CLAAS Engine Mercedes-Benz OM470LA OM471LA Repair Manual PDF

Mercedes-Benz OM470LA
Mercedes-Benz OM471LA
Repair manual
Service & Parts

1451-001
1451-001
Table of contents
Introduction
General Information................................................................................................................................. 4
General repair instructions..................................................................................................................... 8
Torque settings........................................................................................................................................ 21
CCN explanation
CCN (CLAAS Component Number)........................................................................................................ 33
CCN (CLAAS Component Number)

Safety
General Information................................................................................................................................. 37
01 Engine
0102 Complete component..................................................................................................................... 49
0105 Engine suspension......................................................................................................................... 75
0110 Engine housing............................................................................................................................... 78
0115 Engine unit...................................................................................................................................... 119
0120 Cylinder head / Valves / Idler gear................................................................................................ 170
0125 Injection - / Fuel system................................................................................................................. 265
0130 Lubricating oil system.................................................................................................................... 333
0135 Cooling system............................................................................................................................... 355
0140 Exhaust system.............................................................................................................................. 366
0145 Air intake......................................................................................................................................... 432
0150 Engine attachment parts................................................................................................................ 451
0155 Engine control................................................................................................................................. 475
0165 Exhaust gas aftertreatment........................................................................................................... 478
Index.................................................................................................................................... 493
00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 3

Introduction
General Information
1451-001
Introduction
General Information
175821-001
Validity of manual
This manual applies to the Mercedes-Benz diesel
engines below:
Engine Type design Engine no.

OM 470 LA 470.907 470.907-C-xxxxxx
OM 471 LA 471.919 471.919-C-xxxxxx
OM 473 LA 473.905 473.905-C-xxxxxx
123139-005
Handling the manual
This repair manual should help you to maintain
ongoing operational capacity. The high value of the
harvesting machine is ensured through careful
maintenance and technical monitoring by customer
service.
This repair manual is a compilation of our service
technicians' and shop-floor experience.
The picture sequence demonstrates the steps in a
repair procedure. The text provides you with the
information required for making adjustments, using
special tools and further similar information.
Essential repairs are listed in such a way that even
individual and small repairs can be easily found and
followed.
Supplements are added to reflect the ongoing
technical development of the machines and the
manual is thereby continuously being updated as a
reference book.
As a precaution, always compare the setting values
and fill quantities with the most recent operator's
manual and the technical systems documents for the
respective machine.
Texts and figures

Pictures and graphics apply to all models covered by
this manual. Differences are highlighted by captions
below the figures.
In general, texts are short and apply to all models
covered by this manual. Differences are highlighted by
intermediate headings.
Different text categories can be easily identified by the
formatting. The following different formattings are
distinguished:
4 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Introduction
General Information
1451-001
Formatting Meaning Description

Description Descriptive text Further information on the subject.
– Procedure Process Operations which must be carried out one after the
instructions other.
Result Result Result of the processes carried out.
References can be easily identified by corresponding

symbols. The following symbols are distinguished:
Symbol Meaning Description

See index The symbol indicates that further information on
this subject is available in other sections of this
manual.
See the index of the The symbol indicates that further information on
Operator's Manual in this subject is available in the Operator's Manual of
question the machine or of the implement in question.
Document structure based on the assembly

structure
The chapters of the present manual are subdivided
into assemblies as far as contents permit. The
structure of these assemblies is the same in all
chapters.
Different product groups have different assembly
structures. CLAAS makes every effort to keep this
assembly structures identical in any document.
Search and find

Due to the constantly recurring assembly structure,
the subject in question can be quickly found using the
table of contents or the header of this manual.
In addition, the index provided in this manual is a
useful tool for locating a subject. The index can be
found on the last pages of this manual.
Directions
Front, rear, right and left refer to the direction of
forward travel. If necessary, a direction arrow is used
for indicating the direction of travel in figures.

Introduction
General Information
1451-001
Abbreviations
Abbreviation Description
bar bar (unit for pressure)
approx. approximately
cm Centimetre
DIN German Standardization Institute
EC European Community
EN European Standard
GPS Satellite navigation system
h Hours
Ident no. Identification number of machine
ISO International Standardization Organisation
kg Kilogram
kPa Kilopascal
km Kilometre
km/h Kilometres per hour
m Metre
mm Millimetre
Nm Newtonmetre
psi pound per square inch
StVZO German Regulations Authorizing the Use of Vehicles for Road Traffic
e.g. for instance
% percent
°C degrees Celsius (unit for temperature)

Introduction
General Information
1451-001
Technical terms
Technical term Description

recycle Re-use of used, defective or no longer required products
Season Recurring periods of a year
Ignition TDC Ignition top dead centre (diesel engine piston position)
Overlap TDC Valve overlap top dead centre (diesel engine piston position)
BDC Bottom dead centre (diesel engine piston position)
Your CLAAS Service Department

Introduction
General repair instructions
1451-001

123153-003
Technical specifications
Technical specifications, dimensions and weights are
non-binding. Changes reflecting the technical
development and errors reserved.
123192-004
Information on technically correct repairs
► Ensure cleanliness of installation surroundings
and of components in order to avoid damage due
to soiling.
► Mark rotating machine components before
removing or dismounting them in order to ensure
well-balanced component seating on the correct
side after refitting.
► The slots of expansion pins must always point to
the loaded side.
When they are installed with a 90° twist, they
come loose, fall out or shear off.
► Replace cotter pins, locking wires, sheet retention
devices, lock washers and spring washers in the
repair process.
► Align sprockets and V-belt pulleys with one
another.
► Observe the information in the hydraulic system
chapter when working on the hydraulic system.
► Do not mix different oil grades.
123164-004
Self-locking bolts
Self-locking bolts must not come in contact with
sealing compound.
► Tighten self-locking bolt speedily up to the
specified torque.
► The full hardening time can be reduced by
heating-up, e.g. to 15 minutes at + 70 °C.
► The full load capacity is achieved after
24 hours at + 20 °C.
► When unscrewing self-locking bolts, unscrew
them quickly.

Introduction
1451-001
120820-003
Liquid locking compound
► Use liquid locking compound (glue) only at the
spots described in the Repair Manual.
► The surfaces to be joined must be absolutely
clean and free of grease.
► A suitable cleaner and an activator possibly
delivered along with the glue can be used for
cleaning.
► No cleaner residues may remain on the surfaces
to be joined.
This applies in particular to tapped holes with a
bottom.
► Let the surfaces dry well before applying the
1 glue.
151599-001
► Apply the glue only in the areas shown in the
figure if possible.
When applying the glue at an unfavourable spot
or when applying too much glue, the joint may
tear off when loosening.
► Observe the glue producer's instructions for use
and application!
A joint secured by liquid locking compound can be
loosened by heating up to approx. 200 °C.
120771-004
Steel roller chains
Tensioning
Checking the tension of steel roller chains:
A ► Apply a small load to the tight span.
► Push down the slack span in the middle between
the sprockets with your thumb.
You should be able to push down the slack span
around 2 % of the spacing between the axles.
Example:
Axle spacing (A) = 500 mm
x Pushing distance (x) of slack span = approx. 10 mm
2
13827-006

Introduction
1451-001
Chain connector
► The closed side of chain connector (1) must point
in running direction (L)!
1
3
123668-001
120801-006
Taper ring fasteners
Dismounting
► Slacken off tapered ring (1) with a blow.
2 1 ► Use an auxiliary tool (2) if required.
4
154769-001
Installing
13975-003
2
NOTICE! Sticking together at the taper ring fasteners.
The joint cannot be loosened or comes off only with
difficulty.
4 4 ► Do not install parts with tough grease.
3 ► Clean the shaft (1), hub (2), parallel key (3) and
taper ring (4) thoroughly and coat them with
1 grease as specified in the Operator's Manual.
► Tighten to the specified torque.
► In case of several taper ring fasteners fitted
behind one another, tighten those
5 separately.
154486-001
► Use an auxiliary tool (5) if required.

Introduction
1451-001
2
4 5
3
6
154768-001
123163-004
Gib head key joints
Dismounting
► Slacken off gib head key (1) with a blow if
possible.
2 ► Use an auxiliary tool (2) if required.
7
154811-001
► Drive out the gib head key (2) with a key

drawer (1).
► Ensure that the key drawer is used as shown
in the figure.
2
8
154813-001

Introduction
1451-001
9
154812-001
Installation
The gib head key (1) comes in raw condition as a
spare part and must be machined to suit the
application by milling or grinding.
► Grind the gib head key (1) to suit the application

at surface (2).
► Surface (3) must not be machined.
1 3 ► Clean shaft, hub and keyway to be free of grease,
paint and rust prior to assembly.
85675-003
NOTICE! Excessive force employed when installing

the gib head key. Damage to the gib head key joint.
The gib head key cannot be removed any more.
► Drive in the gib head key carefully with a suitable
2 and not too heavy hammer.
10 ► Ensure that the gib head key is driven in only so
154492-001 far that it can still be removed without problems,
using a key extractor.
123167-003
Lock collar bearing
Dismounting
► Slacken off set screw (1).
► Drive off eccentric ring (2) against the shaft's
1 sense of rotation.
► Remove bearing.
11
154814-001

Introduction
1451-001
Installing
► Tighten lock collar bearing (1) on the shaft by
1 twisting eccentric ring (2) over the bearing inner
race (3).
4
► Arrest the eccentric ring with moderate force
in the sense of rotation of the shaft.
► To make dismounting easier, the inner ring
3 and the shaft can be coated with grease as
specified in the Operator's Manual.
► Tighten set screw (4).
2
12
154500-001
120831-003
Adapter sleeve bearings
Dismounting
► Loosen the tab of sleeve nut (3).
1 3
► Slacken off sleeve nut by some turns only.
► Ensure that the thread is still completely
engaged.
2 ► Slacken off expansion pin (2) with a firm blow.
► Pull off adapter sleeve bearing (1) completely.
13
154510-001
Installation
► Clean expansion pin (2) and shaft and check easy
1 3 movement of the sleeve nut (3).
► Install adapter sleeve bearing (1) according to the
conical inside ring (2).
► Tighten the sleeve nut with the suitable special
2 tool and to the prescribed torque.
► Continue tightening the sleeve nut to the specified
degrees.
► Tighten sleeve nut until the nearest tab can be
applied.
► Secure sleeve nut with the tab.
14
154510-001

Introduction
1451-001
144598-003
Chuck bushing
275616-001 15
Possible versions of chuck bushings:

► Version (1): two-piece chuck bushing
► Version (2): four-piece chuck bushing
Dismounting
275615-001 16
► Unscrew bolts (1).

► Screw in bolts (1), or longer bolts if required at (2).
► Screw in bolts until the chuck bushing comes
loose.
► Apply a little oil to bushing if necessary.
► Remove the chuck bushing if required.
Installation
The installation method of the two chuck bushings
differs.
► To ensure correct function of the chuck bushing,
follow the installation method of the chuck
bushing in question precisely.

Introduction
1451-001
Chuck bushing version (1)

► Clean the chuck bushing and the shaft thoroughly.
► Insert chuck bushing.
► Ensure that slots (1) are installed with the
largest angular offset possible.
► Tighten bolts (2) evenly crosswise in three steps.
► Observe the specified torques of the
respective steps.
17
275617-001
Chuck bushing version (2)

► Clean the chuck bushing and the shaft thoroughly.
► Insert chuck bushing.
► Ensure that slots (1) are installed without
angular offset.
► Tighten bolts (2) evenly crosswise in three steps.
► Observe the specified torques of the
respective steps.
18
275619-001

Introduction
1451-001
144716-004
Circlips
144718-002
NOTICE
Overspreading the circlip.
Plastic material deformation.
No safe fixing of component.
► Spread circlip only as far as needed for
installation and dismounting.
► Do not use any circlip already overspread before.
► Insert circlips as shown in the figures.

► Ensure that chamfer (1) does not make
contact with the component to be secured.
1 ► If required, make circlip engage with a slight
blow.
19
Circlip DIN 471 155144-001
20
Circlip DIN 472 155145-001

Introduction
1451-001
120840-004
Ferrule fittings
Screwing in
► Cut off the corresponding tube at right angles.
3 ► Do not use a pipe cutter.
2 In case of pipe bends, the straight pipe end up to
where the bending radius starts must be at least
twice the height of the union nut.
► Slightly deburr the pipe end on the inside and
outside.
► Do not chamfer the pipe end.
► Clean the pipe end.
► Push the union nut (1) and the ferrule (2) on the
1 pipe.
21 ► Push the pipe against the stop in the connector
Ferrule without seal 154515-001 (3) and tighten the union nut until the ferrule
seizes the pipe.
4 This pressure point can be felt because increased
3 power is needed from here.
2 The pipe must be fixed securely during assembly
and must not rotate.
► Tighten the union nut by half a rotation beyond
the first pressure point.
► Check the incision at the cutting edge.
A visible collar must fill the space ahead of the
ferrule face end.
The ferrule may rotate, but axial displacement
1
must not be possible.
22 ► Insert the pre-assembled pipe into the well-oiled
Ferrule with seal 154516-001 threaded joint.
► Screw on the union nut until the power needed to
do this clearly increases.
► After that, continue to screw the union nut on for
half a turn beyond that point.
► Observe the tightening torques. Page
24
Non-tight ferrule connection

► If a connection leaks, loosen the union nut until
some oil escapes.
► Then tighten according to instructions.
► Replace the seal (4) if required.

Introduction
1451-001
123189-002
Sealing cone fittings
► Apply seal (1) on the sealing cone (2).
2 3 ► Tighten the union nut (3) a third of a turn beyond
the point where resistance is felt.
► Observe the tightening torques! Page
25
1
23
154527-001
120856-008
Hydraulic hoses
124582-004
CAUTION
Hydraulic hoses may become leaky due to damage
and ageing. This may make machine parts drop
unintendedly and injure persons.
► Have damaged hydraulic hoses replaced

immediately by a qualified specialist workshop.
► Have hydraulic hoses replaced by a qualified
specialist workshop 6 years after production at the
latest.
To facilitate identifying of hydraulic hoses, each hose

has the CLAAS part number printed on it.
► Check hydraulic lines prior to putting into

operation for the first time and then at least once
XXX / 250 bar/ 13/07 a year.
► Replace the hydraulic hoses when damage or
1 ageing appears.
XXX / 250 bar / 13/07 The date of manufacture can be identified on the hose
fitting (1).
2 3
(2) = Year (e.g. 12 = 2012)
1
(3) = Month (e.g. 07 = July)
XXX / 250 bar / 13/07
24
40202-004

Introduction
1451-001
Laying of hoses
13989-003
NOTICE! Hoses laid in a straight line get shorter as

the hydraulic pressure is built up. Valves may be torn
off.
► Always install hoses with a slight slack.
► Install hoses so that no tension or compression
loads will occur in any operating conditions.
► Check: When moving the hose to either side
at the centre between two fixing/joining
elements (e.g. clamps), the entire play of the
hose is to be 1 cm min.
25
5727-002
► Do not install a hose with a twist.

► In particular not if the hose is subject to
movement.
26
5728-002
27
5729-002
► Avoid external mechanical impacts on hoses.

► Avoid chafing of hoses on one another or on
components by useful arrangement and
fastening.
► Keep an adequate distance from
components.
► Cover up sharp-edged components
permanently.
► When high outside temperatures are involved,
install hoses at a sufficient distance from
components radiating heat.
► If necessary, protect hose by a protective
28
5726-002 guard.

Introduction
1451-001
29
5730-002
157962-002
Treatment of sealing faces
Close all oil, coolant and fuel bores thoroughly prior to
treating the sealing faces.
Ensure that when treating sealing faces of
components containing oil, coolant and fuel, no
abrasives are used. Loose particles cause pollution
and damage.
Ensure that no seal residues, rust, lime and
combustion residues end up in open components
(gearbox halves).
Remove sealing residues, rust, lime and combustion
residues only using scraping tools or cleaning agents.
123155-004
Spare parts
11210-003
WARNING
Use of unauthorised spare parts.
Death or serious injury.
► Spare parts must at least comply with the
technical standards required by the manufacturer
of the implement!
► We recommend using genuine CLAAS spare
parts.
► Please quote the machine identification number

when ordering spare parts or making technical
enquiries.
CLAAS will assume no liability whatsoever for
damage incurred as a result of the use of non-genuine
CLAAS parts, accessories, and ancillary equipment.

Introduction
Torque settings
1451-001
Torque settings
123194-004
Tightening torques for metric standard threads
The tightening torques specified below apply only
when:
– in connection with thread lubricant a coefficient of
friction of µ tot = 0.14 is reached.
To achieve this, surface protection such as A3C
+L, Dacromet or Termosil is recommended.
– no other tightening torque is specified in the
specifications.
– no additional screw retention is used, such as
MK-type bolts or liquid locking compound.
Tightening torque in Nm at a friction coefficient

Bolts and nuts μ tot = 0.14
Strength class 8.8 10.9 12.9

Dimensions
M4 2.9 4.3 5
M5 5.8 8.5 10
M6 10 14.5 17
M8 24.5 36 42
M 10 48.5 71 83.5
Hex. bolts
M 12 83.5 123 144
ISO 4014 to ISO 4018
M 14 133 196 229
M 16 207 304 355
Cheese-head screws
M 18 296 422 494
ISO 4762
M 20 417 594 695
M 22 570 813 951
Hex. nuts
M 24 718 1022 1196
ISO 4032
M 27 1058 1506 1763
M 30 1437 2046 2395
M 33 1944 2770 3240
M 36 2500 3561 4167
M 39 3237 4610 5394

Introduction
Torque settings
1451-001
123196-005
Tightening torque for metric fine threads
The tightening torques specified below apply only
when:
– in connection with thread lubricant a coefficient of
friction of µ tot = 0.14 is reached.
To achieve this, surface protection such as A3C
+L, Dacromet or Termosil is recommended.
– no other tightening torque is specified in the
specifications.
– no additional screw retention is used, such as
MK-type bolts or liquid locking compound.
Tightening torque in Nm at a friction coefficient

Bolts and nuts μ tot = 0.14
Strength class 8.8 10.9 12.9

Dimensions
M8x1 26 38.5 45
M 10 x 1 54 79 92.5
M 10 x 1.25 51 74.5 88
M 12 x 1.25 90.5 134 156
M 12 x 1.5 87 128 150
M 14 x 1.5 143 210 246
M 16 x 1.5 219 323 378
Hex. bolts
M 18 x 1.5 331 470 551
ISO 8765, ISO 8676
M 18 x 2 313 446 522
M 20 x 1.5 459 655 766
Hex. nuts
M 22 x 1.5 622 886 1037
ISO 4032
M 24 x 1.5 809 1152 1348
M 24 x 2 778 1108 1297
M 27 x 1.5 1173 1672 1956
M 27 x 2 1135 1617 1892
M 30 x 2 1580 2251 2634
M 33 x 2 2116 3015 3528
M 36 x 2 2773 3951 4623
M 39 x 2 3557 5067 5930

Introduction
Torque settings
1451-001
123198-002
Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing
cone and O-ring according to DIN 3865
Outside pipe diameter Tightening torque Tightening torque

in mm (light series) (heavy series)
in Nm in Nm
6 10 15
8 15 25
10 25 35
12 35 50
15 50 -
16 - 80
18 80 -
20 - 110
22 110 -
25 - 160
28 160 -
30 - 210
35 210 -
38 - 320
42 320 -

Introduction
Torque settings
1451-001
123197-002
Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861
Outside pipe diameter Tightening torque Tightening torque

in mm (light series) (heavy series)
in Nm in Nm
6 15 25
8 25 35
10 35 50
12 50 80
15 80 -
16 - 110
18 110 -
20 - 160
22 160 -
25 - 210
28 210 -
30 - 320
35 320 -
38 - 400
42 400 -

Introduction
Torque settings
1451-001
123200-004
Tightening torques for SDS hydraulic male connectors
Shape B with sealing edge (cutting edge)
Shape E with soft ring seal
Dimension Tightening torque Tightening torque

(light series) (heavy series)
in Nm in Nm
M5 - -
M6 - -
M8 x 1 - -
M10 x 1 18 -
M12 x 1.5 30 35
M14 x 1.5 45 55
M16 x 1.5 60 70
M18 x 1.5 70 110
M20 x 1.5 - 140
M22 x 1.5 140 170
M26 x 1.5 180 220
M27 x 2 190 250
M33 x 2 300 300
M42 x 2 500 550
M48 x 2 550 600
G 1/8 A 20 25
G 1/4 A 35 40
G 3/8 A 70 90
G 1/2 A 100 150
G 3/4 A 180 270
G1A 250 350
G 1-1/4 A 450 500
G 1-1/2 A 550 600
7/16 - 20 (11.1 mm) - -

1/2 - 20 (UNF) - -
9/16 - 18 (14.3 mm) - -
3/4 - 16 (19.1 mm) - -
7/8 - 14 (22.2 mm) - -

Introduction
Torque settings
1451-001

in Nm in Nm
1-1/16 - 12 (27 mm) - -
1-5/16 - 12 - -
(33.3 mm)
1-5/8 - 12 (UNF) - -
1-7/8 - 12 (UNF) - -
2 - 12 (UNF) - -
Shape F with O-ring and plug

in Nm in Nm
M5 2.8 -
M6 5.2 -
M8 x 1 7 -
M10 x 1 11 -
M12 x 1.5 15 15
M14 x 1.5 25 25
M16 x 1.5 35 35
M18 x 1.5 50 50
M20 x 1.5 - 55
M22 x 1.5 80 80
M26 x 1.5 110 110
M27 x 2 110 160
M33 x 2 160 210
M42 x 2 210 320
M48 x 2 320 420
G 1/8 A - -
G 1/4 A - -
G 3/8 A - -
G 1/2 A - -
G 3/4 A - -
G1A - -
G 1-1/4 A - -

Introduction
Torque settings
1451-001

in Nm in Nm
G 1-1/2 A - -
7/16 - 20 (11.1 mm) 15 20

1/2 - 20 (UNF) 20 25
9/16 - 18 (14.3 mm) 30 30
3/4 - 16 (19.1 mm) 35 60
7/8 - 14 (22.2 mm) 70 90
1-1/16 - 12 (27 mm) 85 100
1-5/16 - 12 150 170
(33.3 mm)
1-5/8 - 12 (UNF) 250 300
1-7/8 - 12 (UNF) 300 350
2 - 12 (UNF) 350 400
Shape H with O-ring and chamber ring
Dimensions Tightening torque Tightening torque

in Nm in Nm
G 1/8 A 20 20
G 1/4 A 40 40
G 3/8 A 75 75
G 1/2 A 85 85
G 3/4 A 180 180
G1A 310 310
G 1-1/4 A 450 450
G 1-1/2 A 540 540

Introduction
Torque settings
1451-001
123204-003
Tightening torques for hydraulic swivel fittings
Dimensions Tightening torque Tightening torque

in Nm in Nm
M10 x 1 20 30
M12 x 1.5 35 40
M14 x 1.5 45 50
M16 x 1.5 60 70
M18 x 1.5 75 80
M20 x 1.5 - 100
M22 x 1.5 125 130
M26 x 1.5 130 -
M27 x 2 130 140
M33 x 2 300 300
M42 x 2 500 500
M48 x 2 600 600
G 1/8 A 20 -
G 1/4 A 40 40
G 3/8 A 65 70
G 1/2 A 90 100
G 3/4 A 130 130
G1A 270 380
G 1-1/4 A 500 600
G 1-1/2 A 600 700

Introduction
Torque settings
1451-001
123206-002
Tightening torques for hollow screws DIN 7643
Dimensions Tightening torque

in Nm
M8 x 1 8
M10 x 1 15
M12 x 1.5 27
M14 x 1.5 38
M16 x 1.5 45
M18 x 1.5 58
M22 x 1.5 95
M26 x 1.5 130
M30 x 1.5 183

Introduction
Torque settings
1451-001
123202-004
Tightening torques for direction-adjustable SDE hydraulic male connectors
Shape F with O-ring
Dimensions Tightening torque Tightening torque Tightening torque

(very light series) (light series) (heavy series)
in Nm in Nm in Nm
M8 x 1 - - -
M10 x 1 20 15 -
M12 x 1.5 - 25 35
M14 x 1.5 - 35 45
M16 x 1.5 - 40 55
M18 x 1.5 - 45 90
M20 x 1.5 - - 140
M22 x 1.5 - 60 170
M26 x 1.5 - 100 190
M27 x 2 - 100 190
M33 x 2 - 160 310
M42 x 2 - 210 330
M48 x 2 - 260 420
7/16 - 20 (11.1 mm) - 15 20

1/2 - 20 (UNF) - 30 40
9/16 - 18 (14.3 mm) - 35 45
3/4 - 16 (19.1 mm) - 55 60
7/8 - 14 (22.2 mm) - 80 90
1-1/16 - 12 (27 mm) - 100 100
1-5/16 - 12 - 150 170
(33.3 mm)
1-5/8 - 12 (UNF) - 290 340
1-7/8 - 12 (UNF) - 325 415
2 - 12 (UNF) - 350 450
Shape H with O-ring and chamber ring

in Nm in Nm in Nm
M8 x 1 10 - -
M10 x 1 20 18 -

Introduction
Torque settings
1451-001

in Nm in Nm in Nm
M12 x 1.5 - 30 35
M14 x 1.5 - 45 55
M16 x 1.5 - 60 80
M18 x 1.5 - 70 105
M20 x 1.5 - - 140
M22 x 1.5 - 125 125
M26 x 1.5 - 180 180
M27 x 2 - 180 180
M33 x 2 - 300 380
M42 x 2 - 450 500
M48 x 2 - 600 600
G 1/8 A 20 20 25
G 1/4 A - 35 45
G 3/8 A - 70 75
G 1/2 A - 100 100
G 3/4 A - 180 180
G1A - 300 300
G 1-1/4 A - 450 450
G 1-1/2 A - 540 540

Introduction
Torque settings
1451-001
123207-004
Tightening torques for brake line screw fittings
Shape F union screws
Shape FS union screws with chime
Dimensions Tightening torque

in Nm
M10 x 1 14+2
123209-003
Tightening torques for worm drive hose clamps
30
8515-001
Width of clip Tightening torques for new hoses Tightening torques for retightening
when installing for the first time or reassembling
7.9 mm (0.31 inch) 0.9 ± 0.2 Nm (8 ± 2 lb in) 0.7 ± 0.2 Nm (6 ± 2 lb in)
123211-002
Tightening torque for spring-loaded worm drive hose clamps
31
37503-001
Width of clip Clamp diameter Tightening torque

12 mm 60 - 80 mm 5 + 0.5 Nm
12 mm 70 - 90 mm 5 + 0.5 Nm

CCN explanation
1451-001
CCN explanation
120555-005
General
The CCN (CLAAS Component Number) arises from a
CLAAS standard for hydraulic and electric systems.
This standard is based on the hydraulic and electric
functions on the machine.
146587-001
Electric systems standard
In the electric systems standard, the components are
subdivided according to their function, using letters.
Pos. Component
A Terminal / module
B Sensor
C Electric / electronic devices
E Lighting
G Voltage source
H Signalling device / lamp
J Information units (required for function diagnosis)
M Motor (electric)
P Gauge
R Potentiometer / resistor
S Switches / pushbuttons - Cab operation
T Switches - Terminal operation
U Switches - External operation
V Electronic component
W Antenna
X Connectors
Y Solenoid coil
Z Actual value switch

CCN explanation
1451-001
146588-001
Hydraulic system standard
In the hydraulic systems standard, the components
are subdivided according to their function, using
number ranges.
Pos. Component
1000 Oil reservoir / oil filter / oil cooler
2000 Pump / motor
3000 Hydraulic cylinder
4000 Restrictor / orifice plate
5000 Pressure accumulator
6000 Valve - mechanically actuated
7000 Valve - hydraulically actuated
8000 Couplings / connections
9000 Measuring point / gauge

1451-001

CCN Index
1451-001
CCN Index
A
A4-MB Control unit........................................................................................................................................476, 481
B
B600-MB Crankshaft position sensor..................................................................................................................... 99
B602-MB Fuel temperature sensor...............................................................................................................300, 310
B605-MB Engine oil fill level sensor........................................................................................................................80
B606-MB Coolant outlet temperature sensor................................................................................................369, 381
B607-MB Coolant inlet temperature sensor..........................................................................................................342
B608-MB Pressure and temperature sensor
Charge air in the charge air tube........................................................................................................... 433, 442
B617-MB Temperature sensor
Charge air in the charge air housing......................................................................................................433, 442
B621-MB Exhaust gas recirculation differential pressure sensor......................................................................... 400
B622-MB Rail pressure sensor..................................................................................................................... 268, 276
B638-MB Fuel filter module pressure sensor........................................................................................................326
G
G002 see G2-MB.................................................................................................................................................. 457
G2-MB Alternator.................................................................................................................................................. 457
M
M021 see M1-MB..................................................................................................................................................453
M047 see M25-MB................................................................................................................................................489
M1-MB Electric starting motor...............................................................................................................................453
M25-MB Urea pump..............................................................................................................................................489
Y
Y488 see Y627-MB...............................................................................................................................................485
Y608-MB Injector.................................................................................................................................................. 286
Y609-MB Injector.................................................................................................................................................. 286
Y610-MB Injector.................................................................................................................................................. 286
Y611-MB Injector.................................................................................................................................................. 286
Y612-MB Injector.................................................................................................................................................. 286
Y613-MB Injector.................................................................................................................................................. 286
Y621-MB Exhaust gas recirculation actuator........................................................................................................394
Y627-MB Urea heater valve..................................................................................................................................485
Y642-MB Fuel controller valve......................................................................................................................316, 320

Safety
General Information
1451-001
Safety
General Information
123229-003
Important!
The instructions contained in this Repair Manual must
be carefully read and observed by all persons
concerned with the operation, maintenance, repair,
service and inspection of this machine in order to
prevent hazards.
Read in particular the "Safety Rules" chapter.
173669-004
Hazard signs
This hazard sign warns of risks of injury.
► To avoid injuries and death, follow all measures

marked by this hazard sign.
181226-001
Signal word
The warnings in this Repair Manual are introduced by
the hazard sign and a signal word. The signal word
expresses the extent of the hazard.
DANGER
DANGER identifies a dangerous situation that leads to
death or serious injury if not avoided.
WARNING
WARNING identifies a dangerous situation that may
lead to death or serious injury if not avoided.
CAUTION
CAUTION identifies a dangerous situation that may
lead to slight injuries if not avoided.
157730-003
Regulations for avoiding accidents with personal injuries
General
– In addition to this manual, the Repair Manual for
the machine must always be observed.
– Observe all general rules concerning safety and
accident prevention.
– Testing, adjusting and repair work may be carried
out only by CLAAS sales partners.

Safety
General Information
1451-001
Testing, adjusting and repair work

1497-002
WARNING
Pinch point from pre-loaded components.
Serious injuries.
► Never move your hands between pre-loaded
components.
– Secure the engine when removing it.

– Keep the engine, ladders, stairs, bridges and their
surroundings free of oil and grease.
– Switch off the battery isolating switch while
working in built-in condition.
– Ensure that the engine is not started accidentally
by unauthorised persons.
Engine operation
160525-002
CAUTION
Bruises and burns when intervening into the starting
process or while the engine is running.
Danger of injury
► Wear closed and tight-fitting working clothes.
► Do not touch any hot or rotating parts.
173-002
CAUTION
Contact with hot liquids or machine parts.
Danger of burns
► Wear suitable protective clothing.
► Let liquids or machine parts cool down.
► Comply with instructions.

Safety
General Information
1451-001
Suspended loads
57765-002
WARNING
Lifting heavy components.
Risk of death or serious injury.
► Use a lifting tool with a sufficient bearing load.
► Use a lifting tool that operates reliably.
► Use the lifting tool on solid and even ground.
► Attach the lifting tool to the component at the
intended or a suitable position.
► Only use faultless and sufficiently dimensioned
lifting accessories.
► Protect lifting accessories against sharp corners
and edges, for example using protectors.
► Do not lift heavy components with your body's

force.
► Ensure that no persons are present beneath
suspended loads.
Working on piping and hoses

157932-002
WARNING
Fire / explosion hazard when handling fuel.
Death or serious injury.
► No fires, sparks, open light and no smoking.
► Fill fuel only into suitable containers.
► Wear protective clothing.
125670-003
CAUTION
Contact with hot liquids.
Risk of burns.
► Release pressure on the system/wait for pressure
to drop.
► Leave liquids to cool.
► Wear suitable protective clothing.

