45111495 Engine Repair

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Trucks • Drive train Mechanical Engine

Components Model Series 457, 500, 900

Advanced Training

Trucks • Drive train

Mechanical Engine Components

Model Series 457, 500, 900

Advanced Training

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

Printed in Germany

This document with all its sections is protected under the laws of copyright. Its use for any purpose whatsoever requires the prior written consent of DaimlerChrysler AG. This applies in particular to its reproduction, distribution, modification, translation, recording on microfilm or storage and/or processing in electronic systems, including databases and on-line services.

Note:

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

1511 1284 02 - 3rd Edition 09/07 156 As at 09/07

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09/07 Trucks • Drive train Mechanical Engine Components Model Series 457, 500, 900 Advanced Training

Content _I ₁

Content

28.09.2007

Title Page Training Course Description NMXM - MM247... 1

Agenda for Training Course NMXM - MM247 ... 2

Learning Objectives, Training Course NMXM-MM247 ... 4

Exercise of measurement NMXM... 6

Poor Fuel Quality ... 8

Maintenance Intervals; Exercise ... 9

Technical Modifications of Model Series 500 EURO 4/5... 10

Technical Modifications of Model Series 457 EURO 4/5... 16

Technical Modifications to Model Series 900 EURO 4 ... 19

Cylinder Head, Model Series 900 EURO 4 ... 21

Coolant pump, Model Series 900 EURO 4 ... 22

Engine Oil Change Interval up to 150,000 km (Code MY8)... 23

Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Installation... 26

Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Function ... 27

Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Exercise... 28

Cylinder Head Fastening, Model Series 457 ... 29

Cylinder Head Fastening, Model Series 500; Exercise ... 32

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Content _I ₂

Cylinder Head Gasket, Model Series 500 - Assignment of Ducts; Exercise ... 35

Cylinder Head Gasket, Model Series 900 - Assignment of Ducts; Exercise ... 36

Cylinder Head Gasket, Model Series 457 / 500, Evaluation... 37

Cylinder Head Gasket, Model Series 500 - New Feature, Bead Seal... 38

Cylinder Head, Model Series 457 / 500, Check ... 39

Cylinder Head, Model Series 457 and 500 EURO 4/ 5, Coolant Loss ... 41

Cylinder Head Model Series 900 - Sealing Surface Assessment... 42

Cylinder Head, Model Series 500, New Feature, Inductively-hardened Sealing Surface ... 43

Cylinder Liners, Model Series 457/500; Exercise ... 45

Cylinder Liners, Model Series 900; Exercise... 50

Cylinder Barrel, Model Series 457/ 500/ 900 - Assessment; Exercise ... 54

Plateau Honing ... 59

Constant Throttle - Fault Symptoms; Exercise ... 60

Nozzle Protection Sleeve, Model Series 457/500; Exercise... 61

Heat Protection Sleeve - Locations... 62

Heat Protection Sleeve - Special Tool ... 63

Heat Protection Sleeve, Model Series 457/ 500/ 900 - Modifications ... 64

Nozzle Holder Assembly and Protective Sleeve - Sealing; Exercise... 65

Oil Pan Torque Specifications, Model Series 500 ... 66

Oil Pan, Model Series 900 - Tightening Torques ... 68

Clean Main Oil Duct; Exercise... 69

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Content _I ₃

Connecting Rod, Model Series 500; Exercise ... 72

Repair Flywheel, Model Series 457/ 500 ... 74

Crankshaft End Play; Exercise... 75

Crankshaft - Measure Journals and Bearings, Model Series 500 ... 76

Crankshaft Seal, Model Series 500; Exercise ... 78

Front Crankshaft Seal, Model Series 457/500 - Replace Radial Sealing Ring ... 79

Piston Projection, Model Series 457/500 ... 81

Remove and Install Camshaft, Model Series 500; Exercise ... 82

Valve Setback, Model Series 457/500; Exercise... 84

Valve Setback, Model Series 900 - Check; Exercise ... 85

Notes ... 86

Model Series 457 Fuel Circuit - Symbolic; Exercise ... 87

Fuel Circuit, Model Series 457 - Requirements; Exercise... 89

Notes ... 90

Model Series 500 Symbolic Fuel Circuit; Exercise ... 91

Notes ... 93

Model Series 900 Fuel Circuit - Symbolic (from Engine 040488); Exercise ... 94

Fuel Circuit, Model Series 900 - Requirements; Exercise... 96

Notes ... 97

Fuel Pressure Test Points, Model Series 500; Exercise... 98

Notes ... 101

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Content _I ₄

Fuel Circuit, Model Series 500 - Symptoms; Exercise... 105

Fuel Filter Housing, Model Series 500/ 457; Exercise ... 107

Unit Pump Magnet - Sealing; Exercise ... 108

Install Unit Pump, Model Serie 500; Exercise ... 110

Install Unit Pump, Model Series 900; Exercise... 112

Unit Pump Classification... 114

Turbocharger, Model Series 457 - Mechanical Check; Exercise... 116

Turbobrake - Location of Components... 117

Turbobrake - Components and Function... 118

Turbobrake - Comparison with other Brake Systems... 121

Turbobrake - Location, Design and Function of the Guide Vane ... 122

Turbobrake - Location, Design and Function of the Vent Element ... 123

Turbobrake - Turbine Speed Sensor, Location and Function... 124

Turbobrake - Electric-pneumatic Converter (EPW), Location, Structure and Function ... 125

Turbobrake - Engine Brake Request... 127

Turbobrake - Troubleshooting, Functions for Operation... 128

Turbobrake - Troubleshooting ... 129

Turbobrake - Troubleshooting; Exercise... 132

Charge Air Manifold, Model Series 457 - Installation; Exercise... 134

Charge Air Manifold, Model Series 500 - Installation; Exercise... 136

Oil Circuit, Model Series 457; Exercise... 138

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Content _I ₅

Oil Circuit Model Series 500 - Location of Components; Exercise ... 140

Oil Circuit Model Series 500 - Task and Function; Exercise ... 141

Oil Circuit Model Series 900 - Location of the Components; Exercise ... 142

Oil Circuit Model Series 900 - Task and Function; Exercise ... 143

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Training Course Description NMXM - MM247 ₁

Training Course Description NMXM - MM247

28.09.2007

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

Target group Drive train repair technician

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

Level Run Method 20% theory, 80% practical work

Duration 4.5 days DCVD

Objectives The participant can:

• Locate malfunctions in mechanical engine components.

