EPA TIER 3 (US EPA 40 CFR Part 89) @ ease also refer tote ina (> 0088 117) Operating Instructions OM 501 LA - OM 502 LA EU Level Ill A (EU 97/68/EC) Mercedes-Benz Introduction Protection of the environment ..... 5 Operating safety 6 Correct use a 1_Atagiance OM 501 LA overview ...... 10 ‘OM 502 LA overview (2 turbochargers) 4 ‘OM 502 LA everviow (1 turbocharger} 18 Location of sensors 2 Engine number 24 2__ Before commissioning General information Type designation Engine data card Descristion of the engine Flame-start system* Engine brake" /constantly-open throttle vales* 5... 2 Tattigent™ engine system. Transport and installation 34 3 Safety Safety precautions 38 Staff qualifications 29 Conversion parts and modifications to the engine ......, 40 Safety /emergency running programs . a Genuine Mercedes-Benz parts ..... 42 4 Operation ‘Starting the engine for the First tim a4 Preparation 44 Starting the engine for the frst ime 46 Starting the engine 49 Monitoring engine operation ot Charge current... -- esses. BI Teligent® engine system 31 Oil pressure ci 2 Flame-stant system* 52 ‘Stopping the engine 53 Winter operation 54Cleaning /protective treatment... 56 Cleaning the engine 56 Cleaning the cooling system... .. 57 Protective treatment 59 Service products 00 Diesel fuels esses esses ot FAME fuels 63 Engine oils ¢ 65 Boole 3 cesevewss miners bron 68! 5 Maintenance Maintenance instructions 70 Work schedule overview .........71 Maintenance service 7 Additional Work... sss seecces PA Additional work with every third maintenance service ” Work schedules ...... os TH Engine: checking for leaks ond general condition n Lines and hoses o7 the engine: Chechingfor lah nd gee ‘condition n ¥ Protection of the environment Environmental note 9 DaimlerChryslers declared poi is one of ‘mepraed environmental protection. This policy starts at the oot causes and encom passes in its management decisions al the cconsequorces for te envconment which 0uld arise from production processes ot the preducts themselves, The objectives are forthe natural resources ‘hich form the basis ofourevstance on this planet tobe used sparingy and in 8 manner ‘which takes the requiraments tort nature and humenity into sceount Operate tre angine in an environmen resporcice manor and you tl hep te > tect the envionment. Engine: cil change and iter replacement. 73 ‘Adjusting the vahe clearance... 78 Fuel connections 80 Heated fuol prefilter with water separator’: eplacing the fiter element at Replacing the fuel iter clement 82 Intake pipe belwoen air cleaner and engine: checking for leaks and general condition a8 Poly-V-belt: checking condition . .. 85, Engine brake": checking condition and adjustment ....... 89 Engine cooling system: checking and correcting the fluid \eve! and the antifreeze /cotosion inhibitor... 90 Cooling and heating system: checking for leaks and seneral condition xi Renewing coolant 94 Fuel consumption and engine wear ders! (on the operating ction Therefore: do not warm up ie ering a te spend swith off the engine curing pviods in Stationary trafic © monitor ful consump © camp out tre specited mainronanee work reguisiy 6 Practical advice Malfunctions, causes and solutions 98 Jumpstarting o.oo occ cers e ee 106 7_Technical data Engine dat 108 Test values and adjustment VAIUES ee eeeee cents sere NS Tightening torques 14 8 Glossary Index aTcca Operating safety The operating slety ofan engine primary depends on its proper installation in the Risk of accident A system a5 2 whole (eg vehicle, machine, ete). However, asthe operator, you also ‘Eine samp ssi have adirec influence on the safe opera cessin an acids tion ofthe engine Some of the requrements for operting, "ir swgenixe Oe the engine stl canbe met by acherng tothe speciied maintenance intel nd teauingthat be requtedrmaterance Risk of accident A wort in cared cut coresty aintenavea wore that ety orate andthe fare to the spared maintenance nts, may However, the safe functioning of the er- gine also depends on correct operation, which includes, for instance, checking the engine oll evel at regular intervals. the era ie af te ng ae cause engin dara eu Therefore, steer the notes on engine meinen in these Operating Ins Operating safety Correct use A ‘The engine is only designed for instalation einen eue in accordance withthe specifications de- Work ineartelly cars an om wean i fined in the contract. isk of accident components and thelr ao.ssr0 cos dip the functioning ofthese enmcnnt ‘The manufacturer of the end praduct is the electronic systems are vores eS personally responsible fr the complete might aso affect systems hat hve st system andin particular forthe corec n- een modfed. stalation end compatiblity ofthis engine Fer this reason, suey have woo. withthe ret ofthe system, rmodiestions 6, eleronc comoaves's The engine must net be meeifed. carte ut ata qualfed specie e's __DaimlerChrsler accepts no responsibilty sop. for damage caused asthe resuk of modi DaimlerChysier recommends that yoiuse cations aMetcedesBert Seviee Cre‘ Correct use of the engine includes acher- Purpose asit has the necessiy su29i8% ing to thege Operating instructions, ad- sowledge and tok for ths wos 3:80 pering to the maintenance intervals and performing maintenance work correct in accordance with these Operating Insiruc- ions.OM 501 LA overview OW 502 LA overview (2 turbochargers) (OM 502 LA overview (1 turbocharger] 1 Location of sensors Engine numberFr 5 IM 501 LA overview : © Coolant pure a: © Charge pressure pipe trom intercooler (with lame-start system") ‘® Charge pressure pipe to the intercooler ® Oi filler opening © Exhaust gas turbocharger © OW trap crankcase ventilation system © Fite pipe (with engine broke throttle waive") @ Oil finer © Fuel iter G Starter motor ® Dipstickz (0M 801 LA overview ‘OM 501 LA overview a Q Oitpon i © NA (engine contol unit — © Frywhee! housing @ bxhaust manifold © Fuel pur with ranged power steering pump"| ® sir compressor? @ Besonator* (only in conjunction with ai compressor) @ START/STOP buttons @ Aeratora (OM 802 LA overview (2 turbochargers) 4 ‘0M 502 LA with two turbochargers OM 502 LA overview (2 turbochargers) : Q Coolant pump 1 @ Chorge pressure pipe rom intervooer oe with rame-start system”) @ Charge pressure pipe to the intercooler @ Oi filler opening © Turbocharger © Oil trap crankcase vention system © Flue pipe (with engine brake thotte valve) @ Oilfiter @ Fuel titer @ Starter motor © DipstickOM 502 LA overview (2 turbochargers) OM 502 LA overview (2 turbochargers) : Q it pan 1 @® MR (engine control) unit _ Fryneei mousing @ Exhaust manifold © Fuel pump (with flanges power steering pump*) @ Air compressor* © Resonator (only in conjunction with air compressor) ® START /STOP buttons © Aternator(OM 802 LA overview (1 turbocharger) (OM 502 LA with one turbocherger OM 502 LA overview (1 turbocharger) @ Coolant pump ® Charge oressure pine trom intercooler {with larme-startsystern") @ Charge pressure pipe tothe intercooler @ Intake opening (trom sir cleaner) © Exhaust ges turbocharger @ Oiltrap crankcase ventilation system @ Oiler opening @ oifiter © Fuel fitter @ Starter motor ® Dipsticki (OM 502 LA overview (1 turbocharger) OM 502 LA overview (1 turbocharger) i @ Oilpan 1 @ MR engine control uit — @ Flywheel housing @ Exhaust manifoe © Fucl pump [wth tanged power steering pump") @ Air compressor” @ START/STOP buttons @ Alternatori Location of sensors Example OM S01 LA Location of sensors a QOillevel sensor 1 ® Crankshatt postion sensor _ {on the Flywheel) @ TDC sensor (on the camshaft sprocket) @ Fuel temperature conser @ Combined cherge-sr pressure / temperature sensor @ Coolant temperature sensor © Oilpressure sensor © Oiltemparature sensorEngine number Location The engine number is algo located on the Information on the engine {ront of the ol fiter housing. AL the engre nuntriscatsd ont et save the manta’ pc rund seeofte rg, enn eet poodgyy, men betomg somite Sparen engin aw DaimlerChrysler AG Qusun ra@ O minors © wvsiseee duaarensvte Information on the engine 2 Q Engine model designation smooch & Engine number Loestionf the engine number om the eR Type approval number hand sige of the fan © Frgine group Location ofthe engine number on the rear lefthand side General information ‘Transport and installationOM 501 LA — om it engine {diesel engine} 501 Engine model! Intercooler ‘A Exhaust gas turbo- charger 1 04 S01 avinder 0 50: Bender Engine data card The engine data carc {A$ sheet) forms an ‘integral part of the documents belonging to the engine and should always be kept ‘with the Maintenance Booklet. It contains details about the engine, including special equipment. ‘The engine data card must be produced for the procurement of genuine parts Description of the engine ‘The OM 501 LA [6-eylinder) and OM 502 LA (G-cylinder} engines are water- cooled 4-stroke direct injection diesel en- ines, The cylinders are arrangedin aV-pattern at ‘an angle of 90°. Each cylinder has two in take valves and two exhaust valves. Each cylinder has a separate fuetinjection ‘ump (unit pump) connected by a short high pressure fuel injection tine tothe mul- tihole nozzle located in the centre af the Combustion camber. The unit pumps are ‘mounted directly on the crankease and civen by the camshaft The engines are fitted with 2 turbocharger and intercooler as standard, The engines ‘can be equipped with an engine brake" a6, an option |throttle valve and canstanty- ‘open throttle valves*) as well as with a flame-star system. Engine data card oe ‘The engine data card describes the scope of delivery from the DaimlerGhrysier factory, later changes tothe scope of delivery are not recoro- ed on the data card, ‘Always keep the engine data card with ‘the Maintenance Booklet. The engines produce particularly low emis- sions. Injection start, injection period and injection quantity are controle fuly elec wonicelly. ‘The control system consists of an engine cntrol unit mounted an the engine, the [MR module, with an integrated heat ex- changer for cooting through the fuel supply system, and the application-dependent FR (drive control) unit or the ADM adaptation module. All these contra units ae inter- ‘connected via the Controller Area Network (can) Flamesstart system” The fame-start system isa cold-start aid for when arnbient teriperatures are low. It reduces the emissions of white smoke ‘once the