00 00 Powertrain Additional Information
00 00 Powertrain Additional Information
00 00 Powertrain Additional Information
Powertrain
Engine mechanical training.
Series 900, 500 and 457
.Additional information
Mercedes Benz DCUK
As at 06-2005
DC 5000
Further ordering or supply of this documentation is not possible
This documentation is intended solely for training use and is not subject to modification.
Printed in Germany
ã 2004 Copyright DaimlerChrysler AG
The work including all parts thereof are protected by copyright. Any exploitation or use requires the prior consent of
DaimlerChrysler AG in writing. This applies, in particular, to duplication, distribution, adaptation, translation,
microfilming and storage and/or processing on electronic systems including databases and online services.
1510 02 - 1st
Edition 12.04 0,15 12 ã 2004 Copyright DaimlerChrysler UK
NM459M Contents (4 day training) 31.10.03
Group 1
Group
Group 1
DAY TWO
Group
Group
Group
Group 1
Home
DAY Three
Group 4
Group
DAY FOUR
Group 1
Assy
Lunch
Assy 1
Group
Final test
Page 0
Quick break 11:50
Group 0 12:05
Page 0 Constant throttle
Lunch 12:40
13:40
Group 0
Group 0
Tea
Page 0 Fuel Circuit Theoretical function, (using PPT animation)
Repair and, coding
Home 16:45
Page 0 0915
Page 0 Fuel circuit series 500 09:45 Theoretical overview, Topographical, and schematic views, and fuel pressures
Page 0 Introduction of series 457 10:30 Theoretical overview, Topographical, and schematic views, and fuel pressures
Coffee 10:50
Page 0 11:10
Page 0 Fuel filter assembly 11:40 Theoretical overview, pre-filters, full-filters and additional filter, servicing and tips
Group 0 Valve gear and Valves 11:55 Service, adjustment, and repair
Lunch 12:40
Group 0 Belt arrange. and Compressor 13:40
Group 0 14:00
Tea 15:00
Page 0 15:20
Home 16:45
N01.00-0392-30
05/00 Engine control on the engines Series 900 and 500 in combination with ADM-FR respectively FR
Engines OM 904/906 LA and OM 501/502 LA 1
71_01 13.05.98 Tex71_01
05/00 Engine control on the engines Series 900 and 500 in combination with ADM-FR respectively FR
Engines OM 904/906 LA and OM 501/502 LA 2
71_01 13.05.98 Tex71_01
Characteristics:
The engine series OM 457 LA is a new development with optimized power and torque characteristics.
The engines are suitable for all operating fields in distribution as well as short-haul and long-haul working.
They are characterized by high economy combined with good fuel consumption and low servicing costs.
With a very low power-to-weight ratio the engine design satisfies market demands for the lowest possible
vehicle weights combined with the highest payload.
Further highlights of the new engine series are their high dependability combined with long service life
with extremely good fuel consumption and at the same time optimal power output.
N01.10-2082-01
10/01 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Engine OM 457 LA 2
71_01 13.05.98 Tex71_01
· Four-valve technology with 2 inlet valves and 2 exhaust valves at each cylinder.
· MR engine control with engine electronics attached to engine.
· Pump-line-nozzle system with solenoid valve-controlled unit pumps.
· Electronically controlled high pressure injection up to 1800 bar.
· Direct injection with centrally positioned 6-hole injection nozzle.
· Engine brake with exhaust flap and pneumatically operated constant throttle valve. Useful engine speed is higher than rated speed.
· Turbocharging with intercooling.
· Turbobrake as special equipment (SA).
· Engine output possible to rear and to front by means of additional belt drives for ancillaries (SA).
· Operation with bio-diesel (RME) possible.
N01.10-2059-50 N01.10-2060-50
10/01 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Engine OM 457 LA 3
71_01 13.05.98 Tex71_01
W01.00-1021-06
You can obtain an overview of the principal technical data from Introductory Manual p. 76 and WIS document SN01.00-W-0001-02C.
10/01 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Engine OM 457 LA 4
71_01 13.05.98 Tex71_01
Group 01 06.06.2002
task
A C A
The next component to consider is the cylinder head gasket. Nothing has
C
changed as regards its handling and installation. The Workshop Manual best E
describes the procedures. For diagnosis purposes, however, it is often
B B
necessary to identify the ducts.
