Mercedes-Benz OM 471 Reference manual

Introduction of engine OM 471 and
exhaust aftertreatment
Introduction into Service Manual
Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart
Bestell-Nr. 6517 1260 02 - HLI 000 000 02 82 – Printed in Germany – 09/11
Introduction of engine OM 471 and
exhaust aftertreatment
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Mercedes>Benz Service
Introduction of engine OM 471 and
exhaust aftertreatment
Technical status
01.09.2011
Daimler AG
.
Technical Information and Workshop Equipment(GSP/OI)
D$70546 Stuttgart
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Information and copyright
Product portfolio
You can also find comprehensive information about our
complete product portfolio on our Internet portal:
Link: http://aftersales.mercedes>benz.com
Questions and suggestions
If you have any questions or suggestions concerning this product, please write
to us.
E>Mail: [email protected]
Telefax: +49>(0)18 05/0 10>79 78
or alternatively
Address: Daimler AG
GSP/OIS,
HPC R822, W002
D>70546 Stuttgart
(Germany)
©2011 by Daimler AG
This document, including all its parts, is protected by copyright.
Any further processing or use requires the previous written consent of
Daimler AG, Department GSP/OIS, HPC R822, W002, D>70546 Stuttgart.
This applies in particular to reproduction, distribution, alteration, translation,
microfilming and storage and/or processing in electronic systems, including
databases and online services.
Image no. of title image: W00.01>1015>00
Order no. of this publication: 6517 1260 02 >HLI 000 000 02 82
09/11
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Preface
SN00.00>W>0001>01HD Preface
The intention behind this brochure is to introduce you to the new
6>cylinder inline diesel engine OM 471 along with the new
exhaust aftertreatment system (EATS).
This brochure is intended for the technical personnel entrusted
with the maintenance and repair of Mercedes>Benz trucks.
The content of this brochure is split up into:
• as>built configuration descriptions
• function descriptions
• component descriptions
All the data listed in this brochure correspond with the technical
status as per September 2011.
Any changes or supplements hereto will be published in the
Workshop Information System (WIS) only.
Additional documents for the OM 471 engine and the EATS, such
as maintenance and repair instructions or wiring diagrams are
also available in the Workshop Information System (WIS).
Mercedes>Benz
W‘rth plant, GSP/TTM
September 2011
i Introduction of engine OM 471 and exhaust aftertreatment >09/2011 > 1
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Contents
2
SN00.00>W>0110HA Overview of as>built configuration and function descriptions 2.8.11
ENGINES 471.9
Overview of new features
Engine OM!471 Page 10
Technical data of diesel engine OM 471 Page 11
As>built configuration
descriptions
Cylinder head cover, as>built configuration Page 12
Cylinder head, as>built configuration Page 13
Cylinder head gasket, as>built configuration Page 18
Crankcase as>built configuration Page 19
Connecting rod, as>built configuration Page 21
Piston, as>built configuration Page 22
Crankshaft, as>built configuration Page 23
Valve control; as>built configuration Page 24
Gear drive, as>built configuration Page 29
Camshaft, as>built configuration Page 31
Belt drive, as>built configuration Page 32
Function descriptions
Crankcase ventilation system function Page 34
Charging, function Page 35
Engine management, function Page 37
Engine management, overall network Page 39
Engine management, behavior in the event
of malfunctions
Page 40
Start procedure, function Page 42
Idle speed control, function Page 44
Working speed control, function Page 46
Driving, function Page 48
Engine shutoff procedure, function Page 50
Determination of the engine speed and
crankshaft angle, function
Page 53
Determination of the compression stroke at
cylinder 1, function
Page 54
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Contents
i Introduction of engine OM 471 and exhaust aftertreatment >09/2011 > 3
Determination of coolant temperature,
function
Page 55
Determination of air mass, function Page 56
Determination of the fuel temperature,
function
Page 57
Function of the specified engine torque
calculation
Page 58
Engine brake, function Page 60
Exhaust gas recirculation, function Page 66
Exhaust aftertreatment, function Vehicles with code (M5R) Engine version
EEV and vehicles with code (M5Y) Engine
version Euro V
Page 68
Vehicles with code (M5Z) Engine version
Euro VI
Page 73
Exhaust aftertreatment, overall network Page 79
Engine oil circuit, function Page 80
Engine oil circuit, diagram Page 82
Coolant circuit, function Page 83
Coolant circuit, diagram Page 86
Engine cooling thermal management,
function
iOnly in vehicles with code (M7T)
Coolant pump, controlled.
