Mercedes-Benz Unimog 435 Service Manual Download

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Summary of Contents for Unimog 435

Page 1: ...Mercedes Benz Unimog Workshop Manual Unimog 435 Volume 1 Service...

Page 2: ...ieBlich der Einspeicherung in elektronische Medien sind vorbehalten Technical details of the vehicle in relation to data and illustrations contained in this manual are subject to change All rights inc...

Page 3: ...d on the first pages of the respective groups Introduction The contents are listed according to unit versions and further subdivided into chapters and sections The contents are subdivided to provide s...

Page 4: ...kp cm2 Kiloponds per square centimeter 1 bar 1 019716 kp cm2 1 02 kp cm2 1 kp cm2 0 980665 bar 0 981 bar 2 Power in kW kilowatt Previous unit HP horsepower 1 kW 1 360 HP 1 HP 0 735 kW Torque in Nm Ne...

Page 5: ...5 111 Vehicle dimensions 435 115 special vehicle with box type body Maximum speeds 435 115 117 Maximum speeds 435 110 111 Weights and trailer loads Service products capacities Special versions conside...

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Page 7: ...General 00 General view UROO 01 tR 435 113 435 113 UKD 30 402 21 42 04 1 1 7...

Page 8: ...00 General General view 435 115 Front with box type body 435 115 Rear with box type body 1 1 8...

Page 9: ...900 7t7 901 transmission Sales designation UG 3140 13 01 GPA UG 3140 13 01 GPA Installation Series or SA Series ft ith SA 35 977 1 Series Auxiliary Model Working or crawler gear transmission Sales des...

Page 10: ...Installation Series or with SA 35 776 Series withSA35976 Series Steering Model pump Sales designation ZF 7672 or ZF 7673 ZF 7672 ZF 7673 Installation Series or SA 35 776 Series Series Drivers gap Mode...

Page 11: ...h Sales designation Installation Main Model 717 931 717 930 ransmission Sales designation UG 63 40 8 13 01 GPA Installation Series Auxiliary Model transmission Sales designation Installation Power Ver...

Page 12: ...231 Sales designalion AU 3 1 S 6 8 Installation Series Rear axle Model 747 231 747 230 Sales designation HU 3 1 S 6 8 Inslallalion Series Sleering Model 765 305 system sales designation LS 7 F Install...

Page 13: ...General 00 General View 435 115 URO 0129 435 115 UKD 30 402 21 42 3 1 1 5...

Page 14: ...00 General General View URO 0128 435 111 URO 0120 435 111 1 1 6...

Page 15: ...0 465 495 Overhang front without winch 0 46 46 46 Overhang front with winch 0 40 40 40 Overhang rear 0 51 51 51 approx Ground clearance front axle laden approx mm 440 435 465 Ground clearance rear axl...

Page 16: ...iew morror mm 2465 2465 2465 2465 Overall height unladen approx mm 3050 3030 3010 3050 Ground clearance on a convex surface unladen approx mm 680 660 640 680 Overhang front 0 48 50 50 50 approx Overha...

Page 17: ...den B At maximum load C Unladen o Upper edge of frame E Upper edge of floor F Laden iil f I I I II I I I I I G Unladen H Transit loading dimension J Inside length o o o o N I I I JJ O r 1 _ Q 2 C e 3...

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Page 19: ...eral 00 Maximum speeds km h at engine rated speed 2800 min Reverse Tires 8 1 2 3 4 51 f 61 71 81 18 20 78 5 6 2 9 0 13 6 18 5 27 2 39 2 59 4 80 9 12 5 202 81 7 6 5 9 3 14 1 19 3 28 4 40 8 61 9 84 2 12...

Page 20: ...c 8041 12 14 18 38 Cl c n 7 84 11 31 17 11 2 2 8 25 11 90 18 0 1 8 11 16 69 17 70 1 Locked with SA 35 985 2 standard 1 3 2 Forwards 4 5 6 7 22 75 33 55 48 39 73 31 23 73 34 99 50047 76 47 25 87 38 15...