Match the holes in the cylinder head gasket to the following terms.
B B
A Push rod ports
B Bolts
D
C Coolant
C
D Oil return
E Oil feed to Rockers
N01.30-2024-12
Group 01 06.06.2002
Task (900 series) m The next component to consider is the cylinder head gasket. Nothing has changed as regards its
handling and installation. The Workshop Manual best describes the procedures. For diagnosis
purposes, however, it is often necessary to identify the ducts.
Match the holes in the cylinder head gasket to the following terms.
C C C C
B B B B A B
C
C
E
B C B C B C B C B
D A A A A A A A A
A = Push rod ports
B = Bolts
C = Engine coolant
D = Oil Separator Return
E = Oil feed to Rocker shaft
N01.30-2039-05
¦ Discuss in your group which drillings of the cylinder head gasket are used
A C A
by the items listed below, and transfer the corresponding letters to the
matching drilling! E
C
B B
B B
A Tappet, oil return flow
B Bolts
C Coolant D
D Oil return flow C
E Oil feed to Rocker shaft
N01.30-2068-12
ExerciseSI01.10-W-0003A m The surface of the contact faces of crankcase / cylinder head is matched to the cylinder head gasket.
When carrying out repairs, particular care should be taken when cleaning the sealing surface.
Use document No. AH01.10-N-0002-01A
Mark the correct statement or statements!
task m Cylinder Head fastening bolts. There are bound to be a few important points here.
Mark the correct statements!
task m „Stretch“ bolts or angle tightened bolts are now in wide use.
The advantages are: -
The clamping forces are accurately calculated.
- No need to retighten the bolts after a running in period.
In most cases the bolts maybe reused providing the bolt is not damaged and is within tolerance!
How is this tolerance checked?
Mark the correct statement after discussion in your group and using the work shop media check your
answer.
1 a By the weight of the bolt. As the bolt gets longer it will have a greater mass.
1 b By the tightening torque. Bolts which are out of tolerance will shear.
! c By the length of the bolt, from under the head to the end of the shank.
1 d By the thickness of the bolt. As the bolt stretches its diameter will reduce.
1 e By the number of dot punch marks on the head of the bolt. Each time a bolt is reused must be
indicated by dot punching the head of the bolt. A bolt may be usedup to a maximum of three.times
1 1 The bolts should be cleaned on a wire wheel if there is any evidence of rust, carbon, or any other
debris.
2 2 The bolt length must be measured and compared with the directives in the workshop media.
3 3 The bolt holes should be checked for debris, coolant and oil contamination.
4 4 Lightly lubricate the threads and under the head of the bolt with engine oil, not 85/90 or grease.
5 5 Torque up the bolts adhering to the sequence and stages.
6 6 Mark the bolt heads for position then angle tighten in sequence.
Top tip:-
The cylinder head bolts at the engine series 457 are marked with 457.
N01.30-2069-01
Exercise m Complete the table below, paying particular attention to the modified diameter.
Refer to the WIS document AR01.30-W-5800-07C as an aid!
Cylinder head
OM 904
OM 906
N01.30-2008-11
Exercise Answers and doc number to complete m The corect clearances are critical for theconstant throttle valve seat and piston,
Discuss in your group, and complete the table.
m
- mas
- ma
Maximum and
Specification Minimum values
- mas
- ma
- ma
Stepped Cap
W07.10-0006-06
Exercise m When it comes to the subject of the constant throttle we also wish to look more closely at the faults
and their symptoms. The problem on a customer's vehicle is that a valve seat of the constant throttle
is worn.
What are the symptoms, which this fault may cause? Discuss this problem case in your group.
Exercise 1 m When it comes to the sealing of the crankshaft, different types of seals are available.
Refer to the table below and select the correct repair combination for the circumstances which exist!
10/01 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Crankshaft sealing engine series 500/457 63
71_01 13.05.98 Tex71_0116/03/0516/03/05
Group 05 06.06.2002
Valve clearance AP05.30-W-0560 A AP05.30-W-0560B
„Valve play“ - a familiar subject, and requiring no extra study. Or does it?