engine has been started. The starter motor and battery are also protect- ed as a result of the shorter start-up time VIR, Flame-start system A flame glow plugs fitted in the charge pressure pipe of the intercooler. Fuel can be ignited at this flame glow plug. The fuel is supplied tothe flame glow pg via @ so- lenoid vaWe with 2 dosing nozzle,General Information Flame-start system indicator lamp [exarnple) Following the preglow time, whichis de- pendent on the outside temperature {max- imum 20 seconds, the flame-start systema is activated and the flamestart indicator lamp goes out (nee the engine has been started, the flame:start system is supplied with fuel by ‘the fuel pump. Engine brake’ /constantly-open throttle valves™ Toincrease the braking power, the engines ‘can be equipped with an exhaust brake salve on the exhaust gas turbocharger in ‘conjunction with constantly open thratle valves on the cylinders, Whereas exhaust gas backpressure, acting through the exhaust orake valves, can be ‘used fo increase the braking power, the constantly-open throttle valves cause 42 reduction of eompcession in the power stroke (3rd stroke}, leaving compression (2nd stroke) practically unaffected, The constantiy-open throttle valves are valves in the cyinder head. When open, they connect the combustion chamber {to the exhaust duct, which generates the sequired decompression in the power stroke, “The flame-start system is only enabled if the engine is started within 30 seconds of the flame-start system incieator lamp g0- ingout. e ltthe flame-start system indicatorlamp does not go out after more than 20 sec fonds, there is a malfunction inthe stame-start system o Fr operation at low outside temper- atures, see algo the “Diosel fuels” (D page 61) and “Coolant” (> page 66) sections. Activation ofthe constantly open throttle valves When the engine brake is activated, the constantly open throttle valves are opened by compressed air. At the same time, the ‘exhaust brake valve on the exhaust ges turbocharger is closed ‘The engine drake is controled by the dive control unit (> page 32) ar the ADM General information The engine broke always remains deacti vatad at engine speeds of below 900 rpm to prevent the engine from stalling. The ‘engine brake is also automaticaly deact- vated if the position sensor is triggered {eg ifthe accelerator pedal is depressea} In the emergency runsing program {constant engine speed), the engine brake can oni be activated in overrun ‘mode at an increased engine soeed. The engine brake is automatically ceac- tivated again once a constant engine speed has been reached.General information Telfigent® engine system ‘The engine has a fully electronic contro! ‘system, which, in action to the engine 2. and associated sonsors, also comprises: ‘© an MR (engine control) unit and © an FR (drive control unit and/or other vehicle-specifc control units, ¢.g. ADM ‘Both are interconnected via @ CAN (Con- ‘roller Area Network) lie, on which all the necessary data /information is exchange. ‘The engine control monitors itself 23 well as the engine. A safely and emergency run hing program is solected automatically, depending on the malfunctions / system failures that occur (D> page 4) ‘This datas evaluated along with deta from the sensors on the engine, such as those for ‘© charge-air pressure and temperatore © coolant temperature > fuel temperature © ol oressure ‘The data is compated with the maps and ‘characteristic curves stored in the engine ‘control unt Injection timing, perioe end volume ere caletiated based on these compar'sons. ‘and the solenoid valves are actuated to ‘adjust the unit purnps accordingly. MR {engine contro!) unit (mounted en ‘the engine) ‘Tne MR (engine control unit's mounted on the right-hand side ofthe engin. ‘ la IMR (engine controf) uit CControt unit ype plate @ Date record @ Centification no. @ Engine number @ Equipment code ‘DaimlerChryster Elect. Control Unit, 2s The MR (engine contra) unit processes data from the deve control unit or the ‘AOM indicating for example the position ‘of the position sensor (accelerator pedal) ‘the engine brake” or engine start/stop, ate. General information e All the information on the control unit ‘ype plate is required to obtain a re placement engine control unit.General information FR (drive control) unit or ADM (mounted fn the equipment) Theengine can be adented to meet various 2 apolicaion-spacifi requirements by <= means of the dive control unit or adapta- tion mori (ADM). FR drive contra) unit ‘The FR (tive contral) unit or the ADM storesa range of application-specttic data, such as idling speed, maximum working speed or speed limitation, Diagnostic socket EUcompliant service connector ‘The FR drive control) unit or the ADM re ‘ceive data from the: © operator (positon ofthe positon sen- sor, engine start/stop) ‘© engine brake switch” 1 other systems le.g, acceleration skid ‘control system} © Mi (engine contro} unit (e-. oll pres- sure and coolant temperature) ‘This data is used to determine the instruc tions for engine contro! (MR contrl uit), which are then sent tothe engine control onthe CAN line ‘The FR drive controll unit ar the ADM con trols various displays, e.g the electronics ‘warning lamp, the engine brake’ ad the constantly-open throttle valves". Organisational measures Risk of injury A Bator operating the on ‘The Operating instructions and Mainte- ‘nance Booklet must be glen to the per sonnel responsibe for operating or car- ‘ng out work on the engine, and should be kept in an easily accessible location where the engine is used. ‘These Operating instructions must oe used to instruct personnel how to handle the en- gine. Io particular, the notes concerning ‘safety must be explained, Thisis espectally Important for persannei who orly work on the engine occasionally If the Teligent™ engine system detects fauit, this ie stored in the control units 2s & fault cod, which can then be read using appropriate diagnostic equipment (STAR DIAGNOSIS or minidig2. In addition, the electronics warning arp lights uo oe ‘The DaimlerChrysler dlagnostic equis- rent can be connected to the equip ‘mentmounted "pin diagnostic sock: ct or using the EU-compliant service ‘connector. This equipment ean be used to read both the malfunction memory and the stored engine dat, General information Al universally applicable, country-specific, legal and other mandatory regulations for ‘ccident prevention and protection ofthe ‘erwironment must be observed in addition 10 these Operating Instructions 2‘Transport and installation Transport Risk of injury SS Theengine can beak cose znd cane nur) te somebody by overturning tag © Only the engin bythe e90 Iiking points an the engine. Oniy use rensport equipment tat has been approved forse by DaimerCheyslee © Oniytttanc transport he engin in the instalation position, Observe the 2st ‘mam angle of 30° wen iting he 29 ie in or out ofthe meshing 2 wenicle, Installation The engine is only designed for installation in accordance withthe specifications oe- fined in the contrac. ‘The manufacturer of the end product is personally cesponsibie for the complete system, and in particular forthe correct in- stallation and compatibility of this engine vith the rest ofthe system, Observe the “Correct use" (> page 7) and “Conversion parts and modifications tthe engine” {D page 40) sections. ‘The “Technical data” section of these Operating Instructions contains informa: tion requited forthe installation ofthe engine. Please consult a Mercedes-Benz Service Centre if you have any questions, e ‘The engine is filled wth engine oil at the factory. ting point, fhyrhee! side (OM 501 LA shown} DR Lufting point, Belt sie (OM 501 LA shawn) ‘Transport and installationSafety precautions Staff qualifications Conversion parts and modifications to the engine Safety /emergency running programs Genuine Mercedes-Benz partsSafety precautions Thesafety precautions inthis section musty a ee ae ek ‘© Note that for etectric welding work, © The control units must be removed a con Re emcee Omori the batteries must be disconnected if temperatures of over 80 °C ae eee TES: ‘and bath cables (**" and “-") (eg. inthe drying oven] are ex: a ‘securely connected to each other pected © Dornot start the engine unless the |-* The connectors for control units © Orly use sutable test leads a2 Eateries are securely connected. must not be disconnected or con- {64g DaimerCheysler connection ‘uniess the eect for taking measurements at © Do not disconnect the batteries La al a art win bescgnctannie, is switched off. ‘connections. a © Incorrect polerityin the ontrclunit |) ® Telephones and two-way radios © Do not use ger to start eae ee ERE power suaply [e.g caused by in- that are not connected to an exteri- correct battery polarity) can cause ‘or aerial can cause malfunctions in © Only perform jump-stating with lereparable damage to the control the vehicle electronics system and separate batteries, units, thereby jeopardise the operating ‘© Note thatthe battery terminals ‘© Tighten the connections on the fuel satay ofthe ena, must be removed for raaio battery injection system to the specified charging. Observe the rapic charger tightening torque, ‘operating inst-uetions, Staff qualifications 'Y Staff qualifications Engines may only be operated, maintained Risk of sccident AX. andrepated oy tained personnel intact fd and autharised by te opera. TMinance and vp wot tthe eine aera -—_ ‘The responsibilities for operation, mainte- cared out ncacecty ean impair bth ts correct operation and safety, ead o 22 ‘dens an nny. ‘nance and repairs must be essignedby the ‘operator ‘The legal minimum age for carrying cut the ‘Always have work on or motcations the ‘work listed above must be observed. engine carrie cut at 2 quatied soars ‘workshop which has the reopen epi ist krowiedge and 00s for he work = uted Mercedes dene recommends thal you use a Mercedes-Gene Service Centre fo this pur pose.Conversion parts and modifications to the engine Risk of accident A ‘Tempering withthe engine to modiy can ‘maak baths corect operation end its safety leacing to accidents an inury. 