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Mercedes-Benz OM 471, Introduction Into Service Manual

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Mercedes-Benz OM 471 Introduction Into Service Manual Download Page 173

System components

GF07.03>W>6120H

Component description for fuel injectors

3.8.11

ENGINES

 471.9 in MODEL 963

W07.03

>

1056

>

12

Location

Y608

Cylinder 1 fuel injector

Y609

Cylinder 2 fuel injector

Y610

Cylinder 3 fuel injector

Y611

Cylinder 4 fuel injector

Y612

Cylinder 5 fuel injector

Y613

Cylinder 6 fuel injector

The fuel injectors for cylinder 1 to 6 (Y608 to Y613) are fastened by
means of clamping pieces at the cylinder head and positioned
centrally between the valves of the respective cylinder.

Task

The purpose of the fuel injectors is to inject fuel at high pressure
into the respective cylinders.
The injection timing point, injection period and the injection
variants (e.g. with or without pressure boosting) are established by
the engine management (MCM) control unit (A4).

W07.03

>

1057

>

76

Design

Shown on cylinder 1 fuel injector (Y608)
1

Electrical connection

2

Coil

3

High pressure feed

4

Pressure booster

5

Coil

6

Spring

7

Nozzle needle

8

Check valve

9

Return spring

Y608

Cylinder 1 fuel injector

Y608 y1    Cylinder 1 pressure booster

solenoid valve

Y608 y2    Cylinder 1 nozzle needle

solenoid valve

170

– This printout will not be recorded by the update service. Status: 09 / 2011 –

Summary of Contents for OM 471

Page 1: ...ion into Service Manual Daimler AG GSP OI HPC R 822 D 70546 Stuttgart Bestell Nr 6517 1260 02 HLI 000 000 02 82 Printed in Germany 09 11 Introduction of engine OM 471 and exhaust aftertreatment This p...

Page 2: ...tion of engine OM 471 and exhaust aftertreatment Technical status 01 09 2011 Daimler AG Technical Information and Workshop Equipment GSP OI D 70546 Stuttgart This printout will not be recorded by the...

Page 3: ...822 W002 D 70546 Stuttgart Germany 2011 by Daimler AG This document including all its parts is protected by copyright Any further processing or use requires the previous written consent of Daimler AG...

Page 4: ...ction descriptions component descriptions All the data listed in this brochure correspond with the technical status as per September 2011 Any changes or supplements hereto will be published in the Wor...

Page 5: ...ilt configuration Page 24 Gear drive as built configuration Page 29 Camshaft as built configuration Page 31 Belt drive as built configuration Page 32 Function descriptions Crankcase ventilation system...

Page 6: ...rtreatment overall network Page 79 Engine oil circuit function Page 80 Engine oil circuit diagram Page 82 Coolant circuit function Page 83 Coolant circuit diagram Page 86 Engine cooling thermal manage...

Page 7: ...stallation without chassis shielding Page 107 Radiator shutters component description A54 A55 i Only in vehicles with code M7K Radiator shutters Page 109 EATU output NOx sensor component description A...

Page 8: ...Page 134 Exhaust temperature sensor upstream of diesel oxidation catalytic converter component description B67 i Only for vehicles with code M5Z Engine version Euro VI Page 135 Exhaust temperature sen...

Page 9: ...temperature sensor B607 Page 151 Charge air pressure and temperature sensor in charge air pipe component description B608 Page 152 Turbine wheel rpm sensor component description B610 i Only for vehic...

Page 10: ...e E5X ADR model class AT Code E5Z Accessories ADR Code E9D Preinstallation for bipolar battery disconnect switch Code E9E ADR preinstallation without chassis shielding Page 165 EMERGENCY OFF switch fr...

Page 11: ...nent description for oil pump Page 189 Oil coolant module component description Page 191 Oil thermostat component description Page 193 Component description for oil water heat exchanger Page 194 Compo...

Page 12: ...ust aftertreatment unit component description i Only for vehicles with code M5Z Engine version Euro VI Page 218 Nozzle unit for DPF regeneration component description i Only for vehicles with code M5Z...

Page 13: ...ents The new injection system the amplified pressure common rail system APCRS 1 is the first common rail system to be used in Mercedes Benz commercial vehicles that minimizes the quantity of fuel requ...

Page 14: ...horsepower 421 449 476 510 Torque Nm 2100 2200 2300 2500 Piston OM 471 Diameter mm 132 Overall height mm 113 Compression height mm 75 Shank length 71 65 Piston pin OM 471 Inside diameter mm 23 5 Outsi...

Page 15: ...to lubricate the valve assembly A prefilter 2 is integrated in the cylinder head cover 1 The prefilter 2 ensures that the engine oil which is swirled by the valve assembly and mixes with the blow by g...

Page 16: ...ion on the thread strength of the respective cylinder head bolt The cylinder head bolts have the M15 2 thread and therefore have the embossing 15 All the cylinder head bolts must be tightened in four...

Page 17: ...readed holes for the charge air manifold attachment x Direction of travel W01 30 1123 76 43 Exhaust ducts 44 Threaded holes for the charge air manifold attachment x Direction of travel 14 This printou...

Page 18: ...block x Direction of travel W01 30 1125 76 46 Inlet valves 47 Exhaust valves 48 Bores for the fuel injectors x Direction of travel i Introduction of engine OM 471 and exhaust aftertreatment 09 2011 1...

Page 19: ...l return flow holes from cylinder head to cylinder crankcase x Direction of travel W01 30 1127 76 51 Coolant short circuit channel from cylinder head to cylinder crankcase 52 Coolant overflow holes fr...

Page 20: ...nd on the exhaust side The advantage is that the coolant first flushes around the fuel injectors and valve seat rings in the lower cooling level 53 of the cylinder head After this the coolant flows in...

Page 21: ...ng KG Opening for the blow by duct to the crankcase ventilation system x Direction of travel The cylinder head gasket consists of a number of layers of stainless steel The cylinder head gasket at the...