Page 87
Engine cooling thermal management,
overall network
Page 90
Fuel supply, function Page 91
Fuel low pressure circuit function Vehicles with code (M5R) Engine version
EEV and vehicles with code (M5Y) Engine
version Euro V
Page 93
Vehicles with code (M5Z) Engine version
Euro VI
Page 96
Fuel high pressure circuit function Page 100
Component descriptions
Central gateway control unit (CGW),
component description
A2 Page 101
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Contents
4
Component description drive control (CPC)
control unit
A3 Page 102
Component description for engine
management (MCM) control unit
A4 Page 103
Electronic Brake Control control unit (EBS),
component description
A10b, A10c Page 105
Parameterizable special module (PSM)
control unit component description
A22 Page 106
Battery disconnect switch control unit,
component description
A33
iOnly in vehicles with one of the
following codes:
• Code (E5T) ADR model class EX/II,
including AT
• Code (E5U) ADR model class EX/III,
including EX/II and AT
• Code (E5V) ADR model class FL,
including EX/II, EX/III and AT
• Code (E5X) ADR model class AT
• Code (E5Z) Accessories, ADR
• Code (E9D) Preinstallation, for bipolar
battery disconnect switch
• Code (E9E) ADR preinstallation, without
chassis shielding
Page 107
Radiator shutters, component description A54, A55
iOnly in vehicles with code (M7K)
Radiator shutters.
Page 109
EATU output NOx sensor, component
description
A57, A57 b1
Vehicles with code (M5R) Engine version
EEV and vehicles with code (M5Y) Engine
version Euro V
Page 110
Vehicles with code (M5Z) Engine version
Euro VI
Page 112
Pump module, component description A58, M25 Page 115
Exhaust aftertreatment (ACM) control unit,
component description
A60
Vehicles with code (M5R) Engine version
EEV and vehicles with code (M5Y) Engine
version Euro V
Page 117
Vehicles with code (M5Z) Engine version
Euro VI
Page 119
AdBlue metering device, component
description
A67 Page 121
EATU input NOx sensor, component
description
A70, A70 b1
Vehicles with code (M5R) Engine version
EEV and vehicles with code (M5Y) Engine
version Euro V
Page 123
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Contents
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Vehicles with code (M5Z) Engine version
Euro VI
Page 125
Auxiliary heater heating unit, component
description
A901
iOnly in vehicles with code (D6M)
Auxiliary water heater, cab or code (D6N)
Auxiliary water heater, cab and electric
motor.
Page 128
Auxiliary heater coolant circulation pump,
component description
A901 M2
iOnly in vehicles with code (D6M)
Auxiliary water heater, cab or code (D6N)
Auxiliary water heater, cab and electric
motor.
Page 130
Travel and speed sensor, component
description
B18 Page 131
Exhaust pressure sensor upstream of diesel
oxidation catalytic converter, component
description
B37
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 132
Exhaust pressure sensor downstream of
diesel particulate filter, component
description
B38
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 133
Component description for accelerator
pedal sensor
B44 Page 134
Exhaust temperature sensor upstream of
diesel oxidation catalytic converter,
component description
B67
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 135
Exhaust temperature sensor downstream of
diesel oxidation catalytic converter, top,
component description
B68
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 136
Exhaust temperature sensor downstream of
diesel oxidation catalytic converter, bottom,
component description
B69
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 137
Exhaust temperature sensor downstream of
diesel particulate filter, component
description
B70
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 138
Exhaust temperature sensor upstream of
SCR catalytic converter, component
description
B72
iOnly in vehicles with code (M5R) Engine
version EEV and in vehicles with code
(M5Y) Engine version Euro V.
Page 139
Exhaust temperature sensor downstream of
SCR catalytic converter, component
description
B73
Vehicles with code (M5R) Engine version
EEV and vehicles with code (M5Y) Engine
version Euro V
Page 140
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Contents
6
Vehicles with code (M5Z) Engine version
Euro VI
Page 141
AdBlue fill level sensor/temperature sensor,
component description
B74 Page 142
Coolant pressure control sensor, component
description
B87
iOnly in vehicles with code (B3H)
Secondary water retarder.
