CLAAS Engine Mercedes-Benz OM470LA OM471LA Repair Manual PDF [PDF]

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Mercedes-Benz OM470LA Mercedes-Benz OM471LA

Repair manual

Service & Parts

1451-001

1451-001

Table of contents Introduction General Information.................................................................................................................................

4

General repair instructions.....................................................................................................................

8

Torque settings........................................................................................................................................

21

CCN explanation CCN (CLAAS Component Number)........................................................................................................

33

CCN (CLAAS Component Number) Safety General Information.................................................................................................................................

37

01 Engine 0102 Complete component.....................................................................................................................

49

0105 Engine suspension.........................................................................................................................

75

0110 Engine housing...............................................................................................................................

78

0115 Engine unit......................................................................................................................................

119

0120 Cylinder head / Valves / Idler gear................................................................................................

170

0125 Injection - / Fuel system.................................................................................................................

265

0130 Lubricating oil system....................................................................................................................

333

0135 Cooling system...............................................................................................................................

355

0140 Exhaust system..............................................................................................................................

366

0145 Air intake.........................................................................................................................................

432

0150 Engine attachment parts................................................................................................................

451

0155 Engine control.................................................................................................................................

475

0165 Exhaust gas aftertreatment...........................................................................................................

478

Index....................................................................................................................................

493

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3

Introduction General Information 1451-001

Introduction General Information 175821-001

Validity of manual This manual applies to the Mercedes-Benz diesel engines below: Engine

Type design

Engine no.

OM 470 LA

470.907

470.907-C-xxxxxx

OM 471 LA

471.919

471.919-C-xxxxxx

OM 473 LA

473.905

473.905-C-xxxxxx 123139-005

Handling the manual This repair manual should help you to maintain ongoing operational capacity. The high value of the harvesting machine is ensured through careful maintenance and technical monitoring by customer service. This repair manual is a compilation of our service technicians' and shop-floor experience. The picture sequence demonstrates the steps in a repair procedure. The text provides you with the information required for making adjustments, using special tools and further similar information. Essential repairs are listed in such a way that even individual and small repairs can be easily found and followed. Supplements are added to reflect the ongoing technical development of the machines and the manual is thereby continuously being updated as a reference book. As a precaution, always compare the setting values and fill quantities with the most recent operator's manual and the technical systems documents for the respective machine. Texts and figures Pictures and graphics apply to all models covered by this manual. Differences are highlighted by captions below the figures. In general, texts are short and apply to all models covered by this manual. Differences are highlighted by intermediate headings. Different text categories can be easily identified by the formatting. The following different formattings are distinguished:

4

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Introduction General Information 1451-001

Formatting

Meaning

Description

Description

Descriptive text

Further information on the subject.

Process

Operations which must be carried out one after the other.

Result

Result of the processes carried out.

– Procedure instructions Result

References can be easily identified by corresponding symbols. The following symbols are distinguished: Symbol

Meaning

Description

See index

The symbol indicates that further information on this subject is available in other sections of this manual. The symbol indicates that further information on this subject is available in the Operator's Manual of the machine or of the implement in question.

See the index of the Operator's Manual in question

Document structure based on the assembly structure The chapters of the present manual are subdivided into assemblies as far as contents permit. The structure of these assemblies is the same in all chapters. Different product groups have different assembly structures. CLAAS makes every effort to keep this assembly structures identical in any document. Search and find Due to the constantly recurring assembly structure, the subject in question can be quickly found using the table of contents or the header of this manual. In addition, the index provided in this manual is a useful tool for locating a subject. The index can be found on the last pages of this manual. Directions Front, rear, right and left refer to the direction of forward travel. If necessary, a direction arrow is used for indicating the direction of travel in figures.

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5

Introduction General Information 1451-001

Abbreviations

6

Abbreviation

Description

bar

bar (unit for pressure)

approx.

approximately

cm

Centimetre

DIN

German Standardization Institute

EC

European Community

EN

European Standard

GPS

Satellite navigation system

h

Hours

Ident no.

Identification number of machine

ISO

International Standardization Organisation

kg

Kilogram

kPa

Kilopascal

km

Kilometre

km/h

Kilometres per hour

m

Metre

mm

Millimetre

Nm

Newtonmetre

psi

pound per square inch

StVZO

German Regulations Authorizing the Use of Vehicles for Road Traffic

e.g.

for instance

%

percent

°C

degrees Celsius (unit for temperature)

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Introduction General Information 1451-001

Technical terms Technical term

Description

recycle

Re-use of used, defective or no longer required products

Season

Recurring periods of a year

Ignition TDC

Ignition top dead centre (diesel engine piston position)

Overlap TDC

Valve overlap top dead centre (diesel engine piston position)

BDC

Bottom dead centre (diesel engine piston position)

Your CLAAS Service Department

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Introduction General repair instructions 1451-001

General repair instructions 123153-003

Technical specifications Technical specifications, dimensions and weights are non-binding. Changes reflecting the technical development and errors reserved. 123192-004

Information on technically correct repairs ► Ensure cleanliness of installation surroundings and of components in order to avoid damage due to soiling. ► Mark rotating machine components before removing or dismounting them in order to ensure well-balanced component seating on the correct side after refitting. ► The slots of expansion pins must always point to the loaded side. When they are installed with a 90° twist, they come loose, fall out or shear off. ► Replace cotter pins, locking wires, sheet retention devices, lock washers and spring washers in the repair process. ► Align sprockets and V-belt pulleys with one another. ► Observe the information in the hydraulic system chapter when working on the hydraulic system. ► Do not mix different oil grades. 123164-004

Self-locking bolts Self-locking bolts must not come in contact with sealing compound. ► Tighten self-locking bolt speedily up to the specified torque. ► The full hardening time can be reduced by heating-up, e.g. to 15 minutes at + 70 °C. ► The full load capacity is achieved after 24 hours at + 20 °C. ► When unscrewing self-locking bolts, unscrew them quickly.

8

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Liquid locking compound

1 151599-001

► Use liquid locking compound (glue) only at the spots described in the Repair Manual. The surfaces to be joined must be absolutely ► clean and free of grease. ► A suitable cleaner and an activator possibly delivered along with the glue can be used for cleaning. ► No cleaner residues may remain on the surfaces to be joined. This applies in particular to tapped holes with a bottom. ► Let the surfaces dry well before applying the glue. ► Apply the glue only in the areas shown in the figure if possible. When applying the glue at an unfavourable spot or when applying too much glue, the joint may tear off when loosening. ► Observe the glue producer's instructions for use and application! A joint secured by liquid locking compound can be loosened by heating up to approx. 200 °C. 120771-004

Steel roller chains Tensioning Checking the tension of steel roller chains: ► Apply a small load to the tight span. ► Push down the slack span in the middle between the sprockets with your thumb. You should be able to push down the slack span around 2 % of the spacing between the axles.

A

Example: Axle spacing (A) = 500 mm x

Pushing distance (x) of slack span = approx. 10 mm 2 13827-006

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Introduction General repair instructions 1451-001

Chain connector ► The closed side of chain connector (1) must point in running direction (L)! 1

3 123668-001 120801-006

Taper ring fasteners Dismounting 2

► Slacken off tapered ring (1) with a blow. ► Use an auxiliary tool (2) if required.

1

4 154769-001

Installing 13975-003

2

4

4 3 1

5 154486-001

10

NOTICE! Sticking together at the taper ring fasteners. The joint cannot be loosened or comes off only with difficulty. ► Do not install parts with tough grease. ► Clean the shaft (1), hub (2), parallel key (3) and taper ring (4) thoroughly and coat them with grease as specified in the Operator's Manual. ► Tighten to the specified torque. ► In case of several taper ring fasteners fitted behind one another, tighten those separately. ► Use an auxiliary tool (5) if required.

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Introduction General repair instructions 1451-001

2

5

4

1

3

6 154768-001 123163-004

Gib head key joints Dismounting ► Slacken off gib head key (1) with a blow if possible. ► Use an auxiliary tool (2) if required.

2

1

7 154811-001

► Drive out the gib head key (2) with a key drawer (1). ► Ensure that the key drawer is used as shown in the figure.

1

2

8 154813-001

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Introduction General repair instructions 1451-001

1

2

9 154812-001

Installation The gib head key (1) comes in raw condition as a spare part and must be machined to suit the application by milling or grinding.

1

► Grind the gib head key (1) to suit the application at surface (2). ► Surface (3) must not be machined. ► Clean shaft, hub and keyway to be free of grease, paint and rust prior to assembly.

3

85675-003

2

10 154492-001

NOTICE! Excessive force employed when installing the gib head key. Damage to the gib head key joint. The gib head key cannot be removed any more. ► Drive in the gib head key carefully with a suitable and not too heavy hammer. ► Ensure that the gib head key is driven in only so far that it can still be removed without problems, using a key extractor. 123167-003

Lock collar bearing Dismounting ► Slacken off set screw (1). ► Drive off eccentric ring (2) against the shaft's sense of rotation. ► Remove bearing.

1

2

11 154814-001

12

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Introduction General repair instructions 1451-001

Installing ► Tighten lock collar bearing (1) on the shaft by twisting eccentric ring (2) over the bearing inner race (3). ► Arrest the eccentric ring with moderate force in the sense of rotation of the shaft. ► To make dismounting easier, the inner ring and the shaft can be coated with grease as specified in the Operator's Manual. ► Tighten set screw (4).

1 4

3

2

12 154500-001 120831-003

Adapter sleeve bearings Dismounting 1

► Loosen the tab of sleeve nut (3). ► Slacken off sleeve nut by some turns only. ► Ensure that the thread is still completely engaged. Slacken off expansion pin (2) with a firm blow. ► ► Pull off adapter sleeve bearing (1) completely.

3

2

13 154510-001

Installation 1

► Clean expansion pin (2) and shaft and check easy movement of the sleeve nut (3). ► Install adapter sleeve bearing (1) according to the conical inside ring (2). ► Tighten the sleeve nut with the suitable special tool and to the prescribed torque. ► Continue tightening the sleeve nut to the specified degrees. ► Tighten sleeve nut until the nearest tab can be applied. ► Secure sleeve nut with the tab.

3

2

14 154510-001

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Introduction General repair instructions 1451-001 144598-003

Chuck bushing

275616-001

15

Possible versions of chuck bushings: ► Version (1): two-piece chuck bushing ► Version (2): four-piece chuck bushing Dismounting

275615-001

16

► Unscrew bolts (1). ► Screw in bolts (1), or longer bolts if required at (2). ► Screw in bolts until the chuck bushing comes loose. ► Apply a little oil to bushing if necessary. ► Remove the chuck bushing if required. Installation The installation method of the two chuck bushings differs. ► To ensure correct function of the chuck bushing, follow the installation method of the chuck bushing in question precisely.

14

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Introduction General repair instructions 1451-001

Chuck bushing version (1) ► Clean the chuck bushing and the shaft thoroughly. ► Insert chuck bushing. ► Ensure that slots (1) are installed with the largest angular offset possible. ► Tighten bolts (2) evenly crosswise in three steps. ► Observe the specified torques of the respective steps.

17 275617-001

Chuck bushing version (2) ► Clean the chuck bushing and the shaft thoroughly. ► Insert chuck bushing. ► Ensure that slots (1) are installed without angular offset. Tighten bolts (2) evenly crosswise in three steps. ► ► Observe the specified torques of the respective steps.

18 275619-001

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15

Introduction General repair instructions 1451-001 144716-004

Circlips 144718-002

NOTICE Overspreading the circlip. Plastic material deformation. No safe fixing of component. ► Spread circlip only as far as needed for installation and dismounting. ► Do not use any circlip already overspread before. ► Insert circlips as shown in the figures. ► Ensure that chamfer (1) does not make contact with the component to be secured. ► If required, make circlip engage with a slight blow.

1

19 Circlip DIN 471

155144-001

1

20 Circlip DIN 472

16

155145-001

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Introduction General repair instructions 1451-001 120840-004

Ferrule fittings Screwing in ► Cut off the corresponding tube at right angles. ► Do not use a pipe cutter. In case of pipe bends, the straight pipe end up to where the bending radius starts must be at least twice the height of the union nut. ► Slightly deburr the pipe end on the inside and outside. ► Do not chamfer the pipe end. ► Clean the pipe end. ► Push the union nut (1) and the ferrule (2) on the pipe. ► Push the pipe against the stop in the connector (3) and tighten the union nut until the ferrule seizes the pipe. This pressure point can be felt because increased power is needed from here. The pipe must be fixed securely during assembly and must not rotate. ► Tighten the union nut by half a rotation beyond the first pressure point. ► Check the incision at the cutting edge. A visible collar must fill the space ahead of the ferrule face end. The ferrule may rotate, but axial displacement must not be possible. ► Insert the pre-assembled pipe into the well-oiled threaded joint. ► Screw on the union nut until the power needed to do this clearly increases. ► After that, continue to screw the union nut on for half a turn beyond that point. ► Observe the tightening torques. Page 24

3 2

1

21 Ferrule without seal

154515-001

4

3

2

1

22 Ferrule with seal

154516-001

Non-tight ferrule connection ► If a connection leaks, loosen the union nut until some oil escapes. ► Then tighten according to instructions. ► Replace the seal (4) if required.

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Introduction General repair instructions 1451-001 123189-002

Sealing cone fittings 2

► Apply seal (1) on the sealing cone (2). ► Tighten the union nut (3) a third of a turn beyond the point where resistance is felt. ► Observe the tightening torques! Page 25

3

1

23 154527-001 120856-008

Hydraulic hoses 124582-004

CAUTION Hydraulic hoses may become leaky due to damage and ageing. This may make machine parts drop unintendedly and injure persons. ► Have damaged hydraulic hoses replaced immediately by a qualified specialist workshop. ► Have hydraulic hoses replaced by a qualified specialist workshop 6 years after production at the latest.

To facilitate identifying of hydraulic hoses, each hose has the CLAAS part number printed on it. ► Check hydraulic lines prior to putting into operation for the first time and then at least once a year. ► Replace the hydraulic hoses when damage or ageing appears. The date of manufacture can be identified on the hose fitting (1).

XXX / 250 bar/ 13/07

1

XXX / 250 bar / 13/07 2

3

(2) = Year (e.g. 12 = 2012)

1

(3) = Month (e.g. 07 = July) XXX / 250 bar / 13/07

24 40202-004

18

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Introduction General repair instructions 1451-001

Laying of hoses 13989-003

NOTICE! Hoses laid in a straight line get shorter as the hydraulic pressure is built up. Valves may be torn off. ► Always install hoses with a slight slack. ► Install hoses so that no tension or compression loads will occur in any operating conditions. ► Check: When moving the hose to either side at the centre between two fixing/joining elements (e.g. clamps), the entire play of the hose is to be 1 cm min. 25 5727-002

► Do not install a hose with a twist. ► In particular not if the hose is subject to movement.

26 5728-002

27 5729-002

28 5726-002

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► Avoid external mechanical impacts on hoses. ► Avoid chafing of hoses on one another or on components by useful arrangement and fastening. ► Keep an adequate distance from components. ► Cover up sharp-edged components permanently. ► When high outside temperatures are involved, install hoses at a sufficient distance from components radiating heat. ► If necessary, protect hose by a protective guard.

19

Introduction General repair instructions 1451-001

29 5730-002 157962-002

Treatment of sealing faces Close all oil, coolant and fuel bores thoroughly prior to treating the sealing faces. Ensure that when treating sealing faces of components containing oil, coolant and fuel, no abrasives are used. Loose particles cause pollution and damage. Ensure that no seal residues, rust, lime and combustion residues end up in open components (gearbox halves). Remove sealing residues, rust, lime and combustion residues only using scraping tools or cleaning agents. 123155-004

Spare parts 11210-003

WARNING Use of unauthorised spare parts. Death or serious injury. ► Spare parts must at least comply with the technical standards required by the manufacturer of the implement! ► We recommend using genuine CLAAS spare parts.

► Please quote the machine identification number when ordering spare parts or making technical enquiries. CLAAS will assume no liability whatsoever for damage incurred as a result of the use of non-genuine CLAAS parts, accessories, and ancillary equipment.

20

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Introduction Torque settings 1451-001

Torque settings 123194-004

Tightening torques for metric standard threads The tightening torques specified below apply only when: – in connection with thread lubricant a coefficient of friction of µ tot = 0.14 is reached. To achieve this, surface protection such as A3C +L, Dacromet or Termosil is recommended. – no other tightening torque is specified in the specifications. – no additional screw retention is used, such as MK-type bolts or liquid locking compound. Tightening torque in Nm at a friction coefficient μ tot = 0.14

Bolts and nuts Strength class

8.8

10.9

12.9

M4

2.9

4.3

5

M5

5.8

8.5

10

M6

10

14.5

17

M8

24.5

36

42

M 10

48.5

71

83.5

M 12

83.5

123

144

M 14

133

196

229

M 16

207

304

355

M 18

296

422

494

M 20

417

594

695

M 22

570

813

951

M 24

718

1022

1196

M 27

1058

1506

1763

M 30

1437

2046

2395

M 33

1944

2770

3240

M 36

2500

3561

4167

M 39

3237

4610

5394

Dimensions

Hex. bolts ISO 4014 to ISO 4018 Cheese-head screws ISO 4762 Hex. nuts ISO 4032

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Introduction Torque settings 1451-001 123196-005

Tightening torque for metric fine threads The tightening torques specified below apply only when: – in connection with thread lubricant a coefficient of friction of µ tot = 0.14 is reached. To achieve this, surface protection such as A3C +L, Dacromet or Termosil is recommended. – no other tightening torque is specified in the specifications. – no additional screw retention is used, such as MK-type bolts or liquid locking compound. Tightening torque in Nm at a friction coefficient μ tot = 0.14

Bolts and nuts Strength class

8.8

10.9

12.9

M8x1

26

38.5

45

M 10 x 1

54

79

92.5

M 10 x 1.25

51

74.5

88

M 12 x 1.25

90.5

134

156

M 12 x 1.5

87

128

150

M 14 x 1.5

143

210

246

M 16 x 1.5

219

323

378

M 18 x 1.5

331

470

551

M 18 x 2

313

446

522

M 20 x 1.5

459

655

766

M 22 x 1.5

622

886

1037

M 24 x 1.5

809

1152

1348

M 24 x 2

778

1108

1297

M 27 x 1.5

1173

1672

1956

M 27 x 2

1135

1617

1892

M 30 x 2

1580

2251

2634

M 33 x 2

2116

3015

3528

M 36 x 2

2773

3951

4623

M 39 x 2

3557

5067

5930

Dimensions

Hex. bolts ISO 8765, ISO 8676 Hex. nuts ISO 4032

22

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Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing cone and O-ring according to DIN 3865 Outside pipe diameter

Tightening torque

Tightening torque

in mm

(light series)

(heavy series)

in Nm

in Nm

6

10

15

8

15

25

10

25

35

12

35

50

15

50

-

16

-

80

18

80

-

20

-

110

22

110

-

25

-

160

28

160

-

30

-

210

35

210

-

38

-

320

42

320

-

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Introduction Torque settings 1451-001 123197-002

Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861

24

Outside pipe diameter

Tightening torque

Tightening torque

in mm

(light series)

(heavy series)

in Nm

in Nm

6

15

25

8

25

35

10

35

50

12

50

80

15

80

-

16

-

110

18

110

-

20

-

160

22

160

-

25

-

210

28

210

-

30

-

320

35

320

-

38

-

400

42

400

-

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Tightening torques for SDS hydraulic male connectors Shape B with sealing edge (cutting edge) Shape E with soft ring seal Dimension

Tightening torque

Tightening torque

(light series)

(heavy series)

in Nm

in Nm

M5

-

-

M6

-

-

M8 x 1

-

-

M10 x 1

18

-

M12 x 1.5

30

35

M14 x 1.5

45

55

M16 x 1.5

60

70

M18 x 1.5

70

110

M20 x 1.5

-

140

M22 x 1.5

140

170

M26 x 1.5

180

220

M27 x 2

190

250

M33 x 2

300

300

M42 x 2

500

550

M48 x 2

550

600

G 1/8 A

20

25

G 1/4 A

35

40

G 3/8 A

70

90

G 1/2 A

100

150

G 3/4 A

180

270

G1A

250

350

G 1-1/4 A

450

500

G 1-1/2 A

550

600

7/16 - 20 (11.1 mm)

-

-

1/2 - 20 (UNF)

-

-

9/16 - 18 (14.3 mm)

-

-

3/4 - 16 (19.1 mm)

-

-

7/8 - 14 (22.2 mm)

-

-

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Introduction Torque settings 1451-001

Dimension

Tightening torque

Tightening torque

(light series)

(heavy series)

in Nm

in Nm

1-1/16 - 12 (27 mm)

-

-

1-5/16 - 12 (33.3 mm)

-

-

1-5/8 - 12 (UNF)

-

-

1-7/8 - 12 (UNF)

-

-

2 - 12 (UNF)

-

-

Shape F with O-ring and plug Dimension

26

Tightening torque

Tightening torque

(light series)

(heavy series)

in Nm

in Nm

M5

2.8

-

M6

5.2

-

M8 x 1

7

-

M10 x 1

11

-

M12 x 1.5

15

15

M14 x 1.5

25

25

M16 x 1.5

35

35

M18 x 1.5

50

50

M20 x 1.5

-

55

M22 x 1.5

80

80

M26 x 1.5

110

110

M27 x 2

110

160

M33 x 2

160

210

M42 x 2

210

320

M48 x 2

320

420

G 1/8 A

-

-

G 1/4 A

-

-

G 3/8 A

-

-

G 1/2 A

-

-

G 3/4 A

-

-

G1A

-

-

G 1-1/4 A

-

-

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Dimension

Tightening torque

Tightening torque

(light series)

(heavy series)

in Nm

in Nm

G 1-1/2 A

-

-

7/16 - 20 (11.1 mm)

15

20

1/2 - 20 (UNF)

20

25

9/16 - 18 (14.3 mm)

30

30

3/4 - 16 (19.1 mm)

35

60

7/8 - 14 (22.2 mm)

70

90

1-1/16 - 12 (27 mm)

85

100

1-5/16 - 12 (33.3 mm)

150

170

1-5/8 - 12 (UNF)

250

300

1-7/8 - 12 (UNF)

300

350

2 - 12 (UNF)

350

400

Shape H with O-ring and chamber ring Dimensions

Tightening torque

Tightening torque

(light series)

(heavy series)

in Nm

in Nm

G 1/8 A

20

20

G 1/4 A

40

40

G 3/8 A

75

75

G 1/2 A

85

85

G 3/4 A

180

180

G1A

310

310

G 1-1/4 A

450

450

G 1-1/2 A

540

540

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Introduction Torque settings 1451-001 123204-003

Tightening torques for hydraulic swivel fittings Dimensions

28

Tightening torque

Tightening torque

(light series)

(heavy series)

in Nm

in Nm

M10 x 1

20

30

M12 x 1.5

35

40

M14 x 1.5

45

50

M16 x 1.5

60

70

M18 x 1.5

75

80

M20 x 1.5

-

100

M22 x 1.5

125

130

M26 x 1.5

130

-

M27 x 2

130

140

M33 x 2

300

300

M42 x 2

500

500

M48 x 2

600

600

G 1/8 A

20

-

G 1/4 A

40

40

G 3/8 A

65

70

G 1/2 A

90

100

G 3/4 A

130

130

G1A

270

380

G 1-1/4 A

500

600

G 1-1/2 A

600

700

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Introduction Torque settings 1451-001 123206-002

Tightening torques for hollow screws DIN 7643 Dimensions

Tightening torque in Nm

M8 x 1

8

M10 x 1

15

M12 x 1.5

27

M14 x 1.5

38

M16 x 1.5

45

M18 x 1.5

58

M22 x 1.5

95

M26 x 1.5

130

M30 x 1.5

183

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29

Introduction Torque settings 1451-001 123202-004

Tightening torques for direction-adjustable SDE hydraulic male connectors Shape F with O-ring Dimensions

Tightening torque

Tightening torque

Tightening torque

(very light series)

(light series)

(heavy series)

in Nm

in Nm

in Nm

M8 x 1

-

-

-

M10 x 1

20

15

-

M12 x 1.5

-

25

35

M14 x 1.5

-

35

45

M16 x 1.5

-

40

55

M18 x 1.5

-

45

90

M20 x 1.5

-

-

140

M22 x 1.5

-

60

170

M26 x 1.5

-

100

190

M27 x 2

-

100

190

M33 x 2

-

160

310

M42 x 2

-

210

330

M48 x 2

-

260

420

7/16 - 20 (11.1 mm)

-

15

20

1/2 - 20 (UNF)

-

30

40

9/16 - 18 (14.3 mm)

-

35

45

3/4 - 16 (19.1 mm)

-

55

60

7/8 - 14 (22.2 mm)

-

80

90

1-1/16 - 12 (27 mm)

-

100

100

1-5/16 - 12 (33.3 mm)

-

150

170

1-5/8 - 12 (UNF)

-

290

340

1-7/8 - 12 (UNF)

-

325

415

2 - 12 (UNF)

-

350

450

Shape H with O-ring and chamber ring Dimensions

30

Tightening torque

Tightening torque

Tightening torque

(very light series)

(light series)

(heavy series)

in Nm

in Nm

in Nm

M8 x 1

10

-

-

M10 x 1

20

18

-

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Introduction Torque settings 1451-001

Dimensions

Tightening torque

Tightening torque

Tightening torque

(very light series)

(light series)

(heavy series)

in Nm

in Nm

in Nm

M12 x 1.5

-

30

35

M14 x 1.5

-

45

55

M16 x 1.5

-

60

80

M18 x 1.5

-

70

105

M20 x 1.5

-

-

140

M22 x 1.5

-

125

125

M26 x 1.5

-

180

180

M27 x 2

-

180

180

M33 x 2

-

300

380

M42 x 2

-

450

500

M48 x 2

-

600

600

G 1/8 A

20

20

25

G 1/4 A

-

35

45

G 3/8 A

-

70

75

G 1/2 A

-

100

100

G 3/4 A

-

180

180

G1A

-

300

300

G 1-1/4 A

-

450

450

G 1-1/2 A

-

540

540

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31

Introduction Torque settings 1451-001 123207-004

Tightening torques for brake line screw fittings Shape F union screws Shape FS union screws with chime Dimensions

Tightening torque in Nm

M10 x 1

14+2 123209-003

Tightening torques for worm drive hose clamps

30 8515-001

Width of clip

Tightening torques for new hoses when installing for the first time

Tightening torques for retightening or reassembling

7.9 mm (0.31 inch)

0.9 ± 0.2 Nm (8 ± 2 lb in)

0.7 ± 0.2 Nm (6 ± 2 lb in)

13.5 mm (0.53 inch)

4.5 ± 0.5 Nm (40 ± 4 lb in)

3.0 ± 0.5 Nm (27 ± 4 lb in)

15.9 mm (0.63 inch)

7.5 ± 0.5 Nm (65 ± 4 lb in)

4.5 ± 0.5 Nm (40 ± 4 lb in) 123211-002

Tightening torque for spring-loaded worm drive hose clamps

31 37503-001

Width of clip

Clamp diameter

Tightening torque

12 mm

60 - 80 mm

5 + 0.5 Nm

12 mm

70 - 90 mm

5 + 0.5 Nm

32

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CCN explanation CCN (CLAAS Component Number) 1451-001

CCN explanation CCN (CLAAS Component Number) 120555-005

General The CCN (CLAAS Component Number) arises from a CLAAS standard for hydraulic and electric systems. This standard is based on the hydraulic and electric functions on the machine. 146587-001

Electric systems standard In the electric systems standard, the components are subdivided according to their function, using letters. Pos.

Component

A

Terminal / module

B

Sensor

C

Electric / electronic devices

E

Lighting

G

Voltage source

H

Signalling device / lamp

J

Information units (required for function diagnosis)

M

Motor (electric)

P

Gauge

R

Potentiometer / resistor

S

Switches / pushbuttons - Cab operation

T

Switches - Terminal operation

U

Switches - External operation

V

Electronic component

W

Antenna

X

Connectors

Y

Solenoid coil

Z

Actual value switch

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33

CCN explanation CCN (CLAAS Component Number) 1451-001 146588-001

Hydraulic system standard In the hydraulic systems standard, the components are subdivided according to their function, using number ranges. Pos.

Component

1000

Oil reservoir / oil filter / oil cooler

2000

Pump / motor

3000

Hydraulic cylinder

4000

Restrictor / orifice plate

5000

Pressure accumulator

6000

Valve - mechanically actuated

7000

Valve - hydraulically actuated

8000

Couplings / connections

9000

Measuring point / gauge

34

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CCN (CLAAS Component Number) CCN (CLAAS Component Number) 1451-001

CCN (CLAAS Component Number)

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35

CCN (CLAAS Component Number) CCN Index 1451-001

CCN Index A A4-MB Control unit........................................................................................................................................476, 481

B B600-MB Crankshaft position sensor..................................................................................................................... 99 B602-MB Fuel temperature sensor...............................................................................................................300, 310 B605-MB Engine oil fill level sensor........................................................................................................................80 B606-MB Coolant outlet temperature sensor................................................................................................369, 381 B607-MB Coolant inlet temperature sensor..........................................................................................................342 B608-MB Pressure and temperature sensor Charge air in the charge air tube........................................................................................................... 433, 442 B617-MB Temperature sensor Charge air in the charge air housing......................................................................................................433, 442 B621-MB Exhaust gas recirculation differential pressure sensor......................................................................... 400 B622-MB Rail pressure sensor..................................................................................................................... 268, 276 B638-MB Fuel filter module pressure sensor........................................................................................................326

G G002 see G2-MB.................................................................................................................................................. 457 G2-MB Alternator.................................................................................................................................................. 457

M M021 see M1-MB..................................................................................................................................................453 M047 see M25-MB................................................................................................................................................489 M1-MB Electric starting motor...............................................................................................................................453 M25-MB Urea pump..............................................................................................................................................489

Y Y488 see Y627-MB...............................................................................................................................................485 Y608-MB Injector.................................................................................................................................................. 286 Y609-MB Injector.................................................................................................................................................. 286 Y610-MB Injector.................................................................................................................................................. 286 Y611-MB Injector.................................................................................................................................................. 286 Y612-MB Injector.................................................................................................................................................. 286 Y613-MB Injector.................................................................................................................................................. 286 Y621-MB Exhaust gas recirculation actuator........................................................................................................394 Y627-MB Urea heater valve..................................................................................................................................485 Y642-MB Fuel controller valve......................................................................................................................316, 320

36

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Safety General Information 1451-001

Safety General Information 123229-003

Important! The instructions contained in this Repair Manual must be carefully read and observed by all persons concerned with the operation, maintenance, repair, service and inspection of this machine in order to prevent hazards. Read in particular the "Safety Rules" chapter. 173669-004

Hazard signs This hazard sign warns of risks of injury. ► To avoid injuries and death, follow all measures marked by this hazard sign. 181226-001

Signal word The warnings in this Repair Manual are introduced by the hazard sign and a signal word. The signal word expresses the extent of the hazard.

DANGER DANGER identifies a dangerous situation that leads to death or serious injury if not avoided.

WARNING WARNING identifies a dangerous situation that may lead to death or serious injury if not avoided.

CAUTION CAUTION identifies a dangerous situation that may lead to slight injuries if not avoided. 157730-003

Regulations for avoiding accidents with personal injuries General – In addition to this manual, the Repair Manual for the machine must always be observed. – Observe all general rules concerning safety and accident prevention. – Testing, adjusting and repair work may be carried out only by CLAAS sales partners.

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37

Safety General Information 1451-001

Testing, adjusting and repair work 1497-002

WARNING Pinch point from pre-loaded components. Serious injuries. ► Never move your hands between pre-loaded components.

– Secure the engine when removing it. – Keep the engine, ladders, stairs, bridges and their surroundings free of oil and grease. – Switch off the battery isolating switch while working in built-in condition. – Ensure that the engine is not started accidentally by unauthorised persons. Engine operation 160525-002

CAUTION Bruises and burns when intervening into the starting process or while the engine is running. Danger of injury ► Wear closed and tight-fitting working clothes. ► Do not touch any hot or rotating parts.

173-002

CAUTION Contact with hot liquids or machine parts. Danger of burns ► Wear suitable protective clothing. ► Let liquids or machine parts cool down. ► Comply with instructions.

38

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Safety General Information 1451-001

Suspended loads 57765-002

WARNING Lifting heavy components. Risk of death or serious injury. ► ► ► ►

Use a lifting tool with a sufficient bearing load. Use a lifting tool that operates reliably. Use the lifting tool on solid and even ground. Attach the lifting tool to the component at the intended or a suitable position. ► Only use faultless and sufficiently dimensioned lifting accessories. ► Protect lifting accessories against sharp corners and edges, for example using protectors.

► Do not lift heavy components with your body's force. ► Ensure that no persons are present beneath suspended loads. Working on piping and hoses 157932-002

WARNING Fire / explosion hazard when handling fuel. Death or serious injury. ► No fires, sparks, open light and no smoking. ► Fill fuel only into suitable containers. ► Wear protective clothing.

125670-003

CAUTION Contact with hot liquids. Risk of burns. ► Release pressure on the system/wait for pressure to drop. ► Leave liquids to cool. ► Wear suitable protective clothing.

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39

Safety General Information 1451-001 124851-001

Environment! Lubricants, operating utilities and fuels escape into the environment. Environmental pollution. ► Collect and store lubricants, operating utilities and fuels in suitable containers and ensure proper disposal.

► Neither retighten nor open any piping and hoses under pressure. Work on the Common Rail System 161964-002

NOTICE Unprofessional installation on Common Rail system. Damage to Common Rail system. ► All work on components of the Common Rail system may be carried out only by specially trained personnel. ► Prior to starting work, the engine must be standing still for at least 5 minutes in order to relieve the pressure in the pressure pipe or pressure reduction must be controlled with the CDS. ► Absolute cleanliness must be ensured during all work in all areas. ► Prior to any work on the clean side of the fuel system, the engine and the engine compartment must be cleaned (e.g. steam jet cleaner) with the fuel system remaining closed. ► Absolutely avoid moisture. ► Slackened-off inlet connectors must always be replaced. ► Plugs once used for high-pressure lines, pressure pipe and injectors must not be re-used. ► Observe the sequence specified in the description when tightening the injectors, high-pressure lines, pressure pipe and inlet connector.

40

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Safety General Information 1451-001 161966-002

NOTICE Unclosed components. Damage to the Common Rail system. ► Dismount only one fuel line at a time. ► Close the component connections immediately with new and clean caps. Working on the electric system ► Start the engine only with firmly connected batteries. ► Do not disconnect the batteries while the engine is running. ► Do not use any quick-charging devices for starting the engine. ► Assist-starting only with separate batteries. ► The connections of control units may be disconnected and connected only with the electric system switched off. ► Incorrect polarity of the control units may cause their destruction. ► Always tighten the connections on the injection system to the specified tightening torques. ► When temperatures above 80 °C must be expected, the control units must be removed. ► Use only suitable testing lines for measurements on connectors. ► Observe the manufacturer's regulations for batteries. ► Wear protective clothing when handling batteries. ► Do not tilt the batteries, acid might escape. ► Measure the voltage only with a suitable measuring device. ► Electrolytic gas may form in closed battery boxes. ► Be particularly careful after the engine has run for an extended period and after charging the battery with a charger. ► When disconnecting the batteries, nondisconnected continuous consumers may generate sparks that ignite the gas. ► Vent the battery box sufficiently prior to disconnecting. ► Avoid short-circuits by wrong polarity or placing metal objects on the battery terminals. Disconnect batteries when the engine has been ► shut down and recharge every four weeks.

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41

Safety General Information 1451-001

Working on the hydraulic system 64831-003

WARNING Residual oil pressure in hoses / hydraulic components. Serious injury of eyes / of skin. ► Relieve the residual oil pressure in the hydraulic system.

11741-003

NOTICE Serious damage to hydraulic circuit components. ► Before installing hydraulic system components, the entire hydraulic circuit and the hydraulic system components remaining on the machine must be flushed. ► The entire hydraulic system must be free of dirt and foreign objects. ► Replace the hydraulic oil filter. Electric welding ► Observe the welding information sheets. ► Disconnect the batteries. ► Fit earthing point of the welder close to the welding spot. ► Disconnect the control units. Painting work ► During painting work, electronic components may be exposed to high temperatures (up to 95 °C) only for a short time. ► Disconnect the batteries. ► Remove sensitive electric components. ► Screw fittings of high-pressure lines must not be painted. Danger of introducing dirt in case of repairs.

42

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Safety General Information 1451-001

Working with urea solution 124844-004

CAUTION Contact with urea solution. Danger of injury. ► Wash your skin thoroughly with water and soap. See a doctor if necessary. ► Flush eyes thoroughly with plenty of water. See a doctor if necessary. ► Flush mouth and drink plenty of water. See a doctor if necessary.

149012-002

NOTICE Foreign substances pollute the system Damage to exhaust gas system. ► Keep foreign substances and residual quantities of diesel fuel out of this system. ► Increased cleanliness requirements during installation work.

124885-005

NOTICE Surfaces get in contact with urea solution. Component corrosion. ► Flush the surfaces concerned with plenty of water immediately. 157737-001

Information on how to avoid damage and premature wear General – Engines are built exclusively for the intended use according to the shipping package. – Unauthorised modifications on the engine will exclude any liability of the manufacturer for any resulting damage. Manipulations on the injection and control system may also influence the output and waste gas behaviour. Meeting the statutory environmental protection requirements is no longer guaranteed in this condition. – If any trouble occurs during operation, locate and remove the reason immediately.

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43

Safety General Information 1451-001

–

– – – – – –

Clean the engine thoroughly before starting repairs. - Ensure that no dirt, sand or foreign objects end up inside the engine. Only use genuine CLAAS spare parts. Never let the engine run dry. Never let the engine run without coolant. Fit a corresponding note on engines that are not ready for operation. Use only operating utilities approved by CLAAS. Do not fill in engine oil beyond the maximum level mark. 157745-001

Liability limitation General ► All information and notes in this manual were compiled considering the standards and regulations in force, the state of the art and many years of experience. ► CLAAS will not assume any liability for damage caused by: ► failure to comply with this manual ► use not in line with the intended use ► use of non-trained personnel ► unauthorised conversions ► technical modifications ► use of non-approved spare part and operating utilities Shutting down and storage ► Shutting down the engine for an extended period of time requires temporary corrosion protection. 157747-001

Regulations for avoiding health and environmental damage Precautionary measures for protection against health and environmental damage ► Avoid extended, excessive or repeated skin contact with operating utilities, auxiliary operating utilities, diluents or solvents. ► Protect your skin by suitable skin protection agents or protective gloves. ► Do not use any operating utilities, auxiliary operating utilities, diluents or solvents for cleaning of skin. ► Wash polluted skin thoroughly with water and soap. ► Change oil-soaked clothing and shoes. ► Do not put any oil-soaked rags into the pockets of your working clothes.

44

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Safety General Information 1451-001

Disposal of operating utilities and auxiliary operating utilities ► Observe the regulations of the local authorities. ► Ensure that no operating utilities will end up in the soil, sewer or in waters. ► Different operating utilities must be collected and disposed of in different containers. ► Use tight containers for draining operating utilities. ► Ensure that food or drink containers are never used - danger of confusion. ► Ensure that operating utilities are correctly disposed of. ► Operating utilities count among the waterhazardous substances! 157748-002

Information for working on the diesel engine Accident protection ► ► ► ►

►

► ► ►

Fuel jets may cut the skin. Fire hazard due to fine spraying of fuel. Avoid standing near the running engine. Never slacken off the screw fittings of fuel lines while the engine is running. The lines may be under very high pressure (up to 1800 bar). The engine must have been stopped for at least 5 minutes before slackening off the fuel lines. ► Check the line pressure values with the CDS if necessary. Do not touch live parts of electric connections while the engine is running. Persons wearing a pacemaker must not come closer than 20 cm to the running engine. Any modifications of the original engine cabling may result in exceeding threshold values of the pacemaker regulations.

Cleanliness Diesel injection components consist of high-precision parts that are subject to extreme loads. In view of this high-precision equipment, maximum cleanliness must be ensured during all work on the fuel system. Even dirt particles measuring more than 0.002 mm may make components fail. Before starting work, absolutely comply with the rules below: ► Clean engine and engine compartment before starting the work. ► Ensure that the fuel system is closed here. ► When using a jet cleaner, do not aim directly on electric components or fit covers. ► Clean tools and working materials before starting work. ► Use only undamaged tools.