Page 22: ...urn duct from oil filter for changing the oil filter 11 Oil feed from oil coolant module from oil filter to crankcase 12 Oil feed from crankcase from the oil pump to oil coolant module 13 Oil hole clo...

Page 23: ...to the design form of the oil return ducts f a compact design due to the low distance from the cylinder The crankcase also has 1 5 mm recesses at the sealing surface to the cylinder head for all cool...

Page 24: ...re forged in steel and are characterized by their high strength The connecting point between the connecting rod 1 and the connecting rod bearing cap 7 is cracked This has the advantages amongst other...

Page 25: ...ith a combustion recess 2 Through the combustion recess 2 the clearance volume is partially transferred into the piston 1 Top land 4 The top land 4 protects the 1st piston ring 6 against excessively h...

Page 26: ...by the applied protective coatings This allows a longer working life and engine damage is avoided by the emergency running characteristics which result from the coating if the lubrication is faulty G...

Page 27: ...he valve control include Two upper recumbent camshafts the intake camshaft 12 and the exhaust camshaft 6 which are driven by the gear drive via the pinion gear drive for the intake camshaft 11 or via...

Page 28: ...springs 19 Adjusting elements for adjusting the valve clearance 23 Adjusting element for engine brake W05 00 1035 75 Design of the exhaust rocker arm spindle 4 4 Exhaust rocker arm spindle 15 Lubrica...

Page 29: ...the engine brake 23 The exhaust rocker arm 1 exhaust rocker arm with hydroelement 2 and brake rocker arm 3 are mounted rotatable on the exhaust rocker arm spindle 4 The exhaust rocker arm spindle 4 i...

Page 30: ...inlet hole 20 If the corresponding brake rocker arm 3 now presses on the piston 21 the check valve 22 is closed by the increased oil pressure Depressurization is prevented and the downward movement of...

Page 31: ...The intake rocker arms 9 are mounted rotatable on the intake rocker arm spindle 10 The intake rocker arm spindle 10 is made out of pipe material for weight reduction and is fitted with a lubrication...

Page 32: ...st camshaft 11 Intake camshaft A Level 1 B Level 2 C Level 3 x Direction of travel W01 40 1133 76 1 Crankshaft 2 Oil pump 3 Double intermediate wheel 4 Compressor 5 Intermediate gear 6 Power steering...

Page 33: ...nd the compressor 4 The gears for level 2 A are straight geared Level 3 C Level 3 C includes the intermediate gear 9 the drive gear for the exhaust camshaft 10 and the drive gear for the intake camsha...

Page 34: ...gear drive There is an intake cam 7 on the intake camshaft 2 for each cylinder The corresponding intake valves are opened via the intake cams 7 and the associated intake rocker arms on the intake rock...

Page 35: ...damper 2 Tensioner pulley for poly V belt A on the tandem clamping device 3 Belt pulley alternator 4 Belt pulley A C compressor 5 Pulley 6 Belt pulley coolant pump 7 Pulley 8 Pulley 9 Guide pulley on...

Page 36: ...y V belt basic belt drive B Poly V belt fan drive C Poly V belt fan drive For a 3 belt drive the fan clutch 15 is mounted on a drive plate 14 which is mounted rotatable on the belt pulley 1 The fan is...

Page 37: ...B Engine oil to drive the centrifuge C Blow by gas with engine oil D Blow by gas clean The blow by gas C generated by internal leakage at the piston rings valve stem seals turbocharger and compressor...

Page 38: ...wer and the torque Reduction of fuel consumption in comparison to not supercharged diesel engines of the same power output Reduction of the pollutant emission Function The turbocharger 1 consists of a...

Page 39: ...Euro VI the rotor speed of the turbocharger 1 as well as the temperature of the intake air are monitored by the air filter A on the compressor inlet to protect the turbocharger This occurs with the ai...

Page 40: ...ioner B607 Intake coolant temperature sensor B608 Charge air pressure and temperature sensor in charge air pipe B611 Temperature sensor downstream of air filter only for code M5Z Engine version Euro V...

Page 41: ...t occurs on the drive train CAN CAN 4 or on a system component for the engine management the engine management MCM control unit A4 proceeds according to a clearly defined pattern depending on the seve...

Page 42: ...g wheel button group S111 Right multifunction steering wheel button group X100 16 Diagnostic socket X102 15 Trailer socket 15 pin X167 12 Electrical connector telematics platform TP X910 Electrical co...

Page 43: ...ms and displayed in the instrument cluster control unit ICUC A1 There is also entry of the condition in the fault memory 2 Response when camshaft position sensor B601 fails If the camshaft position se...

Page 44: ...ubstitute characteristic while the engine is running is because the charge pressure in the charge air housing can differ according to the engine loading and cannot therefore be used as the atmospheric...

Page 45: ...irculation EGR differential pressure sensor B622 Rail pressure sensor B638 Fuel filter module pressure sensor General information The engine start procedure is initiated when a corresponding start req...

Page 46: ...rily geared to the coolant temperature which is determined by the engine management MCM control unit A4 via the exhaust coolant temperature sensor B606 Further influencing factors for the injection qu...

Page 47: ...drive train CAN CAN 4 for example if the idle speed should be higher in order to operate ancillary assemblies at their working speed The higher rotational speed is basically always regulated In other...

Page 48: ...temperature and the turbine inlet temperature of the turbocharger as well as the air fuel ratio n lambda does not exceed or drop below established limits To do this the exhaust gas recirculation rate...

Page 49: ...izable special module PSM control unit A22 Along with a range of other parameters it is possible for example to set the entry requirements such as parking brake tightened or transmission in neutral or...

Page 50: ...and holds this constant f Changing the working speed over the multifunction steering wheel The working speed can be altered step by step in steps of 20 with the aid of keys on the multifunction steer...

Page 51: ...r pedal It is only in certain situations that it can happen that the engine speed is adapted independently of the accelerator pedal position or of the specified torque request for example for downshif...