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

Contents • Mechanical structure of the model series 457, 500, 900 engines • Partial disassembly of the engines

• Fault diagnosis, repair work on the components - mechanical engine components

(crank assembly, valve assembly,...), oil circuit, fuel circuit, charge air system and compressor system in the model series 457, 500 and 900 engines.

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Agenda for Training Course NMXM - MM247 ₂

Agenda for Training Course NMXM - MM247

28.09.2007

Temporal Sequence

Day

Available time

Group A

Group B

1st day

0:45 h _{Welcome, initial test}Training room:

1:15 h _{Introduction to the SCR system function, assignment to work groups}Training room:

4:00 h Model series 457 engine:

Workshop Display <> Model Series 457 Workshop Display <> Model Series 500 Model series 500 engine:

0:30 h _{Comparison / queries}

2nd day

_{0:15 h}

Feedback

1:45 h Presentation of modifications/new features on the engines with EURO 4/5, _{knowledge comparison}

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Agenda for Training Course NMXM - MM247 ₃

Day

Available time

Group A

Group B

3rd day

0:15 h _Feedback

1:45 h Knowledge comparison

Workshop Display <> Model Series 457

Model series 500 engine: Workshop Display <> Model Series 500

0:30 h _{Comparison / queries}

4th day

2:30 h Parts table:

Workshop Display <> Miscellaneous

Model series 900 engine:

Workshop Display <> Model Series 900 - Disassembly

5th day

Workshop Display <> Model Series 900 - Assembly

Parts table:

Workshop Display <> Miscellaneous

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Learning Objectives, Training Course NMXM-MM247 ₄

Learning Objectives, Training Course NMXM-MM247

28.09.2007

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

• Describe the removal and installation of the following components, plan and understand the repair work required for this using WIS, and interpret the necessary measurements:

- Unit pump, fuel feed pump, fuel filter

- Cylinder head, connecting rods, pistons, cylinder liners, oil spray nozzles - Crankcase ventilation, exhaust manifold, turbocharger

- Timing case, flywheel - Roller tappet, camshaft - Main bearings on crankshaft

- Oil filter-, oil filter housing oil pan, oil pump with oil intake line - Turbocharger, Turbobrake

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Learning Objectives, Training Course NMXM-MM247 ₅

• Describe the disassembly and completion of the following components, plan and understand the repair work required for this using WIS, and interpret the necessary measurements:

- Cylinder head with constant throttle - Unit pump

• Describe the tasks and functions of the following components and systems, and locate malfunctions: - Crankcase ventilation

- Fuel circuit in general - Oil circuit in general - Turbobrake

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Exercise of measurement NMXM ₆

Exercise of measurement NMXM

28.09.2007

Exercise 1 P Is it a gange with a fixed measure or a variable measure? Please tick!

Fixed measure Variable measure Depth gange

Outside micrometer Raduis gange

Dial gange

Hardness analyzer for crankshaft Feeler gange

straightedge Tape rule Angle gange Limit plug gange

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Exercise of measurement NMXM ₇

Exercise 2 P What does the difference in height measure from step (B) to step (A) to step (C)? Please fill in the

gaps.

Measure step (B): _____________ mm Measure step (C): _____________ mm

N58.00-2013-11

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Poor Fuel Quality ₈

Poor Fuel Quality

28.09.2007

Exercise 1 P In the future, a customer intends to use his vehicles primarily in the Balkans and in the CIS.

He expresses his misgivings due to the poor fuel quality.

What do you recommend to your customer? Use the workshop literature (AP47.20-W-0783A, AN47.20-W-0001A) to help you.

Exercise 2 P In the CIS and in the Balkans, the sulfur content in fuel is higher than in the EU.

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

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Maintenance Intervals; Exercise ₉

Maintenance Intervals; Exercise

28.09.2007

Exercise 1 P In the future, a customer wants to operate his vehicle with FAME (rape methyl ester [RME]).

What is to be observed? What do you point out to your customer? a The maintenance intervals are reduced.

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

c FAME has harmful effects on seals, and gums up the injection nozzles. Because of this, only EURO 3 engines may be converted.

d In the maintenance system, FAME (if available) or alternatively the sulfur content must be set to 0.3 - 0.8%.

e The fuel and oil filter must be replaced 1,000 km following conversion. f Service Information 00.40-N-0008a must be noted.

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

Exercise 2 P A customer has discovered that only oil as specified according to sheet 228.3 is available in a new

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

a The maintenance intervals are reduced. b The maintenance system must be switched.

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

d The oil specification can only be switched in the workshop using STAR DIAGNOSIS. e Operation with this oil specification is not permissible.

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Technical Modifications of Model Series 500 EURO 4/5 ₁₀

Technical Modifications of Model Series 500 EURO 4/5

28.09.2007

Main changes to the engine

Compression ratio • Increased from a previous 17.75 : 1 to the present 18.50 : 1 Maximum ignition pressure • Increased from 170 to 180 bar

Cylinder liners • Honed plateau with oil ring at the top end

Cylinder head gasket • The bead seal has a considerably greater volume of elastomers at - the coolant passageways

- the oil passageways (pressure oil and return flow) - the tappet passageways

Cylinder head • The sealing surface of the water and oil passage ways of the cylinder heads are covered with circular grooves, to take the increased elastomer volumes of the seal.