² In fact, there are a few things about valve clearance that you do need to know AH 05.30-N-1000BB
8 Valve clearance is measured between the rocker arm and valve bridge.
The valve clearance is measured between the valve bridge and the valve stem.
The valve clearance is set to the specified value, including the test tolerance.
8 The test tolerance serves only to check the valve clearance, and may be +0.2mm to –0.1mm.
8 When checked, the valve clearance at the inlet valve may be +0.30 mm to +0.60 mm.
after setting, the valve clearance at the inlet valve may be +0.30 mm to +0.60 mm
task m Complete the following table with regard to "checking/ setting the valve clearance
> Valve adjusting sequence Engines series 457, 904, and 906. 06.06.2002
Method 1
Set inlet and exhaust valves of each cylinder, in
accordance with the injection order.
A exhaust valve
E inlet valve
X flywheel side
N05.30-2070-01 A01.00-0001-01
> Valve adjusting sequence Engines series 457, 904, and 906. 06.06.2002
Method 2
Set inlet and exhaust valves in two crankshaft
settings, according to the table.
A exhaust valve
E inlet valve
X flywheel side
N01.00-0347-01 N01.00-0348-01
Series OM 904 shown Series OM 906 shown
N03.30-2007-06
> Valve adjusting sequence Engines series 457, 904, and 906. 06.06.2002
Method 1
Adjust inlet and exhaust valves per cylinder,
according to the injection sequence.
The cylinder to be adjusted must be at ignition
TDC, the opposite-running cylinder at valve
overlap TDC.
A exhaust valve
E inlet valve
X flywheel side
N01.00-0200-01 N01.00-0201-01
> Valve adjusting sequence Engines series 457, 904, and 906. 06.06.2002
Method 2
Adjust inlet and exhaust valves in two crankshaft
settings, according to the table.
A exhaust valve
E inlet valve
X flywheel side
N01.00-0200-01 N01.00-0201-01
6-cylinder 8-cylinder
First set 5 cylinder at valve overlap TDC.
th
First set 6 cylinder at valve overlap TDC
th
The valve timing gear has changed substantially compared with series 400; there are some points, which should be considered before dismantling the valve gear.
Task AR 01.30- W-5800B m Using the document „ AR0500- W-5521B “, the workshop media and discuss in your group.
Mark the correct statements.
Task SI05.00-W-0001A m What complaints or types of engine damage require the valve lift to be measured?
m Using the WIS find the document "testing low pressure fuel circuit and print off one main document
for each person
Exercise 1 m Mark the correct positions to check the fuel pressure and fuel quantity test points on the following
diagram.
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 1
71_01 13.05.98 Tex71_01
N07.15-2043-09
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 2
71_01 13.05.98 Tex71_01
Exercise 3 m What pre-test work should be carried out before ANY Fuel pressure tests are carried out?
m List at least six points below!
- Carry out visual inspection of all fuel lines, Screw connections and components.
- if it necessary, parameterise stationary engine speed limit up to 4000 rpm with the D.A.S.
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 3
71_01 13.05.98 Tex71_01
(Actros) Test sheet for fuel system pressure checks on low-pressure fuel circuit 22.01.01
Note Prior to testing the stationary engine speed limit parameter needs setting to4000 rpm, record original setting to be reset on completion of the tests.
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 4
71_01 13.05.98 Tex71_01
Notes m
N 915 039 01 22 05 16mm single depth banjo bolt with M12 x 1.5 threaded fitting
N 915 040 01 22 06 16mm double depth banjo bolt with M12 x 1.5mm threaded fitting
N 915 047 01 22 03 16mm double depth banjo bolt
N 0000 0000 1070 seal ring16mm
A001 990 98 71 M12 x 1.5 90 degree angle fitting
N 0076 0301 4106 Copper sealing washer 14mm
N 0076 0301 2106 Copper sealing washer 12mm
A 01599764 82 Clear plastic pipe
Opening bridge
Opening bridge retaining nut
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 5
71_01 13.05.98 Tex71_01
*INFO! Fuel pre-screener with heated water trap, code K81 12.05.2000
W47.20-1011-05
Field of application: -
It is highly recommended that in countries with a high possibility of refuelling using contaminated fuel through dirt and or high water content the additional filter
K81 is installed.
