Mercedes-Benz Citan 2012 Introduction Into Service Manual Download Page 30 | Manualshive

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4-cylinder diesel engine OM607

Powerplant

29

l

Introduction to CITAN, Model Series 415

Engine OM607, R4 with 1.5 l displacement

Brief description

The OM 607 is a 1.5-liter, 4-cylinder in-line diesel
engine with Common Rail direct injection, single over-
head camshaft and 2 valves per cylinder. An ECO
start/stop system is available as special equipment.

Overview of design

• Valves with mechanical cup tappets with DLC

coating (diamond-like carbon)

• Crankshaft with special surface treatment
• Alternator and AC compressor driven by a belt

drive with six grooves

• High-quality engine mounts
• Optimized VTG turbocharger for high efficiency on

the 81kW diesel engine as of 03/2013, on the
55kW and 66kW variants a wastegate charger is
installed.

• Long-life toothed belt (240 tkm or 10 years) for low

maintenance costs

S01.10-4593-00

– This printout will not be recorded by the update service. Status: 09 / 2012 –

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Summary of Contents for Citan 2012

Page 1: ... This printout will not be recorded by the update service Status 09 2012 ...

Page 2: ...Daimler AG Technical Information and Workshop Equipment GSP OI D 70546 Stuttgart Introduction to CITAN Model series 415 Introduction into Service Manual This printout will not be recorded by the update service Status 09 2012 ...

Page 3: ...aimler AG This document including all its parts is protected by copyright Any further processing or use requires the previous written consent of Daimler AG Department GSP ORS HPC R822 W002 70546 Stuttgart This applies in particular to reproduction distribution alteration translation microfilming and storage and or processing in electronic systems including databases and online services Image no of...

Page 4: ...roduction to CITAN Model Series 415 Preface 7 Overview Models and major assemblies 8 Overall vehicle Exterior 10 Interior 14 Maintenance ASSYST 27 This printout will not be recorded by the update service Status 09 2012 ...

Page 5: ...8 4 cylinder diesel engine OM607 29 4 cylinder gasoline engine M200 30 Start stop function 31 Transmission Transmission data 32 Chassis Axles and suspension 33 Steering 34 Brake system 35 ESP 35 Wheels and tires 36 This printout will not be recorded by the update service Status 09 2012 ...

Page 6: ... Exterior lights 38 Interior lights 40 Safety Active and passive safety 41 Driving assistance systems Overview of systems 43 Comfort Climate control 44 Vehicle protection Central locking 46 Audio and communications Telematics 47 This printout will not be recorded by the update service Status 09 2012 ...

Page 7: ...5 Body Bodyshell and detachable parts 48 Body protection 50 Special tools Vehicle 51 Transmission 53 Engine OM607 56 Workshop equipment Bodywork 58 Annex Abbreviations 59 Index 61 This printout will not be recorded by the update service Status 09 2012 ...

Page 8: ...rmation is available in the Workshop Information System WIS and in the Diagnosis Assistance System DAS WIS is updated monthly Therefore the information available there reflects the latest technical status of our vehi cles This Introduction into Service Manual presents initial information relating to the new Citan in model series 415 and as such is not stored in WIS The contents of these brochures ...

Page 9: ...ards The available body variants are LHD or RHD vehicles Panel van Passenger van Mixto with three different wheelbases 2313mm 2697mm 3081mm Innovations The most important features of the new Citan are The front design is the first to bear the new face of the Mercedes Benz Vans family Robust vehicle in Mercedes Benz quality 4 cylinder diesel engine OM607 or as of 09 10 2013 4 cylinder gasoline engi...

Page 10: ... Extra long A3 Panel van Passenger van Mixto Model Engine Output kW hp Transmission ML 108CDI OM607 55 75 5 speed GK5 10 2012 109CDI 66 90 5 speed GK5 10 2012 111CDI 81 110 6 speed GK6 03 2013 112 M200 84 114 6 speed GK6 09 10 2013 S00 00 4508 00 Citan Class This printout will not be recorded by the update service Status 09 2012 ...