Page 21: ...79 8 33 12 62 17 18 14 5 A 24 1 1 24 1 78 2 70 3 67 5 42 7 81 11 83 16 09 1 28 1 84 2 78 3 80 5 59 8 05 12 19 16 59 14 5 24 c 11 00 20 0 1 15 1 66 2 62 3 42 5 05 7 28 11 03 15 00 1 19 1 72 2 59 3 54 5...

Page 22: ...56 3A9 4 75 6 67 9 26 12 63 17 19 14 5 R 24 on 1 72 2 39 3 27 4 45 6 24 8 66 11 84 16 10 1 78 2 47 3 37 4 59 6 44 8 94 12 20 16 60 14 5 24 on t 11 00 20 1 60 2 23 3 04 4 14 5 81 8 07 11 03 15 00 1 66...

Page 23: ...4 MPT 14 5300 5300 14 75 80R 20 13 00 20 Pilot XL Series 11 00 20 16 with 11 00R20 16 SA 12 00 20 18 35810 12 00R20 18 5300 5800 4450 5600 14 75 80R 20 13 00 20 Pilot XL 12R22 5 13R22 5 14 5 20 MPT 18...

Page 24: ...4 5 R 20 MPT SA 14 5 20 MPT 35776 14 5 R 24 MPT 14 5 24 MPT SA 16170 24 MPT 35810 11 00R20 SA 11 00 20 35968 12R22 5 13 R 22 5 SA 12 00 R 20 35969 12 00 20 14 75 80 R 2C 13 00 20 Pilote XL 1 applicabl...

Page 25: ...ross weight Trailer Model Sales Gross weight of with non continuous with coninuous coupling 11 designation towing vehicle brake over run brake brake kg kg kg 9000 29000 all 10000 3 8000 28000 435 110...

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Page 27: ...ompressed air with anti freeze Ethyl alcohol methylated all year brakes bottle spirits round Iso propyl alcohol 1 Grease nipples Axle chassis cab Lubricating grease 266 all year r Winch at front Trans...

Page 28: ...anti freeze down to 400 C 400 F Anti freeze 325 and corrosion inhibitor Corrosion inhibitor 311 Screen wash Screen wash bottle MB screen wash additive circuit 11 Applicable for military vehicles a On...

Page 29: ...1 35 912 05 35 942 01 35 965 02 35 979 01 35 980 01 35 986 01 35 993 01 53 482 01 82 509 54 82 983 24 Cab 35 765 10 35 928 09 53 472 01 53 473 02 53 474 03 53 477 02 53 478 02 53 479 03 53 480 03 53 4...

Page 30: ...65 35 979 35 980 35 986 35 992 35 993 36 017 36 089 36 139 53 482 53 484 53 496 53 957 53 985 82 509 82 983 Cab 35 847 36 048 53 472 53 473 53 474 53 475 53 480 53 482 53 483 53 484 53 485 53 489 53 4...

Page 31: ...Removal and installation of cylinder head cover 4 Removal and installation of cylinder head 5 Disassembly and assembly of cylinder head 6 Reconditioning of cylinder head Checking exchanging valve guid...

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Page 33: ...X 2 Series from 482 095 353 961 352J fl SA 16 457 26 SA 35 975 from 000 061 SA 83 036 from 509 465 from PS 353 959 352 A V 2 SA 36 019 352 ALll l from PBJ 117 U 1300 U37 from PBJJ 353 961 352 Xl2 Seri...

Page 34: ...01 8 General 352 352 A General View Engine 353 961 Engine 353 959 1 1 2...

Page 35: ...General 01 8 352 A General view UROI 0191 Engine 353 977 UKD 30 402 21 42 02 1 1 3...

Page 36: ...96 kW DIN l I M Nm 500 460 420 380 340 300 L t KW r r r 1401 I _J 1 r 1 i I p l 4 kW DIN 120 t___ _ ____1_ 1 ______ __ 100 I J ___l l r lI t l j 8 0 7 f 1 t 1I i l 60 I M I Nm 401 I L I i r500 i i i t...