Vehicles, which are operated in Eastern Europe or with fuel from these regions to be refuelled, should be mandatory equipped with this additional filter.
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 6
71_01 13.05.98 Tex71_01
Customer benefits:
· Extended durability of the fuel injection system / injection components.
· Long maintenance interval despite heavy operations.
· Higher economy due to less mail functions of the vehicle.
W47.20-1006-11
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 7
71_01 13.05.98 Tex71_01
14.12.1998
08/02 CV Engine management · Engine systems series 500, 900 and 457 Chapter 04
Fuel pressure tests Series 500 8
71_01 13.05.98 Tex71_01
Exercise 1 m Enter the missing designations in the list for the real fuel circuit, using WIS document
A Suction line
B Return flow line
C Low pressure line
D High pressure line
N07.00-2083-09
02/05 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Fuel Circuit Engine Series 457 89
71_01 13.05.98 Tex71_01
Exercise 2 m With the aid of the WIS document SN47.00-W-0003-02A enter the direction of flow of the fuel!
N07.00-2082-09
02/05 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Fuel Circuit Engine Series 457 90
71_01 13.05.98 Tex71_01
Legend for Schematic fuel circuit Series 457. m Mark the fuel circuit test points.
02/05 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Fuel Circuit Engine Series 457 91
71_01 13.05.98 Tex71_01
14.12.1998
02/05 Trucks Engine <> Engine Mechanics - Series 457 - Repairs Advanced Training
Fuel Circuit Engine Series 457 92
71_01 13.05.98 Tex71_01
m Discuss in the group the possible complaints, and problems which can be detected and checked with
these tests
m Carry out all engine tests, and
m Assign the fault or problems to the tests on the relevant pages:-
Engine tests
Getting started.
1 minidiag2 info
- " pipes 2 ecu search routine
- No
F2 darker F3 lighter
- wh off
Engine tests
Getting started.
ecu detection
- No
- wh off
Engine tests
Getting started.
KW 168 / 2 searching
- No
- wh off
Engine tests
Getting started.
- Point of injection
Engine tests
Getting started.
- No
- wh off
Engine tests
- No
- wh off
Engine tests
- 1 voltmeter
2 cylinder cutoff
- 3 compression check
?
4 idle speed balance
5 impact delay time
- The engine idle speed must be between 500 6 pump-line-nozzel ch
Engine tests
1 voltmeter
____________Minidiag 2_____________
What a waste of time:- NEXT!!!
- 1 voltmeter
? 2 cylinder cutoff
- 3 compression check
4 idle speed balance
5 impact delay time
6 pump-line-nozzel ch
Engine tests
2 cylinder cutoff
- 1 voltmeter
2 cylinder cutoff
- 3 compression check
4 idle speed balance
How would you recognise a fault in a particular 5 impact delay time
cylinder? 6 pump-line-nozzel ch
3 compression check
____29___bar. To ___20___bar.
Engine tests
Engine tests
Engine tests
6 pump-line-nozzel ch
Then press OK
-.
-
How would you recognise a fault in a particular
-
cylinder?
Engine tests
6 pump-line-nozzel ch
____________Minidiag 2_____________
-.
Engine tests
6 pump-line-nozzel ch
____________Minidiag 2_____________
Press OK to continue
Press << to escape
-.
Engine tests
6 pump-line-nozzel ch
____________Minidiag 2_____________
-.
Engine tests
6 pump-line-nozzel ch
X_XXX_XXX_XX_XXXXX
____________________________________________
Please enter the injection
pump code like described
in example below:
5--063--868—26--0027
-.
Exercise m Carry out the necessary test at the vehicle. Enter the results on the table.
Cylinder 1 Cylinder 1 %
Cylinder 2 Cylinder 2 %
Cylinder 3 Cylinder 3 %
Cylinder 4 Cylinder 4 %
Cylinder 5 Cylinder 5 %
Cylinder 6 Cylinder 6 %
Group 18 23.02.05
Task (Series 500) m Assign the respective number to the components in the layout!
Use the existing workshop literature.
N18.00-2011-50
Task (Series 500) m Assign the respective number to the components in the layout!
