NR OLLL -ONE 614 -O DATA OMS TA pea assis ® nen ms ee mint Esk Mercedes eneThank you for choosing this Moreedes-Bonz engine. Please get to know your new Mercedes Benz ergine frst. Make sura you read the Operating Instructions in particular before using the engine for the first time. In this way you can ensure successful and safe use. At the semetime you will avoid endan- This symbel means tht you have to do these Operating Instructions: Environmental note QP something This asterisk indicates special > A number of these synbols one efter ‘equipment. Since net all modals tho othar indicates a sequence of 2c- ’An environmental rote gives youtios on the protection ofthe envirorment. have the sare stands equip- tions ment, the layout of your enginemay > , : of youre page Tis eymbolindcsts the poge iettoncetanceitenend JH ; Gh wfich you el find Rathore ilustrations This oto draws yourattontonto poss tomate on de cubes ble harerdsto your engine >> Thi continuation symbol ind. Warning aA o cates an internupted sequence SS of actions thatwillbecortinued ‘Avarningeravsyeuratirton topossble I) Thstipcontsirsathice or further infor cheat pose tea ofouddetand nhytoyumafend fl rae vonine mevsecaa omen > This srmbolintne dossaryot technical terms means that the ‘term following the arrowis also explained, You should therefore aways read and ob- serveal wamingnoticesY Protection of the environment Emironmentalnote g DaimlerChrysler'sdeciared policy sone of integrated envronmertal pratection. This policy starts at the root causes and encom- ppasies in its menegementdecisions al the consequences forthee nvrmment which ‘could arise trom production processes or the products themsahes. The objectives are forthe natural resources whichfom thebasisof oureristenceon his planet to be used sparingly ang in a manner whichtakes the requiramentscf sothnature ‘and humanity intoaccount. Oneratethe engine in an environmentally ‘responsible manner, ang you wil Nelp to protestthe envirenment. ‘Fuel consumption and engine wear depend onthe operating conditions. Therefore you shoul + not warm uptne engine atigie sutton ort ne engine aurng wattng pe- fiods imposed by cperstions © moniter fuel consumption © carrycut the specified maintenance work regulary teres ati)rece esta) Operating safety V Operating safety ‘The operating safety of an engine firstly de- pends on its proper installation into the complete system (e.g.vehide, machine, etc). Seccndly, as operator or service per- sonnel, you also have a direct influence on the safe operation of the engine. Some ofthe requirements for oparating ‘the engine safely can be achieved by ad- hetingto the specified maintenance inter- vals and ensuring thatthe recuired rraintenance work is carriad out correctly Howevor, safe engine operation also de- pends on correct servicing, such as chack- ing the engine oil level at regular intervals. Rink of acident A Improper operation of he angina, eg a ceecingt he permitted maximum engine speed in avertun mode or operating tie en- ginewith too ttle ol, can cause engine damage. Engine damage can lead to an ir- crease m ine nse of acaiert. Therefore, coserve the notes on operating tne engine in tase Operating Instructions. Rink of accident A Faulty maintenance work or flue to cary ‘out maintenarc work ¢g.not changing the olriter ornotopsering tne cowect mainte nance interval, ean ceuse engine damage. Engine damage can lead fo an increase in te nse of accloent. Therefore, observe the notes on engine ‘maintenance in these Operating Insruc- tions.Risk of accident A Work incorectly carried out on electronic componentsandits softwar could impair thefunctioning of hess components. Since: the electron systems are networked, this ‘might also afect sjstems that nave not been modi. ‘Always have work on or modifications to elect onic components carried out ata qual led spesiaist workshop whick nas the nec ‘essary specialist knowledge and teois to carry out the workrequired Mercedea2enz recommends thetyouuses Mercedessenz Service Cenie forthis pur pose, Correctuse ‘The engine is only designed for installation in accordance with the specifications de- termined in the contract. ‘The manufecturer of the end preduct is personally responsible for the complete ‘system of the end product, and in particu- lar for tho correct installation and compat- ibility of this engine with the complete system, The angina must not be modifi. DaimlerChrysler accepts no responsibility for damage caused as the result of modifi cations. Correct use of the engine includes adher- ing to these Operating Instructons, adher- ing to the m antenance intervasand porforming maintonance work correct ‘accordance with these Operating Instruc- ‘ions. Wire asia10 NET Ce ‘OM 904 LA/OM 924 LA ‘OM 906 LA/OM 926 LA Location of sensorsNET OM 904LA/OM 924 LA V OM 904 LA/OM 924 LA@ Fan @ Poly-V-bett tensioning pulley @ Coolant pump @ Charge pressure pips (with lame-start system’) from intercooler @ Charge pressure pipe to intercooler © Crankcase ventilation system @ Heating delivery line* coolant ine © Oilfillerneck © Fuslfiter © Fuel prefiter ick @ Air compressor (with power-steating pump*) @ Engine control unit Ata glance ‘OM 904 LA/OM 924 LANeva ‘OM 904.LA/OM 924 LA@ Flywheel housing @ Charge sirhousing @ Ollfillerneck @ Charge pressure pipe tointercooler @ Cherge pressure pipe (with leme-start system] For intercooler @ Exhaust manifold @ Oiler @ Exhaust gas turbocharger @ Attemator @ Starter motor ee OM 904 LA/OM 924 LAey OM 906 LA/OM 926 LA YOM 906 LA/OM 926 LA cmcenns@ Fan © Poly-V-bel tnsicning pulley @ Coolant pump @ Heating forward line* coolant ine @ Charge pressure pipe Fem intercooler @ Oilfiter @© Charge pressure pivet @ Oililerneck @ Charge-zir housing. @ Gilinder heed cover @ Fue for @ Fuel preter @ Enginecontiolunit @ Aircompressor* @ Dipstick © Power-steering pump role NEE OM 906 LA/OM 926 LAPercy (OM 906 LA/OM 926 LA onion@ Starter motor © Fyuheet housing @ Exhaust gas turbocharger © Extoust ra © Charge-sir housing @ Ojlinder head cover @ Oiiter neck @ Charge pressure pipe tointorcocler @ Charge pressure pipe from intercooler @ Grankcase ventilation system @ Atemator Nes OM 906 LA/OM 926 LAPe vcey Location of sensors Y Location of sensors OM904LA /OM 924 LA (comparabk to OM 906 LA/OM 926 LA) 20@ Oil pressure sensor © Coolant temperature sensor @ Fueltemperature sensor © TC sensor (on the camshatt sprocket) © Grankshatt position sensor (on the fly- whee!) © Combined charge-air /chargezir pres- ‘sure sensor Location of sensorsEngine plate 'Y Engine plate Location ‘The engine plates located on the right hhand side of the engine at the rear under neath the exhaust manifold (arrow). Location of engine plateDES General Transport and installationDC iLrd General YY General Type designation OM 9x LA om oxK L Oil engine (diesel en- ine) type Intercooler A Exhaust gzs turbo- charger Engine data card ‘The engine data card (DIN Ad sheet) forms an integral part of the documents belong- ing to the engine and should always bo kept with the Maintenance Booklet. It con- tains details about the engine's construc tion, including special equipment features. The engine data card must be produced for the procurement of genuine parts. pvt Engine datacard oe The engine data card desoribes the ‘scope of delivery from the factory from whieh the engine was shipped; later changes to the scope of delivery are not included on the data card. ‘Always keep the engine data cerd with the Maintenance Booklet.Description of the engine The OM 904 LA/OM 924 LA (4oplinder) and OM 906 LA /OM 926 LA (cylinder) engnasare water-cooled four-stroke die £0! injection engines. The oylindersare arranged inline and have ‘separate fuebinjection pumps (unit ‘pump with a short high-preseure fuel- injection line to the mult-hole nozzle locat- ed centrally in elation to the combustion chamber. The unit pumps are mounted dt rectly on the crankcase, Theyare driven by the camshatt roller tappets. Each oyiinder has twoinlet valves and oneexhaust valve. ‘The engines are equippad with an exaust ‘gas turbocharger (sometimes with charge- pressure limiting) and intercooler as stand: ard. The engine can be optionally equipped with an engine brake (thrattle and eon- stantly-opan throttle valves). ‘Thanks toits fully electronic contral sys- tem for controlling the injection quantity and injection timing via solanoid valvas, thisis ¢ particularly lon-emission engine. The control syatem comprises an engine resident control module, an engine contral (MR) and an application-elated vehicle Contvol unit (FR) or an adaptation module (ADM), all interconnected via the Control le Area Network (GAN). Cees iCe Crs General Flame-start system’ The tleme-start system is @ cold-start aid for starting at low outside temperatures. It reduces the white smoke omission aftor the engine is started. In addition, itredu- es the strain on the starter motor and bat tories by shortening the startup time. Fuel can be ignited by @ flame glow plug in- tegrated in the cha rge-ir pipe fom the in- tercooler. The fuel is supplied to the flame «glow plug via ¢ solenoid valve witha dosing, jet 26 Flamestart system ‘The flame-start systems primed aftera preglow time (maximum 20 seconds) which is dependent an the outside temper- ‘lure. After this time tho flame-start eys- ‘tem indicator lamp goes out. ‘Once the engine hasstarted, the flame start gystem is sunpliedwith uel bythe en- ‘ine’ fuel delivery pump. Flame-start system indicator lamp The tlame-start system is only operation if the engine is started within 30 seconds of the flame-start system indicatorlamp ‘going out.a IFtheflame-start system indicator lamp does not go cut after more than 20 sec- ‘onds there is a malfunction in the flame-stant system. ‘See also the "Diesel fuels" section [b seepage 60) and "Coolant" section [P seepage 63) for operation of the ox ine at low outside temperatures. Grid heater* ‘The grid heater is a cold-start aid for start- ing at low outside temperatures. The ‘charge-airis preheated by ateater strip im tegyated in the cherge-air pine from thein- tercooler. In addition, t reduces the strain ‘on tho starter motor and battary by short ‘ening the startup time. ‘The white smoke limit is reduced by a run- ‘on heating time of ug to 180 seeondsafter starting the engine. Dee tL eonCeCe General Exhaust brake /constantlyopen throttle valve" ‘To increase braking power, the engine can be equipped with an engine brake valveon the exhaust gas turbocharger in conjunc tion with constan ty-open throtti valves ‘on the cylinders. While the exraust ess back pressure from ‘the engine brake valve is used to increase the braking power, the constantly-open throttle valves cause a pressure reduction in the working cycle [3rd cycle), while com pression (2nd cycle) ispracticaly unaffect es. The constanti-open thrattle valves are small valves inthe cylinder head and locat- ed on the side opposite the exhaust vai. When open, they form a connection from. the combustion chamber to the exhaust port. 28 21 onto nce CConstantly-open throttle valves on a 4-cylin- der engine When the engine brake™ is applied, the constantly-open throttle valves are png matically pressurised on the 4-cylinder en- gine and hydraulically pressurised on the Cylinder engine. This opens the valves. Atthe same time, the engine brake valve oon the exheust gas turbocharger is closed, ‘The constantly-open throttle valves are not controlled at lower engine soeeds (900/ 1,300 rpm) or at temperatures below 40 °C. When tho power units boing usad, these