Safety
General Information
1451-001
124851-001
Environment!
Lubricants, operating utilities and fuels escape into the
environment.
Environmental pollution.
► Collect and store lubricants, operating utilities and
fuels in suitable containers and ensure proper
disposal.
► Neither retighten nor open any piping and hoses

under pressure.
Work on the Common Rail System

161964-002
NOTICE
Unprofessional installation on Common Rail system.
Damage to Common Rail system.
► All work on components of the Common Rail
system may be carried out only by specially
trained personnel.
► Prior to starting work, the engine must be
standing still for at least 5 minutes in order to
relieve the pressure in the pressure pipe or
pressure reduction must be controlled with the
CDS.
► Absolute cleanliness must be ensured during all
work in all areas.
► Prior to any work on the clean side of the fuel
system, the engine and the engine compartment
must be cleaned (e.g. steam jet cleaner) with the
fuel system remaining closed.
► Absolutely avoid moisture.
► Slackened-off inlet connectors must always be
replaced.
► Plugs once used for high-pressure lines, pressure
pipe and injectors must not be re-used.
► Observe the sequence specified in the description
when tightening the injectors, high-pressure lines,
pressure pipe and inlet connector.

Safety
General Information
1451-001
161966-002
NOTICE
Unclosed components.
Damage to the Common Rail system.
► Dismount only one fuel line at a time.
► Close the component connections immediately
with new and clean caps.
Working on the electric system

► Start the engine only with firmly connected
batteries.
► Do not disconnect the batteries while the engine
is running.
► Do not use any quick-charging devices for starting
the engine.
► Assist-starting only with separate batteries.
► The connections of control units may be
disconnected and connected only with the electric
system switched off.
► Incorrect polarity of the control units may cause
their destruction.
► Always tighten the connections on the injection
system to the specified tightening torques.
► When temperatures above 80 °C must be
expected, the control units must be removed.
► Use only suitable testing lines for measurements
on connectors.
► Observe the manufacturer's regulations for
batteries.
► Wear protective clothing when handling batteries.
► Do not tilt the batteries, acid might escape.
► Measure the voltage only with a suitable
measuring device.
► Electrolytic gas may form in closed battery boxes.
► Be particularly careful after the engine has
run for an extended period and after charging
the battery with a charger.
► When disconnecting the batteries, non-
disconnected continuous consumers may
generate sparks that ignite the gas.
► Vent the battery box sufficiently prior to
disconnecting.
► Avoid short-circuits by wrong polarity or placing
metal objects on the battery terminals.
► Disconnect batteries when the engine has been
shut down and recharge every four weeks.

Safety
General Information
1451-001
Working on the hydraulic system

64831-003
WARNING
Residual oil pressure in hoses / hydraulic
components.
Serious injury of eyes / of skin.
► Relieve the residual oil pressure in the hydraulic
system.
11741-003
NOTICE
Serious damage to hydraulic circuit components.
► Before installing hydraulic system components,
the entire hydraulic circuit and the hydraulic
system components remaining on the machine
must be flushed.
► The entire hydraulic system must be free of dirt
and foreign objects.
► Replace the hydraulic oil filter.
Electric welding
► Observe the welding information sheets.
► Disconnect the batteries.
► Fit earthing point of the welder close to the
welding spot.
► Disconnect the control units.
Painting work
► During painting work, electronic components may
be exposed to high temperatures (up to 95 °C)
only for a short time.
► Disconnect the batteries.
► Remove sensitive electric components.
► Screw fittings of high-pressure lines must not be
painted. Danger of introducing dirt in case of
repairs.

Safety
General Information
1451-001
Working with urea solution

124844-004
CAUTION
Contact with urea solution.
Danger of injury.
► Wash your skin thoroughly with water and soap.
See a doctor if necessary.
► Flush eyes thoroughly with plenty of water. See a
doctor if necessary.
► Flush mouth and drink plenty of water. See a
doctor if necessary.
149012-002
NOTICE
Foreign substances pollute the system
Damage to exhaust gas system.
► Keep foreign substances and residual quantities
of diesel fuel out of this system.
► Increased cleanliness requirements during
installation work.
124885-005
NOTICE
Surfaces get in contact with urea solution.
Component corrosion.
► Flush the surfaces concerned with plenty of water
immediately.
157737-001
Information on how to avoid damage and premature wear
General
– Engines are built exclusively for the intended use
according to the shipping package.
– Unauthorised modifications on the engine will
exclude any liability of the manufacturer for any
resulting damage.
Manipulations on the injection and control system
may also influence the output and waste gas
behaviour.
Meeting the statutory environmental protection
requirements is no longer guaranteed in this
condition.
– If any trouble occurs during operation, locate and
remove the reason immediately.

Safety
General Information
1451-001
– Clean the engine thoroughly before starting

repairs.
- Ensure that no dirt, sand or foreign objects
end up inside the engine.
– Only use genuine CLAAS spare parts.
– Never let the engine run dry.
– Never let the engine run without coolant.
– Fit a corresponding note on engines that are not
ready for operation.
– Use only operating utilities approved by CLAAS.
– Do not fill in engine oil beyond the maximum level
mark.
157745-001
Liability limitation
General
► All information and notes in this manual were
compiled considering the standards and
regulations in force, the state of the art and many
years of experience.
► CLAAS will not assume any liability for damage
caused by:
► failure to comply with this manual
► use not in line with the intended use
► use of non-trained personnel
► unauthorised conversions
► technical modifications
► use of non-approved spare part and
operating utilities
Shutting down and storage

► Shutting down the engine for an extended period
of time requires temporary corrosion protection.
157747-001
Regulations for avoiding health and environmental damage
Precautionary measures for protection against
health and environmental damage
► Avoid extended, excessive or repeated skin
contact with operating utilities, auxiliary operating
utilities, diluents or solvents.
► Protect your skin by suitable skin protection
agents or protective gloves.
► Do not use any operating utilities, auxiliary
operating utilities, diluents or solvents for cleaning
of skin.
► Wash polluted skin thoroughly with water and
soap.
► Change oil-soaked clothing and shoes.
► Do not put any oil-soaked rags into the pockets of
your working clothes.

Safety
General Information
1451-001
Disposal of operating utilities and auxiliary

operating utilities
► Observe the regulations of the local authorities.
► Ensure that no operating utilities will end up in the
soil, sewer or in waters.
► Different operating utilities must be collected and
disposed of in different containers.
► Use tight containers for draining operating utilities.
► Ensure that food or drink containers are
never used - danger of confusion.
► Ensure that operating utilities are correctly
disposed of.
► Operating utilities count among the water-
hazardous substances!
157748-002
Information for working on the diesel engine
Accident protection
► Fuel jets may cut the skin.
► Fire hazard due to fine spraying of fuel.
► Avoid standing near the running engine.
► Never slacken off the screw fittings of fuel lines
while the engine is running.
The lines may be under very high pressure (up to
1800 bar).
► The engine must have been stopped for at least 5
minutes before slackening off the fuel lines.
► Check the line pressure values with the CDS
if necessary.
► Do not touch live parts of electric connections
while the engine is running.
► Persons wearing a pacemaker must not come
closer than 20 cm to the running engine.
► Any modifications of the original engine cabling
may result in exceeding threshold values of the
pacemaker regulations.
Cleanliness
Diesel injection components consist of high-precision
parts that are subject to extreme loads. In view of this
high-precision equipment, maximum cleanliness must
be ensured during all work on the fuel system. Even
dirt particles measuring more than 0.002 mm may
make components fail.
Before starting work, absolutely comply with the rules
below:
► Clean engine and engine compartment before
starting the work.
► Ensure that the fuel system is closed here.
► When using a jet cleaner, do not aim directly
on electric components or fit covers.
► Clean tools and working materials before starting
work.
► Use only undamaged tools.

Safety
General Information
1451-001
► Cover up engine compartment areas where dirt

particles may come off with a new and clean dust
film.
► Wash your hands before starting dismounting and
put on fresh working clothing.
► Carry out a visual inspection for leaks and
damage on the fuel system.
► Remove any loose dirt particles such as paint
chips and insulation material with a suitable
suction device.
► When removing and installing components, no
materials such as cloths, cardboard or wood may
be used as these materials may lose particles and
fibres.
► Carefully remove paint chippings resulting from
slackening off bolts before completely removing
the bolts.
► Place the engine in a clean area of the workshop
where no work is carried out that raises dust.
► Avoid air motion (possible raising of dust by
starting engines, workshop ventilation or heating
system, air draught etc.).
► Clean and dry the area of the still closed fuel
system with compressed air.
► After opening the clean-side fuel system, use
of compressed air for cleaning is no longer
allowed.
► Use only non-fluff cleaning cloths on the fuel
system.
► Close connecting openings of all removed parts of
the clean-side fuel system immediately with
suitable caps.
► Caps must be packed dust-tight before use
and must be disposed of after using them
once.
► Keep components carefully in a clean and closed
container.
► Never use pre-used cleaning or testing
liquids for these components.
► New parts may be taken out of their original
packaging only just before using them.
► Carry out work on removed components only at a
workplace equipped for this purpose.
► If removed parts are dispatched, always use the
original packaging of the new part.
Installation instructions
► Piping of all kinds must not be bent, risk of
cracking!
► Regulations for flawless installation of flat seals:
► Only use genuine CLAAS seals.
► Sealing faces must be undamaged and
clean.
► Do not use any sealants or glues.
► Tighten bolts evenly to the specified torque.
► Regulations for flawless installation of round
seals:

Safety
General Information
1451-001
► Only use genuine CLAAS seals.

► Sealing faces must be undamaged and
clean.
► Always wet O-rings with engine oil according
to the manufacturer's specification when
installing.
Engine overhaul
The service life of an engine is influenced by very
different factors. Specifying a certain number of
operating hours for basic overhauls is therefore not
possible.
Opening an engine or a basic overhaul is not
appropriate as long as the engine has good
compression values and the following operating
values have not significantly changed as compared
with those measured and accepted upon
commissioning:
► Charge pressure.
► Exhaust gas temperature.
► Coolant and lubricating oil temperature.
► Oil pressure and oil consumption.
► Smoke behaviour.
The criteria below have major influence on the
engine's service life:
► Correct setting of output, depending on the type of
use.
► Proper installation.
► Acceptance of installation by authorised
personnel.
► Regular maintenance according to the
maintenance schedule.
► Selection and quality of lubricating oil, fuel and
coolant according to the manufacturer's
specifications.
Putting into operation after an engine overhaul
Pre-fill the engine with engine oil after finishing repair,
i.e. in dry condition, before putting it back into
operation. This process can also be applied when
establishing damage and reasons.
On all engines that have not been pre-filled with
lubricating oil, the danger of premature damage to the
bearing surface is very big because the lubrication oil
fed by the oil pump from the oil sump takes relatively
long before it reaches the individual bearings.
Such initial damage will not necessarily make the
bearings fail, but can affect bearing function and
reduce the service life.
Pre-filling the engine with engine oil: Page 336

Safety
General Information
1451-001
123242-003
First aid measures
Inhaling:
– Give the person fresh air and consult a doctor
depending on his or her symptoms.
– Remove the person from the danger area.
Contact with the eyes:
– Rinse the eyes thoroughly with large amounts of
water for several minutes. Consult a doctor if
required.
Contact with the skin:
– Wash thoroughly with plenty of water and soap,
remove polluted and soaked clothing immediately,
consult a doctor if the skin is irritated (e.g.
reddening).
Swallowing:
– Do not induce vomiting; consult a doctor
immediately.

01 Engine
0102 Complete component
1451-001
01 Engine
175847-001
Type design
Series Type design Exhaust gas level Note

OM 470 LA 470.907 TIER 4 / Stage IV
175848-001
Engine data
OM 470 LA
Designation Value
Weight 990 kg
Engine type In-line engine
Number of cylinders 6
Cylinder bore 125 mm
Cylinder stroke 145 mm
Cubic capacity 10700 cm³
Direction of rotation of engine when viewing the flywheel Left
OM 471 LA
Designation Value
Weight 1140 kg
Cubic capacity 12.800 cm³
OM 473 LA
Designation Value
Weight 1277 kg

01 Engine
1451-001
Designation Value
Cubic capacity 15.600 cm³

01 Engine
1451-001
175850-001
Engine description
Engine components
267318-001 32
Pos. Value CCN Designation

1 Exhaust gas return cooler
OM 470 LA
OM 471 LA Page 366
Page 379
2 Exhaust gas recirculation line
OM 470 LA
OM 471 LA Page 366
Page 379
3 G002 Alternator 12 V Page 456
4 Coolant compressor
5 Alternator 24 V Page 456
Alternator 24 V
Applies to: Type design 473.905
6 Air intake tube Page 423

01 Engine
1451-001

7 Oil separator
OM 470 LA
OM 471 LA Page 103
Page 112
8 Exhaust turbo charger
OM 470 LA
OM 471 LA Page 414
Page 423
9 Electric starting motor Page 452
10 Turbo compound unit

01 Engine
1451-001
267319-001 33

1 Common rail
OM 470 LA
OM 471 LA Page 266
Page 274
2 Fuel high-pressure pump Page 299
3 Oil pan Page 79

4 Fuel sediment filter Page 323
5 Fuel filter Page 323
6 Coolant thermostat Page 363
7 Charge air tube
OM 470 LA
OM 471 LA Page 433
Page 442
8 Oil filter Page 334

01 Engine
1451-001
Sensors
267508-001 34

1 B601-MB Camshaft position sensor Page 180
2 B600-MB Crankshaft position sensor Page 98
3 B605-MB Combined oil level / temperature sensor Page 79
4 B602-MB Fuel temperature sensor Page 310
5 B617-MB Charge air temperature sensor in the charge
air housing
OM 470 LA
Page 433
OM 471 LA
Page 442
6 B638-MB Fuel filter module pressure sensor Page 325
7 B608-MB Charge air pressure and temperature sensor
in the charge air tube
OM 470 LA
Page 433
OM 471 LA
Page 442
8 B622-MB Rail pressure sensor
OM 470 LA Page 267
OM 471 LA Page 275

01 Engine
1451-001
267525-001 35

1 B607-MB Coolant inlet temperature sensor Page 341
2 B604-MB Oil pressure sensor
3 B621-MB Exhaust gas recirculation differential Page 400
pressure sensor
4 B606-MB Coolant outlet temperature sensor Page 367

01 Engine
1451-001
267527-001 36

1 B611-MB Temperature sensor downstream of air filter Page 409
2 B610-MB turbocharger speed sensor

01 Engine
1451-001
Actuators
267592-001 37

01 Engine
1451-001

1 Y608-MB Cylinder 1 injector Page 285
1 Y609-MB Cylinder 2 injector
7 Y642-MB Fuel controller valve
OM 470 LA Page 315
OM 471 LA Page 319
8 Y636-MB Charge pressure actuator
OM 470 LA Page 414
OM 471 LA Page 423
9 Y621-MB Exhaust gas recirculation actuator Page 394

01 Engine
1451-001
Ignition order
267384-001 38
The piston (1) is at the ignition top dead centre

(ignition TDC) when the synchronous piston (6) is at
the valve overlap top dead centre (overlap TDC).
The intake valves and the exhaust valves are relieved
at the ignition top dead centre.
When at the overlap top dead centre, the intake
valves and the exhaust valves are loaded.
Piston position Cylinder / injection order

Overlap TDC 1 5 3 6 2 4
Ignition TDC 6 2 4 1 5 3

01 Engine
1451-001
175851-001
Cranking the engine
The engine can be cranked by hand both in built-in
condition and in removed condition.
Depending on the variant, different special tools are
available for this.
– To prevent damage to the special tools, each
special tool should only be used for its specified
application.
This is why this chapter is sub-divided into two
sections:
Cranking the engine in built-in condition: Page
65
Cranking the engine in removed condition: Page
72
Special tool
Special tool (I) Pcs.

Cranking tool 1
00 1992 902 0
39
147485-001
Special tool (II) Pcs.

Template 1
00 1998 587 0
40
271156-001

01 Engine
1451-001
Special tool (III) Pcs.

Punch 1
00 1998 572 0
41
271155-001

01 Engine
1451-001
Special tool for built-in engine

The following tools of special tool kit 00 0181 932 0
are needed:
42
180243-001
Machine Engine type Special tool Part no./dimension

JAGUAR 496 OM470LA Cranking tool 00 0181 751 0 1x
Page 68
Thread adapter 00 0181 609 0 3x
Spacer tube 00 0822 526 0 3x
Hex. bolt 00 0237 463 0 3x
Adapter 00 0181 944 0 3x
Set screw 00 0451 666 2 3x
Page 68
Spacer tube 00 0822 526 0 3x
Hex. bolt 00 0237 463 0 3x
Adapter 00 0181 944 0 3x
Set screw 00 0451 666 2 3x
Page 65
Spacer tube Ø16.5 x Ø 8.5, 87 mm 3x
Hex. bolt 00 0238 416 0 3x
Washer 00 0237 957 0 3x
Page 68
Spacer tube 00 0822 526 0 3x
Hex. bolt 00 0237 463 0 3x
Adapter 00 0181 944 0 3x
Set screw 00 0451 666 2 3x

01 Engine
1451-001

Page 68
Spacer tube 00 0822 526 0 3x
Hex. bolt 00 0237 463 0 3x
Adapter 00 0181 944 0 3x
Set screw 00 0451 666 2 3x
Page 66
Spacer tube 00 0822 526 0 3x
Hex. bolt 00 0237 463 0 3x
Washer 00 0993 398 0 3x
Adapter 00 0181 944 0 3x
Set screw 00 0451 666 2 3x
Page 66
Spacer tube Ø16.5 x Ø 8.5, 87 mm 3x
Hex. bolt 00 0238 416 0 3x
Washer 00 0237 957 0 3x
LEXION C68 OM470LA Cranking tool 00 0181 751 0 1x
Page 70
Hex. bolt 00 0235 586 0 2x
Page 70
Hex. bolt 00 0235 586 0 2x
Page 70
Hex. bolt 00 0235 586 0 2x
Page 70
Hex. bolt 00 0235 586 0 2x
LEXION C77 OM 470LA Cranking tool 00 0181 751 0 1x
Page 70
Hex. bolt 00 0235 586 0 2x

01 Engine
1451-001

Page 70
Hex. bolt 00 0235 586 0 2x
Page 70
Hex. bolt 00 0235 586 0 2x

01 Engine
1451-001
Cranking the engine in built-in condition

JAGUAR.
Applies to:
JAGUAR type 496 with OM473LA diesel engine
43
267655-001
► Screw on the special tool (1) using bolts (2),

washers (3) and a spacer tube.
44
267699-001
► Crank engine at (1) until the desired crankshaft

position is reached.
45
267697-001

01 Engine
1451-001
JAGUAR
Applies to:
► Unscrew the bolts (A).
46
267726-001
► Screw the threaded pin into thread (1).

► Slide the washer onto the threaded pin.
47
267726-001

01 Engine
1451-001
► Screw in the adapter (1).
48
267718-001
► Place the spacer tube (2) on the thread

adapter (3).
► Screw the thread adapter (3) into the adapter (1)
using the spacer tube (2).
49
267727-001
► Screw the cranking tool (2) onto the belt pulley

using bolts (1).
50
267735-001

51
267743-001

01 Engine
1451-001
JAGUAR
Applies to:
52
267726-001
► Screw in the threaded pin into thread (1).
53
267726-001
► Screw in the adapter (1).

► Place the spacer tube (2) on the thread
adapter (3).
► Screw the thread adapter (3) into the adapter (1)
using the spacer tube (2).
54
267744-001

01 Engine
1451-001
► Screw the cranking tool (2) onto the belt pulley

using bolts (1).
55
267735-001

56
267743-001

01 Engine
1451-001
LEXION
Applies to:
LEXION type C68 with OM470LA diesel engine
► Screw in the thread adapter (1).
57
267780-001
► Screw on the cranking tool (1) using bolts (2).
58
267781-001

59
267783-001

01 Engine
1451-001
XERION
Applies to:
XERION type 783 with OM470LA diesel engine
XERION type 783 with OM471LA diesel engine
As in removed condition. Page 72

01 Engine
1451-001
Cranking the engine in removed condition
► Unscrew plate (1).
60
267785-001
Use special tool (I):

► Install special tool Page 60 at (1).
Tightening torque: 30 Nm
► Crank the engine until the desired crankshaft
61
267786-001

01 Engine
1451-001
Setting the engine to ignition TDC
Applies to:
Mercedes-Benz OM 470 LA
Use special tool (I). Page 60

► Turn the flywheel (1) using the cranking tool until
mark (A) on the flywheel reaches the cast edge
(B) on the timing housing (2).
62
271165-001
271204-001 63
Use special tool (II). Page 60

► Insert the bolts (1) into the corresponding drilled
holes on the special tool and screw them in
tightly.
► OM 470 LA engine: Designation 10.6
► If there is a reinforcing frame installed on the
OM 470 LA and OM 471 LA engines, do not
use the spacer (2).
► Check the marks (C) on the gearwheel (3) of the
inlet camshaft and on the gearwheel (4) of the
outlet camshaft.
The marks (C) must match the designations on
the special tool.

01 Engine
1451-001
► If the marks (C) do not match the

designations, the flywheel must be rotated by
another 360°.
Use special tool (III). Page 60

► Disconnect connector (2).
► Unscrew the bolt (3) and remove the
sensor (B600-MB) from the timing housing (1).
► Insert the special tool into the drilled hole for the
sensor (B600-MB) and lock the flywheel (5).
The special tool pin must sit in the groove (D) in
the flywheel.
64
271210-001
Setting the engine to ignition TDC: Removal

► Pull out the special tool (1).
65
271220-001
► Undo the bolts (1) and remove the special tool.
66
271238-001
► Attach the crankshaft position sensor (B600-

MB). Page 98

01 Engine
0105 Engine suspension
1451-001

01 Engine
1451-001
181953-001
Lifting eyes
Applies to:
282421-001 67
Value CCN Remark / designation

1 Rear suspension eyes
2 M14 x 1.5: Mounting bolts for the rear suspension eyes
180 Nm
3 Front suspension eyes
4 Retainers
5 M8: 30 Nm Bracket mounting bolts
M10: 60 Nm
Tightening torques not specified, see section on tightening torques

01 Engine
1451-001
181999-001
Lifting eyes
Applies to:
282429-001 68

1 Rear suspension eyes
2 M14 x 1.5: Mounting bolts for the rear suspension eyes
180 Nm
3 Front suspension eyes
4 Retainers
M10: 60 Nm
6 Cylinder head Page 211
7 Exhaust gas return cooler Page 379

01 Engine
0110 Engine housing
1451-001
0110 Engine housing

01 Engine
0110 Engine housing
1451-001
178664-001
Oil pan
Applies to:
Special tool

1 Sealing compound 1
00 1994 288 0
69
274871-001

01 Engine
0110 Engine housing
1451-001
275490-001 70

1 Seal
2 Oil pan
3 30 Nm Oil pan mounting bolts
Tightening diagram:
– Tighten the bolts in the specified order (3.1-
3.18).
4 10 Nm B605-MB Engine oil fill level sensor
5 15 Nm Mounting bolts for the engine line set
Removal
► Drain the engine oil.
See the Operator's Manual of the machine in
question.

01 Engine
0110 Engine housing
1451-001
► Remove the engine line set (1).
71
274864-001
72
274881-001

The bolts are prevented from falling out.
► Remove the oil pan (2).
73
274887-001
► Remove seal (1) from the oil pan (2).
74
275390-001

01 Engine
0110 Engine housing
1451-001
Only if the oil pan (1) is replaced:

► Remove sensor (B605-MB).
75
275395-001
Installation
► Clean the sealing faces. Page 20
► Install the sensor (B605-MB) together with a new

sealing ring.
Tightening torque: Page 80
76
275395-001

► Apply sealant to the sectioning points (A) for the
timing housing (2) and to the housing cover (1).
77
275397-001

01 Engine
0110 Engine housing
1451-001
► Install the seal (1) in the oil pan (2).

Observe the installation position (B).
78
275398-001
► Install the oil pan (2) and tighten the bolts (1) in
accordance with the tightening diagram.
Tightening diagram: Page 80
79
274887-001
► Connect the plug-in connection (1).
80
274881-001
► Attach the engine line set (1).

81
274864-001

01 Engine
0110 Engine housing
1451-001
► Top up engine oil.

question.
► Start the diesel engine and let it run idling for at
least 1 minute.
► Run the diesel engine at a higher speed.
► Switch off the diesel engine and check for leaks.

01 Engine
0110 Engine housing
1451-001
182097-001
Crankshaft front seal
Applies to:
Special tool

Installation device 1
00 1995 521 0
82
237669-001

Spacer washer 1
00 1998 601 0
83
282747-001

01 Engine
0110 Engine housing
1451-001
282769-001 84

1 Oscillation damper Page 161
2 Radial seal
Observe the installation position.
Coat the inner contact faces slightly with engine
oil.
Removal
► Remove the oscillation damper. Page 162

► Bolt down special tool (I) with bolts (1).
► Ensure that the special tool will not make
contact with the radial seal, unscrew bolt (2)
if required.
► Tighten bolt (2) until the special tool makes
contact with the radial seal.
85
282748-001

01 Engine
0110 Engine housing
1451-001
► Drill two Ø3.5 mm holes into the radial seal

through holes at (1).
Position the drilled holes diagonally on opposite
sides.
86
282749-001
► Tighten radial seal to special tool (I) with two bolts

M4.8x25 (2).
► Unscrew the bolt (1) until the radial seal has been
pulled out of the housing cover (5).
► Pull the special tool (I) off together with the radial
seal.
► Undo the bolts (2) and remove the radial seal.
87
282750-001
► Check the contact face of the radial seal on the

crankshaft flange.
► If there is evidence of run-in, replace the
engine or crankshaft.
Installation
► Insert radial seal (1).
► Coat the crankshaft flange (2) lightly with
engine oil.
► Slide the radial seal onto the crankshaft
flange using the assembly device (3).
► Slide the radial seal off the assembly device
and onto the crankshaft flange, and push it
into the front housing cover (2).
► Remove the assembly device.
88
282770-001

01 Engine
0110 Engine housing
1451-001
Use special tools (I) and (II). Page 85

► Fit the special tool (II) onto the special tool (I), and
screw it on using nuts (1).
89
282761-001
► Screw the special tool (I) onto the crankshaft

flange using bolts (1).
When tightening the bolts (1), ensure that the
special tool is not touching the radial seal and
unscrew the bolt (2) if necessary.
► Push in the radial seal using the special tool by
screwing in the bolt (2) until the stop can be felt.
► Slacken off bolt (2).
► Unscrew the bolts (1) and remove the special tool.
► Remove special tool (II).
90
282762-001
► The distance (2) between the edge of the front

housing cover (3) and the fitted radial seal (1)
must be the same around the entire
circumference.
► If necessary, reinforce the radial seal using
the special tool (I).
91
282768-001
► Install the oscillation damper Page 163

01 Engine
0110 Engine housing
1451-001
179265-001
Crankshaft rear seal
Applies to:
Special tool

Installation tool 1
00 1998 583 0
92
276359-001

01 Engine
0110 Engine housing
1451-001
276360-001 93

1 Flywheel Page 165
2 Timing housing Page 97
3 Crankshaft Page 145
4 Crankshaft rear radial seal
Coat the inner contact face slightly with engine
oil.
Removal
► Remove the flywheel. Page 166

01 Engine
0110 Engine housing
1451-001
► Remove radial seal (1), using a suitable tool (2).
94
276366-001
► Check the contact face of the radial seal on the

flywheel flange on the flywheel.
► If there is evidence of run-in on the flywheel
flange, replace the flywheel. Page 165
Installation
► Coat the new radial seal (1) with engine oil on the
inside sealing lip.
Fit the radial seal on the outer surface when it is
dry.
► Slide the radial seal over the flange (2) of the
special tool.
95
276397-001

► Position the flange (2) with the radial seal (1) on
the crankshaft flange (3) and screw it on using
bolts (4).
The drilled hole (5) must be positioned over the
dowel pin (6).
96
276399-001

01 Engine
0110 Engine housing
1451-001

► Slide the retracting sleeve (2) and disc (3) over
the flange (4).
► Tighten nut (5).
► Push the radial seal (1) into the timing housing (6)
until the stop can be felt.
The installation depth of the radial seal is
predetermined by the special tool.
97
276401-001
► Remove the special tool.

► Check whether the radial seal is damaged.
► Install flywheel. Page 168

01 Engine
0110 Engine housing
1451-001
178643-001
Housing cover
Applies to:
Special tool

1 Punch 1
00 1992 868 0
98
274752-001

01 Engine
0110 Engine housing
1451-001
274782-001 99

1 Housing cover
2 60 Nm Housing lid mounting bolts
Tightening diagram:
– Screw in the mounting bolts (2.1 - 2.10) in
the specified order (2.1 - 2.10).
If a mounting bolt was screwed in too tightly, a
new seal must be used.
3 Dowel pins
4 Radial shaft seal Page 85
5 Seal
6 Seal
– Clean the sealing faces thoroughly.
Removal
► Remove the oscillation damper. Page 162
► Remove oil pan. Page 80

01 Engine
0110 Engine housing
1451-001

► Remove housing lid (2).
100
274758-001
► Remove seal (1).

► Clean the sealing face. Page 20
101
274768-001

I ► Remove the radial seal (1) using the special
tool (I).
Applies to OM 471 LA.
1
102
183752-001

01 Engine
0110 Engine housing
1451-001
Installation
► Fit new seal (1).
103
274768-001
► Place the housing cover (2) over the dowel pins

on the crank case and push it in.
► Screw in the bolts (1) in accordance with the
tightening diagram.
104
274758-001
► Install the radial seal.

See the "Front crankshaft seal" chapter. Page
85
► Install the oscillation damper Page 163
► Install the oil pan. Page 82
► Start the diesel engine and let it run at idle speed
for 10 s min.

01 Engine
0110 Engine housing
1451-001
178869-001
Timing housing
Applies to:

01 Engine
0110 Engine housing
1451-001
275690-001 105

1 Timing housing
2 60 Nm Mounting bolts for the electric starting motor
3 Electric starting motor Page 452
4 Seal
5 Crankshaft rear seal Page 89
6 M8: 30 Nm Timing housing mounting bolts
M10: 60 Nm Tightening diagram:
M14: 120 Nm – Screw in the mounting bolts (6.1 - 6.19) in
7 Seal
8 Cover
9 30 Nm Mounting bolts for the cap
10 Cover
11 Mounting bolts for the cap
12 Seal
13 Nut

01 Engine
0110 Engine housing
1451-001

14 40 Nm Stud
15 Cover
17 B600-MB Crankshaft position sensor
Removal
► Drain the engine oil.
question.
► Remove the engine.
See the repair manual of the machine in question.
► Remove the resonance vessel (OM 470
LA). Page 460
LA). Page 461
► Unscrew the bolts (1) and remove the electric

starting motor (2).
106
275569-001
107
275574-001
► Remove the crankshaft rear seal. Page 90

01 Engine
0110 Engine housing
1451-001
► Unscrew the bolts (2), (3) and (4), and remove the
timing housing (1).
108
275622-001
109
275630-001
Only if the timing housing is replaced:

► Unscrew the bolts (1) and remove the cap (2).
110
275646-001

► Unscrew the studs (1) from the timing housing (2).
► Remove the plugs (3).
111
275648-001

01 Engine
0110 Engine housing
1451-001
Installation
► Clean all sealing faces. Page 20
► Install the plugs (3).

► Screw the studs (1) into the timing housing (2).
112
275648-001

► Install the cap (2) together with a new seal.
► Tighten bolts (1).
113
275646-001
► Fit the new seal (1) above both guide rods (2).
114
275651-001

01 Engine
0110 Engine housing
1451-001
► Fit the timing housing (1).

► Screw in the bolts (2), (3) and (4) in accordance
with the tightening diagram.
115
275622-001
► Install the rear crankshaft seal. Page 91
116
275574-001
► Check if the starter pinion is worn.

► Replace the electric starting motor (2) if
necessary.
► Install the electric starting motor (2) and screw in
the bolts (1).
117
275569-001
► Install the resonance vessel (OM 470

LA). Page 460
LA). Page 461
► Install the engine.
question.

01 Engine
0110 Engine housing
1451-001
176192-001
Oil separator
Applies to:
268079-001 118

1 Oil feed line
2 Electrical cable
3 Retainers
4 Oil separator
5 10 Nm Hex. bolts
6 60 Nm Hex. bolts
7 5 Nm Torx screws
8 6 Nm Torx screws
9 Ventilation hose
10 Vent line

01 Engine
0110 Engine housing
1451-001
Removal
► Disconnect the battery isolating switch.
► Unscrew the bleed hose (1) on the bracket (2).
119
268092-001
► Expose the electrical cable (1) on the vent line (2).