• Cylinder head with internal cast reinforcement for improved distribution of the sealant pressure. Intake valve and seat rings • Intake valve with reinforced plate

• Intake valve seats in Triballoy

• O-ring seal at valve shank

Outlet valve • Seat angle changed to 36 degrees

• Contoured valve fiber

• O-ring seal at valve shank Constant throttle valve • Generally with guide sleeve Injection nozzle • Filter hole, free from leakage oil

Cylinder crankcase • With new vermicular graphite cast iron (GGV) material on diesel engines with more than 300 kW (408 hp) and on OM 502 diesels with 405 kW (551 hp) and more.

Timing case • Improved timing case sealing

Camshaft • Operational reinforcement

Camshaft thrust bearing • With thrust collar (as of 05/2006)

Connecting rods • Surface of large connecting rod laser profiled for better fixing of connecting rod bearing shells Connecting rod and main bearings • Improved connecting rod bearings and main bearings thanks to

– improved strength of steel protective shells (material change from C10 to C22) – bronze layer for greater load bearing (less lead)

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Technical Modifications of Model Series 500 EURO 4/5 ₁₁

Piston • Modified combustion chamber recess

Crankshaft • Use of a new crankshaft with increased strength manufactured from manganese-vanadium material (46 MnVS 6BY)

Oil pump • Oil pump weight higher delivery rate

Oil spray nozzle • Next to the piston cooling with the oil splasher pipe, 3 oil spray bore holes have been drilled in the base plate, also for the purpose of cam lubrication.

Vibration damper • Larger vibration damper

Exhaust pipe • Exhaust gas pipe with improved endurance (double steel pipe on standard engine, cast iron version on turbobrake model)

Turbocharger • Model series 501: Wastegate, 300-350 kW

• Model series 502: Single-turbocharger version, wastegate, 405-440 (480) kW Exhaust flap fittings • Unit flap fittings with SCR nozzle

Engine wiring harness • Axial fan

Fan box • In-engine fan surround for axial fan (350 kW model)

Main modifications in connection with exhaust gas aftertreatment

Engine control unit • Engine electronics MR2 with new engine performance mapping (data records) and SCR control functions Retarder coolant connection • Design modification for securing the "AdBlue" metering unit. On an engine without a retarder, the retarder

connection is still built in but is sealed off.

Throttle housing • Throttle housing with AdBlue nozzle

SCR tank heater solenoid valve • Additional, engine-mounted valve permitting the "AdBlue" circuit to be heated. SCR metering unit • Compressed air and AdBlue mixed to form aerosol

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Technical Modifications of Model Series 500 EURO 4/5 ₁₂

Cylinder Head on Model Series 500 - Sealing Surfaces with Countersinks

The EURO 4/5 engines are fitted with a modified cylinder head and therefore a new cylinder head gasket with increased elastomer thickness. The following bores in the base of the cylinder head have been provided with countersinks with a depth of 1.0 mm:

• Engine oil pressure side (OD) • Engine oil return (OR)

• Coolant supply (WZ) • Coolant return (WR)

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Technical Modifications of Model Series 500 EURO 4/5 ₁₃

Cylinder Head Gasket on Model Series 500 Euro 4/5

On the cylinder head gasket, the elastomer sealing elements at the following bores have been raised by the dimension (X):

• Engine oil pressure side (OD) • Engine oil return (OR)

• Coolant supply (WZ) • Coolant return (WR)

The sealing between the cylinder head and the crankcase is improved because the elastomeric sealing elements are higher.

Moreover, a fire shield (arrow) was vulcanized onto the coolant feed hole (WZ). This fire shield (arrow) is an added protection for the elastomeric sealing element in the event of a possible minor gas leak in the cylinder head gasket.

OD Engine oil pressure side OR Engine oil return

WR Coolant return

WZ Coolant feed

X Dimension

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Technical Modifications of Model Series 500 EURO 4/5 ₁₄

Cylinder Liners in Model Series 500 - Oil Scraper Ring

The cylinder liner (2) has been fitted with an oil scraper ring (3) to prevent carbon buildup. The chrome-molybdenum (CrMo) oil scraper ring (3) has a height of 13.5 mm and a projection of 0.15 mm to the inner diameter of the cylinder barrel in the cylinder liner (2). The oil scraper ring (3) replaces induction hardening in the upper part of the cylinder liner (2).

The oil scraper ring's (3) projection reduces carbon deposits on the top land of the piston (area from the piston crown to the first piston ring groove). This reduces wear on the cylinder barrel of the cylinder liner (2).

2 Cylinder liner

3 Oil scraper ring

4 Sealing ring

The outside diameter on the liner collar has been enlarged to improve the fit of the cylinder liner (2) in the cylinder crankcase.

The sealing ring (4) between the collar of the cylinder liner (2) and the cylinder crankcase is made of stainless steel (X5CrNi 18-10) and has a larger outside diameter than the tombac ring used previously. This results in higher abrasion resistance, reduced wear and improved installation reliability for the sealing ring (4).

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Technical Modifications of Model Series 500 EURO 4/5 ₁₅

Pistons, Model Series 457/500 - Installation with Oil Scraper Ring

Removing the piston from the cylinder liner

• Turn the crankshaft until the piston (1) is located approx. 1 cm beneath the oil scraper ring (2). • Insert the piston ring (4) into the cylinder liner (3) and insert a corresponding feeler gauge (5) into the

piston ring end gap (arrow).

Use only a new keystone ring or a taper-faced ring with internal angle as the piston ring (4). Observe installation position; the "TOP" mark must point downwards in the direction of the piston crown. The feeler gauge (5) prevents compression of the piston ring (4) when pressing out the oil scraper ring (2).

• Turn the crankshaft until the piston (1) with the inserted piston ring (4) presses the oil scraper ring (2) out of the cylinder liner (3).

