Beruflich Dokumente
Kultur Dokumente
97
MODEL 638
1 Plastic nut
2 Mounting screw
3 Inner fender
S88.10-2501-11
ed Removal, installation
1 Unscrew mounting nuts (1)
at top of wheelhouse
2 Unscrew mounting screw on inside i Plastic screw with spreading plug
3 Unscrew mounting screw (2) from beneath
4 Remove inner fender (3)
5 Reinstall in opposite order
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR05.10-S-4650A Removing and installing intermediate gear of high pressure pump 17.9.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 KW)
with CODE (MQ5) Engine OM611 DE22 LA (90 KW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 KW)
S05.10-2507-09
1 Exhaust camshaft 9 Chain tensioner 17 Vacuum pump
2 Inlet camshaft 10 Seal 18 Bolt
3 Retaining pin 11 Cylinder head cover 19 Dowel pin
4 Front cover at cylinder head 12 Slide rail in cylinder head Y20 Injector 1
5 Inlet camshaft sprocket 13 Bolt Y21 Injector 2
6 Exhaust camshaft sprocket 14 Intermediate gear of high Y22 Injector 3
7 Guide pin pressure pump Y23 Injector 4
8 High pressure pump 15 Liner
16 Fuel pump
ed Removing, installing
1 Disconnect ground lead from battery AR54.10-S-0005A
2 Remove injectors (Y20, Y21, Y22, Y23) AR07.16-S-1000A
3 Remove cylinder head cover (11) AR01.20-S-5014D
4 Position piston of cylinder 1 to ignition TDC p Rotate engine at crankshaft. Do not AR01.00-S-0120D
crank engine at the bolt of the camshaft
sprocket. Do not crank engine back.
i Markings of camshaft/camshaft bearing
cap must be aligned.
5 Install retaining lock for crankshaft/starter ring AR03.30-S-5000C
gear
6 Lock inlet camshaft (2) i Insert the retaining pin (3) through the 1st
camshaft bearing cap into the hole (A) in the
inlet camshaft sprocket (5).
l *111589031500
N Remove chain tensioner (9) p Installation: Replace seal (10). AR05.10-S-7800D
8 Remove front cover at cylinder head (4) AR01.30-S-5700A
9 Remove slide rail in cylinder head (12) AR05.10-S-8432A
10 Remove high pressure pump (8) AR07.02-S-1020A
11 Mark camshaft sprocket (6) relative to timing
chain
12 Unbolt camshaft sprocket (6) from exhaust p Installation: Replace bolts of camshaft
camshaft (1) sprocket (13).
n *BA05.10-P-1003-01A
l *001589760900
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13 Take off exhaust camshaft sprocket (6) i Pay attention to guide pin (7).
Take off exhaust camshart sprocket (6) with
timing chain fitted on. Protect timing chain
from dropping down after removing the
exhaust camshaft sprocket (6).
Repair materials
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AR88.00-S-2302A Removing and installing lock cross member 5.5.95
MODEL 638.0 /1 /2
S88.00-2500-09
1 Engine hood lock 3 Front grille mount 4 Lock cross member
2 Holder for supply reservoir
ed Removal, installation
1 Unscrew holder for supply reservoir (2) for
power steering pump
2 Unscrew screws for mounting front grille (3)
3 Unscrew lock cross member (4) n *BA88.00-N-1001-01A
4 Remove lock cross member (4) i Installation: Insert rod for fastening
radiator into lock cross member
5 Unhook control cable on engine hood lock
(1)
6.1 Remove engine hood lock (1) i Only when replacing lock cross member AR88.40-S-3200A
7 Install in opposite order
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR09.20-S-1330A Removing and installing mixing housing with exhaust gas recirculation 15.10.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)
S09.20-2510-09
1 Vacuum hose 7 Vacuum hose 13 Nut
2 Mixing housing 8 EGR valve 14 Bolt
3 Vacuum pump 9 Throttle flap valve 15 Intake manifold
4 Bolt 10 Fuel filter 16 Oil filler pipe
5 Vacuum hose 11 Bolt 17 Seal
6 Vacuum hose 12 Bolt 18 Screw clip
ed Removing, installing
1 Disconnect ground cable at battery AR54.10-S-0005A
2 Remove air cleaner crosspipe AR09.10-S-8031A
3 Take off screw clip (18) at charge air hose i Expose charge air hose (1)
(1) to mixing housing (2) and detach charge
air hose (1)
k *WH58.30-Z-1001-06A
4 Remove vacuum hose at vacuum pump (3)
5 Unscrew bolt (4) at bracket of fuel filter (10) l *001589760900
to mixing housing (2)
6 Unscrew bolt (11) at rear bracket to mixing n *BA09.20-P-1008-01A
housing (2)
l *001589760900
7 Detach vacuum hoses (5, 6, 7) i Pay attention to installation position of
vacuum hoses
8 Unscrew nut (13) at EGR valve (8) to i Installation: replace self-locking nuts
exhaust gas heat exchanger (6) (13). Replace gasket.