Page 37: ...W 140 120 100 80 60 40 20 o o 400 n min 1 Engine 353 959 from engine end No 691 150 UKD 30 402 21 42 02 J I I I I I I 1200 P I 1 M 1 2000 2800 p 124kW DIN Q M Nm 580 540 500 460 420 380 340 300 Genera...

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Page 39: ...d Continuous output kW HP 96 130 124 168 at nominal speed l min 2800 2800 Maximum torque Nm 363 491 1 I 5302 1 I 491 at speed l min 1700 1600 1600 1600 Idle speed l min 700 Start of delivery before TD...

Page 40: ...d Cylinder Bores e Normal Normal I Normal 11 Repair Repair Repair stage I stage 11 stage III mm mm mm mm mm mm 97 010 97 085 97 135 97 510 98 010 98 510 I 96 990 97 065 97 115 97 490 97 990 98 490 97...

Page 41: ...edge of cylinder head mm 1 8 to 2 5 Peak to valley height of lower mating surface mm 0 008 up to 0 016 Valve sea Exhaust a l a Valve seat ring diameter a Inlet mm 42 0 01 for new rings Exhaust mm 34 0...

Page 42: ...inder head e mm 11 20 11 10 Distance between cylinder head face and b 1 mm 2 6 0 2 2 8 0 2 valve seat ring Basic bore in cylinder head mm 38 000 0 025 45 000 0 025 Height of valve seat rings a mm 8 5...

Page 43: ...drift for valve seat rings 346589031500 C 10 Inslaller for valve guide 352 589 00 43 00 C 11 Reamer 9 mm diameter for inlet valve guide 000589105300 C 12 Reamer 10 mm diameter for exhaust valve gUide...

Page 44: ...perma nently above 30 C 86 C F 21 To engine end No 502 247 3 From engine end No 502 248 4 Consisting of water antifreeze and anticorrosion oil 5 For supercharged engines onty use engine oil of S 3 qu...

Page 45: ...o crankcase M 12 80 Timing gear case to crankcase M 10 65 Screw plug for oil passage in crankcase M 20 100 10 Screw plug for oil duct front and rear MI6 40 5 Flywheel to crankshaft Initial torque M 12...

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Page 47: ...lug 95F Sealing ring 97 Camshaft bearing No 1 100 Camshaft bearing Nos 2 3 4 118 Guide tube 121 Cap nut 130 Bracket 133 Flange 137 Bolt 140 Gasket 145 Oil dipstick 148 Sealing ring 151 Flange 154 Seal...

Page 48: ...320 Valve seat ring 62 Nut 325 Sealing ring 287 Cylinder head 328 Protective bushing 290 Screw plug 330 Cylinder head gasket 296 Stopper 332 Gasket set 299 Screw plug 337 Cylinder head cover 303 Inta...

Page 49: ...aper ring have seized Honing pattern destroyed Engine has to be removed Piston skirt cracked Honing pattern still complete Engine can continue working Ring has seized at land side approx 30 mm wide St...

Page 50: ...1 I I I I I j 1 1 1 1 I I I I t 1 1 I 1 j l I I I 1 j t I I I I t t 1 I I 1 1 1 I I 1 I I I I I I I I w _w rn o i i Vi Ir eO r I r e r 0c 0 b rn 0 4 0 1 6 2 Diagnosis chart OF 650 09 057 00 a 167 Daim...

Page 51: ...driver s cab see 60 5 2 1 1 or 60 5 2 211 2 Disconnect battery Note Firstly disconnect then terminal 3 Drain coolant 4 Remove V belt from intermediate fan shaft 5 Detach exhaust pipe from exhaust man...

Page 52: ...Mark and detach alternator wiring harness at oil coo ler and electrical lines at the alternator 8 Detach electrical line at oil pressure pickup and coo lant temperature pickup 9 Remove fuel intake li...

Page 53: ...tion of engine 01 8 352 352 A 10 Detach intake line at air compressor 11 Detach delivery line at air compressor 12 Detach coolant hose at thermostat body and coolant venting hose at radiator 13 Detach...