Use the existing workshop literature.
5 3 9
2 8 11
N18.20-2020-05
task 1 6
1 Oil sump 11
2 Intake pipe with sieve filter
8
3 Oil pump
4 Main lube oil gallery (unfiltered) 13
5 Oil cooler (oil-water heat exchanger)
6 Oil filter
7 Oil spray nozzle for cooling pistons 7
4
8 Oil spray nozzle for camshaft
9 Oil gallery for valve gear
10 Turbocharger return flow line 10
11 Turbocharger feed line
12 Main lube oil gallery (filtered)
13 Oil feed check valve
14 Oil Pressure relief valve 2
3
14 12
N18.00-2011-50
Task (Series 457) Latest doc m Assign the respective number to the components in the layout!
Use the existing workshop literature.
5 7 8 10
N18.20-2020-05
1
5
6
N18.00-2011-50
task
1 oil combi-sensor 3
2 bypass valve
3 service drain valve 4
4 check valve 1
5 riser pipe
N18.20-2013-01 N18.20-2021-03
task m The low-pressure warning may illuminate, what instruction should be given to the driver?
m How does the technician verify the fact that the engine is suffering from low-pressure?
1 a Drive the vehicle slowly, the oil pressure is of no importance, oil flow is the critical factor.
X b Don't run the engine, with the ignition on check “actual values” - oil pressure,
with the engine not-running the approximate value should be 0 bar!
1 c The engine must be run at maximum speed, the oil warning will eventually go out!
1 d The oil pressure sensor must be changed, then run the engine and re-check.
! e A calibrated gauge must be fitted then run the engine.
Task (insert document No.) m Using the workshop media state the minimum oil pressure
Task (insert document No.) m Hardened bearings are fitted to all high performance engines, these hardened surface are
thousandths of a millimetre thick. To help protect the bearing surface the lubrication circuit must be
primed before initial start up.
m Below is a selection of different components. After replacement of which components, is priming of
the lubrication system required with the special device?
Task (insert document No.) m When priming the lubrication system, the pressure should be?
1a 0 - 2 bar
!b 2 - 4 bar
1c 5 - 10 bar
Xd The oil pressure must not fall below 1.5 bar
W18.00-0001-06
Note: When priming the lubrication system with the container, up to15 litres of engine oil will be needed.
task
W18.00-0001-06
Note: When priming the lubrication system with the container, up to15 litres of engine oil will be needed.
1 Connector plug
2 Seal ring
3 Adapter
4 Oil container for priming
5 Shutoff valve
6 Heat exchanger
W18.00-0001-06
W18.00-0004-09
Task Ar18.00-W-4000B m State the task of the oil spray nozzles
Discuss this question in the team and mark the correct answers!
!a Oil from the spray nozzles is used to lubricate the piston pin.
Xb Oil from the spray nozzles is also used to lubricate the roller tappets.
!c The oil spray nozzle fills the oil gallery in the piston and cools the piston ring zone and piston crown.
Xd Oil from the spray nozzles is used to lubricate the pump unit.
Xe Due to piston cooling, exhaust gas emissions are reduced.
!f The oil spray nozzles have to be checked for correct alignment with the special tool.
Xg If the nozzle is damaged, or bent, the nozzle assembly must be renewed.
!h The camshaft is lubricated via an additional spray nozzle. (457)
In contrast to the familiar engine series 500, two oil spray nozzles are installed
for each cylinder on the redesigned engine series 457. One of these (the one on
the right looking in direction of travel) cools the piston in the same way as
before, while the second one (on the left looking in direction of travel) is
positioned separately and performs the task of lubricating the camshaft.
Note:
It is no longer permissible to straighten the oil spray nozzles.
The oil spray pipe is brazed, and straightening can result in initial damage.
Exercise 2
1 a None
1 b High oil consumption
! c Pistons are not cooled
! d "Piston seizure"
1 e Engine becomes hot
1 f Oil dilution
N01.10-2081-12
Exercise 2 m When removing a conrod, you have inadvertently knocked the spray pipe of the oil spray nozzle.
You then carried out an inspection, which reveals that the spray pipe has been considerably
misshapen. What is the procedure you then adopt?