n *BA14.20-N-1004-01C
9 Unscrew bolts (14) at mixing housing (2) to n *BA09.20-P-1007-01A
intake manifold (15)
l *001589760900
10 Remove intake manifold (15) together with p Ensure scrupulous cleanliness
EGR valve (8)
i Installation: replace seals (17)
11 Install in the reverse order
n Intake manifold
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
Number Designation Engine
611.980
001 589 76 09 00
External torx set
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AR13.22-S-1202B Removing and installing poly V-belt 16.10.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)
1 Poly V-belt
2 Tensioning device
3 Tensioning pulley
4 Pin
S13.22-2503-06
e Removing
1 Slacken poly V-belt (1) AR13.22-P-3902-01HB
2 Take off poly V-belt (1) p Slacken tensioning device (2) when
working on engine or on timing case cover.
Inspect belt pulley for dirt and damage,
replace if necessary.
Inspect poly V-belt (1) i Inspect poly V-belt, replace if necessary
according to condition
d Installing
3 Fit on poly V-belt (1) i Do not use belt wax or similar products
Running diagram of poly V-belt AR13.22-P-3902-02HB
4 Tension poly V-belt (1) AR13.22-P-3902-04HB
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR22.10-S-1160B Removing and installing rear engine mount 19.10.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)
1 Bolt
2 Rear engine mount
3 Bolt
4 Axle-engine subframe
5 Bearing cap of middle drive shaft
S22.10-2509-06
ed Removing, installing
1 Unscrew bolt (4) together with nut of rear n *BA22.10-N-1006-01I
engine mounts (2) at axle-engine subframe
2 Unscrew bolt (1) together with nut of rear n *BA22.10-N-1007-01I
engine mount (2) at bearing cap of center
input shaft (5)
3 Remove rear engine mount (2)
4 Install in the reverse order
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR15.30-S-7100C Removing and installing starter 18.10.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 KW)
with CODE (MQ5) Engine OM611 DE22 LA (90 KW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 KW)
1 Nut
2 Nut
3 Bolt
4 Cable
M1 Starter
S15.30-2507-06
ed Removing, installing
1 Disconnect ground cable from battery AR54.10-S-0005A
2 Unscrew nut (1) at cable (4) of starter (M1) n *BA15.30-N-1002-01G
3 Unscrew nut (2) at cable (4) of starter n *BA15.30-N-1003-01G
4 Run cables (4) out of screw stud of starter i Expose cables (4).
(M1)
5 Unscrew bolt (3) of transmission at starter i Hold starter tight.
(M1)
n *BA15.30-N-1001-01G
6 Lift starter (M1) up and out
7 Install in the reverse order
n Starter
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AR43.05-S-1320B Removing and installing vacuum pump 15.6.98
MODEL 638.094 /194 /294 with ENGINE 611.980
with CODE (MQ4) engine OM611 DE22 LA (75 KW)
with CODE (MQ5) engine OM611 DE22 LA (90 KW)
MODEL 638.094 /194 with ENGINE 611.980 with CODE (MQ3) engine OM611 DE22 A (60 KW)
1 Vacuum line
2 Vacuum pump
3 Detent
4 Bolt
5 Sealing ring
6 Engine support
S43.05-2500-12
ed Removing, installing
1 Remove engine support (6) i AR22.10-S-1200B
2 Detach vacuum line (1) from vacuum pump p Press together detent (3) and pull off
(2) vacuum line (1).
i Operate the brake pedal a few times to
reduce the vacuum.
3 Unscrew bolt (4) from vacuum pump (2) n *BA43.05-N-1003-01A
l *001589760900
4 Remove vacuum pump (2) p Installation: Clean sealing surfaces,
replace sealing ring (5).
Pay attention to position of driver on the back
of the pump.