3 Aiways have wark on or modifications to the engine cana out ata qualifies spacast workshop whih has the necessary special= iat knowedge and tools forthe work re aire. Mercedes-Benz recommends that you use 2 Mereases Bora Service Gant tor this pr pose, a Tampering withthe fuetinjection sys- tem and engine electronics may affect the performance and emission levels of the engine. It wauid no longer be possi- ble to guarantee compliance with fac: {ory settings or legal environmental protection conditions. ‘The warranty does not cover damage aris ing from tampering withthe engine. Safety / emergency running programs YW Safety /emergency running programs The engine is equippec with an electronic ‘control system that monitors both the en- gine and itself (sel-iagnostic system), fa malfunction is detected, itis immedi- ately evaluated and one ofthe following measures is automaticaly initiated: © ifthe engine is running, 2 meifunetion is ingicsted by the electranic system ‘warming lamp fighting up. ‘© The fauitcades may be shown on a display on vehicies with the Teligent™ engine system (vehicle diagnostics system, The engine is switched to the appro- priate back-up function for continued (out restricted) operation fag. con stant emergency running speed, fist of acisent A awracanse andteepa atk te 178 Wi ‘cried out ncorectly can impair bate ‘correct operation and safety, lesing to ac- cident and jury Aways have work op or modifestions tthe engine carried outa a quad specialist ‘workshop which has the necessary speci ist koowledge and cols othe work re ues, Mercedes Berzreccmmends nat you ees Mercedes Bone Seige Cente for ti ou pose, and the stored engine data, Electronic aystem warning lamp ‘The DaimlerChrysler diagnostic eauip: ‘ment can be connected to the equip: ‘ment-mourted |-pin diagnostic sock ‘et or using the EU-compliant service ‘connector. This equipment canbe used {to read botn the malfunction memory 3Genuine Mercedes-Benz parts Make sure thatthe replacement parts are suitable for your engine. Parts that lead to ‘an engine /vehicle mosification that: © changes the type of machine vehicle ‘sporoved in te General Operating Permit 3, © poses 2 potentia risk to road users, or ‘© causes a deterioration in exhaust gas ‘emission levels or noise levels will result inthe invalidation of the General ‘Operating Permit fn many countries) The use of non-approves parts can jeopardise safety. Environmental note 9 To combine cast effective rapa wh eae cling, Meroedes Beri iss hors recon sioned engines and parts, These are of he same quality and have the same warranty es new prt ‘Additiona information about recommend ed conversion parts ane accessories and permissible technical modifications is ‘vailable from any Mercedes-Benz Service Gertre. ‘Always quote the engine number and mod- | cesignation when ordering genuine parts. You willfind the numbers on the en gine plate (> page 24) and on the engine data card (> page 26). Starting the engine for the first time Monitoring engine ope: ion Stopping the engine Winter operation Cleaning / protective treatment Service productsStarting the engine for the first time Proparstion Adding coolant When it leaves the factory, the engine is © Coolant composition D> see page 66), filled with an engine ol complying with Filing the cooing system Sheet 228.5 ofthe Mercedes-Benz Specif- ofan, (Sim [see page 94). cation for Service Products = ‘These high-quality engin cis assist the running-n process, enabling the first oil change to take place in accordance with 4 the specified oll change intervals for nor- = maloperation, This eliminates the need or special initial operation ols and the oi ‘change otherwise required, on / Te cundatnatenaeatencicn SOON | nly be observed i engine cis comelying Gy on iter open ‘wih Sheet 2285 ofthe Mercedes Bonz © OF Mer opening Specification fox Service Products are Check the ol evel and, necessary. sed 209 engine oi via filer opening © op to the manimum mark onthe dipstick (D see page 74) Starting the engine for the first time Refueling e Use summer or winter uel depending on Bleed the hested fel prafiter wth war Risk of explosion 4 the season. See sso “Diesl fuels" ter separaor” mounted onthe venle“Z oka (> page 61). ‘of machine with the integrated hand ee and rao cave ity . ure Fre, so res, snaking ans mars 6 When refueling donot allow watecto Checking the batteries sheet onnat parmited nt ncintyot the enter the tans, contaminating the fuel boteres Risk of injury A Bleeding the fuel system ney ES Oniyusebatteresthathave been correctly 4 ithe ue systemisrun dry, the system wil Tau gcosnoan fied and maintained, Grease te batery —— termina with acid-pcoot grease foattery be bled the next time the engine is started asin: terminal grease alter reeling, Automatic continuous bleeding takes place inthe filter © Donat atow anit sith our aki eye ° o “+ Wear suite metetve eating 2: ‘The coble cross-sections ere depend- ‘he battery must be sufiienty biter aid can burn thaugh nova ent on the distance between the bat- charged during the stating procedure St?" ation, rctctve loves {ery ane the starter motor. to ensure that the fue system can be __ °° SY $94Hles sho Le wom, bled ‘+ Rinse aid slashes offimmediately with ‘clean water and consult 8 doctor ec en,Starting the engine for the first time ‘Starting the engine for the first time e , Carry out the work listed under “Prepara- For additional sfety, the Teligent™ en- on” {D> page 44} before operating the en- gine systemis equipped with a function gine for the frst me. that oniy allows the engine tobe start- ‘ed withthe transmission in neutral > sues nine cpnaingcorent, EB > state ei weh the poston en torlegvstaatr peal nthe ig poston og byoesnig START oton Sontag spas 8) Blak of injury A Tha enzine baecmes v0" Not while is ran ‘ving Ar eras for some time after vse bums i touched nas stoop. Selina statin ary woe on te engin, a "cool down o alse ‘Start/stop buttons sr thle les and items of lathing te of saninat Bok engine coma. © START button r ® Stor button Starting the engine for the first time Risk of injury DX Riskot injury dhs Riek ot poisoning A There ie 2 danger of limbs being caught, en» The coolriz storia ressursea Hotcou Therelua ko) py soningit Coolants Saal Dpiademien ene saicsimmmimewie cd © Keen sate cistance between yourset —SkInenES 1+ Newer sto-n coolant mn containers ar. tie ~~ 7" ‘* '* Store cootant out of the reach of chil: “a aoe ee tech ibe cot ok « Marenaieclaratiha alert pice fomimeer > Sceatecmietimt | | eee ecanagetcaey fags ak ‘Fant ange sere me eee, | |e watches ang necklaces. v {the coolant temperature is below 150 °C, check the coolant level again and add coolant i necessary.Starting the engine for the first time ° > Check the engine cillevel approximate: ly 5 minutes ater stopping the engine ifaneaung systems connectestothe A To the maximum mark on cooling system, all heating system ual valves must be opened while the coot- "Me GipstiekIInecesseny ing system is being topped up. Check brackets secured to the engine firm seat ‘Otherwise, there might be too little Soran Saetines coolantin the cooling system afterit sD Check the securing bolts on the ex- filled. ‘aust manifold, engine mountings, a coolant pump, starter mator and air <= Only clase the heating system valves once compressor for tightness the engine has been running fora brie pe- riod and, where applicable, the coolant has been topped up, D> Check the engine for leaks. D> Check the hose fittings, hose clamps and pipe connectians on the engine as well as the ol feed and return lines on the exaust gas turbocharger for leaks ‘and firm seating, and retighten ifnec- essary ‘Starting the engine e Acute temperatures of blow Riskot accident andiniury ff =30 °C Mereese den recommends et ai kl kena ce cee. Teapecy nana aaa I mecca paisctng see ‘entaly be set n motion when the sine’ started, knocking somebody down or tap- Starting procedure ing them. Before stating the engine: For vehicle engines, always secure the ve- ‘Prevent he vehicle from rling ewey _hicle against pulling away inadvertently: ‘by applying the parking bake a sesesn;bysledrg eck urcerine > Aabiythe sking brake, reas. > shift ine transmission into neutral © Shift the transmission ito neutral > inserthe ky into the gion lock and turn t te aive position ° Teteloweginccsoc imp /waring, © CME ore erie ‘Starting the engine for the first time amps light up: 2 ramen varias ae tine @ ramen systune Observe the special measures to be carried out before the engines started alter ithas beer switched off for along. period, see the "Cleaning / protective treatment” section (D> page 56)‘Starting the engine for the first time Tostartthe engine using the START button fthevehcleisequipped withaflame-start » @ ‘on fhemahine-oron Siento: sanre Depending onthe outside temperature, D> Wait untithe flame-start system indi- | the flame-start system’ indicator lamp cator lamp goes out Nights wp. D Stert the engine within 30 seconds us- «from approximately 2 seconds ing the START button on the machine {function check, lame-start system or engine, rot in operation) a ‘© to approximately 20 seconds ‘Keep the engine running at idling speed (maximum pregiow tiene) nti an oll pressure reading i cis- IF the lame-start system” indicator played (do nat rev the engine f0 08 | amp does not go out after 20 seconds, pressure is displayed after approx- ‘there is a malfunction ‘mately 10 seconds, switch off the en | De not place the cold engine under full \ ‘ine, Determine the cause B icad immediacy. (> page 52) : Se necessary, interrupt the starting pro- See cedure after maximum of 20 seconds, @ START button and then repeat after epproximatehy @ STOP button 1 minute. > On the engine: press START burton @)f} The charge curent indicator lamp and on the engine. electronic system waring lamp must {ge out alter tne engine has started. if ‘they remain it his indicates thet tnere is a malfunction; > see page 51) and Monitor the oll pressure gauge immedi- ately after starting the engine. (> page 81 Monitoring engine operation ‘Y Monitoring engine operation Charge current a The charge current incicator amp must go Make sure thatthe poy. V-bet contact outafter the engine has started surfaces are not damaged (e-. tor), oily or glazed a8 this could cause the poly-V-Bel to sip Do not run the engine without a poly-V- belt. The alternator and coolant pump \would not be driven, which would result in engine damage. Electronte system warning tamp Totlgant® engine eyetont Fault codes can be read using sta The electronic system warning amp-must — DainlrCh wt