Page 54: ...etach coolant pipe at coolant pump and re servoir 15 Detach venting line between timing gear case end steering fluid reservoir 16 Detach hydraulic pump and bracket from en gine support Do not remove l...

Page 55: ...wiring harness and venting line from clutch housing Also remove fuel line leakage oil line cold starting line and control cable for idling if SA 35 989 installed 20 Remove fastening bolts for rear en...

Page 56: ...always be renewed immediately 23 Drain engine oil as required 24 Lift out engine using special tool No 19 25 Clean all parts check and replace if necessary Installation Note Engine installation is si...

Page 57: ...ter wiring loom and venting line from clutch housing Also remove fuel line leak off line cold start line and idling control cable as fitted to special version 35 989 Adjust idling setting see 30 4 2 1...

Page 58: ...of engine 352 352 A 2 1 8 8 Attach hydraulic pump and bracket to engine support 9 Attach venting line to timing gear case 10 Attach coolant pipe to coolant pump and re servoir 11 Attach electric line...

Page 59: ...Engine 01 8 12 Connect heater hose 13 Attach coolant hose to thermostat housing and coolant venting hose to radiator 14 Connect delivery line to compressor 15 Attach intake line to compressor UKD 30 4...

Page 60: ...rn lines 2 Note The vent on the fuel filter is no longer fitted from chassis end No 086 284 17 Connect electrical line to oil pressure pickup 18 Referring to marks attach electrical lines to genera to...

Page 61: ...ry 23 Lower cab referring to 60 5 2 1 1 or 60 5 2 2 1 24 Fill with engine oil as required See 1 3 2 for quantity 25 Vent fuel system referring to 07 8 6 1 1 26 Fill with coolant Check cooling system f...

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Page 63: ...and installation of engine parts 01 8 352 352 A Removal Remove engine referring to 2 1 1 2 Drain coolant at crankcase 3 Detach clutch casing and input shaft 4 Detach and remove clutch 5 Detach flywhee...

Page 64: ...8 Removal and installation of engine parts 352 352 A 6 Detach flywheel housing 7 Unscrew air compressor at bracket 8 Detach air compressor lube lines and front en gine support 9 Detach generator 2 2...

Page 65: ...front end of crank case Position engine in trestle 12 Detach coolant reservoir Installation Attach and tighten coolant reservoir 2 Attach engine to special tool No 19 and re move assembling fixture at...

Page 66: ...ealant No 3 apply sealant No 4 to bolts and then tighten See 1 411 for tightening torque 7 Attach and tighten flywheel referring to 1 411 for tightening torque 8 Using special tool No 6 attach and tig...

Page 67: ...take hose at engine breather filter as well as the connection to the turbocharger 4 Unscrew and remove cylinder head cover 5 Clean sealing surface on cylinder head and cylinder head cover 6 Install in...

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Page 69: ...gine model No 353 959 and No 353 961 1 Prop up cab and clean upper parts of engine See 60 5 2 1 1 or 60 5 2 2 1 2 Detach intake pipe 3 Drain coolant 4 Detach coolant reservoir and bracket 5 Detach hea...

Page 70: ...special tool No 14 detach injection lines at injection pump 7 Detach cold starting reservoir 1 and double fuel filter 2 8 Detach cold starting line leak off line and bracket for fuel lines at cylinde...

Page 71: ...ect coolant temperature pickup and de tach coolant pipe at coolant thermostat body 11 Remove cylinder head cover 12 Remove bolts holding rocker arm brackets 13 Remove rocker arm brackets with rocker s...

Page 72: ...pushrods 15 Undo all the cylinder head nuts or cylinder head bolts in the reverse order to the tightening chart 16 Remove studs Note The studs and cylinder head nuts fitted pre viously were replaced...

Page 73: ...urfaces should be refaced to the necessary peak o valley height See table on page 1 2 2 and 1 2 3 for permissible peak to valley height Installation 1 Position new cylinder gasket on crankcase with le...