Page 144
Component description for crankshaft
position sensor
B600 Page 145
Component description for camshaft
position sensor
B601 Page 146
Component description for fuel
temperature sensor
B602 Page 147
Oil pressure sensor, description of
components
B604 Page 148
Component description for engine oil fill
level sensor
B605 Page 149
Component description for exhaust coolant
temperature sensor
B606 Page 150
Component description for intake coolant
temperature sensor
B607 Page 151
Charge air pressure and temperature sensor
in charge air pipe, component description
B608 Page 152
Turbine wheel rpm sensor, component
description
B610
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 153
Component description for temperature
sensor downstream of air filter
B611
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 154
Charge air temperature sensor in charge air
housing, component description
B617 Page 155
Exhaust gas recirculation differential
pressure sensor, component description
B621 Page 156
Component description for rail pressure
sensor
B622 Page 157
Diesel fuel metering device, component
description
B625, B626, Y628, Y629
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 158
Fuel filter module pressure sensor,
component description
B638 Page 159
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Contents
i Introduction of engine OM 471 and exhaust aftertreatment >09/2011 > 7
Component description for coolant pump B640, Y631
iOnly in vehicles with code (M7T)
Coolant pump, controlled.
No component description was created for
vehicles with a rigid coolant pump.
Page 160
Residual heat pump, component description M20
iOnly in vehicles with code (D6I)
Residual heat utilization.
Page 162
Tachograph (TCO) component description P1 Page 163
Electronic ignition lock (EIS), component
description
S1 Page 164
EMERGENCY OFF switch, component
description
S30
iOnly in vehicles with one of the
following codes:
• Code (E5T) ADR model class EX/II,
including AT
• Code (E5U) ADR model class EX/III,
including EX/II and AT
• Code (E5V) ADR model class FL,
including EX/II, EX/III and AT
• Code (E5X) ADR model class AT
• Code (E5Z) Accessories, ADR
• Code (E9D) Preinstallation, for bipolar
battery disconnect switch
• Code (E9E) ADR preinstallation, without
chassis shielding
Page 165
EMERGENCY OFF switch frame, component
description
S31
iOnly in vehicles with one of the
following codes:
• Code (E5T) ADR model class EX/II,
including AT
• Code (E5U) ADR model class EX/III,
including EX/II and AT
• Code (E5V) ADR model class FL,
including EX/II, EX/III and AT
• Code (E5X) ADR model class AT
• Code (E5Z) Accessories, ADR
• Code (E9D) Preinstallation, for bipolar
battery disconnect switch
• Code (E9E) ADR preinstallation, without
chassis shielding
Page 166
Engine start and engine stop button,
component description
S600 Page 167
Heating shutoff valve, component
description
Y49 Page 168
Coolant pressure control solenoid valve,
component description
Y53
iOnly in vehicles with code (B3H)
Secondary water retarder.
Page 169
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Contents
8
Component description for fuel injectors Y608. to Y613 Page 170
Component description for the
electromagnetic viscous coupling
Y616, Y616 b1 Page 174
Component description for exhaust gas
recirculation controller
Y621 Page 176
Component description for engine brake
solenoid valve
Y624, Y625 Page 178
AdBlue“ heater coolant solenoid valve,
component description
Y627 Page 180
Component description for boost pressure
regulator
Y636 Page 181
Component description for quantity control
valve
Y642 Page 182
Oil separator component description Page 183
Component description for fuel system high
pressure pump
Page 184
Pressure limiting valve, component
description
Page 185
Component description for turbocharger Page 186
Component description for exhaust gas
recirculation cooler
Page 187
Component description for AdBlue tank Page 188
Component description for oil pump Page 189
Oil/coolant module, component description Page 191
Oil thermostat, component description Page 193
Component description for oil/water heat
exchanger
Page 194
Component description for coolant
thermostat
Page 195
Retarder, component description iOnly in vehicles with code (B3H)
Secondary water retarder.