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45

Safety General Information 1451-001

► ► ► ► ►

► ► ► ►

► ►

►

► ► ►

Cover up engine compartment areas where dirt particles may come off with a new and clean dust film. Wash your hands before starting dismounting and put on fresh working clothing. Carry out a visual inspection for leaks and damage on the fuel system. Remove any loose dirt particles such as paint chips and insulation material with a suitable suction device. When removing and installing components, no materials such as cloths, cardboard or wood may be used as these materials may lose particles and fibres. Carefully remove paint chippings resulting from slackening off bolts before completely removing the bolts. Place the engine in a clean area of the workshop where no work is carried out that raises dust. Avoid air motion (possible raising of dust by starting engines, workshop ventilation or heating system, air draught etc.). Clean and dry the area of the still closed fuel system with compressed air. ► After opening the clean-side fuel system, use of compressed air for cleaning is no longer allowed. Use only non-fluff cleaning cloths on the fuel system. Close connecting openings of all removed parts of the clean-side fuel system immediately with suitable caps. ► Caps must be packed dust-tight before use and must be disposed of after using them once. Keep components carefully in a clean and closed container. ► Never use pre-used cleaning or testing liquids for these components. New parts may be taken out of their original packaging only just before using them. Carry out work on removed components only at a workplace equipped for this purpose. If removed parts are dispatched, always use the original packaging of the new part.

Installation instructions ► Piping of all kinds must not be bent, risk of cracking! ► Regulations for flawless installation of flat seals: ► Only use genuine CLAAS seals. ► Sealing faces must be undamaged and clean. ► Do not use any sealants or glues. ► Tighten bolts evenly to the specified torque. Regulations for flawless installation of round ► seals:

46

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Safety General Information 1451-001

► Only use genuine CLAAS seals. ► Sealing faces must be undamaged and clean. ► Always wet O-rings with engine oil according to the manufacturer's specification when installing. Engine overhaul The service life of an engine is influenced by very different factors. Specifying a certain number of operating hours for basic overhauls is therefore not possible. Opening an engine or a basic overhaul is not appropriate as long as the engine has good compression values and the following operating values have not significantly changed as compared with those measured and accepted upon commissioning: ► Charge pressure. ► Exhaust gas temperature. ► Coolant and lubricating oil temperature. ► Oil pressure and oil consumption. ► Smoke behaviour. The criteria below have major influence on the engine's service life: ► Correct setting of output, depending on the type of use. ► Proper installation. ► Acceptance of installation by authorised personnel. ► Regular maintenance according to the maintenance schedule. ► Selection and quality of lubricating oil, fuel and coolant according to the manufacturer's specifications. Putting into operation after an engine overhaul Pre-fill the engine with engine oil after finishing repair, i.e. in dry condition, before putting it back into operation. This process can also be applied when establishing damage and reasons. On all engines that have not been pre-filled with lubricating oil, the danger of premature damage to the bearing surface is very big because the lubrication oil fed by the oil pump from the oil sump takes relatively long before it reaches the individual bearings. Such initial damage will not necessarily make the bearings fail, but can affect bearing function and reduce the service life. Pre-filling the engine with engine oil:

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Page 336

47

Safety General Information 1451-001 123242-003

First aid measures Inhaling: – Give the person fresh air and consult a doctor depending on his or her symptoms. – Remove the person from the danger area. Contact with the eyes: – Rinse the eyes thoroughly with large amounts of water for several minutes. Consult a doctor if required. Contact with the skin: – Wash thoroughly with plenty of water and soap, remove polluted and soaked clothing immediately, consult a doctor if the skin is irritated (e.g. reddening). Swallowing: – Do not induce vomiting; consult a doctor immediately.

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01 Engine 0102 Complete component 1451-001

01 Engine 0102 Complete component 175847-001

Type design Series

Type design

Exhaust gas level

OM 470 LA

470.907

TIER 4 / Stage IV

OM 471 LA

471.919

TIER 4 / Stage IV

OM 473 LA

473.905

TIER 4 / Stage IV

Note

175848-001

Engine data OM 470 LA Designation

Value

Weight

990

Engine type

In-line engine

Number of cylinders

6

Cylinder bore

125

mm

Cylinder stroke

145

mm

Cubic capacity

10700

cm³

Direction of rotation of engine when viewing the flywheel

Left

kg

OM 471 LA Designation

Value

Weight

1140

Engine type

In-line engine

Number of cylinders

6

Cylinder bore

132

mm

Cylinder stroke

156

mm

Cubic capacity

12.800

cm³

Direction of rotation of engine when viewing the flywheel

Left

kg

OM 473 LA Designation

Value

Weight

1277

Engine type

In-line engine

Number of cylinders

6

Cylinder bore

139

mm

Cylinder stroke

171

mm

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kg

49

01 Engine 0102 Complete component 1451-001

Designation

Value

Cubic capacity

15.600

Direction of rotation of engine when viewing the flywheel

Left

50

cm³

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01 Engine 0102 Complete component 1451-001 175850-001

Engine description Engine components

267318-001

Pos.

Value

CCN

1

32

Designation Exhaust gas return cooler OM 470 LA OM 471 LA

Page 366 Page 379

2

Exhaust gas recirculation line OM 470 LA OM 471 LA

Page 366 Page 379

3

G002

Alternator 12 V

4

Coolant compressor

5

Alternator 24 V

Page 456

Page 456

Alternator 24 V Applies to: Type design 473.905 6

Air intake tube

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Page 423

51

01 Engine 0102 Complete component 1451-001

Pos. 7

Value

CCN

Designation Oil separator OM 470 LA OM 471 LA

Page 103 Page 112

8

Exhaust turbo charger OM 470 LA OM 471 LA

Page 414 Page 423

9

Electric starting motor

10

Turbo compound unit

52

Page 452

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01 Engine 0102 Complete component 1451-001

267319-001

Pos. 1

Value

CCN

33

Designation Common rail OM 470 LA OM 471 LA

Page 266 Page 274

2

Fuel high-pressure pump

Page 299

3

Oil pan

Page 79

4

Fuel sediment filter

Page 323

5

Fuel filter

Page 323

6

Coolant thermostat

Page 363

7

Charge air tube OM 470 LA OM 471 LA

Page 433 Page 442

8

Oil filter

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Page 334

53

01 Engine 0102 Complete component 1451-001

Sensors

267508-001

Pos.

Value

CCN

Designation

1

B601-MB

Camshaft position sensor

Page 180

2

B600-MB

Crankshaft position sensor

Page 98

3

B605-MB

Combined oil level / temperature sensor

Page 79

4

B602-MB

Fuel temperature sensor

Page 310

5

B617-MB

Charge air temperature sensor in the charge air housing OM 470 LA OM 471 LA

6

B638-MB

Fuel filter module pressure sensor

7

B608-MB

Charge air pressure and temperature sensor in the charge air tube OM 470 LA OM 471 LA

8

54

B622-MB

34

Page 433 Page 442 Page 325

Page 433 Page 442

Rail pressure sensor OM 470 LA

Page 267

OM 471 LA

Page 275

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01 Engine 0102 Complete component 1451-001

267525-001

Pos.

Value

CCN

Designation

1

B607-MB

Coolant inlet temperature sensor

2

B604-MB

Oil pressure sensor

3

B621-MB

Exhaust gas recirculation differential pressure sensor

Page 400

4

B606-MB

Coolant outlet temperature sensor

Page 367

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35

Page 341

55

01 Engine 0102 Complete component 1451-001

267527-001

Pos.

CCN

Designation

1

B611-MB

Temperature sensor downstream of air filter

2

B610-MB

turbocharger speed sensor

56

Value

36

Page 409

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0102 Complete component 1451-001

Actuators

267592-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

37

57

01 Engine 0102 Complete component 1451-001

Pos.

CCN

Designation

1

Y608-MB

Cylinder 1 injector

1

Y609-MB

Cylinder 2 injector

3

Y610-MB

Cylinder 3 injector

4

Y611-MB

Cylinder 4 injector

5

Y612-MB

Cylinder 5 injector

6

Y613-MB

Cylinder 6 injector

7

Y642-MB

Fuel controller valve

8

9

58

Value

Y636-MB

Y621-MB

Page 285

OM 470 LA

Page 315

OM 471 LA

Page 319

Charge pressure actuator OM 470 LA

Page 414

OM 471 LA

Page 423

Exhaust gas recirculation actuator

Page 394

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01 Engine 0102 Complete component 1451-001

Ignition order

267384-001

38

The piston (1) is at the ignition top dead centre (ignition TDC) when the synchronous piston (6) is at the valve overlap top dead centre (overlap TDC). The intake valves and the exhaust valves are relieved at the ignition top dead centre. When at the overlap top dead centre, the intake valves and the exhaust valves are loaded. Piston position

Cylinder / injection order

Overlap TDC

1

5

3

6

2

4

Ignition TDC

6

2

4

1

5

3

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59

01 Engine 0102 Complete component 1451-001 175851-001

Cranking the engine The engine can be cranked by hand both in built-in condition and in removed condition. Depending on the variant, different special tools are available for this. – To prevent damage to the special tools, each special tool should only be used for its specified application. This is why this chapter is sub-divided into two sections: Cranking the engine in built-in condition: 65

Page

Cranking the engine in removed condition: 72

Page

Special tool Special tool (I)

Pcs.

Cranking tool

1

00 1992 902 0

39 147485-001

Special tool (II)

Pcs.

Template

1

00 1998 587 0

40 271156-001

60

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0102 Complete component 1451-001

Special tool (III)

Pcs.

Punch

1

00 1998 572 0

41 271155-001

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61

01 Engine 0102 Complete component 1451-001

Special tool for built-in engine The following tools of special tool kit 00 0181 932 0 are needed:

42 180243-001

Machine

Engine type

Special tool

Part no./dimension

JAGUAR 496 Page 68

OM470LA

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 609 0

3x

Spacer tube

00 0822 526 0

3x

Hex. bolt

00 0237 463 0

3x

Adapter

00 0181 944 0

3x

Set screw

00 0451 666 2

3x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 609 0

3x

Spacer tube

00 0822 526 0

3x

Hex. bolt

00 0237 463 0

3x

Adapter

00 0181 944 0

3x

Set screw

00 0451 666 2

3x

Cranking tool

00 0181 751 0

1x

Spacer tube

Ø16.5 x Ø 8.5, 87 mm

3x

Hex. bolt

00 0238 416 0

3x

Washer

00 0237 957 0

3x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 609 0

3x

Spacer tube

00 0822 526 0

3x

Hex. bolt

00 0237 463 0

3x

Adapter

00 0181 944 0

3x

Set screw

00 0451 666 2

3x

JAGUAR 496 Page 68

JAGUAR 496 Page 65

JAGUAR 497 Page 68

62

OM471LA

OM473LA

OM471LA

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01 Engine 0102 Complete component 1451-001

Machine

Engine type

Special tool

Part no./dimension

JAGUAR 497 Page 68

OM471LA

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 609 0

3x

Spacer tube

00 0822 526 0

3x

Hex. bolt

00 0237 463 0

3x

Adapter

00 0181 944 0

3x

Set screw

00 0451 666 2

3x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 609 0

3x

Spacer tube

00 0822 526 0

3x

Hex. bolt

00 0237 463 0

3x

Washer

00 0993 398 0

3x

Adapter

00 0181 944 0

3x

Set screw

00 0451 666 2

3x

Cranking tool

00 0181 751 0

1x

Spacer tube

Ø16.5 x Ø 8.5, 87 mm

3x

Hex. bolt

00 0238 416 0

3x

Washer

00 0237 957 0

3x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 889 0

2x

Hex. bolt

00 0235 586 0

2x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 889 0

2x

Hex. bolt

00 0235 586 0

2x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 889 0

2x

Hex. bolt

00 0235 586 0

2x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 889 0

2x

Hex. bolt

00 0235 586 0

2x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 889 0

2x

Hex. bolt

00 0235 586 0

2x

JAGUAR 497 Page 66

JAGUAR 497 Page 66

LEXION C68 Page 70

LEXION C74 Page 70

LEXION C75 Page 70

LEXION C76 Page 70

LEXION C77 Page 70

OM473LA

OM473LA

OM470LA

OM470LA

OM470LA

OM473LA

OM 470LA

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01 Engine 0102 Complete component 1451-001

Machine

Engine type

Special tool

Part no./dimension

LEXION C78 Page 70

OM 470LA

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 889 0

2x

Hex. bolt

00 0235 586 0

2x

Cranking tool

00 0181 751 0

1x

Thread adapter

00 0181 889 0

2x

Hex. bolt

00 0235 586 0

2x

LEXION C79 Page 70

64

OM 473LA

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01 Engine 0102 Complete component 1451-001

Cranking the engine in built-in condition JAGUAR. Applies to: JAGUAR type 496 with OM473LA diesel engine JAGUAR type 497 with OM473LA diesel engine

► Unscrew bolts (1).

43 267655-001

► Screw on the special tool (1) using bolts (2), washers (3) and a spacer tube.

44 267699-001

► Crank engine at (1) until the desired crankshaft position is reached.

45 267697-001

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65

01 Engine 0102 Complete component 1451-001

JAGUAR Applies to: JAGUAR type 497 with OM473LA diesel engine

► Unscrew the bolts (A).

46 267726-001

► Screw the threaded pin into thread (1). ► Slide the washer onto the threaded pin.

47 267726-001

66

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01 Engine 0102 Complete component 1451-001

► Screw in the adapter (1).

48 267718-001

► Place the spacer tube (2) on the thread adapter (3). ► Screw the thread adapter (3) into the adapter (1) using the spacer tube (2).

49 267727-001

► Screw the cranking tool (2) onto the belt pulley using bolts (1).

50 267735-001

► Crank engine at (1) until the desired crankshaft position is reached.

51 267743-001

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67

01 Engine 0102 Complete component 1451-001

JAGUAR Applies to: JAGUAR type 496 with OM470LA diesel engine JAGUAR type 496 with OM471LA diesel engine JAGUAR type 497 with OM471LA diesel engine JAGUAR type 497 with OM471LA diesel engine

► Unscrew bolts (1).

52 267726-001

► Screw in the threaded pin into thread (1).

53 267726-001

► Screw in the adapter (1). ► Place the spacer tube (2) on the thread adapter (3). ► Screw the thread adapter (3) into the adapter (1) using the spacer tube (2).

54 267744-001

68

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01 Engine 0102 Complete component 1451-001

► Screw the cranking tool (2) onto the belt pulley using bolts (1).

55 267735-001

► Crank engine at (1) until the desired crankshaft position is reached.

56 267743-001

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69

01 Engine 0102 Complete component 1451-001

LEXION Applies to: LEXION type C68 with OM470LA diesel engine LEXION type C74 with OM470LA diesel engine LEXION type C75 with OM470LA diesel engine LEXION type C76 with OM473LA diesel engine LEXION type C77 with OM470LA diesel engine LEXION type C78 with OM470LA diesel engine LEXION type C79 with OM473LA diesel engine

► Screw in the thread adapter (1).

57 267780-001

► Screw on the cranking tool (1) using bolts (2).

58 267781-001

► Crank engine at (1) until the desired crankshaft position is reached.

59 267783-001

70

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01 Engine 0102 Complete component 1451-001

XERION Applies to: XERION type 783 with OM470LA diesel engine XERION type 783 with OM471LA diesel engine

As in removed condition.

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Page 72

71

01 Engine 0102 Complete component 1451-001

Cranking the engine in removed condition ► Unscrew plate (1).

60 267785-001

Use special tool (I): Page 60 at (1). ► Install special tool Tightening torque: 30 Nm ► Crank the engine until the desired crankshaft position is reached.

61 267786-001

72

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01 Engine 0102 Complete component 1451-001

Setting the engine to ignition TDC Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA Mercedes-Benz OM 473 LA

Use special tool (I).

Page 60

► Turn the flywheel (1) using the cranking tool until mark (A) on the flywheel reaches the cast edge (B) on the timing housing (2).

62 271165-001

271204-001

Use special tool (II).

63

Page 60

► Insert the bolts (1) into the corresponding drilled holes on the special tool and screw them in tightly. ► OM 470 LA engine: Designation 10.6 ► OM 471 LA engine: Designation 12.8 ► OM 473 LA engine: Designation 15.6 ► If there is a reinforcing frame installed on the OM 470 LA and OM 471 LA engines, do not use the spacer (2). ► Check the marks (C) on the gearwheel (3) of the inlet camshaft and on the gearwheel (4) of the outlet camshaft. The marks (C) must match the designations on the special tool. ► OM 470 LA engine: Designation 10.6 ► OM 471 LA engine: Designation 12.8 ► OM 473 LA engine: Designation 15.6

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73

01 Engine 0102 Complete component 1451-001

► If the marks (C) do not match the designations, the flywheel must be rotated by another 360°. Use special tool (III).

Page 60

► Disconnect connector (2). ► Unscrew the bolt (3) and remove the sensor (B600-MB) from the timing housing (1). ► Insert the special tool into the drilled hole for the sensor (B600-MB) and lock the flywheel (5). The special tool pin must sit in the groove (D) in the flywheel.

64 271210-001

Setting the engine to ignition TDC: Removal ► Pull out the special tool (1).

65 271220-001

► Undo the bolts (1) and remove the special tool.

66 271238-001

► Attach the crankshaft position sensor (B600MB). Page 98

74

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01 Engine 0105 Engine suspension 1451-001

0105 Engine suspension

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

75

01 Engine 0105 Engine suspension 1451-001 181953-001

Lifting eyes Applies to: Mercedes-Benz OM 470 LA

Technical specifications

282421-001

Value

CCN

1 2

67

Remark / designation Rear suspension eyes

M14 x 1.5:

Mounting bolts for the rear suspension eyes

180 Nm 3

Front suspension eyes

4

Retainers

5

M8: 30 Nm

Bracket mounting bolts

M10: 60 Nm Tightening torques not specified, see section on tightening torques

76

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01 Engine 0105 Engine suspension 1451-001 181999-001

Lifting eyes Applies to: Mercedes-Benz OM 471 LA

Technical specifications

282429-001

Value

CCN

1 2

68

Remark / designation Rear suspension eyes

M14 x 1.5:

Mounting bolts for the rear suspension eyes

180 Nm 3

Front suspension eyes

4

Retainers

5

M8: 30 Nm

Bracket mounting bolts

M10: 60 Nm 6

Cylinder head

Page 211

7

Exhaust gas return cooler

Page 379

Tightening torques not specified, see section on tightening torques

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77

01 Engine 0110 Engine housing 1451-001

0110 Engine housing

78

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01 Engine 0110 Engine housing 1451-001 178664-001

Oil pan Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool

1

Special tool (I)

Pcs.

Sealing compound

1

00 1994 288 0

69 274871-001

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79

01 Engine 0110 Engine housing 1451-001

Technical specifications

275490-001

Value

CCN

Remark / designation

1

Seal

2

Oil pan

3

30 Nm

70

Oil pan mounting bolts Tightening diagram:

– Tighten the bolts in the specified order (3.13.18). 4

10 Nm

5

15 Nm

B605-MB

Engine oil fill level sensor Mounting bolts for the engine line set

Tightening torques not specified, see section on tightening torques

Removal ► Drain the engine oil. See the Operator's Manual of the machine in question.

80

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01 Engine 0110 Engine housing 1451-001

► Remove the engine line set (1).

71 274864-001

► Disconnect connector (1).

72 274881-001

► Unscrew bolts (1). The bolts are prevented from falling out. ► Remove the oil pan (2).

73 274887-001

► Remove seal (1) from the oil pan (2).

74 275390-001

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81

01 Engine 0110 Engine housing 1451-001

Only if the oil pan (1) is replaced: ► Remove sensor (B605-MB).

75 275395-001

Installation ► Clean the sealing faces.

Page 20

► Install the sensor (B605-MB) together with a new sealing ring. Tightening torque: Page 80

76 275395-001

Use special tool (I).

Page 79

► Apply sealant to the sectioning points (A) for the timing housing (2) and to the housing cover (1).

77 275397-001

82

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01 Engine 0110 Engine housing 1451-001

► Install the seal (1) in the oil pan (2). Observe the installation position (B).

78 275398-001

► Install the oil pan (2) and tighten the bolts (1) in accordance with the tightening diagram. Tightening diagram: Page 80

79 274887-001

► Connect the plug-in connection (1).

80 274881-001

► Attach the engine line set (1). Tightening torque: Page 80

81 274864-001

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83

01 Engine 0110 Engine housing 1451-001

►

► ► ►

84

Top up engine oil. See the Operator's Manual of the machine in question. Start the diesel engine and let it run idling for at least 1 minute. Run the diesel engine at a higher speed. Switch off the diesel engine and check for leaks.

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01 Engine 0110 Engine housing 1451-001 182097-001

Crankshaft front seal Applies to: Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Installation device

1

00 1995 521 0

82 237669-001

Special tool (II)

Pcs.

Spacer washer

1

00 1998 601 0

83 282747-001

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85

01 Engine 0110 Engine housing 1451-001

Technical specifications

282769-001

Value

CCN

84

Remark / designation

1

Oscillation damper

2

Radial seal

Page 161

Observe the installation position. Coat the inner contact faces slightly with engine oil. Tightening torques not specified, see section on tightening torques

Removal ► Remove the oscillation damper. Use special tool (I).

Page 162

Page 85

► Bolt down special tool (I) with bolts (1). ► Ensure that the special tool will not make contact with the radial seal, unscrew bolt (2) if required. ► Tighten bolt (2) until the special tool makes contact with the radial seal.

85 282748-001

86

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01 Engine 0110 Engine housing 1451-001

► Drill two Ø3.5 mm holes into the radial seal through holes at (1). Position the drilled holes diagonally on opposite sides.

86 282749-001

► Tighten radial seal to special tool (I) with two bolts M4.8x25 (2). ► Unscrew the bolt (1) until the radial seal has been pulled out of the housing cover (5). ► Pull the special tool (I) off together with the radial seal. ► Undo the bolts (2) and remove the radial seal.

87 282750-001

► Check the contact face of the radial seal on the crankshaft flange. ► If there is evidence of run-in, replace the engine or crankshaft. Installation ► Insert radial seal (1). Observe the installation position. ► Coat the crankshaft flange (2) lightly with engine oil. ► Slide the radial seal onto the crankshaft flange using the assembly device (3). ► Slide the radial seal off the assembly device and onto the crankshaft flange, and push it into the front housing cover (2). ► Remove the assembly device. 88 282770-001

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87

01 Engine 0110 Engine housing 1451-001

Use special tools (I) and (II).

Page 85

► Fit the special tool (II) onto the special tool (I), and screw it on using nuts (1).

89 282761-001

► Screw the special tool (I) onto the crankshaft flange using bolts (1). When tightening the bolts (1), ensure that the special tool is not touching the radial seal and unscrew the bolt (2) if necessary. ► Push in the radial seal using the special tool by screwing in the bolt (2) until the stop can be felt. ► Slacken off bolt (2). ► Unscrew the bolts (1) and remove the special tool. ► Remove special tool (II). 90 282762-001

► The distance (2) between the edge of the front housing cover (3) and the fitted radial seal (1) must be the same around the entire circumference. ► If necessary, reinforce the radial seal using the special tool (I).

91 282768-001

► Install the oscillation damper

88

Page 163

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01 Engine 0110 Engine housing 1451-001 179265-001

Crankshaft rear seal Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Installation tool

1

00 1998 583 0

92 276359-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

89

01 Engine 0110 Engine housing 1451-001

Technical specifications

276360-001

Value

CCN

93

Remark / designation

1

Flywheel

Page 165

2

Timing housing

Page 97

3

Crankshaft

Page 145

4

Crankshaft rear radial seal Observe the installation position. Coat the inner contact face slightly with engine oil.

Tightening torques not specified, see section on tightening torques

Removal ► Remove the flywheel.

90

Page 166

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01 Engine 0110 Engine housing 1451-001

► Remove radial seal (1), using a suitable tool (2).

94 276366-001

► Check the contact face of the radial seal on the flywheel flange on the flywheel. ► If there is evidence of run-in on the flywheel flange, replace the flywheel. Page 165 Installation Use special tool (I).

Page 89

► Coat the new radial seal (1) with engine oil on the inside sealing lip. Fit the radial seal on the outer surface when it is dry. ► Slide the radial seal over the flange (2) of the special tool.

95 276397-001

Use special tool (I).

Page 89

► Position the flange (2) with the radial seal (1) on the crankshaft flange (3) and screw it on using bolts (4). The drilled hole (5) must be positioned over the dowel pin (6).

96 276399-001

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91

01 Engine 0110 Engine housing 1451-001

Use special tool (I).

Page 89

► Slide the retracting sleeve (2) and disc (3) over the flange (4). ► Tighten nut (5). ► Push the radial seal (1) into the timing housing (6) until the stop can be felt. The installation depth of the radial seal is predetermined by the special tool.

97 276401-001

► Remove the special tool. ► Check whether the radial seal is damaged. Page 168 ► Install flywheel.

92

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01 Engine 0110 Engine housing 1451-001 178643-001

Housing cover Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool

1

Special tool (I)

Pcs.

Punch

1

00 1992 868 0

98 274752-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

93

01 Engine 0110 Engine housing 1451-001

Technical specifications

274782-001

Value

CCN

1 2

99

Remark / designation Housing cover

60 Nm

Housing lid mounting bolts Tightening diagram:

– Screw in the mounting bolts (2.1 - 2.10) in the specified order (2.1 - 2.10). If a mounting bolt was screwed in too tightly, a new seal must be used. 3

Dowel pins

4

Radial shaft seal

5

Seal

6

Seal

Page 85

– Clean the sealing faces thoroughly. Tightening torques not specified, see section on tightening torques

Removal ► Remove the oscillation damper. Page 80 ► Remove oil pan.

94

Page 162

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01 Engine 0110 Engine housing 1451-001

► Unscrew bolts (1). ► Remove housing lid (2).

100 274758-001

► Remove seal (1). ► Clean the sealing face.

Page 20

101 274768-001

Use special tool (I). I

Page 93

► Remove the radial seal (1) using the special tool (I). Applies to OM 471 LA.

1

102 183752-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

95

01 Engine 0110 Engine housing 1451-001

Installation ► Fit new seal (1).

103 274768-001

► Place the housing cover (2) over the dowel pins on the crank case and push it in. ► Screw in the bolts (1) in accordance with the tightening diagram. Tightening diagram: Page 94

104 274758-001

► Install the radial seal. See the "Front crankshaft seal" chapter. Page 85 Page 163 ► Install the oscillation damper Install the oil pan. Page 82 ► ► Start the diesel engine and let it run at idle speed for 10 s min. ► Switch off the diesel engine and check for leaks.

96

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01 Engine 0110 Engine housing 1451-001 178869-001

Timing housing Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

97

01 Engine 0110 Engine housing 1451-001

Technical specifications

275690-001

Value

CCN

1 2

Remark / designation Timing housing

60 Nm

Mounting bolts for the electric starting motor

3

Electric starting motor

4

Seal

5

Crankshaft rear seal

6

M8: 30 Nm M10: 60 Nm M14: 120 Nm

Page 89

Tightening diagram:

– Screw in the mounting bolts (6.1 - 6.19) in the specified order (6.1 - 6.19). Seal

8

Cover 30 Nm

Page 452

Timing housing mounting bolts

7

9

105

Mounting bolts for the cap

10

Cover

11

Mounting bolts for the cap

12

Seal

13

Nut

Tightening torques not specified, see section on tightening torques

98

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0110 Engine housing 1451-001

Value 14

CCN 40 Nm

Stud

15 16 17

Remark / designation

Cover 30 Nm

Mounting bolts for the cap B600-MB

Crankshaft position sensor

Tightening torques not specified, see section on tightening torques

Removal ► Drain the engine oil. See the Operator's Manual of the machine in question. ► Remove the engine. See the repair manual of the machine in question. Page 166 ► Remove the flywheel. Remove oil pan. Page 80 ► ► Remove the resonance vessel (OM 470 LA). Page 460 ► Remove the resonance vessel (OM 471 LA). Page 461 ► Unscrew the bolts (1) and remove the electric starting motor (2).

106 275569-001

► Disconnect connector (1).

107 275574-001

► Remove the crankshaft rear seal.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Page 90

99

01 Engine 0110 Engine housing 1451-001

► Unscrew the bolts (2), (3) and (4), and remove the timing housing (1).

108 275622-001

► Remove seal (1).

109 275630-001

Only if the timing housing is replaced: ► Unscrew the bolts (1) and remove the cap (2).

110 275646-001

Only if the timing housing is replaced: ► Unscrew the studs (1) from the timing housing (2). ► Remove the plugs (3).

111 275648-001

100

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01 Engine 0110 Engine housing 1451-001

Installation ► Clean all sealing faces.

Page 20

► Install the plugs (3). ► Screw the studs (1) into the timing housing (2). Tightening torque: Page 98

112 275648-001

Only if the timing housing is replaced: ► Install the cap (2) together with a new seal. ► Tighten bolts (1). Tightening torque: Page 254

113 275646-001

► Fit the new seal (1) above both guide rods (2).

114 275651-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

101

01 Engine 0110 Engine housing 1451-001

► Fit the timing housing (1). ► Screw in the bolts (2), (3) and (4) in accordance with the tightening diagram. Page 98 Tightening diagram:

115 275622-001

► Install the rear crankshaft seal.

Page 91

► Connect the plug-in connection (1).

116 275574-001

► Check if the starter pinion is worn. ► Replace the electric starting motor (2) if necessary. ► Install the electric starting motor (2) and screw in the bolts (1). Tightening torque: Page 453

117 275569-001

► Install the resonance vessel (OM 470 LA). Page 460 ► Install the resonance vessel (OM 471 LA). Page 461 Page 82 ► Install the oil pan. Page 168 ► Install flywheel. ► Install the engine. See the repair manual of the machine in question. ► Top up engine oil. See the Operator's Manual of the machine in question.

102

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01 Engine 0110 Engine housing 1451-001 176192-001

Oil separator Applies to: Mercedes-Benz OM 470 LA

Technical specifications

268079-001

Value

CCN

118

Remark / designation

1

Oil feed line

2

Electrical cable

3

Retainers

4

Oil separator

5

10 Nm

Hex. bolts

6

60 Nm

Hex. bolts

7

5 Nm

Torx screws

8

6 Nm

Torx screws

9

Ventilation hose

10

Vent line

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

103

01 Engine 0110 Engine housing 1451-001

Removal ► Disconnect the battery isolating switch. ► Unscrew the bleed hose (1) on the bracket (2).

119 268092-001

► Expose the electrical cable (1) on the vent line (2). ► Undo the vent line (2) on the crank case bracket.

120 268097-001

► Disconnect the vent line (1) from the oil separator (2) and remove the vent line (1).

121 268104-001

104

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01 Engine 0110 Engine housing 1451-001

► Disconnect the oil pressure line (1) from the oil separator (2). Hold the screw neck (3) against the oil separator (2).

122 268107-001

► Unscrew bolts (1).

123 268116-001

► Pull the oil separator (1) downwards and remove it.

124 268119-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

105

01 Engine 0110 Engine housing 1451-001

Disassembly ► Unscrew bolts (1). ► Remove the centrifuge housing (1) from the oil separator housing (2).

125 268134-001

► Unscrew bolts (1). ► Remove the cover (2) from the centrifuge housing (3).

126 268149-001

► Remove the spring (1), ring (2) and membrane (3).

127 268151-001

106

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01 Engine 0110 Engine housing 1451-001

► Unscrew bolts (1). ► Remove the connector (2) together with the bracket (3) from the cover (4).

128 268152-001

► Unscrew bolts (1). ► Remove the vent line (2) together with the bracket (3) from the centrifuge housing (4).

129 OM 470 LA engine

268159-001

► Unscrew bolts (1). ► Remove the vent line (2) together with the bracket (3) from the centrifuge housing (4).

130 OM 471 LA engine

268163-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

107

01 Engine 0110 Engine housing 1451-001

Assembly ► Replace the sealing ring (1). ► Screw the vent line (2) together with the bracket (3) onto the centrifuge housing (4) using bolts (5).

131 OM 470 LA engine

268182-001

► Replace the sealing ring (1). ► Screw the vent line (2) together with the bracket (3) onto the centrifuge housing (4) using bolts (5).

132 OM 471 LA engine

268176-001

► Replace the sealing ring (1). ► Screw the connector (2) together with the bracket (3) onto the cover (4) using bolts (5). Tightening torque: Page 103

133 268195-001

108

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01 Engine 0110 Engine housing 1451-001

► Replace the spring (1), ring (2) and membrane (3) if necessary. Observe the installation position of membrane (3).

134 268151-001

► Screw the cover (2) onto the centrifuge housing (3) using bolts (1). Tightening torque: Page 103

135 268149-001

► Screw the centrifuge housing (1) onto the housing (2) using bolts (1). Tightening torque: Page 103

136 268134-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

109

01 Engine 0110 Engine housing 1451-001

Installation ► Clean the sealing surfaces and replace the seal. ► Fit the oil separator (1) from below and screw it onto the crank case using bolts (2). Tightening torque: Page 103

137 268128-001

► Turn the connection (1) upwards.

138 283010-001

► Connect the oil pressure line (1) to the oil separator (2). Hold the screw neck (3) against the oil separator (2).

139 268107-001

110

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01 Engine 0110 Engine housing 1451-001

► Screw the vent line (1) to the oil separator (2). Replace the vent line (1) if necessary. Replace the seal on the quick-release lock for the vent line (1) if necessary.

140 268104-001

► Screw the vent line (2) onto the crank case bracket. ► Fasten the electrical cable (1) to the vent line (2).

141 268097-001

► Screw the bleed hose (1) onto the bracket (2). ► Check the engine oil level and top up the engine oil if necessary.

142 268092-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

111

01 Engine 0110 Engine housing 1451-001 182177-001

Oil separator Applies to: Mercedes-Benz OM 471 LA

Technical specifications

282996-001

Value

CCN

1

Remark / designation Oil separator

2

10 Nm

Mounting bolts

3

60 Nm

Mounting bolts

4

5 Nm

Mounting bolts

5

6 Nm

Mounting bolts

6 7

143

Vent line 30 Nm

Mounting bolts for the vent line

Tightening torques not specified, see section on tightening torques

112

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01 Engine 0110 Engine housing 1451-001

Removal ► Disconnect the battery isolating switch. ► Remove the bleed hose (1) from the oil separator (2). ► Remove the bleed hose (3) from the bracket (4). ► Remove the bleed hose (3) on the crank case. ► Undo the bolts (5) and pull the oil separator (2) downwards and remove it.

144 282975-001

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113

01 Engine 0110 Engine housing 1451-001

Disassembly ► Unscrew bolts (1). ► Remove the centrifuge housing (1) from the oil separator housing (2).

145 268134-001

► Unscrew bolts (1). ► Remove the cover (2) from the centrifuge housing (3).

146 268149-001

► Remove the spring (1), ring (2) and membrane (3).

147 268151-001

114

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01 Engine 0110 Engine housing 1451-001

► Unscrew bolts (1). ► Remove the connector (2) together with the bracket (3) from the cover (4).

148 268152-001

► Unscrew bolts (1). ► Remove the vent line (2) together with the bracket (3) from the centrifuge housing (4).

149 OM 470 LA engine

268159-001

► Unscrew bolts (1). ► Remove the vent line (2) together with the bracket (3) from the centrifuge housing (4).

150 OM 471 LA engine

268163-001

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115

01 Engine 0110 Engine housing 1451-001

Assembly ► Replace the sealing ring (1). ► Screw the vent line (2) together with the bracket (3) onto the centrifuge housing (4) using bolts (5).

151 OM 470 LA engine

268182-001

► Replace the sealing ring (1). ► Screw the vent line (2) together with the bracket (3) onto the centrifuge housing (4) using bolts (5).

152 OM 471 LA engine

268176-001

► Replace the sealing ring (1). ► Screw the connector (2) together with the bracket (3) onto the cover (4) using bolts (5). Tightening torque: Page 112

153 268195-001

116

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01 Engine 0110 Engine housing 1451-001

► Replace the spring (1), ring (2) and membrane (3) if necessary. Observe the installation position of membrane (3).

154 268151-001

► Screw the cover (2) onto the centrifuge housing (3) using bolts (1). Tightening torque: Page 112

155 268149-001

► Screw the centrifuge housing (1) onto the housing (2) using bolts (1). Tightening torque: Page 112

156 268134-001

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117

01 Engine 0110 Engine housing 1451-001

Installation ► Clean the sealing faces.

Page 20

► Fit the oil separator (2) with a new seal from below and screw it onto the crank case using bolts (5). Tightening torque: Page 112 ► Attach the bleed hose (3) to the bracket (4). ► Attach the bleed hose (3) to the crank case. Tightening torque: Page 112 ► Turn the connection (6) upwards. ► Attach the bleed hose (1) to the oil separator (2).

157 282978-001

► Check the engine oil level and top up the engine oil if necessary. ► Test the engine. ► Switch off the engine and check for leaks.

118

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01 Engine 0115 Engine unit 1451-001

0115 Engine unit

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

119

01 Engine 0115 Engine unit 1451-001 178967-001

Piston Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Socket

1

00 1992 952 0

158 147565-001

Special tool (III)

Pcs.

Piston ring compressor

1

00 0147 999 0

159 181552-001

Special tool (IV)

Pcs.

Clock gauge

1

60 0500 530 3

160 39240-002

120

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01 Engine 0115 Engine unit 1451-001

Special tool (V)

Pcs.

Measuring gauge holder

1

00 1992 870 3

161 276005-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

121

01 Engine 0115 Engine unit 1451-001

Technical specifications

c

1.1 1 9

2

3

6

4 5 1

8

7

3 b a 4

5

182244-001

122

162

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01 Engine 0115 Engine unit 1451-001

Value 1

CCN

Remark / designation Piston Marking (1.1) for installation position and installation point. Always replace the piston together with cylinder liner (2).

2

Cylinder liner

Page 138

3

Piston ring - double trapezoidal ring

4

Piston ring - tapered compression ring with inside angle

5

Piston ring - chamfered ring with hose spring

6

Connecting rod

Page 132

7

Crankshaft

Page 145

8

Oil spray nozzle

Page 338

9

Slightly coat piston pin with engine oil

10

Connecting rod bearing cover bolt on the connecting rod Tightening diagram:

– Screw in the bolts in 2 stages in accordance with the tightening specification: Tightening specification:

1 150 Nm (OM 470 LA) 180 Nm (OM 471 LA) 2 90 ° a

Height play of piston rings Applies to: OM 470 LA and OM 471 LA Piston ring (3): Piston ring (4): 0.057 mm to 0.103 mm Piston ring (5): 0.047 mm to 0.093 mm

b

Push play of piston rings Applies to: OM 470 LA and OM 471 LA Piston ring (3): 0.30 mm to 0.45 mm Piston ring (4): 0.70 mm to 0.90 mm Piston ring (5): 0.40 mm to 0.60 mm

c

c

-0.1905 to 0.2305 mm

Piston undershoot to piston overshoot in TDC

-0.2090 to 0.2315 mm

Piston undershoot to piston overshoot in TDC

Applies to: OM 470 LA

Applies to: OM 471 LA

Tightening torques not specified, see section on tightening torques

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123

01 Engine 0115 Engine unit 1451-001

Removal ► ► ► ►

►

► ► ► ►

►

► ►

Remove cylinder head valve cover. Page 172 Remove the reinforcing frame. Page 175 Remove the camshaft housing. Page 181 Remove the cylinder head (OM 470 LA). Page 194 ► Ensure that all bores on the separating face of the crankcase are tightly closed. ► Clean the sealing faces. Page 20 Remove the cylinder head (OM 471 LA). Page 216 ► Ensure that all bores on the separating face of the crankcase are tightly closed. ► Clean the sealing faces. Page 20 Remove oil pan. Page 80 Remove the oil pump. Page 350 Remove the oil spray nozzles. Page 338 Fit a direction arrow indicating the installation position of the piston. ► This is required only when the direction arrow is no longer visible. ► The direction arrow must point away from the power output side. Mark the cylinder number on the piston head. ► This is required only if more than one piston is removed. Twist crankshaft until the piston is at the BDC. See Cranking the engine. Page 60 Protect the piston head (1) and crank case against dirt.

► Carefully loosen any combustion residues on the scraper ring (2) and on the cylinder liner (3) near the head land zone (A) with a scraper and remove them with compressed air.

163 275777-001

124

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01 Engine 0115 Engine unit 1451-001

► ►

► 164 275779-001

►

Turn the crankshaft until the piston (1) is approx. 1 cm below the scraper ring (2). Insert a piston ring (4) below the scraper ring (2) in the cylinder liner (3) and insert a corresponding feeler gauge (5) in the piston ring joint. Only use a double trapezoidal ring as a piston ring (4). The "TOP" designation must point downwards towards the piston head. The feeler gauge prevents compression of the piston ring when pushing out the scraper ring. Rotate the crankshaft until the piston with the inserted piston ring pushes the scraper ring out of the cylinder liner. Back up the cylinder liner if necessary. Remove the scraper ring, feeler gauge and piston ring.