Page 52: ...motor speed drops below 950 rpm the engine management MCM control unit A4 increases the fuel pressure in the rail over the rail quantity control valve Y642 and actuates the fuel injectors for cylinde...

Page 53: ...EX II including AT code E5U ADR model class EX III including EX II and AT code E5V ADR model class FL including EX II EX III and AT code E5X ADR model class AT code E5Z accessories ADR code E9D preins...

Page 54: ...ton S600 Function As soon as the engine management MCM control unit A4 receives a corresponding shutdown request over the drive train CAN CAN 4 or if the engine start and engine stop button S600 is op...

Page 55: ...luding EX II and AT Code E5V ADR model class FL including EX II EX III and AT Code E5X ADR model class AT Code E5Z Accessories ADR Code E9D Preinstallation for bipolar battery circuit breaker Code E9E...

Page 56: ...6 or the angular position of the crankshaft can be recognized Each groove 2 triggers an impulse in the crankshaft position sensor B600 As soon as the engine management MCM control unit A4 receives an...

Page 57: ...tuation of the fuel injectors can be determined that more exactly Function The camshaft sprocket 2 on the intake camshaft has 12 grooves 3 which are respectively distributed at a distance of 30 from e...

Page 58: ...e and boost pressure combination sensor B606 are fitted with a temperature dependent resistance with a negative temperature coefficient NTC that is an electrical resistance which reduces as the temper...

Page 59: ...rmation which is determined by the charge air pressure and temperature sensor in charge air pipe B608 the temperature sensor downstream of the air filter B611 only with code M5Z Euro VI engine version...

Page 60: ...fuel temperature sensor B602 There is a temperature dependent resistance with a negative temperature coefficient NTC in the fuel temperature sensor B602 an electrical resistance which reduces as the t...

Page 61: ...e engine torque status 9 Engine target torque request A60 Exhaust aftertreatment ACM control unit B18 Travel and speed sensor B44 Accelerator pedal sensor CAN 3 Frame CAN CAN 4 Drive train CAN P1 Tach...

Page 62: ...control unit MCM A4 evaluates the current coolant temperature the fuel temperature and the engine rpm to do this The engine management control unit MCM A4 then sends the maximum available engine torq...

Page 63: ...f the BDC in its next operating cycle Operating conditions The engine braking system can be activated under the following conditions f Vehicle in deceleration mode that is the driving and clutch pedal...

Page 64: ...tivated the engine brake solenoid valve stage 1 Y624 and the engine brake solenoid valve stage 2 Y625 are not actuated In this way no oil pressure can find its way out of the engine oil circuit over t...

Page 65: ...oil first flows through the check valve 16 in flow direction and thus the space under the piston 8 is filled If there is no gap anymore between the piston 8 and brake rocker arm 3 then the check valve...

Page 66: ...check valve 16 in flow direction and thus the space under the piston 8 is filled If there is no gap anymore between the piston 8 and brake rocker arm 3 then the check valve 16 is closed by the now ac...

Page 67: ...ons of the engine brake system Providing support during shift operations The engine brake is automatically activated for all normal shift operations without the driver having to do anything Activation...

Page 68: ...standard system There are however parameters in the engine management MCM control unit A4 which ensure that the internal pressure is increased in all cylinders in all engine brake stages over actuatio...

Page 69: ...deteriorates the combustion and the emission of soot particles carbon monoxide CO and hydrocarbon HC increases On the other hand the emission of nitrogen oxides NOx increases if the ratio of fresh or...

Page 70: ...recycled exhaust is increased Furthermore the added quantity of cooled exhaust causes a reduction in the NOx emissions by the lowering of the combustion temperature Once the exhaust has passed throug...

Page 71: ...output of carbon monoxide CO nitrogen oxide NOx hydrocarbons HC and particles PM As a vehicle manufacturer Mercedes Benz must guarantee compliance with these limits for an established time period and...

Page 72: ...re sensor downstream of SCR catalytic converter B74 AdBlue fill level sensor temperature sensor M25 SCR delivery pump Y627 AdBlue heater coolant solenoid valve A57 b1 NOx sensor outlet of EATU A58 SCR...

Page 73: ...y in the exhaust flow the AdBlue flows back again over the AdBlue return line into the AdBlue container This circulation continuously takes place independently of whether AdBlue is injected or not So...

Page 74: ...tween the pump module 1 and the AdBlue metering device A67 are not heated by coolant but instead over in electrically heated heating elements integrated in the line sections Function of AdBlue heating...

Page 75: ...or control unit inlet of EATU A70 A70 b1 Page 123 Component description for exhaust temperature sensor upstream of SCR catalytic converter B72 Page 139 Component description for exhaust temperature se...

Page 76: ...mission of carbon monoxide CO nitrogen oxides NOx hydrocarbons HC and particles PM As the vehicle manufacturer Mercedes Benz must guarantee compliance with these limits for a determined period of time...

Page 77: ...wnstream of SCR catalytic converter B74 AdBlue fill level sensor temperature sensor B625 Fuel pressure sensor inlet B626 Fuel pressure sensor outlet M25 SCR delivery pump Y627 AdBlue heater coolant so...

Page 78: ...AN 13 NOx CAN B625 Fuel pressure sensor inlet B626 Fuel pressure sensor outlet M25 SCR delivery pump Y628 Fuel metering valve Y629 Fuel shutoff valve B37 Exhaust pressure sensor upstream of diesel oxi...

Page 79: ...ally flows through the EATU 4 into the diesel oxidation catalytic converter 7 In it the given hydrocarbons HC and the carbon monoxide CO are converted to carbon dioxide CO2 and water H2O Apart from th...

Page 80: ...ing device A67 are not electrically heated by the coolant but by the heating elements integrated into the line sections Function of AdBlue heating through coolant The AdBlue heater consists of the AdB...