Counterhold the cylinder liner (3) if necessary.

W03.10-1045-11

Installing the piston into the cylinder liner

• Documentation is currently still in progress.

• Lightly lubricate the pistons and piston rings with engine oil.

• Turn the end gap of the oil scraper ring such that it points to the short side of the connecting rod big end.

• Lightly lubricate assembly sleeve on inside and at collar with engine oil, place it over the piston rings and the pistons and screw together at the knurled screw. The collar of the assembly sleeve must point towards the connecting rod. The handle of the assembly sleeve must point to the short side of the connecting rod big end.

• Insert the connecting rod and the piston into the cylinder liner until the collar on the assembly sleeve sits in the cutout of the oil scraper ring and the assembly sleeve lies on the cylinder liner. Turn crankshaft if necessary.

• Press the piston into the cylinder liner and take off the assembly sleeve. • New piston ring compressor band required:

Model series 457: Special tool 457 589 01 14 00 Model series 500: Special tool 541 589 02 14 00

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Technical Modifications of Model Series 457 EURO 4/5 ₁₆

Technical Modifications of Model Series 457 EURO 4/5

28.09.2007

Main changes to the basic engine

Compression ratio • 18.5

Maximum ignition pressure • Ignition pressure 180 bar

Turbobrake _{• Expected as of end 2007}

Cylinder liners • With top fitting (as on OM 460 LA)

• Fine honing pattern • Ignition ring

Cylinder head gasket _{• Bead seal with more elastomers at the oil and water passageways}

Cylinder head • As per Euro III GG 25

• Bead reinforcement as in model series 500 Intake valve and seat rings • Seat angle 30°

• Contoured fibers

Outlet valve • Seat angle 36°

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Technical Modifications of Model Series 457 EURO 4/5 ₁₇

Cylinder crankcase • As per Euro III GG 25

• Firewall-side reinforcement measures

Connecting rods • Connecting rod from OM 460 LA to increase crank pin

Piston _{• AL pistons (Mahle, Alcan, KS)}

• First piston ring 15 mm from piston top edge

Crankshaft • OM 457 LA: Piston ring increase from 90 mm to 94 mm (uniform with OM 460LA).

• Screwed on counterweights (Atlantis Forge) or, as an alternative, solid forged counterweights. Oil pump • Bigger oil pump, wheel width 43 mm (new), with reinforced cover

Crankcase ventilation _{• Cyclone separator for oil mist separation}

Oil spray nozzle _{• Coaxial}

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Technical Modifications of Model Series 457 EURO 4/5 ₁₈

Main modifications via exhaust gas aftertreatment scope

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

Throttle housing • Throttle housing with AdBlue nozzle

SCR tank heater solenoid valve • Additional live power valve, allowing heating up of the "AdBlue circuit".

SCR metering unit • Urea metering unit, made by Purem

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Technical Modifications to Model Series 900 EURO 4 ₁₉

Technical Modifications to Model Series 900 EURO 4

28.09.2007

Main changes to the basic engine

Basic engine OM904/ OM906 OM924/ OM926

Compression ratio • 17.5 : 1 • 17.5 : 1

Maximum ignition pressure • Increase from 170 to 180 bar • Increase from 170 to 190 bar

Cylinder head gasket • Combustion chamber sealing improved

• Oil and water channel sealing more heat-resistant Cylinder head • Coolant flange for tank heater solenoid valve

• Threaded sleeve for metering unit bracket

• Cast material GGV

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

Crankcase • Cast material GGV

• Internal cast reinforcement

• Omission of upper induction hardening on cylinder barrel

Crankshaft • Modified with larger Fillet radii

Piston rings • Optimized • Optimized

Piston • Piston pin diameter increased to 44 mm

Connecting rods • Piston pin diameter increased to 44 mm

• Improved connecting rod material (70MnVs4) Crankshaft and connecting rod

bearing • Improved material

Camshaft • Operational reinforcement • Operational reinforcement

Injection nozzle • 7-hole • 9-hole, improved nozzle material

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Technical Modifications to Model Series 900 EURO 4 ₂₀

Basic engine OM904/ OM906 OM924/ OM926

PLD unit pump _{• Improved roller tappet mounting}

Injection line and pressure pipe

connection • Modified from increased-strength material

Coolant pump _{• Threaded fitting for attaching AdBlue heater return} _{• Threaded fitting for attaching AdBlue heater return}

Scope of exhaust aftertreatment

• Motor electronics MR2, new engine performance maps (data records) • AdBlue metering unit with bracket on cylinder head

• AdBlue nozzle with flanged manifold

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Cylinder Head, Model Series 900 EURO 4 ₂₁

Cylinder Head, Model Series 900 EURO 4

28.09.2007

Shown on engine 926.9

At the rear part of the cylinder head the cap (arrow) has been replaced by the coolant flange for the SCR tank heater solenoid valve. On the side of the cylinder head the caps have been partly replaced by threaded sleeves (1). The bracket for the AdBlue metering device is

mounted on these threaded sleeves (1). The other holes on the sides of the cylinder head are sealed by screw plugs (2).

The cylinder heads in the 924.9 and 926.9 engines have been converted to vermicular graphite cast iron (GGV-40), for greater strength in order to withstand the higher ignition pressure.

1 Threaded sleeve 2 Screw plugs

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Coolant pump, Model Series 900 EURO 4 ₂₂

Coolant pump, Model Series 900 EURO 4

28.09.2007

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

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Engine Oil Change Interval up to 150,000 km (Code MY8) ₂₃

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

28.09.2007

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

Features

• Oil centrifuge in the secondary flow oil circuit • Oil filter cover raised

• Intermediate cover between oil centrifuge and oil filter element • Oil filter element as in series production

• Heat exchanger with 14 plates

• Oil filter housing with return duct from the oil centrifuge into the oil sump

• Thermoplastic oil pan

• Oil quantity for the OM 501 increased by 8 liters

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Engine Oil Change Interval up to 150,000 km (Code MY8) ₂₄

Operation

The oil centrifuge in the secondary engine oil circuit oil filter is mounted on top of the oil filter element (3).