Use special tool (I).

Page 120

► Mark the installation position of the connecting rod (3) and connecting rod bearing cover (2) in relation to each other. ► Unscrew the connecting rod bolts (1) and remove the connecting rod bearing cover. ► Ensure that the cracked separating surface is not damaged at the connecting rod (3) or on the connecting rod bearing cover. Replace the connecting rod and connecting rod bearing cover if necessary. ► Push the connecting rod away from the connecting rod bearing pin on the crankshaft. Rotate the crankshaft if necessary. ► Remove the connecting rod bearing shells (4) and (5) and mark which is for the connecting rod bearing cover and which is for the connecting rod. ► Push the piston (6) with the connecting rod upwards and out of the cylinder liner and remove it. ► Ensure that the cylinder liner is not damaged in this process. ► Replace the cylinder liner if necessary. Page 138 ► Only screw on the connecting rod bearing cover if the connecting rod bearing shell is inserted in the connecting rod. ► Mark the installation position on the piston and the connecting rod to the crank case. The direction arrow must point in the direction of travel. The connecting rod bearing cover and connecting rod are marked in relation to one another using the reference number (7).

165 275794-001

Disassembly ► Clamp the connecting rod with the piston in a vice. ► Ensure to use soft cheeks for clamping.

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125

01 Engine 0115 Engine unit 1451-001

► Remove the piston rings (1), (2) and (3) from top to bottom.

166 275811-001

► Remove the circlips (3). ► Remove piston pin (2). ► Remove the piston (1) from the connecting rod (4).

167 275805-001

Checking ► Check piston for dust damage, seizing traces, scratches, cracks or other traces of wear. Replace piston if necessary. ► Check height play (a) of piston rings (2) on piston (1), using a feeler gauge. Vertical play a: Page 122 ► When one piston ring is worn, all piston rings of the piston in question must be replaced. ► If one of the piston ring grooves is worn, the piston must be replaced.

1 2

a2301252

168 171455-001

126

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01 Engine 0115 Engine unit 1451-001

► Checking the joint play (b) of the piston rings: ► Align the piston rings (2) using the installation position of the piston (1) for the corresponding cylinder liner (3). ► Clean the cylinder liner and lightly oil it with engine oil. ► Insert the piston ring in the upper cylinder liner. ► Push the piston ring with the piston head into the lower unused area of the cylinder liner and then remove the piston again. ► The piston ring is aligned using the piston. ► Remove the hose spring on the chamfered ring. ► Check the joint play (b) on the piston ring using a feeler gauge (4). Page 122 ► Joint play: Check the joint play on all piston rings. ► ► When one piston ring is worn, all piston rings of the piston in question must be replaced.

169 275830-001

170 275839-001

Assembly Page 126 ► Check piston and piston rings. Page 136 ► Check the connecting rods.

1 2 3

171 181396-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

► Assemble piston (2) and connecting rod (3) by inserting the piston pin (1). ► It must be possible to push the piston pin (1) into the piston easily with the fingers and the piston pin must not slide out again due to its own weight. ► Apply a little oil to the piston pin. ► Observe the installation position. ► In addition, observe the specifications of the Page 133 "Connecting rod" chapter. Insert new safety rings. ► The opening on the safety ring must face the connecting rod.

127

01 Engine 0115 Engine unit 1451-001

1

a2301248

172 171363-001

► Insert the hose spring (1) of the piston ring (2) into the corresponding groove on the piston (3). ► Ensure that the hose spring offset from the hose spring joint (6) to the piston ring joint is approx. 180°. ► Install the piston rings (2), (4) and (5). ► Observe the installation position of the different piston rings. ► See technical specifications: Page 122 ► Ensure that the "TOP" mark points to the piston head. ► Ensure that the joint ends of the piston ring are installed with a 120° offset with respect to one another.

173 275870-001

Installation Page 141 ► Check cylinder liners. ► Check connecting rod bearing pin of the crankshaft. Page 147

128

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01 Engine 0115 Engine unit 1451-001

Use special tool (III).

Page 120

► Insert ram (1). Observe the installation position.

III

1

174 181553-001

Use special tool (I).

175 275940-001

176 275957-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Page 120

► Slide the piston (1) into the cylinder line until the connecting rod (3) is almost in contact with the connecting rod bearing pin (8) of the crankshaft. ► Ensure that the cylinder liner is not scratched or damaged in the process. ► Replace the cylinder liner if necessary. ► The direction arrow (2) must point in the direction of travel. ► If necessary, turn the crankshaft so that the connecting rod is not resting on the connecting rod bearing pin or ballast weight. ► Insert connecting rod bearing shell (4). On a used connecting rod bearing shell (4), note the designation on the connecting rod (3). There are various connecting rod bearing shells (4) and (5) fitted in the connecting rod bearing cover (7) and in the connecting rod. The twist lock on the connecting rod bearing shell (4) must be seated in the connecting rod groove. ► Position the connecting rod bearing cover (7) together with the connecting rod bearing shell (5). The twist lock on the connecting rod bearing shell must be seated in the groove for the connecting rod bearing cover. ► The connecting rod bearing cover and connecting rod are marked as a pair by the reference number (6) and must not be swapped. ► Screw in bolts (9). Tightening torque: Page 122

129

01 Engine 0115 Engine unit 1451-001

► Insert scraper ring (1) into the cylinder liner (2). If the piston and the cylinder liner have been replaced, a new scraper ring must be fitted.

177 275983-001

Page ► Measure the piston excess dimension. 122 Page 338 ► Install the oil spray nozzles. Page 351 ► Install the oil pump. Page 82 ► Install the oil pan. Page ► Install the cylinder head (OM 470 LA). 203 Page ► Install the cylinder head (OM 471 LA). 220 Page 185 ► Install the camshaft housing. Page 177 ► Install the reinforcing frame. Page ► Install the cylinder head valve cover. 172 Page 336 ► Fill the oil circuit. Measuring the excess dimension Using special tools (IV) and (V): 1

1

Page 120

► Measure the piston excess dimension (c) without the cylinder head gasket being in place. Piston excess dimension: Page 122 ► Ensure that no deposits or soiling accumulates on the piston head and on the cylinder head surface. ► Measure the piston excess dimension (c) in the direction of the piston pin at (1) in order to eliminate the piston slap play. 178 181596-001

130

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01 Engine 0115 Engine unit 1451-001

IV

1

V

179 250748-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

131

01 Engine 0115 Engine unit 1451-001 179194-001

Connecting rod Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

132

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0115 Engine unit 1451-001

Technical specifications

276286-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

180

133

01 Engine 0115 Engine unit 1451-001

Value 1

CCN

Remark / designation Connecting rod Observe marks at (7).

2

Connecting rod bearing cover Observe marks at (7).

3

Connecting rod bearing bush

4

Slightly coat piston pin with engine oil

5

Connecting rod bearing shells Do not confuse the connecting rod bearing shells.

6

Connecting rod bearing shells Do not confuse the connecting rod bearing shells.

7

Mark of connecting rod - connecting rod bearing cover

8

Connecting rod bolt Applies to: OM 470 LA Tighten the bolts in two steps:

1 150 Nm 2 90° Observe the shaft length (f). 8

Connecting rod bolt Applies to: OM 471 LA Tighten the bolts in two steps:

1 180 Nm 2 90° Observe the shaft length (f). a

Inner diameter of the connecting rod bushing Applies to: OM 470 LA Target value: 55.070 to 55.080 mm

a

Inner diameter of the connecting rod bushing Applies to: OM 471 LA Target value: 58.070 to 58.080 mm

b

Outer diameter of the piston pin Applies to: OM 470 LA Target value: 54.994 to 55.000 mm

Tightening torques not specified, see section on tightening torques

134

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01 Engine 0115 Engine unit 1451-001

Value b

CCN

Remark / designation Outer diameter of the piston pin Applies to: OM 471 LA Target value: 57.994 to 58.000 mm

c

Piston pin clearance Applies to: OM 470 LA Radial: 0.070 to 0.086 mm

c

Piston pin clearance Applies to: OM 471 LA Radial: 0.070 to 0.088 mm

d

Connecting rod bearing inner diameter (with the connecting rod bearing shells inserted) Applies to: OM 470 LA Standard: 90.057 to 90.102 mm Deviation 0.25: 89.807 to 89.852 mm Deviation 0.50: 89.557 to 89.602 mm Deviation 0.75: 89.307 to 89.352 mm Deviation 1.00: 89.057 to 89.102 mm

d

Connecting rod bearing inner diameter (with the connecting rod bearing shells inserted) Applies to: OM 471 LA Standard: 95.060 to 95.115 mm Deviation 0.25: 94.810 to 94.865 mm Deviation 0.50: 94.560 to 94.615 mm Deviation 0.75: 94.310 to 94.365 mm Deviation 1.00: 94.060 to 94.115 mm

e

Connecting rod play Applies to: OM 470 LA Radial: 0.057 to 0.122 mm

e

Connecting rod play Applies to: OM 471 LA Radial: 0.060 to 0.135 mm

f

up to 74,3 mm

Shaft length of connecting rod bolt (8) Applies to: OM 470 LA

f

up to 79 mm

Shaft length of connecting rod bolt (8) Applies to: OM 471 LA

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

135

01 Engine 0115 Engine unit 1451-001

Removal Page 124 ► Remove the piston. Page 125 ► Disassemble the piston. Checking

181 276287-001

182 276288-001

136

► Check the connecting rod bushing (1), connecting rod bearing cover (2) and connecting rod bearing position in the connecting rod (3). ► If it is coloured blue or has scores or grooves, the connecting rod must be replaced. ► Check the piston pin (4): ► If it is coloured blue or has scores or grooves, the piston pin must be replaced. ► Check the piston boss on the piston. ► Replace the piston if necessary. ► Check the inner diameter of the connecting rod bushing within the measuring range (a). ► Check the outer diameter of the piston pin (b): ► Check the measuring positions in the specified order (1., 2. and 3.). ► The second and third measuring positions are offset by around 60° each relative to the first measuring position. ► Calculate the average value from the three measured values. ► Replace the piston pin if necessary. ► Check the piston pin play (c): ► The piston pin play can be determined by subtracting the mean diameter value of the piston pin from the inner diameter of the connecting rod bushing. ► OM 470 LA example: ► Connecting rod bushing inner diameter: 55.070 mm ► Piston pin outer diameter: 55.000 mm ► c = 55.070 mm - 55.000 mm = 0.070 mm ► Replace the piston pin and connecting rod with the connecting rod bearing cover if necessary.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0115 Engine unit 1451-001

► Check the connecting rod bearing shells (1) and (2), the pick-up in the connecting rod (3) and the pick-up in the connecting rod bearing cover (4) for wear and damage: ► If any wear is found, all connecting rod bearing shells can be replaced if all the diameters for the connecting rod bearing pins are within the tolerance range. (See the Page crankshaft technical specifications 147) ► The connecting rod bearing shells must not be reworked. Check the connecting rod bearing inner ► diameter (d): ► Check the connecting rod bearing inner diameter on the assembled connecting rod. ► Check the measuring positions in the specified order (1st, 2nd and 3rd). ► Begin with the measuring distance (1st), offset from the sectioning point (5) by 90°. ► The second and third measuring positions are offset by around 60° each relative to the first measuring position. ► Calculate the average value from the three measured values. ► Replace the connecting rod bearing shells and connecting rod with the connecting rod bearing cover if necessary.

183 276289-001

► Check the connecting rod play (e): ► The connecting rod play can be determined by subtracting the mean diameter value of the connecting rod bearing pin from the mean value of the connecting rod bearing inner diameter. ► OM 470 LA example: ► Connecting rod bearing inner diameter: 90.085 mm ► Diameter of connecting rod bearing pin: 89.994 mm (see crankshaft technical data) Page 147) ► e = 90.085 mm - 89.994 mm = 0.091 mm Installation ► Check the connecting rod bearing pin. See crankshaft. Page 147 Page 136 ► Check the connecting rods. Page 127 ► Assemble the piston. Page 128 ► Install the piston.

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137

01 Engine 0115 Engine unit 1451-001 178581-001

Cylinder liner Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Removal and installation tool

1

00 1998 590 0

184 274349-001

Special tool (II)

Pcs.

Clock gauge

1

60 0500 530 3

185 268255-001

138

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01 Engine 0115 Engine unit 1451-001

Technical specifications

274637-001

Value

CCN

Remark / designation

1

Sealing rings

2

Cylinder liner

3

Crank case

4

Scraper ring

a

0.140 to 0.270 mm

186

Cylinder liner excess length Applies to: OM 470 LA, OM 471 LA Permissible difference between protrusions on a single cylinder liner: Up to 0.09 mm Permissible difference between protrusions across all cylinder liners: Up to 0.09 mm

b

b

124.990 to 125.010 mm

Diameter of cylinder bore

131.990 to 132.010 mm

Diameter of cylinder bore

Applies to: OM 470 LA

Applies to: OM 471 LA

Tightening torques not specified, see section on tightening torques

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139

01 Engine 0115 Engine unit 1451-001

Removal Remove cylinder head valve cover. Page 172 Remove the reinforcing frame. Page 175 Remove the camshaft housing. Page 181 Remove the cylinder head (OM 470 LA). Page 199 Page ► Remove the cylinder head (OM 471 LA). 216 Page 124 ► Remove the piston. ► ► ► ►

Use special tool (I).

Page 138

► Mark the installation position of the cylinder liner (1) in relation to the crankcase (2). ► This is required only if the cylinder liner is reused. ► Tighten the studs (3) until they are hand-tight.

187 274364-001

274365-001

Use special tool (I).

188

Page 138

► Attach the leaf (1) with a joint to the spindle (2). ► Insert the leaf into the cylinder liner (3). The guide collar on the leaf must sit underneath on the collar for the cylinder liner. If the cylinder liner is damaged, the cylinder liner must be replaced. ► Attach the reinforcing bar (4) onto the spindle and studs (6) and screw it in place. ► Screw the nut (5) onto the spindle until the leaf is touching the cylinder liner. Ensure that the leaf is correctly seated on the cylinder liner.

140

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01 Engine 0115 Engine unit 1451-001

► Pull out the cylinder liner (1) by turning the nut (2). ► Remove the special tool.

189 274366-001

► Remove the sealing rings (1) from the cylinder liner (2).

190 274369-001

► Plug all openings tightly. Checking Use brake cleaner and a lint-free cleaning cloth.

191 274408-001

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► Clean the cylinder liner hole. ► Clean the upper centring seat (1). ► Vacuum the upper centring seat and clean it using compressed air. ► Clean the lower collar seat (2). ► If the collar seat is scored or damaged, the crank case must be replaced. ► Clean the separating surface (3). ► Vacuum the separating surface and clean it using compressed air. ► Vacuum all openings and clean them using compressed air. ► Clean the cylinder liner (4). ► Clean the grooves (5), centring chamfer (6) and thread (7). ► Check the centring chamfer (6) and thread (7) for damage. ► Replace the cylinder liner and pistons if necessary. ► Check the centring seat (1) and collar seat (2) for damage.

141

01 Engine 0115 Engine unit 1451-001

► Replace the crank case if necessary. ► Coat the contact face of the cylinder liner with engine oil. Installation ► Check cylinder liners.

Page 141

► Coat the new sealing rings (1) with clean engine oil and position them in the grooves. ► Ensure that the sealing rings are not twisted when inserting them. ► The sealing rings must lie flat against the top of the grooves and the rounded side must face outwards.

192 274369-001

► Insert the cylinder liner (1) in the crank case (2). ► If necessary, observe the markings for the installation position on the cylinder liner. ► If a new cylinder liner is fitted, the piston rings on the piston must be replaced. Page 125

193 274454-001

Use special tool (I).

Page 138

► Tighten the studs (1) until they are hand-tight. ► Screw the assembly handles (2) into the push-in panel (3). ► Fit the push-in panel (3) onto the cylinder liner (4). ► The designation (5) must indicate the opposite side to the power output side.

194 274489-001

142

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01 Engine 0115 Engine unit 1451-001

Use special tool (I).

Page 138

► Lightly lubricate the contact face of the spindle (1) on the push-in panel (4). ► Screw the nut (5) onto the spindle. ► Place the spindle with reinforcing bar (2) on the studs (3) and screw it down. The ball in the spindle must be seated in the depression of the push-in panel. ► Push in the cylinder liner by turning the nut (5). ► Maximum tightening torque for the nuts: 10 Nm 195 274498-001

► Measure the excess dimension of the cylinder liners. Page 139 ► Remove the spindle (1) together with the reinforcing bar (2) and push-in panel (4). ► Unscrew the studs (3). ► Remove the assembly handles (5).

196 274502-001

Page 139 ► Measure the cylinder bore. Page 128 ► Install the piston. Page ► Install the cylinder head (OM 470 LA). 203 Page ► Install the cylinder head (OM 471 LA). 220 Page 185 ► Install the camshaft housing. Page 177 ► Install the reinforcing frame. Install the cylinder head valve cover. Page ► 172

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143

01 Engine 0115 Engine unit 1451-001

Measuring the excess dimension

274682-001

Use special tools (I) and (II).

197

Page 138

► Measure the excess length of the cylinder liners. Cylinder liner excess length (a): Page 139 Carry out four measurements (1 to 4) per cylinder liner. If the excess length of a cylinder liner (a) is outside of the tolerance, the cylinder liner or the crankcase must be replaced. Measuring the cylinder bore Use special tool (II).

Page 138

► Measure the inner diameter at the upper return point of the first piston ring (4). ► Complete the measurements in both measuring directions (b) and (c). ► Inner diameter: Page 139 When measuring an out-of-roundness: ► Replace the cylinder liner. The cylinder liner must not be reworked! 198 274579-001

144

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01 Engine 0115 Engine unit 1451-001 179249-001

Crankshaft Applies to: Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Clock gauge

1

60 0500 530 3

199 268255-001

Special tool (II)

Pcs.

Measuring gauge holder

1

00 1992 874 0

200 268245-001

Special tool (III)

Pcs.

Puller

1

00 1998 582 0

201 148062-002

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

145

01 Engine 0115 Engine unit 1451-001

Special tool (IV)

Pcs.

Slide hammer puller

1

00 1992 873 0

202 282918-001

146

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0115 Engine unit 1451-001

Technical specifications

282895-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

203

147

01 Engine 0115 Engine unit 1451-001

Value

CCN

Remark / designation

1

Crankshaft

2

Connecting rod bearing pin

3

Flange bearing journal

4

Thrust washer for thrust bearing

5

Thrust washer for thrust bearing

6

Thrust bearing

7

Thrust bearing for crankshaft bearing cap

8

Mounting bolts for the crankshaft bearing cap Tightening diagram:

– – – –

Check the shaft length (f). Lightly coat the bolts with engine oil. Tighten the bolts until they are hand-tight. Tighten the bolts (8.1 - 8.14) in the specified order (8.1 -8.14) in four steps in accordance with the tightening specification.

Tightening specification:

1 2 3 4 a

50 Nm 150 Nm 300 Nm 90 °

Connecting rod bearing pin diameter Applies to: OM 470 LA Standard: 89.980 to 90.000 mm Deviation 0.25: 89.730 to 89.750 mm Deviation 0.5: 89.480 to 89.500 mm Deviation 0.75: 89.230 to 89.250 mm Deviation 1.0: 88.980 to 89.000 mm

a

Connecting rod bearing pin diameter Applies to: OM 471 LA Standard: 94.980 to 95.000 mm Deviation 0.25: 94.730 to 94.750 mm Deviation 0.5: 94.480 to 95.500 mm Deviation 0.75: 94.230 to 94.250 mm Deviation 1.0: 93.980 to 94.000 mm

Tightening torques not specified, see section on tightening torques

148

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01 Engine 0115 Engine unit 1451-001

Value b

CCN

Remark / designation Width of connecting rod bearing pin Applies to: OM 470 LA Standard: 45.000 to 45.100 mm Deviation 0.25: 45.000 to 45.100 mm Deviation 0.5: 45.000 to 45.100 mm Deviation 0.75: 45.000 to 45.100 mm Deviation 1.0: 45.000 to 45.100 mm

b

Width of connecting rod bearing pin Applies to: OM 471 LA Standard: 47.500 to 47.600 mm Deviation 0.25: 47.500 to 47.600 mm Deviation 0.5: 47.500 to 47.600 mm Deviation 0.75: 47.500 to 47.600 mm Deviation 1.0: 47.500 to 47.600 mm

c

Inner diameter of the main bearing pin, width of the flange bearing journal Applies to: OM 471 LA Standard: 113.980 to 144.00 mm Width: 47.500 to 47.600 mm Deviation 0.25: 113.7300 to 113.750 mm Width deviation 0.5: 48.000 to 48.100 mm Deviation 0.5: 113.480 to 113.500 mm Width deviation 0.5: 48.500 to 48.100 mm Deviation 0.75: 113.230 to 113.250 mm Width deviation 1.0: 48.500 to 48.600 mm Deviation 1.0: 112.980 to 113.000 mm Width deviation 1.0: 48.500 to 48.600 mm

d

Wall thickness of the thrust washers Applies to: OM 471 LA Standard: 3.500 to 3.550 mm Deviation 0.5: 3.750 to 3.800 mm Deviation 1.0: 4.000 to 4.050 mm

e

Axial play of the main bearing Applies to: OM 471 LA 0.200 to 0.401 mm

Tightening torques not specified, see section on tightening torques

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149

01 Engine 0115 Engine unit 1451-001

Value f

CCN

Remark / designation Bolt shaft length When new: 172,5 mm Permitted value: Up to 175.5 mm

g

Inner diameter of the main crankshaft bearing in installed condition Applies to: OM 471 LA Standard: 114.065 to 114.115 mm Deviation 0.25: 113.815 to 113.865 mm Deviation 0.5: 113.565 to 113.615 mm Deviation 0.75: 113.315 to 113.365 mm Deviation 1.00: 113.065 to 113.115 mm

Tightening torques not specified, see section on tightening torques

Removing the main crankshaft bearing Page 80 ► Remove oil pan. Page 350 ► Remove the oil pump. ► Attach the cranking tool. See Cranking the engine. Page 60 Use special tools (I) and (II).

Page 145

► Attach the special tool (I) with pretension to the thrust-bearing crankshaft bearing cap (1) and the side (2) of the crankshaft. Position the special tool (II) on a flat surface on the thrust-bearing crankshaft bearing cap. ► Use a suitable lever (3) to push and hold the crankshaft in place on the front stop of the thrustbearing crankshaft bearing cap (3). ► Set the scale for the special tool (I) to "0". ► Push the crankshaft against the rear stop of the thrust-bearing crankshaft bearing cap and read the measured value. The axial play can be calculated as the measured value from stop to stop. Axial play: Page 147 ► Remove special tool (I) and (II).

204 282804-001

150

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01 Engine 0115 Engine unit 1451-001

282805-001

205

► Check the designation for the crankshaft bearing cover (1) and thrust-bearing crankshaft bearing cover (2). ► Re-mark them if necessary. ► All crankshaft bearing covers (1) and thrustbearing crankshaft bearing covers (2) are marked with reference numbers. ► The reference numbers are installed in ascending order opposite the power output side. ► Loosen the bolts (3) on the crankshaft bearing covers (1) and the thrust-bearing crankshaft bearing cover (2). The bolts must only be loosened, not fully undone, as this would otherwise cause the crankshaft to lower too far, resulting in damage to the front and rear crankshaft radial seal. Only one crankshaft bearing cap (1) may be removed, as this would otherwise cause the crankshaft to lower too far, resulting in damage to the front and rear crankshaft radial seal. ► Unscrew bolts (2). ► Check whether the crankshaft bearing cap (1) has become loose and could fall down as a result. If the crankshaft bearing cap is damaged, the crank case must be replaced.

206 282808-001

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151

01 Engine 0115 Engine unit 1451-001

Use special tools (III) and (IV).

Page 145

► Insert clamping bolts (1) into the bolt holes and clamp them down by tightening the bolts (2). ► Position the special tool (III), connect it to the clamping bolts and screw it on using the nuts (3). ► Attach the special tool (IV) to the special tool (III). ► Pull out the crankshaft bearing cap (4) using the special tools (IV) and (III). If the crankshaft bearing cap is damaged, the crank case must be replaced. ► Remove the special tool (IV). ► Remove the special tool (III) and remove the clamping bolts (1) by undoing the screws (2).

207 282809-001

► Remove the main bearing housing (1) on the crankshaft bearing cap (2). Mark the installation position of the main bearing housing.

208 282811-001

► Push out and remove the upper main bearing housing (1) from the crank case. ► The slide direction (2) of the main bearing housing must be chosen to ensure that the twist lock (3) of the main bearing housing is pushed out of the crank case. ► If necessary, rotate the crankshaft (4) in the slide direction (2) until the main bearing housing has been pushed out of the crank case and can be removed. ► Clean the main bearing pins on the crankshaft with a lint-free cloth and check them for wear. 209 282813-001

152

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01 Engine 0115 Engine unit 1451-001

► Clean the main bearing housings (1) and (2) with a lint-free cloth and check them for wear. ► Check whether the main bearing housings are fitted as standard or with a deviation. Main bearing housings fitted as standard can be recognised by the stamped STD letter series on the rear. If they are fitted with a deviation, the corresponding deviation is stamped instead. If the main bearing housings are replaced, they must always be fitted in the same way as before.

210 282815-001

211 282821-001

212 282834-001

► Oil the main bearing pins on the crankshaft (2) and the upper main bearing housing (1) with engine oil. ► Push the upper main bearing housing in the slide direction (3) into the crank case and note the position of the twist lock (4) when doing so. The main bearing housing (1) together with the surrounding oil groove and oil hole must be installed in the crank case. If necessary, rotate the crankshaft (2) in the slide direction (3) until the upper main bearing housing has been fully pushed into the crank case. The twist lock (4) on the main bearing housing must be positioned in the groove in the crank case designed for this purpose. ► Check the shaft length of the bolts (4). If the permissible shaft length has been exceeded, the corresponding screw must be replaced. Shaft length: Page 147 Insert the main bearing housing (2) on the ► crankshaft bearing cap (1). ► Oil the contact face of the main bearing housing with engine oil. The twist lock (3) on the main bearing housing (2) must be positioned in the groove in the crankshaft bearing cap (1) designed for this purpose. ► Oil the bolts (4) with engine oil. ► Install the crankshaft bearing cap with the main bearing housing inserted. ► Screw in the bolts into the corresponding crankshaft bearing cap. The bolt heads must be in contact with the crankshaft bearing cap.

213 282836-001

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153

01 Engine 0115 Engine unit 1451-001

282837-001

214

Only one crankshaft bearing cap (1) may be removed, as this would otherwise cause the crankshaft to lower too far, resulting in damage to the front and rear crankshaft radial seal. ► Unscrew the bolts (3) on the thrust-bearing crankshaft bearing cap (2). The thrust-bearing crankshaft bearing cap is marked with the number "6". If the thrust-bearing crankshaft bearing cap is damaged, the crank case must be replaced. ► Insert clamping bolts (1) into the bolt holes and clamp them down by tightening the bolts (2). ► Position the special tool (III), connect it to the clamping bolts and screw it on using the nuts (3). ► Attach the special tool (IV) to the special tool (III). ► Pull out the thrust-bearing crankshaft bearing cap (4) using the special tools (IV) and (III). If the thrust-bearing crankshaft bearing cap is damaged, the crank case must be replaced. ► Remove the special tools (III) and (IV).

215 282838-001

154

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01 Engine 0115 Engine unit 1451-001

► Remove the thrust washers (1) on the thrustbearing crankshaft bearing cap (2). Mark the installation position of the thrust washers in relation to the thrust-bearing crankshaft bearing cap. ► Remove the main bearing housing (3).

216 282839-001

► Push out both upper thrust washers (1) on the thrust bearing from the crank case. Mark the installation position of the thrust washer.

217 282840-001

► Push out and remove the main bearing housing (1) from the crank case. The slide direction (2) of the main bearing housing must be chosen to ensure that the twist lock (3) of the main bearing housing is pushed out of the crank case. If necessary, rotate the crankshaft in the slide direction (2) until the main bearing housing has been pushed out of the crank case and can be removed. ► Clean the main bearing pins on the crankshaft (4) with a lint-free cloth and check them for wear. 218 282843-001

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155

01 Engine 0115 Engine unit 1451-001

► Clean the main bearing housings (1) and (2) with a lint-free cloth and check them for wear. ► Check whether the main bearing housings are fitted as standard or with a deviation. Main bearing housings fitted as standard can be recognised by the stamped STD letter series on the rear. If they are fitted with a deviation, the corresponding deviation is stamped instead. If the main bearing housings are replaced, they must always be fitted in the same way as before.

219 282844-001

► Clean the thrust washers (1) and (2) with a lintfree cloth and check them for wear. Page 147 ► Check the wall thickness. ► Check whether the thrust bearing thrust washers are fitted as standard or with a deviation. You can recognise thrust washers fitted as standard by the stamped STD letter series on the rear. If they are fitted with a deviation, the corresponding deviation is stamped instead. The standard design is marked on some thrust washers with a red mark (3) on the joints. ► Assign the thrust washers to the crankshaft axial play that was measured previously. If the previously measured crankshaft axial play deviates from the target value, it must be balanced out using thrust washers of the appropriate wall thickness. If the thrust washers are replaced, only thrust washers of the same design and the same wall thickness may be installed.

220 282845-001

221 282846-001

156

► Oil the main bearing pins on the crankshaft (1) and upper main bearing housing (2) with engine oil. ► Push the upper main bearing housing (2) in the slide direction (3) into the crank case and note the position of the twist lock (4) when doing so. The main bearing housing together with the surrounding oil groove and oil hole must be installed in the crank case. If necessary, rotate the crankshaft in the slide direction (3) as far as possible until the upper main bearing housing has been fully pushed into the crank case. The twist lock (4) on the main bearing housing must be positioned in the groove in the crank case designed for this purpose.

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01 Engine 0115 Engine unit 1451-001

► Oil the thrust washers (1) with engine oil. ► Push the thrust washers on the thrust bearing into the crank case. When installing thrust washers, note the designation. The oil grooves (2) on the thrust washers must face the sides of the crankshaft (3).

222 282847-001

► Insert the main bearing housing (1) on the crankshaft bearing cap (4). ► Oil the contact faces of the main bearing housing with engine oil. The twist lock (2) on the main bearing housing must be positioned in the groove (3) in the crankshaft bearing cap (4) designed for this purpose. ► Insert the thrust washer (5) on the side of the crankshaft bearing cap (4). ► Oil the contact faces of the thrust washers with engine oil. ► When installing thrust washers, note the designation. The oil grooves (6) on the thrust washers must point outwards.

223 282873-001

► Oil the bolts (1) with engine oil. ► Install the crankshaft bearing cap (2) with the main bearing housing and thrust washer inserted. ► Tighten the bolts (1) until they are hand-tight. The bolt heads must be in contact with the crankshaft bearing cap (2).

224 282881-001

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157

01 Engine 0115 Engine unit 1451-001

Installing the main crankshaft bearing

282805-001

225

► Screw down the bolts (3) on the crankshaft bearing covers (1) and the thrust-bearing crankshaft bearing cover (2) in accordance with the tightening diagram. Tightening diagram: Page 147 Use special tools (I) and (II).

Page 145

► Attach the special tool (I) with pretension to the thrust-bearing crankshaft bearing cap (1) and the side (2) of the crankshaft. Position the special tool (II) on a flat surface on the thrust-bearing crankshaft bearing cap. ► Use a suitable lever (3) to push and hold the crankshaft in place on the front stop of the thrustbearing crankshaft bearing cap (3). ► Set the scale for the special tool (I) to "0". ► Push the crankshaft against the rear stop of the thrust-bearing crankshaft bearing cap and read the measured value. The axial play can be calculated as the measured value from stop to stop. Axial play: Page 147 Remove special tool (I) and (II). ►

226 282804-001

Page 351 ► Install the oil pump. Page 82 ► Install the oil pan. Checking the connecting rod bearing pin ► Check crankshaft for damage and cracks, replace the crankshaft if necessary.

158

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01 Engine 0115 Engine unit 1451-001

► Check the diameter (a) of the connecting rod bearing pin: The diameters of the connecting rod bearing pins must have the same machining step. ► Check the measuring positions in the specified order (1., 2. and 3.). ► The second and third measuring positions are offset by around 60° each relative to the first measuring position. ► Calculate the average value from the three measured values. ► The inner diameters of the connecting rod bearing shells and the diameter of the connecting rod bearing pins must have the same machining step (standard or deviation) in order to achieve the correct connecting rod bearing play. (See the connecting rod technical specifications Page 133) ► Machine or replace the crankshaft (1) if necessary.

227 276448-001

Checking the flange bearing journal ► Clean the flange bearing journal (1) of the crankshaft (2) with a lint-free cleaning cloth. ► Attach the special tool (I) to the quick-release button for the inner measurements (3) and set the outside micrometer on the smallest measurement of the flange bearing journal width (a). Note the 5 mm pretension. Width of the flange bearing journal: Page 147 If the measured value is outside of the tolerance, the crankshaft must be replaced.

228 282889-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

159

01 Engine 0115 Engine unit 1451-001

►

► ► ► 229 282892-001

► ► ►

160

Position the left and right thrust washers (1) on the thrust bearing in the crank case (2). Only thrust washers (1) and (3) with the same wall thickness may be installed. The dimensions specified in the installation stages (standard or deviation) must be maintained. Using an outside micrometer, measure the thrust bearing in the crank case (2) with the two thrust washers (1), and note down the value (b). Remove the thrust washers (1) again. Position both the left and right thrust washers (3) on the thrust-bearing crankshaft bearing cap (4). Only thrust washers (1) and (3) with the same wall thickness may be installed. The dimensions specified in the installation stages (standard or deviation) must be maintained. Using an outside micrometer, measure the thrustbearing crankshaft bearing cap (4) with the two thrust washers (3) and note down the value (c). Remove thrust washers (3). Determine the thickness of the thrust washers (1) and (3). The axial play can be calculated by subtracting value (a) from value (b) or value (c) respectively. Axial play: Page 147

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01 Engine 0115 Engine unit 1451-001 179608-001

Oscillation damper Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Punch

1

00 1992 879 0

230 270995-001

Special tool (II)

Pcs.

Socket

1

00 1992 952 0

231 276724-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

161

01 Engine 0115 Engine unit 1451-001

Technical specifications

276859-001

Value

CCN

Remark / designation

1

Oscillation damper

2

Splash ring

3

200 Nm

232

Mounting bolts

Tightening torques not specified, see section on tightening torques

Removal ► Remove the fan drive belt. See the Operator's Manual of the machine in question. ► Remove the fan drive pulley. See the repair manual of the machine in question. ► Remove the alternator drive belt. See the Operator's Manual of the machine in question. ► Block the engine so it will not rotate. Install the special tool from the "Cranking the engine" chapter. Page 60

162

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01 Engine 0115 Engine unit 1451-001

Use special tools (I) and (II).

Page 161

► Loosen bolts (1). ► Unscrew a bolt on the left-hand side of the oscillation damper (2). ► Screw in the special tool (II). ► Unscrew all other bolts. ► Remove the oscillation damper.

233 276803-001

► Remove the splash ring (1).

234 276804-001

Installation ► Install the splash ring (1). The splash ring must be installed with the flat side against the oscillation damper.

235 276804-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

163

01 Engine 0115 Engine unit 1451-001

Use special tools (I) and (II).

Page 161

► Screw in the special tool (II). ► Install the oscillation damper (2) using the special tool (II). ► Screw in bolts (1) hand-tight. ► Unscrew the special tool (II) and tighten the bolts until they are hand-tight. ► Screw down the bolts. Tightening torque: Page 162

236 276803-001

► Install the alternator drive belt. See the Operator's Manual of the machine in question. ► Install the fan drive pulley. See the repair manual of the machine in question. Install the fan drive belt. ► See the Operator's Manual of the machine in question. Page 74 ► Remove the engine blocking tool.

164

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01 Engine 0115 Engine unit 1451-001 179441-001

Flywheel Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Punch

1

00 1992 879 0

237 270995-001

Special tool (II)

Pcs.

Socket

1

00 1992 952 0

238 276724-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

165

01 Engine 0115 Engine unit 1451-001

Technical specifications

276749-001

Value 1

CCN 29 kg

239

Remark / designation Flywheel

2

Flywheel ring gear

3

Flywheel mounting bolts

– Observe the shaft length (a). – Tighten bolts in 2 steps as per tightening specification. Tightening specification:

1 200 Nm 2 90° a

Shaft length of bolts (3)

Tightening torques not specified, see section on tightening torques

Removal ► Remove the torsion dampers. See the repair manual of the machine in question. ► Block the engine so it will not rotate. ► Install the special tool from the "Cranking the engine" chapter. Page 60

166

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01 Engine 0115 Engine unit 1451-001

► Disconnect the plug-in connection (1) and remove the sensor (B600-MB).

240 275574-001

Use special tool (II).

Page 165

► Undo the bolts (2) on the flywheel (1). ► Unscrew two opposite bolts.

241 276617-001

Use special tools (I) and (II).

Page 165

► Bolt down special tool (I). ► Unscrew bolts (1). ► Remove flywheel (2). ► If necessary, squeeze off the flywheel by screwing in two bolts. ► Remove the flywheel using the special tool (I).

242 276623-001

Checking ► Check the flywheel for wear. ► Replace the flywheel if necessary. Page 168 ► Check if the flywheel ring gear is worn. ► Replace the flywheel if necessary. Page 168 ► Check flywheel flange for wear and run-in traces. ► Replace the flywheel if necessary. Page 168 ► Check the guide bearing in the flywheel. ► If the guide bearing is worn or the flywheel is replaced, replace the guide bearing.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

167

01 Engine 0115 Engine unit 1451-001

► Check the rear crankshaft seal. ► Replace the radial seal if necessary. Page 89 Check the shaft length (a) of the flywheel ► mounting bolts. Page 166 ► Replace the bolts if necessary. Installation Use special tool (I).

Page 165

► Install the flywheel (1) using the fitted special tool (I) and screw it down hand-tight using two bolts (2). ► Observe the installation position of dowel pin (2). ► Screw in bolts (3) hand-tight. ► Remove special tool (I). ► Screw in the remaining two bolts hand-tight.

1 3

243 183444-001

2 1

I

244 183442-001

► Block the engine so it will not rotate. ► Install the special tool from the "Cranking the engine" chapter. Page 60 Use special tool (II).

Page 165

► Tighten all bolts (1) crosswise. Tightening torque: Page 166

245 276653-001

168

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01 Engine 0115 Engine unit 1451-001

► Install the sensor (B600-MB) together with a new seal. Tightening torque: Page 98 ► Connect the plug-in connection (1).

246 275574-001

► Remove the special tool for blocking the engine. Page 74 ► Install the torsion damper. See the repair manual of the machine in question.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

169

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

0120 Cylinder head / Valves / Idler gear

170

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 176086-001

Valve cover Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA Mercedes-Benz OM 473 LA

Technical specifications

268025-001

Value

CCN

247

Remark / designation

1

20 Nm

Mounting bolt for cylinder head valve cover

2

20 Nm

Mounting bolt for cylinder head valve cover

3

Valve cover

4

Seal

Tightening torques not specified, see section on tightening torques

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171

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Removal ► Check the seal (1) for leaks. If no leaks are found, the seal can be reused. ► Unscrew the heat safety guard (1).

248 268032-001

► Undo bolts (1) and (2). The bolts are prevented from falling out. ► Remove cylinder head valve cover (3).

249 268027-001

Installation ► Check the uncoupling discs (1) on bolts (2) and (3) for damage. If the uncoupling discs are damaged, use new bolts with new uncoupling discs.

250 267961-001

172

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Page 20 ► Clean the sealing faces (1): ► Install a new seal (2) if necessary.

251 267963-001

► Install the cylinder head valve cover (3). ► Tighten bolts (1) and (2). Tightening torque: Page 171

252 268027-001

► Attach a heat safety guard (1). Tightening torque: Page 171

253 267936-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

173

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 176058-001

Reinforcing frame Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

174

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

267856-001

Value 1

CCN

254

Remark / designation Reinforcing frame

– Clean the sealing faces thoroughly. 2

Clamp Applies to the OM 471 LA engine

3

10 Nm

Bolts

4

1.5 Nm

Nuts

X601.14

Electrical engine management plug-in connection (MCM)

X602.14

Electrical engine management plug-in connection (MCM)

Tightening torques not specified, see section on tightening torques

Removal ► Remove the valve cover:

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Page 172

175

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Unscrew clamp (1). Applies to the OM 471 LA engine.