Page 11: ...ed elements Rear The rear end equipped either with rear end doors or a liftgate also has familiar Mercedes features The angular lines of the rear window continue into the angular lines of the rear lamps a design which hints at that of the Mercedes Sprinter The red clear glass rear lamps are characterized by a combination of shiny and matt chrome plated lines S00 00 4510 00 Front view S00 00 4511 0...

Page 12: ...all vehicle 11 Introduction to CITAN Model Series 415 l Page The silhouette of the Citan slopes down towards the front S00 00 4509 00 Side view This printout will not be recorded by the update service Status 09 2012 ...

Page 13: ...an opening angle of 90 and 180 to allow a Euro pallet to be loaded easily Sliding doors A right hand sliding door is standard equipment on all LHD model designations with a body length of A2 or A3 A second sliding door on the left is available as special equipment On the Mixto and passenger van models the sliding doors feature a fixed window as standard which cannot be opened Pop out windows and p...

Page 14: ...ting of the interior compartment and further improve the external appearance of the vehicle Their light trans mission is greater than or equal to 70 and energy transmission less than or equal to 45 Wiper washer system The Citan features a parallel windshield wiper system with bracket mounted or flat wiper blades which can be controlled by a rain light sensor SA On vehicles with glazed asymmetric r...

Page 15: ...ich are used in other van model series Seat upholstery The robust non irritant and easy care seat covering fabric used as standard is identical to that of the Vito and Sprinter It features a combination of black 4mm thick textile fabric with gray check pattern center of seat and 2mm thick black flat woven fabric side seat cushions backrests head restraints and armrests The rear of the seat backres...

Page 16: ... Mixto passenger van Stowage compartments in floor in front of rear seats passenger van Overhead stowage in passenger compartment passenger van Center armrest stowage compartment S68 00 4518 00 Stowage compartment above windshield S68 00 4519 00 Left front door pocket i Note The new city van features stowage compartments with a total volume of up to 77 l S68 00 4517 00 Overhead stowage in passenge...

Page 17: ...an be hooked into the cargo area trim on the left and right hand sides This consists of two fixed covering parts which conceal the contents of the cargo area There are three possible positions for the cargo area cover Top whereby one section is folded down and can be placed on the other section Bottom In the storage position at the rear of the rear bench seat Securing loads Anchoring lugs are embe...

Page 18: ...2 3 4 or 2 21 3 or 1 21 With sliding door 2 3 2 Max qty 8 12 6 15 11 Body length Panel van Mixto Passenger van Compact A1 Long A2 Extra long A3 Extra long A3 Long A2 Cargo area length mm 1369 mm 1753 mm 2137 mm 1337 mm 2137 mm Cargo area height mm 1258 mm 1258 mm 1258 mm 1255 mm 1255 mm Min trunk volume with trunk luggage cover VDA 2 4 m3 3 1 m3 3 8 m3 2 4 m3 685 l Max trunk volume with folded rea...

Page 19: ...iew mirror is installed as standard on the passenger van and is otherwise available as an option It can be omitted on panel vans with partition wall but is still installed if a light rain sensor is ordered because this is located in the mirror housing Fixed steel load protection grille on C pillar SA The fixed steel load protection grille is attached to the C pillar behind the rear bench seat It a...

Page 20: ...e rear 2 seater 5 seater As described previously the driver and front passenger seats are separated from the cargo area by a full width partition wall installed as standard on all panel vans The possible seat configurations with the folding front passenger seat and 3 passenger bench seat are illus trated here S91 00 4511 00 S91 00 4512 00 i Note A 3 passenger bench seat with load protection grille...

