Documente Academic
Documente Profesional
Documente Cultură
ENGINE
647370EN
(ENGINE OM 904 LA
120-150-175-CV EURO 3 )
10
ENGINE COMPONENTS LOCATION
page
MERCEDES ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(05/06/2012)
10-03-M184EN
MERCEDES ENGINE
10
Engine cooling
water pump
Oil filter
Alternator
Belt
10-03-M184EN
Fuel pump
and filter
(05/06/2012)
Oil filter
Turbocompressor
Alternator
Starter
motor
(05/06/2012)
10-03-M184EN
10
10
10-03-M184EN
(05/06/2012)
10
ENGINE CONTROL AND ADJUSTMENT
page
ENGINE TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ASSEMBLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(02/08/2012)
10-04-M184EN
10
210 Nm
+ apply Loctite 243
FUEL CIRCUIT
10-04-M184EN
(02/08/2012)
10
ENGINE REMOVAL
page
REMOVING THE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
A - REMOVING THE ALTERNATOR BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B - REMOVING THE ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C - REMOVING THE STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
D - REMOVING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E - REMOVING THE FUEL OIL FILTER AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F - REMOVING THE ENGINE COOLING WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
G - REMOVING THE TURBOCOMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
DISASSEMBLY ORDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVING THE RADIATOR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
(05/06/2012)
10-06-M184EN
ENGINE REMOVAL
10
5
8
6
7
2
Legend:
1
2
3
4
5
6
7
8
Alternator
Starter motor
Alternator belt
Fuel filter
Oil filter
Engine cooling water pump
Fuel pump
Turbocompressor
10-06-M184EN
(05/06/2012)
10
ENGINE REMOVAL
3
4
Insert an unlocking lever on the screw (Ref. 5), tilt the belt
tensioner roller upwards (Ref. 6) and remove the belt (Ref. 7).
7
6
(05/06/2012)
10-06-M184EN
ENGINE REMOVAL
10
1
2
Slacken the screws (Ref. 3) and remove the bracket (Ref. 4) which
supports the air cooling radiator tube (Ref. 5), move the tube
downwards to make it easier to access the alternator.
4
3
10-06-M184EN
(05/06/2012)
ENGINE REMOVAL
10
8
9
(05/06/2012)
10-06-M184EN
ENGINE REMOVAL
10
Slacken the nut (Ref. 1) and remove the electric wires (Ref. 2-3-4)
for the starter motor connection (Ref. 5)
4
1
Remove the starter motor (Ref. 5) from the slot (Ref.f) under the
engine compartment.
10-06-M184EN
(05/06/2012)
10
ENGINE REMOVAL
Slacken the screw (Ref. 1) and remove the belt tensioner (Ref. 2).
Slacken the screws (Ref. 3) and remove the bracket (Ref. 4).
3
1
8
9
Slacken the screw (Ref. 6) to free the alternator (Ref. 7) and rotate
it downwards.
Slacken the screws (Ref. 8) which block the oil filter (Ref. 9) on
the engine supports and remove the filter from the engine.
(05/06/2012)
10-06-M184EN
ENGINE REMOVAL
10
Disconnect the connector (Ref. 2) from the fuel filter (Ref. 3).
Slacken the screws (REf. 4) and remove the fuel filter (Ref. 3)
from the engine.
5
5
10-06-M184EN
(05/06/2012)
10
ENGINE REMOVAL
b
1
4
3
Slacken the 4 screws (Ref. 5) and remove the pulley (Ref. 6).
(05/06/2012)
10-06-M184EN
10
ENGINE REMOVAL
10
Slacken the screw (Ref. 7) and remove the belt tensioner (Ref. 8).
7
8
Slacken the screws (Ref. 9 and 10) and remove the bracket (Ref.
11).
9
10
11
9
Slacken the clamp (Ref. 12) and disconnect the drainage tube
(Ref. 13) from the thermostatic valve.
13
12
15
10-06-M184EN
(05/06/2012)
ENGINE REMOVAL
11
10
Slacken the screws (Ref. 16 and 17) which block the thermostatic
valve (Ref. 14).
16
17
14
Slacken the 7 screws (Ref. 18) remove the pump (Ref. 19) and
the thermostatic valve (Ref. 14).