DainlarChnyserdlagresic eulpnent arpa cureet obese so outaterthe engine has stared. (STAR DIAGNOSIS or miiiog? tester) Ite ingicatorlamp cos not go outorifit the waringlamp does nt go outaritit_ (see page 32). te lctronc system lareapann ee etStEC MC Se upurde teenge sen ere VATMELM Ns wie theengre's the engine and check the poly-v-bel, 2 melfunction in the Teifgent® engine U*VINg, read or determine the fout code syster ach malfunction is stored inthe system with its own fault code. Temporery faults ate also stored,Monitoring engine eperation Oil pressure a After the engine hes reached normal ‘operating temperature, the engine oil pressure must not fall below: © 2.5 barat rated speed © 0.5 barat idling soeed 4 it the oil pressure falls below these vat. tues, stop the engine and trace the Flame-start system* ‘There is a malfunction in the flarme-start system it ‘© the flame-start system indicator lamp Fights up while the engin is running ‘© the indicator amp does not go out within 20 seconds of the engine being started '¥ Stopping the engine Run ine engine at icing speed for one or two minutes without oad after oner- ation at full power or high coolant temperature, ‘Start /atop buttons @ START button, © 810° buttor lame start system indicator lamp example) > @ The ame-start systems automatically deactivated if © the engine isnot started within '30 seconds of the flame-start syS- tem ingicetor lamp going out © the engine is started when the flame-start indicator lamo is lit ‘© the charge current indicator amp does not go out while the engine is running, ‘© the engine reaches a temperature ‘a which te flame start systems, Po longer requires Press $10? button @ on the engine or ‘on the machine-maunted engine shut- down facility a ‘Stop the engine immediately if any of {he following occur: ‘significant drops or Fluctuations in oil pressure © faling power output and engine ‘speed with the position sensor accelerator pedal) in the same position large amounts of exhaust smoke ‘emitted from the exhaust significant increases in coolant and cil temperature sudden, unusual noises from the engine or exhaust gos turbocharger ‘Stopping the engineOperation Winter operation ‘The following points should be observed at Jump-starting. Coolant the start af the cold season: Fuel ia Aish offre LX etermmtcnscaite enon. ora; area scape wie yess when the Faletgh toate Retiees—e Darualaacrpucainp | MEO 4. Beit fte and naked ames and retin from stating equipment, such ae ether oF corp snr soporte meme Smoking when handling {uel ‘Starigilot to start tha engine. emparatures below 99 “© + grosses enya aay vsecolareton esti Engine Assia ae wagotes (ees eae). ‘When changing the engine oil, select an NN ea tna ols compete wih ne SAE * ew tale ese os pate avefenson sn he amber ergo can oe ea Wah trecewpesteavingtmepeosclise |S ID see page 651. Winter operation satires ett erg en ment Tacbialapaagtinaaaiger MERA ng hea Cr ane an fe i a es ‘© Never salon cooent, oores: smtlng and sparks re Hebd tees motte nt pene athe the 1 Never tre cocina conta rar ero he vic ath sappusasie ine Tre ae corte baer Sait 1 Store coolant outa theesch of ch. ana eyes an eons aren . Careful maintenance and low power cone + Op ot law sid 19 come va eontsst__ sumption wil help to maintain the fll bat es. soning ‘ery charge. Starting capacity is greatly of tn coolant in good tine and crease cero 28 reduoedin cold weather at -10 °C, ore amps ony eround 00% of noma co ‘the antifreeze / corrosion inhibitor concen- th pect tective gloves sais area moet Scissor ong seaheeeanenier ten Be re. period of time, stare the batteries ina + Reunsidpenstinemsce th Fated pense roe foo ve can wate and soasult 200 >! tation wen recharging. Check the antifreeze protection oropertiesCleaning/ protective treatment Claaning the engine Fisk of poinoning A (Care and cleaning agenscan be fo2 ond eae to severe poisoning swallows Always keep care and cleering agent ‘conainers lesed and out ofthe resch ‘of onioren [Never store care o cleaning racist comainers for comestsies such as bo tee $025 0 avoid confusion. beers the instructions for using cave And searing orodvcts High-pressure cleaners (Observe the manufacturer's operating in- structions, a ‘Maintain the minimum distance bo- ‘wean the high-pressure cleaner nozzle and the object to be cleaned: approximately 70 cm for rounc- spray jets approximately 30 ern for 25° fat spray jets and concentrated power sets Keag the waterjet moving constantly ‘while clesning, To avoid damage, do ‘ot aim the waterjet aivectlyatz electrical components connectors seals or hoses Ris of fire and injury aA Fst ae high flammable and can consti tute a neath hazar. hey ave used as cletning agents, they can cause Dus ‘skin tation and poisoning ‘Never use fuels for leaning Environmentab nate 9 ‘ng ess no engine ina washing area de- signe forthisrasnose, Dispose o empty paccosing used cleaning mateitsinan epetcnmentyteaponsible mana. Cleaning the cooling system Environmental note 2 Cofect used coolant, cleaning solsions ane detergents and lscose of them in an end ‘onmentalyrasp2sble mannar in accord ‘2nce with elevantSosl regulations. > Blow out any foreign objects (dust, n- sects, ete) from the radiator fins using compressed ar or remove thom by spraying water from the rear side ofthe radiator (against the diction of the cooling ar flow), a Only agply moderate pressure when ‘leaning since the radiator fins could ‘otherwise be damaged, a ‘Make eure that water does nat enter the intake, ventilation or bleed ducts. Proteet the engine atterclezning, Be careful to protect the veltérve from exposure to preservative agents. o Information about suitable cleaning and preservative agents i available from any Mercedes-Benz Service Cen- tee Gleaning/ protective treatment Rise of injury A ig tems prnesaises Hot coo! fant c3” escape under pressure whon ne cooling system fs opened and sale your skin era eves, (nly open the cooing system at conlant temperatures botow 90 °C. Unseen the emp slowly and release any ‘excess pressure completalyuetore ‘ening te cap fly. Wear suitatieorotectve gloves, sroee te clothing anc safety goggles when render cooientCleaning/ protective treatment Risk of poisoning & ‘Tare isk of poisoning cnlant == rowed. Never swallow coolant. © Never store coolat in containers nox rmaty used for drinks ‘© Store costant out of the reach of chk ren. > Drain off coolant when the engine is cold (> page 94). > ta neater is connected to the cooling system, open the Fat the cooling system with a 5% solu- tion of water and 2 mild alkaline clean- ‘er.e-8,"P3Cron'” (50 g cleaning agent perlite of water) > Warm the engine up to approximetely 80 °C (coolant thermostat starts to ‘open} ata moderate engine speed and allow itt run for approximately 5 min utes longer. D> Switch off the engine and allow it to cool to approximately 50 °C. > Drain off the cleaning solution com- pletely D> Immediately afterwards, fill the cooling system with clean water, warm up the engine, and drain off the water after ‘5 move minutes, Then repeat the pro: ‘cedure a second time. > Fill the cooling system with new coo ant [> page 95) end observe the notes in the “Coolant” section (> page 66). e Information is available from any Mercedes-Benz Service Centre. Con- sultation is strongly recommended. Cleaning/ protective treatmentService products Risk of poisoning and injury 4& Servee progucts can cause injury or pom ingif they come inca contact with skin or are eallowes, ‘Observe the relevant regulations when han ing, string end isposing of sence prod- 4 vets, Seniee eroduets could otnerwise endanger people andthe enitonent ‘© Aways wear aporoprate protective clothing 398 breathing mask when handling serie product. Avoid ial ing vapours whors possi © Do not aon service products to come inte contact with your skin, e788 oF clothing. Clean affected areas of skin with soap end waree Sea Diesel fuels Only use commercialy availabe diesel fuels (EN $90}. The use of other fuels {is subject t official approval trom DaimlerChrysler. Fuel additives are not necessary. The use of fuel additives may init your warranty entitlement If diesel fuels with & suiphur content of ‘move than 0.3% by weight are used, the en gine ol must be changed at shorter inter vals. Observe the information in the Maintenance Booklet. Filing the vehicle's fuel tank from drums or canisters may introduce impurities lato the fuel system. This can lead to fuel system ‘malfunctions. The fuel must therefore be fttered when filing the sank. The fuel must not be mixed with water ur- der any circumstances, 4 sence products do come ntocantact vith your eyes so ther thoroughly nth Cran ther se esr a doatort eae Consulta doctor immeriately i sere Ine oroduct is swatiowed. ‘© Keep enigg procucts out of te reach of ehitaren, A Tere von nereased Mak of re when hn dling fuels ondltricane as they ave highly ammatie ‘Aci fe, eked flees and spars, anire- {iain rom smoking when handing service products. Risk of fire Greases and lubricants must be com- patible with engine components. For this reason, only brands that have been tested and approved by DaimlerChrysler st be used. These are listed in the Mercedes Bane Specifications for Service Products ‘Specie! wbricant additives are not neces- sary, The use of special lubricant adawes may limit your warranty entitlement e Information about service products is, ‘availabe from any Mercedes-Benz Senice Centre, ® Dispre> of e27ce produess and parts that corre xo contact with service products, eg. hrs on environmentally respons be manner. Environmental note (Obsersn egal reuirements Diesel fuels in extremely cold weather At low outside temperatures, paraffin sep- ‘aration may atfect the flow characteristics of diese! fuel To prevent operating problems (e.g. 28 0 result of blocked filters), diesel fuels with improved col ow properties are available ‘on the market in the winter manths, Devi tions are possible individual countries and in the transition between the cold and \warm seasons. In Germany, special cold- resistant winter grade diese {ves are availabe that ensure reliable operation ‘own to approximately -20 °C. Winter- grade diesel {ue can normaly be used without risk of mattunctions at the outside temperetures to be expected in the coun- toy of sale IF summer diesel fuel or less cold resistant winter diese fuels used, only