limitations must be taken into ac- count under braking conditions.The engine brake" is controlled by the rive control unit (> page $1) or the ADM. The engine brake" is always disabled be- low 900 rpm to prevent the engine from. stalling. The engine brake” is also auto~ ‘matically deac tivated if the position sensor is triggered (eg. ifthe acceler ator padalis depressed). oe lh emergency running mode (constant ‘engine spend), the engine brake* can ‘only be activated in overrun mode at ahigher engine soeed. The engine brake is automatically disabled again ‘once the constant engine sneed has been reached. Dea Telligent® engine system The ongine hs 2 fully eleetionie control ‘system, which, in addition to the engine and related sensors, also comprises: * anengine contrat unit. and © a drive control unit and/or other vehi le-apecific control unitsor ADM. Both are interconnected vie @ GAN (Con- troller AreaNetwork| ine which exchanges allthe necessary data / information. The engine control monitors itself as well 2s the engine. A safety and emergency run- ing programis selected automatically de- pending on the malfunctions /failures occurring (> page 39),CE CLrd General Engine control unit (engineesident) ‘The engine contro! unitis located on the left-hand side of the engine. ‘coming from the drive control unit or the ADM, such as the position of the setooint value sensor (accelerator pedal), the en- gine brake” or engine start/stoo, ote. 30 This deta is evaluated along with data fram the sensors on the engine, such as those for: © charge-air pressure and temperature © coolant temperature © fuel temperature © il pressure These parameters are compared with the characteristic maos and graphs stored in the engine control unit, Start, durationand amount of injection are ccaloulated from the graphs and the unit pumps are controlled accordingly via the solencid valves. oe Al the information on the control unit type plate is required to obtain ae placement engine control unit The type plate is lacated on the engine ‘contol wiitin the upper right-handcor- ner. Calibration Nr \Certficaton Ne Control unit type plate @ Date record @ Cartfication no. @ Engine plate © Equioment code DaimierChy Buck cont Unt ler zosFR (drive control) unit or ADM (appliance-resident) ‘The engine can be adapted to meet the various application-specific requirements by means of the FR (drive control) unit or ‘adaptation module (ADM). Drive control unit The FR (drive control) unit or the ADM unit stores data for specific apa ications, such as idling speed, maximum working speed ‘and speed limitation. Pe eed The FR (drive control) unit and the ADM re- ceive data from the © operator (position of setpoint value sensor, engize start/ stop) © engine brake switor” ‘© othor systems (e.g. action control) © engine control unit e.g. oll pressure and coolant tamperature) From this data, the instructions for the MR. (ongine control) unit are computed and tranamitted to it via the CAN line. ‘Tho drive control unit and the ADM contrat various disolays, e. the electronigs warn- ing lamp, the engine brake" and the con- stantly-open throttle valvas™.Ce Riad Genoral Ifthe Telligent® engine system detects a fault, this is stored as.a fault code in the control units and can be read using the ap- propriate diagnostic equipment (STAR DIAGNOSIS or Minidiag 2). Inaddition, the alactronies warning lamp is switched on. oe ‘The DaimlerChnysler diagnostic testers can be connestad to the equipment- resident, 14-pin diagnosti« socket. Both the malfunction memory and the stored engine data can be read with this equipment. Diagnostic socket Organisational measures Risk of accident and injury ZK, Before operating the engine, please reed ee eee elem tere Sees eet rere instuctons othe vio or he machine the engine i sald in Saeetttee ateereeetinn gre ar coud jure youre ators ‘The Operating Instructions and Mairte- nance Booklet must be given to the per sonnel responsible for operating the engine or carrying out work on the enging, and should be keot in an easily accessible place where the engine isused. Personnel must be instructed in how to work on the engine using these Operating Instructions. In particular, the safety notes ‘must ba oxplained. This is esposaly im- portantfor personnel who onlywork onthe engine occasionally Inadditionto these Operating Instructions, the country-specific legal and all other binding reguletionsfor accident prevention and protection ofthe envionment must be observed.Y Transport and installation Transport Risk of accident and injury §— ZN ‘The engine can tear loose and cause injury topersons ty overtuing orfelling, ‘© onlylittene engine bythe appropriata iting poirtson the argine. (© Onlyuse transport equipment which ras ‘been approved for use by DaimlerChrysler. "© Only lift and transport the engine in its installationposition. Lifting point, flywheel end eee] Lifting point, timing endCe ers Transport and installation Installation Tneengineis only designed for install in accordance with the specifications de- termined in the contract. The manufacturer of the end product is personally responsible for he complate system of the end product, and in particu- lar for the correct installation and compat: ibilty of this engine with the complete system, Observe the "Correct use" [> paze 9) and "Conversion carts and modificationstothe These Operating Instructions contain in- stallation data in the "Tachnical data" sac- tion. Should you have any questions, please ‘contact a Mereades-Benz Service Cente. The engine is flled with engine oil at the factory.Safety preca Personnel qualifications ations to the engine running program Fede Bane partsSafety precautions Y Safety precautions Make sure that the following safety pre~ ‘cautions are obsened to prevent injury to persons 2s well 2s damage to the engine, ‘components and cable hamess. ‘Only start the engine with securely comected batteries. Do not disconnect the batteries with the engine running. ‘Only start the engine with the rota- tional speed sensor connected. Do not use & rapid charger to start the engine. ‘Only perform jump-starting with separate batteries. Pleaae note that the battery termi nals must be removed for rapid bat tory charging, Observe the rapid ‘charger operating instructions. Note that for electric welding work, ‘thebatteries must be disconnected ‘and both connector leads ("+* and "securely connected to each ‘other. ‘The control unit connectors must ‘only be removed or inserted when the electrical system has been switched off Incorrect polarity of the control unit supply voltage (2g. through incor rect battery polarity) can cause ir- reparable damage to the contral units. Tighten the connections to the fuel- injection system to the specified tightering torque. ‘The control units must be removed if temperatures over 80 °C (ag. the drying oven) are expected. Hu © Only use suitable test leads (e.g. DaimlerChrysler connection set) for measuring connectors. * Telephones and two-way radios whieh are not connected to an ex ternal aerial can cause malfunc- tions to the vehicle's electronics ‘and could therefore endanger the ‘engine's operating safety.V Personnel qualifications Risk of accident and injury ‘Maintonance and repair wor to the engine incorrectly performed cancause engine damage and may lead to personal injury 2s consequence. Maintenance end repair work on the engine may only be carried out by personnel who have undergone the appropriate trahing ‘Alwayshave work on ormedfications to tho engine carried out at a qualified specialist workshop which has the necessary spaciak Ist knowledge and too's to carry out the work required. NercedesBew recommends that youusea MarcedesBarz Service Cente for this pure pose. Personnel qualifications Engines may only be operated, maintzined and repaired by trained personnel instruct (ed and authorised by the operator. Responsibility for operation, maintenance ‘and repairs must be datermined by the op- erator. ‘The legal minimum age for carrying out the ‘work listed above must be observed.Conversion parts and modifications Y Conversion parts and modifications u isk of accident Ne tem and engine electrorics can affect the engine's performance and emis- sions characteristios. Compliance with Tanpeirg with egrewth be rare nto predic modest tea = serbotis caret operation ands, i actor sits ad legal erion- ae ay = mental protection canditions can then Avayshavewarkonor ostestonstote | no longer be euaantens, engine coved cut eta qualified sedlit sterahop which ras he necessary spac. isknonledg arcade to cary tha work required Mercado nz reconmonds that yous Nareedes-SeneSerses Cartas pir ose ‘The warranty does nat cover damage aris- ing from tampering with the engineSafety /emergency running programs Y Safety/ emergency running programs The engine is equipped with an electronic ‘control system which monitors both the engine and itself (sel-diagnostic system). ‘9 s00n as the electronic control eystem has detected and assessed a malfunction, cone of the following measuresis automati- cally implemented: ‘¢ When the engine isin operation, the electronic system warning lama lights up, indicating a malunction, ‘¢ The fault codes may be shown on adis- ley which is part of the Tellgent® engine system (vehicle diagnostic sys tem). © The engine switchesto the appropriate ‘oack-up function for continued (but re- stricted) operation (e.g. constant emer- gency running speed). A Risk of accklent Incorrectly performed mainienarce and re- pair work on tre engine can impair oth its ‘correct operation end safety. leacing to ac- ‘dents and personal injury #8 @ conse ‘quence. ‘Always have work on or modifications tothe ‘engine cared out t a qualified specialist ‘workshop which has the necessary spocial- ist knowedge and tolsto cary outthe worcrequied Mercedos-Benz recommends that you uso a Mercedes Benz Service Centre for this pur- pose. 8 ‘The fault codes can be read from the DaimlerChrysler diagnostic testers (STAR DIAGNOSIS or Minidag 2 test er], connected to the 14-pin diagnostic ‘socket (equioment-resident). WZ ectronic system warning lamp 4Genuine Mercedes-Benz parts Y Genuine Mercedes-Benz parts Make sure that the replacernant parts are suitable for your vehicle. Parts which lead to a vehicle modification, eg. ‘© 2 changein the tyoe of vehicle ap- proved in the General Operating Permit © which could pose 2 threat to road us ets, oF ‘© cause 2 deterioration in exhaust gas, emission levels or noise levels, willresult inthe invalidation of the General Operating Permit (in many counties). The use of non-aperoved parts can imosir safe oa Environmental note g To combine cost-effective repairs with recy- cling, Mercedes Berz also offers recondi- tioned engines end parts. These are of the ‘same qualiy ad have the same warranty as now parts Additionalinformation about recommend @d conversion parts and accessorias and permissible technical modifications is available from ay Mercades-Benz Service Centre. Always quote the eng ne plate and type designation when ordering genuine ‘arts. You vill find the numbers on the en- gine (& page 22) ard on the engine data card (D pagez4).Cet) Commissioning Monitoring engine operation ‘Stopping the engine inter operation ' iipobetis teatmient Service products¥ Commissioning Preparation When it kaves the factory, the engine is filed with engine cilin accordance with ‘Sheet 228.6 of the Mercedes Bene Service Product Guidelines. ‘These high-quality engine oils assist the running:in process, enabling the first