5 Install in reverse order
n Vacuum pump
001 589 76 09 00
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR05.10-S-7800D Removing, installing chain tensioner 25.5.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 KW)
with CODE (MQ5) Engine OM611 DE22 LA (90 KW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 KW)
1 Chain tensioner
2 Seal
3 Guide pulley
4 Bolt
5 Bracket
6 Bolt
7 Cover
S05.10-2506-06
ed Removing, installing
1 Remove guide pulley (3) AR13.22-S-0001B
2 Position piston of cylinder 1 to ignition TDCp Rotate engine at crankshaft. Do not AR01.00-S-0120D
rotate engine at the bolt of the camshaft
sprocket. Do not crank engine back.
a Danger! Risk of explosion from fuel vapors igniting. No fire, naked flames or smoking. Avoid AS47.00-Z-0001-01A
Risk of poisoning from enhaling fuel vapors sparks.
and open working with fuel. Risk of injury Pour fuels only into canisters provided for
from fuel splashing into eyes. this purpose, and store in such canisters.
Wear protective gloves and, if necessary,
eye protection when handling fuel.
3 Detach electric shutoff valve (Y75) AR07.16-S-1040A
4 Unscrew bolt (6) of bracket (5) of fuel supply n *BA07.16-P-1012-01A
shutoff valve (Y75) at timing case cover
l *001589760900
5 Remove chain tensioner (1) i Installation: Replace seal (2).
i Before installing, fill chain tensioner with
engine oil. Position chain tensioner with
thrust pin facing down in engine oil until it is
over the collar at the hexagon. Use a press
or column drill to slowly depress thrust pin
fully 7 - 10 times.
After filling, it must be possible to compress
the chain tensioner slowly and evenly only by
using considerable force.
l *000589109900
n *BA05.10-P-1004-01A
6 Install in the reverse order
g Inspecting
a Danger! Risk of accident from vehicle starting off by Secure vehicle to prevent it moving off by AS00.00-Z-0005-01A
itself when engine running. Risk of injury itself.
from bruises and burns if you hold your hand Wear appropriate workclothes when carrying
into engine when it is started or when it is out work on the vehicle.
running.
N Run engine and inspect for leaks
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
n Timing chain, chain tensioner
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AR01.20-S-5014D Removing, installing cylinder head cover 25.8.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)
1 Injection line
2 Bolt
3 Tensioning claw
4 Bolt
5 Cylinder head cover
6 Cylinder head
7 Bracket
8 Camshaft Hall sensor
9 Gasket
10 Gasket
11 Leak oil line
12 Locking element
13 Bolt
14 Seal
Y20 Injector 1
Y21 Injector 2
Y23 Injector 3
Y24 Injector 4
S01.20-2502-06
ed Removing, installing
a Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. AS47.00-Z-0001-01A
poisoning from inhaling and swallowing fuel. Pour fuels only into suitable and
Risk of injury as a result of fuel coming into appropriately marked containers.
contact with skin and eyes. Wear protective clothing when handling fuel.
1 Remove injectors (Y20, Y21, Y22, Y23) p Installation: to avoid any stresses AR07.16-S-1000A
occurring when installing the injection lines,
these should be fitted on properly before
installing the injectors
l *602589003300
l *611589013300
l *611589006800
l *000589266800
l *001589760900
Notes on injectors p Clean injector recesses and nozzles with aAH07.16-P-1000-01A
wire brush. Grease injector recesses with
special grease, clean injector recesses with a
round brush and cylinder brush, blow out and
cover over. Seal nozzle recesses with a pin
before cleaning.
i Set brush length to about 3 mm for
cleaning the sealing seat.
p Replace injector seal (14) and bolts (2) of
the tensioning claws (3).
Special grease *BR00.45-Z-1036-06A
2 Take off bracket (7) of EGR valve at the n *BA01.20-P-1004-01A
cylinder head cover (5)
l *001589760900
3 Unplug connector at camshaft Hall sensor (8)
4 Unplug lines running over cylinder head i Place lines to the side
cover (5)
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5 Unscrew bolts (4) of cylinder head cover (5) p Installation: do not fully tighten bolts (4)
as injectors (Y20 - Y23) are aligned by
means of the cylinder head cover (5).
Otherwise, this may result in gas leakages
and the injectors (Y20 - Y23) baking tight in
the cylinder head (6), and may also result in
impermissible stresses in the injection lines
(1).
n *BA01.20-P-1001-01A
l *001589760900
6 Remove cylinder head cover (5) i Installation: clean sealing surfaces.
Replace gaskets (9, 10) of cylinder head
cover (5). Ensure scrupulous cleanliness.