Page 197
Component description for fuel pump Page 203
Component description for fuel cooler Page 204
Component description for fuel filter
module
Page 205
Diesel oxidation catalytic converter,
component description
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 208
Component description for SCR catalytic
converter
Vehicles with code (M5R) Engine version
EEV and vehicles with code (M5Y) Engine
version Euro V
Page 209
Vehicles with code (M5Z) Engine version
Euro VI
Page 211
Exhaust aftertreatment unit, component
description
Vehicles with code (M5R) Engine version
EEV and vehicles with code (M5Y) Engine
version Euro V
Page 213
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Contents
i Introduction of engine OM 471 and exhaust aftertreatment >09/2011 > 9
Vehicles with code (M5Z) Engine version
Euro VI
Page 215
Diesel particulate filter of exhaust
aftertreatment unit, component description
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 218
Nozzle unit for DPF regeneration,
component description
iOnly for vehicles with code (M5Z)
Engine version Euro VI.
Page 220
Heating system heat exchanger, component
description
Page 221
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Engine
SN00.00>W>0002>04H Engine OM!471
W01.10>1090>09
1 Amplified Pressure Common>Rail
System (APCRS)
2 Diesel fuel>metering device (for
regeneration of diesel particulate
filter (DPF))
3 Oil/coolant module
9 Cooled and regulated exhaust gas
recirculation (AGR)
G2 Generator
4 Fuel filter module
5 Compressor
6 Power steering pump
7 Oil separator for crankcase
ventilation system
8 Turbocharger
The engine OM 471 is the first 6>cylinder inline engine with two
overhead camshafts to be used in a Mercedes>Benz commercial
vehicle.
Both camshafts are driven by a gear drive which is located at the
output side of the engine. The position of this drive gear makes a
major contribution to reducing noise emission.
The extremely compact design of the engine is based on the
optimized cylinder liner concept in which the overhead seat is
located at the bottom in the crankcase >this design measure
allows the gap between the cylinders to be reduced considerably.
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
The OM 471 engine is available in four output stages between 310
and 375 kW.
Advantages of new 6>cylinder inline engine:
• Lower fuel consumption in relation to high output
• Smooth running characteristics, whereby only four
counterweights are required on the crankshaft
• Excellent application capability for the various emissions
standards
• Implementation of particularly high combustion pressures of
up to 230 bar
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
The positive properties of the new engine have been made
possible by a variety of new technical developments:
• The new injection system, the amplified pressure common
rail system (APCRS) (1), is the first common rail system to be
used in Mercedes>Benz commercial vehicles that minimizes
the quantity of fuel required for combustion. The advantage
of this system lies in the fact that the rail and high>pressure
lines have a relatively low pressure of 900 bar, and the fuel
pressure required for injecting into the injector is generated,
which has a particularly positive effect on material loads and
therefore on component longevity.
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
• The completely redesigned engine brake system has an even
higher braking power.
• The cooled and regulated exhaust gas recirculation (EGR) (9)
and the diesel particulate filter (DPF) as well as the modified
oil separator of the crankcase ventilation system (7) ensure
that tomorrow's emissions regulations can also be met.
• The regulated coolant pump installed in the oil/coolant
module (3), which has already been installed in Actros
vehicles, also contributes to fuel economy.
>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
iWith each maintenance and repair work to the engine as well
as to the ancillary assemblies and detachable parts comes the
danger of property damage caused by soiling and foreign bodies.
The high pressure diesel injection system, the intake system and
the oil circuit, in particular, are at risk here.
To avoid any damage, when conducting repair work not only the
specified special tools must be used along with observance of the
WIS repair instructions, but in addition to this special care must be
given to cleanliness at the workbay.
Additional information is available in the document
AH00.00>N>5000>01H.