oil change to take place at the usual cil ‘change intervals for nornaloperation. This ‘liminates the naed for special initial oper- ation oils and the oil change otherwise re- quired ‘The extended maintenance intervals can be observed if engine oils in accordance with Sheet 228.5 of the Mercedes-Bere ‘Specifications for Sarvice Products are used. Topping up with coolant + * Coolant composition & see page 63) ‘© Filing the cooling system (D see page 94}, Oil filler neck D Check the oil level and add engine oilif necessary via the filler neck (arto) up to the maximum mark on the dipstick (> seepage71}.Crea ‘Commissioning Refueling Checking the batteties Use sumer orwinter fel doencing on yy eee A the season. See also" Diese! fuels" is urning, a (© page 60) (Gass cecapingtrom batavas can owloce ‘The acid contained in batteries burns skin and injure people. a ‘and eyes on contact. ‘Therefore, do not allow fre, naked flames, Mako sure that utmost cleenliness is Do nat allow acd to comeintocontact_ stoking or the croationof sparks nthe v- observed while refuelling and that no with your skin, eyes or clothing. ccinity of batteries. water is allowed to enter the tank © Wea sutale protedive ching, as battery acid can burn through normal Only use batteries which are completely Bleeding the fuel system clotting. inaction protective gloves _filedand have bean porfacly maintained. ‘The ful eytam ised when the enghe i ard safety goggles shouldbe worm. Grease the batty terminals with cod- started after refuelling i the fuel system * ‘Rinse acidsplastesofTimmediatdy wth proof grease (terminal grease). was previously allowed to run dry. Contine cclaan water ard consult a doctor if nec- ° essary. ‘The cable cross-sections aro depond- ‘ent on the distance between the bat- tery ard the starter motor. To ensure that the fuel system can be bled, the battery must have enough charge when the engine is started.Pett) ‘Commissioning Starting the engine for the fist time Canty out the work fisted under "Prepara- tion for commissioning" (> page 42) be- fore operating the engine forthe firs time. > Switch on tho oporating current. Starttheengine with the setpointvalue sensor at idling position (c.g. accolera- tor peda) forinstence by operating the starter switch on the equipment or Start button @ on theengine, (> see page 47). @ Stop button @ Start button e ‘Asa safety feature, the Teligent® ex: ne system isequipped witha function ‘that only allows the engine to be start ‘ed with the tra nsmission in neutral. Risk of burns A The engine becomes very hot wile itis ue ring and remains o for soma tine ater it hha stopoed. wll cause bums you touch ie Before starting ary work on the engine, a lowallengina patsto cool doun or ose wear Suitable goves and items of clothing to protec yourself against hot engine compo- renee.A Risk of injury A Risk of scalding ec Commissioning A Risk of poisoning “Thora is @ darger of limbs being caught, er- ‘repped, crushed or tom off by rotating en- gine parts. Therefore youshould: “© Koop a safo distance between yoursalt ‘and rotating engina parts, including when the engine i being starzac, ‘© Wai until allengine parts have come 10 standstill before caryingout ary work onthe engina. © War work clothing whichis fastened ‘and dloso-Atting. Wear a hair nat if noc ‘essary. Rarnove jewallary such a watchs anc nacklaces “Tho coalingsystem ispressirised. Hot cool- ‘antcan spray out when the cooiing system is opened and scald your skin and ees ‘© Onlyepanthe cooling system at coolant ‘temperatures below 90 °c. “© Unscrow the sealing cop slowly and ro- lease any excass pressure completely before opaning tha cap ful. "© Wear suitable protoctive glaves protac- tive clothing and safety goggles when hrancling cooler. ‘herois arisk f poisoning codants swat loned, ‘© Nevarswallow coolant. ‘© Never put coolant into cartzinar nor rally used for beverages. ‘© Store coolant aut ofthe reach of chil- dren, D To check the coolant level: Leave the engine running at moderate speeds for aoproximately 5 minutes, > Ifthe coolant temparature is below 50 °C, check the coolant evel agan and add coolant if necessary, csTeta Commissioning oe > Check the engine cil level approximate- Iraheating systemis connected to tne —_-('5 minutes alter stopping the engine cooling system, all heating system anda oilup tothe maximum mark an vahes must be opened while the cook _the dipstick it necessary. ing system is being topped up. D Cheek for fim seating of mountings on Otherwise there might be too little the engine coolant in the cooling system after fileB Chock the seeuring bolts on the ex- ing. haust manifold, engine mourtings, coolant purnp, starter motor and cic ‘Only close the heating system vales once compressor for firm seating the engine has neon running for a briof pe- 5_ ‘ioc. Top up with coolant if necessary. > Check the engine for leaks. > Check the hose fittings hose clamps 2nd pipe connaction son the engine as ‘wall 28 the oil feed and return lines on the exra ust gas turbocharger forleaks and firm seating, and tighten if neces- sary. rrnot properly secured, a vahicle might acc ‘dontally be satin motion when tha engine is started, knocking people down or trapping them. Before starting the engine: ‘© Pravent the vehicle fromrolling away by apalyingthe parking brakeand,fnaces- ‘sary, by placing chacks uncer the wheols, ‘© Shift she transmission into naveral. oe Starting the engine for the first time (P soepage sa), Canty out special measures before starting the engine when ithes been stopped for a long period, see the ‘Cleaning/ protective treatment! sec- tion (D> page 5s). e Atoutside temperatures bebw ~30 °C ‘we recommend preheating the coolant (eg, using an electic preheating de- vice) Starting procedure In the case of vehicle engines, secure the vehicle to pravent it from roliing away acc dentally: > Apply the parking brake. > Shift the transmission into neutral, D> Place wheal choeks in front of orbe- hind the wheels. D> Insert the key into the ignition and turn itto the driving position. The fallowing indicator and warning lamps light up: @ Gherge currentindicator lamp @Electronic system werning amp @Fleme-stan sy stem indicator lamp or ‘efi heater ‘Start the engine within 30 saconds of the flame-st Crt) Commissioning indicator lamp going out. >>Ota ‘Commissioning ‘StartStop buttons @ Stopbutton @ Start button > using the starter switch on the equip- ment > using Start button @ on the engine. > Monitor the ol pressure gauge immed ately after starting the engi a Koap the engine running 2t idling speed until an oil pressure reading is dis- layed. If no oil pressure is displayed after approximately 10 seconds, switch off the engine. Determine the cause; see the "Oil pressure" section (> pages). e lfnecessay, break off the starting procedure after 3 maximum of 20 seo- ‘onds, and then repeat after aporoxi- mately 1 minute, The charge current indicator lamp and dlectronic system wa ming lamp must 9 out after the engine has started. If theyremain on, there are malfunctions; (D see page 49) and (D> page 50). e The incicator lap forthe flame start ‘system lights up for approximately 2 seconds (unction check, fame-start ‘system not in operation) to approximate- ly 20 seconds (maximum prego tne) lopand rg onthe ouside temparature If the incicator lama forthe fame-start system does not go out after approxi- rately 20 sends, ther 2 fault; see the Teligent® engine syster section (© page 50) eo ‘The grid heater is controlled by the drive contol unit or the ADM contral unit. The proglow time lasts for approximately -20secands and depends on the temper- ature of the cnolant and the charge ir During the preglow time, the indioator lamplignts uo and then goes cut oncethe pregiow time has finished. At extremely cold temperatures, do nat place the cold engine under a full load im mediataly after starting.‘Y Monitoring engine operation Charge current incicatorlamp Ifthe indicator lamp does not go out or lights up when the engine is running, stop the engine and check the polyV-belt.. tL Monitoring engine operation a The poly-V-belt contact surfaces must not be damaged (2.8. torn), oily or glared. Do not run the engine without a paly-V- belt since the altemator and coolant ‘pump will not be driven. This willre sult in engine damage.Monitoring engine operation Telligent® engine system ‘The electronic system warning lamp must ‘go out after the engine has been started. WZ Electronic system waming lamp if ho waming lamp doos not go out or lights up while the engine is running, there isa faultin the Tellgant® engine system Each fault is stored in the system with a special fault code. Even temporary faults aro stored, ‘The fault codes may be shown on adisplay which is part ofthe Tellgent® engine sys tom (vehicle diagnostic system), Fault codes can be read using DaimiorChryslar diagn ostic squioment (STAR DIAGNOSIS or Minidiag 2-Tester), (© see page 31). the dectranic system ‘warning lamp lights up while the engine is running, read or determine the fault code. Flame-start system? Flame start system indicator lamp ‘Thora is afault in the flame-start system, if: © the flame-start system indicator lemp lights up when the engine is running © the flame-start system indicator lemp doos not go out after more than ap- proxmately 20 seconds when the en gine is startedHave the flame-start system checked at a specialist workshop. DaimlerGnrysler rec ommends that you visit a Mercedes-Benz Service Centre for this purpose esi has the necessary specialist knowledge and tools to carry aut the work required oe ‘The flame-start system switches off au- tomatically, if the engine is not started within 30 seconds of the flame-start sys- tem indicator lamp going out ‘the engine is started while the fame-start systemindicatorlampis stil it © the charge currant indicator lamp does not go out wren the anging is running ‘© the engine reachas a temperature at which the flame-start system is no longer needed Grid heater* a ‘There is a fault with the grid heater it ‘the indicator lamp flashes. etn Monitoring engine operation Oilpressure u ‘Once the operating temperature has been reached, the engine oil pressure must not fall below: © 2.5berat rated speed © 0.5 bar at idling speed Ifthe pressure falls below these values, ‘too the engine and determine theiy ‘Stopping the engine ‘Y Stopping the engine > After drivingatfullpower output or ata Press Stop button @ on the engine or high coolanttemperature, allowtheer on the equipment-resident stopping fa~ ne to idle without load for one ortwo city. minutes. a Stoa the engine immediately if you ob- serve ary of the following signs: © cil pressure drops or fluctustes ‘considerably * power and speed drop while the po~ sion sensor (accelerator pedal po- sition sensor) st2y8 in the same position ‘+ large amounts of exhaust smoke axe emitted from the exhaust coolant and ol temperaturein- crease very quickly © unusual noises suddeniyoccurin © son the engine or exaust ges turbo- ropbutton charger © Start button “seYY Winter operation The following notes should be observed at the start of the cold season: Fuel Risk of fire A Theis an increased risk of fire when han ding fuels as they are highy flammable. Avcid fr, naked flames, and sparis and ro. {rain from seeking when handlingfuels. Use cold-esistant diesel fuel (> seepage 60} When changing the engine oil, select an engine oil that is comoatiale with the SAE class and the ambient temperatures ex pected during the period of use (> seepage 62). Coolant A ‘The cooling