255 267890-001

► Disconnect the plug-in connections (1) and (2).

256 267863-001

► Loosen bolts (1). The bolts are prevented from falling out.

257 267877-001

► Undo the nuts (1) on the fuel injectors (Y608-MB to Y613-MB). The nuts are prevented from falling out.

258 267900-001

176

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Expose the engine line set (1). ► Remove the reinforcing frame (2). Clean all sealing faces.

259 267913-001

Installation ► Install a new seal (1) in the reinforcing frame (2) if necessary.

260 267924-001

► Fit the reinforcing frame (1). ► Position the engine line set (2).

261 267929-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

177

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Screw in the nuts (1) on the fuel injectors (Y608MB to Y613-MB). Tightening torque: Page 175

262 267900-001

► Screw in the bolts (1 to 7) in the specified order (1-7). Tightening torque: Page 175

263 268452-001

► Screw in the plug-in connections (1) and (2).

264 267863-001

► Screw on clamp (1). Applies to the OM 471 LA engine. ► Install the cylinder head valve cover: 172

Page

265 267890-001

178

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 176996-001

Camshaft housing Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool

1

Special tool (I)

Pcs.

Adapter set

1

00 1998 585 0

266 270697-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

179

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

271071-001

Value 1

CCN 25 kg

2

Remark / designation Camshaft housing Seal

– Clean the sealing faces thoroughly. 3

267

10 Nm

Page 20

Bolt for the position sensor (B601-MB)

Tightening torques not specified, see section on tightening torques

180

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value

CCN

4

Remark / designation Mounting bolts for the camshaft housing (OM 470 LA), (OM 471 LA) and (OM 473 LA): M10 x 111 Loosening diagram:

– Undo the mounting bolts (6.23 - 6.22) in the specified order (6.23 - 6.22). – First loosen the mounting bolts (5.21 - 5.8) and (4.7 - 4.1) in the specified order (5.21 4.1), then unscrew them. Tightening diagram:

– Check the shaft length of the bolts (4) and (5). Tighten the mounting bolts (4.1 - 4.7) and – (5.8 - 5.21) until they are hand-tight. – Tighten the mounting bolts (6.22 - 6.23) until they are hand-tight. – Tighten the mounting bolts (4.1 - 4.7) and (5.8 - 5.21) in the specified order (4.1 - 5.21) in two stages in accordance with the tightening specification. Tightening specification:

1 20 Nm 2 50 Nm – Screw in the mounting bolts (6.22 - 6.23) in the specified order (6.22 - 6.23). If a mounting bolt was screwed in too tightly, a new seal must be used. 5

Mounting bolts for the camshaft housing (OM 470 LA), (OM 471 LA) and (OM 473 LA): M10 x 123

6

25 Nm

Mounting bolts for the camshaft housing (OM 470 LA), (OM 471 LA) and (OM 473 LA): M8 x 63

Tightening torques not specified, see section on tightening torques

Removal Page 172 ► Remove cylinder head valve cover. Remove the reinforcing frame. Page 175 ►

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181

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

270714-001

Use special tool (I).

268

Page 179

► Attach the adapter set (1) to the camshaft housing (2). ► Attach the cranking tool to the timing housing. Page 72 ► Set the engine to ignition TDC for the first cylinder and lock it. Page 73 ► Remove the inlet rocker arm mechanism. Page 229 ► Remove the outlet rocker arm mechanism. Page 235 ► Disconnect the plug-in connection (B601-MB).

269 270760-001

► Disconnect the plug-in connection (B622-MB).

270 270762-001

182

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Unscrew bolts (1). ► Remove the bracket (2) for the air intake hose.

271 270798-001

► Remove the high-pressure lines (1) (OM 470 LA). Page 268 ► Remove the high-pressure lines (1) (OM 471 LA). Page 276 ► Remove the fuel return line (2) (OM 470 LA). Page 268 ► Remove the fuel return line (2) (OM 471 LA). Page 276 Remove the high-pressure lines (3) (OM 470 ► LA). Page 268 ► Remove the high-pressure lines (3) (OM 471 LA). Page 276 272 270840-001

270847-001

273

► Remove the bolts (1), (2) and (3) of the camshaft housing in accordance with the loosening diagram. Loosening diagram: Page 180

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183

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Remove the camshaft housing (1) together with the camshaft. ► Remove seal (2).

274 271142-001

270867-001

275

Only if the camshaft housing with camshaft bearing bridges is replaced: ► Remove the adapter set (2) and template (3). ► Remove sealing ring (1).

276 270883-001

184

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Only if the camshaft housing together with the camshaft bearing bridges is replaced: ► Remove the seals (1). ► Remove sensor (B601-MB).

277 270979-001

Only if the camshaft housing together with the camshaft bearing bridges is replaced: Page 190 ► Remove the camshaft. Page 268 ► Remove the rail (OM 470 LA). Page 276 ► Remove the rail (OM 471 LA). Installation ► ► ► ►

Clean the sealing faces. Page 20 Install the rail (OM 470 LA). Page 270 Install the rail (OM 471 LA). Page 278 Install the camshaft. Page 191

► Install the sensor (B601-MB) with new sealing rings. For the tightening torque, see: Page 180 ► Insert new seals (1).

278 270979-001

► Insert new sealing ring (1).

279 270883-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

185

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

270867-001

280

► Attach the adapter set (2) and template (3). ► Insert new seal (2). ► Install the camshaft housing (1). ► Check the position of the marking on the camshaft wheels in relation to the marking on the template (3). ► Align the camshaft wheels if necessary. ► Select the designations on the template depending on the capacity variant.

281 271142-001

270847-001

282

► Screw down the bolts (1), (2) and (3) of the camshaft housing in accordance with the tightening diagram. Tightening diagram: Page 180

186

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► ► ► ► ► ►

Attach the high-pressure lines (3) (OM 470 LA). Page 270 Attach the high-pressure lines (3) (OM 471 LA). Page 278 Attach the fuel return line (2) (OM 470 LA). Page 270 Attach the fuel return line (2) (OM 471 LA). Page 278 Attach the high-pressure lines (1) (OM 470 LA). Page 270 Attach the high-pressure lines (1) (OM 471 LA). Page 278

283 270840-001

► Screw on the bracket (2) using bolts (1).

284 270798-001

► Connect the plug-in connection (B622-MB).

285 270762-001

► Connect the plug-in connection (B601-MB).

286 270760-001

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187

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► ► ►

► ►

Install the inlet rocker arm mechanism. Page 231 Install the outlet rocker arm mechanism. Page 238 Remove the special tool if necessary. See the "Setting the engine to ignition TDC" Page 73 chapter. Attach the crankshaft position sensor (B600MB). Page 98 Remove the cranking tool from the timing housing. Page 74

270714-001

287

► Remove the adapter set (1) from the camshaft housing (2). Page 177 ► Attach the reinforcing frame. Page 172 ► Install the valve cover. ► Start the diesel engine and let it run at idle speed for 10 s min. ► Switch off the diesel engine and check for leaks.

188

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 177397-001

Camshaft Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

271718-001

Value

CCN

Remark / designation

1

Camshaft bearing bridges

2

Camshaft housing

3

6 kg

Intake camshaft

4

7,9 kg

Outlet camshaft

5

288

Gear train

Page 179

Page 251

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

189

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value 6

CCN 25 Nm

Remark / designation Mounting bolts (OM 470 LA), (OM 471 LA) and (OM 473 LA): M8 x 63 Loosening diagram:

– First loosen the mounting bolts (8.28 - 8.15) and (7.14 - 7.8) in the specified order (8.28 7.8), then unscrew them. – First loosen the mounting bolts (6.7 - 6.1) in the specified order (6.7 - 6.1), then unscrew them. Tightening diagram:

– Check the shaft length of the bolts (7) and (8). – Screw on the mounting bolts (6.1 - 6.7) in the specified order (6.1 - 6.7). Tighten the mounting bolts (7.8 - 7.14) and – (8.15 - 8.28) in the specified order (7.8 8.28) in two stages in accordance with the tightening specification. Tightening specification:

1 20 Nm 2 50 Nm 7

Mounting bolts for the camshaft housing (OM 470 LA), (OM 471 LA) and (OM 473 LA): M10 x 111

8

Mounting bolts for the camshaft housing (OM 470 LA), (OM 471 LA) and (OM 473 LA): M10 x 123

Tightening torques not specified, see section on tightening torques

Removal Page 172 ► Remove cylinder head valve cover. Page 175 ► Remove the reinforcing frame. ► Attach the cranking tool to the timing housing. Page 72 Page 73 ► Set the engine to ignition TDC. The setting must not be changed while fitting or removing the camshaft. If necessary, repeat the work steps. Remove the inlet rocker arm ► mechanism. Page 229 ► Remove the outlet rocker arm mechanism. Page 235

190

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

271409-001

289

► Remove the bolts (1), (2) and (3) in accordance with the loosening diagram. Loosening diagram: Page 189 ► Remove the camshaft bearing bridges (1). ► Remove the inlet camshaft (2) and outlet camshaft (3).

290 271423-001

Installation ► Check the camshaft.

Page 193

► Install the inlet camshaft (1) and outlet camshaft (2). Oil the camshafts with engine oil. The designations on the gearwheels (3) must match the designations on the template (4). ► Select the designations on the template depending on the capacity variant.

291 271475-001

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191

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Install the camshaft bearing bridges (1). Note the installation position. The front and rear camshaft bearing bridge is marked with "FRONT" or "REAR". The numbers (3) on the remaining camshaft bearing bridges and in the camshaft housing (2) must match.

292 271616-001

271409-001

293

► Screw in the bolts (1), (2) and (3) in accordance with the tightening diagram. Tightening diagram: Page 189 Page ► Install the inlet rocker arm mechanism. 231 Page ► Install the outlet rocker arm mechanism. 238 ► Remove the cranking tool on the timing housing. Page 74 ► Remove the special tool. See the "Setting the engine to ignition TDC" chapter. Page 74 ► Attach the crankshaft position sensor (B600MB). Page 98 Attach the reinforcing frame. Page 177 ► Page 172 ► Install the valve cover.

192

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Checking ► Check the camshaft bearing bridges (1) and camshaft housing (2) for scores, scratches or other signs of wear. Replace the camshaft bearing bridges and camshaft housing if necessary.

294 271749-001

► Check the outlet camshaft (1) and inlet camshaft (2) for scores, scratches or other signs of wear. Replace the outlet camshaft and inlet camshaft if necessary.

295 271754-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

193

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 176293-001

Cylinder head Applies to: Mercedes-Benz OM 470 LA

Special tool Special tool (I)

Pcs.

Measuring gauge holder

1

00 1992 874 0

296 268245-001

Special tool (II)

Pcs.

Clock gauge

1

60 0500 530 3

297 268255-001

Special tool (III)

Pcs.

Counter-bracket

1

00 1998 570 0

298 273084-001

194

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Special tool (IV)

Pcs.

Ring spanner insert

1

00 1998 568 0

299 272751-001

1

Special tool (V)

Pcs.

Guide pin

1

000 1998 579 0

300 268238-001

1

Special tool (VIII)

Pcs.

Socket

1

00 1992 952 0

301 268241-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

195

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

277542-001

196

302

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value

CCN

Remark / designation

1

Cylinder head

2

Cylinder head screw (OM 470 LA) and (OM 471 LA) Loosening diagram:

– Unscrew the hexagon head bolts (3.39 3.40) in the specified order (3.39 - 3.40). – First loosen the cylinder head screws (2.1 2.38) in the specified order (2.1 - 2.38), then unscrew them. Tightening diagram:

– Check shaft length (a). – Slightly coat the cylinder head screws (2.1 2.38) and hexagon head bolts (3.39 - 3.40) with engine oil on the thread and on the support on the screw head. – Tighten the cylinder head screws (2.1 2.38) and hexagon head bolts (3.39 - 3.40) until they are hand-tight. – Tighten the cylinder head screws (2.1 2.38) in the specified order (2.1 - 2.38) in four steps in accordance with the tightening specification. Tightening specification:

1 50 Nm 2 100 Nm (OM 470 LA) 200 Nm (OM 471 LA) 3 90 ° 4 90 ° If a cylinder head bolt was screwed in too tightly, all bolts must be removed and checked if to see whether they have a permitted shaft length (a). In addition, a new cylinder head gasket must be used.

– Screw in the hexagon head bolts (3.39 3.40) in the specified order (3.39 - 3.40). 3 4

60 Nm

Hex. bolt Cylinder head gasket

– Observe the installation position. – Clean the sealing faces thoroughly. 5

Page 20

Valve guides

– The plug gauge side marked with a "+" must not be able to fit into the valve guide. Tightening torques not specified, see section on tightening torques

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197

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value a

CCN

Remark / designation Shaft length of the cylinder head screw (OM 470 LA) When new: 186 mm Permitted value: Up to 188 mm

b

up to 0,05 mm

Allowed deviation of flatness of the lower separating face over a length of 150 mm

c

0.7 to 1.1 mm (OM 470 LA)

Valve depth

0.7 to 1.1 mm (OM 471 LA) d

9.500 to 9.522 mm (OM 470 LA)

Inner diameter of the valve guide (installed)

9.500 to 9.522 mm (OM 471 LA) Tightening torques not specified, see section on tightening torques

198

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Removal Page 357 ► Drain coolant. ► Remove the air intake pipe if necessary. See the repair manual of the machine in question. ► Remove the exhaust pipe if necessary. See the repair manual of the machine in question. ► Remove the charge air tube if necessary. See the repair manual of the machine in question. ► Remove the coolant line if necessary. See the repair manual of the machine in question. Page 172 ► Remove cylinder head valve cover. Page 175 ► Remove the reinforcing frame. ► Remove the protection panel. See exhaust turbo charger. Page 417 ► Remove the exhaust gas recirculation line upstream of the exhaust gas recirculation cooler. See "Exhaust gas recirculation cooler": Page 370 ► Remove the connecting rod (1) on the lever of the exhaust gas recirculation actuator (2). See "Exhaust gas recirculation actuator". Page 396

303 268807-001

► Remove the bleed hose (1) from the oil separator (2).

304 268737-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

199

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Remove the bracket (1) from the exhaust turbo charger (2).

305 268733-001

► Remove the bolts (1) from the exhaust turbo charger (2) and exhaust manifold (3).

306 268716-001

► Remove the camshaft housing.

Page 181

► Disconnect the plug-in connections (1), (2) and (3). ► Undo the line (4) from the cylinder head. ► Disconnect the plug-in connections (5), (6), (8) and (9). ► Detach the line (7) from the charge air tube.

307 268982-001

200

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tools (III) and (IV).

Page 194

► Remove the fuel lines (1), (2) and (3).

308 268713-001

► Undo the bolts (1) on the connection flange (2). ► Remove the bolts (3) of the connection flange (2) on the charge air tube (4).

309 268742-001

Use the special tool (VIII).

Page 194

► Unscrew the cylinder head screws (1) and hexagon head bolts (2) in accordance with the loosening diagram. Loosening diagram: Page 196

310 268752-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

201

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 57765-002

WARNING Lifting heavy components. Risk of death or serious injury. ► ► ► ►

311 269145-001

Use a lifting tool with a sufficient bearing load. Use a lifting tool that operates reliably. Use the lifting tool on solid and even ground. Attach the lifting tool to the component at the intended or a suitable position. ► Only use faultless and sufficiently dimensioned lifting accessories. ► Protect lifting accessories against sharp corners and edges, for example using protectors.

► Suspend the cylinder head using a suitable lifting device at the suspension eyes (1) intended for this purpose. ► Ensure that the chains are fitted to the lifting device vertically to the lifting eyes! ► Use a suitable supporting arm. ► Weight of the cylinder head: Page 196 ► Raise the cylinder head (1). ► Ensure that the cylinder head is not tilted. ► If the cylinder head is raised, the connecting piece (2) of the coolant flow tube (3) will be pulled out. ► Position the cylinder head on two wooden slats.

312 268872-001

► Remove cylinder head gasket (1).

313 268763-001

202

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Remove the seal (1) between the exhaust turbo charger (2) and exhaust manifold (3).

314 268760-001

Remove the following components if necessary: ► Remove the charge air housing and charge air tube. See the "Charge air housing" chapter. Page 435 ► Remove the exhaust gas recirculation line, exhaust gas recirculation hose and exhaust gas recirculation cooler. See the "Exhaust gas recirculation cooler" chapter. Page 370 Page 403 ► Remove the exhaust manifold. Page 76 ► Remove the rear suspension eyes. ► Remove the gearwheel from the cylinder head. See the "Gearwheel drive" chapter. Page 257 Remove injectors. Page 287 ► Installation Page 208 ► Clean the cylinder head. Page 209 ► Check the cylinder head. Attach the following components if necessary: Page 290 ► Install the injectors. Install the gearwheel in the cylinder head. ► See the "Gearwheel drive" chapter. Page 259 Page 76 ► Attach the rear suspension eyes. Page 404 ► Install exhaust manifold. ► Install the exhaust gas recirculation line, exhaust gas recirculation hose and exhaust gas recirculation cooler. See the "Exhaust gas recirculation cooler" chapter. Page 373 ► Install the charge air housing and charge air tube. See the "Charge air housing" chapter. Page 438

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203

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Install a new cylinder head gasket (1). ► Ensure that the part number on the cylinder head gasket (1) points to the cylinder head. ► Note the centring pins (2) in the crank case.

315 268888-001

► Install a new seal (1) between the exhaust turbo charger (2) and exhaust manifold (3).

316 268760-001

57765-002

WARNING Lifting heavy components. Risk of death or serious injury. ► ► ► ►

317 269146-001

Use a lifting tool with a sufficient bearing load. Use a lifting tool that operates reliably. Use the lifting tool on solid and even ground. Attach the lifting tool to the component at the intended or a suitable position. ► Only use faultless and sufficiently dimensioned lifting accessories. ► Protect lifting accessories against sharp corners and edges, for example using protectors.

► Suspend the cylinder head using a suitable lifting device at the suspension eyes (1) intended for this purpose. ► Ensure that the chains are fitted to the lifting device vertically to the lifting eyes! ► Use a suitable supporting arm. ► Weight of the cylinder head: Page 196

204

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tool (V).

Page 194

► Insert the guide pins (1) in the holes of the cylinder head screws on the front and rear crank case. ► Position the cylinder head (2) over the guide pin (1) using lifting equipment. ► Slide on a new connecting piece (3). Slide on the connecting piece until it reaches the stop on the connector for the oil coolant module (4). 318 269197-001

► Ensure that the front jockey pulley (1) is seated on the ribbed V-belt (2).

319 268896-001

Use the special tool (VIII).

Page 194

► Remove the guide pins. ► Screw in the cylinder head screws (1) and hexagon head bolts (2) in accordance with the tightening diagram. Tightening diagram: Page 196

320 268752-001

► Screw in the bolts (3) of the connection flange (2) on the charge air tube (4). For the tightening torque, see: Page 433 ► Screw the bolts (1) onto the connection flange (2). For the tightening torque, see: Page 433

321 268742-001

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205

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tools (III) and (IV).

Page 194

► Install the fuel lines (1), (2) and (3). ► For the tightening torques, see the "Fuel filter Page 325 module" chapter: ► For the tightening torques, see the "High pressure lines and rail" chapter: Page 267

322 268713-001

► Connect the plug-in connections (1), (2) and (3). ► Attach the line (4) to the cylinder head. ► Connect the plug-in connections (5), (6), (8) and (9). ► Attach the line (7) to the charge air tube.

323 268982-001

► Adjust the pinion backlash. ► Install the camshaft housing.

206

Page 264 Page 185

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Screw the bolts (1) to the exhaust turbo charger (2) and exhaust manifold (3). For the tightening torque, see: Page 415

324 268716-001

► Screw the bracket (1) to the exhaust turbo charger (2) and crank case. For the tightening torque, see: Page 415

325 268733-001

► Attach the bleed hose (1) to the oil separator (2). Replace the sealing ring if necessary.

326 268737-001

► Attach the connecting rod (1) to the lever of the exhaust gas recirculation actuator (2). See "Exhaust gas actuator". Page 397

327 268807-001

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207

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Install the exhaust gas recirculation line upstream of the exhaust gas recirculation cooler. See "Exhaust gas recirculation cooler". Page 373 ► Attach the protection panel. See exhaust turbo charger. Page 420 Install the reinforcing frame. Page 177 ► Page ► Install the cylinder head valve cover. 172 ► Install the charge air tube if necessary. See the repair manual of the machine in question. ► Install the exhaust pipe if necessary. See the repair manual of the machine in question. ► Install the air intake pipe if necessary. See the repair manual of the machine in question. ► Install the coolant line if necessary. See the repair manual of the machine in question. Page 357 ► Top up coolant. Page 336 ► Pre-fill the lubricating oil system. ► Check the oil level. ► See the Operator's Manual of the machine in question. Only if new fuel injectors were installed: ► Program the fuel injectors using the CDS. ► Fill the low-pressure fuel circuit on the engine. ► See the Operator's Manual of the machine in question. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks. Cleaning ► Seal all drilled holes on the separating face of the crank case to prevent dust entering. Clean the cylinder head. ► Page 20 ► Clean the sealing faces. ► Blow out the tapped holes in the crank case using compressed air.

208

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Checking ► Check the cylinder head gasket (1) on the drilled holes of the combustion chamber. ► Area 2: The seal was gas-tight. ► Area 3: The seal was not gas-tight.

328 268837-001

► Check cylinder head gasket (1) near the sealing rings (2). ► If the sealing ring is damaged, the cylinder head gasket will leak gas. ► If the cylinder head gasket is leaking, the cylinder head and crank case sealing faces must be checked.

329 268838-001

► Clean the cylinder head sealing face. ► Evaluate the cylinder head sealing face using the cylinder head gasket. ► Check that the cylinder head sealing face is level. Dimension (b): Page 196 ► Position a straight edge on all areas within the sealing area of the cylinder head gasket on the cylinder-head sealing face. ► When a gap is visible, the cylinder head must be replaced. ► Check the cylinder head screw. Dimension (a): Page 196 ► If the permissible shaft length (a) is exceeded, replace the cylinder head screw.

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209

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tool (II).

Page 194

► Measure the valve depth (c) of valves (1). Valve depth: Page 196 If the valve depth (c) is not within the permitted tolerance, the cylinder head must be replaced.

330 277197-001

Only if the cylinder head and cylinder head gasket are severely damaged: ► Remove the oil filter insert and check the fins of the oil filter insert for abraded metal or bulging from the outside. ► Replace the engine oil and oil filter.

210

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 181998-001

Cylinder head Applies to: Mercedes-Benz OM 471 LA

Work preparation Utilities: ► Copper paste Special tool Special tool (I)

Pcs.

Measuring gauge holder

1

00 1992 874 0

331 268245-001

Special tool (II)

Pcs.

Clock gauge

1

60 0500 530 3

332 268255-001

Special tool (III)

Pcs.

Counter-bracket

1

00 1998 570 0

333 273084-001

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211

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Special tool (IV)

Pcs.

Ring spanner insert

1

00 1998 568 0

334 272751-001

1

Special tool (V)

Pcs.

Guide pin

1

000 1998 579 0

335 268238-001

1

Special tool (VIII)

Pcs.

Socket

1

00 1992 952 0

336 268241-001

212

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

277542-001

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337

213

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value

CCN

Remark / designation

1

Cylinder head

2

Cylinder head screw (OM 470 LA) and (OM 471 LA) Loosening diagram:

– Unscrew the hexagon head bolts (3.39 3.40) in the specified order (3.39 - 3.40). – First loosen the cylinder head screws (2.1 2.38) in the specified order (2.1 - 2.38), then unscrew them. Tightening diagram:

– Check shaft length (a). – Slightly coat the cylinder head screws (2.1 2.38) and hexagon head bolts (3.39 - 3.40) with engine oil on the thread and on the support on the screw head. – Tighten the cylinder head screws (2.1 2.38) and hexagon head bolts (3.39 - 3.40) until they are hand-tight. – Tighten the cylinder head screws (2.1 2.38) in the specified order (2.1 - 2.38) in four steps in accordance with the tightening specification. Tightening specification:

1 50 Nm 2 100 Nm (OM 470 LA) 200 Nm (OM 471 LA) 3 90 ° 4 90 ° If a cylinder head bolt was screwed in too tightly, all bolts must be removed and checked if to see whether they have a permitted shaft length (a). In addition, a new cylinder head gasket must be used.

– Screw in the hexagon head bolts (3.39 3.40) in the specified order (3.39 - 3.40). 3 4

60 Nm

Hex. bolt Cylinder head gasket

– Observe the installation position. – Clean the sealing faces thoroughly. 5

Page 20

Valve guides

– The plug gauge side marked with a "+" must not be able to fit into the valve guide. Tightening torques not specified, see section on tightening torques

214

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value a

CCN

Remark / designation Shaft length of the cylinder head screw (OM 471 LA) When new: 192 mm Permitted value: up to 194 mm

b

up to 0,05 mm

Allowed deviation of flatness of the lower separating face over a length of 150 mm

c

0.7 to 1.1 mm (OM 470 LA)

Valve depth

0.7 to 1.1 mm (OM 471 LA) d

9.500 to 9.522 mm (OM 470 LA)

Inner diameter of the valve guide (installed)

9.500 to 9.522 mm (OM 471 LA) Tightening torques not specified, see section on tightening torques

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215

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Removal Page 357 ► Drain coolant. ► Remove the air intake pipe if necessary. See the repair manual of the machine in question. ► Remove the exhaust pipe if necessary. See the repair manual of the machine in question. ► Remove the charge air tube if necessary. See the repair manual of the machine in question. ► Remove the coolant line if necessary. See the repair manual of the machine in question. Page 172 ► Remove cylinder head valve cover. Page 175 ► Remove the reinforcing frame. ► Remove the protection panel. See exhaust turbo charger. Page 426 ► Remove the connecting rod (1) on the lever of the exhaust gas recirculation actuator (2). See "Exhaust gas recirculation actuator". Page 396

338 268807-001

► Remove the bracket (1) from the exhaust turbo charger (2).

339 268733-001

216

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Remove the bolts (1) from the exhaust turbo charger (2) and exhaust manifold (3).

340 268716-001

► Remove the camshaft housing.

Page 181

► Disconnect the plugs on the sensors (B621-MB), (B606-MB) and (B608-MB).

341 282428-001

Use special tools (III) and (IV).

Page 211

► Remove the fuel lines (1), (2) and (3).

342 268713-001

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217

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Undo the bolts (1) on the connection flange (2). ► Remove the bolts (3) of the connection flange (2) on the charge air tube (4).

343 268742-001

Use the special tool (VIII).

Page 211

► Unscrew the cylinder head screws (1) and hexagon head bolts (2) in accordance with the loosening diagram. Loosening diagram: Page 213

344 268752-001

57765-002

WARNING Lifting heavy components. Risk of death or serious injury. ► ► ► ►

345 269145-001

Use a lifting tool with a sufficient bearing load. Use a lifting tool that operates reliably. Use the lifting tool on solid and even ground. Attach the lifting tool to the component at the intended or a suitable position. ► Only use faultless and sufficiently dimensioned lifting accessories. ► Protect lifting accessories against sharp corners and edges, for example using protectors.

► Suspend the cylinder head using a suitable lifting device at the suspension eyes (1) intended for this purpose. ► Ensure that the chains are fitted to the lifting device vertically to the lifting eyes! ► Use a suitable supporting arm. ► Weight of the cylinder head: Page 213

218

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Raise the cylinder head (1). ► Ensure that the cylinder head is not tilted. ► If the cylinder head is raised, the connecting piece (2) of the coolant flow tube (3) will be pulled out. ► Position the cylinder head on two wooden slats.

346 268872-001

► Remove cylinder head gasket (1).

347 268763-001

► Remove the seal (1) between the exhaust turbo charger (2) and exhaust manifold (3).

348 268760-001

Remove the following components if necessary: ► Remove the charge air housing and charge air tube. See the "Charge air housing" chapter. Page 444 ► Remove the exhaust gas recirculation line, exhaust gas recirculation hose, coolant flow tube and exhaust gas recirculation cooler. See the "Exhaust gas recirculation cooler" chapter. Page 383 ► Remove the guide roller on the cylinder head. See the "Coolant pump" chapter. Page 360 Page 409 ► Remove the exhaust manifold. ► Remove the coolant nozzle.

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219

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

See the "Exhaust gas recirculation cooler" chapter. Page 383 Page 77 ► Remove the rear suspension eyes. Remove the gearwheel from the cylinder head. ► See the "Gearwheel drive" chapter. Page 257 Page 287 ► Remove injectors. Installation Page 224 ► Clean the cylinder head. Page 225 ► Check the cylinder head. Attach the following components if necessary: Page 290 ► Install the injectors. ► Install the gearwheel in the cylinder head. See the "Gearwheel drive" chapter. Page 259 Page 77 ► Attach the rear suspension eyes. ► Install the coolant nozzle. See the "Exhaust gas recirculation cooler" chapter. Page 387 Page 411 ► Install exhaust manifold. ► Install the guide roller on the cylinder head. See the "Coolant pump" chapter. Page 361 Install the exhaust gas recirculation line, exhaust ► gas recirculation hose, coolant flow tube and exhaust gas recirculation cooler. See the "Exhaust gas recirculation cooler" chapter. Page 387 Install the charge air housing and charge air tube. ► See the "Charge air housing" chapter. Page 447 ► Install a new cylinder head gasket (1). ► Ensure that the part number on the cylinder head gasket (1) points to the cylinder head. ► Note the centring pins (2) in the crank case.

349 268888-001

220

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Install a new seal (1) between the exhaust turbo charger (2) and exhaust manifold (3).

350 268760-001

57765-002

WARNING Lifting heavy components. Risk of death or serious injury. ► ► ► ►

Use a lifting tool with a sufficient bearing load. Use a lifting tool that operates reliably. Use the lifting tool on solid and even ground. Attach the lifting tool to the component at the intended or a suitable position. ► Only use faultless and sufficiently dimensioned lifting accessories. ► Protect lifting accessories against sharp corners and edges, for example using protectors.

351 269146-001

► Suspend the cylinder head using a suitable lifting device at the suspension eyes (1) intended for this purpose. ► Ensure that the chains are fitted to the lifting device vertically to the lifting eyes! ► Use a suitable supporting arm. ► Weight of the cylinder head: Page 213 Use special tool (V).

Page 211

► Insert the guide pins (1) in the holes of the cylinder head screws on the front and rear crank case. ► Position the cylinder head (2) over the guide pin (1) using lifting equipment. ► Slide on a new connecting piece (3). Slide on the connecting piece until it reaches the stop on the connector for the oil coolant module (4). 352 269197-001

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221

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Ensure that the front jockey pulley (1) is seated on the ribbed V-belt (2).

353 268896-001

Use the special tool (VIII).

Page 211

► Remove the guide pins. ► Screw in the cylinder head screws (1) and hexagon head bolts (2) in accordance with the tightening diagram. Tightening diagram: Page 213

354 268752-001

► Screw in the bolts (3) of the connection flange (2) on the charge air tube (4). For the tightening torque, see: Page 442 ► Screw the bolts (1) onto the connection flange (2). For the tightening torque, see: Page 442

355 268742-001

Use special tools (III) and (IV).

Page 211

► Install the fuel lines (1), (2) and (3). ► For the tightening torques, see the "Fuel filter module" chapter: Page 325 ► For the tightening torques, see the "High pressure lines and rail" chapter: Page 275

356 268713-001

222

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Connect the plugs on the sensors (B608-MB), (B606-MB) and (B621-MB).

357 282428-001

► Adjust the pinion backlash. ► Install the camshaft housing.

Page 264 Page 185

► Screw the bolts (1) to the exhaust turbo charger (2) and exhaust manifold (3). Coat the bolts with copper paste. Replace the studs if necessary. For the tightening torque, see: Page 424

358 268716-001

► Screw the bracket (1) to the exhaust turbo charger (2) and crank case. First, position all the bolts on the bracket. Then, screw in the bolts on the crank case and then screw in the bolts on the exhaust turbo charger. For the tightening torque, see: Page 424

359 268733-001

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223

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Attach the connecting rod (1) to the lever of the exhaust gas recirculation actuator (2). See "Exhaust gas recirculation actuator". Page 397

360 268807-001

► Attach the protection panel. See exhaust turbo charger. Page 429 Page 177 ► Install the reinforcing frame. Page ► Install the cylinder head valve cover. 172 ► Install the charge air tube if necessary. See the repair manual of the machine in question. ► Install the exhaust pipe if necessary. See the repair manual of the machine in question. ► Install the air intake pipe if necessary. See the repair manual of the machine in question. ► Install the coolant line if necessary. See the repair manual of the machine in question. Page 357 ► Top up coolant. Page 336 ► Pre-fill the lubricating oil system. Check the oil level. ► ► See the Operator's Manual of the machine in question. Only if new fuel injectors were installed: ► Program the fuel injectors using the CDS. ► Fill the low-pressure fuel circuit on the engine. ► See the Operator's Manual of the machine in question. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks. Cleaning ► Seal all drilled holes on the separating face of the crank case to prevent dust entering. Clean the cylinder head. ► Page 20 ► Clean the sealing faces. ► Blow out the tapped holes in the crank case using compressed air.

224

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Checking ► Check the cylinder head gasket (1) on the drilled holes of the combustion chamber. ► Area 2: The seal was gas-tight. ► Area 3: The seal was not gas-tight.

361 268837-001

► Check cylinder head gasket (1) near the sealing rings (2). ► If the sealing ring is damaged, the cylinder head gasket will leak gas. ► If the cylinder head gasket is leaking, the cylinder head and crank case sealing faces must be checked.

362 268838-001

► Clean the cylinder head sealing face. ► Evaluate the cylinder head sealing face using the cylinder head gasket. ► Check that the cylinder head sealing face is level. Dimension (b): Page 213 ► Position a straight edge on all areas within the sealing area of the cylinder head gasket on the cylinder head sealing face. ► When a gap is visible, the cylinder head must be replaced. ► Check the cylinder head screw. Dimension (a): Page 213 ► If the permissible shaft length (a) is exceeded, replace the cylinder head screw.

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225

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tool (II).

Page 211

► Measure the valve depth (c) of valves (1). Valve depth: Page 213 If the valve depth (c) is not within the permitted tolerance, the cylinder head must be replaced.

363 277197-001

Only if the cylinder head and cylinder head gasket are severely damaged: ► Remove the oil filter insert and check the fins of the oil filter insert for abraded metal or bulging from the outside. ► Replace the engine oil and oil filter.

226

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 179801-001

Inlet rocker arm mechanism Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

227

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

277166-001

228

364

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value

CCN

1

Remark / designation Mounting bolts for the rocker shaft If the specified order for undoing and tightening the bolts is not followed, there is a danger that the rocker shaft might break. Loosening diagram:

– Undo each bolt (1.1 - 1.7) by a half revolution in the specified order (1.1 - 1.7). – Undo each bolt (1.1 - 1.7) in the specified order (1.1 - 1.7) until all of the bolts have been completely removed. Tightening diagram:

– Screw in each bolt (1.1 - 1.7) by a half revolution in the specified order (1.1 - 1.7). Screw in each bolt (1.1 - 1.7) in the – specified order (1.1 - 1.7) until all the bolts have been screwed in completely. – Tighten the bolts (1.1 - 1.7) in the specified order (1.1 - 1.7) in two steps in accordance with the tightening specification. Tightening specification:

1 50 Nm 2 90 ° 2

Rocker arm shaft

– Observe the installation position. 3

Rocker lever

– Observe the installation position. – Slightly coat the rocker arm with engine oil. 4

Spacer sleeves (wide)

5

Spacer sleeves (narrow)

6

Adjusting screw

7

50 Nm

Counternut on the adjusting screw (6)

Tightening torques not specified, see section on tightening torques

Removal Page 172 ► Remove cylinder head valve cover. Remove the reinforcing frame. Page 175 ►

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229

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

277098-001

365

Only if the inlet rocker arm mechanism (1) is disassembled: ► Mark the installation position of the rocker arm and spacer sleeves on the rocker arm mechanism (1). ► Unscrew the bolts (2) in accordance with the loosening diagram. Loosening diagram: Page 228 ► Remove the bolts using clamping pieces (3). ► Remove the rocker-arm mechanism. Disassembly

277102-001

366

► Mark the installation position of the rocker arm (1) and spacer sleeves (3) and (4). ► Remove the rocker arm and spacer sleeves from the rocker shaft (2).

230

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Assembly

277103-001

367

► Check the rocker arm (1), spacer sleeves (3) and (4) and rocker shaft (2) for wear. Replace affected parts if necessary. ► Clean the oil holes (5). ► Coat the points of support and the rocker shaft with engine oil. ► Install the rocker arm and spacer sleeves on the rocker shaft. Note the installation positions of the rocker arm and spacer sleeves. Note the "TOP, FRONT" (6) and "TOP, REAR" (7) designation on the rocker shaft. Installation

277104-001

368

► Align the rocker arm and spacer sleeves on the rocker shaft. ► Lubricate the rocker arm sockets and rocker arm mechanism support points using engine oil. ► Install the rocker arm mechanism (1). Note the "TOP, FRONT" (4) and "TOP, REAR" (5) designation for the installation position on the rocker shaft.

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231

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Note the installation position of the clamping pieces (3). ► Screw in the bolts (2) in accordance with the tightening diagram. Page 228 Tightening diagram: Page 242 ► Check the valve clearance. Page 177 ► Install the reinforcing frame. Page ► Install the cylinder head valve cover. 172

232

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 179716-001

Outlet rocker arm mechanism Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Fixing device

1

00 1998 595 0

369 276914-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

233

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

277023-001

234

370

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value 1

CCN

Remark / designation Mounting bolts for the rocker shaft If the specified order for undoing and tightening the bolts is not followed, there is a danger that the rocker shaft might break. Loosening diagram:

– Undo each bolt (1.1 - 1.7) by a half revolution in the specified order (1.1 - 1.7). – Undo each bolt (1.1 - 1.7) in the specified order (1.1 - 1.7) until all of the bolts have been completely removed. Tightening diagram:

– Screw in each bolt (1.1 - 1.7) by a half revolution in the specified order (1.1 - 1.7). Screw in each bolt (1.1 - 1.7) in the – specified order (1.1 - 1.7) until all the bolts have been screwed in completely. – Tighten the bolts (1.1 - 1.7) in the specified order (1.1 - 1.7) in two steps in accordance with the tightening specification. Tightening specification:

1 50 Nm 2 90 ° 2

Rocker arm shaft

– Observe the installation position. 3

Rocker lever

– Observe the installation position. – Slightly coat the rocker arm with engine oil. 4

Spacer rings

Tightening torques not specified, see section on tightening torques

Removal Page 172 ► Remove cylinder head valve cover. Page 175 ► Remove the reinforcing frame.

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235

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

276908-001

371

Only if the outlet rocker arm mechanism (1) is disassembled: ► Mark the installation position of the rocker arm and spacer rings on the outlet rocker arm mechanism (1). ► Unscrew the bolts (2) in accordance with the loosening diagram. Loosening diagram: Page 234 Use special tool (I).

372

Page 233

► Remove springs (2). ► Install special tool (I). The locking pins (3) of the special tool must be undone. Fasten the special tool with the three toggle bolts on the rocker arm mechanism (1). ► Position the locking pins on the sides of the rocker arms and screw them on. ► Tip the rocker arm mechanism in the direction of the arrow using the special tool and then remove it. ► Remove the special tool.

276913-001

Disassembly ► Mark the installation position of the rocker arm (1) and the spacer rings (2). ► Remove the rocker arm and spacer rings from the rocker shaft (3).

373 276965-001

236

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Assembly ► Check the rocker arm (1), spacer rings (2) and rocker shaft (3) for wear. Replace affected parts if necessary.

374 276965-001

► Clean the oil holes (1). ► Coat the points of support and the rocker shaft (2) with engine oil. ► Assemble the rocker arm (3) and spacer rings (4) on the rocker shaft. Note the installation positions of the rocker arm and spacer rings. Note the "TOP, FRONT" (5) and "TOP, REAR" (6) designation on the rocker shaft.

375 276973-001

276979-001

Use special tool (I).

376

Page 233

► Install special tool (I). ► Align the rocker arm (3) and spacer rings (4) on the rocker shaft (2). Align the rocker arm and spacer rings in accordance with the locking pins (1) on the special tool. Do not undo the locking pins.

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237

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Installation

276928-001

Use special tool (I).