W01.40-1021-06 W01.40-1018-06
Task m Name cases of damage with those a cleaning of the oil channels are necessary.
- Aaa
Notes: The work is described in the WIS documents AR01.40-W-8501A and AR01.40-W-8501B.
06.06.2002
Group 20 23.02.05
task m Determine the approved coolant agents /-additives and mixture ratio.
task m Determine the maximum value in per cent, which can be used for a mixture ratio of anti corrosion/
anti freeze and cooling water?
- A higher anti freeze percentage decreases the anti freeze protection and the heat
- dissipation declines.
Coolant
task m The coolant should be changed on regular intervals, because the chemical additives / substances
deteriorates.
m How often should the coolant be changed?
1a Only when a repair was performed, for example, a damaged coolant hose was replaced.
1b Once a year
1c Every 2 years
!d Every 3 years
1e Every 5 years
task m After the repair has been finished and the coolant replaced, are there any additional jobs to do
(Actros, and Atego Heavy)? (see GF00.20-W-3005A)
task m Use the workshop literature and tick the correct statements!
task m Use the workshop literature to complete the following sentences with the team. Use the listed key
words at the bottom of the page.
When degreasing, fill the cooling system with a 5 per cent solution of a mild alkaline cleaner and freshwater. Start and run the engine
at mean speed till temperature has reached 80°C and maintain this temperature for approx 5 min . Switch off the engine and have
the coolant temperature drop to approx. 50°C . Drain the entire solution of the cooling system and refill the system
When decalcifying, fill the cooling system with a 10 per cent solution of citric acid and freshwater. Start and run the engine at
mean speed till temperature has reached 80°C, maintain this temperature for approx. 10 minutes. Switch off the engine and have the coolant
temperature drop to approx. 50°C. Drain the entire solution of the cooling system and refill the system 3 x with freshwater and
Note: The coolant and the chemicals for the cooling system must correspond with approved MB-specification.
Coolant circuit
task m Everybody knows the „short“ and „full“ coolant circuits of a vehicle.
Why do we distinguish these two circuits?
Which component of the cooling system is responsible of the coolant circulation in the respective
circuits?
- Thermostat
task m Define the correct terms to the different descriptions of coolant circulation:
The "short coolant circuit", The "transition period, and the "full coolant circuit".
- Full coolant circuit At engine operating temperature, the coolant has to be cooled by the air stream. Thereby flows the
coolant through the radiator, but only, when the thermostat is fully open. The coolant is maintained at a
constant temperature.
- Transition period In this period, the engine has not reached the operating temperature, the thermostat commences to open
up and therefore the radiator already cools little of the coolant. This period last only for a short time.
- Short coolant circuit When the engine is cold, the coolant in the block has to be warmed up first. Therefore the coolant is not
admitted to the radiator, but only as long as the thermostat is in closed position. The coolant circulates in
the engine block; hence the engine warms up faster, but more importantly more evenly.
task m The 3 layouts show the coolant flow in relation to the operating position of the thermostats.
Define the term to each layout, use the terms from the last task.
B To radiator
C To engine
D From engine coolant pump
Thermostat
task m What are the consequences when thermostats are not installed? Use the layouts of the different
operating positions of the thermostats. Discuss the statements with the team. Tick the correct
answers.
task
W20.10-0010-06
Group 20
W20.10-0010-06
Cooling Systems.
Lime scale and rust particles interfering with the However the debris will eventually be ground to dust, and the sealing surfaces will stabilise after a short
sealing surfaces may cause a slight leakage from period of operation
time to time. If coolant pump is leaking: - Seal, recondition or renew.
task m The coolant circuit can be checked like any other system. Determine, the correct statements
concerning cooling system leak checking. Use the workshop literature.
task m What other Components / systems can be checked or tested using the coolant pressure test?
m Discuss the statements with the team and tick the correct answers.