Page 21: ...t for vehicles with diesel engine is different to that used for gasoline engines rpm range pre glow indicator lamps On vehicles with temperature sensor in the power outside mirrors the outside temperature is also shown on the text display At temperatures between 3 C and 3 C a warning lamp flashes to warn of the risk of icy roads The temperature can be displayed in Celsius C or Fahrenheit F dependi...

Page 22: ...0 Hand brake applied 11 ECO start stop inactive 12 Airbag fault 13 OBD engine indicator lamp 14 ESP active 15 Service lamp 16 ECO start stop active 17 Battery problems 18 Antilock warning light 19 Multifunction display 20 Right turn signal 21 ASR off 22 Fuel reserve 23 Fasten seat belt 24 Tire pressure monitor available as of 2014 25 Door check 26 Tachometer 27 Speedometer 28 Coolant temperature 2...

Page 23: ...cted and displayed on the instrument cluster or the trip odometer can be reset by pressing the button of the onboard computer multiple times Controls Most of the switches and controls of the Citan feature the same functions labels and shapes of the usual Mercedes Benz controls and they offer the same familiar high level of operating comfort The hazard warning system and side turn signals are activ...

Page 24: ... a speed of approx 50 km h is exceeded Vehicle key The vehicle key features a 2 button radio remote control and a transponder It incorporates two buttons a folding key bit and controls for the inte grated immobilizer One button is used to open the vehicle and one button is used to lock the vehicle with the central locking system via a radio remote control CPE The key bit can be folded out by press...

Page 25: ...nter console Overview of center console 1 Gearshift lever 2 Radio 3 AC and heater control 4 ECO off 5 ASR off 7 Hazard warning flasher 8 Door locking system 9 Air vents 10 Trip computer S68 20 4529 00 This printout will not be recorded by the update service Status 09 2012 ...

Page 26: ...7 and door locking system 8 There is an operating switch 10 for the trip computer and onboard computer between the instrument cluster and center console 6 Backup assist Center console center armrest variants There are two variants of the center console Lower center console between seats with stowage compartment standard Center armrest with stowage compartment SA 12V socket standard There is a 12V ...

Page 27: ... for panel van Two seater front passenger seat optional for panel van Seat heaters for the driver and front passenger seat are available The heater is activated and deactivated by pressing the switch Rear bench seats Two different folding 3 passenger bench seats are available for the rear 1st row rear bench seat folding 1 3 2 3 standard on Mixto and passenger van 1st row rear bench seat SA on Mixt...

Page 28: ...s Service maintenance 40tkm 2 years 30tkm 2 years Air filter 80tkm 4 years 90tkm 4 years Coolant replacement interval 160tkm 4 years 150tkm 4 years V belt 240tkm 10 years 180tkm 8 years Toothed belt 240tkm 10 years Timing chain Unit Diesel engine Gasoline engine Oil fill cap of engine with filter Liters 4 6 4 5 Fuel tank reserve Liters 60 6 Coolant Liters 7 2 10 3 i Note The transmission oil does ...

Page 29: ...a customer option fuel filter with water separator improves the opera tional reliability of the engine and injection system when poor quality fuel is used e g fuel with a high water content Engine Output kW hp Displace ment Torque Emissions level Model designation Transmis sion OM607 55 75 1 5 liters 180 Nm Euro 5 108 CDI 5 speed GK5 66 90 1 5 liters 200 Nm Euro 5 109 CDI 5 speed GK5 81 110 1 5 li...

Page 30: ...uipment Overview of design Valves with mechanical cup tappets with DLC coating diamond like carbon Crankshaft with special surface treatment Alternator and AC compressor driven by a belt drive with six grooves High quality engine mounts Optimized VTG turbocharger for high efficiency on the 81kW diesel engine as of 03 2013 on the 55kW and 66kW variants a wastegate charger is installed Long life too...