14
19
18
18
18
18
18
18
(05/06/2012)
18
10-06-M184EN
ENGINE REMOVAL
10
12
Slacken the screws (Ref. 4 and 5) and remove the bracket (Ref. 6).
6
4
Slacken the clamp (Ref. 7) and remove the hose (REf. 8).
10-06-M184EN
(05/06/2012)
ENGINE REMOVAL
13
Slacken the 2 clamps (Ref. 9) and remove the suction hose (REf.
10) on the air radiator.
10
10
Slacken the clamp (Ref. 11) and remove the suction hose (Ref.
12) from the turbocompressor (Ref. 13).
13
11
12
Unscrew the fitting (Ref. 14) and remove the lubrication delivery
tube (Ref. 15) from the turbocompressor.
15
14
Unscrew the fitting (Ref. 16) and remove the lubrication delivery
tube (Ref. 17).
17
16
(05/06/2012)
10-06-M184EN
14
ENGINE REMOVAL
Slacken the 4 screws (Ref. 18) and remove the cover plate (Ref.
19) from the exhaust manifold.
10
19
18
20
Slacken the 2 clamps (Ref. 21) and remove the suction hose
(Ref. 22) from the engine.
21
21
22
Slacken the 8 screws (Ref. 23) and remove the exhaust manifold
(Ref. 24).
23
23
23
24
10-06-M184EN
(05/06/2012)
ENGINE REMOVAL
Slacken the nuts (Ref. 25) and remove the turbocompressor
(Ref. 13) from the exhaust manifold (Ref. 24).
10
13
25
25
24
25
24
25
13
(05/06/2012)
15
10-06-M184EN
16
ENGINE REMOVAL
10
DISASSEMBLY ORDER
Step 1
Step 2
Step 3
10-06-M184EN
(05/06/2012)
ENGINE REMOVAL
17
10
Slacken the screws (Ref. 4) and remove the hood (Ref. 3) from
the vehicle.
Slacken the screws (Ref. 5) and remove the silent blocks (Ref.
6) also in the lower part of the radiator.
6
5
Disconnect the feed pipe (Ref. 7) and drainage pipe (Ref. 8) from
the hydraulic motor (Ref. 9).
Keep the pipes facing upwards to prevent the oil from flowing
out.
9
8
(05/06/2012)
10-06-M184EN
18
ENGINE REMOVAL
Secure the radiator (Ref. 10) to an overhead crane and incline
it as far as possible from the side opposite the engine.
Slacken the screws (Ref. 11) and remove the grille (Ref. 12).
10
10
11
12
Slacken the nuts (Ref. 13) used for fitting the fan (Ref. 14).
14
13
15
Slacken the fixing screws (Ref. 16) and remove the hydraulic
motor
(Ref. 9) from the grille (Ref. 12).
12
16
10-06-M184EN
(05/06/2012)
ENGINE REMOVAL
19
Slacken the clamp (Ref. 4) and remove the hose (Ref. 5).
Also disconnect pipes (Ref. 6 and 7) from the radiator.
6
7
Slacken the clamp (Ref. 9) and remove the hose (Ref. 10).
10
(05/06/2012)
10-06-M184EN
10
20
ENGINE REMOVAL
11
Slacken the screws (Ref. 11) to remove the clamp (Ref. 12) and
remove the tube (Ref. 13).
12
10
13
11
12
Connect the overhead crane (Ref. 15) to the radiator to remove it.
15
16
10-06-M184EN
Remove the radiator (Ref. 16) from the vehicle, and place it on
a pallet.
(05/06/2012)
ENGINE REMOVAL
21
10
6
5
(05/06/2012)
10-06-M184EN
22
ENGINE REMOVAL
Slacken the screws (Ref. 9) and remove the hydraulic pump
(Ref. 10).
10
10
11
11
14
Slacken the clamp (Ref. 12) and remove the hose (Ref. 13) from
the suction duct (Ref. 14).
12
13
Slacken the screws (Ref. 15) and remove the bracket (Ref. 16)
which supports the radiator pipe (Ref. 17).
Shift the pipe downwards to make it easier to remove the engine.
17
16
10-06-M184EN
15
(05/06/2012)
ENGINE REMOVAL
23
10
Slacken the clamp (Ref. 18) and remove the hose (Ref. 19) for
the exhaust gases.
18
19
Slacken the clamp (Ref. 20) and remove the hose (Ref. 21)
entering the radiator.