The oil centrifuge consists of the following components:

• Rotor (4)

• Intermediate cover (5) • Threaded cap (6)

Part of the engine oil flow is conducted through the oil centrifuge as of an engine oil pressure > 2 bar. Two tangentially attached nozzles are located in the lower section of the rotor (4); the cleaned engine oil from the oil centrifuge flows through them and thus generates the rotation of the rotor (4).

The rotor (4) can reach a speed of up to 7,000 rpm. The cleaned engine oil then flows back into the oil pan. When the rotor (4) is rotating, soot particles as well as small metal particles that flow by the oil filter element (3) are separated from the engine oil and collected at the interior walls of the rotor (4) as deposits.

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Engine Oil Change Interval up to 150,000 km (Code MY8) ₂₅

GT18_00_0005_C01 GT18_00_0007_C11

Technical data:

The centrifuge's oil feed pipe contains a valve, which opens at 2.3 ± 0.3 bar.

Via this valve, max. 10 l/min unfiltered oil enter the centrifuge.

Maintenance note:

In the event of maintenance operations, the rotor (4) and the oil filter element (3) have to be replaced.

Repair information:

• The engine must not be operated without centrifuge (oil pressure).

• In the WS control unit, code MY8 is preselected via parameter setting.

• In the MR control unit, the oil pan version is preselected via parameter setting.

GT18_00_0008_C01 GT18_00_0009_C01

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12/06 Trucks • Drive train Mechanical Engine Components Model Series 457, 500, 900 Advanced Training

Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Installation ₂₆

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

28.09.2007

Due to technical advances, the new cyclone separator will be installed as standard in the crankcase ventilation system of model series 457 engines without Turbobrake as of engine end no. 036 947, on these engines without turbobrake as of engine end no. 011 688, and on model series 500 engines as of engine end no. 265 304. The cyclone separator is maintenance free and need not be replaced again.

The cyclone separator should be installed in older engines when maintenance becomes due.

You can see if a cyclone separator is already installed by the form of the cover on the crankcase ventilation system.

Note: W01.40-1062-02 W01.40-1070-03

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

1 Cyclone separator, model series 500 2 Seal

3 Crankcase ventilation system cover, with cyclone separator, model series 500

4 Crankcase ventilation system cover, previous version, model series 500

5 Cyclone separator, model series 457 6 Seal

7 Crankcase ventilation system cover, with cyclone separator, model series 457

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12/06 Trucks • Drive train Mechanical Engine Components Model Series 457, 500, 900 Advanced Training

Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Function ₂₇

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

28.09.2007

Cyclone separator functional principle

The blow-by gases from the crankcase are sent as pre-cleaned crude gases to the cyclone separator insert.

The cyclone separator insert is made up of two cyclones.

The crude gas enters the cyclone from the side (tangentially). The gas stream is forced into a downwards spiral movement in the entry chamber. This causes the floating oil particles to be pitched towards the wall of the cyclone by the centrifugal forces and then slide down the tapered surfaces of the swirl chamber due to gravity and the downwards movement of the gas. The oil comes out through a hole at the lowest point of the cyclone.

As the cyclone tapers towards the bottom, the circumferential speed and centrifugal effect becomes greater so that finer particles can be separated in the lower section.

At the lowest point of the cyclone the whirling gas reverses direction and goes back up and the clean gas is guided out through an outlet pipe (take-off tube) at the top.

The diameter and tapered form of the take-off tube determine the pressure loss and separation quality of the cyclone.

The bypass valve opens up with a high gas flow.

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Crankcase Ventilation System, Model Series 457/500 with Cyclone Separator - Exercise ₂₈

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

28.09.2007

Exercise P Identify the gas stream in the cyclone insert.

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

• Where does pure gas enter the cyclone?

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

• Where is the oil separated out from the cyclone chamber?

• Where does the clean gas emerge from the cyclone chamber?

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

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Cylinder Head Fastening, Model Series 457 ₂₉

Cylinder Head Fastening, Model Series 457

28.09.2007

Exercise 1 P Complete the following table, paying particular attention to the modified diameter. Use WIS document

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

Model series Bolt dimension Max. shank length

Model series 500 M18x2 212 mm

Model series 457 mm

Exercise 2 P Complete the following table.

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

Designation Tightening stages Model series 500 engine Model series 457 engine

Cylinder head bolt to

crankcase 1st stage 10 Nm

2nd stage 50 Nm

3rd stage 100 Nm

4th stage 200 Nm

5th stage 90 Angular degree

6th stage 90 Angular degree

(38)

Cylinder Head Fastening, Model Series 457 ₃₀

Exercise 3 P Install cylinder head gasket, tighten cylinder head bolts -

Identify the correct statements.

a The tightening pattern must be observed precisely.

b The first tightening stage can be skipped, because the torque is very low. c The cylinder head gasket can only be used once.

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

e The bolts' tightening pattern does not necessarily have to be observed. f The cylinder heads must be retightened following the first service.

Note:

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

(39)

Cylinder Head Fastening, Model Series 457 ₃₁

Exercise 4 P Handling the stretch-shank bolts.

Before the bolt is used, points other than the bolt tolerance must be noted.

The bolts must be cleaned with a wire brush, as they should be free of rust, carbon and dirt.

The bolt length must be compared with the data in the workshop literature. (From the lower side of the bolt head to the end of the bolt).

The bolt holes must be free of dirt, coolant and oil.

The bolts should be oiled lightly on the threads and beneath the head with engine oil, but not with 85/90 oil or grease.

The bolts are tightened according to the tightening pattern and in stages. Identify the cylinder heads which have already been tightened.