Page 31: ...Almost quadratic stroke bore ratio Valves with mechanical cup tappets with DLC coating diamond like carbon Gasoline direct injection Controlled variable oil pump with two pressure levels 2 bar under partial load 4 bar with wide open throttle Water cooled turbocharger with low thermal inertia rapid response Friction optimized components e g valves camshaft Environment Overview of environmental char...

Page 32: ...idle neutral position The vehicle has exceeded a speed of approx 5 km h at least once or the distance from the last stop exceeds a certain threshold Maneuvering not detected Vehicle speed below 4 km h ECO start stop function active i e not deactivated by driver using corresponding button Engine hood closed The engine restarts automatically when one of the following conditions is fulfilled The clut...

Page 33: ...ype Diecast aluminum Diecast aluminum Overall length of transmission mm 390 389 Number of transmission shafts 2 2 Synchronization Dual cone synchronization in gears 1 and 2 Single cone synchronization in gears 3 4 and 5 Dual cone synchronization in gears 1 and 2 Single cone synchronization in gears 3 4 5 and 6 Gear selection Cable Cable Clutch Hydraulically controlled single plate clutch Concentri...

Page 34: ... springs and transverse stabilizer bars provide the required driving stability axle guidance and vibration damping The maximum permissible axle load of the rear axle is 1240 kg Depending on the wheel offset of the rims the rear wheel toe is between 1533 mm and 1534 mm The suspension tuning of the Citan ensures Active nimble handling characteristics Few sprung mass vibrations during driving maneuve...

Page 35: ...eering system with a motor on the steering column which uses an elec tronic control system to provide speed dependent variable servo assistance e g it provides greater steering assistance when parking In addition the steering column features manual height adjustment S46 00 4505 00 Steering This printout will not be recorded by the update service Status 09 2012 ...

Page 36: ...ive ESP 9i vehicle dynamics control system from Bosch which is used in the vehicle improves handling characteristics and thus safety because it improves the directional stability and steerability of the vehicle at its critical dynamic driving limits The ESP 9i system can access both the brake system and the engine management system It contin uously evaluates the measurements of the steering angle ...

Page 37: ... S standard O option not available All season tires and tires with optimized rolling resis tance are also available Model Panel van Mixto Passen ger van A1 A2 A3 A3 A2 Tire 185 70 R14 S Tire 195 65 R15 S S Reinforced tire 195 65 R15 95T O S S O Tire 205 55 R16 O O All season tire 195 65 R15T O O 195 65 R15 91T O O This printout will not be recorded by the update service Status 09 2012 ...

Page 38: ...box The fuse box for various electrical devices is located on the left below the instrument cluster The fused components are indicated by corresponding symbols Control systems ESM Energy Smart Management is an intelligent alternator management system which maintains the on board voltage constant irrespective of the driving condition and prevents overvoltage Controlling the alternator also allows f...

Page 39: ...the same unit as the fog lamps in the front bumper They are automatically switched on when the engine is started and improve the visibility of the vehicle for other road users Daytime running lights are compulsory in some countries e g Scandinavia Front fog lamps If the front fog lamp special equipment option is chosen a different lamp with combined daytime running lamp and front fog lamp in the b...

Page 40: ... 415 l Taillamp The single piece 3 chamber rear lamp contains Tail brake lamp Backup lamp Turn signal lamp The rear fog lamp is integrated in the bumper S82 10 4569 00 Overview of rear lamps This printout will not be recorded by the update service Status 09 2012 ...

Page 41: ...3 settings only standard for Mixto and passenger van with 2 load compartment sliding doors Interior lamp on D pillar with switch 3 settings standard for all variants without full trim The lamps with 3 position switch have three different light settings Continuously on Temporary illumination activation when a door is opened and deactivation when the corresponding doors are closed Immediate deactiva...

Page 42: ...icles with liftgate On vehicles with rear end doors it is located on the left hand rear end door offset slightly above the rear window This provides additional warning to following traffic in the event of emergency braking In an accident In the event of a crash the restraint systems and numerous airbag variants provide important additional safety for occupants Many of these systems are part of the...