378 276932-001

377

Page 233

► Align the rocker arm and spacer rings on the rocker shaft and attach the special tool (I). ► Lubricate the rocker arm sockets and rocker arm mechanism support points using engine oil. ► Install the rocker arm mechanism (1). Note the "TOP, FRONT" (5) and "TOP, REAR" (6) designation for the installation position on the rocker shaft. ► Remove special tool (I). ► Install springs (3). ► Screw in the bolts (2) in accordance with the tightening diagram. Tightening diagram: Page 234 Page 242 ► Check the valve clearance. Page 177 ► Install the reinforcing frame. Page ► Install the cylinder head valve cover. 172

238

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 176034-001

Valves Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Feeler gauge

1

00 0409 797 0

379 188124-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

239

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

277483-001

Value 1

CCN

380

Remark / designation Intake valves

– Slightly coat the valve shaft with engine oil. 2

Exhaust valves

– Slightly coat the valve shaft with engine oil. Tightening torques not specified, see section on tightening torques

Removal ► Remove the cylinder head (OM 470 LA). 194 ► Remove the cylinder head (OM 471 LA). 216 ► Remove the valve springs and valve stem seals. Page 245

240

Page Page

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Mark the installation position of the valves (1) in relation to the cylinder head. ► Pull the valve downwards and remove it from the cylinder head.

381 277245-001

Installation ► Check the valves.

Page 241

► Insert the valves (1) in the cylinder head. Note the installation position. ► Oil the valve stems with engine oil.

382 277245-001

► Install the valve springs and valve stem seals. Page 248 Install the cylinder head (OM 470 LA). ► 194 ► Install the cylinder head (OM 471 LA). 220

Page Page

Checking the valves ► Remove fouling deposits on the valves by means of a wire brush. ► Ensure that the valves have no seizing traces or cracks. ► Ensure that the valve seats and valve seat inserts are not damaged or burned. ► Ensure that the valve stems are not damaged.

a2301265

383 171650-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

241

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Adjusting the valve lash

384

267807-001

Value 1-6 A

CCN

Remark / designation Cylinder 1 to 6

0.60 mm

Valve lash of exhaust valves Test tolerance: ±0.05 mm

E

0.40 mm

Valve lash of intake valves Test tolerance: ±0.05 mm

Tightening torques not specified, see section on tightening torques

OM 470 LA / OM 471 LA / OM 473 LA engine: Crankshaft position

1

2

3

4

5

6

Cylinder 6 at overlap TDC

E/A

E

A

E

A

-

Cylinder 1 at overlap TDC

-

A

E

A

E

E/A

► Set cylinder 6 to overlap TDC. Cylinder 1 at ignition TDC. ► Adjust the corresponding exhaust (A) and intake valves (E). ► Set cylinder 1 to overlap TDC. Cylinder 6 at ignition TDC. ► Adjust the corresponding exhaust (A) and intake valves (E). Check and adjust valve lash only on a cold engine.

242

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Page 172 ► Remove the valve cover. Page 175 ► Remove the reinforcing frame. ► Rotate the crankshaft to the corresponding crankshaft position as described in the "Cranking the engine" chapter. Page 242 Use special tool (I).

Page 239

► Check the distance between the valve bridge and the rocker lever at (3). If the deviation exceeds the allowed test tolerances, adjust the valve lash as follows: Slacken off lock nut (1). Turn out adjusting bolt (2) a little. Insert feeler gauge at (3). Readjust the adjusting bolt (2) until the feeler gauge can just be pulled through. ► Tighten lock nut (1). ► Tightening torque: Page 228 ► Test and set the other cylinders in the same manner. ► Rotate the engine further using the rotary device.

► ► ► ► 385 267836-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

243

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 179981-001

Valve springs and valve stem seals Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Valve toolbox

1

00 1998 591 0

386 277279-001

Special tool (II)

Pcs.

Magnetic rod

1

00 0181 842 0

387 32852-001

244

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

277414-001

Value 1

CCN

388

Remark / designation Split valve keepers Observe the installation position!

2

Valve spring retainer

3

Valve spring Do not confuse the valve springs.

4

Valve stem seal Replace seal after every installation process!

5

Valve guide

6

Valve

Page 239

Tightening torques not specified, see section on tightening torques

Removal ► Remove the inlet rocker arm mechanism. Page 229 ► Remove the outlet rocker arm mechanism. Page 235 Page 287 ► Remove the injector. ► Set the corresponding piston to the valve overlap TDC. See Cranking the engine. Page 73

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

245

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tool (I).

Page 244

► Insert the adapter (1) in the assembly cartridge guide (2) and screw it tight.

389 277293-001

► Place the assembly cartridge guide (1) onto the cylinder head (2). ► Screw on the assembly cartridge guide using bolts (3).

390 277294-001

► Screw the grid part (1) into the assembly cartridge guide (2). ► Insert the assembly cartridge (4) into the assembly cartridge guide. ► Hang the pressure fork (3) on the grid part and lay it on the assembly cartridge.

391 277295-001

► Push the pressure fork (1) gently downwards (2) and at the same time, turn the bolts (3) clockwise. Turn the bolt until the split tips of the assembly cartridge (4) engage between the valve collets. ► Push the pressure fork down to the stop. As part of this process, the valve collets are pushed into the assembly cartridge and removed.

392 277298-001

246

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tool (II).

Page 244

► Carefully move the pressure fork (1) upwards. ► Unhook and remove the pressure fork on the grid part (8). ► Remove the assembly cartridge (2) from the assembly-cartridge guide (7). ► Remove the valve spring retainer (5) and valve spring (6) using the special tool (II). ► Pull the bolts (9) upwards and remove the valve collets (3) and (4) from the assembly cartridge. 393 277299-001

► Place the plate (2) on the assembly cartridge guide (3) and screw it on using bolts (1).

394 277301-001

Use special tool (I).

395 277303-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Page 244

► Insert the puller (4) into the assembly cartridge guide (3). ► The puller must be inserted as far as the system on the valve stem seal in the assembly cartridge guide (3). ► Further unscrew the nut (2) or the knurl rod (1) if necessary. ► Screw on the knurl rod. ► Turn the nut clockwise. ► If necessary, re-tighten the knurl rod during the tightening procedure. ► Remove the puller (4) with the valve stem seal from the assembly-cartridge guide. If the valve stem seal has not yet been undone, use the slide hammer puller (5).

247

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Undo the knurl rod (3). ► Remove the valve stem seal (1) from the puller (2). ► Turn the puller nut (4) back.

396 277326-001

► Unscrew the bolt (1) and remove the plate (2). ► Remove the assembly cartridge guide (3) from the cylinder head. ► Clean the valve stems and remove any remaining parts of the old valve stem seals.

397 277301-001

Installation Use special tool (I).

398 277345-001

248

Page 244

► Insert the support disc (4). ► Oil the valve body (2) with engine oil and slide it over the valve stem. ► Slide the new, oiled valve stem seal (3) over the valve body and place it on the valve guide (5). ► Remove the valve body from the valve stem. ► Press the valve stem seal with the punch (1) onto the valve guide. ► Carefully use the punch to realign the valve stem seal until it is flat. ► Remove the punch.

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Place the assembly cartridge guide (1) onto the cylinder head (2). ► Screw on the assembly cartridge guide using bolts (3).

399 277294-001

Use special tools (I) and (II).

400 277299-001

401 277351-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Page 244

► Screw the grid part (8) into the assembly cartridge guide (7). ► Insert the valve spring (6) and valve spring retainer (5) into the assembly cartridge guide. ► Pull the bolts (9) upwards and insert both valve collets (3) and (4) between the split tips in the assembly cartridge (2). ► Insert the assembly cartridge into the assembly cartridge guide. The valve collets are clipped into the assembly cartridge. ► Hang the pressure fork (1) on the grid part and fit it on the assembly cartridge. ► Push the pressure fork (3) downwards (4) until the valve spring is gently pushed together. ► Hold the pressure fork. ► Pull the bolt (1) upwards (2) and hold it in position. ► Push the pressure fork until the stop. The valve collets fall out of the assembly cartridge (5) between the valve spring retainer and the valve stem. ► Carefully move the pressure fork upwards. Hold the bolts in position when doing so. ► Remove the pressure fork. ► Remove the assembly cartridge. ► Check that the valve collets are securely seated.

249

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Unscrew the bolts (1) and remove the assembly cartridge guide (3) along with the grid part (2).

402 277392-001

Page 290 ► Install the injector. ► Install the outlet rocker arm mechanism. 238 ► Install the inlet rocker arm mechanism. 231

250

Page Page

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001 178247-001

Gear drive Applies to: Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Clock gauge

1

60 0500 530 3

403 268255-001

Special tool (II)

Pcs.

Measuring gauge holder

1

00 1992 874 0

404 268245-001

Special tool (III)

Pcs.

Fixing device

1

00 1998 576 0

405 277652-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

251

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Special tool (IV)

Pcs.

Adjusting tool

1

00 1998 575 0

406 277665-001

252

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Special tool (V)

Pcs.

Centring mandrel

1

00 1992 879 0

407 277958-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

253

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Technical specifications

278231-001

254

408

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value

CCN

Remark / designation

1

Gear

2

Gear

3

Gear

4

Gear

5

Cylinder head

6

Crankshaft gear

7

Cover

8

High-pressure fuel pump drive wheel

Page 299

9

Oil pump drive wheel

Page 349

10

Compressor drive wheel

Page 469

11

Outlet camshaft drive wheel

12

Inlet camshaft drive wheel

13

Journal

14

Journal

15

Drilled hole

16

"T" mark

17

30 Nm

Mounting bolts for the cap

18

60 Nm

Bearing pin mounting bolts

19

Mounting bolts for the gearwheel (1) Bolt shaft length (OM 471 LA) When new: 83,5 mm Permitted value: Up to 83.7 mm Tightening specification:

1 40 Nm 2 90 ° 20

Mounting bolts for the gearwheel (2) Bolt shaft length (OM 471 LA) When new: 55 mm Permitted value: Up to 55.3 mm Tightening specification:

1 40 Nm 2 90 ° Tightening torques not specified, see section on tightening torques

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255

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Value 21 a

CCN 60 Nm

OM 471 LA: 0.043 to 0.165 mm

Remark / designation Mounting bolts for the gearwheel (4) (OM 471 LA) Backlash

Tightening torques not specified, see section on tightening torques

256

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Removal ► Remove the engine. See the repair manual of the machine in question. ► Set the engine to the ignition TDC of the first cylinder. See Cranking the engine. Page 73 Page 166 ► Remove the flywheel. Page 99 ► Remove the timing housing. Only if gearwheels (1) and (2) are removed: Page 181 ► Remove the camshaft housing. Only if gearwheels (3) and (5) or the crankshaft gear (4) are removed: ► Remove the air compressor.

Page 471

409 277648-001

Use special tools (III) and (IV).

Page 251

► Lock the crankshaft gear (3) using the special tool (III). The special tool must be inserted on the plugs (4) free of tension. ► Secure the special tool (III) using a bolt. ► Lock the gearwheel (2) using the special tool (IV). The special tool must be inserted on the plugs (5) and in the drilled holes (1) free of tension.

410 277650-001

► Unscrew the bolts (3) and remove the bearing cover (2). ► Remove the bearing pins (5) together with the gearwheel (1) and thrust washers (4). Pull the bearing pins (5) out of the gearwheel (1) ► and remove the thrust washers (4).

411 277670-001

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257

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tool (V).

Page 251

► Remove special tool (III). ► Remove the crankshaft gear (1) from the crankshaft (2) using the special tool (V).

412 277701-001

277704-001

413

► Unscrew the bolts (1) and remove the bearing cover (3). ► Mark the position of the drive wheel for the highpressure fuel pump (5) in relation to the crank case. The "T" mark (7) on the disc (6) must be in the 12 o'clock position. Teeth on the gearwheel (2) may be not concealed at all by the disc (6) on the drive wheel for the high-pressure fuel pump (5). Remove the gearwheel (2) together with the ► bearing pins (4). ► Pull the bearing pins (4) out of the gearwheel (2). ► Remove the special tool (IV). ► Unscrew bolts (2). ► Remove the gearwheel (3) together with the bearing pins (1). ► Pull the bearing pins out of the gearwheel.

414 277706-001

258

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Remove the cover (1) from the cylinder head (2).

415 277709-001

► Unscrew bolts (1). ► Pull the gearwheel (2) together with the bearing pins (3) downwards and remove it from the cylinder head (4). ► Pull the bearing pins (3) out of the gearwheel (2).

416 277841-001

Installation Page 254 ► Check the specified dimensions. Page 262 ► Check the gearwheel drive. ► Coat the bearing surfaces (5) of the gearwheel (2) and the bearing pin (3) with engine oil. ► Slide the gearwheel (2) onto the bearing pins (3). The larger flange on the gearwheel (2) must face the cylinder head (4). ► Insert the gearwheel (2) together with the bearing pins (3) into the cylinder head (4) from below. ► Tighten bolts (1). Tightening torque: Page 254

417 277862-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

259

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tool (IV).

418 277879-001

Page 251

► Coat the bearing surfaces (8) of the gearwheel (3) and the bearing pin (1) with engine oil. ► Slide the gearwheel (3) onto the bearing pins (1). ► Check the position of the drive wheel for the highpressure fuel pump (6). The "T" mark (5) must be in the 12 o'clock position. Teeth on the gearwheel (4) may be not concealed at all by the positioning disc on the drive wheel for the high-pressure fuel pump (6). ► Attach the bearing pins (1) together with the gearwheel (3) to the crank case. The dowel pin (7) must engage in the corresponding hole on the crank case. ► Tighten the bolts (2). Tightening torque: Page 254 ► Install the special tool (IV). The special tool must be inserted on the plugs on the crank case and in the drilled holes on the gearwheel (3) free of tension. ► Check the backlash between gearwheels (1) and (2). Page 254

419 278528-001

277936-001

420

► Coat the bearing surfaces (8) of the gearwheel (2) and the bearing pin (4) with engine oil. ► Slide the gearwheel (2) onto the bearing pins (4). ► Align the drive wheel for the high-pressure fuel pump (5) and place the bearing pins (4) together with the gearwheel (2) on the crank case.

260

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

The "T" mark (7) on the positioning disc (6) must be in the 12 o'clock position. ► Fit the bearing cover (3) and screw it on using bolts (1). Page 254 Tightening torque: Use special tool (V).

Page 251

► Slide the crankshaft gear (1) onto the crankshaft (3) using the special tool (V). The dowel pin on the crankshaft gear (1) must engage in the crankshaft hole (2). ► Attach the special tool (III). The special tool must be inserted on the plugs on the crankshaft gear and on the crank case free of tension. ► Secure the special tool (III) using a bolt. 421 277963-001

► Coat the bearing surfaces of the gearwheel (1), the bearing pin (5) and the thrust washers (4) with engine oil. ► Place thrust washers on both sides of the gearwheel and slide them onto the bearing pins. ► Place the bearing pins together with the thrust washers and gearwheel on the crank case. ► Fit the bearing cover and screw it on using bolts (3). Tightening torque: Page 254

422 277670-001

► Attach the cover (1) together with a new seal to the cylinder head (2).

423 277709-001

► Remove the special tools (III), (IV) and (V). Page 251 Page 473 ► Install the air compressor. Page 185 ► Install the camshaft housing. Install the timing housing. Page 101 ► Page 168 ► Install flywheel.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

261

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Checking ► Clean the gearwheel (1), thrust washers (3) and bearing pin (4), and check them for wear and damage. There must not be any visible evidence of run-in on the bearing surfaces (5) or on the thrust washers (4). Replace the corresponding components if necessary.

424 278314-001

► Clean the gearwheel (1) and bearing pin (3) and check them for wear and damage. There must not be any visible evidence of run-in on the bearing surfaces (4) of the gearwheel and the bearing pin. Replace the corresponding components if necessary.

425 278386-001

► Clean the gearwheel (1) and bearing pin (2) and check for wear and damage. There must not be any visible evidence of run-in on the bearing surfaces (3). Replace the corresponding components if necessary.

426 278396-001

262

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01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

► Clean the gearwheel (1) and bearing pin (2) and check for wear and damage. There must not be any visible evidence of run-in on the bearing surfaces (3). Replace the corresponding components if necessary.

427 278454-001

278276-001

428

► Check the installation position of the gearwheels (1), (2), (3) and (4) and the crankshaft gear (5). The teeth of the gearwheels (1), (2), (3) and (4) and the crankshaft gear (5) must align with their corresponding counterpiece. ► Check the crankshaft gear (5) for wear and damage. Replace the crankshaft gear if necessary. Page 259 Check the drive wheel of the high-pressure fuel ► pump (6) for wear and damage. Replace the drive wheel of the high-pressure fuel pump if necessary. Page 299 ► Check the drive wheel of the oil pump (7) for wear and damage. Replace the oil pump if necessary. Page 349 ► Check the drive wheel of the outlet camshaft (9) and inlet camshaft (10) for wear and damage. Replace the camshafts if necessary. Page 189 ► Check the drive wheel of the air compressor (8) for wear and damage. Replace the drive wheel of the air compressor if necessary. Page 472

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

263

01 Engine 0120 Cylinder head / Valves / Idler gear 1451-001

Use special tools (I) and (II):

429

► Attach the dial gauge (I) to the cylinder head (1) using a dial gauge holder (II). ► Position the check pin of the dial gauge on a tooth of the gearwheel (2) with pre-tension. Turn the gearwheel (2) anti-clockwise until it ► reaches the stop position. ► Set the clock gauge to zero. ► Turn the gearwheel (2) clockwise until it reaches the stop position. ► Read the play on the dial gauge. Backlash (a): Page 254

273777-001

Adjustment ► ► ► ►

► 430 273793-001

► ► ►

Unscrew bolts (2). Remove cover (1). Undo the bolts (3) on the bearing pins (4). Adjust the backlash. Backlash (a): Page 254 ► To reduce the play, turn the bearing pins clockwise (A). ► To increase the play, turn the bearing pins anti-clockwise (B). Tighten bolts (3). Tightening torque: Page 254 Check the backlash and adjust it if necessary. Attach the cover (1) together with a new seal. Tighten the bolts (2). Tightening torque: Page 254

► Remove the dial gauge (I) and dial gauge holder (II) from the cylinder head (1).

431 273796-001

264

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0125 Injection - / Fuel system 1451-001

0125 Injection - / Fuel system

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

265

01 Engine 0125 Injection - / Fuel system 1451-001 178033-001

High-pressure lines and rail Applies to: Mercedes-Benz OM 470 LA

Special tool Special tool (I)

Pcs.

Ring spanner insert

1

00 1998 568 0

432 272751-001

266

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

272948-001

Value

CCN

1

433

Remark / designation Rail

2

40 Nm

Union nuts

3

30 Nm

Hollow screw

4

High-pressure lines

5

Retainers

6

15 Nm

7

M6: 15 Nm

Mounting bolts for the clamp Bracket mounting bolts

M8: 30 Nm 8

25 Nm

9

Bracket mounting bolt Oscillation damper

10

40 Nm

Union nuts

11

40 Nm

Union nut

12

40 Nm

High-pressure line

13

40 Nm

Union

14 15

Seal 15 Nm

Mounting bolts for the seal

Tightening torques not specified, see "Introduction / Tightening torques" chapter

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

267

01 Engine 0125 Injection - / Fuel system 1451-001

Value

CCN

16

Remark / designation Retainers

17

15 Nm

18

70 Nm

Bracket mounting bolts B622-MB

Rail pressure sensor

Tightening torques not specified, see "Introduction / Tightening torques" chapter

Removal ► Drain coolant. Use special tool (I).

Page 357 Page 266

► Unscrew bolt (4). ► Unscrew bolts (5). ► Remove the high-pressure lines (1) and (2) together with the brackets (3).

434 272746-001

► Remove the oscillation damper (1). ► Remove the clamps (2).

435 272764-001

► Detach the fuel return line (1) from the rail (2).

436 272768-001

268

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0125 Injection - / Fuel system 1451-001

► Loosen bolts (1). ► Unscrew the connector (3). ► Unscrew the nut (4) and detach the high-pressure line (5). Only if there is a leak in the seal (2): ► Unscrew the bolts (1) and remove the seal.

437 272779-001

► Seal all openings on the rail. ► Disconnect the plug-in connections (1) and (2).

438 272831-001

► Disconnect the plug-in connections (1) and (2).

439 272845-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

269

01 Engine 0125 Injection - / Fuel system 1451-001

► Unscrew the bolts (1) and remove the bracket (2) and rail (3).

440 272839-001

Installation ► Tighten the rail (3) using a bracket (2) and bolts (1) until it is hand-tight. The cast arrows on the brackets must point upwards.

441 272839-001

Use special tool (I).

Page 266

► Coat the inside of the new seal (2) with engine oil. ► Screw in bolts (1) hand-tight. ► Attach the new high-pressure line (5) and screw on the connectors (3). Tightening torque: Page 267 ► Tighten nut (4). Tightening torque: Page 267 ► Tighten bolts (1). Tightening torque: Page 267 442 272779-001

270

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0125 Injection - / Fuel system 1451-001

► Screw on the rail (3) using a bracket (2) and bolts (1). Tightening torque: Page 267

443 272839-001

► Attach the fuel return line (1) to the rail (2) with new sealing rings. Tightening torque: Page 267

444 272768-001

► Screw the bracket (1) onto the rail (3) using bolts (2). Tightening torque: Page 267 ► Tighten the clamp (5) using bolts (4) until it is hand-tight.

445 272877-001

► Attach the oscillation damper (1) to the new highpressure lines (2) and (3). Replace the oscillation damper if necessary. ► Screw the oscillation damper onto the straight piece downstream of the first bend with a value A of approx. 15°.

446 272879-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

271

01 Engine 0125 Injection - / Fuel system 1451-001

Use special tool (I).

Page 266

► Install the high-pressure lines (1) and (2). Tightening torque: Page 267 ► Screw the clamp (3) onto the bracket (4). Tightening torque: Page 267

447 272894-001

► Connect the plug-in connections (1) and (2).

448 272831-001

► Connect the plug-in connections (1) and (2).

449 272845-001

► Top up coolant.

Page 357

If the rail has been replaced: ► Reset the frequency counter for opening the pressure relief valve using the CDS. ► Remove the CDS. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit.

272

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01 Engine 0125 Injection - / Fuel system 1451-001

► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

273

01 Engine 0125 Injection - / Fuel system 1451-001 177832-001

High-pressure lines and rail Applies to: Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Ring spanner insert

1

00 1998 568 0

450 272751-001

274

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

272948-001

Value

CCN

1

451

Remark / designation Rail

2

40 Nm

Union nuts

3

30 Nm

Hollow screw

4

High-pressure lines

5

Retainers

6

15 Nm

7

M6: 15 Nm

Mounting bolts for the clamp Bracket mounting bolts

M8: 30 Nm 8

25 Nm

9

Bracket mounting bolt Oscillation damper

10

40 Nm

Union nuts

11

40 Nm

Union nut

12

40 Nm

High-pressure line

13

40 Nm

Union

14 15

Seal 15 Nm

Mounting bolts for the seal

Tightening torques not specified, see "Introduction / Tightening torques" chapter

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275

01 Engine 0125 Injection - / Fuel system 1451-001

Value

CCN

16

Remark / designation Retainers

17

15 Nm

18

70 Nm

Bracket mounting bolts B622-MB

Rail pressure sensor

Tightening torques not specified, see "Introduction / Tightening torques" chapter

Removal Page 357 ► Drain coolant. Remove the resonance vessel. ► See the "Air compressor" chapter. Use special tool (I).

Page 461

Page 274

► Unscrew bolt (4). ► Unscrew bolts (5). ► Remove the high-pressure lines (1) and (2) together with the brackets (3).

452 272746-001

► Remove the oscillation damper (1). ► Remove the clamps (2).

453 272764-001

► Detach the fuel return line (1) from the rail (2).

454 272768-001

276

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01 Engine 0125 Injection - / Fuel system 1451-001

► Loosen bolts (1). ► Unscrew the connector (3). ► Unscrew the nut (4) and detach the high-pressure line (5). Only if there is a leak in the seal (2): ► Unscrew the bolts (1) and remove the seal.

455 272779-001

► Seal all openings on the rail. ► Disconnect the plug-in connections (1) and (2).

456 272831-001

► Disconnect the plug-in connections (1) and (2).

457 272845-001

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277

01 Engine 0125 Injection - / Fuel system 1451-001

► Unscrew the bolts (1) and remove the bracket (2) and rail (3).

458 272839-001

Installation ► Tighten the rail (3) using a bracket (2) and bolts (1) until it is hand-tight. The cast arrows on the brackets must point upwards.

459 272839-001

Use special tool (I).

Page 274

► Coat the inside of the new seal (2) with engine oil. ► Screw in bolts (1) hand-tight. ► Attach the new high-pressure line (5) and screw on the connectors (3). Tightening torque: Page 275 ► Tighten nut (4). Tightening torque: Page 275 ► Tighten bolts (1). Tightening torque: Page 275 460 272779-001

278

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01 Engine 0125 Injection - / Fuel system 1451-001

► Screw on the rail (3) using a bracket (2) and bolts (1). Tightening torque: Page 275

461 272839-001

► Attach the fuel return line (1) to the rail (2) with new sealing rings. Tightening torque: Page 275

462 272768-001

► Screw the bracket (1) onto the rail (3) using bolts (2). Tightening torque: Page 275 ► Tighten the clamp (5) using bolts (4) until it is hand-tight.

463 272877-001

► Attach the oscillation damper (1) to the new highpressure lines (2) and (3). Replace the oscillation damper if necessary. ► Screw the oscillation damper onto the straight piece downstream of the first bend with a value A of approx. 15°.

464 272879-001

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279

01 Engine 0125 Injection - / Fuel system 1451-001

Use special tool (I).

Page 274

► Install the high-pressure lines (1) and (2). Tightening torque: Page 275 ► Screw the clamp (3) onto the bracket (4). Tightening torque: Page 275

465 272894-001

► Connect the plug-in connections (1) and (2).

466 272831-001

► Connect the plug-in connections (1) and (2).

467 272845-001

► Install the resonance vessel. Page 357 ► Top up coolant.

Page 461

If the rail has been replaced: ► Reset the frequency counter for opening the pressure relief valve using the CDS. ► Remove the CDS. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit.

280

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01 Engine 0125 Injection - / Fuel system 1451-001

► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

281

01 Engine 0125 Injection - / Fuel system 1451-001 181555-001

Rail pressure relief valve Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

282

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01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

281570-001

Value

CCN

1

2 3

468

Remark / designation Rail

100 Nm

OM 470 LA

Page 266

OM 471 LA

Page 274

Pressure relief valve Seal

– Replace sealing rings in every installation process. Tightening torques not specified, see section on tightening torques

Removal ► Remove the resonance vessel (OM 470 LA). Page 460 ► Remove the resonance vessel (OM 471 LA). Page 461

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283

01 Engine 0125 Injection - / Fuel system 1451-001

► Unscrew the pressure relief valve (1) on the rail (2).

469 281582-001

Installation ► Install a new sealing ring (3). ► Screw the pressure relief valve (1) onto the rail (2). Hold the rail on the flange at the front. Tightening torque: Page 283

470 281585-001

► Install the resonance vessel (OM 470 LA). Page 460 Install the resonance vessel (OM 471 ► LA). Page 461 If the pressure relief valve has been replaced. ► Reset the frequency counter for opening the pressure relief valve using the CDS. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

284

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01 Engine 0125 Injection - / Fuel system 1451-001 177738-001

Injectors Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Utilities: ► Hot bearing grease Tool: ► Protective clothing ► Fuel collecting container Special tool Special tool (I)

Pcs.

Extraction tool

1

00 1998 577 0

471 272537-001

Special tool (II)

Pcs.

Installation tool

1

00 1998 589 0

472 272596-001

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285

01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

272662-001

Value 1

CCN

Remark / designation

Y608-MB (cylinder 1 injector)

Injector

Y609-MB (cylinder 2 injector) Y610-MB (cylinder 3 injector)

473

– Always remove only one injector at a time. – Replace sealing rings in every installation process.

Y611-MB (cylinder 4 injector) Y612-MB (cylinder 5 injector) Y613-MB (cylinder 6 injector) 2

Seal

– Replace the seal with every installation. 3

Sealing ring (black)

– Replace the seal with every installation. 4

Sealing ring (green)

– Replace the seal with every installation. Tightening torques not specified, see "Introduction / Tightening torques" chapter

286

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01 Engine 0125 Injection - / Fuel system 1451-001

Value 5

CCN

Remark / designation Seal

– Replace the seal with every installation. 6

Mounting bolt for the clamping bracket

– Screw in the mounting bolts in two steps in accordance with the tightening specification. Tightening specification (OM 470 LA, OM 471 LA, OM 473 LA):

1 20 Nm 2 90° 7

Clamping bracket

8

Retainers

9

Fuel line

10

Page 266

OM 470 LA

Page 266

OM 471 LA

Page 274

Fuel line OM 470 LA

Page 266

OM 471 LA

Page 274

Tightening torques not specified, see "Introduction / Tightening torques" chapter

Removal ► Open the cover on the compensating reservoir and lower the coolant pressure. ► Close the cover on the compensating reservoir. Page 172 ► Remove cylinder head valve cover. Page 175 ► Remove the reinforcing frame. ► Unscrew the bolts (4) and remove the line (3). ► Unscrew the bolts (2) and remove the bracket (1).

474 272511-001

► Remove the corresponding high-pressure line from the rail to the injector. See the "High pressure lines and rail (OM 470 LA)" chapter. Page 266 See the "High pressure lines and rail (OM 471 LA)" chapter. Page 274

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287

01 Engine 0125 Injection - / Fuel system 1451-001

► Remove the fuel lines (1) and (2).

Page 328

475 272523-001

► Mark the injector (Y608-MB to Y613-MB) in relation to the corresponding cylinder. ► Unscrew the bolt (1) on the clamping bracket (2).

476 272534-001

Use special tool (I).

Page 285

► Guide the special tool (I) over the injector (Y608MB to Y613-MB).

477 272539-001

288

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01 Engine 0125 Injection - / Fuel system 1451-001

►

► ► ► ►

Insert the left and right gripper arms (2) into the groove using the clamping bracket (3) on the injector (Y608-MB to Y613-MB) and slide the sleeve (1) downwards. Undo the injector in the cylinder head using the special tool (I). Remove the injector together with the special tool and clamping bracket. Close all openings in the cylinder head. Remove the special tool and clamping bracket from the injector.

478 272542-001

► Remove sealing rings (1), (2), (3) and (4). ► Clean the injectors and check for wear. Replace the injector if necessary. ► Close all openings on the injector. ► Keep injector in a suitable way.

479 272575-001

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289

01 Engine 0125 Injection - / Fuel system 1451-001

Installation ► Assign the marked injectors to the cylinders. ► Install seal (1). The recess on the sealing ring must face upwards.

480 272587-001

Use special tool (II).

Page 285

► Slide the special tool (II) over the injector (Y608MB to Y613-MB). ► Coat the new black sealing ring (1) with hot bearing grease. ► Roll the sealing ring over the special tool into the upper ring groove of the injector. ► Remove the special tool and check the installation position of the sealing ring. The sealing ring must not be twisted when fitted in the ring groove.

481 272595-001

290

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0125 Injection - / Fuel system 1451-001

► ► ► ►

Slide the special tool (II) over the injector (Y608MB to Y613-MB). Coat the new green sealing ring (1) with hot bearing grease. Roll the sealing ring over the special tool into the lower ring groove of the injector. Remove the special tool and check the installation position of the sealing ring. The sealing ring must not be twisted when it is fitted in the ring groove.

482 272601-001

► Slide the special tool (II) over the fuel supply pipe. ► Coat the new sealing ring (1) with hot bearing grease. ► Roll the sealing ring over the special tool into the ring groove of the injector. ► Remove the special tool and check the installation position of the sealing ring. The sealing ring must not be twisted when it is fitted in the ring groove.

483 272608-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

291

01 Engine 0125 Injection - / Fuel system 1451-001

► Attach the clamping bracket (1) to the injector (Y608-MB to Y613-MB). ► Coat the sealing rings on the injector with hot bearing grease.

484 272613-001

► Insert and align the injector (Y608-MB to Y613MB) with the clamping bracket (1). Screw on the clamping bracket using a new ► bolt (2). Tightening torque (1st step): Page 286 ► Undo the bolt (2) again.

485 272614-001

► Fit a new high-pressure line. See the "High pressure lines and rail (OM 470 LA)" chapter. Page 270 See the "High pressure lines and rail (OM 471 LA)" chapter. Page 274

292

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01 Engine 0125 Injection - / Fuel system 1451-001

► Screw on the clamping bracket (1) using a bolt (2). Tightening torque: Page 286

486 272614-001

► Screw down the bolt (1) on the cover seal (2). See the "High pressure lines and rail (OM 470 LA)" chapter. Page 267 See the "High pressure lines and rail (OM 471 LA)" chapter. Page 274

487 272618-001

► Attach the fuel lines (1) and (2).

Page 330

488 272523-001

Page 177 ► Install the reinforcing frame. Page ► Install the cylinder head valve cover. 172

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293

01 Engine 0125 Injection - / Fuel system 1451-001

► Screw on the bracket (1) using bolts (2). Tightening torque: Page 460 ► Attach the line (3) and screw down the bolt (4).

489 272511-001

Only if new injectors were installed: ► Program the injectors using the CDS. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. Run the diesel engine at a higher speed. ► ► Switch off the diesel engine and check for leaks.

294

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01 Engine 0125 Injection - / Fuel system 1451-001 178558-001

Protective sleeve Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool

1

Special tool (I)

Pcs.

Claw key

1

00 1998 571 0

490 274309-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

295

01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

274308-001

Value

CCN

I 1 2

491

Remark / designation Special tool

50 Nm

Protective sleeve O-ring Apply a thin coat of grease to the O-ring.

Tightening torques not specified, see section on tightening torques

Removal Page 357 ► Drain coolant. Page 287 ► Remove the injector.

296

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Use special tool (I).

Page 295

► Remove the protective sleeve (1) using the special tool (I).

492 274311-001

Installation ► Clean the sealing faces.

Page 20

► Clean the thread (1) on the protective sleeve (2).

493 274316-001

► Install a new O-ring (1).

494 274320-001

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297

01 Engine 0125 Injection - / Fuel system 1451-001

Use special tool (I).

Page 295

► Install and screw on the protective sleeve (1) using the special tool (I). Page 296 Tightening torque:

495 274311-001

Page 290 ► Install the injector. Page 357 ► Top up coolant.

298

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01 Engine 0125 Injection - / Fuel system 1451-001 180602-001

Fuel high-pressure pump Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Tool: ► Protective clothing ► Fuel collecting container ► Coolant collection container Special tool Special tool (I)

Pcs.

Fixing device

1

00 1998 594 0

496 279032-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

299

01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

279295-001

Value

CCN

1 2

Retainers

4

Y642-MB

5

B602-MB

6

30 Nm

9

11

Fuel controller valve OM 470 LA

Page 315

OM 471 LA

Page 319

Fuel temperature sensor Union nuts for the high-pressure lines

7

10

Page 323

Bracket mounting bolts

3

8

Remark / designation Fuel filter module

100 Nm

497

OM 470 LA

Page 267

OM 471 LA

Page 275

Fuel lines

Page 325

Flange mounting bolts for the fuel lines Flange

60 Nm

Mounting bolts for the high-pressure fuel pump Fuel high-pressure pump

Tightening torques not specified, see section on tightening torques

300

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01 Engine 0125 Injection - / Fuel system 1451-001

Value 12

CCN 30 Nm

13 14

Remark / designation Mounting bolts for the bracket on the highpressure fuel pump Fuel lines

30 Nm

15

Page 325

Flange mounting bolts for the fuel lines Seal

– Replace the seal with every installation. 16

Marking

17

Drive gearwheel

18

Positioning disc

19

M6: 10 Nm

Mounting bolts for the positioning disc

M8: 30 Nm 20

250 Nm

Nut

Tightening torques not specified, see section on tightening torques

Removal ► Remove the engine. See the repair manual of the machine in question. Page 357 ► Drain coolant. ► Drain the fuel from the fuel filter module. ► Remove the resonance vessel (OM 471 LA). Page 461

498 278941-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

► Remove air intake line (1). ► Detach the high-pressure lines (2) (OM 470 LA). Page 268 ► Detach the high-pressure lines (2) (OM 471 LA). Page 276 ► Disconnect connector (3). ► Detach the fuel lines (4) with the flange (5). Page 300 Page 300 ► Detach the fuel lines (6). ► Set the engine to the ignition TDC of the first cylinder. See Cranking the engine. Page 60 Disconnect the plug-in connection (7) on the flow ► control valve (Y642-MB) and expose the engine line set (8).

301

01 Engine 0125 Injection - / Fuel system 1451-001

► Remove coolant line (1). Collect any escaping coolant.

499 272011-001

► Remove coolant line (1). ► Remove the bracket (2) and remove the highpressure fuel pump (3).

500 278958-001

Removing the drive gearwheel Use special tool (I).

Page 299

► Attach the high-pressure fuel pump (1) to the special tool (I). Attach the corresponding adapter (3) for the drive gearwheel (2).

501 279033-001

302

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01 Engine 0125 Injection - / Fuel system 1451-001

►

Slacken off nut (1). Do not unscrew the nut. Pull off the drive gearwheel (2). Remove nut (1). Remove the drive gearwheel and parallel key (3). Check the drive gearwheel for damage.

► ► ► ► If the drive gearwheel is damaged, check the counter gearwheel in the crank case for damage. ► Rotate the engine by two revolutions. ► Lock the engine in ignition TDC for the first cylinder. Check the counter gear in the crank case for ► damage. ► Remove the positioning disc (4).

502 279047-001

If the drive gearwheel or positioning disc (4) is replaced: ► Unscrew the bolts (5) and remove the positioning disc (4). Installing the drive gearwheel Use special tool (I).

Page 299

► Attach the positioning disc (1) on the drive gearwheel (2). ► Ensure that the designation (3) faces away from the high-pressure fuel pump (6). ► Screw on the positioning disc using new bolts (4). Tightening torque: Page 300 ► Install parallel key (5). ► Attach the drive gearwheel (2). ► Attach the high-pressure fuel pump (6) to the special tool (I). Attach the corresponding adapter (7) for the drive gearwheel (2). ► Tighten nut (8). Tightening torque: Page 300

503 279063-001

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303

01 Engine 0125 Injection - / Fuel system 1451-001

504 279066-001

Installation ► Set the engine to the ignition TDC of the first cylinder. See Cranking the engine. Page 73 ► Install a new sealing ring (1) on the high-pressure fuel pump (2) and lightly coat it with clean engine oil. ► Check that the designations (3) and (4) are aligned with each other. ► Turn the drive gearwheel (5) if necessary. ► The recess on the positioning disc (6) can only be pushed past the gearwheel in the crank case if it is in this position. ► Insert the bolts into the flange of the highpressure fuel pump. 505 279090-001

279113-001

506

► Insert the high-pressure fuel pump into the crank case (1). ► The drive gearwheel (2) must engage in the gearwheel (3). ► Screw the high-pressure fuel pump onto the crank case. Tightening torque: Page 300

304

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01 Engine 0125 Injection - / Fuel system 1451-001

► Screw the bracket (1) onto the high-pressure fuel pump (3) using bolts (4). Tightening torque: Page 300 ► Screw the bracket (1) onto the crank case (2) using bolts (5). Page 300 Tightening torque:

507 279124-001

► Attach the coolant line (1) together with a new sealing ring. ► Screw on the coolant line (2) using a clamp (3) and bolts (4). Tightening torque: Page 325

508 279129-001

► Connect the plug-in connection (7) to the flow control valve (Y642-MB). Page 74 ► Remove the cranking tool. ► Install the fuel lines (6) together with new O-rings. Tightening torque: Page 300 ► Attach the fuel lines (4) together with new O-rings and flange (5). Replace the flange if necessary. Tightening torque: Page 300 ► Connect the plug-in connection (3). ► Install the high-pressure lines (2) (OM 470 LA). Page 270 ► Install the high-pressure lines (2) (OM 471 LA). Page 278 ► Install the air intake line (1).

509 278941-001

► Attach the resonance vessel (OM 471 LA). Page 461 Page 357 ► Top up coolant. ► Fill the low-pressure fuel circuit on the engine. See the Operator's Manual of the machine in question. If the high-pressure fuel pump has been replaced: ► Reset the programmed values for the highpressure fuel pump using the CDS.

