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Mercedes Om457 Service Manual
Powersystems • Industrial Engines
Maintenance and Repair
Series 457, 500 and 900

Advanced Training

As at 04/03

Powersystems • Industrial Engines

Maintenance and Repair Series 457,
500 d 900 Ad dT i i
This document is provided for training purposes only and is not subject to the normal updates.

Printed in Germany Note:

ã 2003 Copyright DaimlerChrysler AG The term "employee" always refers to both
male and female staff.
Herausgeber: Global Training
This documentation and all its constituent parts are subject to copyright. Any reproduction or re-
use requires written permission from DaimlerChrysler AG in advance. This especially applies to
any duplication, dissemination, editing, translation, and microfilming of this documentation, or
storage and/or processing on electronic systems, databases and online services.

1511 1209 02 - 1st edition 04.03 236 As at 04/03

 Content 07.05.2003

Title Side

Welcome ..................................................................................................................................................................................................................................................1
Engine model series OM 457 LA..............................................................................................................................................................................................................2
Engine OM 457 LA ...................................................................................................................................................................................................................................4
Series 457<>Cylinder head....................................................................................................................................................................................................................11
Series 457<>Cylinder head - cross section (transverse and longitudinal) ............................................................................................................................................12
Series 457 LA<>Port assignments in the cylinder head gasket ............................................................................................................................................................13
Series 457<>Cylinder head bolts - tightening instructions....................................................................................................................................................................14
Series 457<>Setting valve play .............................................................................................................................................................................................................16
Series 457<>Removing/installing the nozzle holder combination........................................................................................................................................................19
Series 457<>Valve cover and valve cover gasket .................................................................................................................................................................................25
Series 457<>Oil pan ..............................................................................................................................................................................................................................26
Series 457<>Pump-line-nozzle injection system ...................................................................................................................................................................................27
Series 457<>Removing/installing the MR/PLD unit pump...................................................................................................................................................................28
Series 457<>Pistons ..............................................................................................................................................................................................................................35
Series 457<>Lubrication schematic diagram ........................................................................................................................................................................................36
Series 457<>Oil spray nozzle.................................................................................................................................................................................................................38
Series 457<>Crankcase and cylinder liner ............................................................................................................................................................................................39
Series 457<>Camshaft ..........................................................................................................................................................................................................................40

05/03 Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Content I 1
Series 457<>Fuel system ......................................................................................................................................................................................................................42
Series 457<>Fuel pump.........................................................................................................................................................................................................................45
Series 457<>Fuel prefilter with heated water separator .......................................................................................................................................................................46
Series 457<>Planetary drive starter ......................................................................................................................................................................................................48
Series 457<>Fan drive and fan systems................................................................................................................................................................................................50
Series 457<>Air compressor .................................................................................................................................................................................................................52
Series 457<>Turbocharger BR S400 .....................................................................................................................................................................................................53
Series 457<>Engine oil and filter change ..............................................................................................................................................................................................54
Series 457<>Replacing the fuel filter ....................................................................................................................................................................................................56
Series 457<>Fuel filter with water separator - replacing the filter element..........................................................................................................................................58
Series 457<>Air cleaner, engine coolant service ..................................................................................................................................................................................60
Series 500<>Engine models ..................................................................................................................................................................................................................62
Series 500<>Technical features ............................................................................................................................................................................................................64
Series 500<>Cylinder head - port assignment ......................................................................................................................................................................................70
Series 500<>Cylinder head....................................................................................................................................................................................................................71
Series 500<>Cylinder head mounting ...................................................................................................................................................................................................73
Series 500<>Cylinder head gasket........................................................................................................................................................................................................74
Series 500<>EURO 2 and EURO 3 cylinder heads compared ...............................................................................................................................................................75
Series 500<>Valve assembly .................................................................................................................................................................................................................77
Series 500<>Pump-line-nozzle injection system (PLD) .........................................................................................................................................................................83
Series 500<>Removing/installing the MR/PLD unit pump...................................................................................................................................................................91
Series 500<>EURO 2 and EURO 3 pistons ......................................................................................................................................................................................... 101