► Undo the vent line (2) on the crank case bracket.
120
268097-001
► Disconnect the vent line (1) from the oil

separator (2) and remove the vent line (1).
121
268104-001

01 Engine
0110 Engine housing
1451-001
► Disconnect the oil pressure line (1) from the oil

separator (2).
Hold the screw neck (3) against the oil
separator (2).
122
268107-001
123
268116-001
► Pull the oil separator (1) downwards and remove

it.
124
268119-001

01 Engine
0110 Engine housing
1451-001
Disassembly
► Remove the centrifuge housing (1) from the oil
separator housing (2).
125
268134-001

► Remove the cover (2) from the centrifuge
housing (3).
126
268149-001
► Remove the spring (1), ring (2) and

membrane (3).
127
268151-001

01 Engine
0110 Engine housing
1451-001

► Remove the connector (2) together with the
bracket (3) from the cover (4).
128
268152-001

► Remove the vent line (2) together with the
bracket (3) from the centrifuge housing (4).
129
OM 470 LA engine 268159-001

130
OM 471 LA engine 268163-001

01 Engine
0110 Engine housing
1451-001
Assembly
► Replace the sealing ring (1).
► Screw the vent line (2) together with the
bracket (3) onto the centrifuge housing (4) using
bolts (5).
131
OM 470 LA engine 268182-001

bolts (5).
132
OM 471 LA engine 268176-001

► Screw the connector (2) together with the
bracket (3) onto the cover (4) using bolts (5).
133
268195-001

01 Engine
0110 Engine housing
1451-001
► Replace the spring (1), ring (2) and membrane (3)

if necessary.
Observe the installation position of membrane (3).
134
268151-001
► Screw the cover (2) onto the centrifuge

housing (3) using bolts (1).
135
268149-001
► Screw the centrifuge housing (1) onto the

136
268134-001

01 Engine
0110 Engine housing
1451-001
Installation
► Clean the sealing surfaces and replace the seal.
► Fit the oil separator (1) from below and screw it
onto the crank case using bolts (2).
137
268128-001
► Turn the connection (1) upwards.
138
283010-001
► Connect the oil pressure line (1) to the oil

separator (2).
Hold the screw neck (3) against the oil
separator (2).
139
268107-001

01 Engine
0110 Engine housing
1451-001
► Screw the vent line (1) to the oil separator (2).

Replace the vent line (1) if necessary.
Replace the seal on the quick-release lock for the
vent line (1) if necessary.
140
268104-001
► Screw the vent line (2) onto the crank case

bracket.
► Fasten the electrical cable (1) to the vent line (2).
141
268097-001
► Screw the bleed hose (1) onto the bracket (2).

► Check the engine oil level and top up the engine
oil if necessary.
142
268092-001

01 Engine
0110 Engine housing
1451-001
182177-001
Oil separator
Applies to:
282996-001 143

1 Oil separator
2 10 Nm Mounting bolts
6 Vent line
7 30 Nm Mounting bolts for the vent line

01 Engine
0110 Engine housing
1451-001
Removal
► Remove the bleed hose (1) from the oil

separator (2).
► Remove the bleed hose (3) from the bracket (4).
► Remove the bleed hose (3) on the crank case.
► Undo the bolts (5) and pull the oil separator (2)
downwards and remove it.
144
282975-001

01 Engine
0110 Engine housing
1451-001
Disassembly
► Remove the centrifuge housing (1) from the oil
separator housing (2).
145
268134-001

► Remove the cover (2) from the centrifuge
housing (3).
146
268149-001
► Remove the spring (1), ring (2) and

membrane (3).
147
268151-001

01 Engine
0110 Engine housing
1451-001

► Remove the connector (2) together with the
bracket (3) from the cover (4).
148
268152-001

149
OM 470 LA engine 268159-001

150
OM 471 LA engine 268163-001

01 Engine
0110 Engine housing
1451-001
Assembly
bolts (5).
151
OM 470 LA engine 268182-001

bolts (5).
152
OM 471 LA engine 268176-001

► Screw the connector (2) together with the
bracket (3) onto the cover (4) using bolts (5).
153
268195-001

01 Engine
0110 Engine housing
1451-001
► Replace the spring (1), ring (2) and membrane (3)

if necessary.
Observe the installation position of membrane (3).
154
268151-001
► Screw the cover (2) onto the centrifuge

155
268149-001
► Screw the centrifuge housing (1) onto the

156
268134-001

01 Engine
0110 Engine housing
1451-001
Installation
► Fit the oil separator (2) with a new seal from

below and screw it onto the crank case using
bolts (5).
► Attach the bleed hose (3) to the bracket (4).
► Attach the bleed hose (3) to the crank case.
► Turn the connection (6) upwards.
► Attach the bleed hose (1) to the oil separator (2).
157
282978-001
► Check the engine oil level and top up the engine

oil if necessary.
► Test the engine.
► Switch off the engine and check for leaks.

01 Engine
0115 Engine unit
1451-001
0115 Engine unit

01 Engine
0115 Engine unit
1451-001
178967-001
Piston
Applies to:
Special tool

Socket 1
00 1992 952 0
158
147565-001

Piston ring compressor 1
00 0147 999 0
159
181552-001
Special tool (IV) Pcs.

Clock gauge 1
60 0500 530 3
160
39240-002

01 Engine
0115 Engine unit
1451-001
Special tool (V) Pcs.

Measuring gauge holder 1
00 1992 870 3
161
276005-001

01 Engine
0115 Engine unit
1451-001
1.1
2 3
6 4
5
1
8 7
3
b
a
4
182244-001 162

01 Engine
0115 Engine unit
1451-001

1 Piston
Marking (1.1) for installation position and
installation point.
Always replace the piston together with cylinder
liner (2).
2 Cylinder liner Page 138
3 Piston ring - double trapezoidal ring
4 Piston ring - tapered compression ring with
inside angle
5 Piston ring - chamfered ring with hose spring
6 Connecting rod Page 132
7 Crankshaft Page 145
8 Oil spray nozzle Page 338
9 Slightly coat piston pin with engine oil
10 Connecting rod bearing cover bolt on the
connecting rod
Tightening diagram:
– Screw in the bolts in 2 stages in accordance
with the tightening specification:
Tightening specification:
1 150 Nm (OM 470 LA)
180 Nm (OM 471 LA)
2 90 °
a Height play of piston rings
Applies to: OM 470 LA and OM 471 LA
Piston ring (3): -
Piston ring (4): 0.057 mm to 0.103 mm
b Push play of piston rings
Applies to: OM 470 LA and OM 471 LA
c -0.1905 to Piston undershoot to piston overshoot in TDC
0.2305 mm
Applies to: OM 470 LA
c -0.2090 to Piston undershoot to piston overshoot in TDC
0.2315 mm

01 Engine
0115 Engine unit
1451-001
Removal
► Remove cylinder head valve cover. Page 172
► Remove the reinforcing frame. Page 175
► Remove the camshaft housing. Page 181
► Remove the cylinder head (OM 470 LA). Page
194
► Ensure that all bores on the separating face
of the crankcase are tightly closed.
216
► Ensure that all bores on the separating face
of the crankcase are tightly closed.
► Remove the oil pump. Page 350
► Remove the oil spray nozzles. Page 338
► Fit a direction arrow indicating the installation
position of the piston.
► This is required only when the direction
arrow is no longer visible.
► The direction arrow must point away from the
power output side.
► Mark the cylinder number on the piston head.
► This is required only if more than one piston
is removed.
► Twist crankshaft until the piston is at the BDC.
See Cranking the engine. Page 60
► Protect the piston head (1) and crank case
against dirt.
► Carefully loosen any combustion residues on the

scraper ring (2) and on the cylinder liner (3) near
the head land zone (A) with a scraper and remove
them with compressed air.
163
275777-001

01 Engine
0115 Engine unit
1451-001
► Turn the crankshaft until the piston (1) is approx.

1 cm below the scraper ring (2).
► Insert a piston ring (4) below the scraper ring (2)
in the cylinder liner (3) and insert a corresponding
feeler gauge (5) in the piston ring joint.
Only use a double trapezoidal ring as a piston
ring (4). The "TOP" designation must point
downwards towards the piston head. The feeler
gauge prevents compression of the piston ring
when pushing out the scraper ring.
► Rotate the crankshaft until the piston with the
inserted piston ring pushes the scraper ring out of
the cylinder liner.
164
275779-001
Back up the cylinder liner if necessary.
► Remove the scraper ring, feeler gauge and piston
ring.

► Mark the installation position of the connecting
rod (3) and connecting rod bearing cover (2) in
relation to each other.
► Unscrew the connecting rod bolts (1) and remove
the connecting rod bearing cover.
► Ensure that the cracked separating surface is
not damaged at the connecting rod (3) or on
the connecting rod bearing cover. Replace
the connecting rod and connecting rod
bearing cover if necessary.
► Push the connecting rod away from the
165 connecting rod bearing pin on the crankshaft.
275794-001
Rotate the crankshaft if necessary.
► Remove the connecting rod bearing shells (4) and
(5) and mark which is for the connecting rod
bearing cover and which is for the connecting rod.
► Push the piston (6) with the connecting rod
upwards and out of the cylinder liner and remove
it.
► Ensure that the cylinder liner is not damaged
in this process.
► Replace the cylinder liner if
necessary. Page 138
► Only screw on the connecting rod bearing
cover if the connecting rod bearing shell is
inserted in the connecting rod.
► Mark the installation position on the piston and the
connecting rod to the crank case.
The direction arrow must point in the direction of
travel. The connecting rod bearing cover and
connecting rod are marked in relation to one
another using the reference number (7).
Disassembly
► Clamp the connecting rod with the piston in a
vice.
► Ensure to use soft cheeks for clamping.

01 Engine
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► Remove the piston rings (1), (2) and (3) from top
to bottom.
166
275811-001
► Remove the circlips (3).

► Remove piston pin (2).
► Remove the piston (1) from the connecting
rod (4).
167
275805-001
Checking
► Check piston for dust damage, seizing traces,
scratches, cracks or other traces of wear.
Replace piston if necessary.
► Check height play (a) of piston rings (2) on

piston (1), using a feeler gauge.
1 Vertical play a: Page 122
► When one piston ring is worn, all piston rings
of the piston in question must be replaced.
2
► If one of the piston ring grooves is worn, the
piston must be replaced.
a2301252 168
171455-001

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► Checking the joint play (b) of the piston rings:

► Align the piston rings (2) using the
installation position of the piston (1) for the
corresponding cylinder liner (3).
► Clean the cylinder liner and lightly oil it with
engine oil.
► Insert the piston ring in the upper cylinder
liner.
► Push the piston ring with the piston head into
the lower unused area of the cylinder liner
and then remove the piston again.
169 ► The piston ring is aligned using the piston.
275830-001
► Remove the hose spring on the chamfered
ring.
► Check the joint play (b) on the piston ring
using a feeler gauge (4).
► Joint play: Page 122
► Check the joint play on all piston rings.
► When one piston ring is worn, all piston rings
of the piston in question must be replaced.
170
275839-001
Assembly
► Check piston and piston rings. Page 126
► Check the connecting rods. Page 136
► Assemble piston (2) and connecting rod (3) by

inserting the piston pin (1).
► It must be possible to push the piston pin (1)
into the piston easily with the fingers and the
1 piston pin must not slide out again due to its
own weight.
2 ► Apply a little oil to the piston pin.
► Observe the installation position.
3
► In addition, observe the specifications of the
"Connecting rod" chapter. Page 133
► Insert new safety rings.
171 The opening on the safety ring must face the
181396-001 connecting rod.

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a2301248 172
171363-001
► Insert the hose spring (1) of the piston ring (2) into
the corresponding groove on the piston (3).
► Ensure that the hose spring offset from the
hose spring joint (6) to the piston ring joint is
approx. 180°.
► Install the piston rings (2), (4) and (5).
► Observe the installation position of the
different piston rings.
► See technical specifications: Page 122
► Ensure that the "TOP" mark points to the
piston head.
► Ensure that the joint ends of the piston ring
are installed with a 120° offset with respect
to one another.
173
275870-001
Installation
► Check cylinder liners. Page 141
► Check connecting rod bearing pin of the
crankshaft. Page 147

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Use special tool (III). Page 120

► Insert ram (1).
III Observe the installation position.
174
181553-001

► Slide the piston (1) into the cylinder line until the
connecting rod (3) is almost in contact with the
connecting rod bearing pin (8) of the crankshaft.
► Ensure that the cylinder liner is not scratched
or damaged in the process.
► Replace the cylinder liner if necessary.
► The direction arrow (2) must point in the
direction of travel.
► If necessary, turn the crankshaft so that the
connecting rod is not resting on the
175 connecting rod bearing pin or ballast weight.
275940-001
► Insert connecting rod bearing shell (4).
On a used connecting rod bearing shell (4), note
the designation on the connecting rod (3). There
are various connecting rod bearing shells (4) and
(5) fitted in the connecting rod bearing cover (7)
and in the connecting rod. The twist lock on the
connecting rod bearing shell (4) must be seated in
the connecting rod groove.
► Position the connecting rod bearing cover (7)
together with the connecting rod bearing shell (5).
The twist lock on the connecting rod bearing shell
must be seated in the groove for the connecting
rod bearing cover.
176 ► The connecting rod bearing cover and
275957-001 connecting rod are marked as a pair by the
reference number (6) and must not be
swapped.
► Screw in bolts (9).

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► Insert scraper ring (1) into the cylinder liner (2).

If the piston and the cylinder liner have been
replaced, a new scraper ring must be fitted.
177
275983-001
► Measure the piston excess dimension. Page

122
► Install the oil spray nozzles. Page 338
► Install the oil pump. Page 351
► Install the cylinder head (OM 470 LA). Page
203
220
► Install the camshaft housing. Page 185
► Install the reinforcing frame. Page 177
► Install the cylinder head valve cover. Page
172
► Fill the oil circuit. Page 336
Measuring the excess dimension

Using special tools (IV) and (V): Page 120
1 ► Measure the piston excess dimension (c) without
1
the cylinder head gasket being in place.
Piston excess dimension: Page 122
► Ensure that no deposits or soiling
accumulates on the piston head and on the
cylinder head surface.
► Measure the piston excess dimension (c) in the
direction of the piston pin at (1) in order to
eliminate the piston slap play.
178
181596-001

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IV
1
V
179
250748-001

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179194-001
Connecting rod
Applies to:

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276286-001 180

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1 Connecting rod
Observe marks at (7).
2 Connecting rod bearing cover
Observe marks at (7).
3 Connecting rod bearing bush
4 Slightly coat piston pin with engine oil
5 Connecting rod bearing shells
Do not confuse the connecting rod bearing
shells.
6 Connecting rod bearing shells
Do not confuse the connecting rod bearing
shells.
7 Mark of connecting rod - connecting rod bearing
cover
8 Connecting rod bolt
Tighten the bolts in two steps:
1 150 Nm
2 90°
Observe the shaft length (f).
8 Connecting rod bolt
Tighten the bolts in two steps:
1 180 Nm
2 90°
Observe the shaft length (f).
a Inner diameter of the connecting rod bushing
Target value: 55.070 to 55.080 mm
a Inner diameter of the connecting rod bushing
b Outer diameter of the piston pin

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b Outer diameter of the piston pin
c Piston pin clearance
Radial: 0.070 to 0.086 mm
c Piston pin clearance
d Connecting rod bearing inner diameter
(with the connecting rod bearing shells inserted)
Standard: 90.057 to 90.102 mm
Deviation 0.25: 89.807 to 89.852 mm
Deviation 0.50: 89.557 to 89.602 mm
Deviation 0.75: 89.307 to 89.352 mm
Deviation 1.00: 89.057 to 89.102 mm
d Connecting rod bearing inner diameter
(with the connecting rod bearing shells inserted)
Deviation 0.25: 94.810 to 94.865 mm
Deviation 0.50: 94.560 to 94.615 mm
Deviation 0.75: 94.310 to 94.365 mm
Deviation 1.00: 94.060 to 94.115 mm
e Connecting rod play
e Connecting rod play
f up to 74,3 mm Shaft length of connecting rod bolt (8)
f up to 79 mm Shaft length of connecting rod bolt (8)

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Removal
► Remove the piston. Page 124
► Disassemble the piston. Page 125
Checking
► Check the connecting rod bushing (1), connecting
rod bearing cover (2) and connecting rod bearing
position in the connecting rod (3).
► If it is coloured blue or has scores or
grooves, the connecting rod must be
replaced.
► Check the piston pin (4):
► If it is coloured blue or has scores or
grooves, the piston pin must be replaced.
► Check the piston boss on the piston.
► Replace the piston if necessary.
181 ► Check the inner diameter of the connecting rod
276287-001 bushing within the measuring range (a).
► Check the outer diameter of the piston pin (b):
► Check the measuring positions in the
specified order (1., 2. and 3.).
► The second and third measuring positions
are offset by around 60° each relative to the
first measuring position.
► Calculate the average value from the three
measured values.
► Replace the piston pin if necessary.
► Check the piston pin play (c):
► The piston pin play can be determined by
182 subtracting the mean diameter value of the
276288-001 piston pin from the inner diameter of the
connecting rod bushing.
► OM 470 LA example:
► Connecting rod bushing inner diameter:
55.070 mm
► Piston pin outer diameter: 55.000 mm
► c = 55.070 mm - 55.000 mm = 0.070 mm
► Replace the piston pin and connecting rod
with the connecting rod bearing cover if
necessary.

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► Check the connecting rod bearing shells (1) and

(2), the pick-up in the connecting rod (3) and the
pick-up in the connecting rod bearing cover (4) for
wear and damage:
► If any wear is found, all connecting rod
bearing shells can be replaced if all the
diameters for the connecting rod bearing pins
are within the tolerance range. (See the
crankshaft technical specifications Page
147)
► The connecting rod bearing shells must not
be reworked.
183 ► Check the connecting rod bearing inner
276289-001 diameter (d):
► Check the connecting rod bearing inner
diameter on the assembled connecting rod.
specified order (1st, 2nd and 3rd).
► Begin with the measuring distance (1st),
offset from the sectioning point (5) by 90°.
measured values.
► Replace the connecting rod bearing shells
and connecting rod with the connecting rod
bearing cover if necessary.
► Check the connecting rod play (e):

► The connecting rod play can be determined
by subtracting the mean diameter value of
the connecting rod bearing pin from the
mean value of the connecting rod bearing
inner diameter.
► OM 470 LA example:
► Connecting rod bearing inner diameter:
90.085 mm
► Diameter of connecting rod bearing pin:
89.994 mm (see crankshaft technical
data) Page 147)
► e = 90.085 mm - 89.994 mm = 0.091 mm
Installation
► Check the connecting rod bearing pin.
See crankshaft. Page 147
► Check the connecting rods. Page 136
► Assemble the piston. Page 127

► Install the piston. Page 128

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178581-001
Cylinder liner
Applies to:
Special tool

Removal and installation tool 1
00 1998 590 0
184
274349-001

Clock gauge 1
60 0500 530 3
185
268255-001

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274637-001 186

1 Sealing rings
2 Cylinder liner
3 Crank case
4 Scraper ring
a 0.140 to Cylinder liner excess length
0.270 mm
Applies to: OM 470 LA, OM 471 LA
Permissible difference between protrusions on a
single cylinder liner: Up to 0.09 mm
Permissible difference between protrusions
across all cylinder liners: Up to 0.09 mm
b 124.990 to Diameter of cylinder bore
125.010 mm
b 131.990 to Diameter of cylinder bore
132.010 mm

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Removal
199
216
► Remove the piston. Page 124

► Mark the installation position of the cylinder
liner (1) in relation to the crankcase (2).
► This is required only if the cylinder liner is re-
used.
► Tighten the studs (3) until they are hand-tight.
187
274364-001
274365-001 188

► Attach the leaf (1) with a joint to the spindle (2).
► Insert the leaf into the cylinder liner (3).
The guide collar on the leaf must sit underneath
on the collar for the cylinder liner.
If the cylinder liner is damaged, the cylinder liner
must be replaced.
► Attach the reinforcing bar (4) onto the spindle and
studs (6) and screw it in place.
► Screw the nut (5) onto the spindle until the leaf is
touching the cylinder liner.
Ensure that the leaf is correctly seated on the
cylinder liner.

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► Pull out the cylinder liner (1) by turning the nut (2).
189
274366-001
► Remove the sealing rings (1) from the cylinder

liner (2).
190
274369-001
► Plug all openings tightly.
Checking
Use brake cleaner and a lint-free cleaning cloth.
► Clean the cylinder liner hole.
► Clean the upper centring seat (1).
► Vacuum the upper centring seat and clean it
using compressed air.
► Clean the lower collar seat (2).
► If the collar seat is scored or damaged, the
crank case must be replaced.
► Clean the separating surface (3).
► Vacuum the separating surface and clean it
using compressed air.
191
274408-001
► Vacuum all openings and clean them using
compressed air.
► Clean the cylinder liner (4).
► Clean the grooves (5), centring chamfer (6) and
thread (7).
► Check the centring chamfer (6) and thread (7) for
damage.
► Replace the cylinder liner and pistons if
necessary.
► Check the centring seat (1) and collar seat (2) for
damage.

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► Replace the crank case if necessary.

► Coat the contact face of the cylinder liner with
engine oil.
Installation
► Check cylinder liners. Page 141
► Coat the new sealing rings (1) with clean engine

oil and position them in the grooves.
► Ensure that the sealing rings are not twisted
when inserting them.
► The sealing rings must lie flat against the top
of the grooves and the rounded side must
face outwards.
192
274369-001
► Insert the cylinder liner (1) in the crank case (2).

► If necessary, observe the markings for the
installation position on the cylinder liner.
► If a new cylinder liner is fitted, the piston
rings on the piston must be
replaced. Page 125
193
274454-001

► Tighten the studs (1) until they are hand-tight.
► Screw the assembly handles (2) into the push-in
panel (3).
► Fit the push-in panel (3) onto the cylinder liner (4).
► The designation (5) must indicate the opposite
side to the power output side.
194
274489-001

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► Lightly lubricate the contact face of the spindle (1)
on the push-in panel (4).
► Screw the nut (5) onto the spindle.
► Place the spindle with reinforcing bar (2) on the
studs (3) and screw it down.
The ball in the spindle must be seated in the
depression of the push-in panel.
► Push in the cylinder liner by turning the nut (5).
► Maximum tightening torque for the nuts:
10 Nm
195
274498-001
► Measure the excess dimension of the cylinder

liners. Page 139
► Remove the spindle (1) together with the

reinforcing bar (2) and push-in panel (4).
► Unscrew the studs (3).
► Remove the assembly handles (5).
196
274502-001
► Measure the cylinder bore. Page 139

► Install the piston. Page 128
203
220
172

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Measuring the excess dimension
274682-001 197

► Measure the excess length of the cylinder liners.
Cylinder liner excess length (a): Page 139
Carry out four measurements (1 to 4) per cylinder
liner.
If the excess length of a cylinder liner (a) is outside of
the tolerance, the cylinder liner or the crankcase must
be replaced.
Measuring the cylinder bore

► Measure the inner diameter at the upper return
point of the first piston ring (4).
► Complete the measurements in both
measuring directions (b) and (c).
► Inner diameter: Page 139
When measuring an out-of-roundness:
► Replace the cylinder liner.
The cylinder liner must not be reworked!
198
274579-001

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179249-001
Crankshaft
Applies to:
Special tool

Clock gauge 1
60 0500 530 3
199
268255-001

00 1992 874 0
200
268245-001

Puller 1
00 1998 582 0
201
148062-002

01 Engine
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Slide hammer puller 1
00 1992 873 0
202
282918-001

01 Engine
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282895-001 203

01 Engine
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1 Crankshaft
2 Connecting rod bearing pin
3 Flange bearing journal
4 Thrust washer for thrust bearing
5 Thrust washer for thrust bearing
6 Thrust bearing
7 Thrust bearing for crankshaft bearing cap
8 Mounting bolts for the crankshaft bearing cap
Tightening diagram:
– Check the shaft length (f).
– Lightly coat the bolts with engine oil.
– Tighten the bolts until they are hand-tight.
– Tighten the bolts (8.1 - 8.14) in the specified
order (8.1 -8.14) in four steps in accordance
with the tightening specification.
1 50 Nm
2 150 Nm
3 300 Nm
4 90 °
a Connecting rod bearing pin diameter
Deviation 0.25: 89.730 to 89.750 mm
Deviation 0.5: 89.480 to 89.500 mm
Deviation 0.75: 89.230 to 89.250 mm
Deviation 1.0: 88.980 to 89.000 mm
a Connecting rod bearing pin diameter
Deviation 0.25: 94.730 to 94.750 mm
Deviation 0.5: 94.480 to 95.500 mm
Deviation 0.75: 94.230 to 94.250 mm
Deviation 1.0: 93.980 to 94.000 mm

01 Engine
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b Width of connecting rod bearing pin
Deviation 0.25: 45.000 to 45.100 mm
Deviation 0.5: 45.000 to 45.100 mm
Deviation 0.75: 45.000 to 45.100 mm
Deviation 1.0: 45.000 to 45.100 mm
b Width of connecting rod bearing pin
Deviation 0.25: 47.500 to 47.600 mm
Deviation 0.5: 47.500 to 47.600 mm
Deviation 0.75: 47.500 to 47.600 mm
Deviation 1.0: 47.500 to 47.600 mm
c Inner diameter of the main bearing pin, width of
the flange bearing journal
Width: 47.500 to 47.600 mm
Deviation 0.25: 113.7300 to 113.750 mm
Width deviation 0.5: 48.000 to 48.100 mm
Deviation 0.5: 113.480 to 113.500 mm
Deviation 0.75: 113.230 to 113.250 mm
Deviation 1.0: 112.980 to 113.000 mm
d Wall thickness of the thrust washers
Deviation 0.5: 3.750 to 3.800 mm
Deviation 1.0: 4.000 to 4.050 mm
e Axial play of the main bearing
0.200 to 0.401 mm

01 Engine
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f Bolt shaft length
When new: 172,5 mm
Permitted value: Up to 175.5 mm
g Inner diameter of the main crankshaft bearing in
installed condition
Standard: 114.065 to 114.115 mm
Deviation 0.25: 113.815 to 113.865 mm
Deviation 0.5: 113.565 to 113.615 mm
Deviation 0.75: 113.315 to 113.365 mm
Deviation 1.00: 113.065 to 113.115 mm
Removing the main crankshaft bearing

► Remove the oil pump. Page 350
► Attach the cranking tool.

► Attach the special tool (I) with pretension to the
thrust-bearing crankshaft bearing cap (1) and the
side (2) of the crankshaft.
Position the special tool (II) on a flat surface on
the thrust-bearing crankshaft bearing cap.
► Use a suitable lever (3) to push and hold the
crankshaft in place on the front stop of the thrust-
bearing crankshaft bearing cap (3).
► Set the scale for the special tool (I) to "0".
► Push the crankshaft against the rear stop of the
thrust-bearing crankshaft bearing cap and read
the measured value.
The axial play can be calculated as the measured
value from stop to stop.
Axial play: Page 147
► Remove special tool (I) and (II).
204
282804-001

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282805-001 205
► Check the designation for the crankshaft bearing

cover (1) and thrust-bearing crankshaft bearing
cover (2).
► Re-mark them if necessary.
► All crankshaft bearing covers (1) and thrust-
bearing crankshaft bearing covers (2) are
marked with reference numbers.
► The reference numbers are installed in
ascending order opposite the power output
side.
► Loosen the bolts (3) on the crankshaft bearing
covers (1) and the thrust-bearing crankshaft
bearing cover (2).
The bolts must only be loosened, not fully
undone, as this would otherwise cause the
crankshaft to lower too far, resulting in damage to
the front and rear crankshaft radial seal.
Only one crankshaft bearing cap (1) may be removed,

as this would otherwise cause the crankshaft to lower
too far, resulting in damage to the front and rear
crankshaft radial seal.
► Check whether the crankshaft bearing cap (1) has
become loose and could fall down as a result. If
the crankshaft bearing cap is damaged, the crank
case must be replaced.
206
282808-001

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Use special tools (III) and (IV). Page 145

► Insert clamping bolts (1) into the bolt holes and
clamp them down by tightening the bolts (2).
► Position the special tool (III), connect it to the
clamping bolts and screw it on using the nuts (3).
► Attach the special tool (IV) to the special tool (III).
► Pull out the crankshaft bearing cap (4) using the
special tools (IV) and (III).
If the crankshaft bearing cap is damaged, the
crank case must be replaced.
► Remove the special tool (IV).
► Remove the special tool (III) and remove the
clamping bolts (1) by undoing the screws (2).
207
282809-001
► Remove the main bearing housing (1) on the

crankshaft bearing cap (2).
Mark the installation position of the main bearing
housing.
208
282811-001
► Push out and remove the upper main bearing

housing (1) from the crank case.
► The slide direction (2) of the main bearing housing
must be chosen to ensure that the twist lock (3) of
the main bearing housing is pushed out of the
crank case.
► If necessary, rotate the crankshaft (4) in the
slide direction (2) until the main bearing
housing has been pushed out of the crank
case and can be removed.
► Clean the main bearing pins on the crankshaft
with a lint-free cloth and check them for wear.
209
282813-001

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► Clean the main bearing housings (1) and (2) with

a lint-free cloth and check them for wear.
► Check whether the main bearing housings are
fitted as standard or with a deviation.
Main bearing housings fitted as standard can be
recognised by the stamped STD letter series on
the rear. If they are fitted with a deviation, the
corresponding deviation is stamped instead.
If the main bearing housings are replaced, they
must always be fitted in the same way as before.
210
282815-001
► Oil the main bearing pins on the crankshaft (2)

and the upper main bearing housing (1) with
engine oil.
► Push the upper main bearing housing in the slide
direction (3) into the crank case and note the
position of the twist lock (4) when doing so.
The main bearing housing (1) together with the
surrounding oil groove and oil hole must be
installed in the crank case.
If necessary, rotate the crankshaft (2) in the slide
direction (3) until the upper main bearing housing
has been fully pushed into the crank case.
The twist lock (4) on the main bearing housing
211
282821-001
must be positioned in the groove in the crank
case designed for this purpose.
► Check the shaft length of the bolts (4).

If the permissible shaft length has been
exceeded, the corresponding screw must be
replaced.
Shaft length: Page 147
► Insert the main bearing housing (2) on the
► Oil the contact face of the main bearing housing
with engine oil.
The twist lock (3) on the main bearing housing (2)
must be positioned in the groove in the crankshaft
bearing cap (1) designed for this purpose.
212 ► Oil the bolts (4) with engine oil.
282834-001
► Install the crankshaft bearing cap with the main
bearing housing inserted.
► Screw in the bolts into the corresponding
crankshaft bearing cap.
The bolt heads must be in contact with the
crankshaft bearing cap.
213
282836-001

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282837-001 214
Only one crankshaft bearing cap (1) may be removed,

as this would otherwise cause the crankshaft to lower
too far, resulting in damage to the front and rear
crankshaft radial seal.
► Unscrew the bolts (3) on the thrust-bearing
The thrust-bearing crankshaft bearing cap is
marked with the number "6".
If the thrust-bearing crankshaft bearing cap is
damaged, the crank case must be replaced.
► Insert clamping bolts (1) into the bolt holes and

clamp them down by tightening the bolts (2).
► Position the special tool (III), connect it to the
clamping bolts and screw it on using the nuts (3).
► Attach the special tool (IV) to the special tool (III).
► Pull out the thrust-bearing crankshaft bearing
cap (4) using the special tools (IV) and (III).
If the thrust-bearing crankshaft bearing cap is
damaged, the crank case must be replaced.
► Remove the special tools (III) and (IV).
215
282838-001

01 Engine
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► Remove the thrust washers (1) on the thrust-

Mark the installation position of the thrust washers
in relation to the thrust-bearing crankshaft bearing
cap.
► Remove the main bearing housing (3).
216
282839-001
► Push out both upper thrust washers (1) on the

thrust bearing from the crank case.
Mark the installation position of the thrust washer.
217
282840-001
► Push out and remove the main bearing

housing (1) from the crank case.
The slide direction (2) of the main bearing housing
must be chosen to ensure that the twist lock (3) of
the main bearing housing is pushed out of the
crank case.
If necessary, rotate the crankshaft in the slide
direction (2) until the main bearing housing has
been pushed out of the crank case and can be
removed.
► Clean the main bearing pins on the crankshaft (4)
with a lint-free cloth and check them for wear.
218
282843-001

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► Clean the main bearing housings (1) and (2) with

a lint-free cloth and check them for wear.
► Check whether the main bearing housings are
fitted as standard or with a deviation.
Main bearing housings fitted as standard can be
recognised by the stamped STD letter series on
the rear. If they are fitted with a deviation, the
corresponding deviation is stamped instead.
If the main bearing housings are replaced, they
must always be fitted in the same way as before.
219
282844-001
► Clean the thrust washers (1) and (2) with a lint-

free cloth and check them for wear.
► Check the wall thickness. Page 147
► Check whether the thrust bearing thrust washers
are fitted as standard or with a deviation.
You can recognise thrust washers fitted as
standard by the stamped STD letter series on the
rear. If they are fitted with a deviation, the
corresponding deviation is stamped instead. The
standard design is marked on some thrust
washers with a red mark (3) on the joints.
► Assign the thrust washers to the crankshaft axial
play that was measured previously.
If the previously measured crankshaft axial play
deviates from the target value, it must be
balanced out using thrust washers of the
appropriate wall thickness.
If the thrust washers are replaced, only thrust
washers of the same design and the same wall
thickness may be installed.
220
282845-001
► Oil the main bearing pins on the crankshaft (1)

and upper main bearing housing (2) with engine
oil.
► Push the upper main bearing housing (2) in the
slide direction (3) into the crank case and note the
position of the twist lock (4) when doing so.
The main bearing housing together with the
surrounding oil groove and oil hole must be
installed in the crank case. If necessary, rotate the
crankshaft in the slide direction (3) as far as
possible until the upper main bearing housing has
been fully pushed into the crank case. The twist
lock (4) on the main bearing housing must be
221 positioned in the groove in the crank case
282846-001 designed for this purpose.