(40)

Cylinder Head Fastening, Model Series 500; Exercise ₃₂

Cylinder Head Fastening, Model Series 500; Exercise

28.09.2007

Exercise 1

The cylinder head is tightened in 6 stages. Use the workshop literature

(AR01.30-W-*****) and enter the values.

1. stage Nm 2. stage Nm 3. stage Nm 4. stage Nm 5. stage ° 6. stage ° W01.30-0010-06

(41)

Cylinder Head Fastening, Model Series 500; Exercise ₃₃

Exercise 2 P Install cylinder head gasket and tighten cylinder head bolts -

Identify the correct statements.

a The tightening pattern must be observed precisely.

b The first tightening stage can be skipped, because the torque is very low. c The cylinder head gasket can only be used once.

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

e The bolts tightening pattern does not necessarily have to be observed. f The cylinder heads must be retightened following the first service.

Exercise 3 P Handling the stretch-shank bolts.

Besides the bolt tolerance, other points must be observed before using stretch-shank bolts. The bolts must be cleaned with a rotating brush, as they must be free of rust, carbon and dirt. The bolt length must be compared with the data in the workshop literature.

(From the lower side of the bolt head to the end of the bolt).

Following removal, stretch-shank bolts may only be reused 3 times. The bolt holes must be free of dirt, coolant and oil.

Engine oil is applied to the bolts at the threads and underneath the bolt head, however W85/90 must not be used to oil or grease the bolts.

The bolts are tightened according to the tightening pattern and in stages. Identify the cylinder heads which have already been tightened.

(42)

Cylinder Head Gasket, Model Series 457 - Assignment of Ducts; Exercise ₃₄

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

28.09.2007

Exercise

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

A Coolant B Bolts C Pressure oil D Oil return

E Tappet, oil return

(43)

Cylinder Head Gasket, Model Series 500 - Assignment of Ducts; Exercise ₃₅

Cylinder Head Gasket, Model Series 500 - Assignment of Ducts; Exercise

28.09.2007

Exercise

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

A Coolant

B Bolts

C Pressure oil

D Oil return

E Tappet, oil return

(44)

Cylinder Head Gasket, Model Series 900 - Assignment of Ducts; Exercise ₃₆

Cylinder Head Gasket, Model Series 900 - Assignment of Ducts; Exercise

28.09.2007

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

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

A = Coolant B = Pressure oil C = Push rods

D = Cylinder head bolts E = Return oil

(45)

Cylinder Head Gasket, Model Series 457 / 500, Evaluation ₃₇

Cylinder Head Gasket, Model Series 457 / 500, Evaluation

28.09.2007

W01.30-1039-71 W01.30-1040-71

Check cylinder head gasket (1) at combustion

chamber.

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

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

Check cylinder head gasket (1) at the sealing

rings.

A damaged sealing ring (elastomer) (C) in the engine oil bore or coolant bore is the result of a cylinder head gasket (1) which is not gas-tight. In the case of a leaky cylinder head gasket, the cylinder head and crankcase sealing surface must also be examined.

(46)

Cylinder Head Gasket, Model Series 500 - New Feature, Bead Seal ₃₈

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

28.09.2007

Excerpt from WIS: BT01.30-W-0005-01A "Modified cylinder head gasket" ENGINE 541.9, 542.9

As of engine end no. 265.000, the cylinder head gasket has been modified to provide a better seal for the combustion chamber and coolant circuit at the cylinder head/crankcase contact surface.

The cylinder head gasket has been improved with a bead (D) to seal the combustion chamber and the sealing element on the coolant feed (E) has been reinforced.

Only the modified cylinder head gasket may be installed during repairs.

(47)

Cylinder Head, Model Series 457 / 500, Check ₃₉

Cylinder Head, Model Series 457 / 500, Check

28.09.2007

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

Check cylinder head for cracks (arrows) in area of cylinder head bolt bores and contact surfaces.

Visible cracks always occur in combination with pitting around the cylinder head bolt bores, most often on the exhaust side only.

The cylinder head must be replaced if there are cracks in it.

W01.30-1041-81

Check contact surfaces around the cylinder head bolt bores for pitting (arrow).

If pitting has occurred, the height (H) of the cylinder head must be measured following stock removal. If too much stock is removed and the measurement falls below minimum, the cylinder head must be replaced.

The cylinder head bolts must always be replaced. Lubricate cylinder head bolt at the collar surface, the thread and the stem using engine oil.

(48)

Cylinder Head, Model Series 457 / 500, Check ₄₀

Visually inspect cylinder head sealing surface for flatness. Note:

In the case of an induction hardened cylinder heads, do not check over the hardened parts (material projection).

Place a straightedge over both coolant bores (WR, WZ) on the cylinder head sealing surface. Check flatness within the sealing area (X) of the cylinder head gasket only.

If a gap forms under the straightedge due to pitting (arrow) of the cylinder head gasket (beaded or crimped) on the cylinder head sealing surface, the cylinder head sealing surface must be face-ground or the cylinder head exchanged.

When face-grinding, the following notes have to be observed:

- Material removal on the cylinder head must not fall below the permissible overall cylinder head height, "minimum height".

- Only face-grind the cylinder head sealing surface through face grinding. - The surface quality of the cylinder head sealing surface must be maintained.

(see WIS, AR01.30-W-7162B / AR01.30-W-7162C)

(49)

41

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

Damage profile

• Cracks between the lower apex of the core hole bore and the sealing surface to the cylinder crankcase

• Occurs on exhaust side only • Occurs on EURO 4/5 engines only

Cause

• Alternating cold/hot temperature stress produces tension in the cylinder head that leads to cracks forming at the shortest point between the core hole bore and the sealing surface

Remedy

• As of October 2007, the sheet metal core hole cover on the exhaust side will be replaced by a solid core hole cover.