system is pressurised. Hot coo ant can spray ou when the cooling systam is opaned and scald your sin and ayes. Only openthe cooling systemat coolant ‘temperatures below 90 °C. “= Unscrew the sealing cap slomly and re lease ary excass prassure completely before cpening tha cap fully '*| Wear sulble protective glaves, protec- ‘ve clothing ana safety goggles when handling coolar. Risk of scalding Risk of poisoning ‘Thereis arisk of poisoning i cacant is swab loved. ‘Check the cootent’s antifroeze protection in good time and inarease the antifreeze/ corrosion inhibitor concentration if neces- sary (D> see page 63). ta Winter operation AN Never swallow coolant. Never put coolant into container nor rally used for beverages. ‘Store coolant cut ofthe reach of chi ren,Winter operation Batteries Have the batteries serviced and recharged more frequently during the coli months of the year A “The acid contained in batteries ume skin ‘and eyes on contact. © Donat allow acidto come into contact with your skin, eyes or clothing. ‘+ Wear suitable protective clthing, as battery ecid can bum through normal clathing. In adaition, protective gloves ‘and safety goggles snould be worn. Rinse acidsslashe soffimmediately wth ‘clean water and consult @ doctor if nec- essary, Risk of acid burns A ‘Gazes escaping frombattorios can cxploda ‘ard injure people. Therefore, donot alow fre, naked flames, ‘andthe creation ofsparks nd donct smoke inthe vicinity of batteries. Risk of explosion Careful maintenance and low power con ‘sumption will help maintain the full battery charge. Starting caoacityis greatly re~ duced in cold weather; for example, at -10 $C it is only about 60% of normal c2- pacity. Ifthe engine is not used for a long period of time, store the batteries in a heated place if possiole. Ensure good ven tiation when recharging.¥ Cleaning/protective treatment ‘leaning the engine Risk of poisoning A ‘Care and cleaning agents can be tose and leadto severe poisoning swallowed. "+ Always keep care and cleening agent ‘containers closed and out of the reach of children. Never store care or cleaning products in foodstuff containers such as battles so ‘sto avoid confision with foodstifs ‘© Obsene the insructions for using care ‘and cleaning producss, Risk of fire and injury A Fuels ere highly fammable and can injure your health. iPthey are used as clearing ‘agents, they cancause res orskin inition ‘and poisoning. Never use fualsfor cleaning. Environmental note @ Observe the regulations forenvirenmental protection. Only clean the engine in 2 washing area de- ‘Signed forthis purpose. Dispose of empty packaging and used clacning materials in an ‘orvirarmentallyresponsible manner. Oe) Cleaning/ protective treatment u Make sure that water does nat enter the intake, ventilation or bleed ducts. Protect the engine after cleaning. Be careful to protect the belt drive against preservative agents. eo Information about suitable cleaning and preservative agants is avzilable from any Mercedes-Benz Service Cen- tre.Ot) Cleaning/ protective treatment High-pressure cleaners Observe the manufacturer's operating i structions. u Maintain the minimum distance be tween the high-pressure cleaner nozle ‘and the object to be cleaned: * approximately 70 om forround- spray jets © approximately 20 om for 25° fiat- spray jets and concentrated-power jets Keep the water jet constantly moving while cleaning. To avoid damage, do not aim the water jet directly at: * electrical components © comectors: © seals or * hoses Information about suitable cleaning and proservative agents ie available from any Mercedes-Benz Servite Centre. Cleaning the cooling system Environmental note g CCllect. used coolant,cleaningsolutions a detergents and dispose of them in accord- fence with current local regulations and in an ceirormentally-esponsible manner. D> Blow out ary foreign objects (dust, in- ‘seats, et. from the radiatorfins using ‘compressed air or remove by s praying, ‘water on the rear side of the radiator {against the direction of the cooling cir flow). a Only apply moderate pressure when ‘cleaning since the radiator fins could ‘othenwise be damaged. Risk of scalding A The cooling systems pressurised. Hot cook ‘ant ean spray out when the cooling system is opened and scald yourskin end eyes. ‘© Only opan the coating system at cankant ‘emmperatures balow 9 °C. "© Unscrew tha sealing cap slonly and ra- Jase any excess pressura comelataly before opening the cap fly ‘+ Wear suiteble protective gloves, protec: tive clothing ard safety goggles when handling cootent. bp20> Drain off coolant whan the enging is cold (D> page 95). D> Ifa heaters attachad to the cooing system, opan the regulating valves fuk be aA “Theteisa risk of poisoning if coolmntis swak lowed, ‘+ Never svallow coolant. ‘+ Never ut coolant into container nor- mally used for beverages. ‘+ Storecoolant out ofthe reach f chit dren. Risk of poi Degreasing > Fil the cooling systern with 25% sok tion of water and a mi ekaline clean- @f, 8.g."P3 Croni" (50 g cleaning agent per ltre of water. > Warmuo the engine at moderate on- gine speed wp to approximately 80 °C (coolant thermostat starts to open) and allow to run for approximately 5 min- utes longer > Switch ofthe engine and alow to cool 10 approximatly 30°C. > Drain off the cleaning solution com- pletely D> Immediately afterwards, fill the cooling system with clean water, warm up the fengine, nd drain off the water after 5 more minutes, Then repeatthe pro- cedure a second time. > Fil the cooling aystem with new coot- ant (> page 96) and follow the instruc- ticns in the "Coolant section (> pageos). Cr Cleaning/ protective treatmentCet Cleaning/ protective treatment Protective treatment ‘Tho special protection required will de- pend on the length of tme the engine is to be out of use as well as the climate of the place where the engine isto be located or stored. Aitercleaning the engine, stare itin a dry, wel-ventibted place as faras possible. If this isnot posseble, the intervals for carry ing out regular protective measures must be halved. Itis essential thet the engine be protected from direct contact with water (rain/spray water) Ifthe engine is to be out of use forless: than 12 months andthe above conditions aremet, no corrosion-protedion measures read to be taxon. IF the engine is to be out of use farmore ‘than 12 months and there are excep- tional storage and transport condi- tions, special protective treatment measures are required. cry Information is available from any Mercedes Bonz Sorvice Contre, Wo strong- ly recommend asking for information,Y Service products A Service products can cause injury or poisor- ingif hey co ment ocontact withskin or are swallowed. Observe the preveilingreg ulations when handing service products and storing and isposing of tham. Service products could ctherwise endanger people and the enviran- ment. Risk of poisoning /injury ‘* Aways wearapproprate protective Clothing and a breathing mask winen handling sorvce products f possible, avoidinnaling vapous. "+ Donctallow service products to come into contect with your skin, eyes or clothing. Gea affected areas of skin with soap and water. ‘© Ifsenice productscocome intoconsact with your ayes, rinse off thoroughly with Clean watar ard consult a doctor if nac- essary. "© Consult a doctor immaciataly fa san Ice producti snaliowed. 1* Keop service products c utof the reach of children. Risk of fire A ‘hora is an increased risk of fire when han- dling fuels end lubricants es they ere highly flammable. ‘Ayaid fire, naked flames, ane sparks andre {fain from smoking whon handling servico products Greases and lubricants must be compati- blewith engine components. Far thisrea- ‘30, only brands that have been tested and ‘agproved by DaimlerChrysler should be used. These are listed in the Mercedes- Benz Specifications for Service Products. Oe) Service products Special lb ricant additives are not neces- ‘sary. The warranty entitlemert may be ro- stricted if special lubricant additives are used. oe Information is available from any Mercedes-Benz Service Centre. Environmental note @ Disposo of service products 2s wollas pants which come into contact wth service prod ucts, g. the fiter, in an environmentally responsible ranner. Obcene the legal requirementsOyen Service products Diesel fuels Only use commerially available vehicle diesel fuels (EN 590), Grades such a8 ma- rine diesel fuel, heating oils, etc. are not permitted. Fuel additives are not necessary. The wer- ranty entitlement may be resticted if fuel additives aro usad. Ifdiesel fuels witha sulphur content above (0.3% by weight are used, carry out anil ‘change at shorter intervals. Ooserve the information provided in the Maintenance Booklet. Filling the vehicle's fuel tank from drums or canisters may introduce impuritiesinta the fuel system This ean lead to fuel system malfunctions. Therefore, filter the fuel when filing the tank. ‘The 900 series engines are suitable for use with FAME fusie in accordance with DINE 51606. if you do 0, you must con- sult a Mercedes-Benz Senvice Centre to havo the exact oparating oroceduras (0.g. maintonance intorvalg) explained. Diesel fuels in extremely cold weather At low outside temperatures, parattin sep- aration may affect the flow characteristics of diese! fuel. To prevent operating problems (eg. as a resut of blacked fiters), diesel fuel with improved cold flow properties is available fon the market in the winter months. Devia~ tions may be possible in the transtion be tween the cold and the warm seasons, and in otter countries. In Germany, epecial cold resistant inter-grade diesel fuels are sold. They ensure refable op eation down to approximately -20 °C. Winter-grade die sel uel can normally be used without rik of mafunctioning at the outside temper tures expect alin the country of sale| summer diesel fuel or winter diesel fuel with less resistance to low temperatures ia used, only add a specific quantity of flaw improver or kerosene, depending on the outside temperatures. Risk of fire and explosion aA ‘Adéing petrol reduces the tash pointfor the diesel fuol and increasas tha risk of fre and cexalosion. '* Therefere, never add petrol to diesel fuel '* For this reason, you must ard fire, na- kg flames and sparc and refrain trom ‘smoking when handing these service products, © Obsene the relevant safety regulations u IF petrolis added, theres a sk of seri ‘ous engine damage. Therefore, never add petrol to diesel fuel. ‘Add the flowimprover additive to the die ‘sel fue! in good time, bofore paraffin sopa- ration affects the diesels flow properties. Malfunctions caused by peraifin separa tion ean only be romediad by warming up the entire fuel system. Do not add additives to especially cold- resistant winter desel fuels, as the fuel's coldflow properties could deteriorate. eet Service products Flow improvers The effectivenes sof flowimproverscannat be guaranteed with all fuels. Comply with the manufacturer's recommendations, In- formation about approved flow impravers is available from any Mercedes-Bera Ser ice Centre, Kerosene ‘Add as little as possible, depending on out- ‘Side tomporatures. The addition of 5% by volume of kerosene improves the cold resistance of diasel fuel by approximately 1°C, Do not exceed the maximum mixing ratio of 50% kerosene.Ol Service products For safety reasons, only mix kerosene with diesel fuel in the fue tank. Add the kero- sene first, then the diesel fuel. Run the em gine for a while to ensure that the additive reaches all parts of the fuel