Mercedes-Benz Engine Manual (EN)

Bild in der Größe 215x70 mm einfügen OM 501 LA – OM 502 LA engines Operating Instructions O rder no. 6462 9807 02 Part n o. 5 41 58 4 09 81 EN Edition A , 0 8/03

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Thank you for choosing this Mercedes-Benz engine. Items of special equipment are marked with an asterisk *. The equipment in your Mercedes-Benz drive train may vary, de- pending on the version. Mercedes-Benz is constantly updating its engines to the state of the art. You cannot, therefore, base any claims on the data, illustrations or descriptions in these Operating Instruc- tions. For further information contact a Mercedes-Benz Service Centre. Please get to know your new Mercedes- Benz engine first. Make sure you read the Operating Instructions in particular before using the engine for the first time. In this way you can ensure successful and safe use.

At the same time you will avoid endan- gering yourself and others when operating the engine. The Operating Instructions and Mainte- nance Booklet belong with the engine. You should therefore always keep them with the engine and pass them on to the new owner if you sell it. The technical documentation team at DaimlerChrysler AG wishes you every success.

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Contents Engine oils . . . . . . . . . . . . . . . . . . . 64 Coolant . . . . . . . . . . . . . . . . . . . . . . 65 The aim of these Operating Instructions . . . . . . . . . . . . . . . . . . . . . 5 Symbols . . . . . . . . . . . . . . . . . . . . . . . . 6 Protection of the environment . . . . . . 7 Operating safety . . . . . . . . . . . . . . . . . 8 Correct use. . . . . . . . . . . . . . . . . . . . 9 Safety precautions . . . . . . . . . . . . . . . 38 Personnel requirements . . . . . . . . . . 39 Commissioning parts and modifications . . . . . . . . . . . . . . . . . . . 40 Safety/emergency running programs . . . . . . . . . . . . . . . . . . . . . . 41 Replacement parts . . . . . . . .

. . . . . . . 42 Maintenance instructions . . . . . . . . . 68 Overview of work plans . . . . . . . . . . . 69 Maintenance service. . . . . . . . . . . . 69 Additional work. . . . . . . . . . . . . . . . 69 Additional work during every 3rd maintenance service . . . . . . . . 69 Work plans . . . . . . . . . . . . . . . . . . . . . 70 Engine: Checking for leaks and general condition . . . . . . . . . . . . . . 70 Lines and hoses on the engine: Checking for leaks and general condition. . . . . . . . . . . . . . . . . . . . . 70 Engine: Oil change and filter replacement . . . . . . . . . . . . . . . . . . 71 Adjusting the valve clearance. . . . . 74 Fuel connections. . . . . . . . . . . . . . .

78 Fuel prefilter with heated water separator*: Replacing the filter element. . . . . . . . . . . . . . . . . . . . . . 79 Replacing the fuel filter element. . . 81 Intake pipe between air cleaner and engine: Checking for leaks and general condition . . . . . . . . . . . . . . 83 OM 501 LA overview . . . . . . . . . . . . . 12 OM 502 LA overview . . . . . . . . . . . . . 16 Location of sensors . . . . . . . . . . . . . . 20 Engine plate . . . . . . . . . . . . . . . . . . . . 22 Commissioning . . . . . . . . . . . . . . . . . . 44 Preparation. . . . . . . . . . . . . . . . . . . 44 Initial commissioning . . . . . . . . . . . 46 Starting the engine . . . . . . . . . . . . .

49 Monitoring engine operation . . . . . . 51 Charge current . . . . . . . . . . . . . . . . 51 Telligent ® engine system . . . . . . . . 52 Oil pressure . . . . . . . . . . . . . . . . . . 52 Flame-start system* . . . . . . . . . . . . 53 Stopping the engine . . . . . . . . . . . . . . 54 Winter operation . . . . . . . . . . . . . . . . 55 Cleaning/protective treatment . . . . 57 Cleaning the engine . . . . . . . . . . . . 57 Cleaning the cooling system. . . . . . 58 Protective treatment. . . . . . . . . . . . 60 Service products . . . . . . . . . . . . . . . . 61 Diesel fuels. . . . . . . . . . . . . . . . . . . 62 General remarks . . . . . . . . . . . . . . . . 26 Type designation . . . .

. . . . . . . . . . 26 Engine data card. . . . . . . . . . . . . . . 26 Description of the engine . . . . . . . . 27 Flame-start system*. . . . . . . . . . . . 28 Engine exhaust brake/constantly- open throttle valves* . . . . . . . . . . . 29 Telligent ® engine system . . . . . . . . 31 Transport/installation . . . . . . . . . . . 35 Introduction 3 Safety 5 Maintenance 1 At a glance 4 Operation 2 Before commissioning

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Contents Poly-V-belt: Checking the condition 83 Engine brake*: Checking the condition and adjustment. . . . . . . . 88 Engine cooling system: Checking and correcting the fluid level and the antifreeze/corrosion inhibitor . 90 Cooling and heating system: Checking for leaks and general condition. . . . . . . . . . . . . . . . . . . . . 91 Renewing coolant . . . . . . . . . . . . . . 93 Malfunctions, causes and solutions 96 Jump-starting . . . . . . . . . . . . . . . . . . 104 Engine data . . . . . . . . . . . . . . . . . . . . 106 Test values and adjustment values 109 Tightening torques . . . . . . . . . . . . . . 110 Technical terms . . . . . . . . . . . . . . . . 113 Index . . . . . . . . .

. . . . . . . . . . . . . . . . 115 6 Practical advice 7 Technical data 8 Glossary and index

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