adda specit= le quantity ef flow improver or kerosene “sutabie forthe outside temperatures, A Risk of explosion ‘ding petro reduces the ist point forthe el and intense the vis of fre 200 explesion 4 Fortis ea900, do net mie etal with the disel uel under ay cicumstances. Forts eason, you must eat! fie, re eg lames acc sparks, nd retain orn smoking when handing these senice products. “+ Observe ihe rlovant stety elationService products Bn Kerosene l. Risk of explosion a There is 2 risk of serious engine dam- Add only as much as is required for the ‘i a& ‘age if petvol is mixed with diesel. prevailing outside temperatures. The ate ah pat of tor oF by volume of Kerosene improves Se Fer is reason 0 90m PD mm Wecoltresstance of deselfuelbyap: i vith the diesel fuel under any circum Crximately 1 °C. Do nat exceed the max- sate mum mixing ratio of 50% kerosene. ‘+ Fo: his weason, avoid fre and naked Sosa tom aking wes Mahe aivewahtne estan gos By nesting nese savin ped 14 time, belore the Now aopertes tN e-em ig ais engine damage ket> tnt bere ihc tefl > set are attected by partfin seoarsion. | Seere ix permanonty mixed sth ie. ma iaucthiamecwnetee: 1 1+ Ferret erosone an thon the de tion can only be remedied by warming up =o the entire fuel system Itis therefore not permissible to mix : Kerosene with diesel on a permanent» Ouscrve the relevant safety eguations, (0 not mix editves with special cold: os resistant winter diesel fuels as the cold: flow properties of the ful could deter yn the engine fora white o ensure thet pe the adeltive reaches al parts of the fuel Flow improvers system The effectiveness of low improvers cannot bbe guaranteed with al fuels, Observe the ‘manufacturer's recommendations. Infor- imation about approved flow improvers is avaliable from any Mercedes-Bene Service Centre FAME fuels a a The OM $01 Lard OM 802 A egies fF * Thefulfiterand engine oifter f * Onkyuse FAME Wes comating ate sable for peratn with FAME uel | -mustbe replaces approximate, wrth EM T4214 Speci ais (bediesel uel compying win EN 14214. | 200 operingousulovingcon- | Fert permite The we offs ‘ono AE ss co basin ane Te olewng eet ite om opraton Theron ul er mtb re En 14214 standard the ton . placed with every engine oil of special additives may lead to © signer ints consution cone echanioen secret re: + Fatvetulastockosntadsirtoces, 4 Immediately igo of he FAME ful wth water before it haste toreadt wh the ptwrk Use onty eng ols comphyng wih Neroages ene Speen for Servoe radios sheet tuber 2185 01 226.3 © aiightly reduced engine power output _—-* FAME fuels reduce the service ite of a conventional fut fit. "© increased white smoke development shar cold sigeaeant | The engine oil change and filter placement intervas are sigificant- ly reduced. The engine ot change ‘and fiter replacement must be car ried out atleast once a year. Before operation with any FAME fuel, Mercedes-Benz Service Centre must be ‘consulted to claily the precise proce- dures for use (eg, maintenance intarvals Observe the following points for operation with FAME fet: oeService products a LO reserwinaccnacaonppicny [> tied onneetiecmernnces, _ Snsianmntstan 9 EF inthe fuel syster to stick if the ene DainierCheysler does net accept | | neice sutcnevotorleng pe. Meusbolpwevegnabiealsasan | wnt whe io ada Forth esos lip Ue aerate to diesel or FANE ks, Ah Hos ter dea mato Uptheamoutot FAME Tuelremam ff Treuse of pur vegetable i can Yeh he engine lus be cole ing in the foe! tank and retuel with leadta engine damage ising from eee i ane claed conventional ese! fuel before the Coking and ol ude forming 25 aa ee engine iscwtched of ering ert well as posts ncombuston oMuindnge ol) ae eto rece 4, ccssRuntheenzine toratieastone chambers ere ‘oor before the vehicle sparked bua the pei esa aol uo. dition onthe sposat eng oso + The qualtyofhoses adjacent tothe rman is "ble rom any cued ee eigre on carneted omnenstne fab wai oo99 or Meresab- Ber Seven vehiieormachine, must satay the cane requirements of FAME fuels. Service products etcdes Bo nest ace worn FAME odes atlow Eng lat apc ete Samoreovget temperate sutby orca oureges Forts + necuseotteconaeisioary —FA\Efuie ae rlsbe soma oonice MEN ary egre cl van a woycoreestone sseols RUE tenperauresel seaman rein Povey ets Bez Tes tet fuel that does nat comply with the accordance with EN 14214, iS ls lel Service Products. Observe the information in the Maintenance Booklet EN 18244 standara + the regulation ofsheet number 135 of Flew improvers the Mercedes-Benz Specifications for Theatition of aw imravers ax kerosene Service Products concerning operation has no tfecton the cold stability of Fatde | TRe Use of romapproved engine oi with FAME fuels Fave nor been ob- fuels brands may limit your waranty entitie- served ment Engine ails ‘© malfunctions or consequential damage (e.g, gaint damage) arse from the nan- ‘dng of of operation witn FAME fue's SAE engine cl classesService products ‘The oil change intervals will change if en gine oils of a diferent quality grace are Used, Information is available ftom any Mercedes Benz Service Centre, Select the SAE engine il classin accordarce withthe ‘outside ternperature. When maintenance work is carried out, Confirmation ofthe engine oil change is tered in the Maintenance Booklet slong with the engine ol bran, its grade anc its — SAE class. e ‘The properties ofthe engine oll deter- orate if lower grade is used to top up the engine oil evel; the engine ail change and fiter replacement must therefore be carried out at shorter in tervals Only use engine ols of the same quality grade and SAE class when topping up. Antifreeze /corrosion inhibitor Observe the following ta prevent damage to the cooling system: © Only use an approved corrosion inhibitor antifreeze. Information is available from any Mercedes-Benz Service Centre, When topping up (after a loss of cool. ant), 2 corrosion inhibitor /anttreeze concentration of 80% by volume must be ensured antifreeze protection down ta-37 °C) a "the concentration s toe low, there is arigk of engine camage as a conse quence of corrosion / cavitation, Do not use an antifreeze / corrosion in hibitor concentration af mare than 55% by volume (maximum antifreeze aro- tection). Above this concentration, a titeeze protection deteriorates and heat dissication is less effective. Coolant ‘Coolant is 2 mixture of water and anti- ‘reeze/ cortosian inhibitor. Te protect ‘against corrosion and raise the boiling paint, coalant must remain inthe cooling system all year round, Risk of poisoning “There is ask of pesoning if cools mak rowed © Nove swale enol 3) Sater see aot rly ase for re, Coolant mixing ratio: Antifreeze pro- 37 approx. tection down 45 toe Water % by vol 50 45 Corrosion max $5 inhibitor /anth freeze % by vol In exceptional cases, when no antifreeze / Corrosion inhibitors available and /or no antireeze protection is required {in topi- cal zones), use an approves coolant eda- tive without antifreeze properties (see Mercedes-Benz Specifications for Service Products) a In this case, the coolant must bere newed every year. Information is available from any Mercedes Senz Service Cente, a ‘The effectiveness of the coolants ant ‘corresion protection decreases over time. You should therefore replace the coo!- ant, depending on the antifreeze / corrosion inhibitor used, every 3 or 5 years (see Mercedes-Benz Specitics tions for Service Products), Water Water without adaitves snot permitted as, a coolant, even i antifreeze pronerties are not necessary. The coolant water must satisfy cestain r= quirements which are not always fulled by drinking water. It the water isnot of sufficient quality, it must be treated. Jformation is avaliable from any Mercedes-Benz Service Centre service products fll Disposat Environmantal rote e ‘We covants ceseried ae bionegredabie suestonces. Observe the aga eguirernents ste ster regulation in the county shen isaosingof used coolams vrmend 2" ye Sonaut the ele vont focal water authsly for advice on the (Fevesat of contont, ut themonicn tasen that uae coolant must pero, maroc recysing consisting simply f ecnariealpre-cieen ine must be categorically rejected =Maintenance instructions Work schedule overview Work schedulesMaintenance Instructions ‘This section describes all maintenance work to be carried out onthe engine aA Before having maintenance ori ‘earned out, please make sure thst you res ‘the relevant sections ofthe technics Soe ‘mentation relating to maintenance ond co pair measures, eg: © Operating instructions and workshop 6 tormatin, You should ls faiiase you'se fst ‘the legal requirements, such «= © nexth and safety as wal prevention regulations. You could cthervse fal to reco g2r8 and could injure yours or Risk of injury Y Work schedule overview: Maintenance service Engin: Dil change and iter replacement o For operation with dese fuel © Change the engine oiend replace the “il filter at least avery two years, '¥ operated with FAME fuel bio-diesel fuel) Change the engine oiland replace tne visvalinspection atthe engine fr conalition Tamas a RCE, signs of leakage. 