system. Riskoffire and explosion — /\ ‘Adding kerasone racucos the flesh point of the ciesel fuel end increases the risk offre and explosion + Forisreas youmistawidtre tagnoal EAEcaasne ed Hane andes ying dea speci tested or slab ity in ow engines. Therefore, only use en- products. gine oil brands approved by Mercedes * Observe the relevent safety regulations. Bonz. These are listed in the Mercedes- Benz Specifications for Service Products. Observe the information provided in the Maintenance Booklet. oe The use of non-eppraved engine cil brands can restrict the warranty ent tlement.ongina oils of adifferant grade 2re used, the oil change intervals will alter. Informa- tion is available from any Mercades-Benz Service Contre. Select the SAE class of en- gine ol in accordance with the outside temperatures. ‘After maintenance work, the engine oil change is entered in the Maintenance Booklet along with the engine oil brand, grado and SAE clase. Only use engine cilsof the same graie and SAE class when topping up. e If engine oil of 2 lower grade is used to top up, the properties of the en; are impaired and the engine oil and fil ter changes must therefore be carried cut at shorter in tervals Coolant A ‘There isarisk of polsoningifcedant is swal- loned. Never swallow coolant Risk of poisoning ‘© Never put coolant int container nor. mally used for beverages. ‘+ Store coolent out ofthe reach of chil dren. ‘The coolant is a mixture of water and anti- freeze /corrosion inhioitor. The coolant ‘must remain in the cooling system all year round to ensue antieorrasion protection ‘and to increase the boiling point. e Renew the coolant avery three years, since the lael of corrosion protestion gradually deareases. ty Service products Water Water without additives is nat permitted as coolant, even if antifreeze properties are not necessary. The coolant wator must satisfy certain 1e- ‘quirements which are not always fulfilled by drinking water. Ifthe water ig not of sufficient quaiity,it must be treated. oe Information is available from any Mercedes-Benz Service Centre.ert) Service products Antifreeze /corrosion inhibitor To prevent damage to the cooling gystare © Only use approved antifreeze /coro- sion infibitor. Information is available from any Mercedes-Benz Service Cen- tre. ‘© Whan topping up (after coolant loss), make gure that the antifreeze /eorro- sion inhibitor concentration is 50S y volume (thisensures antifreeze protec- tion down to -37 °C). a Ifthe concentration is too low, there is. a risk of engine damage as a resut of corrosion/ cavitation. © Donot use an antitresze /corrosion in hibitor concentration af over 55% by volume (maximum antifreeze protec tion). Abave this concentration, anti- freeze protection deteriorstesand heat pation is less effective. Coolant mixing ratio: Antifreeze 37°C approxi- protection downto Water % by vol. 50, 45 Antifreeze /cor- 50 maximum rosioninhibitor 98 ‘by vol. In exceptional cases, when no antifreeze/ ‘corrosion inhibitor is avzilaole and/or no antiteeze orotestion is required (in tropi- «al regions), use an approved coolent additive without antifreeze properties in ‘accordance with Shee 312.0 of the Meredes Benz Specifications for Services Products (e.g. MB carrasian inhibitor ‘A 000 9891 3 2510 by DaimlorChyyslor AG ‘oran approved additive from anather man- ufacturer). a In this case, the coolant must be re nowod avary year. Disposal Environmental note @ ‘The coolants mentioned arebiodegredable substances. When disposing of used cool- ants, observe the lagel requirements and ‘waste water regulations inthe country con- cemed, ‘We recommend that you ask the relovant ‘ator authority for advice on the disposal of coolant. Due to the complex tasks which a medern coolant must perform, impropar ‘recyciing” consisting simply ofa mechanical oreclean- ing must be emphatically rejectedLET cor uo’ Maintenance instructions ‘Overview of work plans Work plans:WET cur Tt Maintenance instructions Y Maintenance instructions This section doseribes all maintenance ‘work which concerns the engine. A Before any maintenance work cr repairs are carried cut, please make sure that you reac the relevant sections of the technical docu- mentation concemed with servicing andre- pais, for exemple: ‘© Operating Instructions and workshopin- formation ‘You should also famiarise yourself fst with ‘the logalre quiraments, For example: ‘© wok safety nd accident prevention regulations ‘You coulé ctherwae fail 1 recognise dan- gers and could injure yourself or thers. Risk of accident nt A Fauity maintenance work or failure tocarry ‘out meintenance work, eg. not changing ‘theoll ter or nat observing the correct maintenance irerval, can cause engine ‘éamago. Engine damago can lead to an in- ‘cresiod risk of accident, For tis reeson, pleese observe the instruc- tons on servicing the engine given in these: ‘Operating Instructions. Risk of acci oe Allmaintenance intervals and mainte- nance work refer to genuine Mercedes- Benzpartsand accessories specifically approved for the engine by DaimlerChrysler. The scope of maintanance and frequency of maintenance work depend on the differ ‘ent operating conditions and are listed in the Maintenance Booklet, Have tho work which is carried out eon- firmed in the Maintenance Booklet, This root of regular maintenance is abways re- quired for any werranty claims. Also obsorve the maintenance regulations tor special aocessories. a ‘The engine oil filed at the factory in accordance with Sheet 228.5 of the Mercedes-Benz Specifications for Sere ice Products must be changed if more than 12 months elapse before the en- gine is op erated for the first time.Y Overview of work plans Maintenance service Engine: (il change and filter placement Change the engine oil and replace the il fiker at least once a year. Poly-V-belt: Check condition Checking for leaks and general condl- tion Check for points of abrasion and incorrect, positioning: Engine Lines and hoses on the engine Intake pipe between aircleaner and en- gine Cooling and heating system Checking end correcting the fluid level If more fluid is lost than can be accounted for by normal conaumption, trace the cause and rectify. Engine cooling system: Check and correct fluid level and ‘antifreeze / corrosion inhibitor concen tration Additional work Cheek and adjust vahe clearance The valve clearance must be adjusted during the first maintenance service {nd then during the 3rd, Sth, 7th main tenance services and so on. Additional work during every rd maintenance service LET Sorted Overview of work plans Ful praflter: Clean filter element Fual filter: Reolace fiter Fud prdflter with water separator: Replace filter element Engine brake": Check condition end setting Ronow coolant e Renewal interval depends ca the cool- ant additive used (see Mercedes-Benz Specifications for Service Products).WET orto Work plans y Work plans Engine: Checking for leaks and ‘general condition D> Visual inspection of the engine for Lines and hoses on the engine: (Checking for leaks and general condition signs of leakage > Make a visual inspection of ines and Sealing penta woih ae sight dampare _Ne#es-Also makes Estning check for harmless, * bas u «check for undamaged condition Remedy mor sigifant eck aval © hate sree routing end ing constant oil loss immediately. © correct mounting Risk of burns aA “The engine's very hot when t fsrunring and alzofor some time afterit has bacn swit- ched oft may cause bums ifyou touch it. Before starting ary work on the angine, low all engine parts tococl down or ele ‘wwar suitable glare sanditems ofothingto protect yoursaff againsthetangine compo- rents, re A ‘There is @ denger oflimbs being caught, en- trapped, crushed or torn off ky retatng ere so pat. Trerotoreyou shout eee eee and tating engine pars, incding when the engine fs bing stated “© Waic unct a engino cares nave come to 1 stanoil before carving ou any Werk onthoe nce. ‘+ Wearworkslothng whichis fastened and close‘iting Wear» ei net Fre ‘essary. Remove jewellery such as watches and necklaces.Engine: Oil chenge and filter replacement o Onlychangeengine oll when the engine is at normal operating temperature, Risk of scalding A Hot engine oil spraying out can sca your skin and eyes. Wiear suitable protectve gloves, protective clothingand eye protection > Remove the oil fiter cap using the socket soannarinsert (WAF 36). Allow «il to drein from the fiter housing. > Unscrew cap @ and oilfiterelement ond remove element @ trom the ‘cap by pressing the lower edge on the sides. Oilfilter cap a Make surethat no foreign objects enter the filter housing. Never wipe the filter housing out. Dont Work plansCap with oil fitor olomont Oc @ Sealingting © Oil iter lernent > Replace the sealing ring on cap @ > Insert new fitter elament in the cap and clip it into place by pressing on it > Screw the cap on the oil fiter housing: and tighten it Tightening torque: 25 Nm. Extracting and draining the engine oil Extrection: > Bdract the engine ol through the dip ‘stick guide pipe. To do this, pul out the dipstick and insert the scavenging de- vice sealed with an O-ring into the Bide cig. aos Dipetick guide pipo a ‘Observe the operating instructions for ‘the angine oil scavenging device.Draining: > Piece a suitable collecting receptacle «Environmental note 9 rca te aie Pligon the underside” oace of engine oll and fitrs in accord ance with the regulation in force atthe > Unscrew the drain plug aretuly end at- place ofuse of the engine. low the oi to drain out Renewing: > Screw the drain plug back in withanew ‘sealing ring and tighten. Tightening torque: M20x 1.5- 60Nm Mz6x 1.5- 85m > Add new engine cil into the engine via the oil filer neck up to the maximum mark on the dipstick. il drain plug,Work plans D> D> Startthe engine with the setpoint value sensor in the iding position. Monitor the oil pressure gauge. u Keep the engine running at idlingspeed until an oil pressure reading is dis- played. If no oil pressure is displayed aiteraporoximately 10 seconds, switch off the engine and establish the cause. D Check the fiter and drain plug for leaks. b> Stop the engine. Check the oil level af- teraporoximately 5 minutes. Topup cil tothe mavimum mark on the dipstiok if necessary.Adjusting the valve clearance Layout of cylinders and valves: > = inlet vaiwe « X__ =iywheet end ‘exhaust valve ‘Special tools Rotation device: 904 589 04 63 00 Valve clearance: Inlet valves = 0.40 mm Exhaustvalwe = 060mm eo ‘Adjust the valve clearance when the engine is cold (stleast 30 minutesatter the engine was stopped, even ifit was ‘only operated for a brief period). ‘Clean vary diy oylinder head covers bofore removing. Work plans Risk of injury A Trot prope secured, vehicle might ace cently ba set in moto necking poopla down cr rapping ther ard athenice cais- ing a accident end ining you eres. + lvayscocurethovonice against ling ‘uray by apy to pareng braeo and, if necessary, by plecing cocks under the wheel + Shitthe transmission nto neutral Only turn the engine over using the rota. tion davice provided forthis purpose.Work plans. Removing and fitting the cylinder head — a ® Charge-air manifold @ Cylinder head cover @ Allen bolt @ Sealingwasher © Cover seal © Engine breather hose breatherhose @ trom the cylinder head cover. > Unsorew Allen bolt @ from the oy: der head cover together with sealing washers @, > Remove cylinder head cover @ Fitting: > Clean the ayinder head and the aylin- der head cover Sealing surfaces. > Chek the gasket between the oylinder heed cover and charge-air manifold @ and repiace if necessary. > Always replace the gasket between the cylinder head cover and the cylinder heed. > Position theeyitder head cover FitAllen bolts @ with new sealing washers @ andtigh tn Tightening torque: 30 Nm. Hywheal housing Inspection hole > Fitrotation device (904 589 04 63.00) ‘on the flywhee! housing ingpection hale.