Page 81: ...r component description B69 Page 137 Exhaust temperature sensor downstream of diesel particulate filter component description B70 Page 138 Exhaust temperature sensor downstream of SCR catalytic conver...

Page 82: ...it output for exhaust aftertreatment unit CAN 4 Drive train CAN CAN 13 NOx CAN Z4 Drive CAN bus star point A58 SCR control unit A60 Exhaust aftertreatment ACM control unit A70 NOx sensor control unit...

Page 83: ...engine is started the oil pump 1 sucks in engine oil in the oil pan through the oil intake manifold 2 and the oil strainer 2 1 fastened to it and pumps it to the oil coolant module 3 At an engine tem...

Page 84: ...with engine oil through the external oil pressure line The engine oil is returned by way of return ducts and return holes in the camshaft housing cylinder head and in the crankcase i The engine oil f...

Page 85: ...dle 16 Exhaust camshaft bearing lubrication point 17 Exhaust rocker arm 18 Exhaust rocker arm with hydroelement 19 Brake rocker arm 20 Intermediate gear lubrication point to camshafts B604 Oil pressur...

Page 86: ...icles with code M7T Coolant pump control of the speed of the coolant pump 1 2 is permanently monitored by the engine management MCM control unit A4 with the aid of the coolant pump rpm sensor B640 and...

Page 87: ...t utilization the additional residual heat pump M20 upstream of the heater shutoff valve Y49 ensures that the coolant is circulated in the heater circuit when the engine is switched off This in turn m...

Page 88: ...Only in vehicles with code B3H Secondary water retarder Page 169 Component description for exhaust gas recirculation controller Y621 Page 176 AdBlue heater coolant solenoid valve component descriptio...

Page 89: ...eater for auxiliary water heater only with code D6M Cab auxiliary water heater or code D6N Cab and engine auxiliary water heater A901 M2 Circulation pump only with code D6M Cab auxiliary water heater...

Page 90: ...rate through the engine to be reduced to the amount required for each operating condition The engine radiator s cooling air flow rate is also regulated by the fan clutch as a function of the operatin...

Page 91: ...ed f Outside air temperature f Coolant temperature f Boost air temperature f Engine speed Depending on the listed information the drive control CPC control unit A3 uses a characteristics map to calcul...

Page 92: ...ent temperature Open Open Engine cooling thermal management overall network Page 90 Drive control CPC control unit component description A3 Page 102 Engine management control unit MCM component descri...

Page 93: ...control CPC control unit A4 Engine management control unit MCM LIN 5 Radiator shutters LIN Z4 Drive CAN bus star point A54 Lower radiator shutters controller unit A55 Upper radiator shutters controlle...

Page 94: ...3 Cylinder 6 fuel injector Y628 Fuel metering valve only with code M5Z Engine version Euro VI Y629 Fuel shutoff valve only with code M5Z Engine version Euro VI Y642 Quantity control valve General info...

Page 95: ...626 Fuel metering valve Y628 Fuel shutoff valve Y629 Fuel high pressure circuit The fuel high pressure circuit of the APCRS consists of the following components Fuel system high pressure pump 4 which...

Page 96: ...er 2 fuel injector Y610 Cylinder 3 fuel injector Y611 Cylinder 4 fuel injector Y612 Cylinder 5 fuel injector Y613 Cylinder 6 fuel injector Y642 Quantity control valve A Fuel feed suction side B Fuel f...

Page 97: ...valve After leaving the water separator 8 the fuel flows through the fuel filter 9 Extremely small contamination 2 om is filtered out in the fuel filter 9 similarly to the water separator 8 If air has...

Page 98: ...returned to the fuel low pressure circuit via the fuel return bypass 42 just upstream of the fuel prefilter 7 The fuel quantity is determined by the throttle 11 and the check valve 12 in the fuel retu...

Page 99: ...pressure sensor Y608 Cylinder 1 fuel injector Y609 Cylinder 2 fuel injector Y610 Cylinder 3 fuel injector Y611 Cylinder 4 fuel injector Y612 Cylinder 5 fuel injector Y613 Cylinder 6 fuel injector Y62...

Page 100: ...pump to diesel fuel metering device 35 Fuel return line from 2 stage valve 36 Fuel return line of pressure booster 37 Fuel return line of nozzle needle 38 Fuel return line from pressure limiting valv...

Page 101: ...ing the water separator 8 the fuel flows through the fuel filter 9 Extremely fine contamination 2 om is filtered out in the fuel filter 9 as it is in the water separator 8 If air has gathered in the w...

Page 102: ...nozzle needle valves 37 has the task of achieving the required back pressure of about 2 bar while the engine is running and therefore ensuring that the fuel injectors work perfectly Part of the retur...

Page 103: ...nt MCM control unit A4 If the maximum permissible rail pressure has been exceeded the mechanical pressure limiting valve 5 opens and the excess fuel flows back from the pressure limiting valve 7 to th...

Page 104: ...re and issues a corresponding fault code In addition the failure is displayed on the instrument cluster control unit ICUC A1 Network management The central gateway control unit CGW A2 is responsible f...

Page 105: ...C A1 f Central gateway CGW control unit A2 f Engine management MCM control unit A4 f Transmission TCM control unit A5 f Cab signal acquisition and actuation module SCA control unit A7 f Antilock brake...

Page 106: ...icle side Both control units are networked together via the drive train CAN CAN 4 and the CAN bus drive neutral point Z4 The engine management MCM control unit A4 takes on a number of tasks On the one...

Page 107: ...629 and the fuel metering valve Y628 are located together with the fuel pressure sensor inlet B625 and the fuel pressure sensor outlet B626 in one metering device This ensures that diesel fuel is mete...

Page 108: ...r A20a the rear axle axle modulator A21 or A21a the ABS solenoid valves Y1 Y2 and the trailer control valve Y6 or Y6a with the corresponding electrical signals to apply the specified brake pressures f...