Page 43: ...tection of the torso in serious accidents involving a side impact The windowbags for the driver and front passenger are housed in the headliner above the doors on the driver and front passenger side respectively In the event of a major side impact with high lateral acceleration sensors cause the windowbags to be triggered down wards The windowbags position themselves like a curtain in front of the...

Page 44: ...to maintain the maximum speed on downhill sections Light rain sensor The combined light rain sensor is housed in the base of the inside rearview mirror on the inside of the wind shield Backup assist The backup assist system is an acoustic parking aid with four ultrasonic sensors in the rear bumper An acoustic signal sounds when reverse gear is engaged However it is important to ensure that the ult...

Page 45: ...m for selectively controlling the temperature in the vehicle in several stages In addition fogged windows are cleared more quickly due to the dehumidifying effect of the air conditioning system The intensity of the air conditioning output can be controlled via the blower control system If this is set to stage 0 the air conditioning is automatically switched off even if the A C switch is activated ...

Page 46: ...ndard for passenger van The hot air duct to the passenger compartment is an air shaft on the vehicle floor running to the rear below the front seats which outputs temperature controlled air behind the driver front passenger seat into the passenger compartment The hot air duct thus ensures that the temperature of the passenger compartment can be controlled quickly and comfortably through heating co...

Page 47: ...It is automatically activated and deactivated via the radio remote control of the key It includes an electronic immobilizer with locking system and radio remote control as well as a visual signal to confirm that the vehicle has been locked Retrofitting of the antitheft alarm system is possible with an ex factory preinstallation This printout will not be recorded by the update service Status 09 201...

Page 48: ...lay an AUX interface and a USB interface to allow additional external devices to be connected The USB interface can also be used to access the 12 volt on board electrical system e g to charge the battery of a music player An AM FM antenna and 4 or 6 speakers 2 tweeters 2 bass speakers 2 rear speakers in passenger van are included The Radio Entry Renault with CD drive also allows track information ...

Page 49: ...e 1 Not available until 2013 The bodyshell of the Citan has largely been taken over from Renault except engine hood and liftgate The Citan demonstrated a high level of robustness during rough road hydro pulse tests meaning that no signif icant modifications to the bodyshell were necessary Only the detachable parts were modified Citan Compact1 A1 Length 3937 mm Long A2 Length 4321 mm Extra long A3 ...

Page 50: ...us be adapted to a very wide range of industries As a result body equipment mounting directives will be produced for body manufacturers to provide them with all of the relevant details For example an increased payload is available as special equipment if necessary Roof carrier systems In addition to the standard cargo area there are two additional options which further improve the flexible transpo...

Page 51: ...riants to improve both corrosion protection and noise charac teristics All cavities are also coated with wax in addition to their cavity preservation Continuous plastic sealing strips around the doors and a PVC seam seal also provide corrosion protection Paintwork The range of paints for the Citan includes 6 metallic paints SA and 6 standard finishes standard some of which are available exclusivel...

Page 52: ...he entire unit MB number W415 589 00 62 00 FG 01 Set C Category Mercedes Benz Van Basic Operations Compulsory Alternative Cooperation Note Release fork set S58 20 4504 00 Use Release forks for the rear seat stops MB number W415 589 00 63 00 FG 91 Set B Category Mercedes Benz Van Basic Operations Note This printout will not be recorded by the update service Status 09 2012 ...

Page 53: ...Series 415 l Puller S58 20 4505 00 Use For pulling supporting joint off transverse control arm MB number W415 589 00 33 00 FG 33 Set B Category Mercedes Benz Van Basic Operations Note This printout will not be recorded by the update service Status 09 2012 ...