1 Visual and aural check for leaks rom ye sorsam off by flag em fines and hoses. Also check that a lines and hoses are undamaged, routed ‘Sealing points which are slighty damp can fre pers, Terafare you shoul be ignored 4 Hoey asa sr3e petweom ours si imsucha way that there wil benechat- * #7002 ae etowrn yours a a sceetc Soe wenthe ge s beng sted More significant leaks volving con- : “yo ut atenghe pas nave stopped Fartol basin bereciedtnpctl- ie of inby A * tetaleeepeen tps stay. the enn 5 Theergebecomenven enhIRIEC™™ |r inn tasted ring and eemains for sons ime ater has topped. wil ause burns upon ees tact. frat oose fing, Wear 2 Pair nt ine essay, Renews jewellery svch as ‘and necklaces. © Botoresatng any vk onthe engine, ‘low a cone pis 0 coc! owe or wont suites lens ond ters of th Ingo proteet yourself against "ot en: Bine compress. Work schedules Engine: oil change and filter Oil filter replacement roplacement (ga ere ° a , a) Only change the engine oil when the 7 Unscrew itr cap @ using these @ Senin rng ae eee eect, fhe socket spanner inert war 36). © Ol ite element housing out becevae Int or dit can en- Aw the oll to drei from the iter Unscrew after cap @ with ol fier ter the oil circuit. housing. clemert @) and unc fiterclemont @ trom the cap by pressing on the Sides ofthe bottom edge.Work schedules > Replace sealing ring @ on oi iter ap Dwithanew one, The sealing rng ‘must be lightly greased. Insert new oifiter element into oi {iter cap @ and press unlit clips nto place > Screw on cap @ wih the ol fiter ele- ment and tighten, Tightening torque: 40 Nm ‘Siphoning and draining engine oi = To siphon: © Oi drain plug 5 © Obeene the operating ntti for bapa ple pipe the engine ol ecto unt, To drain: D Place a suitable collecting receptacle uncer drain plug @ on the underside of > Todo this, pull out ol dipstick @ and the ail sump. Unscrew drain plug © carefully and al- Cate apse guirgeegy ” ™ Une ansa © > Siphon off the engine ail through the dipstick guide pipe. Work schedules, 8 Environmental note ® Keeptheengine running ting space = unt anol pressure readings ds- Dispose of engine ol and fiers nce wth the regulations inforce-anero the wales (Bom. FP layed. no oll pressures displayed aos 4 Sf horaoproomatety 10 seconds ten tele pT ttn te: stemne tne ease fe > Screw ne ol sain pug back h wih Rx peel ell alice ‘Bear hecho tern ain pr Tiguenig torue 60 Nm ae D Stop the engine. Check the cil level af } ter approximately 5 minutes. Top up ; the oil to the maximum mark on the & dipstick if necessary, = Adding engine olf \ ) \ sc © Oil iter opening D> Start the engine and run it ating ‘speed {wth the positon sensor in the ‘ding postion) and monitor the oil pressure gauge > Addnew engine oto the engine via the oilfileropering @ up tothe meximum ‘mark on the ot distick. —Work schedules ‘Adjusting the valve elesrance OOx: “OOs: “O@e: “OOs. a Fae Layout of cylinders and valves <= intake vane > - exhaust vave X= fiywneot end Removing and fitting the cylinder head > Undo hexagon bolts @ on oyinger head cover @. > Remove cylinder head cover (D. To ref, follow the instructions for remov- ing inthe reverse order. Oylinder head cover maunting Special tools Turning too! 904 589 04 63.00, Valve adjustment toot 422 589 00 11 00 Valve clearance: lake valves 0.40.00 Exhaustvahe + 040mm e Adjust the valve clearance when the engin colt east 30 minutes ater stoppiog the engine, even fit was only operated fora bit pee Clean very ity cylinder head covers elore removal Risk of accident a 9 enlele might ech «n.tneeking some ern0r causing an oo or ners, © Wisse premant the vehicle fom ating ‘away 5 ering the packing brake an, ¥¥ necessary, by placing chocks under tne wrens 1 htt he transmission into nut he oncine over using the rove eon device arouse fr ti purpose. “ur Fiywhes!ingpection hole Unscrew the cap from the inspection hole in the flywheel housing, D> Fit turing too! 904 589 04 63 00 to the fiywhee! housing inspection note. a Concluding work After adjusting the valves: > Refit the cyinder nead cover (D see poge 77} > Remove the turning tl from the fy- ‘whee! housing inspection hole. Seal the inspection hole withthe cap. Tightening torque: 25 No. e © Vahe clegrance agjustment ‘OM 501 LA. > page 78. © Valve clearance adjustment (OM 502 LA: page 79.Work schedules Valve clearance adjustment OM 501 LA Engine Crankshaft position OM 501 LA Stheylinder valve overtap Seylinder Ist eylinder valve overay otake valve E- exhaust vale Adjust al valve clearances in 2 crankshaft positions. D> Use the turning toa to turn the erank- shaft until the Sth cylinders at overtap ‘TDC{ st cylinder inignition TOC), Then move the tt eyinder to overlap TDC (6th cylinder in ignition TOC}. D Check and adjust the valves in accord ‘ance with the table above, Valve clearence edjustment OM 502 LA Engine Crankshaft position OM502LA bth oylinder valve avorlap Beeylinder 1st cylinder valve overlap | intake vale E- exhaust vale ‘Adjust all valve clearances in 2 crankshaft positions. > Use the turning tool to turn the erank- shaft untilthe 6th cylinders at overlap TOC {1st cylinder in ignition TDC), Then move the tt cylinder to overlap TOC (6th eyinder in igition TOC). > Check and adjust the valves in accord ‘ance with the table above Cylinder /valves to be adjusted 1 7 2 i ' ‘Checking and adjusting the vaive clear- Q Adjustment sorew @ Counternut Cyfinder/ valves to be adjusted 1 2 Wee = 1 Checking and adjusting the valve cle ance 0-3 @ => @ Adjustment screw © Coumernst 3 4 1 E E Se ~~ 4 6 6 e = 1 ‘ VE e > Measure the valve clearance between the rocker arm andvahe bridge usinge feeler gauge (arto). It must 02 possi- ble to pul the feeler gauge through ‘with only ght resistance. Loosen counternut @ to permit justment ofthe valve clearence. Adjust the valve cleacance by turning adjust- ment screw (. > Retighten the countesnut; tightening, torque 50.Nm. Check the valve clearance again and readjust if necessary, ove 4 e > Measure the valve clearance between the rocker and vue bridgeusing@ feoler gouge (aro). must be possi: bie to pull ne fete gauge through with only ight resistance > Loosen counternut @ to permit ad- justment ofthe vale clearance. Adjust the valve clearance by turing aus: ment screw @. > Retigten the counternu:ightoning torque 50 Nm > Check the valve clearance again and readjust if necessaryWork schedules Fuel connections Low pressure foe circuit Q From the tut tank © To the fuel pump @ Tathe fuel iter @ Tathe unit pumps © Return tine to the fuel tank © Return tine to the unit pumps Heated fuel preflter with water separator”: replacing the filter clemant Risk of fire A Tecvis ms cenod ak te tenon ings iy ry Female. ‘Avoid fire, naked flees snd sparks, 2n3 r= frzin 9 gmokiog when handling ues Environmental note ? Dispose of used fte eloments, seals ane fuel residue in secordance with elevertl- cal eegultions Heated fuel profiter wth water saparator* @ Fue! hand pump, @ iter housing @ Water separator @ Water drain vatveWork schedules > pan water dain sve @ andthe Sled stew Cole the fl / water trbaure tm the iter element ing conta > Unscrew fiterhousing ©. > nscrewnateseperter @ fom iter esing @ ard lean or replace 33, eves Refitin te rverse order, Use ne seal, Sam Screw fier housing @ onto the fiter head tightly by hand, > Close the drain valve ang fil the pref- ter using fuel hand pump ©. Then lose the bleed scvew. D Start the engine and bleed the fuel ys ter, e The fuel prefiter is fitted on the ma- chine or venice, ‘Observe the operating and mainte- nance instrections in the machine / vehicle operating instructions for the fuel pefiter ak Replacing the fuel ite element Olan @ Run the engine for approximately 1 minute. The fuel system bleeds auto- ‘matically. f the engine stlis or does not start, bleed the fuel system manu- aly 1 Star the engine, check the prefiter for leaks. Open the tank cap to prevent excess pressure in the fuel tank Unscrew fue! fter cap © using the socket spanner insert (WAF 26}, Pull cap @ withthe fiter element out of filter housing @ slighty. Allow the fuel to flow out. Remove the cap and filter element. Un- clip the tar element by pressing the sides of the lower edge ofthe terete ment. ‘Make sure that no foreign objects center the filer housing. © Never wipe the iter housing out © The ingress of water must bo pre: vented. Replacing the fuel filter element Risk of fire A Therese uminosed om offre when Ran ting unis ay se ay lammadse Avoid fx, ke lames end sparks, and ve fran fom smok=3 when andl fuels. Environmental note ® Dispenso) od iter elements, seals ane ‘ue! “due in eccordance with relevant I> al agin Work schedules aS 1. Fuel fiter element Q Cap @ Seating ring @ Filter element > Replace sealing ng @ with anew one (grease lim. > Clip new iter element @ ito cap ©.>> EelWork schedules > Scrowoncep Qwithiiterstoment® yp @ saciueiens ‘Tg bleed the system manually, the ma- Tettegne tormenta Nie chine or vehicle must be equipped with b indintnieantssntlst | seni eccanlanie D Stortheengieand cee Sse re chen thet ter a un the engine for approximately bs natal nb @ poe oreo ‘matically. Ifthe diese! Fuel tevel (luat tank) is abowe: ~E. | tne engine stals or doesnot stat bleed the fuel system manually. ‘engice eight the feedine must be cise ‘when te fer isvep'ced, Diesel fuel coud otherwise ow out Check the fuel filter fr leaks with the engine running, Work schedules Intake pipe botweonsircleaner and Poly.Wbelt:checking condition «Check the poh. Vel for damage see: See eed ‘on by section todo ths, tun the en gine or poly-Vtelt gradually using the teneral condition = isk of nhry choc he rubber sleeves, nak pipes & turing too un te hak mat ‘and connection hoses for damage and Faully pal reached agein. ieaks, tne bet ay rm ey a > check the hose clamps, aged ons ns EE thers Fepace te polyV-bek toro ofthe anGintake manfoKtorfom seeing, * Maye otsana tw scciourcide- forage plea shove onthe next oes at ar pate’ detected. Forinormation on ft + roomoge iw aiteced lee the coly fing and remouig the pobbet ‘sal cocenoa tency (see pase 87 5 Special tole > Remove the turning tol i Teri took 908 HO OAT scat cap back no the inspection hole in the tywneel housing, Fit the turning tool to the fywheet Tepedniag eigade2s Ni housing inspection hole. D> Make a chalk mark on the paly-V-belt.Work schedules Damage patterns @ Conaition as new jas reterence:trape- 2oidal ribs) @ One-sided wear: wedge-shaped ribs @ Cord visble at the base ofthe ribs @ Ribs sot © Transverse cracks in sever ros © Rubber nodules ot the base ofthe bet © deposits of cit or stones @ Rib detached from the base ofthe belt © Cord tom cut at the sive @ Outer cord ayes @ Teanaverse cracks onthe back ofthe bet @ Transverse cracks in several rvs Remaving and fitting the poly-V-belt hendle with extension inthe ten- sioning device @ Work schedules Risk of injury A The ersening orice sping tensloned tien ite acs: netted there is 2 of nary From crusiegeentrapment a arate 1 For this reason, atways carry out work on the tensioning deve wth extreme "hat the toot is mandi cor Fit the clamping handle with 1/2" ex tension into the tensioning device. > Swing the tensioning pulley down and remove the poly V-belt Swing back the tensioning deviee.Work schedules > heck thet both the tensioning dovice and the bel pulley are in perfect cond tion (e.g chek for worn bearings on the tensioning device, tensioning put ley and gue pulleys as well s for wear on belt pulleys); replace parts if necessary > Lay the poly-V-belt new) on all belt pul loys, except forthe tensioning pulley {see ilstrations for poyeV-blt rout ing) Swing he tensioning pulley down using the