Page 109: ...r CAN PSM CAN 7 and the body CAN PSM CAN 8 serve as external interfaces The parameterizable special module control unit PSM A22 allows for the implementation of complex controls and functions Full acc...

Page 110: ...C7T Integral rear end A33 Battery disconnect switch control unit BESO In vehicles with standard rear end the battery disconnect switch BESO control unit A33 is installed below the vehicle battery in...

Page 111: ...anagement MCM control unit A4 initiates the switching off of the engine due to this message The on board electrical system is disconnected by a bistable relay integrated into the battery disconnect sw...

Page 112: ...m1 f Voltage converter 24 V 14 V A55 t1 Function The lower radiator shutters controller unit A54 and the upper radiator shutters controller unit A55 are actuated by the drive control control unit CPC...

Page 113: ...EATU output NOx sensor A57 b1 are connected to each other via a non separable electrical line and form one unit The EATU output NOx sensor A57 b1 is similar in design to a wide band oxygen sensor It...

Page 114: ...easure for the residual oxygen content in the exhaust The traces of HC CO and H2 in the exhaust oxygenate at the electrode made out of platinum The gas then passes over a further diffusion barrier and...

Page 115: ...the diesel oxidation catalytic converter DOC The exhaust aftertreatment unit outlet NOx sensor A57 is attached to a bracket at the exhaust aftertreatment unit 1 Both components form a single unit Tas...

Page 116: ...permeable ceramic body inside made out of zirconium dioxide The surfaces of the ceramic body are fitted on both sides with electrodes made out of a thin platinum layer The measuring probe is in contac...

Page 117: ...boundary surfaces This is the measure for the residual oxygen content in the exhaust The traces of HC CO and H2 in the exhaust oxygenate at the electrode made out of platinum The gas then passes over...

Page 118: ...AdBlue metering device A67 The SCR control unit A58 calculates the injection period and the injection quantity W14 40 1570 76 Design 3 Electronics housing 4 Connecting body 5 Filter housing 6 Electri...

Page 119: ...ough circulating AdBlue AdBlue is pumped continuously irrespective of whether injection is necessary or not The AdBlue that is not required or not injected flows back through the return line to the Ad...

Page 120: ...for exhaust aftertreatment unit A57 b1 NOx sensor output for exhaust aftertreatment unit A58 SCR control unit in pump module B73 Exhaust temperature sensor downstream of SCR catalytic converter B74 A...

Page 121: ...It receives the NOx sensor signals over CAN connections and communicates with the SCR control unit A58 and the engine management MCM control unit A4 AdBlue injection It uses the data supplied by the S...

Page 122: ...l unit A60 is fastened to a bracket on the inside of the EATU 1 Task The exhaust aftertreatment ACM control unit A60 regulates and controls practically all the exhaust aftertreatment system functions...

Page 123: ...pstream of diesel oxidation catalytic converter B68 Exhaust temperature sensor downstream of upper diesel oxidation catalytic converter B69 Exhaust temperature sensor downstream of lower diesel oxidat...

Page 124: ...n the direction of travel The injection nozzle of the AdBlue metering device A67 protrudes here into the hydrolysis segment of the EATU 1 Task The AdBlue metering device A67 injects the AdBlue quantit...

Page 125: ...n the engine is switched off Injection The AdBlue metering device A67 receives the signals from the SCR control unit A58 for the currently delivered AdBlue quantity The pressure sensor 12 and temperat...

Page 126: ...ompute the NOx concentration in the exhaust after exhaust aftertreatment by the SCR catalytic converter and ammonia slip catalytic converter W14 40 1587 12 Design 2 Electrical connection A70 EATU inpu...

Page 127: ...iffusion barrier into the first chamber 8 In this case the O2 concentration is regulated at a defined value by means of the so called pump voltage applied to an electrode until the oxygen content diff...

Page 128: ...locking catalytic converter The exhaust aftertreatment unit inlet NOx sensor A70 is attached to a bracket at the exhaust aftertreatment unit 1 Both components form a single unit Task The exhaust after...

Page 129: ...housing with openings and a gas permeable ceramic body inside made out of zirconium dioxide The surfaces of the ceramic body are fitted on both sides with electrodes made out of a thin platinum layer...

Page 130: ...aces This is the measure for the residual oxygen content in the exhaust The traces of HC CO and H2 in the exhaust oxygenate at the electrode made out of platinum The gas then passes over a further dif...

Page 131: ...liary water heater unit A901 is used for f preheating f continuous heating f stationary heating and f heat boosting W83 70 1457 06 Auxiliary heater code D6M Cab hot water auxiliary heater 1 Burner ins...

Page 132: ...tection A901 M1 Combustion air blower A Exhaust outlet K Fuel inlet KA Coolant outlet KE Coolant inlet V Combustion air inlet W83 70 1459 05 Auxiliary heater code D6N Cab and engine hot water auxiliar...

Page 133: ...Coolant inlet The circulation pump A901 M2 is connected on the outside to the heater Task The circulation pump A901 M2 pumps coolant out of the engine s cooling circuit through the heater unit s heat...

Page 134: ...travel and speed sensor B18 and the tachograph TCO P1 are harmonized i e a common working code is defined Tasks while driving f Registers the rotational speed of the transmission output shaft as an an...

Page 135: ...nsor housing there is a basic unit to which two electrodes are attached The inner electrode is the measuring electrode and the outer electrode is the reference electrode Above this exposed to the exha...

Page 136: ...unit to which two electrodes are attached The inner electrode is the measuring electrode and the outer electrode is the reference electrode Above this exposed to the exhaust pressure there is a pressu...

Page 137: ...tor pedal position Design The accelerator pedal sensor B44 consists of two Hall sensors Function The Hall sensors integrated in the accelerator pedal sensor B44 transmit a respectively anticyclical si...

Page 138: ...dation catalytic converter DOC Design The sensor consists of a stainless steel housing The housing contains a measuring element a PTC resistor PTC stands for Positive Temperature Coefficient and means...