01 Engine
0115 Engine unit
1451-001
► Oil the thrust washers (1) with engine oil.

► Push the thrust washers on the thrust bearing into
the crank case.
When installing thrust washers, note the
designation. The oil grooves (2) on the thrust
washers must face the sides of the crankshaft (3).
222
282847-001
► Insert the main bearing housing (1) on the

► Oil the contact faces of the main bearing housing
with engine oil.
The twist lock (2) on the main bearing housing
must be positioned in the groove (3) in the
crankshaft bearing cap (4) designed for this
purpose.
► Insert the thrust washer (5) on the side of the
► Oil the contact faces of the thrust washers with
engine oil.
► When installing thrust washers, note the
designation.
The oil grooves (6) on the thrust washers must
point outwards.
223
282873-001
► Oil the bolts (1) with engine oil.

► Install the crankshaft bearing cap (2) with the
main bearing housing and thrust washer inserted.
► Tighten the bolts (1) until they are hand-tight.
The bolt heads must be in contact with the
224
282881-001

01 Engine
0115 Engine unit
1451-001
Installing the main crankshaft bearing
282805-001 225
► Screw down the bolts (3) on the crankshaft

bearing covers (1) and the thrust-bearing
crankshaft bearing cover (2) in accordance with
the tightening diagram.

► Attach the special tool (I) with pretension to the
thrust-bearing crankshaft bearing cap (1) and the
side (2) of the crankshaft.
Position the special tool (II) on a flat surface on
the thrust-bearing crankshaft bearing cap.
► Use a suitable lever (3) to push and hold the
crankshaft in place on the front stop of the thrust-
► Set the scale for the special tool (I) to "0".
► Push the crankshaft against the rear stop of the
thrust-bearing crankshaft bearing cap and read
the measured value.
The axial play can be calculated as the measured
value from stop to stop.
► Remove special tool (I) and (II).
226
282804-001
► Install the oil pump. Page 351

Checking the connecting rod bearing pin

► Check crankshaft for damage and cracks, replace
the crankshaft if necessary.

01 Engine
0115 Engine unit
1451-001
► Check the diameter (a) of the connecting rod

bearing pin:
The diameters of the connecting rod bearing pins
must have the same machining step.
specified order (1., 2. and 3.).
measured values.
► The inner diameters of the connecting rod
227
276448-001 bearing shells and the diameter of the
connecting rod bearing pins must have the
same machining step (standard or deviation)
in order to achieve the correct connecting rod
bearing play. (See the connecting rod
technical specifications Page 133)
► Machine or replace the crankshaft (1) if
necessary.
Checking the flange bearing journal

► Clean the flange bearing journal (1) of the
crankshaft (2) with a lint-free cleaning cloth.
► Attach the special tool (I) to the quick-release
button for the inner measurements (3) and set the
outside micrometer on the smallest measurement
of the flange bearing journal width (a).
Note the 5 mm pretension.
Width of the flange bearing journal: Page 147
If the measured value is outside of the tolerance,
the crankshaft must be replaced.
228
282889-001

01 Engine
0115 Engine unit
1451-001
► Position the left and right thrust washers (1) on

the thrust bearing in the crank case (2).
Only thrust washers (1) and (3) with the same wall
thickness may be installed. The dimensions
specified in the installation stages (standard or
deviation) must be maintained.
► Using an outside micrometer, measure the thrust
bearing in the crank case (2) with the two thrust
washers (1), and note down the value (b).
► Remove the thrust washers (1) again.
► Position both the left and right thrust washers (3)
on the thrust-bearing crankshaft bearing cap (4).
229 Only thrust washers (1) and (3) with the same wall
282892-001 thickness may be installed. The dimensions
specified in the installation stages (standard or
deviation) must be maintained.
► Using an outside micrometer, measure the thrust-
bearing crankshaft bearing cap (4) with the two
thrust washers (3) and note down the value (c).
► Remove thrust washers (3).
► Determine the thickness of the thrust washers (1)
and (3).
The axial play can be calculated by subtracting
value (a) from value (b) or value (c) respectively.

01 Engine
0115 Engine unit
1451-001
179608-001
Oscillation damper
Applies to:
Special tool

Punch 1
00 1992 879 0
230
270995-001

Socket 1
00 1992 952 0
231
276724-001

01 Engine
0115 Engine unit
1451-001
276859-001 232

1 Oscillation damper
2 Splash ring
Removal
► Remove the fan drive belt.
question.
► Remove the fan drive pulley.
► Remove the alternator drive belt.
question.
► Block the engine so it will not rotate.
Install the special tool from the "Cranking the
engine" chapter. Page 60

01 Engine
0115 Engine unit
1451-001

► Loosen bolts (1).
► Unscrew a bolt on the left-hand side of the
oscillation damper (2).
► Screw in the special tool (II).
► Unscrew all other bolts.
► Remove the oscillation damper.
233
276803-001
► Remove the splash ring (1).
234
276804-001
Installation
► Install the splash ring (1).
The splash ring must be installed with the flat side
against the oscillation damper.
235
276804-001

01 Engine
0115 Engine unit
1451-001

► Screw in the special tool (II).
► Install the oscillation damper (2) using the special
tool (II).
► Screw in bolts (1) hand-tight.
► Unscrew the special tool (II) and tighten the bolts
until they are hand-tight.
► Screw down the bolts.
236
276803-001
► Install the alternator drive belt.

question.
► Install the fan drive pulley.
► Install the fan drive belt.
question.
► Remove the engine blocking tool. Page 74

01 Engine
0115 Engine unit
1451-001
179441-001
Flywheel
Applies to:
Special tool

Punch 1
00 1992 879 0
237
270995-001

Socket 1
00 1992 952 0
238
276724-001

01 Engine
0115 Engine unit
1451-001
276749-001 239

1 29 kg Flywheel
2 Flywheel ring gear
3 Flywheel mounting bolts
– Observe the shaft length (a).
– Tighten bolts in 2 steps as per tightening
specification.
1 200 Nm
2 90°
a Shaft length of bolts (3)
Removal
► Remove the torsion dampers.
► Install the special tool from the "Cranking the

01 Engine
0115 Engine unit
1451-001
► Disconnect the plug-in connection (1) and remove

the sensor (B600-MB).
240
275574-001

► Undo the bolts (2) on the flywheel (1).
► Unscrew two opposite bolts.
241
276617-001

► Bolt down special tool (I).
► Remove flywheel (2).
► If necessary, squeeze off the flywheel by
screwing in two bolts.
► Remove the flywheel using the special
tool (I).
242
276623-001
Checking
► Check the flywheel for wear.
► Replace the flywheel if necessary. Page
168
► Check if the flywheel ring gear is worn.
168
► Check flywheel flange for wear and run-in traces.
168
► Check the guide bearing in the flywheel.
► If the guide bearing is worn or the flywheel is
replaced, replace the guide bearing.

01 Engine
0115 Engine unit
1451-001
► Check the rear crankshaft seal.

► Replace the radial seal if
necessary. Page 89
► Check the shaft length (a) of the flywheel
mounting bolts. Page 166
► Replace the bolts if necessary.
Installation
► Install the flywheel (1) using the fitted special
1 tool (I) and screw it down hand-tight using two
bolts (2).
3
► Observe the installation position of dowel
pin (2).
► Remove special tool (I).
► Screw in the remaining two bolts hand-tight.
243
183444-001
2
1
244
183442-001

► Install the special tool from the "Cranking the

► Tighten all bolts (1) crosswise.
245
276653-001

01 Engine
0115 Engine unit
1451-001

seal.
246
275574-001
► Remove the special tool for blocking the

engine. Page 74
► Install the torsion damper.

01 Engine
0120 Cylinder head / Valves / Idler gear
1451-001

01 Engine
1451-001
176086-001
Valve cover
Applies to:
268025-001 247

1 20 Nm Mounting bolt for cylinder head valve cover
2 20 Nm Mounting bolt for cylinder head valve cover
3 Valve cover
4 Seal

01 Engine
1451-001
Removal
► Check the seal (1) for leaks.
If no leaks are found, the seal can be reused.
► Unscrew the heat safety guard (1).
248
268032-001
► Undo bolts (1) and (2).

► Remove cylinder head valve cover (3).
249
268027-001
Installation
► Check the uncoupling discs (1) on bolts (2) and
(3) for damage.
If the uncoupling discs are damaged, use new
bolts with new uncoupling discs.
250
267961-001

01 Engine
1451-001
► Clean the sealing faces (1): Page 20

► Install a new seal (2) if necessary.
251
267963-001
► Install the cylinder head valve cover (3).

► Tighten bolts (1) and (2).
252
268027-001
► Attach a heat safety guard (1).

253
267936-001

01 Engine
1451-001
176058-001
Reinforcing frame
Applies to:

01 Engine
1451-001
267856-001 254

1 Reinforcing frame
2 Clamp
Applies to the OM 471 LA engine
3 10 Nm Bolts
4 1.5 Nm Nuts
X601.14 Electrical engine management plug-in
connection (MCM)
X602.14 Electrical engine management plug-in
connection (MCM)
Removal
► Remove the valve cover: Page 172

01 Engine
1451-001
► Unscrew clamp (1).

Applies to the OM 471 LA engine.
255
267890-001
► Disconnect the plug-in connections (1) and (2).
256
267863-001

257
267877-001
► Undo the nuts (1) on the fuel injectors (Y608-MB

to Y613-MB).
The nuts are prevented from falling out.
258
267900-001

01 Engine
1451-001
► Expose the engine line set (1).

► Remove the reinforcing frame (2).
Clean all sealing faces.
259
267913-001
Installation
► Install a new seal (1) in the reinforcing frame (2) if

necessary.
260
267924-001
► Fit the reinforcing frame (1).

► Position the engine line set (2).
261
267929-001

01 Engine
1451-001
► Screw in the nuts (1) on the fuel injectors (Y608-

MB to Y613-MB).
262
267900-001
► Screw in the bolts (1 to 7) in the specified order

(1-7).
263
268452-001
► Screw in the plug-in connections (1) and (2).
264
267863-001
► Screw on clamp (1).

Applies to the OM 471 LA engine.
► Install the cylinder head valve cover: Page
172
265
267890-001

01 Engine
1451-001
176996-001
Camshaft housing
Applies to:
Special tool

1 Adapter set 1
00 1998 585 0
266
270697-001

01 Engine
1451-001
271071-001 267

1 25 kg Camshaft housing
2 Seal
– Clean the sealing faces thoroughly. Page 20
3 10 Nm Bolt for the position sensor (B601-MB)

01 Engine
1451-001

4 Mounting bolts for the camshaft
housing (OM 470 LA), (OM 471 LA) and
(OM 473 LA):
M10 x 111
Loosening diagram:
– Undo the mounting bolts (6.23 - 6.22) in the
specified order (6.23 - 6.22).
– First loosen the mounting bolts (5.21 - 5.8)
and (4.7 - 4.1) in the specified order (5.21 -
4.1), then unscrew them.
Tightening diagram:
– Check the shaft length of the bolts (4) and
(5).
– Tighten the mounting bolts (4.1 - 4.7) and
(5.8 - 5.21) until they are hand-tight.
– Tighten the mounting bolts (6.22 - 6.23) until
they are hand-tight.
(5.8 - 5.21) in the specified order (4.1 - 5.21)
in two stages in accordance with the
tightening specification.
1 20 Nm
2 50 Nm
If a mounting bolt was screwed in too tightly, a
new seal must be used.
(OM 473 LA):
M10 x 123
6 25 Nm Mounting bolts for the camshaft
(OM 473 LA):
M8 x 63
Removal

01 Engine
1451-001
270714-001 268

► Attach the adapter set (1) to the camshaft
housing (2).
► Attach the cranking tool to the timing

housing. Page 72
► Set the engine to ignition TDC for the first cylinder
and lock it. Page 73
► Remove the inlet rocker arm
mechanism. Page 229
► Remove the outlet rocker arm
mechanism. Page 235
► Disconnect the plug-in connection (B601-MB).
269
270760-001
► Disconnect the plug-in connection (B622-MB).
270
270762-001

01 Engine
1451-001

► Remove the bracket (2) for the air intake hose.
271
270798-001
► Remove the high-pressure lines (1) (OM 470

LA). Page 268
LA). Page 276
► Remove the fuel return line (2) (OM 470
LA). Page 268
► Remove the fuel return line (2) (OM 471
LA). Page 276
LA). Page 268
LA). Page 276
272
270840-001
270847-001 273
► Remove the bolts (1), (2) and (3) of the camshaft

housing in accordance with the loosening
diagram.
Loosening diagram: Page 180

01 Engine
1451-001
► Remove the camshaft housing (1) together with

the camshaft.
274
271142-001
270867-001 275
Only if the camshaft housing with camshaft bearing

bridges is replaced:
► Remove the adapter set (2) and template (3).
► Remove sealing ring (1).
276
270883-001

01 Engine
1451-001
Only if the camshaft housing together with the

camshaft bearing bridges is replaced:
► Remove the seals (1).
277
270979-001
Only if the camshaft housing together with the

camshaft bearing bridges is replaced:
► Remove the camshaft. Page 190
► Remove the rail (OM 470 LA). Page 268
► Remove the rail (OM 471 LA). Page 276
Installation
► Install the rail (OM 470 LA). Page 270
► Install the rail (OM 471 LA). Page 278
► Install the camshaft. Page 191
► Install the sensor (B601-MB) with new sealing

rings.
For the tightening torque, see: Page 180
► Insert new seals (1).
278
270979-001
► Insert new sealing ring (1).
279
270883-001

01 Engine
1451-001
270867-001 280
► Attach the adapter set (2) and template (3).
► Insert new seal (2).

► Install the camshaft housing (1).
► Check the position of the marking on the
camshaft wheels in relation to the marking on
the template (3).
► Align the camshaft wheels if necessary.
► Select the designations on the template
depending on the capacity variant.
281
271142-001
270847-001 282
► Screw down the bolts (1), (2) and (3) of the

camshaft housing in accordance with the
tightening diagram.

01 Engine
1451-001
► Attach the high-pressure lines (3) (OM 470

LA). Page 270
LA). Page 278
► Attach the fuel return line (2) (OM 470
LA). Page 270
► Attach the fuel return line (2) (OM 471
LA). Page 278
LA). Page 270
LA). Page 278
283
270840-001
► Screw on the bracket (2) using bolts (1).
284
270798-001
► Connect the plug-in connection (B622-MB).
285
270762-001
► Connect the plug-in connection (B601-MB).
286
270760-001

01 Engine
1451-001
► Install the inlet rocker arm mechanism. Page

231
► Install the outlet rocker arm mechanism. Page
238
► Remove the special tool if necessary.
See the "Setting the engine to ignition TDC"
chapter. Page 73
MB). Page 98
► Remove the cranking tool from the timing
housing. Page 74
270714-001 287
► Remove the adapter set (1) from the camshaft

housing (2).
► Attach the reinforcing frame. Page 177

► Install the valve cover. Page 172
► Start the diesel engine and let it run at idle speed
for 10 s min.

01 Engine
1451-001
177397-001
Camshaft
Applies to:
271718-001 288

1 Camshaft bearing bridges
2 Camshaft housing Page 179
3 6 kg Intake camshaft
4 7,9 kg Outlet camshaft
5 Gear train Page 251

01 Engine
1451-001

6 25 Nm Mounting bolts (OM 470 LA), (OM 471 LA) and
(OM 473 LA):
M8 x 63
Loosening diagram:
– First loosen the mounting bolts (8.28 - 8.15)
and (7.14 - 7.8) in the specified order (8.28 -
7.8), then unscrew them.
– First loosen the mounting bolts (6.7 - 6.1) in
the specified order (6.7 - 6.1), then unscrew
them.
Tightening diagram:
– Check the shaft length of the bolts (7) and
(8).
– Screw on the mounting bolts (6.1 - 6.7) in
(8.15 - 8.28) in the specified order (7.8 -
8.28) in two stages in accordance with the
tightening specification.
1 20 Nm
2 50 Nm
(OM 473 LA):
M10 x 111
(OM 473 LA):
M10 x 123
Removal
housing. Page 72
► Set the engine to ignition TDC. Page 73
The setting must not be changed while fitting or
removing the camshaft. If necessary, repeat the
work steps.
mechanism. Page 229
mechanism. Page 235

01 Engine
1451-001
271409-001 289
► Remove the bolts (1), (2) and (3) in accordance

with the loosening diagram.
► Remove the camshaft bearing bridges (1).

► Remove the inlet camshaft (2) and outlet
camshaft (3).
290
271423-001
Installation
► Check the camshaft. Page 193
► Install the inlet camshaft (1) and outlet

camshaft (2).
Oil the camshafts with engine oil.
The designations on the gearwheels (3) must
match the designations on the template (4).
► Select the designations on the template
depending on the capacity variant.
291
271475-001

01 Engine
1451-001
► Install the camshaft bearing bridges (1).

Note the installation position. The front and rear
camshaft bearing bridge is marked with "FRONT"
or "REAR".
The numbers (3) on the remaining camshaft
bearing bridges and in the camshaft housing (2)
must match.
292
271616-001
271409-001 293
► Screw in the bolts (1), (2) and (3) in accordance

with the tightening diagram.

231
238
► Remove the cranking tool on the timing
housing. Page 74
See the "Setting the engine to ignition TDC"
chapter. Page 74
MB). Page 98
► Attach the reinforcing frame. Page 177
► Install the valve cover. Page 172

01 Engine
1451-001
Checking
► Check the camshaft bearing bridges (1) and
camshaft housing (2) for scores, scratches or
other signs of wear.
Replace the camshaft bearing bridges and
camshaft housing if necessary.
294
271749-001
► Check the outlet camshaft (1) and inlet

camshaft (2) for scores, scratches or other signs
of wear.
Replace the outlet camshaft and inlet camshaft if
necessary.
295
271754-001

01 Engine
1451-001
176293-001
Cylinder head
Applies to:
Special tool

00 1992 874 0
296
268245-001

Clock gauge 1
60 0500 530 3
297
268255-001

Counter-bracket 1
00 1998 570 0
298
273084-001

01 Engine
1451-001

Ring spanner insert 1
00 1998 568 0
299
272751-001

1 Guide pin 1
000 1998 579 0
300
268238-001
Special tool (VIII) Pcs.

1 Socket 1
00 1992 952 0
301
268241-001

01 Engine
1451-001
277542-001 302

01 Engine
1451-001

1 Cylinder head
2 Cylinder head screw (OM 470 LA) and
(OM 471 LA)
Loosening diagram:
– Unscrew the hexagon head bolts (3.39 -
3.40) in the specified order (3.39 - 3.40).
– First loosen the cylinder head screws (2.1 -
2.38) in the specified order (2.1 - 2.38), then
unscrew them.
Tightening diagram:
– Check shaft length (a).
– Slightly coat the cylinder head screws (2.1 -
2.38) and hexagon head bolts (3.39 - 3.40)
with engine oil on the thread and on the
support on the screw head.
– Tighten the cylinder head screws (2.1 -
2.38) in the specified order (2.1 - 2.38) in
four steps in accordance with the tightening
specification.
1 50 Nm
2 100 Nm (OM 470 LA)
200 Nm (OM 471 LA)
3 90 °
4 90 °
If a cylinder head bolt was screwed in too tightly,
all bolts must be removed and checked if to see
whether they have a permitted shaft length (a).
In addition, a new cylinder head gasket must be
used.
– Screw in the hexagon head bolts (3.39 -
3 60 Nm Hex. bolt
4 Cylinder head gasket
– Observe the installation position.
5 Valve guides
– The plug gauge side marked with a "+" must
not be able to fit into the valve guide.

01 Engine
1451-001

a Shaft length of the cylinder head
screw (OM 470 LA)
When new: 186 mm
Permitted value: Up to 188 mm
b up to 0,05 mm Allowed deviation of flatness of the lower
separating face over a length of 150 mm
c 0.7 to 1.1 mm Valve depth
(OM 470 LA)
0.7 to 1.1 mm
(OM 471 LA)
d 9.500 to Inner diameter of the valve guide (installed)
9.522 mm
(OM 470 LA)
9.500 to
9.522 mm
(OM 471 LA)

01 Engine
1451-001
Removal
► Drain coolant. Page 357
► Remove the air intake pipe if necessary.
► Remove the exhaust pipe if necessary.
► Remove the charge air tube if necessary.
► Remove the coolant line if necessary.
► Remove the protection panel.
See exhaust turbo charger. Page 417
► Remove the exhaust gas recirculation line
upstream of the exhaust gas recirculation cooler.
See "Exhaust gas recirculation cooler": Page
370
► Remove the connecting rod (1) on the lever of the

exhaust gas recirculation actuator (2).
See "Exhaust gas recirculation actuator". Page
396
303
268807-001
► Remove the bleed hose (1) from the oil

separator (2).
304
268737-001

01 Engine
1451-001
► Remove the bracket (1) from the exhaust turbo

charger (2).
305
268733-001
► Remove the bolts (1) from the exhaust turbo

charger (2) and exhaust manifold (3).
306
268716-001
► Disconnect the plug-in connections (1), (2) and

(3).
► Undo the line (4) from the cylinder head.
► Disconnect the plug-in connections (5), (6), (8)
and (9).
► Detach the line (7) from the charge air tube.
307
268982-001

01 Engine
1451-001

► Remove the fuel lines (1), (2) and (3).
308
268713-001
► Undo the bolts (1) on the connection flange (2).

► Remove the bolts (3) of the connection flange (2)
on the charge air tube (4).
309
268742-001
Use the special tool (VIII). Page 194

► Unscrew the cylinder head screws (1) and
hexagon head bolts (2) in accordance with the
loosening diagram.
310
268752-001

01 Engine
1451-001
57765-002
WARNING
311 intended or a suitable position.
269145-001
► Suspend the cylinder head using a suitable lifting

device at the suspension eyes (1) intended for
this purpose.
► Ensure that the chains are fitted to the lifting
device vertically to the lifting eyes!
► Use a suitable supporting arm.
► Weight of the cylinder head: Page 196
► Raise the cylinder head (1).

► Ensure that the cylinder head is not tilted.
► If the cylinder head is raised, the connecting
piece (2) of the coolant flow tube (3) will be
pulled out.
► Position the cylinder head on two wooden slats.
312
268872-001
► Remove cylinder head gasket (1).
313
268763-001

01 Engine
1451-001
► Remove the seal (1) between the exhaust turbo

314
268760-001
Remove the following components if necessary:

► Remove the charge air housing and charge air
tube.
See the "Charge air housing" chapter. Page
435
► Remove the exhaust gas recirculation line,
exhaust gas recirculation hose and exhaust gas
recirculation cooler.
See the "Exhaust gas recirculation cooler"
chapter. Page 370
► Remove the exhaust manifold. Page 403
► Remove the rear suspension eyes. Page 76
► Remove the gearwheel from the cylinder head.
See the "Gearwheel drive" chapter. Page 257
► Remove injectors. Page 287
Installation
► Clean the cylinder head. Page 208
► Check the cylinder head. Page 209
Attach the following components if necessary:
► Install the injectors. Page 290
► Install the gearwheel in the cylinder head.
► Attach the rear suspension eyes. Page 76
► Install exhaust manifold. Page 404
► Install the exhaust gas recirculation line, exhaust
gas recirculation hose and exhaust gas
recirculation cooler.
chapter. Page 373
► Install the charge air housing and charge air tube.
438

01 Engine
1451-001
► Install a new cylinder head gasket (1).

► Ensure that the part number on the cylinder
head gasket (1) points to the cylinder head.
► Note the centring pins (2) in the crank case.
315
268888-001
► Install a new seal (1) between the exhaust turbo

316
268760-001
57765-002
WARNING
269146-001

this purpose.

01 Engine
1451-001
Use special tool (V). Page 194

► Insert the guide pins (1) in the holes of the
cylinder head screws on the front and rear crank
case.
► Position the cylinder head (2) over the guide
pin (1) using lifting equipment.
► Slide on a new connecting piece (3).
Slide on the connecting piece until it reaches the
stop on the connector for the oil coolant
module (4).
318
269197-001
► Ensure that the front jockey pulley (1) is seated on

the ribbed V-belt (2).
319
268896-001

► Remove the guide pins.
► Screw in the cylinder head screws (1) and
tightening diagram.
320
268752-001
► Screw in the bolts (3) of the connection flange (2)

► Screw the bolts (1) onto the connection flange (2).
321
268742-001

01 Engine
1451-001

► Install the fuel lines (1), (2) and (3).
► For the tightening torques, see the "Fuel filter
module" chapter: Page 325
► For the tightening torques, see the "High
pressure lines and rail" chapter: Page
267
322
268713-001
► Connect the plug-in connections (1), (2) and (3).

► Attach the line (4) to the cylinder head.
► Connect the plug-in connections (5), (6), (8) and
(9).
► Attach the line (7) to the charge air tube.
323
268982-001
► Adjust the pinion backlash. Page 264


01 Engine
1451-001
► Screw the bolts (1) to the exhaust turbo

324
268716-001
► Screw the bracket (1) to the exhaust turbo

charger (2) and crank case.
325
268733-001
► Attach the bleed hose (1) to the oil separator (2).

Replace the sealing ring if necessary.
326
268737-001
► Attach the connecting rod (1) to the lever of the

See "Exhaust gas actuator". Page 397
327
268807-001

01 Engine
1451-001
► Install the exhaust gas recirculation line upstream

of the exhaust gas recirculation cooler.
See "Exhaust gas recirculation cooler". Page
373
► Attach the protection panel.
172
► Install the charge air tube if necessary.
► Install the exhaust pipe if necessary.
► Install the air intake pipe if necessary.
► Install the coolant line if necessary.
► Top up coolant. Page 357
► Pre-fill the lubricating oil system. Page 336
► Check the oil level.
► See the Operator's Manual of the machine in
question.
Only if new fuel injectors were installed:
► Program the fuel injectors using the CDS.
► Fill the low-pressure fuel circuit on the engine.
question.
least 1 minute.
► If the engine does not start or only runs for a
brief period, fill the low-pressure fuel circuit.
question.
Cleaning
► Seal all drilled holes on the separating face of the
crank case to prevent dust entering.
► Clean the cylinder head.
► Blow out the tapped holes in the crank case using
compressed air.

01 Engine
1451-001
Checking
► Check the cylinder head gasket (1) on the drilled
holes of the combustion chamber.
► Area 2: The seal was gas-tight.
► Area 3: The seal was not gas-tight.
328
268837-001
► Check cylinder head gasket (1) near the sealing

rings (2).
► If the sealing ring is damaged, the cylinder
head gasket will leak gas.
► If the cylinder head gasket is leaking, the
cylinder head and crank case sealing faces
must be checked.
329
268838-001
► Clean the cylinder head sealing face.

► Evaluate the cylinder head sealing face using the
cylinder head gasket.
► Check that the cylinder head sealing face is level.
Dimension (b): Page 196
► Position a straight edge on all areas within
the sealing area of the cylinder head gasket
on the cylinder-head sealing face.
► When a gap is visible, the cylinder head must
be replaced.
► Check the cylinder head screw. Dimension (a):
Page 196
► If the permissible shaft length (a) is
exceeded, replace the cylinder head screw.

01 Engine
1451-001

► Measure the valve depth (c) of valves (1).
Valve depth: Page 196
If the valve depth (c) is not within the permitted
tolerance, the cylinder head must be replaced.
330
277197-001
Only if the cylinder head and cylinder head gasket are

severely damaged:
► Remove the oil filter insert and check the fins of
the oil filter insert for abraded metal or bulging
from the outside.
► Replace the engine oil and oil filter.

01 Engine
1451-001
181998-001
Cylinder head
Applies to:
Work preparation
Utilities:
► Copper paste
Special tool

00 1992 874 0
331
268245-001

Clock gauge 1
60 0500 530 3
332
268255-001

Counter-bracket 1
00 1998 570 0
333
273084-001

01 Engine
1451-001

00 1998 568 0
334
272751-001

1 Guide pin 1
000 1998 579 0
335
268238-001
Special tool (VIII) Pcs.

1 Socket 1
00 1992 952 0
336
268241-001

01 Engine
1451-001
277542-001 337

01 Engine
1451-001

1 Cylinder head
2 Cylinder head screw (OM 470 LA) and
(OM 471 LA)
Loosening diagram:
– Unscrew the hexagon head bolts (3.39 -
– First loosen the cylinder head screws (2.1 -
2.38) in the specified order (2.1 - 2.38), then
unscrew them.
Tightening diagram:
– Check shaft length (a).
– Slightly coat the cylinder head screws (2.1 -
with engine oil on the thread and on the
support on the screw head.
2.38) in the specified order (2.1 - 2.38) in
four steps in accordance with the tightening
specification.
1 50 Nm
2 100 Nm (OM 470 LA)
200 Nm (OM 471 LA)
3 90 °
4 90 °
If a cylinder head bolt was screwed in too tightly,
all bolts must be removed and checked if to see
whether they have a permitted shaft length (a).
In addition, a new cylinder head gasket must be
used.
– Screw in the hexagon head bolts (3.39 -
3 60 Nm Hex. bolt
4 Cylinder head gasket
5 Valve guides
– The plug gauge side marked with a "+" must
not be able to fit into the valve guide.

01 Engine
1451-001

a Shaft length of the cylinder head
screw (OM 471 LA)
When new: 192 mm
Permitted value: up to 194 mm
b up to 0,05 mm Allowed deviation of flatness of the lower
separating face over a length of 150 mm
c 0.7 to 1.1 mm Valve depth
(OM 470 LA)
0.7 to 1.1 mm
(OM 471 LA)
d 9.500 to Inner diameter of the valve guide (installed)
9.522 mm
(OM 470 LA)
9.500 to
9.522 mm
(OM 471 LA)

01 Engine
1451-001
Removal
► Remove the exhaust pipe if necessary.
► Remove the connecting rod (1) on the lever of the

396
338
268807-001
► Remove the bracket (1) from the exhaust turbo

charger (2).
339
268733-001

01 Engine
1451-001
► Remove the bolts (1) from the exhaust turbo

340
268716-001
► Disconnect the plugs on the sensors (B621-MB),

(B606-MB) and (B608-MB).
341
282428-001

► Remove the fuel lines (1), (2) and (3).
342
268713-001

01 Engine
1451-001
► Undo the bolts (1) on the connection flange (2).

► Remove the bolts (3) of the connection flange (2)
343
268742-001

► Unscrew the cylinder head screws (1) and
loosening diagram.
344
268752-001
57765-002
WARNING
269145-001

this purpose.

01 Engine
1451-001
► Raise the cylinder head (1).

► Ensure that the cylinder head is not tilted.
► If the cylinder head is raised, the connecting
piece (2) of the coolant flow tube (3) will be
pulled out.
► Position the cylinder head on two wooden slats.
346
268872-001
► Remove cylinder head gasket (1).
347
268763-001
► Remove the seal (1) between the exhaust turbo

348
268760-001
Remove the following components if necessary:

► Remove the charge air housing and charge air
tube.
444
► Remove the exhaust gas recirculation line,
exhaust gas recirculation hose, coolant flow tube
and exhaust gas recirculation cooler.
chapter. Page 383
► Remove the guide roller on the cylinder head.
See the "Coolant pump" chapter. Page 360
► Remove the exhaust manifold. Page 409
► Remove the coolant nozzle.

01 Engine
1451-001

chapter. Page 383
► Remove the rear suspension eyes. Page 77
► Remove the gearwheel from the cylinder head.
► Remove injectors. Page 287
Installation
► Clean the cylinder head. Page 224
► Check the cylinder head. Page 225
Attach the following components if necessary:
► Install the injectors. Page 290
► Install the gearwheel in the cylinder head.
► Attach the rear suspension eyes. Page 77
► Install the coolant nozzle.
chapter. Page 387
► Install exhaust manifold. Page 411
► Install the guide roller on the cylinder head.
See the "Coolant pump" chapter. Page 361
► Install the exhaust gas recirculation line, exhaust
gas recirculation hose, coolant flow tube and
exhaust gas recirculation cooler.
chapter. Page 387
► Install the charge air housing and charge air tube.
447
► Install a new cylinder head gasket (1).