lever, ay the polyV-bet onthe ten- soning pulley and swing the tensioning pumas puley back. Polybet routing without refrigerant com Poly-Vbelt routing with refrigerant com > Remove the camping handle and _—-EBFOFOM 801 LA/OM 802 LA pressor OM 501 LA/OM 502 LA check for correct seating ofthe pal-- @ Coolant pump pulley © Coolant pump puley belt onthe belt pulleys @ Grankshatt pulley @ Grankshatt pulley @ Tensioning pul (tensioning device) @ Tensioning pul (tensioning device) @ Aerator @ Retrigecant compressor puley © Alternator Work schedules Engine brakes checking condition Ramove the wr pro ne en and austment fine brake oyinder bel socket > Prise of the bl socket rom trate vale evr @ bal peck Check the engine brake eynder, bal peck aba soe! os wel a he thot valve hat for wes. Check the trot vale ever onthe throttle ve shat frm cating ae a talighen the Camping sens neces: | sary. Checking condition Lubricate the all socket withthe spec: 2 Wied grease. bias Press thebillsocker back onto the bat Thtte wave ever in active position ec, fit te we lip. Gisuber @ Trotvevave ever ob Thott value ever ininacive poston Q Retainer ® Trot valve everLssbestbindeashacnel Work schedules Checking adjustment e ‘When the engine brake is epplied, thyottie valve lever @ must make con- tact with retainer @ when the trottle vahe lever isin its active position (ey inaer extended) The throttle valve lever must also make ‘contact with the retainer when the en- gine brake cylinder is in ts inactive po- sition (cylinder retracted}; if this is the 5_ | case the retum spring pretension of the engine brake cylinder is edequate. Check the position of the throtie valve shaft: when the engine brake is nac- tive, the slot (D> page 89, ilustration on left} must be vertical. When the engine brake isin the active pasition, the slot | {© page 88, itustration on right) must | be horizontal 0 Only check and correct the coolant lev- ‘el when the coolant temperature is below 50 °C. Check the antifreeze / ‘corrosion inhibitor concentration be- fore correcting the coolant level. Only ‘se a prepared coolant with an anti- freeze/ corrosion inhibitor concenta- tion of 50% by volume for topping up > Open the engine cooling system cap slowiy, relieving the excess pressure. > Check the antifreeze / corrosion in- hititor concentration using @ testing device. The specified antifreeze /corr0- sian inhibitor concentration of 50% by volume is present if antifreeze protee- tion is ensured down to -37 °C. Ifless antifreeze pratection is displayed, cor- rect the mixing rato Engine cooling system: checking ‘and correcting the fluid level and the antifreeze /corrosion inhibitor Risk of injury A antaan eesrie cesaling system is opened and scald your skin sr a, ‘© Onlyopenthe cooing system at conte the soalhg en Sowhy and re lease any excess pressure cori befor ooening se thing an story pogats when handling coolant a If tne concentration is too low. there is 2 risk of engine damage as a result of corrosion / cavitation inthe coating system, 0 ‘Avoid antifreeze / corrosion inhibitor ‘concentrations of more than 55% by volume, othennise maximum antifreeze protection down to -45 °C will ot be ‘achieved. Heat dissipation and ant: freeze protection deteriorate at higher concentrations. Check the cootant level. The cooling system is correctly filed i the coolant reaches the mark inthe fil- erneck. ik ot pateaning A “hve sar sveoning ool oak some Never sore stint eontaness not Store copia) ou ofthe reach of ena a ‘Only use service products approved by DaimlerChrysler (see specification for somvice products). Work schedules Cooling and heating system: checking for leaks and general condition v v emenee e The “Engine cooling system: checking and correcting the fuid level and antifreeze / corrosion inhibitor” opera tion must nave already been carried out. Carty outa visual inspection of the ra- diator for leaks and damage, a It damage / faults are detectee, repair the radiator or replace it (Check the radiator for external drt ‘The fins must not be dirty 5Work schedules > Check the radiators, coolant pump, ene gine ol radiator and engine cap for leaks. > Check that all cooling and heating sys- tem lines and hoses are undamaged, that they are routed in such a way that chafing avoided and that they are se cured in accordance with regulations. Pressure tester speci too! ® Special too! Pressure tester 001 889 83 21 00 > Onheating systems: open the regulat: ing valves and shut-off valves, isk oftjury AX Riskot poisoning A Tae cong yam Trevis parecer coal ot Gee pater aopeacdedseayiet ——. hgceniiow sco, stinond pes Nero eottin containers ne © Onlyapenthe coaing system at contant temperstures Below 90 °C. Unscrew the cap slowiy ar ets amy excess pressire sorsciny telers pening the ap fy 18 Wear state protective ves, setae tive clothing ane safety Rages when hanaing cootnt. realy se fo ks, © Store eosin cut ofthe reach of chil er, Work schedules Remove the cootant expansion tank cap. > Fit the pressure tester. > Connect the compressedair hose with tyre inflator connection to the valve and buildup atest pressure equal to the cooling system opening pressure, e ‘The cooling system opering pressure ‘can be determined from the cade on the cap or pressure telief valve, 3 Example: code 70 » 0.7 bar overpres: sure, The cooling system pressure tester has a bult-in pressure relief valve 50 that 2 pressure of 1.2 bar cannot be ex- ceeded,Work schedules Renewing coolant Draining coolant Risk of poisoning aA Ris of injury LX Wecmarecioncoangiccamnsial hk __/b " eee b a “Toe caning ystemis possi He cuca uetpenawuhene, —¢ Neat hnaion cot ese cooing system opened aod ns yer «Never store coca in contains ne skin and ees aly wen for dis + Store cocam cut the each oti ‘© Only openthe cooing system at =e temperatures low 90°C oven + Unsere thecapstonty a8 cease excess pressure cet tre a , (apni the ean fy: ‘Only use antifreeze / corrosion inhibitor S + Wear suiale pct» wows ser ff aporovedby Mercedes enz, (see (ne ‘tive clothing and safery kore! specifications for service products). weno noes nancing alt ‘coolant drain plug eo > Open the engine coolir Before renewing the coolant, check the slowly, relieving the excess pressure, coding and heating eystom forloaks and remove it and condition. Have the coolant renew on heating systems: open the heating al confirmed in the Maintenance Book”) Nerang actors feeuating let valves. od Work schedules > Gomect the dain nose tothe coolant Clear lacked dsinageoperings of de. 5g Gee Pee (bserve eny further information inthe Solent. > Fitanew seal tothe coolant drain plug operating instructions from the ma- > Unscrew coolant arin plug @ from on the engine and retighten chine /vehile manufacturer et ra aeee sa THECOO! pit oddtonel drain plugs (without hose. sina SURRDIS recep ces connections) with new seals and screw ° them in tight Fist cover the lines, etc, under the drain plugs and place a suitable recep- tacle underneath, large enough to cok Start the engine and runit at varying lect the amount of coolant inthe ene ‘speeds for approximately | minute. sine Adding coolant > Add coolant of the specified compas! ‘ion untiit reaches the lower edge of the iter neck, Environmental note 9 > Switch off the engine and seal tne cool Dispose of used coolant in aeordance wi ing system again, prevaling loca regulations (> 200 page 67),Malfunctions, causes and solutions Jump-startingMalfunctions, causes and solutions. hie crf operation end maintenance tft eng arc eseriial hls alsolmpor- Risk of accent A {ont het maltuneton be remedied in = trod ine Youwdldturherinferation Wario nt par wa ote nga onthe measures described under *Solu- cars cut ncorecty can cause engine tian” in the "Maintenance" or “Tests and saroge. Engine damage can lea oan ‘other work for remedying problems” sec- guna nk of arsinents tions. Nasinienance and vopa watt onthe engioe You can rectify certain faults yourself ay ony be carrea a never! ni (> page 99). ‘nove undergone te aeerepiste sing, Have faults that you cannot remedy your- _Altays have work on or mostficarions othe self rectified ata qualified specialist work- «PTE caries cul ata quaiten spectaist stor. verona ast cen we iat knoatedge an yale fer the work re 6 DaimlerCheyslorrecommendsthatyouuse 3” — aMercedes-Bene Service Centre for this purpose ast has the necessary specialist a knowledge and tools forthe work required, Merced Benz Sensce Cara fort pr Mercedes Bonz recommends hety9U use 2 In particular, work relevant to safety ron P=" safety elated systems must be carried out at quafied specialist workshop. Malfunctions, causes and solutions General troubleshooting Malfunction Cause Solution Starter pinion does not tum ortums top Batiexy is nt sulicienty charge > Gharge the battery stony Connecting cable to the starter motor ig Tighten the able onthe trminsl loose necessary, solder on a new teminat Starter motor solenoid switen matintion De Have checked at» qualified speci 6 starter motor mattunetion ist workshoo Engine doesnot stator stalls again Fuel tank empty > Refues imeeaately Fuel titer blocked v Replace the filter element (> page 82) Water sonarater, refiter sr fuel iter Clean frepiace locked Fuel system or fits leaking Replace te seals é Fuel not resistant to cold lean the arefiter i> page 81, — Replace the fue fier vv Use winter ful {D> page 61)Matfunetions, causes and solutions aonction cause solution Engine does not star or ia again nme incre engine ll vssosy > tertne engine osiscostyfsthe on Gately sions vse Engine srs Jum (engine come rit matution Dea out the MR fngine contr unit, * oa have it checked at @ qualified specialist woreshep Lesks erinsticient pressure inthe low Check for ieoks esl check: have pressor ul sat the aressre ested a gulf se. Sitat workshop Engine stoss nacerenty Jum ongne con unit olution Have checked at a quai speci teal fe istwokshon Por supp to the MRY/ADM contol ‘Have checked at a quale spect Grits nuerupted shen Skew mwrng ‘is woop Leats ornsfeiant pressure inthe Jom Check for enki check! have pressure cut ovafuehesivery the prestae tasted a uid spe ump deve malfunction cialis worksheo Malfunctions, causes and solutions Malfunction Cause Solution Engine in emergency running made Data flow interruption MR/ADM contro! be Read out the malfunction memory of vies the control acts and have them 8 qualified specialist