20
21
Slacken the clamp (Ref. 22) and remove the hose (Ref. 23) from
the turbocompressor.
23
22
25
26
24
25
Slacken the screws (Ref. 24) and remove the brackets (Ref. 25).
Remove the cooling system pipe (Ref. 26).
Slacken the screws (Ref. 27) and remove the support (Ref. 28)
from the vehicle.
24
28
27
(05/06/2012)
10-06-M184EN
24
ENGINE REMOVAL
Slacken the screws (Ref. 29) and slacken the clamps (Ref. 30).
Disconnect the upper (Ref. 31) and lower (REf. 32) heating pipes.
10
31
29
30
29
30
32
Slacken the clamp (Ref. 33) and remove the hose (Ref. 34) from
the water pump.
33
34
Secure the engine to the overhead crane and slacken the screws
(Ref. 35) which fix the engine to the chassis.
Remove the four silent blocks (Ref. 36).
35
36
37
38
10-06-M184EN
(05/06/2012)
ENGINE REMOVAL
25
10
Remove the engine with the help of the overhead crane and
place it on a pallet.
(05/06/2012)
10-06-M184EN
ENGINE REMOVAL
10
26
10-06-M184EN
(05/06/2012)
10
ENGINE REFIT
page
REINSERTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
REASSEMBLY ORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REINSERTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REINSERTING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REINSERTING THE RADIATOR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REINSERTING THE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
A - REINSERTING THE TURBOCOMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B - REINSERTING THE ENGINE COOLING WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
C - REINSERTING THE FUEL OIL FILTER AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D - REINSERTING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E - REINSERTING THE STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F - REINSERTING THE ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
G - REINSERTING THE ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
(25/11/2011)
10-07-M184EN
ENGINE REFIT
10
REASSEMBLY ORDER
Step 1
Step 2
Step 3
10-07-M184EN
(25/11/2011)
ENGINE REFIT
10
Fit the screws (Ref. 2) to block the engine and remove the
hydraulic jack, positioned under the hydraulic pump (Ref. 3)
during the disassembly.
Insert the hose (Ref. 6) on the water pump and tighten the
clamp (Ref. 7).
(25/11/2011)
10-07-M184EN
ENGINE REFIT
Connect the upper (Ref. 8) and lower (Ref. 9) heating pipes.
Tighten the clamps (Ref. 10) by tightening the screws (Ref. 11).
10
10
11
11
10
15
14
15
16
Fit the support (Ref. 12) on the vehicle by means of the screws
(Ref. 13).
Insert the cooling system pipe (Ref. 14) and tighten the brackets
(Ref. 15) by means of the screws (Ref. 16).
16
12
13
20
Insert the hose (Ref. 19) on the radiator pipe and tighten the
clamp (Ref. 20).
19
10-07-M184EN
(25/11/2011)
ENGINE REFIT
10
Insert the hose (Ref. 21) for the exhaust gases and tighten the
clamp (Ref. 22).
22
21
24
25
27
28
26
Connect the tubes (Ref. 29) for the air conditioner on the
compressor.
29
(25/11/2011)
29
10-07-M184EN
ENGINE REFIT
Insert the hydraulic pump (Ref. 30) and fit the screws (Ref. 31).
10
31
30
33
35
34
36
10-07-M184EN
37
(25/11/2011)
ENGINE REFIT
Connect the plug (Ref. 38) on the engine control unit (Ref. 39).
10
39
38
Insert the pipe (Ref. 3) and fit the brackets (Ref. 4) using the
screws (Ref. 5).
4
3
(25/11/2011)
10-07-M184EN
ENGINE REFIT
Insert the hose (Ref. 6) and screw the clamp (Ref. 7).
10
12
11
9
10
13
14
15
10-07-M184EN
(25/11/2011)
ENGINE REFIT
10
Tighten the nuts (Ref. 5) used for fitting the fan (Ref. 6).
7
8
(25/11/2011)
10-07-M184EN
10
ENGINE REFIT
Reconnect the feed pipe (Ref. 9) and drainage pipe (Ref. 10) of
the hydraulic motor (Ref. 1).
10
1
10
Fit the silent blocks (Ref. 11), also in the lower part of the radiator,
using the screws (Ref. 12).
11
11
12
Fit the hood (Ref. 13) on the vehicle by means of the screws
(Ref. 14).