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Technical data
SN00.00>W>0002>05H Technical data of diesel engine OM 471
General information
OM 471
Displacement (l) 12,8
No. of cylinders 6 (in line)
Valve control DOHC
Valve number for each cylinder
(intake/exhaust)
2/2
Idle speed (rpm) 560
Compression ratio (f) 17,3
Stroke (mm) 156
Stroke:bore ratio 1,18
Weight (kg) approx. 1200
Power categories
OM 471 with
code M3A
OM 471 with
code M3B
OM 471 with
code M3C
OM 471 with
code M3D
Output (kW) 310 330 350 375
Output (horsepower) 421 449 476 510
Torque (Nm) 2100 2200 2300 2500
Piston
OM 471
Diameter (mm) 132
Overall height (mm) 113
Compression height (mm) 75
Shank length 71,65
Piston pin
OM 471
Inside diameter (mm) 23.5
Outside diameter (mm) 58
Length (mm) 88
Fuel system
OM 471
Rail pressure, max. (bar) 900
Crankshaft bearing
OM 471
Diameter (mm) 114
Width (mm) 36
Connecting rod
OM 471
Length (mm) 268
Connecting rod bearing
OM 471
Diameter (mm) 95
Width (mm) 36,4
Crankcase, cylinder liner (wet)
OM 471
Cylinder diameter (mm) 132
Cylinder distance (mm) 165
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As>built configurations
GF01.20>W>0801H Cylinder head cover, as>built configuration 1.7.11
ENGINES 471.9
W01.20>1046>76
1 Cylinder head cover
2 Prefilter
3 Elastomer element
4 Elastomer seal
x Direction of travel
The cylinder head cover (1) consists of plastic and, on the one
hand, prevents ingress of water and foreign objects into the valve
assembly. On the other hand it seals the camshaft case to the
outside using an elastomer seal (4) and prevents escape of the
engine oil used to lubricate the valve assembly.
A prefilter (2) is integrated in the cylinder head cover (1). The
prefilter (2) ensures that the engine oil which is swirled by the
valve assembly and mixes with the blow>by gases is roughly
separated before the blow>by gases are passed on to the oil
separator for the crankcase ventilation system.
For acoustic decoupling of the cylinder head cover (1) an
elastomer element (3) is inserted in all through holes which serve
to attach the cylinder head cover (1) to the camshaft case. The
elastomer elements (3) reduce noise emissions and possible
damage which can occur due to vibrations.
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As>built configurations
GF01.30>W>0800H Cylinder head, as>built configuration 1.7.11
ENGINES 471.9
The engine OM 471 has a one>piece cylinder head.
There are two intake valves and two exhaust valves for each
cylinder in the cylinder head. The narrow engine design means
that overall a symmetrical location of the valves can ensue. This
symmetrical valve pattern is optimum for the combustion.
W01.30>1105>78
Tightening procedure for cylinder head
bolts
1 >38 Cylinder head bolt (M15¥2) 40 Bolt (M10)39 Bolt (M10)
Cylinder head bolts
In order to ensure that the correct bolts are used when installing
the cylinder head, on each bolt head there is an embossing which
provides information on the thread strength of the respective
cylinder head bolt.
The cylinder head bolts have the M15 2 thread and therefore have
the embossing "15".
All the cylinder head bolts must be tightened in four stages as per
a set tightening pattern. The tightening torques and the
tightening angle can be obtained from the repair instructions.
As the cylinder head bolts elongate due to assembly, the shank
length for each bolt which has already been used once must be
measured before it is reassembled.
The relevant bolt must be replaced when the permissible shank
length is exceeded.
iThe cylinder head bolts are no longer assembled when the
valve assembly is mounted. The valve assembly must be removed
before dismantling the cylinder head.
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As>built configurations
W01.30>1122>76
41 Intake ports
42 Threaded holes for the charge air
manifold attachment
x Direction of travel
W01.30>1123>76
43 Exhaust ducts
44 Threaded holes for the charge air
manifold attachment
x Direction of travel
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As>built configurations
W01.30>1124>76
45 Connectors for coolant collector block
x Direction of travel
W01.30>1125>76
46 Inlet valves
47 Exhaust valves
48 Bores for the fuel injectors
x Direction of travel
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As>built configurations
W01.30>1126>76
49 OiI overflow holes from cylinder
crankcase to cylinder head
50 Oil return flow openings or oil return
flow holes from cylinder head to
cylinder crankcase
x Direction of travel
W01.30>1127>76
51 Coolant short>circuit channel from
cylinder head to cylinder crankcase
52 Coolant overflow holes from cylinder
crankcase to cylinder head
x Direction of travel
16
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As>built configurations
W01.30>1128>76
Cooling levers
53 Lower cooling level
54 Upper cooling level
Cooling
The cylinder head has a divided coolant jacket. This means that
the coolant, after it has flushed around the cylinders, flows into
the cylinder head on the inlet side and on the exhaust side. The
advantage is that the coolant first flushes around the fuel
injectors and valve seat rings in the lower cooling level (53) of the
cylinder head.
After this the coolant flows into the upper cooling level (54) of the
cylinder head and cools the valve guides. The coolant is collected
there and directed outwards.
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