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01 Engine 0125 Injection - / Fuel system 1451-001

► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

306

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01 Engine 0125 Injection - / Fuel system 1451-001 182059-001

2-step valve Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

282602-001

Value 1 2

CCN 35 Nm

510

Remark / designation 2-step valve Seal

– Coat the sealing ring with fuel. 3

Seal

– Coat the sealing ring with fuel. 4

2-step valve for the piston

– Check whether the piston can move freely and replace the 2-step valve if necessary. 5

Plug-in connection for the fuel temperature sensor

6

Flange

7

Air intake line

Page 300

Page 460

Tightening torques not specified, see section on tightening torques

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307

01 Engine 0125 Injection - / Fuel system 1451-001

Value

CCN

Remark / designation

8

Fuel lines

Page 300

9

Fuel high-pressure pump

Page 299

Tightening torques not specified, see section on tightening torques

Installation instructions Removing: – Drain the fuel from the fuel filter module. Page 460 – Remove the air intake line (7). – Disconnect connector (5). Page 301 – Remove the fuel lines (8). Installing: Page 304 – Attach the fuel lines (8). Connect the plug-in connection (5). – Page 460 – Attach the air intake line (7).

308

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01 Engine 0125 Injection - / Fuel system 1451-001 182056-001

Fuel pump Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Tool: ► Protective clothing ► Fuel collecting container Special tool Special tool (I)

Pcs.

Socket

1

00 1992 865 0

511 282578-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

309

01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

282575-001

Value

CCN

1 2

Remark / designation Fuel filter module

20 Nm

B602-MB

512

Page 323

Fuel temperature sensor

– Replace the seal with every installation. 3

Fuel high-pressure pump

4

Fuel pump

5

8 Nm

Page 299

Fuel pump mounting bolts

6

Drive flange

7

Seal

– Replace seal in every installation process. Tightening torques not specified, see section on tightening torques

Removal ► Drain the fuel from the fuel filter module.

310

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01 Engine 0125 Injection - / Fuel system 1451-001

► Remove bracket (1). ► Remove the fuel lines (2) and (3). See the "Fuel filter module" chapter. Page 328 See the "High-pressure fuel pump" chapter. Page 301 ► Disconnect the plug-in connections (4) and (5).

513 282569-001

► Unscrew the bolts (1) and remove the fuel pump (2). Collect any escaping fuel.

514 282571-001

Installation ► Clean the sealing faces.

Page 20

282572-001

515

► Install new seal (3). ► Align the drive flange (4) with the drive in the highpressure fuel pump (5). ► Bolt down fuel pump (2) with bolts (1). Tightening torque: Page 310

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

311

01 Engine 0125 Injection - / Fuel system 1451-001

► Connect the plug-in connections (4) and (5). ► Attach the new sealing rings to fuel lines (2) and (3). Page See the "Fuel filter module" chapter. 330 See the "High-pressure fuel pump" chapter. Page 304 Install bracket (1). ►

516 282569-001

► Fill the low-pressure fuel circuit on the engine. See the Operator's Manual of the machine in question. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. Run the diesel engine at a higher speed. ► ► Switch off the diesel engine and check for leaks.

312

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01 Engine 0125 Injection - / Fuel system 1451-001 182061-001

Pressure relief valve Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

282636-001

Value 1 2

CCN 35 Nm

517

Remark / designation Pressure relief valve Seal

– Coat the sealing ring with fuel. 3

Pressure relief valve for the piston

– Check whether the piston can move freely and replace the pressure relief valve if necessary. 4

Fuel lines

Page 300

5

Fuel high-pressure pump

Page 299

Tightening torques not specified, see section on tightening torques

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313

01 Engine 0125 Injection - / Fuel system 1451-001

Installation instructions Removing: – Drain the fuel from the fuel filter module. Page 301 – Remove the fuel lines (4). Installing: – Attach the fuel lines (4).

314

Page 304

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01 Engine 0125 Injection - / Fuel system 1451-001 180504-001

Fuel controller valve Applies to: Mercedes-Benz OM 470 LA

Work preparation Tool: ► Protective clothing ► Fuel collecting container

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315

01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

278572-001

Value 1 2

CCN

Remark / designation

Y642-MB

Fuel controller valve

518

Mounting bolts for the flow control valve Tightening specification:

1 4 Nm 2 8 Nm 3

Fuel high-pressure pump

4

Seal

Page 299

– Replace seal in every installation process. Tightening torques not specified, see section on tightening torques

Removal ► Drain the fuel from the fuel filter module.

316

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01 Engine 0125 Injection - / Fuel system 1451-001

Page 301 ► Remove the fuel lines (1) and (2). ► Disconnect the plug-in connection (3) on the flow control valve (Y642-MB).

519 278558-001

► Remove the bracket (1) on the high-pressure fuel pump (2) and on the crank case. ► Unscrew bolts (3). ► Remove the flow control valve (Y642-MB) from the housing flange (2).

520 278566-001

Installation ► Coat the new sealing rings (1) with fuel and insert them.

521 278568-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

317

01 Engine 0125 Injection - / Fuel system 1451-001

► Insert the flow control valve (Y642-MB) in the housing flange (2) and tighten the bolts (3). Tightening torque: Page 316 ► Attach the bracket (1) to the high-pressure fuel pump (2). Page 316 Tightening torque: Install the bracket (1) on the crank case. ► Tightening torque: Page 316

522 278566-001

► Connect the plug-in connection (3) to the flow control valve (Y642-MB). Page 304 ► Attach the fuel lines (1) and (2).

523 278558-001

► Fill the low-pressure fuel circuit on the engine. See the Operator's Manual of the machine in question. If the flow control valve has been replaced: ► Reset the programmed values for the highpressure fuel pump using the CDS. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

318

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01 Engine 0125 Injection - / Fuel system 1451-001 180491-001

Fuel controller valve Applies to: Mercedes-Benz OM 471 LA

Work preparation Tool: ► Protective clothing ► Fuel collecting container

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319

01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

278572-001

Value 1 2

CCN

Remark / designation

Y642-MB

Fuel controller valve

524

Mounting bolts for the flow control valve Tightening specification:

1 4 Nm 2 8 Nm 3

Fuel high-pressure pump

4

Seal

Page 299

– Replace seal in every installation process. Tightening torques not specified, see section on tightening torques

Removal Page 328 ► Remove the fuel filter module. Drain coolant. Page 357 ► ► Drain the fuel from the fuel filter module.

320

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01 Engine 0125 Injection - / Fuel system 1451-001

► ► ► ►

Remove the bracket (2) on the fuel filter module (1). Remove the fuel lines (3) and (4). Page 301 Disconnect the plug-in connection (5) on the flow control valve (Y642-MB). Remove coolant line (6).

525 278647-001

► Remove the bracket (1) on the high-pressure fuel pump (2) and on the crank case. ► Unscrew bolts (3). ► Remove the flow control valve (Y642-MB) from the housing flange (2).

526 278566-001

Installation ► Coat the new sealing rings (1) with fuel and insert them.

527 278568-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

321

01 Engine 0125 Injection - / Fuel system 1451-001

► Insert the flow control valve (Y642-MB) in the housing flange (2) and tighten the bolts (3). Tightening torque: Page 320 ► Attach the bracket (1) to the high-pressure fuel pump (2). Page 320 Tightening torque: Attach the bracket (1) to the crank case. ► Tightening torque: Page 320

528 278566-001

Page 330 ► Attach the fuel filter module (1). ► Install coolant line (6). ► Connect the plug-in connection (5) to the flow control valve (Y642-MB). Page 304 ► Attach the fuel lines (3) and (4). ► Attach the bracket (2) to the fuel filter module (1). Page 325

529 278647-001

► Fill the low-pressure fuel circuit on the engine. See the Operator's Manual of the machine in question. Page 357 ► Top up coolant. If the flow control valve has been replaced: ► Reset the programmed values for the highpressure fuel pump using the CDS. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

322

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01 Engine 0125 Injection - / Fuel system 1451-001 177576-001

Fuel filter module Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Utilities: ► Multi-purpose transmission oil, e.g.: CLAAS AGRISHIFT 4 SC SAE 80 W - 90 00 0147 373 0 Tool: ► ► ► ►

Protective clothing Fuel collecting container Coolant collection container Assembly pins (I) (2 pieces), self-made (attach the fuel filter module) Auxiliary tool (I)

A

M8 x 1.25 (OM 470 LA) M10 x 1.5 (OM 471 LA and OM 473 LA)

B

15 mm

C

50 mm

D

Ø 8 to 8.5 mm or 10 to 10.5 mm

530 Assembly pins for installing the fuel filter module

272054-001

Special tool Special tool (I)

Pcs.

Counter-bracket

1

00 1998 570 0

531 273084-001

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323

01 Engine 0125 Injection - / Fuel system 1451-001

Special tool (II)

Pcs.

Ring spanner insert

1

00 1998 568 0

532 272751-001

324

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01 Engine 0125 Injection - / Fuel system 1451-001

Technical specifications

282489-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

533

325

01 Engine 0125 Injection - / Fuel system 1451-001

Value 1

CCN 8,5 kg

Remark / designation Fuel filter module

2

Fuel line

3

Fuel line

4

Fuel line

5

30 Nm

Fuel lines hollow screws

6

55 Nm

Screw neck for the cylinder head

7

25 Nm

Union nut for the fuel line

8 9 10

Fuel lines 30 Nm

Hex. bolts

M8: 30 Nm

Hex. bolts

M10: 11

30 Nm

12

20 Nm

Hex. bolt B638-MB

Fuel filter module pressure sensor

– Replace the seal with every installation. 13

30 Nm

Mounting bolt for the coolant line clamp

14

60 Nm

Union nut for the fuel line

15

Fuel cooler

16

Mounting bolts for the fuel cooler Tightening diagram:

– Tighten the mounting bolts until they are hand-tight. – Tighten the mounting bolts (16.1 - 16.6) in the specified order (16.1 - 16.6) in two steps in accordance with the tightening specification. Tightening specification:

1 5 Nm 2 12 Nm 17

Seal

– The seal should not be coated with oil or fuel. Replace seal in every installation process. 18

Seal

– The seal should not be coated with oil or fuel. Replace seal in every installation process. 19

Seal

– The seal should not be coated with oil or fuel. Replace seal in every installation process. Tightening torques not specified, see section on tightening torques

326

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01 Engine 0125 Injection - / Fuel system 1451-001

Value 20 21

CCN 15 Nm

Remark / designation Hand pump Seal

– Replace the seal with every installation. Tightening torques not specified, see section on tightening torques

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327

01 Engine 0125 Injection - / Fuel system 1451-001

Removal ► Drain coolant.

Page 357

► Drain the fuel from the fuel module (1). ► Unscrew bolts (4). ► Remove the fuel lines (2) and (3).

534 271937-001

► Disconnect the plug-in connection (1) on the sensor (B638-MB).

535 271941-001

► Unscrew bolt (1). ► Remove clamp (2).

536 271997-001

328

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01 Engine 0125 Injection - / Fuel system 1451-001

► Unscrew bolts (1).

537 271998-001

► Disconnect connector (1). ► Unscrew the bolts (2) and (3).

538 272006-001

► Unscrew bolt (1). ► Remove the fuel lines (2) and (3).

539 272008-001

► Remove coolant line (1). Collect any escaping coolant.

540 272011-001

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329

01 Engine 0125 Injection - / Fuel system 1451-001

► Unscrew the bolts (1) and pull the fuel filter module (2) upwards and remove it.

541 272030-001

Installation ► Clean the sealing faces.

Page 20

542

272076-001

Use the auxiliary tool (I) (assembly pins). 323

Page

► Oil the coolant hole (1) on the crank case and the new sealing nozzles (2) with CLAAS AGRISHIFT 4 SC SAE 80 W - 90. Page 323 Insert the sealing nozzles (2) into the connector ► on the fuel cooler (3). ► Screw the auxiliary tool (I) into the tapped holes (4). ► Attach the fuel filter module (1) and tighten the bolts (2) until they are hand-tight. ► Unscrew the auxiliary tool (I) and tighten the bolts (3) until they are hand-tight. ► Tighten the bolts (2) and (3). Tightening torque: Page 325

543 272089-001

330

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01 Engine 0125 Injection - / Fuel system 1451-001

► Install coolant line (1).

544 272011-001

► Attach the new sealing rings to fuel lines (2) and (3). ► Tighten bolt (1). Tightening torque: Page 325

545 272008-001

► Attach the new sealing rings to fuel lines (1) and (2). ► Tighten bolts (3). Tightening torque: Page 476 ► Tighten bolt (4). Tightening torque: Page 476 ► Connect the plug-in connection (5).

546 272096-001

► Attach the new sealing rings to the fuel lines (1), (2) and (3). ► Tighten bolts (4). Tightening torque: Page 325

547 272104-001

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331

01 Engine 0125 Injection - / Fuel system 1451-001

► Screw on the clamp (2) using bolts (1). Tightening torque: Page 267

548 271997-001

► Connect the plug-in connection (1) to the sensor (B638-MB).

549 271941-001

► Attach the new sealing rings to fuel lines (1) and (2). ► Tighten bolts (3). Tightening torque: Page 325

550 272149-001

Page 357 ► Top up coolant. ► Fill the low-pressure fuel circuit on the engine. See the Operator's Manual of the machine in question. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. Run the diesel engine at a higher speed. ► ► Switch off the diesel engine and check for leaks.

332

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01 Engine 0130 Lubricating oil system 1451-001

0130 Lubricating oil system

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

333

01 Engine 0130 Lubricating oil system 1451-001 181851-001

Lubricating oil system Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Adapter

1

00 1992 893 0

551 282185-001

Special tool (II)

Pcs.

Oil filling container

1

00 1992 872 0

552 282187-001

334

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01 Engine 0130 Lubricating oil system 1451-001

282184-001

Value

CCN

553

Remark / designation

1

Oil suction manifold

2

Crankshaft bearing lubrication point

3

Oil spray nozzle

Page 338

4

Oil thermostat

Page 352

5

Oil cooler

Page 347

6

Oil filter See "Oil coolant module"

Page 340

7

Camshaft bearings lubrication points

8

Intake rocker arm axle

Page 227

9

Outlet rocker arm axle

Page 233

10

Auxiliary power take-off lubrication point

11

Turbo Compound transmission lubrication (OM 473 LA only)

12

Oil separator for the crankcase breather

13

OM 470 LA

Page 103

OM 471 LA

Page 112

Oil pump

Page 349

Tightening torques not specified, see section on tightening torques

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335

01 Engine 0130 Lubricating oil system 1451-001

Pre-filling Special tools (I) and (II).

554 OM 470 LA

282190-001

OM 471 LA

282192-001

Page 334

► Unscrew the screw plug (2) on the oil coolant module (1). ► Screw on the special tool (I) with a sealing ring. ► Attach the hose from the special tool (II) to the special tool (I). ► Fill the oil reservoir (II) with engine oil according to the instructions in the Operator's Manual for the machine in question. ► Charge the oil container (II) to an overpressure of around 2.5 bar using the built-in hand pump. ► The shut-off valve (3) must be closed. ► Open the shut-off valve (3) on the special tool (II) until approx. 5 litres of engine oil have been pumped into the oil channels. ► Do not let the pressure in the oil container drop below 1.5 bar. ► Do not empty the oil container completely as otherwise air is pushed into the lubricating oil system.

555 ► Top up the engine oil using the filler neck as specified in the relevant Operator's Manual. ► Check the engine oil level as specified in the Operator's Manual in question. ► Remove the hose for the special tool (II) from the special tool (I). ► Unscrew the special tool (I) together with the sealing ring. ► Screw the screw plug (2) together with a new sealing ring to the oil coolant module (1). Tightening torque: 70 Nm

556 OM 470 LA

336

282190-001

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01 Engine 0130 Lubricating oil system 1451-001

557 OM 471 LA

282192-001

► Rotate the diesel engine with the electric starting motor. ► Carry out a compression test using the CDS. ► Repeat this process approximately three times. ► This process ensures that the system is filled with engine oil before the engine is started. Disconnect the CDS from the machine. ► ► Carry out a test run. ► Switch off the diesel engine and check for leaks. ► Check the engine oil level as specified in the Operator's Manual in question.

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337

01 Engine 0130 Lubricating oil system 1451-001 181862-001

Oil spray nozzle Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

282210-001

Value

CCN

1

558

Remark / designation Piston cooling oil spray nozzle

– Check whether the oil spray nozzle is clear, and clean or replace it if necessary. – If the oil spray nozzle was damaged during assembly work, replace the nozzle. – If the cylinder liner is removed, it is recommended that the nozzle be replaced. 2

30 Nm

Mounting bolt for the oil spray nozzle

Tightening torques not specified, see section on tightening torques

Installation instructions Removal: Page 80 – Remove oil pan. Remove the oil pump. Page 350 – – Turn the crankshaft until the oil spray nozzle which is to be removed can be accessed.

338

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01 Engine 0130 Lubricating oil system 1451-001

- See the "Cranking the engine" chapter. Page 60 Installation: – Remove the cranking tool. - See the "Cranking the engine" chapter. Page 60 Page 351 – Install the oil pump. Page 82 – Install the oil pan.

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339

01 Engine 0130 Lubricating oil system 1451-001 181884-001

Oil coolant module Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Tool: ► ► ► ►

Protective clothing Engine oil collection container Coolant collection container Assembly pins (I) (2 pieces), self-made

Auxiliary tool (I) A

M8 x 1.25 (OM 470 LA) M10 x 1.5 (OM 471 LA)

B

15 mm

C

50 mm

D

Ø 8 to 8.5 mm or 10 to 10.5 mm

559 Assembly pins for installing the oil coolant module

340

272054-001

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01 Engine 0130 Lubricating oil system 1451-001

Technical specifications

282333-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

560

341

01 Engine 0130 Lubricating oil system 1451-001

Value

CCN

Remark / designation

1

55 Nm

Oil filter lid

2

70 Nm

Drain plug (OM 470 LA)

2

50 Nm

Drain plug (OM 471 LA)

3

Oil coolant module

4

Coolant hose

5

Coolant hose

6

Coolant line

7 8

B607-MB

Coolant inlet temperature sensor Seal

– Replace for every assembly. 9

Oil filter insert

10

Oil cooler

11

Seal

Page 347

– Replace for every assembly. 12

Seal

– Replace for every assembly. 13

Seal

– Replace for every assembly. 14

Cover

15

Connector

16

Mounting bolts for the oil coolant module Tightening diagram:

– Tighten the bolts (16.1 - 16.11) in the specified order (16.1 - 16.11) in two steps in accordance with the tightening specification. Tightening specification:

1 10 Nm 2 60 Nm Tightening torques not specified, see section on tightening torques

342

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01 Engine 0130 Lubricating oil system 1451-001

Removal ► Let the engine cool down. Page 357 ► Drain coolant. Remove the charge air tube. ► See the "Charge air housing" (OM 470 LA) chapter. Page 435 See the "Charge air housing" (OM 471 LA) chapter. Page 444

282272-001

561

► Unscrew lid (1). ► Drain the coolant from the drain plug (2) of the oil coolant module (3). Collect any escaping coolant. ► Remove the coolant hoses (4) and (5). ► Remove coolant line (6). ► Disconnect the plug-in connection (7) on the sensor (B607-MB). ► Remove the coolant flow tube to the exhaust gas recirculation cooler (OM 470 LA). Page 370 ► Remove the coolant flow tube to the exhaust gas recirculation cooler (OM 471 LA). Page 383 Remove any machine drive belts that may be in ► the way if required. See the repair manual of the machine in question. ► Remove the alternator drive belt. See the Operator's Manual of the machine in question.

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343

01 Engine 0130 Lubricating oil system 1451-001

► Remove the oil coolant module (1). Collect any escaping engine oil. Only if the oil coolant module is replaced: ► Remove the coolant thermostat (2) on the oil coolant module (1). Page 364

562 282295-001

Installation ► Clean the sealing faces.

Page 20

Only if the oil coolant module is replaced: ► Attach the coolant thermostat (2) to the oil coolant module (1) together with a new sealing ring. Page 365

563 282295-001

564

282314-001

Use the auxiliary tool (I) (assembly pins). 340

Page

► Screw the auxiliary tool (I) onto the crank case using the two opposite tapped holes. ► Install new seal (1). ► Attach the oil coolant module (2) and screw in the upper bolts.

344

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01 Engine 0130 Lubricating oil system 1451-001

Before installation, fit a new cable strap to each bracket (3). ► Unscrew the auxiliary tool (I) and screw down the bolts for the oil coolant module in accordance with the tightening diagram. Page 341 Tightening diagram: ► Install the alternator drive belt. See the Operator's Manual of the machine in question. ► Install any machine drive belts that may have been in the way if applicable. See the repair manual of the machine in question. ► Install the coolant flow tube to the exhaust gas recirculation cooler (OM 470 LA). Page 373 ► Install the coolant flow tube to the exhaust gas recirculation cooler (OM 471 LA). Page 387

282272-001

565

► Connect the plug-in connection (7) to the sensor (B607-MB). ► Install coolant line (6). ► Attach the coolant hoses (4) and (5). ► Screw on the drain plug (2) for the oil coolant module (3) together with a new sealing ring. Tightening torque: Page 341 ► Bolt down the cover (1). Tightening torque: Page 341 ► Attach the charge air tube. See the "Charge air housing" (OM 470 LA) chapter. Page 438 See the "Charge air housing" (OM 471 LA) chapter. Page 447 Page 357 ► Top up coolant. Page 336 ► Pre-fill the lubricating oil system. ► Top up engine oil as specified in the relevant Operator's Manual. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit.

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345

01 Engine 0130 Lubricating oil system 1451-001

► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

346

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01 Engine 0130 Lubricating oil system 1451-001 181933-001

Oil cooler Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

282337-001

Value

CCN

1

Remark / designation Oil coolant module

2

30 Nm

Mounting bolt for the oil cooler (OM 470 LA)

2

20 Nm

Mounting bolt for the oil cooler (OM 471 LA)

3

566

Oil cooler

– Replace the oil cooler if it is damaged. 4

Sealing rings

– Replace for every assembly. Tightening torques not specified, see section on tightening torques

Installation instructions Removing: – Remove the oil coolant module.

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Page 343

347

01 Engine 0130 Lubricating oil system 1451-001

Installing: Page 20 – Clean the sealing faces. Page 344 – Install the oil coolant module.

348

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01 Engine 0130 Lubricating oil system 1451-001 181871-001

Oil pump Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

282214-001

Value

CCN

567

Remark / designation

1

Oil pump

2

Oil suction manifold

3

Oil pipe (delivery side)

4

Oil pipe (suction side)

5

Seal

– Replace for every assembly. 6

Seal

– Replace for every assembly. 7

Seal

– Replace for every assembly. 8

30 Nm

Oil pump mounting bolts

Tightening torques not specified, see section on tightening torques

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349

01 Engine 0130 Lubricating oil system 1451-001

Value 9

OM 470 LA M10: -

CCN

Remark / designation Mounting bolts for the oil suction manifold Light alloy

OM 471 LA M10: 60 Nm 9

OM 470 LA M8: 30 Nm

Mounting bolts for the oil suction manifold Plastic

OM 471 LA M8: 30 Nm Tightening torques not specified, see section on tightening torques

Removal ► Remove oil pan.

Page 80

► Unscrew bolts (1). ► Remove the oil pump (2) together with the oil suction manifold (3) and the oil pipes (4) and (5).

568 282221-001

Disassembly ► Clean the oil filter on the oil suction pipe for the oil suction manifold (2). ► Remove the oil suction manifold (2) from the oil pipes (3) and (4). ► Remove the oil pipes (3) and (4) from the oil pump (1). ► Remove the sealing rings (5) and (6). ► Clean the oil pump, oil suction manifold and oil pipes and check them for wear. Replace the components if necessary. 569 282225-001

350

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01 Engine 0130 Lubricating oil system 1451-001

Assembly ► Install new sealing rings (5) and (6) on the oil pipes (3) and (4). Lightly coat the sealing rings with engine oil. Insert the oil pipes into the oil pump (1). ► ► Insert the oil pipes into the oil suction manifold (2).

570 282225-001

Installation ► Clean the sealing faces.

Page 20

282226-001

571

► Install new seal (5). ► Fill the oil pump (1) with engine oil. ► Attach the oil pump (1) together with the oil suction manifold (2) and the oil pipes (3) and (4). ► Tighten bolts (6). Tightening torque: Page 349 ► Tighten bolts (7). Tightening torque: Page 349 Page 82 ► Install the oil pan. Pre-fill the lubricating oil system. ►

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Page 336

351

01 Engine 0130 Lubricating oil system 1451-001 181934-001

Oil thermostat Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Socket

1

00 1998 586 0

572 282342-001

Technical specifications

282338-001

352

573

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01 Engine 0130 Lubricating oil system 1451-001

Value

CCN

Remark / designation

1

Oil filter lid

2

Cover

3

50 Nm

Page 341

Oil thermostat

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

353

01 Engine 0130 Lubricating oil system 1451-001

Removal Use special tool (I).

Page 352

► Open the oil filter cover (1). Clean the oil filter cover before opening it. Opening the oil filter cover will release the oil return valve, causing engine oil to run into the crank case. ► Remove cover (2). Collect any escaping engine oil. ► Unscrew the oil thermostat (3).

574 282339-001

Installation ► Clean the sealing faces. Use special tool (I).

Page 20

Page 352

► Screw on the oil thermostat (3) together with a new sealing ring. Tightening torque: Page 352 ► Attach the cover (2) together with a new seal. ► Screw on the oil filter cover (1). Tightening torque: Page 341

575 282339-001

354

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0135 Cooling system 1451-001

0135 Cooling system

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

355

01 Engine 0135 Cooling system 1451-001 176607-001

Coolant Special tool

1

Special tool (I)

Pcs.

Cleaner

1

00 0147 907 0

576 253134-001

1

Special tool (VI)

Pcs.

Ring spanner insert

1

00 1998 568 0

577 268239-001

356

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0135 Cooling system 1451-001

Technical specifications

578

269199-001

Value 1

CCN 30 Nm

Remark / designation Coolant drain plug OM 471 LA

– Screw in bolts with a new sealing ring. Tightening torques not specified, see section on tightening torques

Draining ► Drain the coolant from the machine radiator. See the Operator's Manual of the machine in question. 157892-002

WARNING! Drain the coolant from the engine block. Danger of skin and eye injury from hot coolant. Danger of poisoning when swallowed. ► Open the cooling system only if the coolant temperature is below 90 °C. ► Open the cooling system slowly and relieve the excess pressure. ► Wear protective clothing. ► Unscrew the coolant drain plug carefully and drain coolant. ► Refit the plug immediately after draining. ► Tightening torque: Page 357 Filling up ► Top up coolant only as described in the Operator's Manual of the machine in question. Cleaning the coolant circuit ► Start the diesel engine and bring it to operating temperature. Then stop the diesel engine. ► Disconnect the battery isolating switch of the machine. ► Park the machine safely and secure it against rolling away.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

357

01 Engine 0135 Cooling system 1451-001

► To allow the oil to precipitate upwards, allow a 30minute rest period. ► Check if there is oil in the cooling system compensating tank. Withdraw coolant from the compensating tank if required and dispose of it properly. Page 357 ► Drain coolant. WARNING! Filling undiluted cleaning concentrate into the cooling system. Damage to cooling system. ► Mix the cleaning concentrate with clear and warm water outside of the cooling system. ► Produce a 3 % cleaning solution with cleaning agent (00 0147 907 0) and clear, warm water. Observe the coolant filling quantity for the machine in question. See the Operator's Manual of the machine in question. ► Remove the compensating tank. See the repair manual of the machine in question. ► Flush the compensating tank with 3 % cleaning solution. After that, flush the compensating tank with warm water. ► Install the compensating tank. See the repair manual of the machine in question. Fill the coolant circuit with 3 % cleaning solution. ► ► Switch on the battery isolating switch of the machine. ► Set the cab heater to maximum heating capacity. ► Start the diesel engine and heat up the coolant to around 80 °C at medium speed. ► Maintain the coolant temperature at 80 °C for about 5 minutes. Cover up the radiator if required. Ensure that a hydraulic oil cooler that may be installed is not covered up in this process! ► Stop the diesel engine. ► Let the coolant cool down to around 50 °C. ► Drain the 3 % cleaning solution completely. ► Flush the coolant circuit with clear water at least twice. Let the diesel engine run for about 5 minutes with every flushing filling. Ensure that no cleaning solution remains in the cooling system after the last flushing process. If necessary, carry out further flushing processes with clear water. Page 357 ► Top up coolant.

358

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0135 Cooling system 1451-001 181165-001

Coolant pump Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Tool: ► Protective clothing ► Coolant collection container

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

359

01 Engine 0135 Cooling system 1451-001

Technical specifications

280726-001

Value

CCN

1

579

Remark / designation Coolant pump pulley

2

30 Nm

Coolant pump mounting bolts

3

2,4 kg

Coolant pump

– Replace seal in every installation process. 4

25 Nm

5

M10: 60 Nm

Pulley mounting bolts Guide roller mounting bolt

M16: 100 Nm 6

60 Nm

Guide roller mounting bolt

Tightening torques not specified, see section on tightening torques

Removal ► Let the engine cool down. Page 357 ► Drain coolant. ► Remove the alternator drive belt. See the Operator's Manual of the machine in question.

360

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0135 Cooling system 1451-001

► Unscrew bolts (1) and remove pulley (2).

580 280662-001

► Unscrew bolts (1) and remove coolant pump (2). ► Remove seal (3). ► Clean the sealing faces. Page 20

581 280667-001

Installation ► Screw on the coolant pump (2) together with a new seal (3) and bolts (1). Tightening torque: Page 360

582 280667-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

361

01 Engine 0135 Cooling system 1451-001

► Screw on the belt pulley (2) with new bolts (1). Tightening torque: Page 360

583 280662-001

► Install the alternator drive belt. See the Operator's Manual of the machine in question. Page 357 ► Top up coolant. ► Start the diesel engine. ► Run the diesel engine until the operating temperature is reached. ► Check tightness of coolant pump. ► Check coolant level as described in the relevant Operator's Manual.

362

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0135 Cooling system 1451-001 181944-001

Coolant thermostat Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA Mercedes-Benz OM 473 LA

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

363

01 Engine 0135 Cooling system 1451-001

Technical specifications

282356-001

Value

CCN

584

Remark / designation

1

Coolant pump

Page 359

2

Oil coolant module

Page 340

3

Coolant thermostat

4

30 Nm

Mounting bolts for the coolant thermostat

Tightening torques not specified, see section on tightening torques

Removal ► Let the engine cool down. Page 357 ► Drain coolant. ► Remove the charge air tube. See the "Charge air housing" (OM 470 LA) chapter. Page 435 See the "Charge air housing" (OM 471 LA) chapter. Page 444

364

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0135 Cooling system 1451-001

► Remove the coolant thermostat (1) from the oil coolant module (2). Collect any escaping coolant. ► Remove the coolant hose (3).

585 282375-001

Installation ► Attach the coolant thermostat (1) to the oil coolant module (2) together with a new sealing ring. Tightening torque: Page 364 ► Attach the coolant hose. See the repair manual of the machine in question.

586 282375-001

► Attach the charge air tube. See the "Charge air housing" (OM 470 LA) chapter. Page 438 See the "Charge air housing" (OM 471 LA) chapter. Page 447 Page 357 ► Top up coolant. Start the diesel engine. ► ► Run the diesel engine until the operating temperature is reached. ► Run the diesel engine at a higher speed. ► Check tightness of thermostat housing. ► Check coolant level as described in the relevant Operator's Manual.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

365

01 Engine 0140 Exhaust system 1451-001

0140 Exhaust system 176664-001

Exhaust gas return cooler Applies to: Mercedes-Benz OM 470 LA

Special tool Special tool (I)

Pcs.

Leakage test device

1

00 1998 593 0

587 269858-001

Special tool (II)

Pcs.

Pressure pump

1

00 1998 565 0

588 269855-001

366

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Technical specifications

269265-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

589

367

01 Engine 0140 Exhaust system 1451-001

Value

CCN

1 2

Remark / designation Coolant hose

35 Nm

Coolant nozzle

3

Exhaust gas return cooler 0 bar

Pressure drop at a test pressure of 1.5 bar and a test time of 2 minutes

4

Coolant flow tube

5

Connecting piece

6

Coolant discharge nozzle

7

Sealing rings

– Replace the sealing rings during assembly. 8

20 Nm

Mounting bolts

9

Support

10

Clamps

11

Heat safety guard

12

Electrical cable

13

Brackets

14

Exhaust turbo charger

15

Hex. bolts

16

Heat safety guard

Page 415

17

Connecting rod

Page 394

18

Exhaust gas recirculation valve

Page 394

19

12 Nm

Exhaust manifold

21

Exhaust gas recirculation line B621-MB

23 24

Exhaust gas recirculation differential pressure sensor

2 Nm

Page 400

Clamps Exhaust gas recirculation hose

26

Exhaust gas recirculation line

27

Charge air tube 30 Nm

Coolant hose

30

Clamp 30 Nm

Page 433

Hex. bolts

29

31

Page 401

Exhaust gas recirculation line

25

28

Page 414

Clamp

20

22

Page 415

Mounting bolts for the coolant flow tube

Tightening torques not specified, see section on tightening torques

368

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Value

CCN

Remark / designation

32

Coolant flow tube

33

Clamp

34

Coolant hose

35

M8: 30 Nm

Hex. bolts

M10: 60 Nm 36 37

Exhaust gas recirculation hose B606-MB

Coolant outlet temperature sensor

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

369

01 Engine 0140 Exhaust system 1451-001

Removal ► Switch off the ignition. Page 357 ► Drain coolant. Disconnect the battery isolating switch of the ► machine. ► Remove the coolant hose (1).

590 269286-001

► Remove the protection panel. See exhaust turbo charger. Page 417 ► Remove the connecting rod (1). See "Exhaust gas recirculation actuator". 396

Page

591 269349-001

► Undo the bolts (5) on the clamps (3). ► Detach the exhaust gas recirculation line (1) from the exhaust gas recirculation cooler (2). ► Remove the exhaust gas recirculation line (1) from the exhaust manifold (4).

592 269765-001

370

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Undo the line (1) from the exhaust gas recirculation line (3). ► Disconnect connector (2).

593 269627-001

► Unscrew the bolts (1) from the exhaust gas recirculation line (2).

594 269641-001

► Undo the clamp (1) on the exhaust gas recirculation hose (2). ► Unscrew bolts (3).

595 269650-001

► Remove the exhaust gas recirculation lines (1) and (3) together with the exhaust gas recirculation hose (2).

596 269658-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

371

01 Engine 0140 Exhaust system 1451-001

► Undo the bolt (1) for the clamp on the coolant hose (2).

597 281920-001

► Unscrew bolts (1). ► Pull the coolant flow tube (2) sideways out of the coolant hose (3). ► Pull the coolant flow tube (2) sideways out of the exhaust gas recirculation cooler (4).

598 281923-001

► ► ► ► ►

Slacken off bolt (1). Pull off the coolant hose (2). Slacken off bolt (5). Unscrew bolts (3). Pull the coolant flow tube (4) out of the coolant hose (6).

599 281925-001

► Loosen bolts (1). The bolts are prevented from falling out. ► Swivel the clamps (2) upwards and pull the exhaust gas recirculation cooler (3) upwards and remove it.

600 269706-001

372

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Installation ► Clean the sealing faces.

Page 20

► Install new sealing rings on the coolant nozzle (2). ► If the exhaust gas recirculation cooler (1) is replaced, install new coolant nozzles (2). ► For the tightening torque, see: Page 367

601 269720-001

► Install the exhaust gas recirculation cooler (3) and swivel the clamps (2) downwards. ► Tighten bolts (1). For the tightening torque, see: Page 367

602 269707-001

603 281925-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

► Replace the coolant hose (6) and clamps if necessary. ► Insert the coolant flow tube (4) into the coolant hose (6). ► Tighten bolts (3). Tightening torque: Page 367 ► Tighten bolt (5). Tightening torque: Page 367 ► Install the coolant hose (2). Replace the coolant hose if necessary. ► Tighten bolt (1). Tightening torque: Page 367 Replace the clamp if necessary.

373

01 Engine 0140 Exhaust system 1451-001

► Install a new connecting piece (1) in the coolant flow tube (2).

604 281930-001

► Insert the coolant flow tube (2) into the coolant hose (3) and exhaust gas recirculation cooler (4). Replace the coolant hose and clamps if necessary. ► Tighten bolts (1). Tightening torque: Page 367

605 281923-001

► Screw down the bolt (1) for the clamp on the coolant hose (2). Tightening torque: Page 367

606 281920-001

► Install the exhaust gas recirculation lines (2) and (4) together with the exhaust gas recirculation hose (3). ► Replace the seal (5) on the charge air tube (6). ► Replace the exhaust gas recirculation hoses (3) and (7) and clamp (1) if necessary.

607 270177-001

374

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Tighten bolts (3). For the tightening torque, see: Page 367 ► Screw on the clamp (1) on the exhaust gas recirculation hose (2). Page 367 For the tightening torque, see:

608 269650-001

► Screw the bolts (1) to the exhaust gas recirculation line (2). For the tightening torque, see: Page 367

609 269641-001

► Connect the plug-in connection (2). ► Screw the line (1) onto the exhaust gas recirculation line (3).

610 269627-001

► Attach the exhaust gas recirculation line (1) together with the clamps (3) to the exhaust gas recirculation cooler (2) and exhaust manifold (4). ► The clamp bolts (5) must be situated underneath. ► For the tightening torque, see: Page 367 ► Replace the clamps (3) if necessary.

611 269765-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

375

01 Engine 0140 Exhaust system 1451-001

► Install the connecting rod (1). See "Exhaust gas recirculation actuator". 397

Page

612 269349-001

► Install the protection panel. See exhaust turbo charger.

Page 420

► Attach the coolant hose (1).

613 269286-001

Page 357 ► Top up coolant. Switch on the battery isolating switch of the ► machine. ► Start the diesel engine and run it at a higher speed. ► Switch off the diesel engine and check for leaks.

376

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Checking ► Open the cover on the coolant compensating reservoir to relieve the overpressure in the coolant circuit. ► Slacken off clamp (1). ► Unscrew bolts (2). ► Remove the exhaust gas recirculation line (3).

614 269876-001

► Undo the bolts (5) on the clamps (3). ► Detach the exhaust gas recirculation line (1) from the exhaust gas recirculation cooler (2). ► Detach the exhaust gas recirculation line (1) from the exhaust manifold (3).

615 269765-001

Use special tool (I).

Page 366

► Clean the interior of the exhaust gas recirculation hose (2). ► Attach the locking device (1) to the exhaust gas recirculation hose (2) using the clamp (3). For the tightening torque, see: Page 367 ► Replace the clamp if necessary.

616 269883-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

377

01 Engine 0140 Exhaust system 1451-001

Use special tools (I) and (II).

Page 366

► Attach the flange (1) to the exhaust gas recirculation cooler (2) using the clamp (3). Page 367 For the tightening torque, see: Attach the pressure pump (4) to the flange (1). ► ► Pressurise the exhaust gas recirculation cooler (2) with compressed air. For test pressure, see: Page 367 The test pressure must not be exceeded.

617 269916-001

► Detach the locking device (1) from the exhaust gas recirculation hose (2).

618 269923-001

► Detach the locking device (1) and pressure pump (3) from the exhaust gas recirculation cooler (2).

619 269927-001

► Attach the exhaust gas recirculation line (1) together with the clamps (3) to the exhaust gas recirculation cooler (2) and exhaust manifold (4). ► The clamp bolts (5) must be situated underneath. ► For the tightening torque, see: Page 367 ► Replace the clamps (3) if necessary.

620 269765-001

378

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Insert the exhaust gas recirculation line (3). ► Tighten the bolts (2). For the tightening torque, see: Page 367 ► Screw on clamp (1). For the tightening torque, see: Page 367

621 269876-001

► Close the cover for the coolant compensating reservoir. ► Start the diesel engine and run it at a higher speed. ► Switch off the diesel engine and check for leaks. 181566-001

Exhaust gas return cooler Applies to: Mercedes-Benz OM 471 LA

Special tool Special tool (I)

Pcs.

Leakage test device

1

00 1998 593 0

622 269858-001

Special tool (II)

Pcs.