Page 139: ...sor upstream of the upper diesel oxidation catalytic converter B68 Design The sensor consists of a stainless steel housing The housing contains a measuring element a PTC resistor PTC stands for Positi...

Page 140: ...converter B69 Design The sensor consists of a stainless steel housing The housing contains a measuring element a PTC resistor PTC stands for Positive Temperature Coefficient and means that the electr...

Page 141: ...sor downstream of the diesel particulate filter B70 Design The sensor consists of a stainless steel housing The housing contains a measuring element a PTC resistor PTC stands for Positive Temperature...

Page 142: ...stream of SCR catalytic converter B72 consists of a stainless steel housing The inside contains a measuring element a PTC resistor PTC stands for Positive Temperature Coefficient and means that the el...

Page 143: ...The exhaust temperature sensor downstream of SCR catalytic converter B73 consists of a stainless steel housing The inside contains a measuring element a PTC resistor PTC stands for Positive Temperatur...

Page 144: ...3 Design The sensor consists of a stainless steel housing The housing contains a measuring element a PTC resistor PTC stands for Positive Temperature Coefficient and means that the electrical resistan...

Page 145: ...metering device 3 AdBlue outlet feed line to pump module 4 Coolant outlet to pump module 5 Coolant inlet from engine 6 Electrical connection 7 Float 8 Bayonet ring 9 Immersion tube 10 AdBlue filter 11...

Page 146: ...st aftertreatment ACM control unit A60 to the engine management MCM control unit A4 Using the resistance value this calculates the associated fill level Determination of temperature The AdBlue surroun...

Page 147: ...re control sensor B87 is located on the coolant expansion reservoir Task The coolant pressure control sensor B87 monitors the pressure in the coolant circuit The signals from the coolant pressure cont...

Page 148: ...inductive sensor and is fitted with a sensor coil as well as a permanent magnet Function The permanent magnet on the camshaft position sensor B600 generates a magnetic field Once the flywheel is rota...

Page 149: ...failure of the crankshaft position sensor the engine speed or crankshaft position can be determined Design The camshaft position sensor B601 is a Hall sensor and is fitted with a permanent magnet as w...

Page 150: ...NTC resistor inside the fuel temperature sensor B602 NTC stands for Negative Temperature Coefficient which means that electrical resistance falls as temperature rises Function The fuel at the fuel tem...

Page 151: ...c analysis system which also serves for signal amplification and signal correction The electronic analysis system is powered by the engine management MCM control unit A4 with 5 V direct voltage The re...

Page 152: ...vel is correct The NTC resistor is located at the tip of the sensor Function Determine engine oil level Engine oil passes via a feed hole into the measuring probe of the engine oil fill level sensor B...

Page 153: ...CM control unit A4 to determine the current coolant temperature at the engine outlet Design There is an NTC resistor inside the exhaust coolant temperature sensor B606 NTC stands for Negative Temperat...

Page 154: ...wnstream of the coolant pump Design There is an NTC resistor inside the intake coolant temperature sensor B607 NTC stands for Negative Temperature Coefficient which means that electrical resistance fa...

Page 155: ...strain measuring resistors which are arranged in a silicon membrane as well as an electronic analysis system which is supplied with a 5 V DC voltage via the engine management MCM control unit A4 Tempe...

Page 156: ...vely high rotational speeds Design The turbine wheel rpm sensor B610 is an inductive sensor and possesses a permanent magnet as well as a sensor coil Function The permanent magnet on the turbine wheel...

Page 157: ...t MCM control unit A4 recognizes amongst other things whether the boost pressure regulator Y636 is actuated and whether the injection must be adapted in order to protect the turbocharger against an ex...

Page 158: ...om the exhaust recirculation AGR differential pressure sensor B621 which plays a significant role in calculating the exhaust recirculation rate Design There is an NTC resistor located inside the charg...

Page 159: ...he membrane in the bridge circuit The membrane is exposed on one side to the exhaust and thus the pressure The EGR AGR differential pressure sensor B621 is fitted with an electronic analysis system an...

Page 160: ...lification and signal correction The electronics analysis system itself is provided with a 5 V DC voltage by the engine management MCM control unit A4 The resistors in the sensor membrane 2 are arrang...

Page 161: ...metering valve Y629 Fuel shutoff valve The diesel fuel metering device 1 is a component that is permeated with fuel channels and has an aluminum body The sensors that are placed on it have their meas...

Page 162: ...ich is supplied with a 5 V DC voltage via the engine management control unit MCM Function The fuel pressure acts upon the silicon membrane with the four pressure dependent resistors and deforms it The...

Page 163: ...ugh an electromagnetic viscous coupling This means that the delivery rate is reduced in particular in the partial load range The reduced delivery rate cuts the required drive energy whereupon the fuel...

Page 164: ...iscous disk 5 thereby reducing the pump impeller s 13 mechanical power The constant balancing between drive and output speed enables the engine management MCM control unit A4 to detect the current del...

Page 165: ...ion M20 Residual heat pump The residual heat pump M20 is located at the left under the cab Task The residual heat pump M20 ensures coolant circulation with the engine switched off The heater core is t...

Page 166: ...lates the vehicle speed route and trip mileage covered f Transmits the calculated data over the frame CAN CAN 3 to the instrument cluster control unit ICUC A1 f Serves for registration storage display...

Page 167: ...asks f Reading in input factors Input factors are red in over the interior CAN CAN 2 f Output of signals Signal output is over the interior CAN CAN 2 and over a direct line to the sensor and actuator...

Page 168: ...The EMERGENCY OFF switch S30 is located in the instrument panel to the right next to the steering wheel in instrument panel switch module 3 A46 Task The switching positions of the EMERGENCY OFF switc...

Page 169: ...hand drive vehicle S31 Frame EMERGENCY OFF switch The frame EMERGENCY OFF switch S31 is located on the driver side behind the cab at the level of the wheel arch Task The switching positions of the fra...

