46 0 40MB
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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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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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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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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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.
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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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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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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.
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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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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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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
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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.
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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
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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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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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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.
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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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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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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.
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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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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
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01 Engine 0102 Complete component 1451-001
Actuators
267592-001
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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
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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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63
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
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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.
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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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
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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
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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
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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
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► 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
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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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
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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
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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
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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.
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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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
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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
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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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
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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
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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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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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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.
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
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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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
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 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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
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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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01 Engine 0125 Injection - / Fuel system 1451-001
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
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► 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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305
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
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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
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015
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
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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
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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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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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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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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