Pressure pump

1

00 1998 565 0

623 269855-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

379

01 Engine 0140 Exhaust system 1451-001

Technical specifications

281871-001

380

624

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Value

CCN

1

Exhaust gas return cooler 0 bar

2

Pressure drop at a test pressure of 1.5 bar and a test time of 2 minutes B621-MB

3

Exhaust gas recirculation differential pressure sensor

Page 400

Exhaust gas recirculation line

4

30 Nm

5

30 Nm

6

30 Nm

7 8

Remark / designation

Mounting bolts for the exhaust gas recirculation line B606-MB

Coolant outlet temperature sensor Coolant nozzle mounting bolts Coolant nozzle

30 Nm

Mounting bolts for the exhaust gas recirculation cooler Tightening diagram:

– Tighten the mounting bolts (8.1 - 8.17) in the specified order (8.1 - 8.17) until they are hand-tight. – Screw down the mounting bolts (8.1 - 8.17) in the specified order (8.1 - 8.17). 9

35 Nm

10

Hollow screw Seal

– Replace the sealing ring during assembly. 11

Ring piece

12

Mounting bolts for the exhaust gas recirculation cooler

13

Exhaust gas recirculation line

14 15

12 Nm

Pipe clamps Seal

– Replace seal for installation. 16

Seal

– Replace seal for installation. 17

Connecting piece

18

Coolant flow tube

19

Connecting piece

20

Clamp

21

Exhaust gas recirculation hose

22

Clamp

23

Exhaust gas recirculation line

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

381

01 Engine 0140 Exhaust system 1451-001

Value 24

CCN

M8: 30 Nm M10: 60 Nm

25

30 Nm

Remark / designation Mounting bolts for the exhaust gas recirculation line Bracket mounting bolts

26

Retainers

27

Exhaust gas recirculation hose

28

2 Nm

Clamp

Tightening torques not specified, see section on tightening torques

382

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Removal ► Switch off the ignition. Page 357 ► Drain coolant. Disconnect the battery isolating switch of the ► machine. ► Remove the charge air line from the exhaust turbo charger. See the repair manual of the machine in question. ► Detach the air intake pipe from the exhaust turbo charger. See the repair manual of the machine in question. ► Undo the bolt (1) on the clamps (2). ► Detach the exhaust gas recirculation line (3).

625 281759-001

► Disconnect the plug-in connection (1) on the sensor (B621-MB).

626 281760-001

► Undo the clamp bolts (1).

627 281765-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

383

01 Engine 0140 Exhaust system 1451-001

► Unscrew the bolts (1) on the exhaust gas recirculation line (2).

628 281768-001

► Unscrew the bolts (1) on the exhaust gas recirculation line (2). ► Detach the exhaust gas recirculation line (2) and (4) together with the exhaust gas recirculation hose (3).

629 281771-001

► Unscrew the bolts (1) and remove the bracket (2). ► Pull the coolant flow tube (3) out of the connector for the oil coolant module (4) and out of the exhaust gas recirculation cooler (5).

630 281772-001

► Remove the coolant lines. See the repair manual of the machine in question.

384

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Disconnect the plug-in connection (1) on the sensor (B606-MB).

631 281790-001

► Undo the bolts (1) on the coolant nozzle (2). The bolts cannot be pulled out.

632 281791-001

► Unscrew the bolts (1) and remove the protection panel (2).

633 281793-001

► Unscrew the coolant line (1) on the exhaust gas recirculation cooler (4). ► Slacken off bolts (2) and (3). The bolts (2) cannot be unscrewed from the exhaust gas recirculation cooler. Only loosen the bolts; do not fully undo them (3). ► Pull the exhaust gas recirculation cooler upwards and remove it.

634 281795-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

385

01 Engine 0140 Exhaust system 1451-001

281797-001

635

► Remove the seals (1) and (2) on the exhaust gas recirculation cooler (3). ► Unscrew the bolts (1) and remove the coolant nozzle (2).

636 281804-001

386

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Installation ► Clean the sealing faces.

Page 20

► Install a new seal (1) in the coolant nozzle (2).

637 281808-001

► Attach the coolant nozzle (2) and tighten the bolts (1) until they are hand-tight.

638 281804-001

281797-001

639

► Fit the new seals (1) and (2) together with the guide rods in the exhaust gas recirculation cooler (3).

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

387

01 Engine 0140 Exhaust system 1451-001

► Install the exhaust gas recirculation cooler (4) and tighten the bolts (2) and (3) in accordance with the tightening diagram. Tightening diagram: Page 380 ► Screw the coolant line (1) to the exhaust gas recirculation cooler (4). Page 380 Tightening torque:

640 281795-001

► Screw down the bolts (1) on the coolant nozzle (2). Tightening torque: Page 380

641 281804-001

► Attach the protection panel (2) and screw down the bolts (1). Tightening torque: Page 407

642 281793-001

► Connect the plug-in connection (1) to the sensor (B606-MB).

643 281790-001

388

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Attach the coolant lines. See the repair manual of the machine in question. ► Slide on the new connecting piece (2) until it reaches the stop on the connector (4). ► Install a new connecting piece (1) in the coolant flow tube (3). ► Insert the coolant flow tube (3) into the exhaust gas recirculation cooler (5) and into the connecting piece (2). ► Screw on the bracket (6) using bolts (7). Tightening torque: Page 380

644 281816-001

► Install the exhaust gas recirculation line (2) and (4) together with the exhaust gas recirculation hose (3). Install a new seal on the exhaust gas recirculation line (4). Replace the exhaust gas recirculation hose (3) and clamps if necessary. ► Screw the bolts (1) to the exhaust gas recirculation line (2). Tightening torque: Page 380

645 281771-001

► Screw the bolts (1) to the exhaust gas recirculation line (2). Tightening torque: Page 380

646 281768-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

389

01 Engine 0140 Exhaust system 1451-001

► Screw in the clamp bolts (1). Replace the exhaust gas recirculation hose and clamps if necessary. Tightening torque: Page 380

647 281765-001

► Connect the plug-in connection (1) to the sensor (B621-MB).

648 281760-001

► Attach the exhaust gas recirculation line (3) using clamps (2). Replace the clamps if necessary. The bolts (1) for the clamps must be situated underneath. ► Screw in the clamp bolts (1). Tightening torque: Page 380

649 281759-001

Page 357 ► Top up coolant. ► Attach the air intake pipe to the exhaust turbo charger. See the repair manual of the machine in question. ► Install charge air line on the exhaust turbo charger. See the repair manual of the machine in question. Switch on the battery isolating switch of the ► machine. ► Start the diesel engine and run it at a higher speed. ► Switch off the diesel engine and check for leaks.

390

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Checking ► Open the cover on the coolant compensating reservoir to relieve the overpressure in the coolant circuit. ► Slacken off clamp (1). ► Unscrew bolts (2). ► Remove the exhaust gas recirculation line (3).

650 269876-001

► Undo the bolts (5) on the clamps (3). ► Detach the exhaust gas recirculation line (1) from the exhaust gas recirculation cooler (2). ► Detach the exhaust gas recirculation line (1) from the exhaust manifold (3).

651 269765-001

Use special tool (I).

Page 379

► Clean the interior of the exhaust gas recirculation hose (2). ► Attach the locking device (1) to the exhaust gas recirculation hose (2) using the clamp (3). For the tightening torque, see: Page 380 ► Replace the clamp if necessary.

652 269883-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

391

01 Engine 0140 Exhaust system 1451-001

Use special tools (I) and (II).

Page 379

► Attach the flange (1) to the exhaust gas recirculation cooler (2) using the clamp (3). Page 380 For the tightening torque, see: Attach the pressure pump (4) to the flange (1). ► ► Pressurise the exhaust gas recirculation cooler (2) with compressed air. For test pressure, see: Page 380 The test pressure must not be exceeded.

653 269916-001

► Detach the locking device (1) from the exhaust gas recirculation hose (2).

654 269923-001

► Detach the locking device (1) and pressure pump (3) from the exhaust gas recirculation cooler (2).

655 269927-001

► Attach the exhaust gas recirculation line (1) together with the clamps (3) to the exhaust gas recirculation cooler (2) and exhaust manifold (4). ► The clamp bolts (5) must be situated underneath. ► For the tightening torque, see: Page 380 ► Replace the clamps (3) if necessary.

656 269765-001

392

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Insert the exhaust gas recirculation line (3). ► Tighten the bolts (2). For the tightening torque, see: Page 380 ► Screw on clamp (1). For the tightening torque, see: Page 380

657 269876-001

► Close the cover for the coolant compensating reservoir. ► Start the diesel engine and run it at a higher speed. ► Switch off the diesel engine and check for leaks.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

393

01 Engine 0140 Exhaust system 1451-001 176834-001

Exhaust gas recirculation actuator Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

269997-001

Value 1

CCN 20 Nm

658

Remark / designation Nuts

– Replace the nuts during assembly. 2

30 Nm

Hex. bolts

3

Coolant lines

4

Exhaust gas recirculation valve

5

20 Nm

Nuts

– Replace the nuts during assembly. 6

40 Nm

Union nuts

7 8

Connecting rod Y621-MB

Exhaust gas recirculation actuator

Tightening torques not specified, see section on tightening torques

394

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Value

CCN

9 10

Remark / designation Lever

30 Nm

Hex. bolt

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

395

01 Engine 0140 Exhaust system 1451-001

Removal ► Switch off the ignition. ► Disconnect the battery isolating switch of the machine. Page 357 ► Drain coolant. ► Remove the exhaust pipe downstream of the exhaust turbo charger. See the repair manual of the machine in question. ► Remove the lever (1). ► Hold on the lever for undoing the nut (2).

659 270053-001

► Slacken off nuts (1). ► Remove the coolant lines (2). ► Collect any escaping coolant.

660 270062-001

► Undo the line (1) from the vent line (3). ► Disconnect connector (2).

661 270076-001

396

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Unscrew the bolts (1) and (2) and remove the exhaust gas recirculation actuator (3).

662 270081-001

► Unscrew the nuts (1) and (3). ► Remove the connecting rod (4) from the lever (5) and the exhaust gas recirculation valve (2).

663 270084-001

Installation ► Attach the connecting rod (4) to the lever (5) and the exhaust gas recirculation valve (2). ► Tighten the nuts (1) and (3). For the tightening torque, see: Page 394

664 270084-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

397

01 Engine 0140 Exhaust system 1451-001

► Screw on the exhaust gas recirculation actuator (3) using bolts (1) and (2). Note the different lengths of the bolts (1) and (2). For the tightening torque, see: Page 394

665 270081-001

► Connect the plug-in connection (2). ► Screw the line (1) onto the vent line (3).

666 270076-001

► Screw on the coolant lines (2) using nuts (1). For the tightening torque, see: Page 394

667 270062-001

► Screw on the lever (1) using the nuts (2). For the tightening torque, see: Page 394

668 270053-001

398

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

►

► ► ► ►

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Attach the exhaust pipe downstream of the exhaust turbo charger. See the repair manual of the machine in question. Top up coolant. Page 357 Switch on the battery isolating switch of the machine. Start the diesel engine and run it at a higher speed. Switch off the diesel engine and check for leaks.

399

01 Engine 0140 Exhaust system 1451-001 176936-001

Differential pressure sensor Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

270452-001

Value

CCN

Remark / designation

1

Exhaust gas recirculation line

2

Electrical cable

3

M6: 15 Nm

669

Page 367

Hex. bolts

M8: 20 Nm 4

B621-MB

Exhaust gas recirculation differential pressure sensor

– Replace the sealing rings during assembly. – Clean the sealing faces thoroughly.

Page 20

Tightening torques not specified, see section on tightening torques

400

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001 181216-001

Exhaust manifold Applies to: Mercedes-Benz OM 470 LA

Work preparation Utilities: ► Copper paste

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

401

01 Engine 0140 Exhaust system 1451-001

Technical specifications

280932-001

Value 1

CCN 25 Nm

Remark / designation Guard mounting bolts

2

Guard

3

Guard

4

25 Nm

670

Exhaust manifold mounting bolts Tightening diagram:

– Tighten the mounting bolts (4.1 - 4.24) in the specified order (4.1 - 4.24) until they are hand-tight. – Screw the mounting bolts (4.1 - 4.24) in the specified order (4.1 - 4.24) until they are hand-tight. 5

Exhaust manifold

6

Flexible tube

7

Pipe clamps

8

Exhaust manifold

9

Guide bushing

10

Exhaust manifold mounting bolts

11

Exhaust manifold

Tightening torques not specified, see section on tightening torques

402

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Value

CCN

Remark / designation

12

Guide bushing

13

Seal

– Replace seal for installation. – Clean the sealing faces thoroughly. – Observe the installation position of the seal. 14

Seal

15

Seal

Page 20

– Replace seal for installation. – Clean the sealing faces thoroughly. – Observe the installation position of the seal. 16

Page 20

Page 20

Seal

– Replace seal for installation. – Clean the sealing faces thoroughly. – Observe the installation position of the seal.

Page 20

Tightening torques not specified, see section on tightening torques

Removal ► Let the engine cool down. ► Disconnect the battery isolating switch of the machine. ► Remove the charge air line from the exhaust turbo charger. See the repair manual of the machine in question. Detach the air intake pipe from the exhaust turbo ► charger. See the repair manual of the machine in question. ► Remove the exhaust gas recirculation line upstream of the exhaust gas recirculation cooler. Page 370 ► Unscrew the bolts (1) and remove the protection panels (2).

671 280874-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

403

01 Engine 0140 Exhaust system 1451-001

► Unscrew the bolts (1) on the exhaust manifold (2).

672 280854-001

► Unscrew bolts (1) and remove washers (2). ► Remove the exhaust manifold (3) and the seals (4).

673 280895-001

Installation ► Clean the sealing faces.

Page 20

Insert new seals (4). Fit exhaust gas manifold (3). Coat the new bolts (1) with copper paste. Screw on the new bolts (1) together with the new washers (2) until they are hand-tight. Note the different bolt lengths. ► Tighten the bolts in accordance with the tightening diagram. Tightening diagram: Page 402

► ► ► ►

674 280895-001

404

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Screw the bolts (1) onto the exhaust manifold (2). Tightening torque: Page 415

675 280854-001

► Insert the protection panels (2). ► Tighten bolts (1). Tightening torque: Page 402

676 280874-001

► Install the exhaust gas recirculation line upstream of the exhaust gas recirculation cooler. Page 373 ► Attach the charge air line from the exhaust turbo charger. See the repair manual of the machine in question. ► Attach the air intake pipe to the exhaust turbo charger. See the repair manual of the machine in question. ► Switch on the battery isolating switch of the machine. ► Start the diesel engine and let it run idling for at least 1 minute. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

405

01 Engine 0140 Exhaust system 1451-001 181253-001

Exhaust manifold Applies to: Mercedes-Benz OM 471 LA

Work preparation Utilities: ► Copper paste

406

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Technical specifications

l

281492-001

Value 1

CCN 25 Nm

677

Remark / designation Guard mounting bolts

2

Guard

3

Guard

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

407

01 Engine 0140 Exhaust system 1451-001

Value 4

CCN 40 Nm

Remark / designation Exhaust manifold mounting bolts If the entire exhaust manifold (5, 8 and 11) is installed: Tightening diagram:

– Tighten the mounting bolts (4.1 - 4.12) in the specified order (4.1 - 4.12) until they are hand-tight. – Screw in the mounting bolts (4.1 - 4.12) in the specified order (4.1 - 4.12). If only the front section of the exhaust manifold (11) is installed: Tightening diagram:

– Tighten the mounting bolts (4.5 - 4.8) in the specified order (4.5 - 4.8) until they are hand-tight. – Screw in the mounting bolts (4.5 - 4.8) in the specified order (4.5 - 4.8). If only the rear section of the exhaust manifold (5) is installed: Tightening diagram:

– Tighten the mounting bolts (4.9 - 4.12) in the specified order (4.9 - 4.12) until they are hand-tight. – Screw in the mounting bolts (4.9 - 4.12) in the specified order (4.9 - 4.12). If only the centre section (8) and the rear section (5) of the exhaust manifold is installed:

– Tighten the mounting bolts (4.1 - 4.4) in the specified order (4.1 - 4.4) until they are hand-tight. – Tighten the mounting bolts (4.9 - 4.12) in the specified order (4.9 - 4.12) until they are hand-tight. – Screw in the mounting bolts (4.1 - 4.4) in the specified order (4.1 - 4.4). – Screw in the mounting bolts (4.9 - 4.12) in the specified order (4.9 - 4.12). 5

Rear section for the exhaust manifold

6

Flexible tube

7

7 Nm

Pipe clamps

8

Centre section for the exhaust manifold

9

Guide bushing

10

Exhaust manifold mounting bolts

11

Front section for the exhaust manifold

12

Guide bushing

Tightening torques not specified, see section on tightening torques

408

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Value

CCN

13

Remark / designation Seal

– Replace seal for installation. – Clean the sealing faces thoroughly. – Observe the installation position of the seal. 14

Seal

15

Seal

Page 20

– Replace seal for installation. – Clean the sealing faces thoroughly. – Observe the installation position of the seal. 16

17

19

Page 20

Seal

– Replace seal for installation. – Clean the sealing faces thoroughly. – Observe the installation position of the seal.

18

Page 20

Exhaust turbo charger 6 Nm

Page 20 Page 423

Clamp for the air intake pipe Air intake tube

Tightening torques not specified, see section on tightening torques

Removal ► Let the engine cool down. ► Disconnect the battery isolating switch of the machine. ► Remove the charge air line from the exhaust turbo charger. See the repair manual of the machine in question. ► Detach the air intake pipe from the exhaust turbo charger. See the repair manual of the machine in question. ► Disconnect the electrical cable (1) from the temperature sensor downstream of the air filter (B611-MB). ► Slacken off clamp (2). ► Detach the air intake pipe (3) from the exhaust turbo charger (4).

678 280998-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

409

01 Engine 0140 Exhaust system 1451-001

281059-001

679

► Remove the protection panel (1) on the centre section (2) of the exhaust manifold. ► Remove the protection panel (3) on the front section (4) of the exhaust manifold. ► Remove clamp (5). ► Unscrew the bolts (6) together with the discs (7) and remove the front section (4) of the exhaust manifold. ► Remove the exhaust turbo charger. 426

Page

281064-001

680

► Remove the exhaust gas recirculation line (1) upstream of the exhaust gas recirculation cooler. Page 383 ► Remove the protection panel (2) on the rear section (3) of the exhaust manifold. ► Remove clamp (4). ► Unscrew the bolts (5) together with the discs (6) and remove the rear section of the exhaust manifold.

410

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

281091-001

681

► Remove the connecting rod (1) on the lever (2). Page 397 ► Unscrew the bolts (3) together with the discs (4) and remove the centre section (5) of the exhaust manifold. ► Remove the seal (6), (7) and (8). Only if the centre section of the exhaust manifold or the connecting rod is replaced: ► Remove the connecting rod and lever. Installation ► Clean the sealing faces.

Page 20

281091-001

682

► Install a new seal (6), (7) and (8). ► Check the centre section (5) of the exhaust manifold for damage and replace it if necessary. ► Coat the new bolts (3) with copper paste. ► Attach the centre section (5) of the exhaust manifold and screw it on using new bolts (3) and new discs (4) in accordance with the tightening diagram. Tightening diagram: Page 407

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

411

01 Engine 0140 Exhaust system 1451-001

281064-001

683

► Coat the new bolts (5) with copper paste. ► Attach the rear section (3) of the exhaust manifold and screw it on using new bolts (5) and new discs (6) in accordance with the tightening diagram. Tightening diagram: Page 407 ► Screw on the new clamp (4). Tightening torque: Page 407 ► Attach the protection panel (2) to the rear section (3) of the exhaust manifold. Tightening torque: Page 407 ► Install the exhaust gas recirculation line (1) upstream of the exhaust gas recirculation cooler. Page 387 ► Attach the exhaust turbo charger.

Page 429

281059-001

684

► Coat the new bolts (6) with copper paste. ► Attach the front section (3) of the exhaust manifold and screw it on using new bolts (6) and new discs (7) in accordance with the tightening diagram. Tightening diagram: Page 407 ► Screw on the new clamp (5). Tightening torque: Page 407 ► Attach the protection panel (3) to the front section (4) of the exhaust manifold.

412

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Tightening torque: Page 407 ► Attach the protection panel (1) to the centre section (2) of the exhaust manifold. Page 407 Tightening torque: ► Attach the air intake pipe (3) to the exhaust turbo charger (4). Replace the clamp (2) if necessary. Tightening torque: Page 407 ► Connect the electrical cable (1) on the temperature sensor downstream of the air filter (B611-MB).

685 280998-001

► Install charge air line on the exhaust turbo charger. See the repair manual of the machine in question. ► Attach the air intake pipe to the exhaust turbo charger. See the repair manual of the machine in question. ► Switch on the battery isolating switch of the machine. ► Start the diesel engine and let it run idling for at least 1 minute. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

413

01 Engine 0140 Exhaust system 1451-001 178059-001

Exhaust turbo charger Applies to: Mercedes-Benz OM 470 LA

Work preparation Utilities: ► Copper paste Tool: ► Protective clothing ► Engine oil collection container

414

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Technical specifications

273590-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

686

415

01 Engine 0140 Exhaust system 1451-001

Value 1

CCN 22,5 kg

2 3

Remark / designation Exhaust turbo charger Guard

25 Nm

Guard mounting bolts

4

Guard

5

Electrical cable

6

Brackets

7

25 Nm

Guard mounting bolts

8

50 Nm

Exhaust turbo charger mounting bolts

9

Exhaust manifold

10

Seal

Page 414

– Replace seal in every installation process. 11

35 Nm

Oil pressure line hollow screw

– Replace sealing rings in every installation process. 12

Line

– Replace sealing rings in every installation process. 13

30 Nm

14 15

Oil return line 30 Nm

16 17

Mounting bolt for the oil return line

Mounting bolt for the oil return line Electric plug-in connection

M8: 25 Nm

Mounting bolt for the exhaust turbo charger

M10: 60 Nm 18

M8: 25 Nm

Mounting bolt for the crank case

M10: 60 Nm 19

Retainers

20

Oil feed line

21

35 Nm

Oil pressure line hollow screw

– Replace sealing rings in every installation process. 22

25 Nm

Hollow screw

– Replace sealing rings in every installation process. 23

Line on the charge pressure actuator

Tightening torques not specified, see section on tightening torques

416

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Removal ► Let the engine cool down. ► Disconnect the battery isolating switch. ► Unscrew the bolts (1) and take off the protection panel (2).

687 268474-001

► Unscrew the bolts (1) and remove the protection panel (2).

688 273233-001

► Remove the air intake lines. ► Remove the charge air lines. ► Remove the exhaust pipework. See the repair manual of the machine in question. ► Unscrew bolts (1). ► Unscrew the bolts (3) and detach the oil return line (2). Collect any escaping engine oil.

689 273214-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

417

01 Engine 0140 Exhaust system 1451-001

► Remove seals (1) and (2).

690 273225-001

► Detach the line (2) from the bracket (1). ► Disconnect connector (3).

691 273230-001

► Unscrew bolts (1) and (2) and remove the bracket (3).

692 273239-001

► Detach lines (1) and (2) from the charge pressure actuator (Y636-MB).

693 273454-001

418

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Unscrew bolts (1) and (3) and remove the oil pressure line (2).

694 273361-001

► Unscrew bolts (1). ► Remove the exhaust turbo charger (2) and the seal (3).

695 273265-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

419

01 Engine 0140 Exhaust system 1451-001

Installation ► Check whether the oil pressure and oil return lines are dirty or damaged and replace them if necessary. Page 20 ► Clean the sealing faces. ► Fill the bearing housing of the exhaust turbo charger with engine oil and turn the exhaust turbo charger shaft when doing so. See the Operator's Manual of the machine in question. ► Coat the bolts (1) with copper paste. ► Screw on the exhaust turbo charger (2) and the new seal (3) using bolts. Page 415 Tightening torque:

696 273265-001

► Screw on the oil pressure line (2) using new sealing rings and bolts (1) and (3). Tightening torque: Page 415

697 273361-001

► Attach the lines (1) and (2) to the charge pressure actuator (Y636-MB). Tightening torque: Page 415

698 273454-001

420

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► ► ► ►

Attach new cable straps to the bracket (3). Tighten the bolts (1) and (2) until they are handtight. Tighten the bolts (2). Tightening torque: Page 415 Tighten bolts (1). Tightening torque: Page 415

699 273239-001

► Fasten the line (2) to the bracket (1). ► Connect the plug-in connection (3).

700 273230-001

► Install the new seals (1) and (4). ► Fasten the new cable straps (3) to the bracket (2).

701 273381-001

► Attach the oil return line (2) and tighten the bolts (1) and (3) until they are hand-tight. ► Tighten bolt (3). Tightening torque: Page 415 ► Tighten bolts (1). Tightening torque: Page 415

702 273214-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

421

01 Engine 0140 Exhaust system 1451-001

► Attach the exhaust pipework. ► Attach the charge air lines. ► Attach the air intake lines. See the repair manual of the machine in question. ► Screw on the protection panel (2) using bolts (1). Tightening torque: Page 415

703 273233-001

► Screw on the protection panel (2) using bolts (1). Tightening torque: Page 415

704 268474-001

► Check the engine oil level as specified in the Operator's Manual of the machine in question. ► Start the diesel engine and let it run idling for at least 1 minute. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

422

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001 180745-001

Exhaust turbo charger Applies to: Mercedes-Benz OM 471 LA

Work preparation Utilities: ► Copper paste Tool: ► Protective clothing ► Engine oil collection container

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

423

01 Engine 0140 Exhaust system 1451-001

Technical specifications

279387-001

424

705

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Value 1

CCN 22,5 kg

2 3

Remark / designation Exhaust turbo charger Guard

25 Nm

Guard mounting bolts

4

Guard

5

Electrical cable

6

Brackets

7

25 Nm

Guard mounting bolts

8

50 Nm

Exhaust turbo charger mounting bolts

9

Exhaust manifold

10

Seal

Page 406

– Replace seal in every installation process. 11

35 Nm

Oil pressure line hollow screw

– Replace sealing rings in every installation process. 12

Line

– Replace sealing rings in every installation process. 13

30 Nm

14 15

Oil return line 30 Nm

16 17

Mounting bolt for the oil return line

Mounting bolt for the oil return line Electric plug-in connection

M8: 25 Nm

Mounting bolt for the exhaust turbo charger

M10: 60 Nm 18

M8: 25 Nm

Mounting bolt for the crank case

M10: 60 Nm 19

Retainers

20

Oil feed line

21

35 Nm

Oil pressure line hollow screw

– Replace sealing rings in every installation process. 22

25 Nm

Hollow screw

– Replace sealing rings in every installation process. 23

Line on the charge pressure actuator

24

Retainers

25

25 Nm

Bracket mounting bolt

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

425

01 Engine 0140 Exhaust system 1451-001

Removal ► Let the engine cool down. ► Disconnect the battery isolating switch. ► Unscrew the bolts (1) and take off the protection panel (2).

706 268474-001

► Unscrew the bolts (1) and remove the protection panel (2).

707 273233-001

► Remove the air intake lines. ► Remove the charge air lines. ► Remove the exhaust pipework. See the repair manual of the machine in question. ► Unscrew bolts (1). ► Unscrew the bolts (3) and detach the oil return line (2). Collect any escaping engine oil.

708 273214-001

426

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Remove seals (1) and (2).

709 273225-001

► Detach the line (2) from the bracket (1). ► Disconnect connector (3).

710 273230-001

► Unscrew bolts (1) and (2) and remove the bracket (3).

711 273239-001

► Detach lines (1) and (2) from the charge pressure actuator (Y636-MB).

712 273454-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

427

01 Engine 0140 Exhaust system 1451-001

► Unscrew bolts (1) and (3) and remove the oil pressure line (2).

713 273361-001

► Unscrew bolts (1). ► Remove the exhaust turbo charger (2) and the seal (3).

714 273265-001

428

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

Installation ► Check whether the oil pressure and oil return lines are dirty or damaged and replace them if necessary. Page 20 ► Clean the sealing faces. ► Fill the bearing housing of the exhaust turbo charger with engine oil and turn the exhaust turbo charger shaft when doing so. See the Operator's Manual of the machine in question. ► Check the studs (1) on the exhaust turbo charger (2). Replace the studs if necessary.

715 279388-001

► Coat the bolts (1) with copper paste. ► Screw on the exhaust turbo charger (2) and the new seal (3) using bolts. Tightening torque: Page 424

716 273265-001

► Screw on the oil pressure line (2) using new sealing rings and bolts (1) and (3). Tightening torque: Page 424

717 273361-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

429

01 Engine 0140 Exhaust system 1451-001

► Attach the lines (1) and (2) to the charge pressure actuator (Y636-MB). Tightening torque: Page 424

718 273454-001

► Attach new cable straps to the bracket (3). ► Tighten the bolts (1) and (2) until they are handtight. ► Tighten the bolts (2). Tightening torque: Page 424 ► Tighten bolts (1). Tightening torque: Page 424

719 273239-001

► Fasten the line (2) to the bracket (1). ► Connect the plug-in connection (3).

720 273230-001

► Install the new seals (1) and (4). ► Fasten the new cable straps (3) to the bracket (2).

721 273381-001

430

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0140 Exhaust system 1451-001

► Attach the oil return line (2) and tighten the bolts (1) and (3) until they are hand-tight. ► Tighten bolt (3). Tightening torque: Page 424 Tighten bolts (1). ► Tightening torque: Page 424

722 273214-001

► Attach the exhaust pipework. ► Attach the charge air lines. ► Attach the air intake lines. See the repair manual of the machine in question. ► Screw on the protection panel (2) using bolts (1). Tightening torque: Page 424

723 273233-001

► Screw on the protection panel (2) using bolts (1). Tightening torque: Page 424

724 268474-001

► Check the engine oil level as specified in the Operator's Manual of the machine in question. Start the diesel engine and let it run idling for at ► least 1 minute. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

431

01 Engine 0145 Air intake 1451-001

0145 Air intake

432

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001 178292-001

Charge air housing Applies to: Mercedes-Benz OM 470 LA

Technical specifications

274250-001

Value

CCN

1

725

Remark / designation Charge air housing

2

30 Nm

Mounting bolts for the charge air diffuser

3

30 Nm

4

30 Nm

Mounting bolts for the connection flange

5

25 Nm

Mounting bolts for the charge air housing

B617-MB

6

Charge air temperature sensor in the charge air housing

Uncoupling disc

– Replace damaged discs during assembly. 7 8 9

30 Nm

Mounting bolts for the charge air tube bracket B608-MB

Charge air pressure and temperature sensor in the charge air tube Charge air housing

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

433

01 Engine 0145 Air intake 1451-001

Value

CCN

10

Remark / designation Seals

– Replace the seals during installation – Clean the sealing faces thoroughly. 11

10 Nm

Page 20

Mounting bolts for the charge air pressure sensor and temperature sensor

Tightening torques not specified, see section on tightening torques

434

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001

Removal ► Remove the charge air line. See the repair manual of the machine in question. Page 357 ► Drain coolant. ► Disconnect connector (1). ► Detach the line set (2) from the charge air tube (3).

726 274101-001

► Detach the hose (1) from the exhaust gas recirculation line (2). See the "Exhaust gas recirculation cooler" chapter: Page 370

727 274112-001

► Loosen bolts (1). ► Unscrew the bolts (3) and detach the connection flange (2) from the charge air tube (4).

728 268742-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

435

01 Engine 0145 Air intake 1451-001

► Unscrew bolts (1). ► Detach the charge air tube (2).

729 274123-001

► Remove the exhaust gas recirculation line (1). See the "Exhaust gas recirculation cooler" chapter: Page 370

730 274133-001

Only if the charge air tube is replaced: ► Remove sensor (B608-MB).

731 274143-001

Page 343 ► Remove the oil coolant module. Page 328 ► Remove the fuel filter module. Page ► Remove the high-pressure fuel pump. 301

436

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001

► Disconnect connector (1).

732 273909-001

► Undo the line set (1) from the charge air housing (2).

733 273928-001

► Unscrew the bolts (1) and remove the charge air housing (2).

734 273961-001

Only if the charge air housing is replaced: ► Remove the sensor (B617-MB).

735 273972-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

437

01 Engine 0145 Air intake 1451-001

Installation ► Clean the sealing faces.

Page 20

► Install the sensor (B617-MB) together with a new sealing ring. Page 433 Tightening torque:

736 273972-001

► Fit new seals (1) with guide rods in the charge air housing (2).

737 273993-001

► Install new discs (1) on the bolts (2) if necessary.

738 273996-001

438

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001

► Attach the charge air housing (2) and screw it on using bolts (1). Tightening torque: Page 433

739 273961-001

► Attach the line set (1) to the charge air housing (2).

740 273928-001

► Connect the plug-in connection (1).

741 273909-001

Page 304 ► Install the high-pressure fuel pump. Page 330 ► Install the fuel filter module. Page 344 ► Install the oil coolant module.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

439

01 Engine 0145 Air intake 1451-001

► Install the sensor (B608-MB) together with a new sealing ring. Tightening torque: Page 433

742 274143-001

► Install the exhaust gas recirculation line (1). See the "Exhaust gas recirculation cooler" chapter: Page 373

743 274133-001

► Attach the charge air tube (2) together with a new sealing ring and screw it on using bolts (1). Tightening torque: Page 433

744 274123-001

► Screw the connection flange (2) onto the charge air tube (4) using bolts (3). Tightening torque: Page 433 ► Tighten bolts (1). Tightening torque: Page 433

745 268742-001

440

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001

► Attach the hose (1) to the exhaust gas recirculation line (2). See the "Exhaust gas recirculation cooler" chapter: Page 373

746 274112-001

► Attach the line set (2) to the charge air tube (3). ► Connect the plug-in connection (1).

747 274101-001

Page 357 ► Top up coolant. Install the charge air line. ► See the repair manual of the machine in question.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

441

01 Engine 0145 Air intake 1451-001 180946-001

Charge air housing Applies to: Mercedes-Benz OM 471 LA

Technical specifications

274250-001

Value

CCN

1

748

Remark / designation Charge air housing

2

30 Nm

Mounting bolts for the charge air diffuser

3

30 Nm

4

30 Nm

Mounting bolts for the connection flange

5

25 Nm

Mounting bolts for the charge air housing

B617-MB

6

Charge air temperature sensor in the charge air housing

Uncoupling disc

– Replace damaged discs during assembly. 7 8 9

30 Nm

Mounting bolts for the charge air tube bracket B608-MB

Charge air pressure and temperature sensor in the charge air tube Charge air housing

Tightening torques not specified, see section on tightening torques

442

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001

Value

CCN

10

Remark / designation Seals

– Replace the seals during installation – Clean the sealing faces thoroughly. 11

10 Nm

Page 20

Mounting bolts for the charge air pressure sensor and temperature sensor

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

443

01 Engine 0145 Air intake 1451-001

Removal ► Remove the charge air line. See the repair manual of the machine in question. Page 357 ► Drain coolant. ► Disconnect connector (1). ► Detach the line set (2) from the charge air tube (3).

749 274101-001

► Detach the hose (1) from the exhaust gas recirculation line (2). See the "Exhaust gas recirculation cooler" chapter: Page 383

750 274112-001

► Loosen bolts (1). ► Unscrew the bolts (3) and detach the connection flange (2) from the charge air tube (4).

751 268742-001

444

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001

► Unscrew bolts (1). ► Detach the charge air tube (2).

752 274123-001

► Remove the exhaust gas recirculation line (1). See the "Exhaust gas recirculation cooler" chapter: Page 383

753 274133-001

Only if the charge air tube is replaced: ► Remove sensor (B608-MB).

754 274143-001

► Remove the oil coolant module. ► Remove the fuel filter module.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Page 343 Page 328

445

01 Engine 0145 Air intake 1451-001

► Remove the high-pressure lines (1). See the "High pressure lines and rail" chapter: Page 276

755 280240-001

► Disconnect connector (1).

756 273909-001

► Unscrew the bolts (1) and remove the charge air housing (2).

757 273961-001

Only if the charge air housing is replaced: ► Remove the sensor (B617-MB).

758 273972-001

446

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001

Installation ► Clean the sealing faces.

Page 20

► Install the sensor (B617-MB) together with a new sealing ring. Page 442 Tightening torque:

759 273972-001

► Fit new seals (1) with guide rods in the charge air housing (2).

760 280242-001

► Install new discs (1) on the bolts (2) if necessary.

761 280241-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

447

01 Engine 0145 Air intake 1451-001

► Attach the charge air housing (2) and screw it on using bolts (1). Tightening torque: Page 442

762 273961-001

► Connect the plug-in connection (1).

763 273909-001

► Install the high-pressure lines (1). See the "High pressure lines and rail" chapter: Page 278

764 280240-001

► Install the fuel filter module. ► Install the oil coolant module.

448

Page 330 Page 344

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0145 Air intake 1451-001

► Install the sensor (B608-MB) together with a new sealing ring. Tightening torque: Page 442

765 274143-001

► Install the exhaust gas recirculation line (1). See the "Exhaust gas recirculation cooler" chapter: Page 387

766 274133-001

► Attach the charge air tube (2) together with a new sealing ring and screw it on using bolts (1). Tightening torque: Page 442

767 274123-001

► Screw the connection flange (2) onto the charge air tube (4) using bolts (3). Tightening torque: Page 442 ► Tighten bolts (1). Tightening torque: Page 442

768 268742-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

449

01 Engine 0145 Air intake 1451-001

► Attach the hose (1) to the exhaust gas recirculation line (2). See the "Exhaust gas recirculation cooler" chapter: Page 387

769 274112-001

► Attach the line set (2) to the charge air tube (3). ► Connect the plug-in connection (1).

770 274101-001

Page 357 ► Top up coolant. Install the charge air line. ► See the repair manual of the machine in question.

450

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

0150 Engine attachment parts

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

451

01 Engine 0150 Engine attachment parts 1451-001 181756-001

Electric starting motor Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

452

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

Technical specifications

282134-001

Value

CCN

1

30 Nm

2

M12: 30 Nm

771

Remark / designation Earth line, terminal 31 Line, terminal 30

M10: 18 Nm 3 4

Solenoid switch 4 Nm

Line, terminal 50

5 6

Starter pre-switch relay 13 kg

M1-MB

Electric starting motor

(M021) 7 8

Timing housing 60 Nm

Mounting bolts for the electric starting motor

Tightening torques not specified, see section on tightening torques

Removal ► Switch off the engine and let it cool down. ► Disconnect the battery. See the repair manual of the machine in question.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

453

01 Engine 0150 Engine attachment parts 1451-001

282126-001

772

► Detach the earth line (1). ► Detach the lines (2) from the solenoid switch (3). ► Detach the line (4) from the starter pre-switch relay (5). ► Detach the electric starting motor (6) from the timing housing (7), pull it downwards and remove it. Installation ► Attach the cranking tool to the timing housing. Page 72 ► Rotate the flywheel using the cranking tool and check the ring gear for wear. ► Replace flywheel if necessary. Page 165 ► Check if the starter pinion is worn. ► Replace the electric starting motor if necessary.

282126-001

773

► Attach the electric starting motor (6) to the timing housing (7). Tightening torque: Page 453 ► Attach the line (4) to the starter pre-switch relay (5). Tightening torque: Page 453 ► Attach the line (2) to the solenoid switch (3).

454

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

Tightening torque: Page 453 ► Attach the earth line (1) to the timing housing (7). Tightening torque: Page 453 ► Connect the battery. See the repair manual of the machine in question.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

455

01 Engine 0150 Engine attachment parts 1451-001 181818-001

Alternator Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

456

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

Technical specifications

282175-001

Value 1

9 kg

CCN

Remark / designation

G2-MB

Alternator

774

(G002) 2

Alternator drive belt See the Operator's Manual of the machine in question.

3

Pulley

4

15 Nm

5

6 Nm

6

40 Nm

Nut for B+ terminal Earth line screw Mounting bolts for the alternator

Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

457

01 Engine 0150 Engine attachment parts 1451-001

Removal ► Let the engine cool down. ► Disconnect the battery. See the repair manual of the machine in question. Remove the charge air tube if necessary. ► See the repair manual of the machine in question. ► Remove the air intake pipe if necessary. See the repair manual of the machine in question. ► Remove the coolant line if necessary. See the repair manual of the machine in question. ► Remove any machine drive belts that may be in the way if required. See the repair manual of the machine in question. ► Remove the alternator drive belt. See the Operator's Manual of the machine in question. ► Unlock the plug-in connection (1) and disconnect it from the alternator (3). ► Remove the line (2) from the alternator B+ terminal. ► Remove the earth line (4). ► Unscrew the bolts (5) and remove the alternator (3).

775 282164-001

Installation ► Check the belt pulley (6) for wear. ► Replace the alternator (3) if necessary. ► Insert the alternator (3) and screw it down using bolts (5). Tightening torque: Page 457 ► Attach the earth line (4) to the alternator (3). Tightening torque: Page 457 Attach the line (2) to the alternator B+ terminal. ► Tightening torque: Page 457 ► Connect the plug-in connection (1) to the alternator (3) and lock it in place. 776 282173-001

► Install the alternator drive belt. See the Operator's Manual of the machine in question. ► Install any machine drive belts that may have been in the way if applicable. See the repair manual of the machine in question. ► Attach the coolant line if necessary. See the repair manual of the machine in question.