Important information for service

• If a customer with a EURO 4/5 vehicle complains of coolant loss, always check the area between the core hole bore and the sealing surface for cracks.

• The cracks may sometimes be very fine.

• If cracks are found, replace the affected cylinder head.

(50)

Cylinder Head Model Series 900 - Sealing Surface Assessment ₄₂

Cylinder Head Model Series 900 - Sealing Surface Assessment

28.09.2007

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

Check flatness of the cylinder head sealing surface via visual inspection.

In the area of the lines, place a straightedge over the coolant bores (W) on the cylinder head sealing surface. Check flatness within the sealing area (X) of the cylinder head gasket only.

If a gap forms under the straightedge on the cylinder head sealing surface, the cylinder head sealing surface must be face-ground or the cylinder head

exchanged.

When face-grinding, the following notes have to be observed: - Only carry out face-grinding if an impermissible deviation in - flatness is measured in the longitudinal direction.

- Material removal on the cylinder head must not fall below the permissible - overall cylinder head height, "minimum height".

- Only face-grind the cylinder head sealing surface via face grinding.

- The surface quality of the cylinder head sealing surface must be maintained.

(51)

Cylinder Head, Model Series 500, New Feature, Inductively-hardened Sealing Surface ₄₃

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

28.09.2007

Excerpt from WIS: BT01.30-W-0004-01A, AR01.30-W-5800-15A ENGINE 541.9, 542.9

As of engine end no. 263.000, the cylinder heads have been modified.

The cylinder head sealing surface has been inductively hardened at four points (arrows).

This inductive hardening is visible by a slight increase in height at the four points (arrows). This increases the contact pressure on the cylinder head gasket.

Repair information:

Cylinder head sealing surfaces with the four inductively hardened points (arrows) may only be visually checked for flatness in the sections where there are no raised areas due to inductive hardening.

The cylinder head generally has to be exchanged if there is any distortion to the cylinder head or wear to the cylinder head sealing surface caused by the beaded cylinder head gasket, otherwise a seal between the cylinder head and crankcase cannot be ensured.

The cylinder head sealing surface may not be reworked (ground).

(52)

Cylinder Head, Model Series 500, New Feature, Inductively-hardened Sealing Surface ₄₄ The modified cylinder heads can be recognized by a production ID (C).

The ID is located near the outlet duct and can also be read with an installed cylinder head and exhaust manifold. Production ID (C) example: Meaning of ID 541 - 54 part no. A 541 010 54 20 10.03.03 manufacture date 10.03.2003 ID number "5" (arrow)

The new, inductively-hardened cylinder heads are identified with the ID number "5" (arrow) or higher.

W01.30-1051-81

(53)

Cylinder Liners, Model Series 457/500; Exercise ₄₅

Cylinder Liners, Model Series 457/500; Exercise

28.09.2007

Assignment of cylinder liner and piston

Exercise 1 P The piston and the cylinder liners are identified with letters. These provide information on the

installation tolerance.

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

W03.10-0029-02

Bushing

Pistons A B C

BA BC

(54)

Cylinder Liners, Model Series 457/500; Exercise ₄₆

Remove/install cylinder liner

Complete the following tasks with the aid of the overview WIS AR01.00-Z-9457OB.

Exercise 2 P Operations for removing cylinder liners.

Complete the table. Use the workshop literature.

a Identify cylinder liner to the crankcase. b Identify cylinder liner with cylinder number.

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

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

e Use the extraction device to remove the cylinder liner.

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

(55)

Cylinder Liners, Model Series 457/500; Exercise ₄₇

Exercise 3 P On installation of the cylinder liner, certain points must be observed.

Discuss this in your group. Complete the table. Use the workshop literature.

Important actions: Exchange Cleaning Install

dry

Coat with engine oil

Coat with ATE grease

Measure for.... Tombac ring contact surface on liner collar and crankcase

Grooves in the crankcase for Viton oval ring grooves Viton oval rings

Tombac ring

Sealing surface of the Viton oval rings on the cylinder liner Cylinder bore following installation of cylinder liner

Cylinder liner collar following installation of cylinder liner

Exercise 4 P How can you check whether the Viton oval rings are correctly seated in their groove after pressing in

the cylinder liner?

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Cylinder Liners, Model Series 457/500; Exercise ₄₈

Cylinder liner projection

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

Exercise 5 P Look up the values in the workshop literature and enter them in the table below.

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

Specified value Actual value

Tightening torque for fastening plate --

Cylinder liner projection

Maximum difference between the 4 measurements

Exercise 6 P Incorrect liner projection may cause various symptoms.

Assign possible symptoms to the liner projection status. Symptoms: Status Compression gases in the coolant Coolant in the engine oil External coolant loss

Engine oil in the coolant

Fuel in the engine oil

Liner projection > normal Liner projection < normal

(57)

Cylinder Liners, Model Series 457/500; Exercise ₄₉

Exercise 7 P Assume the liner projection is incorrect. Which repair options are available?

Discuss this in your group and use the workshop literature. a Staged Tombac rings are available.

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

c Only 1 Tombac ring may be installed. d A repair stage of 0.5 mm exists.

e The cylinder liner shoulder must be adapted. f The cylinder liner collar must not be reworked.

Exercise 8 P How can the lower cylinder liner O-rings be checked for leaks?

Which symptoms exist if leaks are present? Check:

Symptoms:

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Cylinder Liners, Model Series 900; Exercise ₅₀

Cylinder Liners, Model Series 900; Exercise

28.09.2007

Cylinder barrels and cylinder liners

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

(59)

Cylinder Liners, Model Series 900; Exercise ₅₁

Exercise 1

On an engine, the cylinder barrels have been measured for wear. Assuming the basic dimension, the following measurement results were determined and transferred to the table. Use the workshop literature

(AR01.40-W-9202A). Evaluate the results.