Page 54: ...aling rings MB number W700 589 00 15 00 FG 26 Set B Category Mercedes Benz Van Basic Operations Note Drift S58 20 4507 00 Use Drift for knocking in radial shaft sealing rings MB number W700 589 01 15 00 FG 26 Set B Category Mercedes Benz Van Basic Operations Note This printout will not be recorded by the update service Status 09 2012 ...

Page 55: ...aling ring MB number W700 589 01 14 00 FG 26 Set B Category Mercedes Benz Van Basic Operations Note Socket S58 20 4509 00 Use For removing installing the reverse gear switch MB number W700 589 00 14 00 FG 26 Set B Category Mercedes Benz Van Basic Operations Note This printout will not be recorded by the update service Status 09 2012 ...

Page 56: ...odel Series 415 l Drift S58 20 4510 00 Use Drift for fitting retaining ring to planetary gear MB number W700 589 02 15 00 FG 26 Set B Category Mercedes Benz Van Basic Operations Note This printout will not be recorded by the update service Status 09 2012 ...

Page 57: ...B number W607 589 01 40 00 FG 03 Set B Category Mercedes Benz Van Basic Operations Compulsory no exemptions Note Retaining lock S58 20 4512 00 Use For locking the camshaft sprocket in place MB number W607 589 02 40 00 FG 05 Set C Category Mercedes Benz Van Basic Operations Note This printout will not be recorded by the update service Status 09 2012 ...

Page 58: ... Van Basic Operations Recommendation Note In combination with pressure pump W124 589 24 21 00 Tester cap S58 20 4514 00 Use For leak testing and filling the cooling system MB number W415 589 00 91 00 FG 01 Set A Category Mercedes Benz Van Basic Operations Compulsory no exemptions Note In combination with pressure pump W124 589 24 21 00 This printout will not be recorded by the update service Statu...

Page 59: ... to the A 353 EVO with supple mentary kit A 353 KITEVO Supplier address GOTIS online http gotis aftersales mercedes benz com under K 60 65 Bodyshell body straight ening systems GOTIS online http gotis aftersales mercedes benz com under K 60 65 Bodyshell body straight ening systems Universal mounts Manufacturer Erwin Schairer GmbH Werner Weitner GmbH Article Universal mount for MB van engines Unive...

Page 60: ...Broadcasting DC AC Direct Current Alternating Current DE Direct Injection DI DEH Direct injection homogeneous mode DES Direct injection stratified charge DSP Digital Signal Processor EBV Electronic brake force distribution EBD EDW Anti theft alarm system ATA ESP Electronic Stability Program ETS Electronic Traction System EZS Electronic ignition lock FBS Drive authorization system DAS FKW Fluorocar...

Page 61: ...gy ME Motor Electronics ME SFI MOST Media Oriented System Transport NEFZ New European Driving Cycle NEDC PVC Polyvinyl Chloride RDK Tire pressure monitor TPM ROZ Research octane number RON SA Special equipment SMC Sheet Molding Compound TPM Cruise control USB Universal Serial Bus WIS Workshop Information System This printout will not be recorded by the update service Status 09 2012 ...

Page 62: ... start stop function 31 Engine M200 R4 with 1 2 l displacement 30 Engine OM607 R4 with 1 5 l displacement 29 ESP 35 F Filling capacities 27 Front 10 Front fog lamps 38 Fuse box 37 H Heating ventilation air conditioning 44 I In an accident 41 In the event of danger 41 Individual light functions 40 Innovations 8 Interfaces for external data exchange 37 Interior 16 L Light rain sensor 43 Locking syst...

Page 63: ...er unit 20 Steering wheel 22 Stowage concept 15 T Taillamp 39 Thorax sidebag and windowbags 42 Trailer hitch 49 Trim panels and other interior materials 14 V Vehicle 8 Vehicle concept 8 Vehicle key 23 W Windows 13 Wiper washer system 13 This printout will not be recorded by the update service Status 09 2012 ...

Page 64: ... This printout will not be recorded by the update service Status 09 2012 ...

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