► Ensure that the part number on the cylinder
head gasket (1) points to the cylinder head.
► Note the centring pins (2) in the crank case.
349
268888-001

01 Engine
1451-001
► Install a new seal (1) between the exhaust turbo

350
268760-001
57765-002
WARNING
269146-001

this purpose.

► Insert the guide pins (1) in the holes of the
cylinder head screws on the front and rear crank
case.
► Position the cylinder head (2) over the guide
pin (1) using lifting equipment.
► Slide on a new connecting piece (3).
Slide on the connecting piece until it reaches the
stop on the connector for the oil coolant
module (4).
352
269197-001

01 Engine
1451-001
► Ensure that the front jockey pulley (1) is seated on

the ribbed V-belt (2).
353
268896-001

► Remove the guide pins.
► Screw in the cylinder head screws (1) and
tightening diagram.
354
268752-001
► Screw in the bolts (3) of the connection flange (2)

► Screw the bolts (1) onto the connection flange (2).
355
268742-001

► Install the fuel lines (1), (2) and (3).
► For the tightening torques, see the "Fuel filter
module" chapter: Page 325
► For the tightening torques, see the "High
pressure lines and rail" chapter: Page
275
356
268713-001

01 Engine
1451-001
► Connect the plugs on the sensors (B608-MB),

(B606-MB) and (B621-MB).
357
282428-001
► Adjust the pinion backlash. Page 264

► Screw the bolts (1) to the exhaust turbo

Coat the bolts with copper paste.
Replace the studs if necessary.
358
268716-001
► Screw the bracket (1) to the exhaust turbo

charger (2) and crank case.
First, position all the bolts on the bracket. Then,
screw in the bolts on the crank case and then
screw in the bolts on the exhaust turbo charger.
359
268733-001

01 Engine
1451-001
► Attach the connecting rod (1) to the lever of the

397
360
268807-001
► Attach the protection panel.

172
► Install the charge air tube if necessary.
► Install the exhaust pipe if necessary.
► Install the air intake pipe if necessary.
► Install the coolant line if necessary.
► Check the oil level.
question.
Only if new fuel injectors were installed:
► Program the fuel injectors using the CDS.
question.
least 1 minute.
question.
Cleaning
► Seal all drilled holes on the separating face of the
crank case to prevent dust entering.
► Clean the cylinder head.
► Blow out the tapped holes in the crank case using
compressed air.

01 Engine
1451-001
Checking
► Check the cylinder head gasket (1) on the drilled
holes of the combustion chamber.
► Area 2: The seal was gas-tight.
► Area 3: The seal was not gas-tight.
361
268837-001
► Check cylinder head gasket (1) near the sealing

rings (2).
► If the sealing ring is damaged, the cylinder
head gasket will leak gas.
► If the cylinder head gasket is leaking, the
cylinder head and crank case sealing faces
must be checked.
362
268838-001
► Clean the cylinder head sealing face.

► Evaluate the cylinder head sealing face using the
cylinder head gasket.
► Check that the cylinder head sealing face is level.
Dimension (b): Page 213
► Position a straight edge on all areas within
the sealing area of the cylinder head gasket
on the cylinder head sealing face.
► When a gap is visible, the cylinder head must
be replaced.
► Check the cylinder head screw. Dimension (a):
Page 213
► If the permissible shaft length (a) is
exceeded, replace the cylinder head screw.

01 Engine
1451-001

► Measure the valve depth (c) of valves (1).
Valve depth: Page 213
If the valve depth (c) is not within the permitted
tolerance, the cylinder head must be replaced.
363
277197-001
Only if the cylinder head and cylinder head gasket are

severely damaged:
► Remove the oil filter insert and check the fins of
the oil filter insert for abraded metal or bulging
from the outside.
► Replace the engine oil and oil filter.

01 Engine
1451-001
179801-001
Inlet rocker arm mechanism
Applies to:

01 Engine
1451-001
277166-001 364

01 Engine
1451-001

1 Mounting bolts for the rocker shaft
If the specified order for undoing and tightening
the bolts is not followed, there is a danger that
the rocker shaft might break.
Loosening diagram:
– Undo each bolt (1.1 - 1.7) by a half
revolution in the specified order (1.1 - 1.7).
– Undo each bolt (1.1 - 1.7) in the specified
order (1.1 - 1.7) until all of the bolts have
been completely removed.
Tightening diagram:
– Screw in each bolt (1.1 - 1.7) by a half
– Screw in each bolt (1.1 - 1.7) in the
specified order (1.1 - 1.7) until all the bolts
have been screwed in completely.
order (1.1 - 1.7) in two steps in accordance
1 50 Nm
2 90 °
2 Rocker arm shaft
3 Rocker lever
– Slightly coat the rocker arm with engine oil.
4 Spacer sleeves (wide)
5 Spacer sleeves (narrow)
6 Adjusting screw
7 50 Nm Counternut on the adjusting screw (6)
Removal

01 Engine
1451-001
277098-001 365
Only if the inlet rocker arm mechanism (1) is

disassembled:
► Mark the installation position of the rocker arm
and spacer sleeves on the rocker arm
mechanism (1).
► Unscrew the bolts (2) in accordance with the
loosening diagram.
► Remove the bolts using clamping pieces (3).
► Remove the rocker-arm mechanism.
Disassembly
277102-001 366
► Mark the installation position of the rocker arm (1)

and spacer sleeves (3) and (4).
► Remove the rocker arm and spacer sleeves from
the rocker shaft (2).

01 Engine
1451-001
Assembly
277103-001 367
► Check the rocker arm (1), spacer sleeves (3) and

(4) and rocker shaft (2) for wear.
Replace affected parts if necessary.
► Clean the oil holes (5).
► Coat the points of support and the rocker shaft
with engine oil.
► Install the rocker arm and spacer sleeves on the
rocker shaft.
Note the installation positions of the rocker arm
and spacer sleeves.
Note the "TOP, FRONT" (6) and "TOP, REAR" (7)
designation on the rocker shaft.
Installation
277104-001 368
► Align the rocker arm and spacer sleeves on the

rocker shaft.
► Lubricate the rocker arm sockets and rocker
arm mechanism support points using engine
oil.
► Install the rocker arm mechanism (1).
designation for the installation position on the
rocker shaft.

01 Engine
1451-001
Note the installation position of the clamping

pieces (3).
tightening diagram.
► Check the valve clearance. Page 242

172

01 Engine
1451-001
179716-001
Outlet rocker arm mechanism
Applies to:
Special tool

Fixing device 1
00 1998 595 0
369
276914-001

01 Engine
1451-001
277023-001 370

01 Engine
1451-001

1 Mounting bolts for the rocker shaft
If the specified order for undoing and tightening
the bolts is not followed, there is a danger that
the rocker shaft might break.
Loosening diagram:
– Undo each bolt (1.1 - 1.7) by a half
– Undo each bolt (1.1 - 1.7) in the specified
order (1.1 - 1.7) until all of the bolts have
been completely removed.
Tightening diagram:
– Screw in each bolt (1.1 - 1.7) by a half
– Screw in each bolt (1.1 - 1.7) in the
specified order (1.1 - 1.7) until all the bolts
have been screwed in completely.
order (1.1 - 1.7) in two steps in accordance
1 50 Nm
2 90 °
2 Rocker arm shaft
3 Rocker lever
– Slightly coat the rocker arm with engine oil.
4 Spacer rings
Removal

01 Engine
1451-001
276908-001 371
Only if the outlet rocker arm mechanism (1) is

disassembled:
► Mark the installation position of the rocker arm
and spacer rings on the outlet rocker arm
mechanism (1).
► Unscrew the bolts (2) in accordance with the
loosening diagram.

► Remove springs (2).
► Install special tool (I).
The locking pins (3) of the special tool must be
undone. Fasten the special tool with the three
toggle bolts on the rocker arm mechanism (1).
► Position the locking pins on the sides of the rocker
arms and screw them on.
► Tip the rocker arm mechanism in the direction of
the arrow using the special tool and then remove
it.
372 ► Remove the special tool.
276913-001
Disassembly
► Mark the installation position of the rocker arm (1)
and the spacer rings (2).
► Remove the rocker arm and spacer rings from the
rocker shaft (3).
373
276965-001

01 Engine
1451-001
Assembly
► Check the rocker arm (1), spacer rings (2) and
rocker shaft (3) for wear.
Replace affected parts if necessary.
374
276965-001
► Clean the oil holes (1).

► Coat the points of support and the rocker shaft (2)
with engine oil.
► Assemble the rocker arm (3) and spacer rings (4)
on the rocker shaft.
Note the installation positions of the rocker arm
and spacer rings.
designation on the rocker shaft.
375
276973-001
276979-001 376

► Install special tool (I).
► Align the rocker arm (3) and spacer rings (4) on
the rocker shaft (2).
Align the rocker arm and spacer rings in
accordance with the locking pins (1) on the
special tool.
Do not undo the locking pins.

01 Engine
1451-001
Installation
276928-001 377

► Align the rocker arm and spacer rings on the
rocker shaft and attach the special tool (I).
► Lubricate the rocker arm sockets and rocker
arm mechanism support points using engine
oil.
► Install the rocker arm mechanism (1).
designation for the installation position on the
rocker shaft.
378 ► Install springs (3).
276932-001
tightening diagram.
► Check the valve clearance. Page 242

172

01 Engine
1451-001
176034-001
Valves
Applies to:
Special tool

Feeler gauge 1
00 0409 797 0
379
188124-001

01 Engine
1451-001
277483-001 380

1 Intake valves
– Slightly coat the valve shaft with engine oil.
2 Exhaust valves
– Slightly coat the valve shaft with engine oil.
Removal
194
216
► Remove the valve springs and valve stem
seals. Page 245

01 Engine
1451-001
► Mark the installation position of the valves (1) in

relation to the cylinder head.
► Pull the valve downwards and remove it from the
cylinder head.
381
277245-001
Installation
► Check the valves. Page 241
► Insert the valves (1) in the cylinder head.

Note the installation position.
► Oil the valve stems with engine oil.
382
277245-001
► Install the valve springs and valve stem

seals. Page 248
194
220
Checking the valves

► Remove fouling deposits on the valves by means
of a wire brush.
► Ensure that the valves have no seizing traces or
cracks.
► Ensure that the valve seats and valve seat inserts
are not damaged or burned.
► Ensure that the valve stems are not damaged.
a2301265 383
171650-001

01 Engine
1451-001
Adjusting the valve lash
267807-001 384

1-6 Cylinder 1 to 6
A 0.60 mm Valve lash of exhaust valves
Test tolerance: ±0.05 mm
E 0.40 mm Valve lash of intake valves
Test tolerance: ±0.05 mm
OM 470 LA / OM 471 LA / OM 473 LA engine:
Crankshaft position 1 2 3 4 5 6
Cylinder 6 at overlap TDC E/A E A E A -
Cylinder 1 at overlap TDC - A E A E E/A
► Set cylinder 6 to overlap TDC.

Cylinder 1 at ignition TDC.
► Adjust the corresponding exhaust (A) and
intake valves (E).
► Set cylinder 1 to overlap TDC.
Cylinder 6 at ignition TDC.
► Adjust the corresponding exhaust (A) and
intake valves (E).
Check and adjust valve lash only on a cold engine.

01 Engine
1451-001
► Remove the valve cover. Page 172

► Rotate the crankshaft to the corresponding
crankshaft position as described in the "Cranking
the engine" chapter. Page 242

► Check the distance between the valve bridge and
the rocker lever at (3).
If the deviation exceeds the allowed test tolerances,
adjust the valve lash as follows:
► Slacken off lock nut (1).
► Turn out adjusting bolt (2) a little.
► Insert feeler gauge at (3).
► Readjust the adjusting bolt (2) until the feeler
gauge can just be pulled through.
385 ► Tighten lock nut (1).
267836-001 ► Tightening torque: Page 228
► Test and set the other cylinders in the same
manner.
► Rotate the engine further using the rotary
device.

01 Engine
1451-001
179981-001
Valve springs and valve stem seals
Applies to:
Special tool

Valve toolbox 1
00 1998 591 0
386
277279-001

Magnetic rod 1
00 0181 842 0
387
32852-001

01 Engine
1451-001
277414-001 388

1 Split valve keepers
Observe the installation position!
2 Valve spring retainer
3 Valve spring
Do not confuse the valve springs.
4 Valve stem seal
Replace seal after every installation process!
5 Valve guide
6 Valve Page 239
Removal
mechanism. Page 229
mechanism. Page 235
► Remove the injector. Page 287
► Set the corresponding piston to the valve overlap
TDC.

01 Engine
1451-001

► Insert the adapter (1) in the assembly cartridge
guide (2) and screw it tight.
389
277293-001
► Place the assembly cartridge guide (1) onto the

cylinder head (2).
► Screw on the assembly cartridge guide using
bolts (3).
390
277294-001
► Screw the grid part (1) into the assembly cartridge

guide (2).
► Insert the assembly cartridge (4) into the
assembly cartridge guide.
► Hang the pressure fork (3) on the grid part and lay
it on the assembly cartridge.
391
277295-001
► Push the pressure fork (1) gently downwards (2)

and at the same time, turn the bolts (3) clockwise.
Turn the bolt until the split tips of the assembly
cartridge (4) engage between the valve collets.
► Push the pressure fork down to the stop.
As part of this process, the valve collets are
pushed into the assembly cartridge and removed.
392
277298-001

01 Engine
1451-001

► Carefully move the pressure fork (1) upwards.
► Unhook and remove the pressure fork on the grid
part (8).
► Remove the assembly cartridge (2) from the
assembly-cartridge guide (7).
► Remove the valve spring retainer (5) and valve
spring (6) using the special tool (II).
► Pull the bolts (9) upwards and remove the valve
collets (3) and (4) from the assembly cartridge.
393
277299-001
► Place the plate (2) on the assembly cartridge

guide (3) and screw it on using bolts (1).
394
277301-001

► Insert the puller (4) into the assembly cartridge
guide (3).
► The puller must be inserted as far as the system
on the valve stem seal in the assembly cartridge
guide (3).
► Further unscrew the nut (2) or the knurl
rod (1) if necessary.
► Screw on the knurl rod.
► Turn the nut clockwise.
► If necessary, re-tighten the knurl rod during
395 the tightening procedure.
277303-001
► Remove the puller (4) with the valve stem seal
from the assembly-cartridge guide.
If the valve stem seal has not yet been undone,
use the slide hammer puller (5).

01 Engine
1451-001
► Undo the knurl rod (3).

► Remove the valve stem seal (1) from the
puller (2).
► Turn the puller nut (4) back.
396
277326-001
► Unscrew the bolt (1) and remove the plate (2).

► Remove the assembly cartridge guide (3) from the
cylinder head.
► Clean the valve stems and remove any remaining
parts of the old valve stem seals.
397
277301-001
Installation
► Insert the support disc (4).
► Oil the valve body (2) with engine oil and slide it
over the valve stem.
► Slide the new, oiled valve stem seal (3) over the
valve body and place it on the valve guide (5).
► Remove the valve body from the valve stem.
► Press the valve stem seal with the punch (1) onto
the valve guide.
► Carefully use the punch to realign the valve
stem seal until it is flat.
398 ► Remove the punch.
277345-001

01 Engine
1451-001
► Place the assembly cartridge guide (1) onto the

cylinder head (2).
► Screw on the assembly cartridge guide using
bolts (3).
399
277294-001

► Screw the grid part (8) into the assembly cartridge
guide (7).
► Insert the valve spring (6) and valve spring
retainer (5) into the assembly cartridge guide.
► Pull the bolts (9) upwards and insert both valve
collets (3) and (4) between the split tips in the
assembly cartridge (2).
► Insert the assembly cartridge into the assembly
cartridge guide.
The valve collets are clipped into the assembly
cartridge.
400
277299-001
► Hang the pressure fork (1) on the grid part and fit
it on the assembly cartridge.
► Push the pressure fork (3) downwards (4) until the

valve spring is gently pushed together.
► Hold the pressure fork.
► Pull the bolt (1) upwards (2) and hold it in position.
► Push the pressure fork until the stop.
The valve collets fall out of the assembly
cartridge (5) between the valve spring retainer
and the valve stem.
► Carefully move the pressure fork upwards.
Hold the bolts in position when doing so.
► Remove the pressure fork.
401 ► Remove the assembly cartridge.
277351-001
► Check that the valve collets are securely seated.

01 Engine
1451-001
► Unscrew the bolts (1) and remove the assembly

cartridge guide (3) along with the grid part (2).
402
277392-001
► Install the injector. Page 290

238
231

01 Engine
1451-001
178247-001
Gear drive
Applies to:
Special tool

Clock gauge 1
60 0500 530 3
403
268255-001

00 1992 874 0
404
268245-001

Fixing device 1
00 1998 576 0
405
277652-001

01 Engine
1451-001

Adjusting tool 1
00 1998 575 0
406
277665-001

01 Engine
1451-001

Centring mandrel 1
00 1992 879 0
407
277958-001

01 Engine
1451-001
278231-001 408

01 Engine
1451-001

1 Gear
2 Gear
3 Gear
4 Gear
5 Cylinder head
6 Crankshaft gear
7 Cover
8 High-pressure fuel pump drive wheel Page 299
9 Oil pump drive wheel Page 349
10 Compressor drive wheel Page 469
11 Outlet camshaft drive wheel
12 Inlet camshaft drive wheel
13 Journal
14 Journal
15 Drilled hole
16 "T" mark
18 60 Nm Bearing pin mounting bolts
19 Mounting bolts for the gearwheel (1)
Bolt shaft length (OM 471 LA)
When new: 83,5 mm
1 40 Nm
2 90 °
20 Mounting bolts for the gearwheel (2)
Bolt shaft length (OM 471 LA)
When new: 55 mm
1 40 Nm
2 90 °

01 Engine
1451-001

21 60 Nm Mounting bolts for the
gearwheel (4) (OM 471 LA)
a OM 471 LA: Backlash
0.043 to
0.165 mm

01 Engine
1451-001
Removal
► Set the engine to the ignition TDC of the first
cylinder.
► Remove the timing housing. Page 99
Only if gearwheels (1) and (2) are removed:

Only if gearwheels (3) and (5) or the crankshaft
gear (4) are removed:
► Remove the air compressor. Page 471
409
277648-001

► Lock the crankshaft gear (3) using the special
tool (III).
The special tool must be inserted on the plugs (4)
free of tension.
► Secure the special tool (III) using a bolt.
► Lock the gearwheel (2) using the special tool (IV).
The special tool must be inserted on the plugs (5)
and in the drilled holes (1) free of tension.
410
277650-001
► Unscrew the bolts (3) and remove the bearing

cover (2).
► Remove the bearing pins (5) together with the
gearwheel (1) and thrust washers (4).
► Pull the bearing pins (5) out of the gearwheel (1)
and remove the thrust washers (4).
411
277670-001

01 Engine
1451-001

► Remove special tool (III).
► Remove the crankshaft gear (1) from the
crankshaft (2) using the special tool (V).
412
277701-001
277704-001 413
► Unscrew the bolts (1) and remove the bearing

cover (3).
► Mark the position of the drive wheel for the high-
pressure fuel pump (5) in relation to the crank
case.
The "T" mark (7) on the disc (6) must be in the 12
o'clock position.
Teeth on the gearwheel (2) may be not concealed
at all by the disc (6) on the drive wheel for the
high-pressure fuel pump (5).
► Remove the gearwheel (2) together with the
bearing pins (4).
► Pull the bearing pins (4) out of the gearwheel (2).
► Remove the special tool (IV).

► Remove the gearwheel (3) together with the
bearing pins (1).
► Pull the bearing pins out of the gearwheel.
414
277706-001

01 Engine
1451-001
► Remove the cover (1) from the cylinder head (2).
415
277709-001

► Pull the gearwheel (2) together with the bearing
pins (3) downwards and remove it from the
cylinder head (4).
► Pull the bearing pins (3) out of the gearwheel (2).
416
277841-001
Installation
► Check the specified dimensions. Page 254
► Check the gearwheel drive. Page 262
► Coat the bearing surfaces (5) of the gearwheel (2)

and the bearing pin (3) with engine oil.
► Slide the gearwheel (2) onto the bearing pins (3).
The larger flange on the gearwheel (2) must face
the cylinder head (4).
► Insert the gearwheel (2) together with the bearing
pins (3) into the cylinder head (4) from below.
417
277862-001

01 Engine
1451-001
Use special tool (IV). Page 251

► Check the position of the drive wheel for the high-
pressure fuel pump (6).
The "T" mark (5) must be in the 12 o'clock
position.
Teeth on the gearwheel (4) may be not concealed
at all by the positioning disc on the drive wheel for
the high-pressure fuel pump (6).
418 ► Attach the bearing pins (1) together with the
277879-001
gearwheel (3) to the crank case.
The dowel pin (7) must engage in the
corresponding hole on the crank case.
► Tighten the bolts (2).
► Install the special tool (IV).
The special tool must be inserted on the plugs on
the crank case and in the drilled holes on the
gearwheel (3) free of tension.
► Check the backlash between gearwheels (1) and

(2). Page 254
419
278528-001
277936-001 420

► Align the drive wheel for the high-pressure fuel
pump (5) and place the bearing pins (4) together
with the gearwheel (2) on the crank case.

01 Engine
1451-001
The "T" mark (7) on the positioning disc (6) must

be in the 12 o'clock position.
► Fit the bearing cover (3) and screw it on using
bolts (1).

► Slide the crankshaft gear (1) onto the
crankshaft (3) using the special tool (V).
The dowel pin on the crankshaft gear (1) must
engage in the crankshaft hole (2).
► Attach the special tool (III).
The special tool must be inserted on the plugs on
the crankshaft gear and on the crank case free of
tension.
► Secure the special tool (III) using a bolt.
421
277963-001
► Coat the bearing surfaces of the gearwheel (1),

the bearing pin (5) and the thrust washers (4) with
engine oil.
► Place thrust washers on both sides of the
gearwheel and slide them onto the bearing pins.
► Place the bearing pins together with the thrust
washers and gearwheel on the crank case.
► Fit the bearing cover and screw it on using
bolts (3).
422
277670-001
► Attach the cover (1) together with a new seal to

the cylinder head (2).
423
277709-001
► Remove the special tools (III), (IV) and

(V). Page 251
► Install the air compressor. Page 473
► Install the timing housing. Page 101

01 Engine
1451-001
Checking
► Clean the gearwheel (1), thrust washers (3) and
bearing pin (4), and check them for wear and
damage.
There must not be any visible evidence of run-in
on the bearing surfaces (5) or on the thrust
washers (4).
Replace the corresponding components if
necessary.
424
278314-001
► Clean the gearwheel (1) and bearing pin (3) and

check them for wear and damage.
on the bearing surfaces (4) of the gearwheel and
the bearing pin.
necessary.
425
278386-001

check for wear and damage.
on the bearing surfaces (3).
necessary.
426
278396-001

01 Engine
1451-001

check for wear and damage.
on the bearing surfaces (3).
necessary.
427
278454-001
278276-001 428
► Check the installation position of the

gearwheels (1), (2), (3) and (4) and the crankshaft
gear (5).
The teeth of the gearwheels (1), (2), (3) and (4)
and the crankshaft gear (5) must align with their
corresponding counterpiece.
► Check the crankshaft gear (5) for wear and
damage.
Replace the crankshaft gear if
necessary. Page 259
► Check the drive wheel of the high-pressure fuel
pump (6) for wear and damage.
Replace the drive wheel of the high-pressure fuel
pump if necessary. Page 299
► Check the drive wheel of the oil pump (7) for wear
and damage.
Replace the oil pump if necessary. Page 349
► Check the drive wheel of the outlet camshaft (9)
and inlet camshaft (10) for wear and damage.
Replace the camshafts if necessary. Page
189
► Check the drive wheel of the air compressor (8)
for wear and damage.
Replace the drive wheel of the air compressor if
necessary. Page 472

01 Engine
1451-001
Use special tools (I) and (II):

► Attach the dial gauge (I) to the cylinder head (1)
using a dial gauge holder (II).
► Position the check pin of the dial gauge on a tooth
of the gearwheel (2) with pre-tension.
► Turn the gearwheel (2) anti-clockwise until it
reaches the stop position.
► Set the clock gauge to zero.
► Turn the gearwheel (2) clockwise until it reaches
the stop position.
► Read the play on the dial gauge.
429 Backlash (a): Page 254
273777-001
Adjustment
► Remove cover (1).
► Undo the bolts (3) on the bearing pins (4).
► Adjust the backlash.
Backlash (a): Page 254
► To reduce the play, turn the bearing pins
clockwise (A).
► To increase the play, turn the bearing pins
anti-clockwise (B).
430 ► Check the backlash and adjust it if necessary.
273793-001
► Attach the cover (1) together with a new seal.
► Remove the dial gauge (I) and dial gauge

holder (II) from the cylinder head (1).
431
273796-001

01 Engine
0125 Injection - / Fuel system
1451-001

01 Engine
1451-001
178033-001
High-pressure lines and rail
Applies to:
Special tool

00 1998 568 0
432
272751-001

01 Engine
1451-001
272948-001 433

1 Rail
2 40 Nm Union nuts
3 30 Nm Hollow screw
4 High-pressure lines
5 Retainers
6 15 Nm Mounting bolts for the clamp
M8: 30 Nm
8 25 Nm Bracket mounting bolt
10 40 Nm Union nuts
11 40 Nm Union nut
12 40 Nm High-pressure line
13 40 Nm Union
14 Seal
15 15 Nm Mounting bolts for the seal
Tightening torques not specified, see "Introduction / Tightening torques" chapter

01 Engine
1451-001

16 Retainers
17 15 Nm Bracket mounting bolts
18 70 Nm B622-MB Rail pressure sensor
Removal

► Unscrew bolt (4).
► Remove the high-pressure lines (1) and (2)
together with the brackets (3).
434
272746-001
► Remove the oscillation damper (1).

► Remove the clamps (2).
435
272764-001
► Detach the fuel return line (1) from the rail (2).
436
272768-001

01 Engine
1451-001

► Unscrew the connector (3).
► Unscrew the nut (4) and detach the high-pressure
line (5).
Only if there is a leak in the seal (2):
► Unscrew the bolts (1) and remove the seal.
437
272779-001
► Seal all openings on the rail.
438
272831-001
439
272845-001

01 Engine
1451-001
► Unscrew the bolts (1) and remove the bracket (2)

and rail (3).
440
272839-001
Installation
► Tighten the rail (3) using a bracket (2) and
bolts (1) until it is hand-tight.
The cast arrows on the brackets must point
upwards.
441
272839-001

► Coat the inside of the new seal (2) with engine oil.
► Attach the new high-pressure line (5) and screw
on the connectors (3).
442
272779-001

01 Engine
1451-001
► Screw on the rail (3) using a bracket (2) and

bolts (1).
443
272839-001
► Attach the fuel return line (1) to the rail (2) with
new sealing rings.
444
272768-001
► Screw the bracket (1) onto the rail (3) using

bolts (2).
► Tighten the clamp (5) using bolts (4) until it is
hand-tight.
445
272877-001
► Attach the oscillation damper (1) to the new high-

pressure lines (2) and (3).
Replace the oscillation damper if necessary.
► Screw the oscillation damper onto the
straight piece downstream of the first bend
with a value A of approx. 15°.
446
272879-001

01 Engine
1451-001

► Install the high-pressure lines (1) and (2).
► Screw the clamp (3) onto the bracket (4).
447
272894-001
► Connect the plug-in connections (1) and (2).
448
272831-001
449
272845-001
If the rail has been replaced:

► Reset the frequency counter for opening the
pressure relief valve using the CDS.
► Remove the CDS.
least 1 minute.

01 Engine
1451-001

question.

01 Engine
1451-001
177832-001
High-pressure lines and rail
Applies to:
Special tool

00 1998 568 0
450
272751-001

01 Engine
1451-001
272948-001 451

1 Rail
2 40 Nm Union nuts
4 High-pressure lines
5 Retainers
6 15 Nm Mounting bolts for the clamp
M8: 30 Nm
10 40 Nm Union nuts
11 40 Nm Union nut
12 40 Nm High-pressure line
13 40 Nm Union
14 Seal
15 15 Nm Mounting bolts for the seal

01 Engine
1451-001

16 Retainers
18 70 Nm B622-MB Rail pressure sensor
Removal
► Remove the resonance vessel.
See the "Air compressor" chapter. Page 461

► Remove the high-pressure lines (1) and (2)
together with the brackets (3).
452
272746-001
► Remove the oscillation damper (1).

► Remove the clamps (2).
453
272764-001
► Detach the fuel return line (1) from the rail (2).
454
272768-001

01 Engine
1451-001

► Unscrew the connector (3).
► Unscrew the nut (4) and detach the high-pressure
line (5).
Only if there is a leak in the seal (2):
► Unscrew the bolts (1) and remove the seal.
455
272779-001
► Seal all openings on the rail.
456
272831-001
457
272845-001

01 Engine
1451-001
► Unscrew the bolts (1) and remove the bracket (2)

and rail (3).
458
272839-001
Installation
► Tighten the rail (3) using a bracket (2) and
bolts (1) until it is hand-tight.
The cast arrows on the brackets must point
upwards.
459
272839-001

► Coat the inside of the new seal (2) with engine oil.
► Attach the new high-pressure line (5) and screw
on the connectors (3).
460
272779-001

01 Engine
1451-001
► Screw on the rail (3) using a bracket (2) and

bolts (1).
461
272839-001
► Attach the fuel return line (1) to the rail (2) with
new sealing rings.
462
272768-001
► Screw the bracket (1) onto the rail (3) using

bolts (2).
► Tighten the clamp (5) using bolts (4) until it is
hand-tight.
463
272877-001
► Attach the oscillation damper (1) to the new high-

pressure lines (2) and (3).
Replace the oscillation damper if necessary.
► Screw the oscillation damper onto the
straight piece downstream of the first bend
with a value A of approx. 15°.
464
272879-001

01 Engine
1451-001

► Install the high-pressure lines (1) and (2).
► Screw the clamp (3) onto the bracket (4).
465
272894-001
466
272831-001
467
272845-001
► Install the resonance vessel. Page 461

If the rail has been replaced:

► Remove the CDS.
least 1 minute.

01 Engine
1451-001

question.

01 Engine
1451-001
181555-001
Rail pressure relief valve
Applies to:

01 Engine
1451-001
281570-001 468

1 Rail
OM 470 LA Page 266
OM 471 LA Page 274
2 100 Nm Pressure relief valve
3 Seal
– Replace sealing rings in every installation
process.
Removal
LA). Page 460
LA). Page 461

01 Engine
1451-001
► Unscrew the pressure relief valve (1) on the

rail (2).
469
281582-001
Installation
► Install a new sealing ring (3).
► Screw the pressure relief valve (1) onto the
rail (2).
Hold the rail on the flange at the front.
470
281585-001

LA). Page 460
LA). Page 461
If the pressure relief valve has been replaced.

least 1 minute.
question.

01 Engine
1451-001
177738-001
Injectors
Applies to:
Work preparation
Utilities:
► Hot bearing grease
Tool:
► Protective clothing
► Fuel collecting container
Special tool

Extraction tool 1
00 1998 577 0
471
272537-001

Installation tool 1
00 1998 589 0
472
272596-001

01 Engine
1451-001
272662-001 473

1 Y608-MB (cylinder Injector
1 injector)
– Always remove only one injector at a
Y609-MB (cylinder time.
2 injector) – Replace sealing rings in every
installation process.
Y610-MB (cylinder
3 injector)
Y611-MB (cylinder
4 injector)
Y612-MB (cylinder
5 injector)
Y613-MB (cylinder
6 injector)
2 Seal
– Replace the seal with every installation.
3 Sealing ring (black)
4 Sealing ring (green)

01 Engine
1451-001

5 Seal
6 Mounting bolt for the clamping bracket
– Screw in the mounting bolts in two steps
in accordance with the tightening
specification.
Tightening specification (OM 470 LA, OM
471 LA, OM 473 LA):
1 20 Nm
2 90°
7 Clamping bracket
8 Retainers Page 266
9 Fuel line
OM 470 LA Page 266
OM 471 LA Page 274
10 Fuel line
OM 470 LA Page 266
OM 471 LA Page 274
Removal
► Open the cover on the compensating reservoir
and lower the coolant pressure.
► Close the cover on the compensating reservoir.
► Unscrew the bolts (4) and remove the line (3).

► Unscrew the bolts (2) and remove the bracket (1).
474
272511-001
► Remove the corresponding high-pressure line

from the rail to the injector.
See the "High pressure lines and rail (OM 470
LA)" chapter. Page 266

01 Engine
1451-001
► Remove the fuel lines (1) and (2). Page 328
475
272523-001
► Mark the injector (Y608-MB to Y613-MB) in

relation to the corresponding cylinder.
► Unscrew the bolt (1) on the clamping bracket (2).
476
272534-001

► Guide the special tool (I) over the injector (Y608-
MB to Y613-MB).
477
272539-001

01 Engine
1451-001
► Insert the left and right gripper arms (2) into the
groove using the clamping bracket (3) on the
injector (Y608-MB to Y613-MB) and slide the
sleeve (1) downwards.
► Undo the injector in the cylinder head using the
special tool (I).
► Remove the injector together with the special tool
and clamping bracket.
► Close all openings in the cylinder head.
► Remove the special tool and clamping bracket
from the injector.
478
272542-001
► Remove sealing rings (1), (2), (3) and (4).