‘Adjusting the valve clearance Engine Crankshaft position (0M 904/924 LA 4th cylinder vahe overian st cylinder valve overlap (0M 906/926 LA 6th cylinder vahe averian Ist oyinder valve overlap | inlet valve E = exhaust vale Adjust all valve clearances in 2 crankshaft positions, > Use the rotation device toturn the crankshaft untilno. 4 ar cylinder is at averiap TDC (no. 1 eylinder at ignition TDC). Then tum no. 1 cylinder to over- lap TDG (no. & or 6 eyknder at ignition TDC). > Check the valves in accordance with the above table and adjust Ve VE Gylinder/ valves tobe adjust ed WorkplansLET corto Work plans Checking and adjusting the valve clearance ® Adjustment serew @ Counternut Measure the valve clearance between the rocker armand valve stem (exhaust valve) of velve bridge (inlet vake) with a fecler gauge (arrow). It must be possible to pull the fealer Buge through with only light resist- ance. Slacken counternut @to adjust the valve clearance. Adjust the valve cleer- anceby turning adjustment serew (). Retighten thecountemnut, Tightening torqua: 25 Nm. Check the vehe clearance again and readjustif necossary. Concluding work D> Refit the cylinder head cover (b see page74}, > Remove the rotation device from the flywheel housing inspection hole.Fuel prefilter: Cleaning the filter element Fuel prefer Qe © Filter eran © Seating ring A ‘There is en increased risk o fre when han- ding fuels as they ar highly flammable, ‘Avoid Fre, naked fama and sparks andra- frei from smoking when hending fuels. Risk of fire Open the tank cap to remove excess pressure in the fuel tank. Clean the outside of the fuel prefiter ‘and cover any hoses /lines under the prefiter. > Unscrew cao @ and pull it out of the filter housing together with filter element ©. D Clean cap Dand fiter element @. Replace tha filtar aloment itis very dirty or damage. Work plans Environmental note e Dispose ofused fiter elementsend uel res: due in accordance with current local regula- ons. > Cheok sealing ring @ for the capand replace if necessary > Insert the fiter element in the cap and ‘ocew the cap onto the filter housing, Tightening torque: 25 Nm.DUEL Work plans Fuel prefilter with heated water Nee Recta tethen Rick offre AS creme 9 “Thera is an incressed risk offire when har- Dispase of used iter elaments andtuel = ding futs as they are highly flammable. iduein eccordence withcurentlocslreguls- tions. ‘Awd fire, raked lames and sparks and re {rain rom smikirg whan handing Fuel. > Remove the separator vessel from the > Open the drain valve and loosen the filter clement and clean or re place as, vent sorew Golleat the fuel/ water necessary. mixture from the fiterelement in p> Rafit in the reverse order. Use new suitble recestacte. sealing rings when fitting. b> Remave the heater connector. D Unscrew the filter element. Fucl profiter with hoated water separator” @ Hend puna © Filter housing @ Water separator (heated) © Water drain valve 7)LPT Corer} a Sorew the filter element onto the filter head tightly by hand, D> Close the drain valve and fill the pre- filter using the fuel hand pumo. Then close the vent screw. D Start the engine and bieed the fuel sys- tem Leave the engine running for aperoxi- matey 1 minute. The fuel system bleeds automatically. D Check the prefer for leaks.Maintenance Fuel far Oc» @ Filter housing Pr Rick offre A ‘Thora isn increased rick of fre whanhan- dling fuels as they are highly flammable. Avid fre naked Names and the creation of ‘sparks rain fom stroking when handing fuels. © Open the tank cap to prevent excess pressure in the fuel tank, D Unscrew fuel fiter cap with the ‘socket spanner insert (WAF 36). > Pull cap @ end filter lement slightly cut of fiter housing @). Allow fuel to flow out. Oop @ Sealing ring Q filter element © Dirttrap @ Filter housing bebe vv — Remove the cap and fiterelement. Ur- lip filter element @by pressing the lower edge of the filter element on the sides. Pulldirt trap @ cutof the fterhousing by the tabs, u Neither art nor water should enter the filter housing, do not empty dirt trap @ into the fiter housing. Glean cap @ and dirt trap @. Replace sealing ring @). Clip new fiter element @ into cap @. Aouad Work plans o oe If the level of the diesel fuelinthe tack J Leave the engine runing for aporoxe is higher than the level of the engine, mately 1 minute. The fuel system the feed line must be closed when re- ff bleeds automaticaly placing the fiter, ‘The diesel fuel could flow out, D Cheok the fuel filter for leaks with the ‘engine running. D Lightly grease sealing ring@ end the @ fier element seals, Ingert diet trap @intofilter housing @; observe the correct installation po- sition Screw on cap and fitter element and tighten. Tightering torque: 25 Nev. To ensure the fuel system can be bled, the battery must have enough charge when the engine is started, since the {fuel system must fil up with fus! fist. Start the engine and bleed the fuel sys tem.Doh’ Work plans Intake pipe between air cleaner and ‘engine: Checking for leaks and general condition D> Check the rubber sleeves, intake pine ‘and connection hoses for damage and leaks. D> Check the hase clamps, flanged joints and intake manifold for frm seating.Pol-V-be lt: Checking the condition Risk of jury A Faulty pol- V-belts may tear and parts or all ‘of the belt may be thrown aff, thereby caus- ing injury to persons. "+ Always obsarve tha specified mainta- ‘nance intorvalsfor poly-V-belts. ‘© ifdamage is dotacod, roplacathe poly- ‘batt concamed imrmaciatly. ‘Special tools Rotation devices: 904 589 04 63.00 > Fit the rotation device to the flywheel housing inspection hole, > Moke a chalk mark on the paly-V-belt. Check the paly-V-belt for damage in sec tons: rotate the engine and poly-V-oelt a lite at a time Flywheel housing inspection hole D rotate further using the rotation device until the chalk mark is reached again, > Remove the rotation device LET -urUtcy oe Reolace ihe polyV-bet if one of the ‘Gamage patterns shown on the next page is detected. For information on r= staling and removing the poly-belt (> see page 86),UT Work plans Evy2oidal ris) @ One-sided wear: wedge-shaped ribs © Cord visible in the base of the ribs @ Ris solit © Transverse cracks in several ribs @ Rubber lumps in the base of the belt © Deposits of dirt or stones @ Rib detached from the base of the belt © Gord torn out to the side © Outer cord frayed @ Transverse cracks on the back of the belt @ Transverse cracks in several ribs LETT cura}UTC Work plans Removing and installing the poly--belt Risk of injury A When tis loosened or tightenag, there isa tisk oF injury from hands or fingers being ‘crushad or trapped in pretensoned parts ‘© Make sure thatthe tol is handled cor- rectly. ‘+ Keep your fingers out ofthe area be- ‘tween the belt pulley andthe poly-V-beit hen iting er dismanting the poy-V- bet "+ Wear work gloves nhen working on the tensioner. ‘Spanner withextension inthe tension’ device > Attach spanner @ with the 17 mm socket to the hexegon bolt of tension- @ Tensioning pulley ing pulley @. @ Spanner > Swing the tensioning pulley upwards ‘and remove the poly-V-bet. “The tensioning device’ spring-tensioned v Swing back the tensioning device. ‘Check that the tensioning device and baltpulley are in perfecteondition (eg. ‘check for worn bearings on the ten- sioning device, tensioning oulley and deflection pulleys as well as weer on belt pulleys); replace oarts if necessary. Lay the poly-V-belt (nev) on all belt pul lays, except for the tensioning pulley (Gee illustrations for poly-V-2elt rout- ing). ‘Swing the tensioning pulley upwerds using the lever, insert the poly-V-belt and swing back the tensioning oulley. Remove the spanner and check for eor- rect seating of the poly-\-belt on the bult pulley,Routing of the poly-V-belt (engine ‘without refrigerant compressor) @ Atternetor @ Coolant pump @ Tensioning pulley @ Crankshatt Work, Routing of the poly-V-belt (engine with refrigerant compressor) @ Atternator @ Coolant pump @ Tensioning pulley @ Refrigerant comoressor @ Deflection and guide pulley © CrankshaftWTR Work plans Engine brake: Checking the ‘condition and setting Throttle valve lever in rest position Thoottle valve lever @ Retainer “Throttle valve lever In working position Throtte valve lever © Retainer Checking the condition > > » Remove the wire ciclo from the b al cup on the engine oyknder. Force the ball cup off the ball neck of thrattle vabe lever ©. Check the engine brake oylinder, bal neck and ball cup, and the thratlle vehe shaft for wear. Check the fir seating of the thotile vehe lever on the throtte valve shaft Tighten screws if necessary. Grease the ball cue with the grease specified. Push the ball cup back onto the ballChecking the adjustment oe Throttle valve lever @ must lie against bracket @ in the ooerating position (orlinder extended) when the engine broke is operated When the engine brake cylinder (with the cylinder retracted) sin the rest po~ sition, the throtf evalve lever must also lie against the bracket: the pre-tension of the engine brake cylinder return springis then sufficient. Check the position of the throttle wave ‘shaft: the notches must be horizontal when the engine brake isin therest po- sition (D> page 86, ilustration on the left-hand side). The notches must be vertical in the working position (© page 86, illustration o9 the right hand sida), Work plansLUE Centon Work plans Engine cooling system: Checking andcorrecting the fluid level andthe antifreeze/ corrosion inbibitor Risk of scalding A The cooling system is pressurised. Hot cool- ant can soray out when the cooling system Is opened and scald your skin and eyas. ‘© Onlyopen the cooling systamat coolant ‘temperatures below 90 =C. ‘© Unsorow the sealing cap slonly and ra- lease any excess pressure complotely before opening the cap fully © Wearsuitsble protective gloves, protec: tive clothing and safety gogelas whan handling colant. 