Page 74: ...thread and at the head contact surface and screw in Important Do not pour oil into the threaded holes Note Only cylinder head bolts are stocked in the spare parts store The cylinder head bolts can be...

Page 75: ...10 Adjust valve clearance refer to 05 8 2 1 1 11 Install cylinder head cover For tightening torques see 1 411 12 Attach coolant pipe with new gasket on coolant regulator housing connect coolant temper...

Page 76: ...ine leakage fuel line and brack ets for fuel lines to cylinder head 15 Install cold start reservoir 1 and double fuel filter 2 16 Using special tool No 1 connect injection lines to injection pump and...

Page 77: ...te The equalization tank should be two thirds fill Important Upon completion of the installation warm up engine loosen each nut individually in sequence shown in the tightening diagram and then finall...

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Page 79: ...manifold and coolant rail from cylinder head 4 Remove injector pipes from injecto with special tool No 1 5 Release injector pipes from cylinder head and remove Do not bend injector pipes 6 Remove lea...

Page 80: ...1 1 13 Check valve seats and reface or renew if nec essary See 6 2 1 or 6 3 1 14 Check injector nozzles see 07 8 4 2 1 Assembly Insert new sealing ring for the protective sleeve into cylinder head 2 I...

Page 81: ...8 Fit injector pipes fit locking bolt 24 mm with sealant No 5 renew rubber seals at the bushings and tighten locking bolt 17 mm 9 Tighten without tensioning the injector pipes using special tool No 15...

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Page 83: ...o 16 or No 18 Exchanging Drive out valve guide using special tool No 7 or No 8 2 Clean and check basic bore in cyl inder head See 1 2 4 for table 3 If repair stage valve guides are to be fitted ream b...

Page 84: ...10 over valve guide 8 Knock valve guide into position using special tool No 10 9 Check valve guide for firm fit either by knock ing with hammer or by applying test pressure Loose valve guides are to...

Page 85: ...ilot into valve guide so that stop of slotted rod rests on valve guide If necessary press slotted rod ownwards using screwdriver and tighten pilot 6 Fasten cutting tool to slide rest Note Make sure th...

Page 86: ...irregular at this position After turning once release coupling nut of quick action adjuster and move tool back to inner setting 12 Release locking screw 1 and turn knurled collar 2 anti clockwise by...

Page 87: ...on page 1 2 3 Note For valve seats with 450 seat angles the 450 side of the cutter head is for cutting the seat whereas the 300 side is for the clearing cut For valve seats with 300 angles the two si...

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Page 89: ...l slip cutter over pilot turn screw 1 quick action ad justment until tool contacts pilot and then slide cut ter downwards until tool is located in center of valve seat ring 7 Hold cutter at this posit...

Page 90: ...sly hold knurled col lar 2 which has to be briefly released as torsion in creases slightly This serves to turn groove in valve seat ring to depth of about 2 to 3 mm Note Avoid coarse cuts Cutter must...

Page 91: ...e valve seat rings out of liquid oxygen and place on bore of heated cylinder head 4 Knock valve seat rings into position using spe cial tool No 9 Note Do not delay in fitting the valve seat rings Do n...

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Page 93: ...bore and then slide cutter downwards until tool rests on cy linder head Important Fit tools carefully so as not to damage carbide tip 4 Release locking screw 1 force pilot support 2 downwards until i...

Page 94: ...nut 2 Note You are advised to reduce tool setting by 0 1 mm in diameter for first cut 9 Turn horizontal stop screw 1 fu IIy home a gainst body and tighten screw 2 beneath so pre venting stop screw fro...

Page 95: ...nd simultaneously hold lower knurled collar for horizontal feed Reface bottom end surface until stop screw contacts body 13 Remove cutter and measure bore be sure to obtain valve seat ring bore overla...

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Page 97: ...pression pressure tester to special tool No 17 4 Place recording card in tester and set appro priate cylinder 5 Move hand throttle to stop position and start engine several times 6 Note pressure readi...

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