Page 170: ...engine rpm starts increasing after 3 s until the engine reaches the maximum governed rpm or until the engine start and engine stop button S600 is released again After releasing the engine start and en...

Page 171: ...required temperature control flaps set to cold Function in vehicles with code D6M Hot water auxiliary heater cab or code D6N Hot water auxiliary heater cab and engine The auxiliary heater only heats t...

Page 172: ...ached If the pressure increases beyond the stored value the pressure is released from the expansion reservoir When in an operating temperature condition a pressure of between p 480 mbar and max 1480 m...

Page 173: ...ive cylinder Task The purpose of the fuel injectors is to inject fuel at high pressure into the respective cylinders The injection timing point injection period and the injection variants e g with or...

Page 174: ...ure lines as well as components in the fuel injectors are countersunk since only few components have the highest pressure applied to them Therefore each injection nozzle is fitted with a second soleno...

Page 175: ...inder 1 fuel injector Y608 3 High pressure feed 4 Pressure booster 6 Spring 7 Nozzle needle 8 Check valve 9 Return spring 10 Fuel return for pressure booster 11 Fuel return for nozzle needle Y608 Cyli...

Page 176: ...r needle 11 The nozzle needle 7 is lifted at first with the aid of the adjacent rail pressure During injection the pre compressed fuel from the rail is compressed by the pressure booster 4 to a high f...

Page 177: ...to do so by the engine management MCM control unit A4 The actuation that is dependent on the engine operating condition as well as external factors such as e g the charge air temperature reduces fuel...

Page 178: ...flushed with the maximum possible volume of silicone oil In other words the fan wheel 1 rotates at the current engine speed or the rotational speed that matches the belt drive s step up ratio The eng...

Page 179: ...rculated exhaust gas through deflection of the throttle valve 4 W14 20 1026 76 Design 1 Exhaust gas recirculation cooler 4 Throttle valve 5 Coolant line 6 Coolant line 7 Actuator rod 8 Lever 9 Electri...

Page 180: ...ment MCM control unit A4 so that more or less exhaust is branched off towards the exhaust gas recirculation cooler Influence on the engine braking system The exhaust gas recirculation positioner Y621...

Page 181: ...tage 2 The engine brake solenoid valve stage 1 Y624 is installed in the front rocker arm bracket the Engine brake solenoid valve stage 2 Y625 in the rear rocker arm bracket in the camshaft case Task T...

Page 182: ...enoid valve stage 1 Y624 just as soon as the driver activates the engine brake over the engine brake switch The energization of the coil 1 the valve body 2 is presses into the downstop The pressure oi...

Page 183: ...management MCM control unit A4 The AdBlue fill level sensor temperature sensor B74 enables the engine management MCM control unit A4 to recognize whether the temperature of the AdBlue is approaching...

Page 184: ...limits the boost pressure or the rotor speed in that it actuates the boost pressure regulator Y636 with an appropriate pulse width modulated signal The engine management MCM control unit A4 can use th...

Page 185: ...he fuel high pressure pump for Engine stop W07 05 1003 81 Design 1 Fuel high pressure pump housing 2 Coil 3 Float needle 4 Valve spring Y642 Quantity control valve Function The engine management MCM c...

Page 186: ...2 into the oil separator 1 In the oil separator 1 the blow by gas C is led to the centrifuge 3 The centrifuge 3 is caused to turn driven by the centrifuge drive wheel 4 which is driven by the engine...

Page 187: ...igh pressure pistons 4 and led via the respective high pressure connection 9 and corresponding high pressure lines to the rail Both roller tappets 6 on the double cams of the camshaft 7 are pressed to...

Page 188: ...t MCM control unit A4 recognizes that the pressure limiting valve 1 is open it activates the limp home mode W07 04 1052 01 Design 2 Compression spring 3 Cutoff bore 4 Pressure plate 5 Cutoff throttle...

Page 189: ...he suctioned air W09 40 1230 76 Body Shown code M5Z Engine version Euro VI 1 Turbocharger 2 Turbine wheel 3 Vacuum cell 4 Shaft 5 Compressor impeller 6 Compressor housing 7 Oil supply connection 8 Tur...

Page 190: ...iculate filter regeneration 8 Coolant outlet 9 Exhaust outlet to charge air pipe 10 Coolant output to coolant pump 11 Exhaust inlet from exhaust manifold 12 Front end cover 13 Rear end cover 14 Coolan...

Page 191: ...uring refueling the magnetic field of the magnetic adapter actuates a solenoid switch located in the outlet pipe of the nozzle thereby enabling the tank to be refueled This system also prevents incorr...

Page 192: ...side of the engine Task The oil pump 1 supplies the oil circuit of the engine with engine oil It ensures that engine oil is available under all operating conditions in adequate quantities and at the...

Page 193: ...hen flowing through the return flow check valve 7 and the main oil duct s feed line into the engine oil circuit Regulation of the engine oil pressure takes place via the pressure regulator valve 10 Th...

Page 194: ...lant module 1 is used to Filter the engine oil Regulate the engine oil temperature Regulate the coolant temperature Support the coolant pump W18 20 1037 82 Body 1 Oil coolant module 2 Oil thermostat 3...

Page 195: ...ownwards and then to the rear of the oil coolant module 1 where the engine oil outlet 10 is located The filtered engine oil then flows through the engine oil outlet 10 into the crankcase and the main...

Page 196: ...erating piston 2 5 Expansion element 3 O ring A Oil thermostat open B Oil thermostat closed W18 30 1017 74 Function 2 Oil thermostat 5 Oil water heat exchanger A Oil thermostat open B Oil thermostat c...

Page 197: ...ed to cool the engine oil W20 00 1045 11 Design 2 Oil water heat exchanger P Plates The oil water heat exchanger 2 consists of a number of plates P in which engine oil circulates Function From an engi...

Page 198: ...ousing with integral sliding ring valve thermostat Function The coolant thermostat 2 regulates the flow of coolant through the engine radiator and thereby the temperature of the coolant in the coolant...