90 ee A “There isa tsk ofpoisoningifcoolent i siral= twee. “© Nover swallowcoolant. '* Never put coolant into containers nor- mally used for beverages. ‘+ Store coolant out of the reach of chil dren. a Only use service products approved by DaimlerChrysler, (D> see page 63). oe Only chack and correct the coolant lee ‘al when the coolant temperature ia below 50 °C. Check the antitreeze/ ‘corrosion inhibitor befare correcting tha coolant leval. Only use precared ‘coolant with 50% by voluma anti {reeze /corrosion inhibitor for topping up. ‘Open the engine cooling aystem radia- tor cap slowly. Relieve excess pres- Check the antitteeze / corrosion inhibi- tor using testing device. The correct ‘concentration af 50% by volume antitreaze /corro sion inhibitorin the ‘coolant is indicated when there is anti- freeze protection down to-37 °C. If less antifreeze protections displayed, correet the mixing ratio.u If the concentration is too low, the arisk of engine damage asa result of corrosion /cavitation in the cooling system. a ‘Avoid concentrations of more than 55% boy volume antifreeze /corrosion inhib> tor, otherwise maximum antifreeze pro- tection down to ~45 °C will not be achieved. Ifthe concentration ishigher, heat dissipation and antifreeze protec- tion doteriorate. > Check the coolant vel ‘The cooing system is correctly fled # the ccoalant reaches the mark in the filler neck. ‘Cooling and heating system: Checking for lesks and general condition The "Engine cooling system: Checking and correcting the fluid lovel and antifrecze/ corrosion inhibitor wark item must have already been carried out. > Carty out a visual inspection of the ra- diatorfor leaks and undamaged cond> tion, a If damage /faults are found, repair the radiator or replace it. > Check the radiator for extemal dit. The fins must not be dicty > Check that all lines and hoses are un- damaged, that thay are routed to avoid ‘chafing and that they are secured in ac- cordance with the regulations. Work plansWork plans ‘Spectal tool: Pressure tester 001 569 8321.00 Risk of poisoning A There isa isk ofpoisoningifcoolentis saa Risk of scalding LX towed. The cooling system is pressurised. Hotcocl. * Never swellowcoclent. ‘ent can spray outwhen the cooling system * Never putcoolantinto containers nor- is opened and scalé your skin and eyos mally used for beverages. * “Onyenenthecoolngsytemat acant "ST stlartout othe reach of ch ‘temperatures below 90 °C. s “+ Unscrew the sealing cap slomly and ra lease ary excess pressurecomletely pe On heating systems: Open the regulat- before opening the cap fly ing valves and shutoff valves. reecoanest + Wear sukable protectvaglovas, PIES Remove the coolant expansion tank _—Presaure tester special tool te clothing ad safety gogeles whan oe ° oes ” handlingcoolant. D Fitthe testing equioment.Workplans >> D> Gonnect the compressed-air hose with thetyreinflatorconnectionto thevalve and build up a test pressure equal to the cooling system opening pressure, ‘The cooling system opaning preseure can bbe seen onthe codeon the capor pressure relief valve. Example: Code 71 oe A pressure reliaf valve is integrated in the testing equia ment so that a pres- sure of 1.2 bar cannot be exceeded 0.7 bar ressure.DCL Work plans Renewing coolant isk of scalding A ‘The cooling system is pressrised. Hat cook ‘ant can spray cutwhen the coaling system is opaned and sceld your skin and eyes. "+ onlyopen thecoaling system at coolant ‘emperatures below 90 °C. “© Unscraw the sealing cap siowly and ro- lease any excess pressure comet aly before opening the cap fully. "+ Wear suitable protective gloves, protec: tive clothing end safety goggles when handiingcoolant 94 Risk of poisoning A “There isa isk ofpoisoningifcoolantis swal- lowe. © Never swellowcoolant. ‘+ Never put coolent into containers nor- mally used for bevereges, Store coolant out ofthe reach of chit dren. a Onlyuse antifreeze / corrosion nhibitor ‘gproved by Mercedes-Benz (> see page 59). eo Before renewing the coolant, check the ‘cooling and heating system for leaks ‘and condition. Have the coolant renew- al confirmed in the Maintenance Book- ket.Acura Work plans Draining coolant, 0 There we additional drain pugs on the radiztor. e First cover thelines, etc. beneath the rain plugs and place 2 receptacle suit- able for the volume of coolant. Risk of scalding A Hot coolent wil scald your skin and eyes. "© Only camy out work on the cooling sys- ‘am at coolant temperatures balow 50°C. “+ War suitable protective gloves, protc- ‘ive clothing and safety goggles whon handiirg coolant. > Oven the engine cooking system radis- 2 tor cap slowiy. Let off excess pressure and remove the radiator cap. Coolant drain plug > On heating systems: Open the heating be Piace the drain hose on the coolant temporature selector (regulating ‘ain plug on the engine (arrow). vahe). > Loosen the drain plug (1 to 2 turns) The coolant flows out. 95Work plans Environmental note ? Dispose of used coalartin accordonce wth provaling local regulations (© seepage 64) > Clear blocked drain openings from de- posts. > Retighten the coolant drain plugon the engine. > Pulloff the drain hose. > Fit additional drain plugs (without hose connections with naw sezls and screw tight. Adding coolant D> Start the engine and allovrit to run at different spaeds for approximately T minute, > Add coolant in the specified ratio until it reaches the lower edge of the filer neck. > Switch off the engine and close the coaling system again. oe Far further information, see the vel manufacturers ope atinginstructions.Malfunctions, causes and solutions Jump-startingPractical advice Malfunctions, causes and solutions Y Malfunctions, causes and solutions Besides careful operation and mainte nance of the engine, itis important that ‘malfunctions are remedied in good time. Further informationan the measures Isted under "Solution" can be found in tha *Main- tenance" or Tests and other work for rem edying problems* section. You can rectify certain faults yourself (> page 99). Always have faults that you cannot remedy yousolf rectified at a qualified specialist workshop. DaimlerChryslor recommands that you vi ita Mercedes-Bere Sevice Centre for this purpose as it has the nacessary special knowledge and tools to carry out the work required. in particular, work relevant to safety or on safety-related systome must be carried out ata qualified soecialist workshop. A Incorrect maintenanceand reairwork to the engine can cause ergina demage and may cause persorel inlury es 6 conse~ quence, Risk of accident and injury Maintenance and repair work on the engine may only be carried out by persannel whe have undergone the appropiate taining. Always have work on or madfics ions tothe ergine caried out ata qualified technical \workshopwhicnhas the necassary special ist knowledge and tod to camy out the work required. Mercades-Bonz racemmende that you uso a Mercedes-Berz Senice Centre forthis cur- pose.General troubleshooting Malfunction ‘Starter pinion does not turn or turns too slonly Engine doos not start or stops 2g diately Malfunctions, causes and solutions Cause Battory is not sufficiently charged > Connecting cable to the startermotor is D> loose Starter motor solenoid switch malfunction D> Fuol tank empty > Fuel fitar blocked v Fuel line, pre-cleaner or screen in the fuel tank blocked Fuel system or filter leaking > Fuso! not resistant to cold > > > Outside temperature too low > Solution ere ECT) ‘Charge the battery Tighten the cable on the terminal. If necessary, colder on a now terminal. Have it checked by specialists Rofuel ‘Clean or replace the filter aement (© page 80) ‘Clean and bleed the system Seal ‘Clean the pro-ftr (D> page78) Replace fuel filter Use winter fuel (D page 60) ‘Observe measurestfor winter operation (> page 53)ere eT ty Malfunction Engine starts badly Engine stops unexpectedly Malfunctions, ca uses and solutions Cause Fuel temparature too high or sensor mak function Engine control unit matfunction Leakeges or oresaure too low in the lon pressure fuel circuit Engine control unit malfune on (total fait ure) Electrical system interrupted; short circuit in cabling orn Stoo button; engine control unit malfunction Leakages or pressure too low in the lon pressure fuel circuit or fud delivery pump drive defective Solution > > Replace fual temperature sensor; cor sua qualified specialist workshop ead engine control unit maiunetion memory, consult a qualified specialist workshop ‘Test for leaks (visual insoection); have pressuretesied at aquaiied specialist workshop Consult qualified specs st workshop Consult 2 qualified specialist workshop Test forlaaks (visual inspection); have pressure tested at a qualified specialist ‘workshopMalfunction Engine in emergency running mode: Constant speed 1,300 rpm En surges, vibrates or runs irregularly Poor engine output (18k of power) Cause Engine control unit or drive control unit malfunction Grankshaft postion sensor or TDC sensor (camshaft angle sensor) polarity reversed (Che rge-airpressure sansormalfunction Charge-air temperature too high or temperature sensor malfunction Fuol temporature too low Goolant tempe rature too high eee eG Malfunctions, causes and solutions Solution > Read malfunction memory in control units; consult a quaiified specialist workshop Db Removeeach sensor; sensor polarity is raversad if engine runs better (emer gency running engine speed] - reverse polarity Consult a qualified specialist workshop Chock with DaimlerChrysler diagnostic tester replace if necessary, consulta qualified specialist workshop > Check tomporature sensor; raplaca if necessary; cons ulta qualified specialist workshop Chock temperature sensor; roplace if necessary, check fan speed cut: point; consult a qualified specialist workshop > Check temoerature sensor: replace if necessary; check fan speed cutin point; consult a qualified specialist workshopPietra Malfunctions, causes and solutions Malfunction Cause Poor engine o utput (lack of power Engine brake vdve* defe ctive Fault in the fuel system (blocked, leaking) Engine control or drive control module ‘malfunction Tractive force interruption Loose contactsin the dectrical supply Leakages or prassure too low in the lon pressure fuel circuit Poor engine braking power Diive control unit malfunction Constantly-open thrattle valve™ detective Engine brake flap* defective rtrd Solution > Carry out function or visual inspection > Carry out visuali nspestion for leaks, ‘consult a qualified specialist workshop > Read control unit ma Function memory: ‘consult a qualified specialist workshop > Check battery terminal clamps and connector on engine control unit for fir seating and corrosion > Test forleaks (visual inspection); have pressure tested at aquelified specialist workshop > Read drive control unit malfunction memory; consult @ qualified specialist ‘workshop > Cheek contro consult a qualified spe- cialist workshoo > Carry outa function /visual inspection; ‘consult a qualified specialist workshopMalfunction Fudl consumation too high Engine cutoff too early (maximum revs ‘cannot be reached) Engine gets too hot (according to coolant temper ature gauge) ert ad Malfunctions, causes and solutions Cause Solution Fual tomperatur etoo high or sensarmk function Turbocharger leaking on presaure (deliv ery) side Connection points (unit pump line andin- jectors) defective or leaking Drive cantrol unit or ADM control unit de- |B fective or incorrectly programmed Gooiant temperature sensor malfunction Ingufficient coolant or cooling system not fully bled Pay V-belt damaged > Fan dogs not switch on correctly » Radiator dirty on inside or choked with limescale; radiator very dirty on outside Thermostat malfunction » Roplace fuel temperature sensor; con- sult @ qualified specialist workshap Garry out a test for leaks; cons ulta qualified specialist workshop Sot pumps using STAR DIAGNOSIS or Miridiag 2; consult a quaiified spe ciat ist workshop Consulta qualified specialist workshop Replace sensor Topup, bleed (> page 76) see Replacing the poly-V-belt a (> page 86) Consulta qualified specialist workshop Clean or remove limescale Check, replace if necessary; consult 2 qualified specialist workshopPeete Malfunctions, causes and solutions ‘Malfunction Cause Charge current indicator lamodoesnot Bub malfunction or suaply line broken light up while the vehicle is stationary Charge eurrentindicator lamp lights up Poly'V-belt too slack when the engine ia running. Poly-V-belt tom ‘Akemator or ragulator malfunction Engine emits black smoke Char g-air sensor, cnolant sensorar fuel temperature sensor dafective Injector defective Exhaust gas turbocharger or charge-air pipe defective, air cleaner dirty Constantly open throttle valve defective Exhaust fumes are blue Oil level in the engine too highs engine oil entering combustion