458

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

► Attach the air intake pipe if necessary. See the repair manual of the machine in question. ► Attach the charge air tube if necessary. See the repair manual of the machine in question. ► Connect the battery. See the repair manual of the machine in question. ► Start the diesel engine. ► Run the diesel engine until the operating temperature is reached. ► Switch off the diesel engine and check for leaks.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

459

01 Engine 0150 Engine attachment parts 1451-001 181025-001

Resonance vessel Applies to: Mercedes-Benz OM 470 LA

Technical specifications

280353-001

Value

CCN

1 2

Remark / designation Resonance vessel

25 Nm

Mounting bolts for the resonance vessel

3

Air intake line

4

Air intake line

5

Retainers

6

777

25 Nm

Bracket mounting bolt

Tightening torques not specified, see section on tightening torques

460

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001 181067-001

Resonance vessel Applies to: Mercedes-Benz OM 471 LA

Technical specifications

280452-001

Value

CCN

1 2 3

778

Remark / designation Resonance vessel

10 Nm

Mounting bolts for the resonance vessel Air intake line

– Check the sealing ring and replace the air intake line if necessary. 4

Journal

– Ensure that the plugs are correctly seated in the resonance vessel guides (1). 5

Journal

– Ensure that the plugs are correctly seated in the resonance vessel guides (1). 6

Air intake line

– Check the sealing ring and replace the air intake line if necessary. Tightening torques not specified, see section on tightening torques

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

461

01 Engine 0150 Engine attachment parts 1451-001

Installation instructions Removing: – Remove air intake line (6). See the Operator's Manual of the machine in question. Installing: – Attach the air intake line (6). See the Operator's Manual of the machine in question.

462

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001 180981-001

Air compressor Applies to: Mercedes-Benz OM 470 LA

Work preparation Tool: ► Protective clothing ► Fuel collecting container ► Coolant collection container Special tool Special tool (I)

Pcs.

Fixing device

1

00 1998 594 0

779 279032-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

463

01 Engine 0150 Engine attachment parts 1451-001

Technical specifications

280421-001

Value

CCN

Remark / designation

1

Air compressor

2

Air intake line (resonance vessel)

3

Coolant line

4

Coolant line

5

M14 x 1.5: 40 Nm

780

Page 460

Coolant line union

M16 x 1.5: 50 Nm M18 x 1.5: 45 Nm M26 x 1.5: 100 Nm 6

60 Nm

Compressor mounting bolts

7

50 Nm

Mounting bolt for the bracket on the air compressor

8

30 Nm

Mounting bolts for the bracket on the crank case

9

Retainers

Tightening torques not specified, see "Introduction / Tightening torques" chapter

464

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

Value

CCN

10

Remark / designation Seal

– Replace the seal with every installation. 11

Seal

– Replace the seal with every installation. 12

Drive gear

13

230 Nm

14

75 Nm

15

M14 x 1.5: 40 Nm

Drive wheel nut Union nut for the compressed air line on the compressor connector Compressed air line connector

M26 x 1.5: 100 Nm 16

Control line

Tightening torques not specified, see "Introduction / Tightening torques" chapter

Removal ► Drain coolant.

Page 357

► Detach the air intake line (1) from the air compressor (2). ► Detach the compressed air line (3) on the connector (4). ► Remove the connector. ► Detach the control line (5).

781 280308-001

► Remove coolant line (1). Collect any escaping coolant. ► Remove coolant line (2). Collect any escaping coolant. If the air compressor is replaced or the connectors for coolant lines (1) and (2) are leaking, remove the connectors.

782 280312-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

► Expose the electrical cable (3) on the bracket (4). ► Remove the bracket. ► Unscrew the bolts (5) and (6) and remove the air compressor (7). Collect any escaping engine oil.

465

01 Engine 0150 Engine attachment parts 1451-001

► Remove the sealing rings (1) and (2) from the air compressor (3). If the air compressor is replaced or the connector (4) is leaking, remove the connector (4).

783 280315-001

Removing the drive gearwheel Use special tool (I).

Page 463

► Check the drive gearwheel (1) for damage. If the drive gearwheel is damaged, check the counter gearwheel in the crank case for damage. ► Clamp the special tool (I) in the vice. Attach the adapter (2) that corresponds to the drive gearwheel. ► Attach the air compressor (3) to the special tool. ► Slacken off nut (4). Observe the left thread of the nut. The nut remains on the shaft to secure the drive wheel. ► Undo the drive wheel (1). ► Unscrew the nut. ► Remove the drive wheel.

784 280324-001

466

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

Installing the drive gearwheel Use special tool (I).

Page 463

► Attach the drive wheel (1) to the air compressor (3). ► Attach the air compressor to the special tool (I). Attach the adapter (2) that corresponds to the drive gearwheel. ► Tighten nut (4). Observe the left thread of the nut. Page 464 Tightening torque: ► Remove the special tool.

785 280324-001

Installation ► Install new sealing rings (1) and (2) in the air compressor (3). ► Install new connectors (4) with new sealing rings if necessary.

786 280315-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

467

01 Engine 0150 Engine attachment parts 1451-001

►

► ►

► ► 787 280312-001

788 280308-001

► ► ►

Screw on the new connectors of coolant lines (1) and (2) with new sealing rings if necessary. Tightening torque: Page 464 Insert the bolt (6). Install the air compressor (7). Twist the drive wheel of the air compressor if necessary. Tighten the bolts (5) and (6). Tightening torque: Page 464 Install the bracket (4). Tightening torque: Page 464 Fasten the electrical cable (3) on the bracket. Install coolant line (2). Install coolant line (1).

► Connect the control line (5) together with a new sealing ring. ► Screw on the connector (4) together with a new sealing ring. Tightening torque: Page 464 ► Check the compressed air line (3) for coking. Replace the compressed air line and affected components if necessary. ► Screw on the compressed air line on the connector. Tightening torque: Page 464 Attach the air intake line (1) to the air ► compressor (2). Page 357 ► Top up coolant. ► Top up engine oil. See the Operator's Manual of the machine in question. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

468

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001 181069-001

Air compressor Applies to: Mercedes-Benz OM 471 LA

Work preparation Tool: ► Protective clothing ► Fuel collecting container ► Coolant collection container Special tool Special tool (I)

Pcs.

Fixing device

1

00 1998 594 0

789 279032-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

469

01 Engine 0150 Engine attachment parts 1451-001

Technical specifications

280528-001

Value

CCN

Remark / designation

1

Air compressor

2

Air intake line (resonance vessel)

3

Coolant line

4

Coolant line

5

M14 x 1.5: 40 Nm

790

Page 461

Coolant line union

M16 x 1.5: 50 Nm M18 x 1.5: 45 Nm M26 x 1.5: 100 Nm 6

60 Nm

Compressor mounting bolts

7

50 Nm

Mounting bolt for the bracket on the air compressor

8

30 Nm

Mounting bolts for the bracket on the crank case

9

Retainers

Tightening torques not specified, see "Introduction / Tightening torques" chapter

470

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

Value

CCN

10

Remark / designation Seal

– Replace the seal with every installation. 11

Seal

– Replace the seal with every installation. 12

Drive gear

13

230 Nm

14

75 Nm

15

M14 x 1.5: 40 Nm

Drive wheel nut Union nut for the compressed air line on the compressor connector Compressed air line connector

M26 x 1.5: 100 Nm 16

M14 x 1.5: 40 Nm

Compressed air line connector

M26 x 1.5: 100 Nm Tightening torques not specified, see "Introduction / Tightening torques" chapter

Removal ► Drain coolant.

Page 357

► Detach the air intake line (1) from the air compressor (3). ► Remove the compressed air line (2).

791 280454-001

► Remove coolant line (1). Collect any escaping coolant. ► Remove coolant line (2). Collect any escaping coolant. If the air compressor is replaced or the connectors for coolant lines (1) and (2) are leaking, remove the connectors.

792 280455-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

► Expose the electrical cable (3) on the bracket (4). ► Remove the bracket. ► Unscrew the bolts (6) and (7) and remove the air compressor (5). Collect any escaping engine oil.

471

01 Engine 0150 Engine attachment parts 1451-001

► Remove the sealing rings (1) and (2) from the air compressor (3). If the air compressor is replaced or the connector (4) is leaking, remove the connector (4).

793 280315-001

Removing the drive gearwheel Use special tool (I).

Page 469

► Check the drive gearwheel (1) for damage. If the drive gearwheel is damaged, check the counter gearwheel in the crank case for damage. ► Clamp the special tool (I) in the vice. Attach the adapter (2) that corresponds to the drive gearwheel. ► Attach the air compressor (3) to the special tool. ► Slacken off nut (4). Observe the left thread of the nut. The nut remains on the shaft to secure the drive wheel. ► Undo the drive wheel (1). ► Unscrew the nut. ► Remove the drive wheel.

794 280324-001

472

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0150 Engine attachment parts 1451-001

Installing the drive gearwheel Use special tool (I).

Page 469

► Attach the drive wheel (1) to the air compressor (3). ► Attach the air compressor to the special tool (I). Attach the adapter (2) that corresponds to the drive gearwheel. ► Tighten nut (4). Observe the left thread of the nut. Page 470 Tightening torque: ► Remove the special tool.

795 280324-001

Installation ► Install new sealing rings (1) and (2) in the air compressor (3). ► Install new connectors (4) with new sealing rings if necessary.

796 280315-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

473

01 Engine 0150 Engine attachment parts 1451-001

►

► ►

► ► 797 280455-001

► ► ►

Screw on the new connectors of coolant lines (1) and (2) with new sealing rings if necessary. Tightening torque: Page 470 Insert the bolt (7). Install the air compressor (5). Twist the drive wheel of the air compressor if necessary. Tighten the bolts (6) and (7). Tightening torque: Page 470 Install the bracket (4). Tightening torque: Page 470 Fasten the electrical cable (3) on the bracket. Install coolant line (2). Install coolant line (1).

► Check the compressed air line (2) for coking. Replace the compressed air line and affected components if necessary. ► Screw on the compressed air line on the connector. Tightening torque: Page 470 ► Attach the air intake line (1) to the air compressor (3).

798 280454-001

Page 357 ► Top up coolant. ► Top up engine oil. See the Operator's Manual of the machine in question. ► Start the diesel engine and let it run idling for at least 1 minute. ► If the engine does not start or only runs for a brief period, fill the low-pressure fuel circuit. ► See the Operator's Manual of the machine in question. ► Run the diesel engine at a higher speed. ► Switch off the diesel engine and check for leaks.

474

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

01 Engine 0155 Engine control 1451-001

0155 Engine control

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

475

01 Engine 0155 Engine control 1451-001 180537-001

Control unit Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Technical specifications

278790-001

Value 1

CCN 25 Nm

Remark / designation Mounting bolts for the plug-in connection

2 3

Electric plug-in connection 25 Nm

Retainers

4

Fuel line

5

15 Nm

Mounting bolts for the control unit

6

50 Nm

Fuel line hollow screw

7

25 Nm

Bracket mounting bolt

8 9 10

799

Retainers A4-MB

Control unit Fuel line

Tightening torques not specified, see section on tightening torques

476

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01 Engine 0155 Engine control 1451-001

Value 11 12

CCN 50 Nm

Remark / designation Fuel line hollow screw Rubber dampers

Tightening torques not specified, see section on tightening torques

Installation instructions Removing: – Read out and save the parametrization of the control unit with the CDS. – Unscrew the fuel lines. - Disconnect fuel lines. - Collect any escaping fuel. Installing: – Screw in the fuel lines. - Use new sealing rings. – Load the control unit parametrization with the CDS. – Start the diesel engine. – Check if fuel lines are tight.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

477

01 Engine 0165 Exhaust gas aftertreatment 1451-001

0165 Exhaust gas aftertreatment

478

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01 Engine 0165 Exhaust gas aftertreatment 1451-001 181738-001

Exhaust treatment system Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Tool: ► Urea collecting tank ► Observe the safety precautions for storage of urea solution! ► Protective clothing Special tool Special tool (I)

Pcs.

Test strips

1

00 1145 145 0

1

800 165495-001

1

801 165530-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

479

01 Engine 0165 Exhaust gas aftertreatment 1451-001

1

Special tool (II)

Pcs.

Refractometer with pipette

1

00 1145 146 0

802 165517-001

1

803 165541-001

Special tool (III)

Pcs.

Tongs

1

(zipper of urea lines) 00 0175 997 0

804 236351-001

480

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01 Engine 0165 Exhaust gas aftertreatment 1451-001

Technical specifications

283020-001

Value 1

CCN

Remark / designation

M25-MB

Urea pump

805

Page 487

(M047) 2

NOx sensor

3

NOx sensor

4

Fill level sensor, temperature sensor and quality sensor

5

Y627-MB

Urea heater valve

Page 484

Control unit

Page 476

(Y488) 6 7

A4-MB

Urea dosing unit

Tightening torques not specified, see section on tightening torques

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481

01 Engine 0165 Exhaust gas aftertreatment 1451-001

Checking the urea solution (purity) This check detects traces of hydrocarbons, e.g. diesel fuel, in the urea solution. The injection system components are very sensitive against hydrocarbons and can be damaged. Flawless function of the exhaust gas treatment system then is no longer guaranteed. ► Disconnect the battery isolating switch of the machine. ► Wait for at least five minutes after stopping the diesel engine for the residual pressure in the system to be relieved. ► Remove urea filter as described in the relevant Operator's Manual. ► Slide a test strip of the special tool (I) between the lamellas of the removed filter (1) and impregnate it with the sticking urea solution. A bright discolouration (2) of the test strip indicates that the urea solution is free of impurities (hydrocarbons).

1

A dark discolouration (3) or (4) of the test strip indicates that the urea solution is polluted with hydrocarbons.

I

806 165543-001

I

2

3

4

807 165544-001

► Install urea filter as described in the relevant Operator's Manual.

482

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01 Engine 0165 Exhaust gas aftertreatment 1451-001

Checking the urea solution (density) This check establishes the density of the urea solution. The usable urea solution consists of 32.5 % urea and 67.5 % distilled water. When the water portion is too high, the function of the exhaust gas treatment system will be affected. ► Disconnect the battery isolating switch of the machine. ► Wait for at least five minutes after stopping the diesel engine for the residual pressure in the system to be relieved. ► Remove urea filter as described in the relevant Operator's Manual.

I

► Use the pipette (1) of special tool (I) and withdraw a urea solution sample from the removed filter and from the urea tank. ► Put the withdrawn sample on the refractometer prism (2). ► The white area is to stop at the characteristic curve (3) of the urea solution. When the white area is below the characteristic curve (3), the urea solution does not contain the specified percentage rate of urea.

2 1

808 165550-001

When the white area is slightly above the characteristic curve (3), this can be considered as normal, depending on the urea solution producer.

3

809 165551-001

► Install urea filter as described in the relevant Operator's Manual.

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483

01 Engine 0165 Exhaust gas aftertreatment 1451-001 181747-001

Urea heater valve Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Tool: ► Cooling water collecting tank ► Protective clothing Special tool

1

Special tool (I)

Pcs.

Hose clamp

2

00 0181 867 0

810 124108-001

484

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01 Engine 0165 Exhaust gas aftertreatment 1451-001

Technical specifications

3 3 1

2

186114-001

Value 1

CCN

Remark / designation

Y627-MB

Urea heater valve

(Y488)

Position of valve:

811

See chapter "Location of components" in the relevant Technical Systems documentation. 2

Urea heater valve mounting bolts

3

Coolant lines

Tightening torques not specified, see section on tightening torques

Removal ► Allow the diesel engine to cool down. ► Disconnect the battery isolating switch of the machine. ► Wait for at least 5 minutes after stopping the diesel engine for the residual pressure in the system to be relieved.

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485

01 Engine 0165 Exhaust gas aftertreatment 1451-001

Use special tool (I).

Page 484

► Disconnect connector at (1). ► Disconnect cooling water hoses (2) and (3) with special tool (I). ► Mark and unlock the cooling water hoses (2) and (3) and remove them from the valve (4). Collect any escaping coolant. ► Remove the valve (4). See the repair manual of the machine in question.

812 282099-001

Installation ► Attach the valve (4). See the repair manual of the machine in question. ► Plug on and lock cooling water hoses (2) and (3). ► Remove special tool (I). ► Connect the cable plug at (1).

813 282099-001

Page 357 ► Top up coolant. ► Start the diesel engine. ► Run the diesel engine until the operating temperature is reached. ► Check if exhaust treatment system and coolant circuit are tight. ► Check coolant level as described in the relevant Operator's Manual.

486

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01 Engine 0165 Exhaust gas aftertreatment 1451-001 181706-001

Urea pump Applies to: Mercedes-Benz OM 470 LA Mercedes-Benz OM 471 LA

Work preparation Tool: ► Urea collecting tank ► Cooling water collecting tank ► Protective clothing Special tool

1

Special tool (I)

Pcs.

Hose clamp

2

00 0181 867 0

814 124108-001

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

487

01 Engine 0165 Exhaust gas aftertreatment 1451-001

Technical specifications

282043-001

488

815

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01 Engine 0165 Exhaust gas aftertreatment 1451-001

Value 1

1.5 kg

CCN

Remark / designation

M25-MB

Urea pump

(M047)

Position of pump: See chapter "Location of components" in the relevant Technical Systems documentation.

2

Coolant inlet connection (coolant flow line)

3

Coolant outlet connection (coolant return line)

4

Urea outlet connection

5

14 Nm

6

5 Nm

Urea inlet connection Screw plug

– Replace the screw plug for every assembly. – Replace O-ring in every installation process. 7

Pressure relief valve

– Remove any dirt from the drilled hole for the pressure relief valve. 8

Separation membrane

9

Frost-protection pressure piece

10

Frost-protection cover

11

4 Nm

Mounting bolts for the frost-protection cover

12

Sealing bead

13

Vent opening

14

80 Nm

Filter housing

15

Seal

16

Frost-protection membrane

17

Filter element

18

Seal

19

Guide Studs

20

Filter

Tightening torques not specified, see section on tightening torques

Removal ► Switch off the diesel engine and allow it to cool down. ► Disconnect the battery isolating switch of the machine. ► Open the cover on the coolant compensating reservoir to relieve the overpressure in the coolant circuit. See the Operator's Manual of the machine in question.

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489

01 Engine 0165 Exhaust gas aftertreatment 1451-001

Use special tool (I).

Page 487

► Use a special tool to clamp the coolant lines at the connectors (1) and (2). ► Detach the coolant lines at the connectors (1) and (2). Mark the coolant lines in relation to the connectors (1) and (2). Collect the coolant in a collection container. ► Detach the urea line from the connectors (3). Collect any escaping urea and dispose of it. ► Detach the urea line from the connectors (4). Collect any escaping urea and dispose of it.

816 282063-001

► Remove the urea pump. See the repair manual of the machine in question. Installation ► Install the urea pump. See the repair manual of the machine in question.

490

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01 Engine 0165 Exhaust gas aftertreatment 1451-001

► ► ► ►

Attach the urea line to the connectors (4). Attach the urea line to the connectors (3). Attach the coolant lines to the connectors (1) and (2). Remove special tool (I).

817 282063-001

Page 357 ► Top up coolant. ► Start the diesel engine. ► Run the diesel engine until the operating temperature is reached. ► Check if exhaust treatment system and coolant circuit are tight. ► Check coolant level as described in the relevant Operator's Manual.

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491

01 Engine 0165 Exhaust gas aftertreatment 1451-001

Removing the inlet nozzle filter Use special tool (I).

Page 487

► Use a special tool to clamp the urea lines at the connectors (1) and (2). ► Detach the urea line from the connectors (1). Collect any urea in a collection container and dispose of it. ► Detach the urea line from the connectors (2). Collect any urea in a collection container and dispose of it. ► Remove union (1). ► Remove the filter (3) from the urea inlet (4). Use an M5 screw to pull out the filter.

818 282067-001

Installing the inlet nozzle filter ► Install the filter (3) in the urea inlet (4). Carefully slide the filter into the inlet until the filter collar is flush with it. ► Install the connectors (1). Tightening torque: Page 488 Attach the urea line to the connectors (2). ► ► Attach the urea line to the connectors (1).

819 282067-001

492

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1451-001

Index A Accident prevention regulations..............................................................................................................................37 Actuators.................................................................................................................................................................57 Air compressor..............................................................................................................................................463, 469 Drive gearwheel Installation.......................................................................................................................................467, 473 Removal..........................................................................................................................................466, 472 Installation..............................................................................................................................................467, 473 Removal.................................................................................................................................................465, 471 Special tool............................................................................................................................................ 463, 469 Technical specifications.........................................................................................................................464, 470 Work preparation................................................................................................................................... 463, 469 Air intake tube......................................................................................................................................................... 51 Alternator.............................................................................................................................................................. 456 Installation......................................................................................................................................................458 Removal.........................................................................................................................................................458 Technical specifications.................................................................................................................................457 Alternator 12 V........................................................................................................................................................ 51 Avoiding Of damage....................................................................................................................................................... 43 Of environmental damage................................................................................................................................44 Of health damage............................................................................................................................................ 44 Of premature wear...........................................................................................................................................43

C Camshaft...............................................................................................................................................................189 Checking........................................................................................................................................................193 Installation......................................................................................................................................................191 Removal.........................................................................................................................................................190 Technical specifications.................................................................................................................................189 Camshaft housing................................................................................................................................................. 179 Installation......................................................................................................................................................185 Removal.........................................................................................................................................................181 Special tool.................................................................................................................................................... 179 Technical specifications.................................................................................................................................180 Charge air housing........................................................................................................................................433, 442 Installation..............................................................................................................................................438, 447 Removal.................................................................................................................................................435, 444 Technical specifications.........................................................................................................................433, 442 Charge air tube....................................................................................................................................................... 53 Common rail............................................................................................................................................................53 Compressor see Air compressor.................................................................................................................. 463, 469 Connecting rod......................................................................................................................................................132 Checking........................................................................................................................................................136 Installation......................................................................................................................................................137 Removal.........................................................................................................................................................136 Technical specifications.................................................................................................................................133 Connecting rod bearing pin Checking........................................................................................................................................................158 Control unit............................................................................................................................................................476 Installation instructions...................................................................................................................................477 Technical specifications.................................................................................................................................476 Coolant..................................................................................................................................................................356 Cleaning the coolant circuit............................................................................................................................357 Special tool............................................................................................................................................. 356 Draining..........................................................................................................................................................357

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493

1451-001

Filling up.........................................................................................................................................................357 Technical specifications.................................................................................................................................357 Coolant flow tube.......................................................................................................................................... 366, 379 Installation..............................................................................................................................................373, 387 Removal.................................................................................................................................................370, 383 Technical specifications.........................................................................................................................367, 380 Coolant pump........................................................................................................................................................359 Installation......................................................................................................................................................361 Removal.........................................................................................................................................................360 Technical specifications.................................................................................................................................360 Work preparation........................................................................................................................................... 359 Coolant thermostat..........................................................................................................................................53, 363 Installation......................................................................................................................................................365 Removal.........................................................................................................................................................364 Technical specifications.................................................................................................................................364 Crankcase venting.................................................................................................................................................. 52 Cranking the engine................................................................................................................................................60 Cranking the engine in built-in condition..........................................................................................................65 Cranking the engine in removed condition.......................................................................................................72 Setting the engine to ignition TDC................................................................................................................... 73 Removal....................................................................................................................................................74 Special tool...................................................................................................................................................... 60 Special tool for built-in engine..........................................................................................................................62 Crankshaft.............................................................................................................................................................145 Main bearing Installation...............................................................................................................................................158 Removal..................................................................................................................................................150 Special tool.................................................................................................................................................... 145 Technical specifications.................................................................................................................................147 Cylinder head................................................................................................................................................194, 211 Checking................................................................................................................................................209, 225 Clean......................................................................................................................................................208, 224 Installation..............................................................................................................................................203, 220 Removal.................................................................................................................................................199, 216 Special tool............................................................................................................................................ 194, 211 Technical specifications.........................................................................................................................196, 213 Cylinder head gasket.................................................................................................................................... 194, 211 Installation..............................................................................................................................................203, 220 Removal.................................................................................................................................................199, 216 Special tool............................................................................................................................................ 194, 211 Technical specifications.........................................................................................................................196, 213 Cylinder liner......................................................................................................................................................... 138 Checking........................................................................................................................................................141 Installation......................................................................................................................................................142 Measuring the cylinder bore...........................................................................................................................144 Measuring the excess dimension...................................................................................................................144 Removal.........................................................................................................................................................140 Special tool.................................................................................................................................................... 138 Technical specifications.................................................................................................................................139

D Diesel engine Information for working on the engine..............................................................................................................45 Differential pressure sensor.................................................................................................................................. 400 Technical specifications.................................................................................................................................400

494

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E Electric starting motor............................................................................................................................. 52, 452, 452 Installation......................................................................................................................................................454 Removal.........................................................................................................................................................453 Technical specifications.................................................................................................................................453 Electric systems standard....................................................................................................................................... 33 Engine components................................................................................................................................................ 51 Engine data.............................................................................................................................................................49 Engine description.................................................................................................................................................. 51 Exhaust gas recirculation actuator........................................................................................................................394 Installation......................................................................................................................................................397 Removal.........................................................................................................................................................396 Technical specifications.................................................................................................................................394 Exhaust gas recirculation line................................................................................................................................. 51 Exhaust gas return cooler....................................................................................................................... 51, 366, 379 Checking................................................................................................................................................377, 391 Installation..............................................................................................................................................373, 387 Removal.................................................................................................................................................370, 383 Special tool............................................................................................................................................ 366, 379 Technical specifications.........................................................................................................................367, 380 Exhaust gas return pipe................................................................................................................................ 366, 379 Installation..............................................................................................................................................373, 387 Removal.................................................................................................................................................370, 383 Technical specifications.........................................................................................................................367, 380 Exhaust gas treatment.......................................................................................................................................... 479 Technical specifications.................................................................................................................................481 Exhaust manifold.......................................................................................................................................... 401, 406 Installation..............................................................................................................................................404, 411 Removal.................................................................................................................................................403, 409 Technical specifications.........................................................................................................................402, 407 Work preparation................................................................................................................................... 401, 406 Exhaust turbo charger.............................................................................................................................52, 414, 423 Installation..............................................................................................................................................420, 429 Removal.................................................................................................................................................417, 426 Technical specifications.........................................................................................................................415, 424 Work preparation........................................................................................................................... 211, 414, 423

F First aid measures.................................................................................................................................................. 48 Flange bearing journal Checking........................................................................................................................................................159 Flywheel................................................................................................................................................................165 Checking........................................................................................................................................................167 Installation......................................................................................................................................................168 Removal.........................................................................................................................................................166 Special tool.................................................................................................................................................... 165 Technical specifications.................................................................................................................................166 Fuel controller valve......................................................................................................................................315, 319 Installation..............................................................................................................................................317, 321 Removal.................................................................................................................................................316, 320 Technical specifications.........................................................................................................................316, 320 Work preparation................................................................................................................................... 315, 319 Fuel filter................................................................................................................................................................. 53 Fuel filter module.................................................................................................................................................. 323 Installation......................................................................................................................................................330 Removal.........................................................................................................................................................328 Special tool.................................................................................................................................................... 323 Technical specifications.................................................................................................................................325

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495

1451-001

Work preparation........................................................................................................................................... 323 Fuel high-pressure pump................................................................................................................................ 53, 299 2-step valve....................................................................................................................................................307 Installation instructions........................................................................................................................... 308 Technical specifications..........................................................................................................................307 Drive gearwheel Installation...............................................................................................................................................303 Removal..................................................................................................................................................302 Installation......................................................................................................................................................304 Removal.........................................................................................................................................................301 Special tool.................................................................................................................................................... 299 Technical specifications.................................................................................................................................300 Work preparation........................................................................................................................................... 299 Fuel pump............................................................................................................................................................. 309 Installation......................................................................................................................................................311 Pressure relief valve...................................................................................................................................... 313 Installation instructions........................................................................................................................... 314 Technical specifications..........................................................................................................................313 Removal.........................................................................................................................................................310 Special tool.................................................................................................................................................... 309 Technical specifications.................................................................................................................................310 Work preparation........................................................................................................................................... 309 Fuel sediment filter..................................................................................................................................................53

G Gear drive............................................................................................................................................................. 251 Adjusting........................................................................................................................................................ 264 Checking........................................................................................................................................................262 Installation......................................................................................................................................................259 Removal.........................................................................................................................................................257 Special tool.................................................................................................................................................... 251 Technical specifications.................................................................................................................................254

H Handling the manual................................................................................................................................................. 4 Abbreviations..................................................................................................................................................... 6 Directions...........................................................................................................................................................5 Search and find..................................................................................................................................................5 Technical terms..................................................................................................................................................7 Hazard signs Warnings..........................................................................................................................................................37 High-pressure lines OM 470 LA.....................................................................................................................................................266 Installation...............................................................................................................................................270 Removal..................................................................................................................................................268 Special tool............................................................................................................................................. 266 Technical specifications..........................................................................................................................267 OM 471 LA.....................................................................................................................................................274 Installation...............................................................................................................................................278 Removal..................................................................................................................................................276 Special tool............................................................................................................................................. 274 Technical specifications..........................................................................................................................275 Housing cover......................................................................................................................................................... 93 Installation........................................................................................................................................................96 Removal...........................................................................................................................................................94 Special tool...................................................................................................................................................... 93 Technical specifications...................................................................................................................................94 Hydraulic system standard......................................................................................................................................34

496

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I Ignition order........................................................................................................................................................... 59 Information for working on the diesel engine.......................................................................................................... 45 Injectors................................................................................................................................................................ 285 Installation......................................................................................................................................................290 Removal.........................................................................................................................................................287 Special tool.................................................................................................................................................... 285 Technical specifications.................................................................................................................................286 Work preparation........................................................................................................................................... 285 Inlet rocker arm mechanism..................................................................................................................................227 Assembly....................................................................................................................................................... 231 Disassembly...................................................................................................................................................230 Installation......................................................................................................................................................231 Removal.........................................................................................................................................................229 Technical specifications.................................................................................................................................228

L Liability limitation.....................................................................................................................................................44 Lifting eyes........................................................................................................................................................76, 77 Lifting eyes.................................................................................................................................................76, 77 Technical specifications.............................................................................................................................76, 77 Lubricating oil system........................................................................................................................................... 334 Pre-filling........................................................................................................................................................336 Special tool.................................................................................................................................................... 334

O Oil coolant module................................................................................................................................................ 340 Installation......................................................................................................................................................344 Removal.........................................................................................................................................................343 Technical specifications.................................................................................................................................341 Work preparation........................................................................................................................................... 340 Oil cooler...............................................................................................................................................................347 Installation instructions...................................................................................................................................347 Technical specifications.................................................................................................................................347 Oil filter....................................................................................................................................................................53 Oil pan...............................................................................................................................................................53, 79 Installation........................................................................................................................................................82 Removal...........................................................................................................................................................80 Special tool...................................................................................................................................................... 79 Technical specifications...................................................................................................................................80 Oil pump................................................................................................................................................................349 Assembly....................................................................................................................................................... 351 Disassembly...................................................................................................................................................350 Installation......................................................................................................................................................351 Removal.........................................................................................................................................................350 Technical specifications.................................................................................................................................349 Oil separator................................................................................................................................................. 103, 112 Assembly............................................................................................................................................... 108, 116 Disassembly...........................................................................................................................................106, 114 Removal.................................................................................................................................................104, 113 Technical specifications.........................................................................................................................103, 112 Oil spray nozzle.................................................................................................................................................... 338 Installation instructions...................................................................................................................................338 Technical specifications.................................................................................................................................338 Oil thermostat........................................................................................................................................................352 Installation......................................................................................................................................................354 Removal.........................................................................................................................................................354 Special tool.................................................................................................................................................... 352

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1451-001

Technical specifications.................................................................................................................................352 Oscillation damper................................................................................................................................................ 161 Installation......................................................................................................................................................163 Removal.........................................................................................................................................................162 Special tool.................................................................................................................................................... 161 Technical specifications.................................................................................................................................162 Outlet rocker arm mechanism...............................................................................................................................233 Assembly....................................................................................................................................................... 237 Disassembly...................................................................................................................................................236 Installation......................................................................................................................................................238 Removal.........................................................................................................................................................235 Special tool.................................................................................................................................................... 233 Technical specifications.................................................................................................................................234

P Piston.................................................................................................................................................................... 120 Assembly....................................................................................................................................................... 127 Checking........................................................................................................................................................126 Disassembly...................................................................................................................................................125 Installation......................................................................................................................................................128 Measuring the excess dimension...................................................................................................................130 Piston rings Checking.................................................................................................................................................126 Installation...............................................................................................................................................127 Removal..................................................................................................................................................125 Removal.........................................................................................................................................................124 Special tool.................................................................................................................................................... 120 Technical specifications.................................................................................................................................122 Pressure relief valve Rail.................................................................................................................................................................282 Installation...............................................................................................................................................284 Removal..................................................................................................................................................283 Technical specifications..........................................................................................................................283 Protective sleeve...................................................................................................................................................295 Installation......................................................................................................................................................297 Removal.........................................................................................................................................................296 Special tool.................................................................................................................................................... 295 Technical specifications.................................................................................................................................296

R Rail OM 470 LA.....................................................................................................................................................266 Installation...............................................................................................................................................270 Removal..................................................................................................................................................268 Special tool............................................................................................................................................. 266 Technical specifications..........................................................................................................................267 OM 471 LA.....................................................................................................................................................274 Installation...............................................................................................................................................278 Removal..................................................................................................................................................276 Special tool............................................................................................................................................. 274 Technical specifications..........................................................................................................................275 Reinforcing frame..................................................................................................................................................174 Installation......................................................................................................................................................177 Removal ........................................................................................................................................................175 Technical specifications.................................................................................................................................175 Repair information Adapter sleeve bearings.................................................................................................................................. 13 Chuck bushing................................................................................................................................................. 14

498

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1451-001

Circlips............................................................................................................................................................. 16 Ferrule fittings.................................................................................................................................................. 17 Gib head key joints.......................................................................................................................................... 11 Hydraulic hoses............................................................................................................................................... 18 Liquid locking compound................................................................................................................................... 9 Lock collar bearing...........................................................................................................................................12 Sealing cone fittings.........................................................................................................................................18 Self-locking bolts................................................................................................................................................8 Spare parts...................................................................................................................................................... 20 Specifications, dimensions and weights............................................................................................................ 8 Steel roller chains Chain connector........................................................................................................................................10 Tensioning.................................................................................................................................................. 9 Taper ring fasteners.........................................................................................................................................10 Technically correct repairs.................................................................................................................................8 Resonance vessel.........................................................................................................................................460, 461 Installation instructions...................................................................................................................................462 Technical specifications.........................................................................................................................460, 461 Rocker lever..................................................................................................................................................227, 233

S Safety precautions.................................................................................................................................................. 37 Safety regulations................................................................................................................................................... 37 Seal Crankshaft front............................................................................................................................................... 85 Installation.................................................................................................................................................87 Removal....................................................................................................................................................86 Special tool............................................................................................................................................... 85 Technical specifications............................................................................................................................86 Crankshaft rear................................................................................................................................................ 89 Installation.................................................................................................................................................91 Removal....................................................................................................................................................90 Special tool............................................................................................................................................... 89 Technical specifications............................................................................................................................90 Sensors...................................................................................................................................................................54 Signal word Warnings..........................................................................................................................................................37 Special tool Air compressor.......................................................................................................................................463, 469 Camshaft housing..........................................................................................................................................179 Cleaning the coolant circuit............................................................................................................................356 Crankshaft......................................................................................................................................................145 Cylinder head.........................................................................................................................................194, 211 Cylinder head gasket............................................................................................................................. 194, 211 Cylinder liner..................................................................................................................................................138 Exhaust gas return cooler......................................................................................................................366, 379 Flywheel.........................................................................................................................................................165 Fuel filter module........................................................................................................................................... 323 Fuel high-pressure pump...............................................................................................................................299 Fuel pump......................................................................................................................................................309 Gear drive...................................................................................................................................................... 251 Housing cover..................................................................................................................................................93 Injectors......................................................................................................................................................... 285 Lubricating oil system.................................................................................................................................... 334 Oil pan..............................................................................................................................................................79 Oil thermostat.................................................................................................................................................352 OM 470 LA High-pressure lines.................................................................................................................................266 Rail..........................................................................................................................................................266

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499

1451-001

OM 471 LA High-pressure lines.................................................................................................................................274 Rail..........................................................................................................................................................274 Oscillation damper......................................................................................................................................... 161 Outlet rocker arm mechanism........................................................................................................................233 Piston.............................................................................................................................................................120 Protective sleeve............................................................................................................................................295 Seal Crankshaft front........................................................................................................................................ 85 Crankshaft rear......................................................................................................................................... 89 Urea heater valve...........................................................................................................................................484 Urea pump..................................................................................................................................................... 487 Urea solution..................................................................................................................................................479 Valve springs................................................................................................................................................. 244 Valve stem seals............................................................................................................................................244 Steel roller chains..................................................................................................................................................... 9

T Thermostat See Coolant thermostat................................................................................................................................. 363 Tightening torques Air conditioner screw fittings............................................................................................................................ 23 Brake line screw fittings................................................................................................................................... 32 Direction-adjustable SDE hydraulic male connectors...................................................................................... 30 Hollow screws..................................................................................................................................................29 Hydraulic swivel fittings....................................................................................................................................28 Hydraulic system fittings With ferrule............................................................................................................................................... 24 With sealing cone..................................................................................................................................... 23 Metric fine thread............................................................................................................................................. 22 Metric standard thread.....................................................................................................................................21 SDS hydraulic male connectors.......................................................................................................................25 Worm drive hose clamps................................................................................................................................. 32 spring-loaded............................................................................................................................................ 32 Timing housing........................................................................................................................................................97 Installation......................................................................................................................................................101 Removal...........................................................................................................................................................99 Technical specifications...................................................................................................................................98 Treating sealing faces.............................................................................................................................................20 Turbo charger See Exhaust turbo charger.................................................................................................................... 414, 423 Turbo compound unit.............................................................................................................................................. 52 Type design............................................................................................................................................................ 49

U Urea heater valve..................................................................................................................................................484 Installation......................................................................................................................................................486 Removal.........................................................................................................................................................485 Special tool.................................................................................................................................................... 484 Technical specifications.................................................................................................................................485 Work preparation........................................................................................................................................... 484 Urea pump............................................................................................................................................................ 487 Inlet nozzle filter Installation...............................................................................................................................................492 Removal..................................................................................................................................................492 Installation......................................................................................................................................................490 Removal.........................................................................................................................................................489 Special tool.................................................................................................................................................... 487

500

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1451-001

Technical specifications.................................................................................................................................488 Work preparation........................................................................................................................................... 487 Urea solution Checking the density......................................................................................................................................483 Checking the purity........................................................................................................................................ 482 Special tool.................................................................................................................................................... 479 Work preparation........................................................................................................................................... 479

V Validity Of manual.......................................................................................................................................................... 4 Valve cover........................................................................................................................................................... 171 Installation......................................................................................................................................................172 Removal.........................................................................................................................................................172 Technical specifications.................................................................................................................................171 Valve springs........................................................................................................................................................ 244 Installation......................................................................................................................................................248 Removal.........................................................................................................................................................245 Special tool.................................................................................................................................................... 244 Technical specifications.................................................................................................................................245 Valve stem seals...................................................................................................................................................244 Installation......................................................................................................................................................248 Removal.........................................................................................................................................................245 Special tool.................................................................................................................................................... 244 Technical specifications.................................................................................................................................245 Valves................................................................................................................................................................... 239 Adjusting the valve lash................................................................................................................................. 242 Checking........................................................................................................................................................241 Installation......................................................................................................................................................241 Removal.........................................................................................................................................................240 Special tool.................................................................................................................................................... 239 Technical specifications.................................................................................................................................240

W Warnings Hazard signs....................................................................................................................................................37 Signal word...................................................................................................................................................... 37 Water pump See Coolant pump......................................................................................................................................... 359 Working on the diesel engine..................................................................................................................................45

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At CLAAS KGaA mbH we are constantly improving our products to reflect the latest technological developments. For this reason, we reserve the right to make changes to diagrams and descriptions in this documentation without incurring any obligation to alter any machines previously delivered. Specifications, dimensions and weights are nonbinding. Responsibility for errors or omissions not accepted. Reproduction or translation of this publication, in whole or in part, is not permitted without the written consent of CLAAS KGaA mbH. All rights under the provision of the Copyright Act are reserved. CLAAS KGaA mbH 33416 HARSEWINKEL Germany

Our contribution to the environment: CLAAS have printed this manual on 100 % chlorine free paper.

CLAAS KGaA mbH Postfach 1163 33416 Harsewinkel Tel. +49 (0)5247 12-0 www.claas.com

00 0300 667 0 RHB Dieselmotor OM470/471LA EN - 05/2015 Printed in Germany