Meas uring point Measurement results Out-of-roundness Cylinder wear A B I 0.09 0.11 II 0.04 0.04 W01.40-0034-06

Exercise 2 P Can the engine still be used?

(60)

Cylinder Liners, Model Series 900; Exercise ₅₂

Crankcase marking following machining

Exercise 3

On a reconditioned engine, cylinder liners have been inserted. The crankcase sealing surface was also reworked by 0.6 mm.

Indicate the identification used to document machining on the signing surface in field 6 (AR01.40-W-9273-01A).

(61)

Cylinder Liners, Model Series 900; Exercise ₅₃

Exercise 4 P What must be noted with regard to the pistons after machining the crankcase sealing surface?

The piston crown must be reworked. A thicker cylinder head gasket is required.

(62)

Cylinder Barrel, Model Series 457/ 500/ 900 - Assessment; Exercise ₅₄

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

28.09.2007

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

W01.40-1044-81 W01.40-1042-74

Matt gray surface, honing pattern visible, dry cylinder barrel, without oil residues, without shining areas or reflecting areas of smoothness. There should not be any burn marks or streaks on the cylinder barrels or liners. Individual, slight drawing scores are non-critical.

The honing pattern is more or less clearly recognizable over the cylinder barrel. At the reversal point of the piston ring, the honing pattern may be partially eroded.

The cylinder liner or the crankcase can be reused.

With engines 904.9, 906.9 only

The stripe profile (arrows) in the upper area of the cylinder barrel arises due to induction hardening on production of the crankcase, and is to be regarded as the normal condition.

The longer the engine's operating time, the less visible the stripe pattern becomes.

(63)

Cylinder Barrel, Model Series 457/ 500/ 900 - Assessment; Exercise ₅₅

Exercise 1

Different types of damage to the cylinder barrel.

How would you decide?

W01.40-1051-81 W01.40-1052-81

The following applies if carbon is present in

the top land area:

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

Clean the top land area and reuse the

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

Replace the cylinder liner or the crankcase. The cylinder liner or the crankcase can be

reused if slight scratches or score marks are present.

Additionally remove the piston and assess the

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Cylinder Barrel, Model Series 457/ 500/ 900 - Assessment; Exercise ₅₆

Exercise 2

W01.40-1053-81 W01.40-1055-81

The following applies if ring shaped

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

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

The cylinder liner or the crankcase can be

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

The cylinder liner or the crankcase must be

exchanged.

The cylinder liner must be replaced.

The cause may be poor engine oil quality

(65)

Cylinder Barrel, Model Series 457/ 500/ 900 - Assessment; Exercise ₅₇

Exercise 3

W01.40-1035-81 W01.40-1041-81

The following applies in the case of

imperceptible dry friction marks or deposits (arrow) on the cylinder barrel running downwards from the 2nd or 3rd piston ring:

The following applies if the honing pattern is only barely or not visible or there is a

perceptible wear step at the upper reversal point of the first piston ring (arrow):

Caused by soot particles and fuel washings of

the engine oil film.

The cylinder liner is unusable and must be replaced.

Caused by damaged piston rings If the model series 900 engine reveals no

in-engine complaints, e.g. noises or

The cylinder liner is unusable and must be

replaced. The piston should also be replaced.

increased engine oil consumption, the crankcase can be reused.

If the model series 900 engine reveals

in-engine complaints, e.g. noises or increased engine oil consumption, the crankcase can be reworked.

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Cylinder Barrel, Model Series 457/ 500/ 900 - Assessment; Exercise ₅₈

Exercise 4

W01.40-1036-81

If the cylinder barrel is perceptibly roughened

along its entire length or material deposits and perceptible traces of scoring are found on the cylinder barrel and on the piston skirt, the following applies:

replaced.

The crankcase is unusable and must be

replaced or machined.

Additionally check the pistons and piston rings, replace if necessary.

machined.

Additionally check the pistons and piston rings, replace if necessary.

45111495 Engine Repair

Trucks • Drive train Mechanical Engine

Components Model Series 457, 500, 900

Advanced Training

Trucks • Drive train

Mechanical Engine Components

Model Series 457, 500, 900

Advanced Training

Content

28.09.2007

Training Course Description NMXM - MM247

28.09.2007

Agenda for Training Course NMXM - MM247

28.09.2007

Temporal Sequence

Day

Available time

Group A

Group B

1st day

2nd day

Day

Available time

Group A

Group B

3rd day

4th day

5th day

Learning Objectives, Training Course NMXM-MM247

28.09.2007

Exercise of measurement NMXM

28.09.2007

Poor Fuel Quality

28.09.2007











Maintenance Intervals; Exercise

28.09.2007

Technical Modifications of Model Series 500 EURO 4/5

28.09.2007

Cylinder Head on Model Series 500 - Sealing Surfaces with Countersinks

Cylinder Head Gasket on Model Series 500 Euro 4/5

Cylinder Liners in Model Series 500 - Oil Scraper Ring

Pistons, Model Series 457/500 - Installation with Oil Scraper Ring

Technical Modifications of Model Series 457 EURO 4/5

28.09.2007

Technical Modifications to Model Series 900 EURO 4

28.09.2007

Cylinder Head, Model Series 900 EURO 4

28.09.2007

Coolant pump, Model Series 900 EURO 4

28.09.2007

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

28.09.2007

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

28.09.2007

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

28.09.2007

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

28.09.2007

Cylinder Head Fastening, Model Series 457

28.09.2007

Cylinder Head Fastening, Model Series 500; Exercise

28.09.2007

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

28.09.2007

Cylinder Head Gasket, Model Series 500 - Assignment of Ducts; Exercise

28.09.2007

Cylinder Head Gasket, Model Series 900 - Assignment of Ducts; Exercise

28.09.2007

Cylinder Head Gasket, Model Series 457 / 500, Evaluation

28.09.2007

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

28.09.2007

Cylinder Head, Model Series 457 / 500, Check

28.09.2007

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