► Clean the injectors and check for wear.
Replace the injector if necessary.
► Close all openings on the injector.
► Keep injector in a suitable way.
479
272575-001

01 Engine
1451-001
Installation
► Assign the marked injectors to the cylinders.
► Install seal (1).

The recess on the sealing ring must face
upwards.
480
272587-001

► Slide the special tool (II) over the injector (Y608-
MB to Y613-MB).
► Coat the new black sealing ring (1) with hot
bearing grease.
► Roll the sealing ring over the special tool into the
upper ring groove of the injector.
► Remove the special tool and check the installation
position of the sealing ring.
The sealing ring must not be twisted when fitted in
the ring groove.
481
272595-001

01 Engine
1451-001
► Slide the special tool (II) over the injector (Y608-

MB to Y613-MB).
► Coat the new green sealing ring (1) with hot
bearing grease.
lower ring groove of the injector.
The sealing ring must not be twisted when it is
fitted in the ring groove.
482
272601-001
► Slide the special tool (II) over the fuel supply pipe.
► Coat the new sealing ring (1) with hot bearing
grease.
ring groove of the injector.
The sealing ring must not be twisted when it is
fitted in the ring groove.
483
272608-001

01 Engine
1451-001
► Attach the clamping bracket (1) to the

injector (Y608-MB to Y613-MB).
► Coat the sealing rings on the injector with hot
bearing grease.
484
272613-001
► Insert and align the injector (Y608-MB to Y613-

MB) with the clamping bracket (1).
► Screw on the clamping bracket using a new
bolt (2).
Tightening torque (1st step): Page 286
► Undo the bolt (2) again.
485
272614-001
► Fit a new high-pressure line.


01 Engine
1451-001
► Screw on the clamping bracket (1) using a

bolt (2).
486
272614-001
► Screw down the bolt (1) on the cover seal (2).

487
272618-001
► Attach the fuel lines (1) and (2). Page 330
488
272523-001

172

01 Engine
1451-001

► Attach the line (3) and screw down the bolt (4).
489
272511-001
Only if new injectors were installed:

► Program the injectors using the CDS.

least 1 minute.
question.

01 Engine
1451-001
178558-001
Protective sleeve
Applies to:
Special tool

1 Claw key 1
00 1998 571 0
490
274309-001

01 Engine
1451-001
274308-001 491

I Special tool
1 50 Nm Protective sleeve
2 O-ring
Apply a thin coat of grease to the O-ring.
Removal
► Remove the injector. Page 287

01 Engine
1451-001

► Remove the protective sleeve (1) using the
special tool (I).
492
274311-001
Installation
► Clean the thread (1) on the protective sleeve (2).
493
274316-001
► Install a new O-ring (1).
494
274320-001

01 Engine
1451-001

► Install and screw on the protective sleeve (1)
using the special tool (I).
495
274311-001
► Install the injector. Page 290


01 Engine
1451-001
180602-001
Fuel high-pressure pump
Applies to:
Work preparation
Tool:
► Coolant collection container
Special tool

Fixing device 1
00 1998 594 0
496
279032-001

01 Engine
1451-001
279295-001 497

1 Fuel filter module Page 323
3 Retainers
OM 470 LA Page 315
OM 471 LA Page 319
5 B602-MB Fuel temperature sensor
6 Union nuts for the high-pressure lines
OM 470 LA Page 267
OM 471 LA Page 275
7 Fuel lines Page 325
8 30 Nm Flange mounting bolts for the fuel lines
9 Flange
10 60 Nm Mounting bolts for the high-pressure fuel pump
11 Fuel high-pressure pump

01 Engine
1451-001

12 30 Nm Mounting bolts for the bracket on the high-
pressure fuel pump
14 30 Nm Flange mounting bolts for the fuel lines
15 Seal
16 Marking
17 Drive gearwheel
18 Positioning disc
19 M6: 10 Nm Mounting bolts for the positioning disc
M8: 30 Nm
20 250 Nm Nut
Removal
► Drain the fuel from the fuel filter module.
LA). Page 461
► Remove air intake line (1).

► Detach the high-pressure lines (2) (OM 470
LA). Page 268
► Detach the high-pressure lines (2) (OM 471
LA). Page 276
► Detach the fuel lines (4) with the
flange (5). Page 300
► Detach the fuel lines (6). Page 300
cylinder.
498 See Cranking the engine. Page 60
278941-001 ► Disconnect the plug-in connection (7) on the flow
control valve (Y642-MB) and expose the engine
line set (8).

01 Engine
1451-001
► Remove coolant line (1).

Collect any escaping coolant.
499
272011-001

► Remove the bracket (2) and remove the high-
500
278958-001
Removing the drive gearwheel

► Attach the high-pressure fuel pump (1) to the
special tool (I).
Attach the corresponding adapter (3) for the drive
gearwheel (2).
501
279033-001

01 Engine
1451-001
► Slacken off nut (1).

Do not unscrew the nut.
► Pull off the drive gearwheel (2).
► Remove nut (1).
► Remove the drive gearwheel and parallel key (3).
► Check the drive gearwheel for damage.
If the drive gearwheel is damaged, check the counter
gearwheel in the crank case for damage.
► Rotate the engine by two revolutions.
► Lock the engine in ignition TDC for the first
cylinder.
502
279047-001 ► Check the counter gear in the crank case for
damage.
► Remove the positioning disc (4).
If the drive gearwheel or positioning disc (4) is
replaced:
► Unscrew the bolts (5) and remove the positioning
disc (4).
Installing the drive gearwheel

► Attach the positioning disc (1) on the drive
gearwheel (2).
► Ensure that the designation (3) faces away
from the high-pressure fuel pump (6).
► Screw on the positioning disc using new bolts (4).
► Install parallel key (5).
► Attach the drive gearwheel (2).
► Attach the high-pressure fuel pump (6) to the
special tool (I).
Attach the corresponding adapter (7) for the drive
gearwheel (2).
503
279063-001

01 Engine
1451-001
504
279066-001
Installation
cylinder.
► Install a new sealing ring (1) on the high-pressure

fuel pump (2) and lightly coat it with clean engine
oil.
► Check that the designations (3) and (4) are
aligned with each other.
► Turn the drive gearwheel (5) if necessary.
► The recess on the positioning disc (6) can
only be pushed past the gearwheel in the
crank case if it is in this position.
► Insert the bolts into the flange of the high-
pressure fuel pump.
505
279090-001
279113-001 506
► Insert the high-pressure fuel pump into the crank

case (1).
► The drive gearwheel (2) must engage in the
gearwheel (3).
► Screw the high-pressure fuel pump onto the crank
case.

01 Engine
1451-001
► Screw the bracket (1) onto the high-pressure fuel

pump (3) using bolts (4).
► Screw the bracket (1) onto the crank case (2)
using bolts (5).
507
279124-001
► Attach the coolant line (1) together with a new

sealing ring.
► Screw on the coolant line (2) using a clamp (3)
and bolts (4).
508
279129-001
► Connect the plug-in connection (7) to the flow

control valve (Y642-MB).
► Remove the cranking tool. Page 74
► Install the fuel lines (6) together with new O-rings.
► Attach the fuel lines (4) together with new O-rings
and flange (5).
Replace the flange if necessary.
► Install the high-pressure lines (2) (OM 470
509 LA). Page 270
278941-001 ► Install the high-pressure lines (2) (OM 471
LA). Page 278
► Install the air intake line (1).
► Attach the resonance vessel (OM 471

LA). Page 461
question.
If the high-pressure fuel pump has been replaced:

► Reset the programmed values for the high-
pressure fuel pump using the CDS.

01 Engine
1451-001

least 1 minute.
question.

01 Engine
1451-001
182059-001
2-step valve
Applies to:
282602-001 510

1 35 Nm 2-step valve
2 Seal
– Coat the sealing ring with fuel.
3 Seal
4 2-step valve for the piston
– Check whether the piston can move freely
and replace the 2-step valve if necessary.
5 Plug-in connection for the fuel temperature Page 300
sensor
6 Flange
7 Air intake line Page 460

01 Engine
1451-001

Removing:
– Drain the fuel from the fuel filter module.
– Remove the air intake line (7). Page 460
– Disconnect connector (5).
– Remove the fuel lines (8). Page 301
Installing:
– Attach the fuel lines (8). Page 304
– Connect the plug-in connection (5).
– Attach the air intake line (7). Page 460

01 Engine
1451-001
182056-001
Fuel pump
Applies to:
Work preparation
Tool:
Special tool

Socket 1
00 1992 865 0
511
282578-001

01 Engine
1451-001
282575-001 512

1 Fuel filter module Page 323
2 20 Nm B602-MB Fuel temperature sensor
4 Fuel pump
5 8 Nm Fuel pump mounting bolts
6 Drive flange
7 Seal
– Replace seal in every installation process.
Removal

01 Engine
1451-001
► Remove bracket (1).

► Remove the fuel lines (2) and (3).
See the "Fuel filter module" chapter. Page
328
See the "High-pressure fuel pump"
chapter. Page 301
513
282569-001
► Unscrew the bolts (1) and remove the fuel

pump (2).
Collect any escaping fuel.
514
282571-001
Installation
282572-001 515
► Install new seal (3).

► Align the drive flange (4) with the drive in the high-
► Bolt down fuel pump (2) with bolts (1).

01 Engine
1451-001

► Attach the new sealing rings to fuel lines (2) and
(3).
See the "Fuel filter module" chapter. Page
330
See the "High-pressure fuel pump"
chapter. Page 304
► Install bracket (1).
516
282569-001

question.
least 1 minute.
question.

01 Engine
1451-001
182061-001
Pressure relief valve
Applies to:
282636-001 517

1 35 Nm Pressure relief valve
2 Seal
3 Pressure relief valve for the piston
– Check whether the piston can move freely
and replace the pressure relief valve if
necessary.

01 Engine
1451-001
Removing:
– Drain the fuel from the fuel filter module.
– Remove the fuel lines (4). Page 301
Installing:
– Attach the fuel lines (4). Page 304

01 Engine
1451-001
180504-001
Fuel controller valve
Applies to:
Work preparation
Tool:

01 Engine
1451-001
278572-001 518

2 Mounting bolts for the flow control valve
1 4 Nm
2 8 Nm
4 Seal
Removal

01 Engine
1451-001

► Disconnect the plug-in connection (3) on the flow
519
278558-001
► Remove the bracket (1) on the high-pressure fuel

pump (2) and on the crank case.
► Remove the flow control valve (Y642-MB) from
the housing flange (2).
520
278566-001
Installation
► Coat the new sealing rings (1) with fuel and insert
them.
521
278568-001

01 Engine
1451-001
► Insert the flow control valve (Y642-MB) in the

housing flange (2) and tighten the bolts (3).
► Attach the bracket (1) to the high-pressure fuel
pump (2).
► Install the bracket (1) on the crank case.
522
278566-001

523
278558-001

question.
If the flow control valve has been replaced:


least 1 minute.
question.

01 Engine
1451-001
180491-001
Fuel controller valve
Applies to:
Work preparation
Tool:

01 Engine
1451-001
278572-001 524

2 Mounting bolts for the flow control valve
1 4 Nm
2 8 Nm
4 Seal
Removal
► Remove the fuel filter module. Page 328

01 Engine
1451-001
► Remove the bracket (2) on the fuel filter

module (1).
► Disconnect the plug-in connection (5) on the flow
525
278647-001
► Remove the bracket (1) on the high-pressure fuel

pump (2) and on the crank case.
► Remove the flow control valve (Y642-MB) from
the housing flange (2).
526
278566-001
Installation
► Coat the new sealing rings (1) with fuel and insert
them.
527
278568-001

01 Engine
1451-001
► Insert the flow control valve (Y642-MB) in the

housing flange (2) and tighten the bolts (3).
► Attach the bracket (1) to the high-pressure fuel
pump (2).
► Attach the bracket (1) to the crank case.
528
278566-001
► Attach the fuel filter module (1). Page 330

► Install coolant line (6).
► Attach the bracket (2) to the fuel filter
module (1). Page 325
529
278647-001

question.
If the flow control valve has been replaced:


least 1 minute.
question.

01 Engine
1451-001
177576-001
Fuel filter module
Applies to:
Work preparation
Utilities:
► Multi-purpose transmission oil, e.g.:
CLAAS AGRISHIFT 4 SC SAE 80 W - 90 -
00 0147 373 0
Tool:
► Assembly pins (I) (2 pieces), self-made (attach
the fuel filter module)
Auxiliary tool (I)

A M8 x 1.25 (OM 470 LA)
M10 x 1.5 (OM 471 LA and OM 473 LA)
B 15 mm
C 50 mm
D Ø 8 to 8.5 mm or 10 to 10.5 mm
530
Assembly pins for installing the fuel filter module 272054-001
Special tool

Counter-bracket 1
00 1998 570 0
531
273084-001

01 Engine
1451-001

00 1998 568 0
532
272751-001

01 Engine
1451-001
282489-001 533

01 Engine
1451-001

1 8,5 kg Fuel filter module
2 Fuel line
3 Fuel line
4 Fuel line
5 30 Nm Fuel lines hollow screws
6 55 Nm Screw neck for the cylinder head
7 25 Nm Union nut for the fuel line
8 Fuel lines
9 30 Nm Hex. bolts
10 M8: 30 Nm Hex. bolts
M10: -
11 30 Nm Hex. bolt
12 20 Nm B638-MB Fuel filter module pressure sensor
13 30 Nm Mounting bolt for the coolant line clamp
14 60 Nm Union nut for the fuel line
15 Fuel cooler
16 Mounting bolts for the fuel cooler
Tightening diagram:
– Tighten the mounting bolts until they are
hand-tight.
– Tighten the mounting bolts (16.1 - 16.6) in
the specified order (16.1 - 16.6) in two steps
in accordance with the tightening
specification.
1 5 Nm
2 12 Nm
17 Seal
– The seal should not be coated with oil or
fuel.
Replace seal in every installation process.
18 Seal
fuel.
19 Seal
fuel.

01 Engine
1451-001

20 15 Nm Hand pump
21 Seal

01 Engine
1451-001
Removal
► Drain the fuel from the fuel module (1).

534
271937-001
► Disconnect the plug-in connection (1) on the

sensor (B638-MB).
535
271941-001

► Remove clamp (2).
536
271997-001

01 Engine
1451-001
537
271998-001

► Unscrew the bolts (2) and (3).
538
272006-001

539
272008-001

540
272011-001

01 Engine
1451-001
► Unscrew the bolts (1) and pull the fuel filter

module (2) upwards and remove it.
541
272030-001
Installation
272076-001 542
Use the auxiliary tool (I) (assembly pins). Page

323
► Oil the coolant hole (1) on the crank case and the
new sealing nozzles (2) with CLAAS AGRISHIFT
4 SC SAE 80 W - 90. Page 323
► Insert the sealing nozzles (2) into the connector
on the fuel cooler (3).
► Screw the auxiliary tool (I) into the tapped
holes (4).
► Attach the fuel filter module (1) and tighten the

bolts (2) until they are hand-tight.
► Unscrew the auxiliary tool (I) and tighten the
► Tighten the bolts (2) and (3).
543
272089-001

01 Engine
1451-001
544
272011-001

(3).
► Tighten bolt (1).
545
272008-001

(2).
546
272096-001
► Attach the new sealing rings to the fuel lines (1),

(2) and (3).
547
272104-001

01 Engine
1451-001
► Screw on the clamp (2) using bolts (1).

548
271997-001
► Connect the plug-in connection (1) to the

sensor (B638-MB).
549
271941-001

(2).
550
272149-001

question.
least 1 minute.
question.

01 Engine
0130 Lubricating oil system
1451-001

01 Engine
1451-001
181851-001
Lubricating oil system
Applies to:
Special tool

Adapter 1
00 1992 893 0
551
282185-001

Oil filling container 1
00 1992 872 0
552
282187-001

01 Engine
1451-001
282184-001 553

1 Oil suction manifold
2 Crankshaft bearing lubrication point
3 Oil spray nozzle Page 338
4 Oil thermostat Page 352
5 Oil cooler Page 347
6 Oil filter
See "Oil coolant module" Page 340
7 Camshaft bearings lubrication points
8 Intake rocker arm axle Page 227
9 Outlet rocker arm axle Page 233
10 Auxiliary power take-off lubrication point
11 Turbo Compound transmission lubrication
(OM 473 LA only)
12 Oil separator for the crankcase breather
OM 470 LA Page 103
OM 471 LA Page 112
13 Oil pump Page 349

01 Engine
1451-001
Pre-filling
Special tools (I) and (II). Page 334
► Unscrew the screw plug (2) on the oil coolant
module (1).
► Screw on the special tool (I) with a sealing ring.
► Attach the hose from the special tool (II) to the
special tool (I).
► Fill the oil reservoir (II) with engine oil according to
the instructions in the Operator's Manual for the
machine in question.
► Charge the oil container (II) to an overpressure of
around 2.5 bar using the built-in hand pump.
554 ► The shut-off valve (3) must be closed.
OM 470 LA 282190-001 ► Open the shut-off valve (3) on the special tool (II)
until approx. 5 litres of engine oil have been
pumped into the oil channels.
► Do not let the pressure in the oil container
drop below 1.5 bar.
► Do not empty the oil container completely as
otherwise air is pushed into the lubricating oil
system.
555
OM 471 LA 282192-001
► Top up the engine oil using the filler neck as

specified in the relevant Operator's Manual.
► Check the engine oil level as specified in the
Operator's Manual in question.
► Remove the hose for the special tool (II) from the
special tool (I).
► Unscrew the special tool (I) together with the
sealing ring.
► Screw the screw plug (2) together with a new
sealing ring to the oil coolant module (1).
Tightening torque: 70 Nm
556
OM 470 LA 282190-001

01 Engine
1451-001
557
OM 471 LA 282192-001
► Rotate the diesel engine with the electric starting

motor.
► Carry out a compression test using the CDS.
► Repeat this process approximately three
times.
► This process ensures that the system is filled
with engine oil before the engine is started.
► Disconnect the CDS from the machine.
► Carry out a test run.
Operator's Manual in question.

01 Engine
1451-001
181862-001
Oil spray nozzle
Applies to:
282210-001 558

1 Piston cooling oil spray nozzle
– Check whether the oil spray nozzle is clear,
and clean or replace it if necessary.
– If the oil spray nozzle was damaged during
assembly work, replace the nozzle.
– If the cylinder liner is removed, it is
recommended that the nozzle be replaced.
2 30 Nm Mounting bolt for the oil spray nozzle
Removal:
– Remove oil pan. Page 80
– Remove the oil pump. Page 350
– Turn the crankshaft until the oil spray nozzle
which is to be removed can be accessed.

01 Engine
1451-001
- See the "Cranking the engine"

chapter. Page 60
Installation:
– Remove the cranking tool.
- See the "Cranking the engine"
chapter. Page 60
– Install the oil pump. Page 351
– Install the oil pan. Page 82

01 Engine
1451-001
181884-001
Oil coolant module
Applies to:
Work preparation
Tool:
► Engine oil collection container
► Assembly pins (I) (2 pieces), self-made
Auxiliary tool (I)

A M8 x 1.25 (OM 470 LA)
M10 x 1.5 (OM 471 LA)
B 15 mm
C 50 mm
D Ø 8 to 8.5 mm or 10 to 10.5 mm
559
Assembly pins for installing the oil coolant module 272054-001

01 Engine
1451-001
282333-001 560

01 Engine
1451-001

1 55 Nm Oil filter lid
2 70 Nm Drain plug (OM 470 LA)
2 50 Nm Drain plug (OM 471 LA)
3 Oil coolant module
4 Coolant hose
5 Coolant hose
6 Coolant line
7 B607-MB Coolant inlet temperature sensor
8 Seal
– Replace for every assembly.
9 Oil filter insert
10 Oil cooler Page 347
11 Seal
12 Seal
13 Seal
14 Cover
15 Connector
16 Mounting bolts for the oil coolant module
Tightening diagram:
– Tighten the bolts (16.1 - 16.11) in the
specified order (16.1 - 16.11) in two steps in
accordance with the tightening specification.
1 10 Nm
2 60 Nm

01 Engine
1451-001
Removal
► Let the engine cool down.
► Remove the charge air tube.
See the "Charge air housing" (OM 470 LA)
chapter. Page 435
chapter. Page 444
282272-001 561
► Unscrew lid (1).

► Drain the coolant from the drain plug (2) of the oil
coolant module (3).
► Remove the coolant hoses (4) and (5).
sensor (B607-MB).
► Remove the coolant flow tube to the exhaust gas

recirculation cooler (OM 470 LA). Page 370
► Remove the coolant flow tube to the exhaust gas
► Remove any machine drive belts that may be in
the way if required.
question.

01 Engine
1451-001
► Remove the oil coolant module (1).

Collect any escaping engine oil.
Only if the oil coolant module is replaced:
► Remove the coolant thermostat (2) on the oil
coolant module (1). Page 364
562
282295-001
Installation
Only if the oil coolant module is replaced:

► Attach the coolant thermostat (2) to the oil coolant
module (1) together with a new sealing
ring. Page 365
563
282295-001
282314-001 564
Use the auxiliary tool (I) (assembly pins). Page

340
► Screw the auxiliary tool (I) onto the crank case
using the two opposite tapped holes.
► Attach the oil coolant module (2) and screw in the
upper bolts.

01 Engine
1451-001
Before installation, fit a new cable strap to each

bracket (3).
► Unscrew the auxiliary tool (I) and screw down the
bolts for the oil coolant module in accordance with
the tightening diagram.

question.
► Install any machine drive belts that may have
been in the way if applicable.
► Install the coolant flow tube to the exhaust gas
► Install the coolant flow tube to the exhaust gas
282272-001 565

sensor (B607-MB).
► Attach the coolant hoses (4) and (5).
► Screw on the drain plug (2) for the oil coolant
module (3) together with a new sealing ring.
► Bolt down the cover (1).
► Attach the charge air tube.

chapter. Page 438
chapter. Page 447
► Top up engine oil as specified in the relevant
Operator's Manual.
least 1 minute.

01 Engine
1451-001

question.

01 Engine
1451-001
181933-001
Oil cooler
Applies to:
282337-001 566

1 Oil coolant module
2 30 Nm Mounting bolt for the oil cooler (OM 470 LA)
2 20 Nm Mounting bolt for the oil cooler (OM 471 LA)
3 Oil cooler
– Replace the oil cooler if it is damaged.
4 Sealing rings
Removing:
– Remove the oil coolant module. Page 343

01 Engine
1451-001
Installing:
– Clean the sealing faces. Page 20
– Install the oil coolant module. Page 344

01 Engine
1451-001
181871-001
Oil pump
Applies to:
282214-001 567

1 Oil pump
2 Oil suction manifold
3 Oil pipe (delivery side)
4 Oil pipe (suction side)
5 Seal
6 Seal
7 Seal
8 30 Nm Oil pump mounting bolts

01 Engine
1451-001

9 OM 470 LA Mounting bolts for the oil suction manifold
M10: -
Light alloy
OM 471 LA
M10: 60 Nm
9 OM 470 LA Mounting bolts for the oil suction manifold
M8: 30 Nm
Plastic
OM 471 LA
M8: 30 Nm
Removal

► Remove the oil pump (2) together with the oil
suction manifold (3) and the oil pipes (4) and (5).
568
282221-001
Disassembly
► Clean the oil filter on the oil suction pipe for the oil
suction manifold (2).
► Remove the oil suction manifold (2) from the oil
pipes (3) and (4).
► Remove the oil pipes (3) and (4) from the oil
pump (1).
► Remove the sealing rings (5) and (6).
► Clean the oil pump, oil suction manifold and oil
pipes and check them for wear.
Replace the components if necessary.
569
282225-001

01 Engine
1451-001
Assembly
► Install new sealing rings (5) and (6) on the oil
pipes (3) and (4).
Lightly coat the sealing rings with engine oil.
► Insert the oil pipes into the oil pump (1).
► Insert the oil pipes into the oil suction manifold (2).
570
282225-001
Installation
282226-001 571

► Fill the oil pump (1) with engine oil.
► Attach the oil pump (1) together with the oil
suction manifold (2) and the oil pipes (3) and (4).


01 Engine
1451-001
181934-001
Oil thermostat
Applies to:
Special tool

Socket 1
00 1998 586 0
572
282342-001
282338-001 573

01 Engine
1451-001

1 Oil filter lid Page 341
2 Cover
3 50 Nm Oil thermostat

01 Engine
1451-001
Removal
► Open the oil filter cover (1).
Clean the oil filter cover before opening it.
Opening the oil filter cover will release the oil
return valve, causing engine oil to run into the
crank case.
► Remove cover (2).
► Unscrew the oil thermostat (3).
574
282339-001
Installation

► Screw on the oil thermostat (3) together with a
new sealing ring.
► Attach the cover (2) together with a new seal.
► Screw on the oil filter cover (1).
575
282339-001

01 Engine
0135 Cooling system
1451-001
0135 Cooling system

01 Engine
0135 Cooling system
1451-001
176607-001
Coolant
Special tool

1 Cleaner 1
00 0147 907 0
576
253134-001
Special tool (VI) Pcs.

1 Ring spanner insert 1
00 1998 568 0
577
268239-001

01 Engine
0135 Cooling system
1451-001
269199-001 578

1 30 Nm Coolant drain plug OM 471 LA
– Screw in bolts with a new sealing ring.
Draining
► Drain the coolant from the machine radiator.
question.
157892-002
WARNING! Drain the coolant from the engine block.

Danger of skin and eye injury from hot coolant.
Danger of poisoning when swallowed.
► Open the cooling system only if the coolant
temperature is below 90 °C.
► Open the cooling system slowly and relieve the
excess pressure.
► Wear protective clothing.
► Unscrew the coolant drain plug carefully and drain
coolant.
► Refit the plug immediately after draining.
► Tightening torque: Page 357
Filling up
► Top up coolant only as described in the
Operator's Manual of the machine in question.
Cleaning the coolant circuit

► Start the diesel engine and bring it to operating
temperature.
Then stop the diesel engine.
► Disconnect the battery isolating switch of the
machine.
► Park the machine safely and secure it against
rolling away.

01 Engine
0135 Cooling system
1451-001
► To allow the oil to precipitate upwards, allow a 30-

minute rest period.
► Check if there is oil in the cooling system
compensating tank.
Withdraw coolant from the compensating tank if
required and dispose of it properly.
WARNING! Filling undiluted cleaning concentrate into
the cooling system. Damage to cooling system.
► Mix the cleaning concentrate with clear and warm
water outside of the cooling system.
► Produce a 3 % cleaning solution with cleaning
agent (00 0147 907 0) and clear, warm water.
Observe the coolant filling quantity for the
machine in question.
question.
► Remove the compensating tank.
► Flush the compensating tank with 3 % cleaning
solution.
After that, flush the compensating tank with warm
water.
► Install the compensating tank.
► Fill the coolant circuit with 3 % cleaning solution.
► Switch on the battery isolating switch of the
machine.
► Set the cab heater to maximum heating capacity.
► Start the diesel engine and heat up the coolant to
around 80 °C at medium speed.
► Maintain the coolant temperature at 80 °C for
about 5 minutes.
Cover up the radiator if required.
Ensure that a hydraulic oil cooler that may be
installed is not covered up in this process!
► Stop the diesel engine.
► Let the coolant cool down to around 50 °C.
► Drain the 3 % cleaning solution completely.
► Flush the coolant circuit with clear water at least
twice.
Let the diesel engine run for about 5 minutes with
every flushing filling.
Ensure that no cleaning solution remains in the
cooling system after the last flushing process.
If necessary, carry out further flushing processes
with clear water.

01 Engine
0135 Cooling system
1451-001
181165-001
Coolant pump
Applies to:
Work preparation
Tool:

01 Engine
0135 Cooling system
1451-001
280726-001 579

1 Coolant pump pulley
2 30 Nm Coolant pump mounting bolts
3 2,4 kg Coolant pump
4 25 Nm Pulley mounting bolts
5 M10: 60 Nm Guide roller mounting bolt
M16: 100 Nm
6 60 Nm Guide roller mounting bolt
Removal
question.

01 Engine
0135 Cooling system
1451-001
► Unscrew bolts (1) and remove pulley (2).
580
280662-001
► Unscrew bolts (1) and remove coolant pump (2).

581
280667-001
Installation
► Screw on the coolant pump (2) together with a
new seal (3) and bolts (1).
582
280667-001

01 Engine
0135 Cooling system
1451-001
► Screw on the belt pulley (2) with new bolts (1).

583
280662-001

question.
► Start the diesel engine.
► Run the diesel engine until the operating
temperature is reached.
► Check tightness of coolant pump.
► Check coolant level as described in the relevant
Operator's Manual.

01 Engine
0135 Cooling system
1451-001
181944-001
Coolant thermostat
Applies to:

01 Engine
0135 Cooling system
1451-001
282356-001 584

1 Coolant pump Page 359
2 Oil coolant module Page 340
3 Coolant thermostat
4 30 Nm Mounting bolts for the coolant thermostat
Removal
► Remove the charge air tube.
chapter. Page 435
chapter. Page 444

01 Engine
0135 Cooling system
1451-001
► Remove the coolant thermostat (1) from the oil

coolant module (2).
► Remove the coolant hose (3).
585
282375-001
Installation
► Attach the coolant thermostat (1) to the oil coolant
module (2) together with a new sealing ring.
► Attach the coolant hose.
586
282375-001
► Attach the charge air tube.

chapter. Page 438
chapter. Page 447
► Check tightness of thermostat housing.
Operator's Manual.

01 Engine
0140 Exhaust system
1451-001
0140 Exhaust system

176664-001
Exhaust gas return cooler
Applies to:
Special tool

Leakage test device 1
00 1998 593 0
587
269858-001

Pressure pump 1
00 1998 565 0
588
269855-001

01 Engine
0140 Exhaust system
1451-001
269265-001 589

01 Engine
0140 Exhaust system
1451-001

1 Coolant hose
2 35 Nm Coolant nozzle
0 bar Pressure drop at a test pressure of 1.5 bar and
a test time of 2 minutes
4 Coolant flow tube
5 Connecting piece
6 Coolant discharge nozzle
7 Sealing rings
– Replace the sealing rings during assembly.
9 Support
10 Clamps
11 Heat safety guard Page 415
12 Electrical cable
13 Brackets
14 Exhaust turbo charger Page 414
15 Hex. bolts
16 Heat safety guard Page 415
17 Connecting rod Page 394
18 Exhaust gas recirculation valve Page 394
19 12 Nm Clamp
20 Exhaust manifold Page 401
22 B621-MB Exhaust gas recirculation differential pressure Page 400
sensor
24 2 Nm Clamps
25 Exhaust gas recirculation hose
27 Charge air tube Page 433
28 30 Nm Hex. bolts
29 Coolant hose
30 Clamp
31 30 Nm Mounting bolts for the coolant flow tube

01 Engine
0140 Exhaust system
1451-001

32 Coolant flow tube
33 Clamp
34 Coolant hose
M10: 60 Nm
37 B606-MB Coolant outlet temperature sensor

01 Engine
0140 Exhaust system
1451-001
Removal
► Switch off the ignition.
machine.
► Remove the coolant hose (1).
590
269286-001

► Remove the connecting rod (1).

396
591
269349-001
► Undo the bolts (5) on the clamps (3).

► Detach the exhaust gas recirculation line (1) from
the exhaust gas recirculation cooler (2).
► Remove the exhaust gas recirculation line (1)
from the exhaust manifold (4).
592
269765-001

01 Engine
0140 Exhaust system
1451-001
► Undo the line (1) from the exhaust gas

recirculation line (3).
593
269627-001
► Unscrew the bolts (1) from the exhaust gas

594
269641-001
► Undo the clamp (1) on the exhaust gas

recirculation hose (2).
595
269650-001
► Remove the exhaust gas recirculation lines (1)

and (3) together with the exhaust gas recirculation
hose (2).
596
269658-001

01 Engine
0140 Exhaust system
1451-001
► Undo the bolt (1) for the clamp on the coolant

hose (2).
597
281920-001

► Pull the coolant flow tube (2) sideways out of the
coolant hose (3).
► Pull the coolant flow tube (2) sideways out of the
exhaust gas recirculation cooler (4).
598
281923-001

► Pull off the coolant hose (2).
► Pull the coolant flow tube (4) out of the coolant
hose (6).
599
281925-001

► Swivel the clamps (2) upwards and pull the
exhaust gas recirculation cooler (3) upwards and
remove it.
600
269706-001

01 Engine
0140 Exhaust system
1451-001
Installation
► Install new sealing rings on the coolant nozzle (2).

► If the exhaust gas recirculation cooler (1) is
replaced, install new coolant nozzles (2).
► For the tightening torque, see: Page 367
601
269720-001
► Install the exhaust gas recirculation cooler (3) and

swivel the clamps (2) downwards.
602
269707-001
► Replace the coolant hose (6) and clamps if

necessary.
► Insert the coolant flow tube (4) into the coolant
hose (6).
► Install the coolant hose (2).
Replace the coolant hose if necessary.
603 Tightening torque: Page 367
281925-001 Replace the clamp if necessary.