14
13
Fit the screw (Ref. 15) to block the gas spring (Ref. 16) on the
engine hood (Ref. 13).
15
16
13
10-07-M184EN
(25/11/2011)
ENGINE REFIT
11
10
4
1
3
2
7
Legend:
1
2
3
4
5
6
7
8
Turbocompressor
Fuel pump
Engine cooling water pump
Oil filter
Fuel filter
Alternator belt
Starter motor
Alternator
(25/11/2011)
10-07-M184EN
ENGINE REFIT
10
12
Refit the exhaust manifold (Ref. 2) on the engine base using the
8 screws (Ref. 4); use a 30 Nm tightening torque.
4
4
4
10-07-M184EN
(25/11/2011)
ENGINE REFIT
13
10
6
6
10
11
(25/11/2011)
10-07-M184EN
14
ENGINE REFIT
Refit the lubrication delivery pipe (Ref. 12) on the turbocompressor
by screwing in the fitting (Ref. 13).
10
12
13
15
14
Refit the suction hose (Ref. 16) on the air radiator and tighten
the 2 clamps (Ref. 17).
16
17
17
Refit the hose (Ref. 18) and tighten the clamp (Ref. 19).
18
19
10-07-M184EN
(25/11/2011)
ENGINE REFIT
15
Refit the bracket (Ref. 20) on the air unit by means of the screws
(Ref. 21 and 22).
21
10
22
20
21
Refit the air suction pipe (Ref. 23) locking it by means of the 2
brackets (Ref. 24) and the two nuts (Ref. 25).
24
23
25
(25/11/2011)
10-07-M184EN
ENGINE REFIT
10
16
Replace the gaskets with new ones, refit the pump (Ref. 1) and
the thermostatic valve (Rif. 2) on the engine by means of the
7 screws (Ref. 3), on which Loctite threadlock must be applied;
use a 25 Nm tightening torque.
1
3
3
3
3
4
5
2
2
6
10-07-M184EN
(25/11/2011)
ENGINE REFIT
17
10
7
8
Refit the bracket (Ref. 9) on the air unit by means of the screws
(Ref. 10 and 11).
10
11
9
10
Refit the belt tightener (Ref. 12) by means of screws (Ref. 13)
on which Loctite threadlock must be applied, using a 50 Nm
tightening torque.
13
12
Refit the pulley (Ref. 14) by means of the screws (Ref. 15) on
which Loctite threadlock must be applied.
14
15
(25/11/2011)
10-07-M184EN
18
ENGINE REFIT
Reconnect the upper hose (Ref. 16) on the pump and screw the
2 clamps (Ref. 17) back on.
10
17
16
17
Reconnect the lower hose (Ref. 18) on the pump and screw the
2 clamps (Ref. 19) back on.
18
19
19
20
10-07-M184EN
Fill the cooling system tank (Ref. 20) with the liquid concerned;
the liquid level must be between the two notches indicating
the minimum and maximum levels (approx. 18 litres).
Remove the containers from under the engine compatment.
(25/11/2011)
19
10
ENGINE REFIT
Reconnect the fuel inlet and outlet pipes (Ref. 6) to the filter
(Ref. 3).
(25/11/2011)
10-07-M184EN
ENGINE REFIT
10
20
Release the oil inlet pipe (Ref. 5) from the clamp by means of
which it is fixed in the disassembly phase and refit it on the
filter (Ref. 1).
9
7
10-07-M184EN
(25/11/2011)
21
10
ENGINE REFIT
3
2
6
7
(25/11/2011)
10-07-M184EN
ENGINE REFIT
10
22
2
3
10-07-M184EN
(25/11/2011)
ENGINE REFIT
23
10
6
7
Refit the hose (Ref. 8) on the air cooling radiator pipe and tighten
the clamps (Ref. 9).
9
8
(25/11/2011)
10-07-M184EN
ENGINE REFIT
10
24
1
2
Refit the belt (Ref. 1) on all the pulleys with the exception of
the belt tightener roller.
Lift the belt tensioner roller (Ref. 2) by means of a lever positioned
on the screw (Ref. 3), apply the belt, then bring the belt tensioner
roller backwards.
Remove the release lever and check to ensure the belt is housed
correctly on the pulleys.
5
6
10-07-M184EN
(25/11/2011)