Page 199: ...tlet to engine KE1 Coolant inlet from bypass line KE2 Coolant inlet from cooler For a coolant inlet temperature 87 C and 95 C the coolant thermostat 2 opens partially and the coolant flows at the same...

Page 200: ...o convert the flow energy of the engine coolant into mechanical braking energy when requested by the driver or a driving assistance system W43 30 1298 05 Design The secondary water retarder 1 is desig...

Page 201: ...when requested by the retarder control unit RCM A11 W43 30 1324 11 Valve block 5 The valve block 5 consists of an actuator 6 a switching valve 7 a control valve 10 the switching valve compression spri...

Page 202: ...hut off the side channel pump 11 pumps the engine coolant in the working chamber back into the coolant circuit The side channel pump 11 is connected directly to the retarder shaft 15 and is actuated v...

Page 203: ...d with engine coolant on its sealing surfaces in order to minimize the frictional heat Accordingly the possibility of small quantities of engine coolant escaping to the outside via the sealing surface...

Page 204: ...n by the retarder shaft 15 via the twisted teeth 13 and feeds the engine coolant to the stator 18 through the rotational movement of its blades W43 30 1329 11 Stator 18 The stator 18 which is fixed to...

Page 205: ...B933 records the coolant temperature of the coolant which is fed back to the cooling circuit of the engine The signals from the coolant temperature sensor B933 are read in directly by the retarder co...

Page 206: ...the left gearwheel it turns simultaneously in the opposite direction The rotating movement of both gearwheels and the design of the pump chamber cause the fuel to be drawn in via the fuel inlet 2 and...

Page 207: ...Fuel cooling ducts 9 Coolant duct A Fuel B Coolant The fuel cooler 2 is designed as a shell cooler Function The warmed fuel from the fuel injector pressure boosters flows through the fuel cooling duc...

Page 208: ...r 5 Fuel accumulator 6 Hand operated delivery pump 7 Filling valve 8 Mechanical drain valve 9 Shutoff valves 10 Fuel connection to fuel pump 11 Fuel connection from fuel pump 12 Fuel connection to the...

Page 209: ...uel lines between the fuel tank and the fuel filter module 1 W47 20 1078 72 Function Fuel prefilter 2 Fuel prefilter 16 Fuel inlet 17 Filter element 18 Elastomer ball 19 Wastegate 20 Fuel outlet D Not...

Page 210: ...ea in the water separator insert 21 When removing the water separator insert 21 clipped on the cover a drain bore to the fuel collector 5 is released so that fuel can flow out of the water separator h...

Page 211: ...to convert the carbon monoxide CO and hydrocarbon HC in the exhaust into less harmful carbon dioxide CO2 and water H2O Design The diesel oxidation catalytic converter DOC 4 consists of two cylindrica...

Page 212: ...with the ammonia slip catalytic converter 2 Task The poisonous nitrogen oxides NOx generated during combustion are reduced into non toxic nitrogen N2 and water H2O in the SCR catalytic converter 3 The...

Page 213: ...onia molecules NH3 energy in the form of heat is released Only nitrogen N2 and water vapor H2O are left over as products of this chemical reaction which are not harmful to the environment For this pro...

Page 214: ...a single unit together with the ammonia blocking catalytic converter 2 Task The SCR catalytic converter 6 reduces the toxic nitrous oxides NOx generated by fuel combustion into non toxic nitrogen N2 a...

Page 215: ...neycomb structure that it contains The nitrous oxide molecules collide with the ammonia molecules NH3 and energy is released in the form of heat Only nitrogen N2 and water vapor H2O are left over as p...

Page 216: ...iting emissions Furthermore it also keeps noise emission as low as possible in its function as a muffler W14 40 1602 76 Design 2 Ammonia slip catalytic converter 3 SCR catalytic converter A57 EATU out...

Page 217: ...talytic converter and ammonia slip catalytic converter c Exhaust cleaned to atmosphere F Direction of travel 5 Inlet pipe 6 Outlet pipe a Exhaust from the engine The exhaust from the engine a flows th...

Page 218: ...er W14 40 1575 76 Design 2 Ammonia blocking catalytic converter 3 SCR catalytic converter A57 Exhaust aftertreatment unit outlet NOx sensor control unit A57 b1 Exhaust aftertreatment unit outlet NOx s...

Page 219: ...rs 1 Exhaust aftertreatment unit 2 Ammonia blocking catalytic converter 3 SCR catalytic converter 4 Diesel oxidation catalytic converter DOC 5 Diesel particulate filter DPF A57 b1 Exhaust aftertreatme...

Page 220: ...cted and flows through the diesel oxidation catalytic converter 4 from the rear and then flows through the diesel particulate filter 5 At the front of the exhaust aftertreatment unit 1 the exhaust is...

Page 221: ...sor downstream of diesel particulate filter The diesel particulate filter DPF 5 is integrated in the exhaust aftertreatment unit It is the second location downstream of the diesel oxidation catalytic...

Page 222: ...ceptibly to the driver while the vehicle is being driven Because of the diesel oxidation catalytic converter DOC 4 upstream of the diesel particulate filter DPF 5 the exhaust contains carbon dioxide C...

Page 223: ...ed for injecting the correct quantity of diesel fuel provided by the metering device for DPF regeneration 1 into the exhaust flow during active diesel particulate filter DPF regeneration W49 20 1019 1...

Page 224: ...xchanger The heater heat exchanger 2 is in the heater blower unit 1 Task The heater heat exchanger 2 gives off the heat of the coolant into the air that flows through it The temperature of the vehicle...

Page 225: ...ion into Service Manual Daimler AG GSP OI HPC R 822 D 70546 Stuttgart Bestell Nr 6517 1260 02 HLI 000 000 02 82 Printed in Germany 09 11 Introduction of engine OM 471 and exhaust aftertreatment This p...

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