01 Engine
0140 Exhaust system
1451-001
► Install a new connecting piece (1) in the coolant

flow tube (2).
604
281930-001
► Insert the coolant flow tube (2) into the coolant

hose (3) and exhaust gas recirculation cooler (4).
Replace the coolant hose and clamps if
necessary.
605
281923-001
► Screw down the bolt (1) for the clamp on the

coolant hose (2).
606
281920-001
► Install the exhaust gas recirculation lines (2) and

(4) together with the exhaust gas recirculation
hose (3).
► Replace the seal (5) on the charge air
tube (6).
► Replace the exhaust gas recirculation hoses (3)
and (7) and clamp (1) if necessary.
607
270177-001

01 Engine
0140 Exhaust system
1451-001

► Screw on the clamp (1) on the exhaust gas
recirculation hose (2).
608
269650-001
► Screw the bolts (1) to the exhaust gas

609
269641-001

► Screw the line (1) onto the exhaust gas
610
269627-001
► Attach the exhaust gas recirculation line (1)

together with the clamps (3) to the exhaust gas
recirculation cooler (2) and exhaust manifold (4).
► The clamp bolts (5) must be situated
underneath.
► Replace the clamps (3) if necessary.
611
269765-001

01 Engine
0140 Exhaust system
1451-001
► Install the connecting rod (1).

397
612
269349-001
► Install the protection panel.

► Attach the coolant hose (1).
613
269286-001

machine.
► Start the diesel engine and run it at a higher
speed.

01 Engine
0140 Exhaust system
1451-001
Checking
► Open the cover on the coolant compensating
reservoir to relieve the overpressure in the coolant
circuit.
► Slacken off clamp (1).

► Remove the exhaust gas recirculation line (3).
614
269876-001

the exhaust manifold (3).
615
269765-001

► Clean the interior of the exhaust gas recirculation
hose (2).
► Attach the locking device (1) to the exhaust gas
recirculation hose (2) using the clamp (3).
► Replace the clamp if necessary.
616
269883-001

01 Engine
0140 Exhaust system
1451-001

► Attach the flange (1) to the exhaust gas
recirculation cooler (2) using the clamp (3).
► Attach the pressure pump (4) to the flange (1).
► Pressurise the exhaust gas recirculation cooler (2)
with compressed air.
For test pressure, see: Page 367
The test pressure must not be exceeded.
617
269916-001
► Detach the locking device (1) from the exhaust

gas recirculation hose (2).
618
269923-001
► Detach the locking device (1) and pressure

pump (3) from the exhaust gas recirculation
cooler (2).
619
269927-001

underneath.
620
269765-001

01 Engine
0140 Exhaust system
1451-001
► Insert the exhaust gas recirculation line (3).

621
269876-001
► Close the cover for the coolant compensating

reservoir.
speed.
181566-001
Exhaust gas return cooler
Applies to:
Special tool

Leakage test device 1
00 1998 593 0
622
269858-001

Pressure pump 1
00 1998 565 0
623
269855-001

01 Engine
0140 Exhaust system
1451-001
281871-001 624

01 Engine
0140 Exhaust system
1451-001

0 bar Pressure drop at a test pressure of 1.5 bar and
a test time of 2 minutes
2 B621-MB Exhaust gas recirculation differential pressure Page 400
sensor
4 30 Nm Mounting bolts for the exhaust gas recirculation
line
5 30 Nm B606-MB Coolant outlet temperature sensor
6 30 Nm Coolant nozzle mounting bolts
7 Coolant nozzle
8 30 Nm Mounting bolts for the exhaust gas recirculation
cooler
Tightening diagram:
the specified order (8.1 - 8.17) until they are
hand-tight.
– Screw down the mounting bolts (8.1 - 8.17)
in the specified order (8.1 - 8.17).
10 Seal
– Replace the sealing ring during assembly.
11 Ring piece
12 Mounting bolts for the exhaust gas recirculation
cooler
14 12 Nm Pipe clamps
15 Seal
– Replace seal for installation.
16 Seal
17 Connecting piece
18 Coolant flow tube
19 Connecting piece
20 Clamp
22 Clamp

01 Engine
0140 Exhaust system
1451-001

24 M8: 30 Nm Mounting bolts for the exhaust gas recirculation
line
M10: 60 Nm
26 Retainers
28 2 Nm Clamp

01 Engine
0140 Exhaust system
1451-001
Removal
machine.
► Remove the charge air line from the exhaust turbo
charger.
► Detach the air intake pipe from the exhaust turbo
charger.
► Undo the bolt (1) on the clamps (2).

► Detach the exhaust gas recirculation line (3).
625
281759-001

sensor (B621-MB).
626
281760-001
► Undo the clamp bolts (1).
627
281765-001

01 Engine
0140 Exhaust system
1451-001
► Unscrew the bolts (1) on the exhaust gas

628
281768-001
► Unscrew the bolts (1) on the exhaust gas

► Detach the exhaust gas recirculation line (2) and
hose (3).
629
281771-001
► Unscrew the bolts (1) and remove the bracket (2).

► Pull the coolant flow tube (3) out of the connector
for the oil coolant module (4) and out of the
exhaust gas recirculation cooler (5).
630
281772-001
► Remove the coolant lines.


01 Engine
0140 Exhaust system
1451-001

sensor (B606-MB).
631
281790-001
► Undo the bolts (1) on the coolant nozzle (2).

The bolts cannot be pulled out.
632
281791-001
► Unscrew the bolts (1) and remove the protection

panel (2).
633
281793-001
► Unscrew the coolant line (1) on the exhaust gas

recirculation cooler (4).
► Slacken off bolts (2) and (3).
The bolts (2) cannot be unscrewed from the
exhaust gas recirculation cooler.
Only loosen the bolts; do not fully undo them (3).
► Pull the exhaust gas recirculation cooler upwards
and remove it.
634
281795-001

01 Engine
0140 Exhaust system
1451-001
281797-001 635
► Remove the seals (1) and (2) on the exhaust gas

► Unscrew the bolts (1) and remove the coolant

nozzle (2).
636
281804-001

01 Engine
0140 Exhaust system
1451-001
Installation
► Install a new seal (1) in the coolant nozzle (2).
637
281808-001
► Attach the coolant nozzle (2) and tighten the

638
281804-001
281797-001 639
► Fit the new seals (1) and (2) together with the
guide rods in the exhaust gas recirculation
cooler (3).

01 Engine
0140 Exhaust system
1451-001
► Install the exhaust gas recirculation cooler (4) and

tighten the bolts (2) and (3) in accordance with the
tightening diagram.
► Screw the coolant line (1) to the exhaust gas
640
281795-001
► Screw down the bolts (1) on the coolant

nozzle (2).
641
281804-001
► Attach the protection panel (2) and screw down

the bolts (1).
642
281793-001

sensor (B606-MB).
643
281790-001

01 Engine
0140 Exhaust system
1451-001
► Attach the coolant lines.

► Slide on the new connecting piece (2) until it

reaches the stop on the connector (4).
► Install a new connecting piece (1) in the coolant
flow tube (3).
► Insert the coolant flow tube (3) into the exhaust
gas recirculation cooler (5) and into the
connecting piece (2).
644
281816-001
► Install the exhaust gas recirculation line (2) and

hose (3).
Install a new seal on the exhaust gas recirculation
line (4).
Replace the exhaust gas recirculation hose (3)
and clamps if necessary.
645
281771-001

646
281768-001

01 Engine
0140 Exhaust system
1451-001
► Screw in the clamp bolts (1).

Replace the exhaust gas recirculation hose and
clamps if necessary.
647
281765-001

sensor (B621-MB).
648
281760-001
► Attach the exhaust gas recirculation line (3) using

clamps (2).
Replace the clamps if necessary.
The bolts (1) for the clamps must be situated
underneath.
► Screw in the clamp bolts (1).
649
281759-001

► Attach the air intake pipe to the exhaust turbo
charger.
► Install charge air line on the exhaust turbo
charger.
machine.
speed.

01 Engine
0140 Exhaust system
1451-001
Checking
circuit.

650
269876-001

the exhaust manifold (3).
651
269765-001

► Clean the interior of the exhaust gas recirculation
hose (2).
► Attach the locking device (1) to the exhaust gas
recirculation hose (2) using the clamp (3).
► Replace the clamp if necessary.
652
269883-001

01 Engine
0140 Exhaust system
1451-001

► Attach the flange (1) to the exhaust gas
recirculation cooler (2) using the clamp (3).
► Attach the pressure pump (4) to the flange (1).
► Pressurise the exhaust gas recirculation cooler (2)
with compressed air.
For test pressure, see: Page 380
The test pressure must not be exceeded.
653
269916-001
► Detach the locking device (1) from the exhaust

gas recirculation hose (2).
654
269923-001
► Detach the locking device (1) and pressure

pump (3) from the exhaust gas recirculation
cooler (2).
655
269927-001

underneath.
656
269765-001

01 Engine
0140 Exhaust system
1451-001
► Insert the exhaust gas recirculation line (3).

657
269876-001
► Close the cover for the coolant compensating

reservoir.
speed.

01 Engine
0140 Exhaust system
1451-001
176834-001
Exhaust gas recirculation actuator
Applies to:
269997-001 658

1 20 Nm Nuts
– Replace the nuts during assembly.
2 30 Nm Hex. bolts
3 Coolant lines
4 Exhaust gas recirculation valve
5 20 Nm Nuts
– Replace the nuts during assembly.
6 40 Nm Union nuts
7 Connecting rod
8 Y621-MB Exhaust gas recirculation actuator

01 Engine
0140 Exhaust system
1451-001

9 Lever
10 30 Nm Hex. bolt

01 Engine
0140 Exhaust system
1451-001
Removal
machine.
► Remove the exhaust pipe downstream of the
exhaust turbo charger.
► Remove the lever (1).

► Hold on the lever for undoing the nut (2).
659
270053-001
► Slacken off nuts (1).

► Remove the coolant lines (2).
► Collect any escaping coolant.
660
270062-001
► Undo the line (1) from the vent line (3).

661
270076-001

01 Engine
0140 Exhaust system
1451-001
► Unscrew the bolts (1) and (2) and remove the

662
270081-001
► Unscrew the nuts (1) and (3).

► Remove the connecting rod (4) from the lever (5)
and the exhaust gas recirculation valve (2).
663
270084-001
Installation
► Attach the connecting rod (4) to the lever (5) and

the exhaust gas recirculation valve (2).
► Tighten the nuts (1) and (3).
664
270084-001

01 Engine
0140 Exhaust system
1451-001
► Screw on the exhaust gas recirculation

actuator (3) using bolts (1) and (2).
Note the different lengths of the bolts (1) and (2).
665
270081-001

► Screw the line (1) onto the vent line (3).
666
270076-001
► Screw on the coolant lines (2) using nuts (1).

667
270062-001
► Screw on the lever (1) using the nuts (2).

668
270053-001

01 Engine
0140 Exhaust system
1451-001
► Attach the exhaust pipe downstream of the

exhaust turbo charger.
machine.
speed.

01 Engine
0140 Exhaust system
1451-001
176936-001
Differential pressure sensor
Applies to:
270452-001 669

1 Exhaust gas recirculation line Page 367
2 Electrical cable
M8: 20 Nm
4 B621-MB Exhaust gas recirculation differential pressure
sensor
– Replace the sealing rings during assembly.
Page 20

01 Engine
0140 Exhaust system
1451-001
181216-001
Exhaust manifold
Applies to:
Work preparation
Utilities:
► Copper paste

01 Engine
0140 Exhaust system
1451-001
280932-001 670

1 25 Nm Guard mounting bolts
2 Guard
3 Guard
4 25 Nm Exhaust manifold mounting bolts
Tightening diagram:
hand-tight.
– Screw the mounting bolts (4.1 - 4.24) in the
specified order (4.1 - 4.24) until they are
hand-tight.
5 Exhaust manifold
6 Flexible tube
7 Pipe clamps
8 Exhaust manifold
9 Guide bushing
10 Exhaust manifold mounting bolts
11 Exhaust manifold

01 Engine
0140 Exhaust system
1451-001

12 Guide bushing
13 Seal
– Observe the installation position of the seal.
14 Seal Page 20
15 Seal
16 Seal
Removal
machine.
charger.
charger.
► Remove the exhaust gas recirculation line
upstream of the exhaust gas recirculation
cooler. Page 370

panels (2).
671
280874-001

01 Engine
0140 Exhaust system
1451-001
► Unscrew the bolts (1) on the exhaust manifold (2).
672
280854-001
► Unscrew bolts (1) and remove washers (2).

► Remove the exhaust manifold (3) and the
seals (4).
673
280895-001
Installation
► Insert new seals (4).

► Fit exhaust gas manifold (3).
► Coat the new bolts (1) with copper paste.
► Screw on the new bolts (1) together with the new
washers (2) until they are hand-tight.
Note the different bolt lengths.
► Tighten the bolts in accordance with the tightening
diagram.
674
280895-001

01 Engine
0140 Exhaust system
1451-001
► Screw the bolts (1) onto the exhaust manifold (2).

675
280854-001
► Insert the protection panels (2).

676
280874-001
► Install the exhaust gas recirculation line upstream

of the exhaust gas recirculation cooler. Page
373
► Attach the charge air line from the exhaust turbo
charger.
charger.
machine.
least 1 minute.

01 Engine
0140 Exhaust system
1451-001
181253-001
Exhaust manifold
Applies to:
Work preparation
Utilities:
► Copper paste

01 Engine
0140 Exhaust system
1451-001
l 281492-001 677

2 Guard
3 Guard

01 Engine
0140 Exhaust system
1451-001

4 40 Nm Exhaust manifold mounting bolts
If the entire exhaust manifold (5, 8 and 11) is
installed:
Tightening diagram:
hand-tight.
If only the front section of the exhaust
manifold (11) is installed:
Tightening diagram:
– Tighten the mounting bolts (4.5 - 4.8) in the
hand-tight.
– Screw in the mounting bolts (4.5 - 4.8) in the
If only the rear section of the exhaust
manifold (5) is installed:
Tightening diagram:
hand-tight.
If only the centre section (8) and the rear
section (5) of the exhaust manifold is installed:
– Tighten the mounting bolts (4.1 - 4.4) in the
hand-tight.
hand-tight.
– Screw in the mounting bolts (4.1 - 4.4) in the
5 Rear section for the exhaust manifold
6 Flexible tube
7 7 Nm Pipe clamps
8 Centre section for the exhaust manifold
9 Guide bushing
10 Exhaust manifold mounting bolts
11 Front section for the exhaust manifold
12 Guide bushing

01 Engine
0140 Exhaust system
1451-001

13 Seal
14 Seal Page 20
15 Seal
16 Seal
17 Exhaust turbo charger Page 423
18 6 Nm Clamp for the air intake pipe
19 Air intake tube
Removal
machine.
charger.
charger.
► Disconnect the electrical cable (1) from the

temperature sensor downstream of the air
filter (B611-MB).
► Detach the air intake pipe (3) from the exhaust
turbo charger (4).
678
280998-001

01 Engine
0140 Exhaust system
1451-001
281059-001 679
► Remove the protection panel (1) on the centre

section (2) of the exhaust manifold.
► Remove the protection panel (3) on the front
► Unscrew the bolts (6) together with the discs (7)
and remove the front section (4) of the exhaust
manifold.
► Remove the exhaust turbo charger. Page

426
281064-001 680
► Remove the exhaust gas recirculation line (1)

cooler. Page 383
► Remove the protection panel (2) on the rear
and remove the rear section of the exhaust
manifold.

01 Engine
0140 Exhaust system
1451-001
281091-001 681
► Remove the connecting rod (1) on the

lever (2). Page 397
and remove the centre section (5) of the exhaust
manifold.
► Remove the seal (6), (7) and (8).
Only if the centre section of the exhaust manifold or
the connecting rod is replaced:
► Remove the connecting rod and lever.
Installation
281091-001 682
► Install a new seal (6), (7) and (8).

► Check the centre section (5) of the exhaust
manifold for damage and replace it if necessary.
► Attach the centre section (5) of the exhaust
manifold and screw it on using new bolts (3) and
new discs (4) in accordance with the tightening
diagram.

01 Engine
0140 Exhaust system
1451-001
281064-001 683

► Attach the rear section (3) of the exhaust manifold
and screw it on using new bolts (5) and new
discs (6) in accordance with the tightening
diagram.
► Screw on the new clamp (4).
► Attach the protection panel (2) to the rear
► Install the exhaust gas recirculation line (1)
cooler. Page 387
► Attach the exhaust turbo charger. Page 429
281059-001 684

► Attach the front section (3) of the exhaust
manifold and screw it on using new bolts (6) and
new discs (7) in accordance with the tightening
diagram.
► Screw on the new clamp (5).
► Attach the protection panel (3) to the front

01 Engine
0140 Exhaust system
1451-001

► Attach the protection panel (1) to the centre
► Attach the air intake pipe (3) to the exhaust turbo

charger (4).
Replace the clamp (2) if necessary.
► Connect the electrical cable (1) on the
temperature sensor downstream of the air
filter (B611-MB).
685
280998-001
► Install charge air line on the exhaust turbo

charger.
charger.
machine.

least 1 minute.

01 Engine
0140 Exhaust system
1451-001
178059-001
Exhaust turbo charger
Applies to:
Work preparation
Utilities:
► Copper paste
Tool:

01 Engine
0140 Exhaust system
1451-001
273590-001 686

01 Engine
0140 Exhaust system
1451-001

1 22,5 kg Exhaust turbo charger
2 Guard
4 Guard
5 Electrical cable
6 Brackets
8 50 Nm Exhaust turbo charger mounting bolts
10 Seal
11 35 Nm Oil pressure line hollow screw
process.
12 Line
process.
13 30 Nm Mounting bolt for the oil return line
14 Oil return line
16 Electric plug-in connection
17 M8: 25 Nm Mounting bolt for the exhaust turbo charger
M10: 60 Nm
18 M8: 25 Nm Mounting bolt for the crank case
M10: 60 Nm
19 Retainers
20 Oil feed line
process.
process.
23 Line on the charge pressure actuator

01 Engine
0140 Exhaust system
1451-001
Removal
► Unscrew the bolts (1) and take off the protection

panel (2).
687
268474-001

panel (2).
688
273233-001
► Remove the air intake lines.

► Remove the charge air lines.
► Remove the exhaust pipework.

► Unscrew the bolts (3) and detach the oil return
line (2).
689
273214-001

01 Engine
0140 Exhaust system
1451-001
► Remove seals (1) and (2).
690
273225-001
► Detach the line (2) from the bracket (1).

691
273230-001
► Unscrew bolts (1) and (2) and remove the

bracket (3).
692
273239-001
► Detach lines (1) and (2) from the charge pressure

actuator (Y636-MB).
693
273454-001

01 Engine
0140 Exhaust system
1451-001
► Unscrew bolts (1) and (3) and remove the oil

pressure line (2).
694
273361-001

► Remove the exhaust turbo charger (2) and the
seal (3).
695
273265-001

01 Engine
0140 Exhaust system
1451-001
Installation
► Check whether the oil pressure and oil return lines
are dirty or damaged and replace them if
necessary.
► Fill the bearing housing of the exhaust turbo
charger with engine oil and turn the exhaust turbo
charger shaft when doing so.
question.
► Coat the bolts (1) with copper paste.

► Screw on the exhaust turbo charger (2) and the
new seal (3) using bolts.
696
273265-001
► Screw on the oil pressure line (2) using new

sealing rings and bolts (1) and (3).
697
273361-001
► Attach the lines (1) and (2) to the charge pressure

actuator (Y636-MB).
698
273454-001

01 Engine
0140 Exhaust system
1451-001
► Attach new cable straps to the bracket (3).

► Tighten the bolts (1) and (2) until they are hand-
tight.
699
273239-001
► Fasten the line (2) to the bracket (1).

700
273230-001
► Install the new seals (1) and (4).

► Fasten the new cable straps (3) to the bracket (2).
701
273381-001
► Attach the oil return line (2) and tighten the

bolts (1) and (3) until they are hand-tight.
702
273214-001

01 Engine
0140 Exhaust system
1451-001
► Attach the exhaust pipework.

► Attach the charge air lines.
► Attach the air intake lines.
► Screw on the protection panel (2) using bolts (1).

703
273233-001

704
268474-001

least 1 minute.

01 Engine
0140 Exhaust system
1451-001
180745-001
Exhaust turbo charger
Applies to:
Work preparation
Utilities:
► Copper paste
Tool:

01 Engine
0140 Exhaust system
1451-001
279387-001 705

01 Engine
0140 Exhaust system
1451-001

1 22,5 kg Exhaust turbo charger
2 Guard
4 Guard
5 Electrical cable
6 Brackets
8 50 Nm Exhaust turbo charger mounting bolts
10 Seal
process.
12 Line
process.
14 Oil return line
17 M8: 25 Nm Mounting bolt for the exhaust turbo charger
M10: 60 Nm
18 M8: 25 Nm Mounting bolt for the crank case
M10: 60 Nm
19 Retainers
20 Oil feed line
process.
process.
23 Line on the charge pressure actuator
24 Retainers

01 Engine
0140 Exhaust system
1451-001
Removal
► Unscrew the bolts (1) and take off the protection

panel (2).
706
268474-001

panel (2).
707
273233-001
► Remove the air intake lines.

► Remove the charge air lines.
► Remove the exhaust pipework.

► Unscrew the bolts (3) and detach the oil return
line (2).
708
273214-001

01 Engine
0140 Exhaust system
1451-001
► Remove seals (1) and (2).
709
273225-001
► Detach the line (2) from the bracket (1).

710
273230-001
► Unscrew bolts (1) and (2) and remove the

bracket (3).
711
273239-001
► Detach lines (1) and (2) from the charge pressure

actuator (Y636-MB).
712
273454-001

01 Engine
0140 Exhaust system
1451-001
► Unscrew bolts (1) and (3) and remove the oil

pressure line (2).
713
273361-001

► Remove the exhaust turbo charger (2) and the
seal (3).
714
273265-001

01 Engine
0140 Exhaust system
1451-001
Installation
► Check whether the oil pressure and oil return lines
are dirty or damaged and replace them if
necessary.
► Fill the bearing housing of the exhaust turbo
charger with engine oil and turn the exhaust turbo
charger shaft when doing so.
question.
► Check the studs (1) on the exhaust turbo

charger (2).
Replace the studs if necessary.
715
279388-001
► Coat the bolts (1) with copper paste.

► Screw on the exhaust turbo charger (2) and the
new seal (3) using bolts.
716
273265-001
► Screw on the oil pressure line (2) using new

sealing rings and bolts (1) and (3).
717
273361-001

01 Engine
0140 Exhaust system
1451-001
► Attach the lines (1) and (2) to the charge pressure

actuator (Y636-MB).
718
273454-001
► Attach new cable straps to the bracket (3).

► Tighten the bolts (1) and (2) until they are hand-
tight.
719
273239-001
► Fasten the line (2) to the bracket (1).

720
273230-001
► Install the new seals (1) and (4).

► Fasten the new cable straps (3) to the bracket (2).
721
273381-001

01 Engine
0140 Exhaust system
1451-001
► Attach the oil return line (2) and tighten the

bolts (1) and (3) until they are hand-tight.
722
273214-001
► Attach the exhaust pipework.

► Attach the charge air lines.
► Attach the air intake lines.

723
273233-001

724
268474-001

least 1 minute.

01 Engine
0145 Air intake
1451-001
0145 Air intake

01 Engine
0145 Air intake
1451-001
178292-001
Charge air housing
Applies to:
274250-001 725

1 Charge air housing
2 30 Nm Mounting bolts for the charge air diffuser
3 30 Nm B617-MB Charge air temperature sensor in the charge air
housing
4 30 Nm Mounting bolts for the connection flange
5 25 Nm Mounting bolts for the charge air housing
6 Uncoupling disc
– Replace damaged discs during assembly.
7 30 Nm Mounting bolts for the charge air tube bracket
8 B608-MB Charge air pressure and temperature sensor in
the charge air tube

01 Engine
0145 Air intake
1451-001

10 Seals
– Replace the seals during installation
11 10 Nm Mounting bolts for the charge air pressure
sensor and temperature sensor

01 Engine
0145 Air intake
1451-001
Removal
► Remove the charge air line.

► Detach the line set (2) from the charge air
tube (3).
726
274101-001
► Detach the hose (1) from the exhaust gas

chapter: Page 370
727
274112-001

► Unscrew the bolts (3) and detach the connection
flange (2) from the charge air tube (4).
728
268742-001

01 Engine
0145 Air intake
1451-001

► Detach the charge air tube (2).
729
274123-001

chapter: Page 370
730
274133-001
Only if the charge air tube is replaced:

731
274143-001
► Remove the oil coolant module. Page 343

► Remove the high-pressure fuel pump. Page
301

01 Engine
0145 Air intake
1451-001
732
273909-001
► Undo the line set (1) from the charge air

housing (2).
733
273928-001
► Unscrew the bolts (1) and remove the charge air

housing (2).
734
273961-001
Only if the charge air housing is replaced:

► Remove the sensor (B617-MB).
735
273972-001

01 Engine
0145 Air intake
1451-001
Installation

sealing ring.
736
273972-001
► Fit new seals (1) with guide rods in the charge air
housing (2).
737
273993-001
► Install new discs (1) on the bolts (2) if necessary.
738
273996-001

01 Engine
0145 Air intake
1451-001
► Attach the charge air housing (2) and screw it on

using bolts (1).
739
273961-001
► Attach the line set (1) to the charge air

housing (2).
740
273928-001
741
273909-001
► Install the high-pressure fuel pump. Page 304

► Install the fuel filter module. Page 330
► Install the oil coolant module. Page 344

01 Engine
0145 Air intake
1451-001

sealing ring.
742
274143-001
► Install the exhaust gas recirculation line (1).

chapter: Page 373
743
274133-001
► Attach the charge air tube (2) together with a new

sealing ring and screw it on using bolts (1).
744
274123-001
► Screw the connection flange (2) onto the charge

air tube (4) using bolts (3).
745
268742-001

01 Engine
0145 Air intake
1451-001
► Attach the hose (1) to the exhaust gas

chapter: Page 373
746
274112-001
► Attach the line set (2) to the charge air tube (3).
747
274101-001

► Install the charge air line.

01 Engine
0145 Air intake
1451-001
180946-001
Charge air housing
Applies to:
274250-001 748

2 30 Nm Mounting bolts for the charge air diffuser
3 30 Nm B617-MB Charge air temperature sensor in the charge air
housing
4 30 Nm Mounting bolts for the connection flange
5 25 Nm Mounting bolts for the charge air housing
6 Uncoupling disc
– Replace damaged discs during assembly.
7 30 Nm Mounting bolts for the charge air tube bracket
8 B608-MB Charge air pressure and temperature sensor in
the charge air tube

01 Engine
0145 Air intake
1451-001

10 Seals
– Replace the seals during installation
11 10 Nm Mounting bolts for the charge air pressure
sensor and temperature sensor

01 Engine
0145 Air intake
1451-001
Removal
► Remove the charge air line.

► Detach the line set (2) from the charge air
tube (3).
749
274101-001
► Detach the hose (1) from the exhaust gas

chapter: Page 383
750
274112-001

► Unscrew the bolts (3) and detach the connection
flange (2) from the charge air tube (4).
751
268742-001

01 Engine
0145 Air intake
1451-001

► Detach the charge air tube (2).
752
274123-001

chapter: Page 383
753
274133-001
Only if the charge air tube is replaced:

754
274143-001
► Remove the oil coolant module. Page 343


01 Engine
0145 Air intake
1451-001
► Remove the high-pressure lines (1).

See the "High pressure lines and rail"
chapter: Page 276
755
280240-001
756
273909-001
► Unscrew the bolts (1) and remove the charge air

housing (2).
757
273961-001
Only if the charge air housing is replaced:

► Remove the sensor (B617-MB).
758
273972-001

01 Engine
0145 Air intake
1451-001
Installation

sealing ring.
759
273972-001
► Fit new seals (1) with guide rods in the charge air
housing (2).
760
280242-001
► Install new discs (1) on the bolts (2) if necessary.
761
280241-001

01 Engine
0145 Air intake
1451-001
► Attach the charge air housing (2) and screw it on

using bolts (1).
762
273961-001
763
273909-001
► Install the high-pressure lines (1).

See the "High pressure lines and rail"
chapter: Page 278
764
280240-001
► Install the fuel filter module. Page 330

► Install the oil coolant module. Page 344

01 Engine
0145 Air intake
1451-001

sealing ring.
765
274143-001
► Install the exhaust gas recirculation line (1).

chapter: Page 387
766
274133-001
► Attach the charge air tube (2) together with a new

sealing ring and screw it on using bolts (1).
767
274123-001
► Screw the connection flange (2) onto the charge

air tube (4) using bolts (3).
768
268742-001

01 Engine
0145 Air intake
1451-001
► Attach the hose (1) to the exhaust gas

chapter: Page 387
769
274112-001
► Attach the line set (2) to the charge air tube (3).
770
274101-001

► Install the charge air line.

01 Engine
0150 Engine attachment parts
1451-001

01 Engine
1451-001
181756-001
Electric starting motor
Applies to:

01 Engine
1451-001
282134-001 771

1 30 Nm Earth line, terminal 31
2 M12: 30 Nm Line, terminal 30
M10: 18 Nm
3 Solenoid switch
4 4 Nm Line, terminal 50
5 Starter pre-switch relay
6 13 kg M1-MB Electric starting motor
(M021)
7 Timing housing
8 60 Nm Mounting bolts for the electric starting motor
Removal
► Switch off the engine and let it cool down.
► Disconnect the battery.

01 Engine
1451-001
282126-001 772
► Detach the earth line (1).

► Detach the lines (2) from the solenoid switch (3).
► Detach the line (4) from the starter pre-switch
relay (5).
► Detach the electric starting motor (6) from the
timing housing (7), pull it downwards and remove
it.
Installation
housing. Page 72
► Rotate the flywheel using the cranking tool and
check the ring gear for wear.
► Replace flywheel if necessary. Page 165
► Check if the starter pinion is worn.
► Replace the electric starting motor if
necessary.
282126-001 773
► Attach the electric starting motor (6) to the timing

housing (7).
► Attach the line (4) to the starter pre-switch
relay (5).
► Attach the line (2) to the solenoid switch (3).

01 Engine
1451-001

► Attach the earth line (1) to the timing housing (7).
► Connect the battery.


01 Engine
1451-001
181818-001
Alternator
Applies to:

01 Engine
1451-001
282175-001 774

1 9 kg G2-MB Alternator
(G002)
2 Alternator drive belt
question.
3 Pulley
4 15 Nm Nut for B+ terminal
5 6 Nm Earth line screw
6 40 Nm Mounting bolts for the alternator

01 Engine
1451-001
Removal
► Disconnect the battery.
► Remove any machine drive belts that may be in
the way if required.
question.
► Unlock the plug-in connection (1) and disconnect

it from the alternator (3).
► Remove the line (2) from the alternator B+
terminal.
► Remove the earth line (4).
► Unscrew the bolts (5) and remove the
alternator (3).
775
282164-001
Installation
► Check the belt pulley (6) for wear.
► Replace the alternator (3) if necessary.
► Insert the alternator (3) and screw it down using
bolts (5).
► Attach the earth line (4) to the alternator (3).
► Attach the line (2) to the alternator B+ terminal.
alternator (3) and lock it in place.
776
282173-001

question.
► Install any machine drive belts that may have
been in the way if applicable.
► Attach the coolant line if necessary.

01 Engine
1451-001
► Attach the air intake pipe if necessary.

► Attach the charge air tube if necessary.
► Connect the battery.


01 Engine
1451-001
181025-001
Resonance vessel
Applies to:
280353-001 777

1 Resonance vessel
2 25 Nm Mounting bolts for the resonance vessel
3 Air intake line
4 Air intake line
5 Retainers

01 Engine
1451-001
181067-001
Resonance vessel
Applies to:
280452-001 778

1 Resonance vessel
2 10 Nm Mounting bolts for the resonance vessel
3 Air intake line
– Check the sealing ring and replace the air
intake line if necessary.
4 Journal
– Ensure that the plugs are correctly seated in
the resonance vessel guides (1).
5 Journal
– Ensure that the plugs are correctly seated in
the resonance vessel guides (1).
6 Air intake line
– Check the sealing ring and replace the air
intake line if necessary.