work Engine surges, vibrates or runs imegutsrly Crankshaft pastion sensor accemshafl Visita qualified spectlst workshop position sensor faulty oF no signal Maitunstion the ut sytem Read ut the au code, nave hacked als quotied spect work stop oor engine out ack ef power) Air loaner dirty or blocked > Replace the sicleanersioment Charges temperate eo igh sue to Clean te outedes of he charg ae dy charge at coer or asator cooler end radiator Goolet temperature to high > checktemperturesenserandreisce oom if oacessany, check on speed: vist ‘qualified specialist workshop Fault in the fue system (blocked, leaking) visual chock for leaks, visit a qualified specialist workshop‘Malfunctions, causes and solutions. Matfunetion cause Solution Poor engine output (lack of poser} Charge airsystem not tight. hoseclampon Check for tightness ata qualified spe ‘charge air hose loose or faulty Cialist workshop CCharge-air pressure sensor malfunction Check with diagnostic eauioment and replace if necessary. vist 3 qualified “specialist workshop Engine brake Hap* is faulty or slack > Function test oF vieual check Interruption in tractive power Increased voltage diop t0 MR /ADM can- De Check the battery termina! clamps and trot unit loase contiet} tne connectors on the MR ADM con vol unit for Fm seating and eorresion oor engine braking power Engine brake flap” malfunction or fault in Function test/visual check; visit @ the contrat ‘qualified specialist workshon Fuel consumption too high Connection peints (unit pump» ine and Check for tightness at a qualified spe Injectors) feaking cialist workshop Misfiring > Have the engine checked at s qualified specialist workshop Malfunctions, causes and solutions Malfunction Cause Solution Engine euts-offtooearly{maximumengine F& or ADM contra! urit defective or incor Pe Visita qualified specialist workshop speed cannot be reached) reatly programmed Engine gets too hot (ancording ta coolant Not enough coolant in the cooling system Be Top up bleed (> page 95) ‘emaerature gouge) Coolant tarrperature sensor ar digolay Replace sensor or display foutty Poly V-belt damaged > See “Replacing the pol-V-b08" ( page 87) Fan does not switch on correctly > Visits qualified specialist workshop Radiator ity on inside or choked with Clean or remove timescale Timescale: radiator very dity on outside “TRermastat metfunction > check, enlace ft necessary; sit 2 qualified specialist workston 6‘Malfunctions, causes and solutions Malfunction ‘Charge current indicator lamp does aot tight up avile the engine is not running Charge current indicator amp lights up ‘when the engine is unning Engine emits black smoke Malfunction Exhaust fumes are Bue Exhaust fumas are wits Engine “knocks” Knocking noise from ihe bearings Abnormal noises cause Bulb defective or supply line intertuption Poly-V-beit too slack Poty-v-belt torn ‘Alternator or regulator malfunction Av eleanor dity or blocked Engine brake faulty Turbochorger faulty isting, injector faulty Solution > Replace aulb or repair interruption > Check belt tensioner for proper opera tion > Replace the poly V-belt (b> oage 87) check: visit a qualfcd specialist work shop > Replace the sir cleaner element Vist 2 quaifiee specialist workshop > Visual check: visita qualified specialist workshop D Visit 2 qualified specialist workshop Cause Oil eve in the engine too high: crankoase ventilation system faulty, engine oll enter- ing combustion chamber Coolant entering combustion chamber sisting Beating damage Leaks in intake pine and exhaust give causes whistling noise ‘urine or compressor wheel is soraping the housing: feign ebjecis isthe som, pressor or turbine: seized bearing in rotat ing parts Volve clearance tor great Malfunctions, causes and solutions Solution D Comract the ol evel, have the eran cease ventilation system checked at 2 ‘alifieg specialist workshop > Locate damaged cylinder using pres- sure ls test vist 2 qualified «pect Ist woreaton > Visit 2 qualified specialist workshoo Visit a qualified specialist workshop D Repainlacks, replace seuisit necessary > Have the exhaus! gas turbocharger checked at a qualified specialist work g ‘shop D Check the valve clearance, adjust necessaryLicense ado Jump-sterting ihe battery is iene the engine an a bestared using jump leads anda donor Risk of exleston A PP mnotaticntere a Gases leaking From batons may explode eager BO ee Speake en een trust nol te exceeded (ss woud pik tinny A - Cause cestni damage othe contol aaigeor cnet cst > Conecte postive termina ft and 5 enameemadalsnetine theme negtve temo etal anos oes chy a te eo suai piee.e sng so | Make sure thatthe tatters have the Sarthe engine (> see page 49) an seme nominal votage. A battery could run it for @ short while otherwise be ireparably dameged. Remove the jump leads in the reverse Do not place any metal objects on the order. batteries. There is a risk of shor cir- cuit. battery acid can bur t= clothing. adn, ‘and salty goggles shoul ‘Only use insuated jump leads (cabie ‘ross section approximately 70 mm’) ‘and insulated terminal clams. There is risk of short circul A discharged battery can freeze at about -10 °C;it must have thawes out before ump-starting. Engine data Test values and adjustment values Tightening torquesbocce al Engine data Dimensions . (standerd version, other versions on re vest) OM 501 LA Engine tenet 1.160 mm B= Engine wicth 1,020 mm e C= Engine height 1.130 mm Ee: - : 8 OM 501 LA om 501k Zz Engine data OM 50218 (2 turbochargers} A Engine tength 1300mm 8 = Engine width 1195 mm > Engine height 1.080 mn c 2 a ~ - ‘ (0M 502 LA (turbochargers) (0M 502 La (2 turbochargers)Engine data om 502 La (1 turbocharger) A Engine length 1,360. mm 8 = Engine wieth 1,030 mm G Engine height 1,199 mm (0M 02 LA (1 turbocharger) ‘0M 502 LA (1 turbochsreer Engine data Weights (0M 501 LA (0M 502 LA(2 turbochargers) OM 502 L& {1 turbocharger) Engine, B85 ke 1.125 ke 1125 ke, without figs Engine, with fluids 935 ke 1.180 kg 1180 ke. General data OM 50718 om 502 La Type engine with exhaust gas turbocharger and intercboler 8 3 injection Type af cooling systems Farce cireulnvon Gombustion principle A stroke diesel di Number of cylinders 2 5 ytinder bore 180 mm Piston stroke 180 mn Displacement 11,926 om ts.927 0n7 Direction of rotation of engine when looking at Slywhes! side of Anticlochwise engine Starter Electric Coolant capacity of engine without intercooler D Engine ol capacity including ol fter minimum 28 lees; remum 5 maximum 34 Bares maximum 38 itesEngine data Dota: Starter motor, battery and slternator (standard) Starter motor Voltore utput Battery (notin soon of dation) vottage Cold test current in accordance with DIN 72311 maxim 7 Cold start ability without jump-starting and 75% bettery charge down to maximum -20 °C Alternator Voltage Current rating 38/008 2ey Test values and adjustment values 'V Test values end adjustment values Engine oll pressure (minimum) atidting speed 205 bar at rated speed 225 bar Valve clearance Intake valve 08 em Exhaust valve bamTightening torques 6 Allthrezds on mechanical parts and re- lated contact surfaces must be clean, ‘smoath and lubricated with engine ol other lubricants require significantly ferent tightening torques. Al tightening torques are specified in Nm and apply for the OM 501 LA and. for the OM 502 LA Engine block Nm Bot securing cinder heed cover othe cylinder head 20 ok secungigntaloy ol sump to the exonkence % Blt secirng slermator tensioning pulley support to the crankcase 160 ot seeung tensioning pute tthe suopor veo 10 %0 tives a 18 0 Tightening torques Fuel /injection system Nm Injection fine to the umit pump pressure pipe connection 38 Banjo bots for fuel lines Thread M 1601.5 50 Thvead M Ba) 18 ‘Cap to the fue! iter housing, B Starter motor /alternator Nm ‘Starter motor to the timing case 8 Alternator support to the oyinder crankcase 100Tightening torques OW circuit it dean plug to the light-alloy oil sump Twead M 20%1.5 Thread M 2618.5 it iter Fit radiator to eylindercrankease Dit fiter cap tothe of fier housing Screw securing cap to the oll separator Cooling circuit CCootant line with thermostat valve to the coolant pump Coolant pump tothe cylinder crankcase eft pulley to the coolant pump fb Vale adjustment |. CCountert te the cocker arm adjustment screw SOTERA Adaptation module . ‘Adjusting the valve clearance OM SOT LA... 0M 502 LA ADM... Antifreeze corrosion inhibitor pes a Battery . 45, 106, 112 Biodiesel 63 DEAR SSRE ‘Charge current per) ‘Conversion parts ‘and modifications 40 Coolant. 66 Mixing re0 “7 Renew... S94 Coolant level 9 Cooling system Cleening . 7 Degreasing... 59 Cylinder head cover Removing and fitting 7 Diesel .... -61 Diesel fuels In extremely cold weather ........ Sulphur content... 8 Dimensions 108 Disposal of service products ...... 67 aed Emergency running program ...... 29 Engine Checking for ieaks ‘and general condition n Cleaning ....... : 56 Oil change and fiterreptacement .. 73, Starting 9 Stopping 53 Engine brake 2. 29 Checking concition and adjustment 89 Engine data ..... ce 108 Engine data card 26 Engine oll ‘SAE classifications . 65 ‘Siphoning, draining eat Engine plate ....... sve Environmental note 5 Nm oo a0 50 40 Nim 0 ” Now FAME Fuels Flow improvers FR (drive control} unit .. High-pressure cleaners 87 aS Insteltetion oes. .eeeeevseseeee 35 Intake pipe CCheoking for leaks a5 | aRETERE Jumpsterting ..... 38, 10861,62 (enon er eee Maintenance instructions Maintenance intervals Maintenance service MAR (engine contra!) unit. _aRERRENS: Oit fier replacement c Git pressure 2 Operating safety 6 Overview OM 501A. see 1. (OM 502 LA (1 turbocharger] 18 (OM 502 LA (2 turbochargers) ..... 14 EE ESTE Personnel ........ Et Poly-V-belt Checking condition «2... ..-2.1 +. 89 Removing and fitting 7 88 Routing + 8,93,40 89 Renewal interval Engine of ssa ef il fiter 7 Replacing the fuel filter element ... 82 eRe Safety and emergency running program Safety precautions Service products ..... Special lubricant additives Starter motor Starting the engine for the first time Starting using a donor battery EEE Telligent” engine system ...... 32.51 Test values snd adjustment valuee Tightening torques Transport... ‘Transport and installation Troubleshooting Gause .. General Solution Type designation er Warranty entitlement ...2.....24, 60 Water ee 86 Winter operation 54 Work schedules 0. 2... 78