Copyright DaimlerChrysler AG 29.03.2005 CD-Ausgabe G/09/04 . This WIS print-out will not be recorded by Modification services. Page 2
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Copyright DaimlerChrysler AG 29.03.2005 CD-Ausgabe G/09/04 . This WIS print-out will not be recorded by Modification services. Page 3
Copyright DaimlerChrysler AG 29.03.2005 CD-Ausgabe G/09/04 . This WIS print-out will not be recorded by Modification services. Page 4
PE07.15-W-2002-60C Legend of wiring diagram of engine
control(MR)
Copyright DaimlerChrysler AG 29.03.2005 CD-Ausgabe G/09/04 . This WIS print-out will not be recorded by Modification services. Page 1
(186) Unit pumps power output stages 51C
(209) Engine start/engine stop 17C
(232) Oil pressure 37C
(233) Oil level 27C
(234) Oil temperature 42C
(235) TDC cylinder 1 48C
(266) Signal acquisition and evaluation 26C
(267) Temperature sensor signal acquisition and evaluation 40C
(273) Voltage supply 2C
(279) Starter actuation 15C
(285) Control logic 6B
17B
29B
40B
51B
62B
(309) V6 engine 49L
(310) V8 engine 49H
(312) Cables twisted 5E
5H
46F
50F
50I
57F
57I
(350) optionally depending on version 13H
(430) Fan speed detection 11C
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Copyright DaimlerChrysler AG 20.03.2003 CD-Ausgabe G/04/01 Will not be recorded by Modification services Page 1
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Copyright DaimlerChrysler AG 20.03.2003 CD-Ausgabe G/04/01 Will not be recorded by Modification services Page 4
LEGEND ADM (Version 4)
A 501 Instrument cluster 30 L
A 501 e1 Oil level warning lamp. (0.2A max) 28 L
A 501 e2 Oil pressure warning lamp. (0.2A max) 28 L
A 501 e3 Coolant temperature warning lamp. (0.2A max) 29 L
A 501 e4 ADM - FR/ MR Fault lamp (0.2A max) 30 L
G1 Alternator. 9L
G2 Battery (12/24V) 7L
G3 Alternator 2. 14 L
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LEGEND ADM (Version 4) 2
K 501 Relay 1 alternator 1. 18 L
K 502 Relay 1 alternator 2. 20 L
K 503 Retarder relay (out put) 0.5A. 23 L
K 504 Engine brake relay (out put) 1.2 A. 25 L
K 505 Kickdown relay (max 0.2A). 56 L
K 506 Idle relay 2 (max 0.2A). 58 L
K 507 Relay 3 (max 0.2A). 59 L
K 508 Relay 4 (max 0.2A). 61 L
K 509 Engine brake Relay out put (max 1.2A). 69 L
S509 Special function 0 switch Input wired to positive (anti gas accel- 48 L
-erator pedal lock) &ABS signal from conventional ABS ECU.
S510 Special function 1 switch Input wired to ground (anti gas accel-- 51 L
-erator pedal lock) &ABS signal from conventional ABS ECU.
S511 Engine brake switch (input). 49 L
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LEGEND ADM (Version 4) 3 (Foot notes)
U501 Valid for actual value 2. (PWM output signal). 26 K
U502 Valid for hand throttle signal. (Input). 52 K
U503 Valid for vehicle speed signal. (C3 from tacho). 39 K
U504 Valid for actual value for foot throttle actuator (output). 53 K
U505 Valid for analogue input 1. (Vacant). 54 K
U506 Valid for connection relay 1-4 (kickdown, Idle, and two vacant). 56 F
U507 Valid for connection lamp 1-4 (kickdown, Idle, and two vacant). 62 F
U508 Valid for engine CAN-Bus. 71 J
U509 Connections Must be fitted. __ A
U510 Pins can be connected for additional monitoring equipment. 29 A
U511*** *Kl 15 to ADM and MR 32 B
Contact must be made at the same time(on/off)
Emergency stop, switch Kl 15 at ADM and MR by a "ground
held" relay.
U512 1. MBRA1 engine brake output.(Constant throttle [KDR] or 25 A
constant throttle with Brake flap [BK]). 69 A
2.MBRA2 brake flap (BK) (In combination with MBRA 1 constant
throttle (KDR).
U 518 Twisted wires 71 E
U 519 Valid for customer specific relays (terminals Kl D+ G1 and G2). 17 J
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22 04 ADM FR 01 R Wyllie
04.01 ADM FR 02 R Wyllie
04.01 ADM FR 03 R Wyllie
04.01 ADM FR 04 R Wyllie
ADM FR (version 4)
Plug 1 15 Pins.