7.1 Remove camshaft Hall sensor (8) i Only if cylinder head cover is replaced AR15.10-S-2000B
8 Install in the reverse order
611 589 01 33 00
Extraction claw
Repair materials
Number Designation Order number
BR00.45-Z-1036-06A Special grease A 001 989 42 51 10
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AR01.20-S-5015A Removing, installing trim panel of cylinder head cover 16.9.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)
S01.20-2503-06
ed Removing, installing
1 Remove mixing housing with exhaust gas AR09.20-S-1330A
recirculation (1)
2 Remove bolts (2) of bracket (3) at cylinder n *BA01.20-P-1004-01A
head cover (4)
l *001589760900
3 Remove bolts (5) of trim panel of cylinder n *BA01.20-P-1002-01A
head cover (6)
l *001589760900
4 Remove trim panel of cylinder head cover (6) i Installation: ensure that the crankcase
ventilation hose (7) is correctly inserted
5 Install in the reverse order
001 589 76 09 00
External torx set
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AR01.00-S-0120D Rotate the engine from the front part of the crankshaft 17.8.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)
S01.00-2503-12
ed Removing, installing
1 Separate ground cable from battery
2 Rotate crankshaft with the bolt of the belt p Always rotate in direction of running of
pulley/vibration damper (1) engine
3 Install in the reverse order
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AR13.22-P-3902-02HB Running diagram of poly V-belt
1 Tensioning pulley
2 Crankshaft
3 Coolant pump
4 Alternator
5 Guide pulley
7 Power steering pump
P13.22-0267-01
Illustrated on engine 611, 612.961/962/963/967/990, belt drive with coolant compressor
1 Tensioning pulley
2 Crankshaft
3 Coolant pump
4 Alternator
5 Guide pulley
6 Refrigerant compressor
7 Power steering pump
P13.22-0268-01
Shown on ENGINE 612.965/966, belt drive, with coolant
compressor
1 Tensioning pulley
2 Crankshaft
3 Coolant pump
4 Alternator
5 Guide pulley
6 Refrigerant compressor
7 Power steering pump
8 Guide pulley
P13.00-2032-11
Illustrated on engine 613, 646, 647, 648, belt drive with coolant compressor
1 Tensioning pulley
2 Crankshaft
3 Coolant pump
4 Alternator
5 Guide pulley
6 Refrigerant compressor
7 Power steering pump
8 Guide pulley
P13.22-2013-01
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AR13.22-P-3902-01HB Slacken poly V-belt
y Pin for locking poly V-belt tensioning device
Engine 611.960/961/962/980, WF58.50-P-1325-02A
612.961/962/963/965/966/967/990,
613.960/961, 646.951/961/962/963,
647.961, 648.960/961
1 Turn front part of tensioning device (1) in anti-clockwise direction (arrow) against the
force of the spring.
P13.22-0270-01
2 Insert pin (2) (shop-made tool) in the turned end position through the holes positioned
one above the other, into front part (1) and housing (3) in order to lock tensioning pulley
(4) in this position.
P13.22-0272-01
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AR13.22-P-3902-04HB Tension poly V-belt
y Pin for locking poly V-belt tensioning device
Engine 611.960/961/962/980, WF58.50-P-1325-02A
612.961/962/963/965/966/967/990,
613.960/961, 646.951/961/962/963,
647.961, 648.960/961
1 Pull pin (2) (shop-made tool) out of the holes in the front part (1) and housing (3) of the
tensioning device in order to be able to turn tensioning pulley (4) into the initial position.
i Hold front part (1) of tensioning device tight when removing the pin (2) in order to
prevent the tensioning pulley (4) snapping back suddenly.
P13.22-0273-01
2 Slowly turn front part (1) of tensioning device in clockwise direction (arrow) until the poly
V-belt is automatically tensioned by the force of the spring.
P13.22-0271-01
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AR01.30-P-5800-01HB Tightening diagram of cylinder head bolts
2nd stage E° 90 90 90
Step 3 E° 90 90 90
2nd stage E° 90
Step 3 E° 90
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AR05.20-P-6992-05A Unbolting camshaft bearing caps
n Camshaft
1 Remove camshaft bearing caps at bearing points 1,3,5 and also 6,8,10 (arrows).
P05.20-0343-01
2 Slacken bolts of camshaft bearing caps 2,4 and 7,9 (arrows) in steps each of one turn
until the backpressure is eliminated.
p Camshafts must not be tilted when slackening the camshaft bearing caps.
P05.20-0349-01
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1