ........ (opening pressure 2.3...3.0 bar ) is installed in the housing unit underneath the oil/water heat exchanger and is connected to the oil filter via an oil duct. The ........ is normally closed. If the oil filter element is clogged, the pressure increase in the oil filter housing causes the ......... to open. This ensures that the engine remains lubricated, although the engine oil that flows through the filter ........ is not filtered.

12/06


Oil Circuit Model Series 900 - Location of the Components; Exercise

28.09.2007

Exercise 

Assign the corresponding numbers to the components in the list. Use the available workshop literature GF18.00-W-0001A.

1

Oil pan Oil pump Oil filter housing Main oil duct Camshaft bearing Rocker arm with oil hole Rocker arm spindle Pressure limiting valve Oil pump strainer with oil intake tube Oil/water heat exchanger Oil duct to the cylinder head Oil pressure line to the turbocharger Oil spray nozzle Main bearings/connecting rod bearings of crankshaft Rear cross duct for oil Oil duct to the unit pumps W18.00-1005-06

09/07



28.09.2007


Exercise

Enter the appropriate valve in the table below. Use WIS function description GF18.00-W-0001A.

The....................

Tasks and functions The ..... (opening pressure 0.03...0.07 bar) is located in the oil filter housing and is intended to prevent engine oil flowing back into the oil ducts or the oil pan when the engine is stationary. As a result, the oil ducts are always filled with engine oil. This ensures optimal lubrication of the components from the moment the engine is started again. The ...... is located underneath the oil pump and serves to limit the maximum oil pressure. If the maximum oil pressure is exceeded, the ........ opens up and lets the engine oil flow directly from the oil pump back into the oil pan. The ....... is located in the oil filter housing underneath the oil filter insert and opens when the oil filter cover is removed. This ensures a clean oil filter change with little environmental pollution since the amount of oil remaining in the filter element at the time of disposal is reduced. The ........ (opening pressure 1.8...2.6 bar) is installed at the top in the oil filter element's support dome (oil filter housing). The ........ is normally closed. If the oil filter element is clogged, the pressure increase in the oil filter housing causes the ......... to open. This ensures that the engine remains lubricated, although the engine oil that flows through the filter ........ is not filtered.

09/07


Oil Cooler- Oil Filter Housing, Model Series 500 - Location of Components; Exercise

28.09.2007

Exercise Match the numbers to the components in the graphic. Use the available workshop literature.

The following components are integrated in the aluminum die casting housing of this add-on unit:

1 2 3 4 5 6 7 8 9 10 11

Full-flow oil filter Filter drain valve Filter bypass valve Oil temperature sensor Oil pressure sensor Oil/water heat exchanger (flat-tube) Coolant temperature sensor Connection for bypass filter (outlet) Connection for bypass filter (inlet) Riser Connection for oil circuit filling

N01.20-2020-05

09/07


Oil Filter Housing, Model Series 900 - Location of Components; Exercise

28.09.2007

Exercise An oil drain valve is installed in the filter housing to make clean oil changes possible. The task can be equated to that of the fuel drain valve. But it is different in terms of location and function. Identify the components in the graphic. 1 Oil combination sensor 2 Oil drain valve 3 Filter bypass valve 4 Riser 5 Return flow check valve

3 4 1 5

2 N18.20-2013-01

09/07


N18.20-2021-03

45111495 Engine Repair

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