01 Engine
1451-001
Removing:
– Remove air intake line (6).
question.
Installing:
– Attach the air intake line (6).
question.

01 Engine
1451-001
180981-001
Air compressor
Applies to:
Work preparation
Tool:
Special tool

Fixing device 1
00 1998 594 0
779
279032-001

01 Engine
1451-001
280421-001 780

1 Air compressor
2 Air intake line (resonance vessel) Page 460
3 Coolant line
4 Coolant line
5 M14 x Coolant line union
1.5: 40 Nm
M16 x
1.5: 50 Nm
M18 x
1.5: 45 Nm
M26 x
1.5: 100 Nm
6 60 Nm Compressor mounting bolts
7 50 Nm Mounting bolt for the bracket on the air
compressor
8 30 Nm Mounting bolts for the bracket on the crank case
9 Retainers

01 Engine
1451-001

10 Seal
11 Seal
12 Drive gear
13 230 Nm Drive wheel nut
14 75 Nm Union nut for the compressed air line on the
compressor connector
15 M14 x Compressed air line connector
1.5: 40 Nm
M26 x
1.5: 100 Nm
16 Control line
Removal
► Detach the air intake line (1) from the air

compressor (2).
► Detach the compressed air line (3) on the
connector (4).
► Remove the connector.
► Detach the control line (5).
781
280308-001

If the air compressor is replaced or the connectors for
coolant lines (1) and (2) are leaking, remove the
connectors.
► Expose the electrical cable (3) on the bracket (4).
► Remove the bracket.
► Unscrew the bolts (5) and (6) and remove the air
compressor (7).
782 Collect any escaping engine oil.
280312-001

01 Engine
1451-001
► Remove the sealing rings (1) and (2) from the air
compressor (3).
If the air compressor is replaced or the connector (4)
is leaking, remove the connector (4).
783
280315-001

► Check the drive gearwheel (1) for damage.
► Clamp the special tool (I) in the vice.
Attach the adapter (2) that corresponds to the
drive gearwheel.
► Attach the air compressor (3) to the special tool.
Observe the left thread of the nut.
The nut remains on the shaft to secure the drive
wheel.
► Undo the drive wheel (1).
► Unscrew the nut.
► Remove the drive wheel.
784
280324-001

01 Engine
1451-001

► Attach the drive wheel (1) to the air
compressor (3).
► Attach the air compressor to the special tool (I).
drive gearwheel.
785
280324-001
Installation
► Install new sealing rings (1) and (2) in the air
compressor (3).
► Install new connectors (4) with new sealing rings if
necessary.
786
280315-001

01 Engine
1451-001
► Screw on the new connectors of coolant lines (1)

and (2) with new sealing rings if necessary.
► Insert the bolt (6).
► Install the air compressor (7).
Twist the drive wheel of the air compressor if
necessary.
► Install the bracket (4).
787 ► Fasten the electrical cable (3) on the bracket.
280312-001
► Connect the control line (5) together with a new

sealing ring.
► Screw on the connector (4) together with a new
sealing ring.
► Check the compressed air line (3) for coking.
Replace the compressed air line and affected
components if necessary.
► Screw on the compressed air line on the
connector.
► Attach the air intake line (1) to the air
788 compressor (2).
280308-001

question.
least 1 minute.
question.

01 Engine
1451-001
181069-001
Air compressor
Applies to:
Work preparation
Tool:
Special tool

Fixing device 1
00 1998 594 0
789
279032-001

01 Engine
1451-001
280528-001 790

1 Air compressor
2 Air intake line (resonance vessel) Page 461
3 Coolant line
4 Coolant line
5 M14 x Coolant line union
1.5: 40 Nm
M16 x
1.5: 50 Nm
M18 x
1.5: 45 Nm
M26 x
1.5: 100 Nm
6 60 Nm Compressor mounting bolts
7 50 Nm Mounting bolt for the bracket on the air
compressor
8 30 Nm Mounting bolts for the bracket on the crank case
9 Retainers

01 Engine
1451-001

10 Seal
11 Seal
12 Drive gear
13 230 Nm Drive wheel nut
14 75 Nm Union nut for the compressed air line on the
compressor connector
1.5: 40 Nm
M26 x
1.5: 100 Nm
1.5: 40 Nm
M26 x
1.5: 100 Nm
Removal
► Detach the air intake line (1) from the air

compressor (3).
► Remove the compressed air line (2).
791
280454-001

If the air compressor is replaced or the connectors for
coolant lines (1) and (2) are leaking, remove the
connectors.
► Expose the electrical cable (3) on the bracket (4).
► Remove the bracket.
► Unscrew the bolts (6) and (7) and remove the air
compressor (5).
792 Collect any escaping engine oil.
280455-001

01 Engine
1451-001
► Remove the sealing rings (1) and (2) from the air
compressor (3).
If the air compressor is replaced or the connector (4)
is leaking, remove the connector (4).
793
280315-001

► Check the drive gearwheel (1) for damage.
► Clamp the special tool (I) in the vice.
drive gearwheel.
► Attach the air compressor (3) to the special tool.
The nut remains on the shaft to secure the drive
wheel.
► Undo the drive wheel (1).
► Unscrew the nut.
► Remove the drive wheel.
794
280324-001

01 Engine
1451-001

► Attach the drive wheel (1) to the air
compressor (3).
► Attach the air compressor to the special tool (I).
drive gearwheel.
795
280324-001
Installation
► Install new sealing rings (1) and (2) in the air
compressor (3).
► Install new connectors (4) with new sealing rings if
necessary.
796
280315-001

01 Engine
1451-001
► Screw on the new connectors of coolant lines (1)

and (2) with new sealing rings if necessary.
► Insert the bolt (7).
► Install the air compressor (5).
Twist the drive wheel of the air compressor if
necessary.
► Install the bracket (4).
797 ► Fasten the electrical cable (3) on the bracket.
280455-001
► Check the compressed air line (2) for coking.

Replace the compressed air line and affected
components if necessary.
► Screw on the compressed air line on the
connector.
► Attach the air intake line (1) to the air
compressor (3).
798
280454-001

question.
least 1 minute.
question.

01 Engine
0155 Engine control
1451-001
0155 Engine control

01 Engine
0155 Engine control
1451-001
180537-001
Control unit
Applies to:
278790-001 799

1 25 Nm Mounting bolts for the plug-in connection
3 25 Nm Retainers
4 Fuel line
5 15 Nm Mounting bolts for the control unit
6 50 Nm Fuel line hollow screw
8 Retainers
9 A4-MB Control unit
10 Fuel line

01 Engine
0155 Engine control
1451-001

11 50 Nm Fuel line hollow screw
12 Rubber dampers
Removing:
– Read out and save the parametrization of the
control unit with the CDS.
– Unscrew the fuel lines.
- Disconnect fuel lines.
- Collect any escaping fuel.
Installing:
– Screw in the fuel lines.
- Use new sealing rings.
– Load the control unit parametrization with the
CDS.
– Start the diesel engine.
– Check if fuel lines are tight.

01 Engine
0165 Exhaust gas aftertreatment
1451-001

01 Engine
1451-001
181738-001
Exhaust treatment system
Applies to:
Work preparation
Tool:
► Urea collecting tank
► Observe the safety precautions for storage of
urea solution!
Special tool

Test strips 1
00 1145 145 0
1
800
165495-001
801
165530-001

01 Engine
1451-001

Refractometer with pipette 1
1 00 1145 146 0
802
165517-001
803
165541-001

Tongs 1
(zipper of urea lines)
00 0175 997 0
804
236351-001

01 Engine
1451-001
283020-001 805

1 M25-MB Urea pump Page 487
(M047)
2 NOx sensor
3 NOx sensor
4 Fill level sensor, temperature sensor and quality
sensor
5 Y627-MB Urea heater valve Page 484
(Y488)
6 A4-MB Control unit Page 476
7 Urea dosing unit

01 Engine
1451-001
Checking the urea solution (purity)

This check detects traces of hydrocarbons, e.g. diesel
fuel, in the urea solution.
The injection system components are very sensitive
against hydrocarbons and can be damaged.
Flawless function of the exhaust gas treatment system
then is no longer guaranteed.
machine.
► Wait for at least five minutes after stopping the
diesel engine for the residual pressure in the
system to be relieved.
► Remove urea filter as described in the relevant
Operator's Manual.
► Slide a test strip of the special tool (I) between the

lamellas of the removed filter (1) and impregnate
1 it with the sticking urea solution.
A bright discolouration (2) of the test strip indicates
that the urea solution is free of impurities
(hydrocarbons).
A dark discolouration (3) or (4) of the test strip

indicates that the urea solution is polluted with
I hydrocarbons.
806
165543-001
2 3 4
807
165544-001
► Install urea filter as described in the relevant

Operator's Manual.

01 Engine
1451-001
Checking the urea solution (density)

This check establishes the density of the urea
solution.
The usable urea solution consists of 32.5 % urea and
67.5 % distilled water.
When the water portion is too high, the function of the
exhaust gas treatment system will be affected.
machine.
► Wait for at least five minutes after stopping the
► Remove urea filter as described in the relevant
Operator's Manual.
► Use the pipette (1) of special tool (I) and withdraw

a urea solution sample from the removed filter
and from the urea tank.
► Put the withdrawn sample on the refractometer
prism (2).
I 2 ► The white area is to stop at the characteristic
curve (3) of the urea solution.
1
When the white area is below the characteristic
curve (3), the urea solution does not contain the
specified percentage rate of urea.
When the white area is slightly above the

808 characteristic curve (3), this can be considered as
165550-001 normal, depending on the urea solution producer.
809
165551-001
► Install urea filter as described in the relevant

Operator's Manual.

01 Engine
1451-001
181747-001
Urea heater valve
Applies to:
Work preparation
Tool:
► Cooling water collecting tank
Special tool

Hose clamp 2
1 00 0181 867 0
810
124108-001

01 Engine
1451-001
186114-001 811

1 Y627-MB Urea heater valve
(Y488) Position of valve:
See chapter "Location of components" in the
relevant Technical Systems documentation.
2 Urea heater valve mounting bolts
3 Coolant lines
Removal
► Allow the diesel engine to cool down.
machine.
► Wait for at least 5 minutes after stopping the

01 Engine
1451-001

► Disconnect connector at (1).
► Disconnect cooling water hoses (2) and (3) with
special tool (I).
► Mark and unlock the cooling water hoses (2)
and (3) and remove them from the valve (4).
► Remove the valve (4).
812
282099-001
Installation
► Attach the valve (4).
► Plug on and lock cooling water hoses (2) and (3).
► Connect the cable plug at (1).
813
282099-001

► Check if exhaust treatment system and coolant
circuit are tight.
Operator's Manual.

01 Engine
1451-001
181706-001
Urea pump
Applies to:
Work preparation
Tool:
► Urea collecting tank
► Cooling water collecting tank
Special tool

Hose clamp 2
1 00 0181 867 0
814
124108-001

01 Engine
1451-001
282043-001 815

01 Engine
1451-001

1 1.5 kg M25-MB Urea pump
(M047) Position of pump:
See chapter "Location of components" in the
relevant Technical Systems documentation.
2 Coolant inlet connection (coolant flow line)
3 Coolant outlet connection (coolant return line)
4 Urea outlet connection
5 14 Nm Urea inlet connection
6 5 Nm Screw plug
– Replace the screw plug for every assembly.
– Replace O-ring in every installation process.
7 Pressure relief valve
– Remove any dirt from the drilled hole for the
pressure relief valve.
8 Separation membrane
9 Frost-protection pressure piece
10 Frost-protection cover
11 4 Nm Mounting bolts for the frost-protection cover
12 Sealing bead
13 Vent opening
14 80 Nm Filter housing
15 Seal
16 Frost-protection membrane
17 Filter element
18 Seal
19 Guide Studs
20 Filter
Removal
► Switch off the diesel engine and allow it to cool
down.
machine.
circuit.
question.

01 Engine
1451-001

► Use a special tool to clamp the coolant lines at the
connectors (1) and (2).
► Detach the coolant lines at the connectors (1) and
(2).
Mark the coolant lines in relation to the
Collect the coolant in a collection container.
► Detach the urea line from the connectors (3).
Collect any escaping urea and dispose of it.
Collect any escaping urea and dispose of it.
816
282063-001
► Remove the urea pump.

Installation
► Install the urea pump.

01 Engine
1451-001
► Attach the urea line to the connectors (4).

► Attach the coolant lines to the connectors (1) and
(2).
817
282063-001

► Check if exhaust treatment system and coolant
circuit are tight.
Operator's Manual.

01 Engine
1451-001
Removing the inlet nozzle filter

► Use a special tool to clamp the urea lines at the
Collect any urea in a collection container and
dispose of it.
Collect any urea in a collection container and
dispose of it.
► Remove union (1).
► Remove the filter (3) from the urea inlet (4).
Use an M5 screw to pull out the filter.
818
282067-001
Installing the inlet nozzle filter

► Install the filter (3) in the urea inlet (4).
Carefully slide the filter into the inlet until the filter
collar is flush with it.
► Install the connectors (1).
819
282067-001

1451-001
Index
A
Accident prevention regulations..............................................................................................................................37
Actuators.................................................................................................................................................................57
Air compressor..............................................................................................................................................463, 469
Drive gearwheel
Installation.......................................................................................................................................467, 473
Removal..........................................................................................................................................466, 472
Installation..............................................................................................................................................467, 473
Removal.................................................................................................................................................465, 471
Special tool............................................................................................................................................ 463, 469
Technical specifications.........................................................................................................................464, 470
Work preparation................................................................................................................................... 463, 469
Air intake tube......................................................................................................................................................... 51
Alternator.............................................................................................................................................................. 456
Installation......................................................................................................................................................458
Removal.........................................................................................................................................................458
Technical specifications.................................................................................................................................457
Alternator 12 V........................................................................................................................................................ 51
Avoiding
Of damage....................................................................................................................................................... 43
Of environmental damage................................................................................................................................44
Of health damage............................................................................................................................................ 44
Of premature wear...........................................................................................................................................43
C
Camshaft...............................................................................................................................................................189
Checking........................................................................................................................................................193
Installation......................................................................................................................................................191
Removal.........................................................................................................................................................190
Camshaft housing................................................................................................................................................. 179
Installation......................................................................................................................................................185
Removal.........................................................................................................................................................181
Special tool.................................................................................................................................................... 179
Charge air housing........................................................................................................................................433, 442
Installation..............................................................................................................................................438, 447
Removal.................................................................................................................................................435, 444
Charge air tube....................................................................................................................................................... 53
Common rail............................................................................................................................................................53
Compressor see Air compressor.................................................................................................................. 463, 469
Connecting rod......................................................................................................................................................132
Checking........................................................................................................................................................136
Installation......................................................................................................................................................137
Removal.........................................................................................................................................................136
Connecting rod bearing pin
Checking........................................................................................................................................................158
Control unit............................................................................................................................................................476
Installation instructions...................................................................................................................................477
Coolant..................................................................................................................................................................356
Cleaning the coolant circuit............................................................................................................................357
Special tool............................................................................................................................................. 356
Draining..........................................................................................................................................................357

1451-001
Filling up.........................................................................................................................................................357
Coolant flow tube.......................................................................................................................................... 366, 379
Installation..............................................................................................................................................373, 387
Removal.................................................................................................................................................370, 383
Coolant pump........................................................................................................................................................359
Installation......................................................................................................................................................361
Removal.........................................................................................................................................................360
Work preparation........................................................................................................................................... 359
Coolant thermostat..........................................................................................................................................53, 363
Installation......................................................................................................................................................365
Removal.........................................................................................................................................................364
Crankcase venting.................................................................................................................................................. 52
Cranking the engine................................................................................................................................................60
Cranking the engine in built-in condition..........................................................................................................65
Cranking the engine in removed condition.......................................................................................................72
Setting the engine to ignition TDC................................................................................................................... 73
Removal....................................................................................................................................................74
Special tool...................................................................................................................................................... 60
Special tool for built-in engine..........................................................................................................................62
Crankshaft.............................................................................................................................................................145
Main bearing
Installation...............................................................................................................................................158
Removal..................................................................................................................................................150
Special tool.................................................................................................................................................... 145
Cylinder head................................................................................................................................................194, 211
Checking................................................................................................................................................209, 225
Clean......................................................................................................................................................208, 224
Installation..............................................................................................................................................203, 220
Removal.................................................................................................................................................199, 216
Special tool............................................................................................................................................ 194, 211
Cylinder head gasket.................................................................................................................................... 194, 211
Installation..............................................................................................................................................203, 220
Removal.................................................................................................................................................199, 216
Special tool............................................................................................................................................ 194, 211
Cylinder liner......................................................................................................................................................... 138
Checking........................................................................................................................................................141
Installation......................................................................................................................................................142
Measuring the cylinder bore...........................................................................................................................144
Measuring the excess dimension...................................................................................................................144
Removal.........................................................................................................................................................140
Special tool.................................................................................................................................................... 138
D
Diesel engine
Information for working on the engine..............................................................................................................45
Differential pressure sensor.................................................................................................................................. 400

1451-001
E
Electric starting motor............................................................................................................................. 52, 452, 452
Installation......................................................................................................................................................454
Removal.........................................................................................................................................................453
Electric systems standard....................................................................................................................................... 33
Engine components................................................................................................................................................ 51
Engine data.............................................................................................................................................................49
Engine description.................................................................................................................................................. 51
Exhaust gas recirculation actuator........................................................................................................................394
Installation......................................................................................................................................................397
Removal.........................................................................................................................................................396
Exhaust gas recirculation line................................................................................................................................. 51
Exhaust gas return cooler....................................................................................................................... 51, 366, 379
Checking................................................................................................................................................377, 391
Installation..............................................................................................................................................373, 387
Removal.................................................................................................................................................370, 383
Special tool............................................................................................................................................ 366, 379
Exhaust gas return pipe................................................................................................................................ 366, 379
Installation..............................................................................................................................................373, 387
Removal.................................................................................................................................................370, 383
Exhaust gas treatment.......................................................................................................................................... 479
Exhaust manifold.......................................................................................................................................... 401, 406
Installation..............................................................................................................................................404, 411
Removal.................................................................................................................................................403, 409
Exhaust turbo charger.............................................................................................................................52, 414, 423
Installation..............................................................................................................................................420, 429
Removal.................................................................................................................................................417, 426
Work preparation........................................................................................................................... 211, 414, 423
F
First aid measures.................................................................................................................................................. 48
Flange bearing journal
Checking........................................................................................................................................................159
Flywheel................................................................................................................................................................165
Checking........................................................................................................................................................167
Installation......................................................................................................................................................168
Removal.........................................................................................................................................................166
Special tool.................................................................................................................................................... 165
Fuel controller valve......................................................................................................................................315, 319
Installation..............................................................................................................................................317, 321
Removal.................................................................................................................................................316, 320
Fuel filter................................................................................................................................................................. 53
Fuel filter module.................................................................................................................................................. 323
Installation......................................................................................................................................................330
Removal.........................................................................................................................................................328
Special tool.................................................................................................................................................... 323

1451-001

Fuel high-pressure pump................................................................................................................................ 53, 299
2-step valve....................................................................................................................................................307
Installation instructions........................................................................................................................... 308
Technical specifications..........................................................................................................................307
Drive gearwheel
Installation...............................................................................................................................................303
Removal..................................................................................................................................................302
Installation......................................................................................................................................................304
Removal.........................................................................................................................................................301
Special tool.................................................................................................................................................... 299
Fuel pump............................................................................................................................................................. 309
Installation......................................................................................................................................................311
Pressure relief valve...................................................................................................................................... 313
Installation instructions........................................................................................................................... 314
Removal.........................................................................................................................................................310
Special tool.................................................................................................................................................... 309
Fuel sediment filter..................................................................................................................................................53
G
Gear drive............................................................................................................................................................. 251
Adjusting........................................................................................................................................................ 264
Checking........................................................................................................................................................262
Installation......................................................................................................................................................259
Removal.........................................................................................................................................................257
Special tool.................................................................................................................................................... 251
H
Handling the manual................................................................................................................................................. 4
Abbreviations..................................................................................................................................................... 6
Directions...........................................................................................................................................................5
Search and find..................................................................................................................................................5
Technical terms..................................................................................................................................................7
Hazard signs
Warnings..........................................................................................................................................................37
High-pressure lines
OM 470 LA.....................................................................................................................................................266
Installation...............................................................................................................................................270
Removal..................................................................................................................................................268
Special tool............................................................................................................................................. 266
OM 471 LA.....................................................................................................................................................274
Installation...............................................................................................................................................278
Removal..................................................................................................................................................276
Special tool............................................................................................................................................. 274
Housing cover......................................................................................................................................................... 93
Installation........................................................................................................................................................96
Removal...........................................................................................................................................................94
Special tool...................................................................................................................................................... 93
Technical specifications...................................................................................................................................94
Hydraulic system standard......................................................................................................................................34

1451-001
I
Ignition order........................................................................................................................................................... 59
Information for working on the diesel engine.......................................................................................................... 45
Injectors................................................................................................................................................................ 285
Installation......................................................................................................................................................290
Removal.........................................................................................................................................................287
Special tool.................................................................................................................................................... 285
Inlet rocker arm mechanism..................................................................................................................................227
Assembly....................................................................................................................................................... 231
Disassembly...................................................................................................................................................230
Installation......................................................................................................................................................231
Removal.........................................................................................................................................................229
L
Liability limitation.....................................................................................................................................................44
Lifting eyes........................................................................................................................................................76, 77
Lifting eyes.................................................................................................................................................76, 77
Technical specifications.............................................................................................................................76, 77
Lubricating oil system........................................................................................................................................... 334
Pre-filling........................................................................................................................................................336
Special tool.................................................................................................................................................... 334
O
Oil coolant module................................................................................................................................................ 340
Installation......................................................................................................................................................344
Removal.........................................................................................................................................................343
Oil cooler...............................................................................................................................................................347
Oil filter....................................................................................................................................................................53
Oil pan...............................................................................................................................................................53, 79
Installation........................................................................................................................................................82
Removal...........................................................................................................................................................80
Special tool...................................................................................................................................................... 79
Oil pump................................................................................................................................................................349
Assembly....................................................................................................................................................... 351
Disassembly...................................................................................................................................................350
Installation......................................................................................................................................................351
Removal.........................................................................................................................................................350
Oil separator................................................................................................................................................. 103, 112
Assembly............................................................................................................................................... 108, 116
Disassembly...........................................................................................................................................106, 114
Removal.................................................................................................................................................104, 113
Oil spray nozzle.................................................................................................................................................... 338
Oil thermostat........................................................................................................................................................352
Installation......................................................................................................................................................354
Removal.........................................................................................................................................................354
Special tool.................................................................................................................................................... 352

1451-001
Oscillation damper................................................................................................................................................ 161
Installation......................................................................................................................................................163
Removal.........................................................................................................................................................162
Special tool.................................................................................................................................................... 161
Outlet rocker arm mechanism...............................................................................................................................233
Assembly....................................................................................................................................................... 237
Disassembly...................................................................................................................................................236
Installation......................................................................................................................................................238
Removal.........................................................................................................................................................235
Special tool.................................................................................................................................................... 233
P
Piston.................................................................................................................................................................... 120
Assembly....................................................................................................................................................... 127
Checking........................................................................................................................................................126
Disassembly...................................................................................................................................................125
Installation......................................................................................................................................................128
Measuring the excess dimension...................................................................................................................130
Piston rings
Checking.................................................................................................................................................126
Installation...............................................................................................................................................127
Removal..................................................................................................................................................125
Removal.........................................................................................................................................................124
Special tool.................................................................................................................................................... 120
Pressure relief valve
Rail.................................................................................................................................................................282
Installation...............................................................................................................................................284
Removal..................................................................................................................................................283
Protective sleeve...................................................................................................................................................295
Installation......................................................................................................................................................297
Removal.........................................................................................................................................................296
Special tool.................................................................................................................................................... 295
R
Rail
OM 470 LA.....................................................................................................................................................266
Installation...............................................................................................................................................270
Removal..................................................................................................................................................268
Special tool............................................................................................................................................. 266
OM 471 LA.....................................................................................................................................................274
Installation...............................................................................................................................................278
Removal..................................................................................................................................................276
Special tool............................................................................................................................................. 274
Reinforcing frame..................................................................................................................................................174
Installation......................................................................................................................................................177
Removal ........................................................................................................................................................175
Repair information
Adapter sleeve bearings.................................................................................................................................. 13
Chuck bushing................................................................................................................................................. 14

1451-001
Circlips............................................................................................................................................................. 16
Ferrule fittings.................................................................................................................................................. 17
Gib head key joints.......................................................................................................................................... 11
Hydraulic hoses............................................................................................................................................... 18
Liquid locking compound................................................................................................................................... 9
Lock collar bearing...........................................................................................................................................12
Sealing cone fittings.........................................................................................................................................18
Self-locking bolts................................................................................................................................................8
Spare parts...................................................................................................................................................... 20
Specifications, dimensions and weights............................................................................................................ 8
Steel roller chains
Chain connector........................................................................................................................................10
Tensioning.................................................................................................................................................. 9
Taper ring fasteners.........................................................................................................................................10
Technically correct repairs.................................................................................................................................8
Resonance vessel.........................................................................................................................................460, 461
Rocker lever..................................................................................................................................................227, 233
S
Safety precautions.................................................................................................................................................. 37
Safety regulations................................................................................................................................................... 37
Seal
Crankshaft front............................................................................................................................................... 85
Installation.................................................................................................................................................87
Removal....................................................................................................................................................86
Special tool............................................................................................................................................... 85
Technical specifications............................................................................................................................86
Crankshaft rear................................................................................................................................................ 89
Installation.................................................................................................................................................91
Removal....................................................................................................................................................90
Special tool............................................................................................................................................... 89
Technical specifications............................................................................................................................90
Sensors...................................................................................................................................................................54
Signal word
Warnings..........................................................................................................................................................37
Special tool
Air compressor.......................................................................................................................................463, 469
Camshaft housing..........................................................................................................................................179
Cleaning the coolant circuit............................................................................................................................356
Crankshaft......................................................................................................................................................145
Cylinder head.........................................................................................................................................194, 211
Cylinder head gasket............................................................................................................................. 194, 211
Cylinder liner..................................................................................................................................................138
Exhaust gas return cooler......................................................................................................................366, 379
Flywheel.........................................................................................................................................................165
Fuel filter module........................................................................................................................................... 323
Fuel high-pressure pump...............................................................................................................................299
Fuel pump......................................................................................................................................................309
Gear drive...................................................................................................................................................... 251
Housing cover..................................................................................................................................................93
Injectors......................................................................................................................................................... 285
Lubricating oil system.................................................................................................................................... 334
Oil pan..............................................................................................................................................................79
Oil thermostat.................................................................................................................................................352
OM 470 LA
High-pressure lines.................................................................................................................................266
Rail..........................................................................................................................................................266

1451-001
OM 471 LA
High-pressure lines.................................................................................................................................274
Rail..........................................................................................................................................................274
Oscillation damper......................................................................................................................................... 161
Outlet rocker arm mechanism........................................................................................................................233
Piston.............................................................................................................................................................120
Protective sleeve............................................................................................................................................295
Seal
Crankshaft front........................................................................................................................................ 85
Crankshaft rear......................................................................................................................................... 89
Urea heater valve...........................................................................................................................................484
Urea pump..................................................................................................................................................... 487
Urea solution..................................................................................................................................................479
Valve springs................................................................................................................................................. 244
Valve stem seals............................................................................................................................................244
Steel roller chains..................................................................................................................................................... 9
T
Thermostat
See Coolant thermostat................................................................................................................................. 363
Tightening torques
Air conditioner screw fittings............................................................................................................................ 23
Brake line screw fittings................................................................................................................................... 32
Direction-adjustable SDE hydraulic male connectors...................................................................................... 30
Hollow screws..................................................................................................................................................29
Hydraulic swivel fittings....................................................................................................................................28
Hydraulic system fittings
With ferrule............................................................................................................................................... 24
With sealing cone..................................................................................................................................... 23
Metric fine thread............................................................................................................................................. 22
Metric standard thread.....................................................................................................................................21
SDS hydraulic male connectors.......................................................................................................................25
Worm drive hose clamps................................................................................................................................. 32
spring-loaded............................................................................................................................................ 32
Timing housing........................................................................................................................................................97
Installation......................................................................................................................................................101
Removal...........................................................................................................................................................99
Treating sealing faces.............................................................................................................................................20
Turbo charger
See Exhaust turbo charger.................................................................................................................... 414, 423
Turbo compound unit.............................................................................................................................................. 52
Type design............................................................................................................................................................ 49
U
Urea heater valve..................................................................................................................................................484
Installation......................................................................................................................................................486
Removal.........................................................................................................................................................485
Special tool.................................................................................................................................................... 484
Urea pump............................................................................................................................................................ 487
Inlet nozzle filter
Installation...............................................................................................................................................492
Removal..................................................................................................................................................492
Installation......................................................................................................................................................490
Removal.........................................................................................................................................................489
Special tool.................................................................................................................................................... 487

1451-001
Urea solution
Checking the density......................................................................................................................................483
Checking the purity........................................................................................................................................ 482
Special tool.................................................................................................................................................... 479
V
Validity
Of manual.......................................................................................................................................................... 4
Valve cover........................................................................................................................................................... 171
Installation......................................................................................................................................................172
Removal.........................................................................................................................................................172
Valve springs........................................................................................................................................................ 244
Installation......................................................................................................................................................248
Removal.........................................................................................................................................................245
Special tool.................................................................................................................................................... 244
Valve stem seals...................................................................................................................................................244
Installation......................................................................................................................................................248
Removal.........................................................................................................................................................245
Special tool.................................................................................................................................................... 244
Valves................................................................................................................................................................... 239
Adjusting the valve lash................................................................................................................................. 242
Checking........................................................................................................................................................241
Installation......................................................................................................................................................241
Removal.........................................................................................................................................................240
Special tool.................................................................................................................................................... 239
W
Warnings
Hazard signs....................................................................................................................................................37
Signal word...................................................................................................................................................... 37
Water pump
See Coolant pump......................................................................................................................................... 359
Working on the diesel engine..................................................................................................................................45

At CLAAS KGaA mbH we are constantly improving
our products to reflect the latest technological
developments. For this reason, we reserve the right to
make changes to diagrams and descriptions in this
documentation without incurring any obligation to alter
any machines previously delivered.
Specifications, dimensions and weights are non-
binding. Responsibility for errors or omissions not
accepted.
Reproduction or translation of this publication, in
whole or in part, is not permitted without the written
consent of CLAAS KGaA mbH.
All rights under the provision of the Copyright Act are
reserved.
CLAAS KGaA mbH
33416 HARSEWINKEL
Germany
Our contribution to the environment: CLAAS

have printed this manual on 100 % chlorine
free paper.
CLAAS KGaA mbH
Postfach 1163
33416 Harsewinkel
Tel. +49 (0)5247 12-0
www.claas.com
00 0300 667 0
RHB Dieselmotor OM470/471LA
EN - 05/2015
Printed in Germany

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CLAAS Engine Mercedes-Benz OM470LA OM471LA Repair Manual PDF

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Mercedes-Benz OM470LA

Service & Parts

CCN (CLAAS Component Number)

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 3

Engine Type design Engine no.

Texts and figures

4 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Formatting Meaning Description

References can be easily identified by corresponding

Symbol Meaning Description

Document structure based on the assembly

Search and find

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 5

6 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Technical term Description

Your CLAAS Service Department

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 7

General repair instructions

8 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 9

10 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

► Drive out the gib head key (2) with a key

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 11

► Grind the gib head key (1) to suit the application

NOTICE! Excessive force employed when installing

12 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 13

Possible versions of chuck bushings:

► Unscrew bolts (1).

14 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Chuck bushing version (1)

Chuck bushing version (2)

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 15

► Insert circlips as shown in the figures.

16 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Non-tight ferrule connection

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 17

► Have damaged hydraulic hoses replaced

To facilitate identifying of hydraulic hoses, each hose

► Check hydraulic lines prior to putting into

18 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

NOTICE! Hoses laid in a straight line get shorter as

► Do not install a hose with a twist.

► Avoid external mechanical impacts on hoses.

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 19

► Please quote the machine identification number

20 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Tightening torque in Nm at a friction coefficient

Strength class 8.8 10.9 12.9

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 21

Tightening torque in Nm at a friction coefficient

Strength class 8.8 10.9 12.9

22 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Outside pipe diameter Tightening torque Tightening torque

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 23

Outside pipe diameter Tightening torque Tightening torque

24 00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015

Dimension Tightening torque Tightening torque

7/16 - 20 (11.1 mm) - -

00 0300 667 0 - RHB Dieselmotor OM470/471LA - 05/2015 25

Dimension Tightening torque Tightening torque

Shape F with O-ring and plug

Dimension Tightening torque Tightening torque