chamber ‘Solution > Replace bulb or repair break > Check bett tansion; roplace tensioning pulley if necessary > Replace the poly-V-belt (> page 86) > Chock; consult a qualified specialist vworkshoo > Check with DaimlerChrysler diagnostic ‘estar; consult a qualified specialist workshoo > Consulta qualified specialist workshop > Carry out visual inspection; consult a qualified specialist workshop > Consulta qualified specialist workshop > Correct oil level have it checked at a ‘qualified specialist workshopMalfunction Exhaust fumes are white Engine "knocks" Knocking noise from the bearings ‘Abnormal noises Malfunctions, causes and solutions Cause Cylinder head ar oylinder head gasket leaking: coolant entering the combustion chamber Combustion malfunction Damage to bearings: Leakage in intake pipe and exhaust pipe causes whistling noise Turbine or compressor wheel scrapes on the housing; foreign object in the compras- ‘sor or turbine; seized bearing in rotating parts Solution > > > > » Locate damaged cylinder using pres- ‘sure lass tests consult a qualified spe ciast workshop Consulta qualified speviclist workshop Consult a qualitied specialist workshop: Remedy leckage; replete seas if nec essery Have the exhaust gas turbocharger re paced at « qualified specialist work- shoprere ei Jump-starting Y Jump-starting Ifthe batteryis discharged, the engine can be started using jump leads and a donor —_Risk of explosion A battery. Gases escaping frombatteries can explode Risk ofburning ZX —_ardinjure people. —.reretere, avoid fro, naked teres and ‘The acid contained inbatteriesbumsskin sparksandrefranfromsmakinginthe vcin- ‘and eyes on contact. ity of batteries. ‘= Avoid contact of cc wth yeu skin eyes orcleting. u pea oe cue he prceatve cote Make sure that the donor battery and battery ecd can bum through nornel the stator battery have the same nom clething and also wear protective inal voltago. Otherwise a battery could enn eaa be imeparably damaged. * Rinse acidsolashe soffimmediately vith ccleanwater and consult zdectorif nec- ff Do not place any metal parts on the essary. batteries, There isa risk of short cir- cuit. Only use insulated jumo leeds (cable cress section aparaximataly 70 mm?) andingulated torminal clamps. Thorois a risk of short circuit. A discharged battery ean froeze at about ~10 °G;it must have thawed out before jume-starting. > > > a ‘When jump-starting the engine, the maximum on-board voltage of 26 V must not be exceeded (as this would ‘cause electronic damage tothe control part), ‘Connect the positiveterminalsfirstand then the negative battery terminals, Start the engine (> see page 47) and allow torun far @ short while. Remove the jump leads in the evarse order.Bn rey Enginedata Test values and adjustment values Tightening torquesBee Ete) Engine data Y Engine data Dimensions in mm: (Standard version, other versions on re- quest) (OM 904 LA (OM 924 LA A= Engine longh 830 mm B= Engine width 645 mm C= Engine height 925 mm (OM 906 La (OM 926 LA A= Engine longh 1,078 mm B= Engine with 645 mm (G=Engine height 940 mm Mustrated: OM 904/924L8 lhustrated:OM 908/924LAWeights (0M 904 LA (0M 924 LA Engine, dry Engine, wet General data ‘Type ‘Type of cooling sy ster ‘Combustion princiale Number of cylinders ‘OM 904 LA/OM 924 LA: (OM 906 LA/ OM 926 LA: Cylinder bore (0M 904 LA/OM 906 LA (OM 924 LA/OM926LA Piston stroke (0M 904 LA/ OM 906 LA (OM 924 LA/ OM 926 LA AL) Engine data Inline engine with exraust ges turbocharger and intercooler Forced circulation cooling ‘4-stroke diosal direct injection 4 6 102mm 106 mm 8 130mm 136mmBrie) Engine data General data continued Displacement (OM 908 LA/ OM 924 LA: (OM 906 LA/ OM 926 LA: Direqtion of rotation of engine viewed from flywheal Type of stating Coolant capacity of engine without intercooler (OM 904 LA/ OM 924 LA: (OM 906 LA/ OM 926 LA: Engine oll capacity including oil filter ‘OM 904 LA/ OM 924 LA: (OM 906 LA/ OM 976 LA: 4,290¢nF /4,800 om? 6,370 em /7,200 om? Anticlockwvise Eleotric B51 1251 min. 13 I:max. 161 n. 24.1; max. 291Data: Starter motor, battery and alter nator (standard) Starter motor Voltage Output Battery (notin scope of delivery) Voltage Cold test eurrantin accordance with DIN7 231 1 Cold start ability without jump-starting ai 75% battery charge down to Alternator Voltage Current rating 2av 40 W av max. 450 A max. -20 °C. 28V aA Engine dataTest values and adjustment values ¥ Test values and adjustment values Engine oil pressure (min) at idling spocd 20.5 bar atrated speed 22.5 bar Valve clearance Inlet valve 0.4 mn Exhaust valve 0.6 mn‘Y Tightening torques eo Allthreads on mechanical parts and re- lated contact surfacas must be clean ‘and smooth and lubricated withengine cil other lubricants raquire significant |y itferent tightening torques. Designation Engine block Cylinder head cover to cylinder head bolt Gil sumo bolt to cylinder crankease Poly'V-belt tensioning device to cylinder crankcase /to hy draulle pump retainer /to support Fuel/injection system Injestion ine to unit pump pressure pipe connection Benjo batts for fuel lines Cap to fudl fiter housing Starter motor/alternator ‘Starter motor to timingease Altemator support to eylinder arankcase Bun Lie) Tightening torques: & 8 & 100Bete Lt) Tightoning torques Designation Altemator to support Altemator to retainer Oil circuit Ol drain plug in ol sump M20 x 1.5 thread M26 x 1.5 thread Altemator retainer to oll ter Oilfilterh ousing to cylinder crankcase Oillfiterh ousing support to cylinder crankoase Oilfitercap to al fiter housing Pressure sensorto ol fter housing. Valve adjustment Gounternut on rocker arm set screw Cooling circuit Coolant line with themostat vale to coolant pump Coolant pump to eylinder crankcase Belt pulley to coolant pump hub 6 5 85 40 25 25 2 25 25 25 25 28ADM ‘Contiol modulo as interface botwoen the engine and the vehiale electronics. Belt drive Drive connection from the engine to the engine assemblizs, such as the ak temator, coolant oump or refrigerant ‘compressor. CAN (Controller Area Network) ‘Serial data transfer system which net ‘works tho ve hide's electronic systame ‘and allows an organised mutual data ‘exchange. At the seme time the numbar of components raquirad is ow er. This reduction of potential maltunc tion sources improves refability and maintananee frionalinass. Constantlyopen throttle valve Valve fitted in the cylinder head in con- Junction with throttle valve brake or Turbobrake. When the engine brakeis ‘operated, the constantly-open throttle valve causes @ reduction in the cylinder praseure during the working stroke. Control unit Partof the electronic system which ‘controls the engine or transmission functions, far example. Emergency running program Special program inthe Telligent® er- gine system whieh allows limited ‘engine operation if electronic comao- nents have failed. Engine ol viscosity Meagurament of the internal friction (viscosity| of an oll atadefined temoer- ature. The viscosity is better the higher the tomporature the oil can withstand without becoming too thin, orthelower the temperature the oll can withstand without bacoming too thick. Engine plate Number specified by the manufacturer aad macked on the cylinder head to clearly identity each engine. Exhaust brake algo throttle valve brake, Works by ‘losing the exhaust oioe. Bren hci FAME fuels (Fatty Acid Methy! Estor) FAME fuels are bio-diesel fuels based on fatty acid methyl esters. Flame-start system Thisisa coli-sta rt aid forthe engine. It can be used to preheat the charge air using fuel combustion. FR (Drive contro) control unit, The drive contol is @ monitored alactronie sys tem and is connected to the engine contal via the CAN bus. The FR is pe~ ‘manantlyinetalladintho drivar'sea0. It controls vehicle-relevant functionsand switcheson the engine control via CAN bus commands, e.2. engine torque ro quest via 2ecelerator pedal position. Grid heater Thisisa coli-sta ct aid forthe engine. It can be used to preheat the charge air using a heater coi.DaimlerChrysler AG electronic diag nostic tal for reading faults and pa- rameters on commercial vehicles MR {Engine control) control uri controls a monitored elestronie sys- ‘tem which forms part of the Telligent® ‘engine system. I controls the engine functions, such as the engine idling ‘speed and exchanges data with the drivecontrol. ou Engine name, ebbrevie gine = diesel engine. Sensor Electronic comparent which converts certain parameters (ag. oil tempera ture, engine speed and others) into electrical values for use in the engine ‘eontol unit. 9) STARDIAGNoSIS: DaimlerChrysler AG electronic diag nostic system ; term for the upper po- sition of the piston in the cylinder. Telligent® engine system Mercedes-Benz electronic engine con- trol. Controls fuel injection period and ‘quantity depending on the curent oo- erating conditions and driver's re- quests. Tightening torque (Nm) Product of force and lever arm length ‘with which bolted connactions, e.g. cylinder head bolts, are tightened. (Nm Newton metres)Adaptation module .............. 31 ‘Adjusting the valve clearance .. 73, 75 ADM. 23 Alternator . Antifreeze /corrosion inhibitor... 6& Lo = 43, 106, 111 Gharge cu ment. 49 Commissioning 42 Constantlyopen throttle valve..... 28 Conversion parts and modifications 38 Coolant Mixing ratio. o 64 Renewing... 294 Coolant level. 90 Gooling system Clearing Degreasing... Cylinder head cover Removing and fitting. DRE reine control Diagnostic socket 32 Enginedata Diagnostic testers . 32 Engine data’ card Diese! fuels Engine oil Inextremely cold weather... 60 _ Extracting, draining. Subphur content 0 : Dimensions. Disposelof service products |... 64 Exhaustbrake. th Drivecontoluni | CE Fee start syste Emergency running program 29 How improvers. Engine Fuel Checking for laaks and general Filing the tank . condition...» Fitor element. Gleaning............5 woes Profilter. Ol change and filterreplacement... 69 Fuel additives . staring Fuel system Stopping... . Beeding ... ee cine tn Ee ‘Checking the adjustment ‘ Genuine Mercedes-Benz parts ..... Checking the-condition. Cenuine we of 9em pressure cleaners. Personnel ....... 32 Poly-V-belt — ‘Chacking the condition. 83 Indicator lamp - Removing and instali Intake pipe Gheoking forleeks ....... 82 Tensioning pullay . . Protectionof the Safety and emergency running pro- gram. wee Sofety precautions. Service products . ‘Special lubricant additives Starter motor Starting the engine for the first time 29) 1 Operating safety |... Overview M904 LA/OM 924 LA 712 Telligent® engine system Test values and adjustment values m2 Tighteningtorquues..... ns Transport and installation 33 Type designation. 24 Valve clearance . 2 Adjusting. Agjustmant.. Checking. m Warning lamp... AT Werranty entitlement ... 289 Water. - 263 Weights. 109 Winter operation . 283 Work plans 67Contact Mercedes-Benz will be happy to answer any queries you may have: Mercedes-Benz Contact Telephone:00800 1 777 7777 Intemational: +49 69 95 3072.77 Internet Further information about Mercedes-Benz and DaimlerChrysler can be found on the following websites: ww.rnercedes-berz.com ‘vow. daimlerchrysler.com Editorial office You are welcome to forward any queries ‘or suggestions you may have regarding these Operating Instructions to the technical documentation team at the following address: DaimlerChrysler AG, HPC: R822, 70546 Stuttgart, Germany ‘Ag at: 28.05.2003, Title illustration number NOO.01-2 194-31 Not to be reprinted, translated or otherwise reproduced, in whole or in part, without written permission,