Pin Input/ Mandatory/ Designation Signal Monit Description Param
numb Output Optional. type ored eterNo
1 Input Mandatory Kl 30 -- -- Supply voltage.
2 Output Optional. P OEL A -- Signal for conventional oil pressure gauge.
3 Output Optional. LA ADM A -- Warning lamp ADM-FR and MR.
4 Output Optional. RET A A YES Retarder deactivation via foot throttle.
5 Input Mandatory Kl 31 -- -- Ground terminal.
6 Output Optional. MBRA 1 A YES Output to engine brake 1.
7 Output Optional. T MOT A -- Signal for conventional temperature gauge.
8 Output Optional. FFG 2+ -- -- Accelerator pedal 2, (supply).
9 Output Optional. BUZZER A -- Serious fault warning buzzer.
10 Output Optional. IWA 2 A -- Actual value output 2, Hz, speed, PWM, load
11 Output Optional. FFG1 -- -- Accelerator pedal 1, (supply).
12 Output Optional. LA T MOT A -- Coolant over temperature warning lamp.
13 Output Optional. LA OEL ST A -- Impermissibly low oil level warning lamp.
14 Output Optional. LA P OEL A -- Low oil pressure at current engine rpm.
15 Input Mandatory Kl 15 DE -- Terminal 15 Input.
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ADM FR (version 4)
Plug II 18 Pins.
Pin Input/ Mandatory/ Designation Signal Monit Description Param
numb Output Optional. type ored eter
No
1 Input Mandatory C3 (B7) IE Speed input from tachograph.
2 Input MBRE DE Engine brake input, (for MBRA1 and MBRA2 Y
outputs).
3 Input Mandatory Kl W IE Plausibility of engine speed, (from engine
speed sensors).
4 Input KLIMA IE 1 Working speed increase.
2 To reflect a change over between ADR and
Driving mode.
5 Input Mandatory Kl 50 IE Input for engine start signal, from start
switch (must also go to MR).
6 Input ADR + DE 1 ADR mode-"working speed increase".
2 Driving mode-"Idle speed increase".
7 Input ADR 0 DE 1 Activating selected limits.
2 To reflect a change over between ADR and
Driving mode.
8 Input DSF1 DE "Special Function", In put wired to GROUND,
with programmable function-"Anti-Gas"
accelerator pedal lock for conventional ABS
control units
9 Input Mandatory NE DE Neutral position from transmission. (Start
Inhibitor).
10 Output N_MOT A Output for Kl W (conventional RPM counter).
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ADM FR (version 4)
Plug III 12 Pins.
Pin Input/ Mandatory/ Designation Signal Monit Description Pera-
numb Output Optional. type ored meter
No
1 VACANT
2 VACANT
3 VACANT
4 Input AE 1 Analogue Input
5 Input MKLE Engine cover. (bus). Kl 31 switched
6 Input TROE Door open.(bus). Kl 15 switched.
7 Output REL4 Output Relay 4 (via Kl 15)
8 Output REL3 Output Relay 3 (via Kl 15)
9 Output REL2 Output Relay 2 (via Kl 15)
10 Output REL1 Output Relay 1 (Kick down).
11 Output IWA1 Actual value FFG Output1 (Auto
transmission)
12 Output MBRA2 Engine brake output (1.2A)
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ADM FR (version 4)
Plug IV 9 Pins.
Pin Input/ Mandatory/ Designation Description Param
numb Output Optional. eterNo
1 Bi Optional CAN-HH CAN- High speed, High signal.
2 VACANT
3 Bi Optional CAN-HL CAN- High speed, Low signal.
4 Mandatory if HF-GND CAN Ground (shielding).
using pins 1&3
5 Bi Optional Diagnosis.
6 Mandatory HF-GND CAN Ground (shielding).
7 Bi Mandatory CAN-LH CAN- Low speed, high signal.
8 VACANT
9 Bi Mandatory CAN-LL CAN- Low speed, Low signal.
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ADM FR (version 4)
Plug 1 15 Pins.
Pin Input/ Mandatory/ Designation Description Param
numb Output Optional. eterNo
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