05/03 Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Content I 2
Series 500<>Connecting rod .............................................................................................................................................................................................................. 102
Series 500<>Crankcase...................................................................................................................................................................................................................... 103
Series 500<>Cylinder liners................................................................................................................................................................................................................ 104
Series 500<>EURO 2 and EURO 3 cylinder liners compared ............................................................................................................................................................. 107
Series 500<>Crankcase ventilation system ....................................................................................................................................................................................... 108
Series 500<>Fuel system ................................................................................................................................................................................................................... 112
Series 500<>Oil cooler and oil filter housing – component locations................................................................................................................................................ 124
Series 500<>Oil circuit ....................................................................................................................................................................................................................... 128
Series 500<>Engine oil system........................................................................................................................................................................................................... 129
Series 500<>Oil spray nozzle.............................................................................................................................................................................................................. 130
Series 500<>Water guide ................................................................................................................................................................................................................... 134
Series 500<>Thermostat location....................................................................................................................................................................................................... 136
Series 500<>Supercharging system and charge air ducting .............................................................................................................................................................. 137
Series 500<>Engine oil and filter change ........................................................................................................................................................................................... 140
Series 500<>Cleaning the fuel prefilter / filter insert ........................................................................................................................................................................ 144
Series 500<>-Fuel prefilter with water separator - replacing the filter element ................................................................................................................................ 146
Series 500<>Replacing the oil separator insert ................................................................................................................................................................................. 148
Series 500<>Replacing the fuel filter - air cleaner - coolant .............................................................................................................................................................. 150
Engines OM 904 and 906 ................................................................................................................................................................................................................... 152
Engine series 900 ............................................................................................................................................................................................................................... 153
Series 900<>Technical features ......................................................................................................................................................................................................... 156
Series 900<>Port assignments in the cylinder head gasket .............................................................................................................................................................. 159

05/03 Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Content I 3
Series 900<>Tightening instructions for cylinder head bolts ............................................................................................................................................................. 160
Series 900<>Valve control.................................................................................................................................................................................................................. 162
Series 900<>Setting valve play .......................................................................................................................................................................................................... 164
Series 900<>Pump-line-nozzle injection system (PLD) ...................................................................................................................................................................... 167
Series 900<>Crankcase...................................................................................................................................................................................................................... 185
Series 900<>Ölspritzdüsen - Unterschiede ........................................................................................................................................................................................ 188
Series 900<>Pistons and piston rings ................................................................................................................................................................................................ 189
Series 900<>Connecting rod .............................................................................................................................................................................................................. 190
Series 900<>Pistons and connecting rod - modifications .................................................................................................................................................................. 191
Series 900<>Engine oil circuit ............................................................................................................................................................................................................ 192
Series 900<>Removing/installing the oil pan .................................................................................................................................................................................... 196
Series 900<>Fuel system ................................................................................................................................................................................................................... 200
Series 900<>Supercharging system and charge air ducting .............................................................................................................................................................. 212
Series 900<>Removing/installing the coolant thermostatic control ................................................................................................................................................. 216
Series 900<>Engine oil and filter change ........................................................................................................................................................................................... 218
Series 900<>Cleaning the fuel prefilter - filter insert ......................................................................................................................................................................... 221
Series 900<>Fuel prefilter with water separator - replacing the filter element ................................................................................................................................. 223
Series 900<>Replacing the fuel filter - air cleaner - coolant .............................................................................................................................................................. 226

05/03 Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Content I 4
 Welcome 07.05.2003

OM 457 LA OM 502 LA OM 906 LA

N01.10-2073-50 N01.10-0341-50 N01.00-2301-50

05/03 Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Welcome 1
 Series 500<>Engine models 07.05.2003

The 500 engine model series is future-ready, and

comes in V6 and V8 cylinder variants with 2 litre
swept volume per cylinder.
Model series 500
The sales designation is formed in the same way
as the 400 model series:

6-cylinder engine: OM 501 LA V6 V8

8-cylinder engine: OM 502 LA
OM 501 LA OM 502 LA
At the same time, the OM 457 LA engine was
developed with the same basic design as the V- VH = 12l VH = 16l
engines.

The Series 2000 V12 and V16 MTU engines are OM 501 LA
derived from the BR 500, and are intended for Turbocharger
industrial applications.
Charge air cooler
1=6-cylinder V-engine
2=8-cylinder V-engine
Model series 500
Diesel engine

05/03 Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Engine models 62
 N01.10-2026-11 N01.10-2028-11

The development of the 500 series encapsulates all the knowledge and experience gained from the 1 million V-engines manufactured since 1969, when
production of the OM 403 V10 engine began.

05/03 Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Engine models 63
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Mercedes Om457 Service Manual
Series 500<>Technical features 07.05.2003

Þ Outstanding power output and torque characteristics over the whole Þ Viscous fan clutch, electromagnetic fan clutch and high-speed fan
rpm range drive on the most powerful engines
Þ Rated engine speed 1,800 rpm or 2000 rpm
Þ Dynamic start-off characteristics and pulling power
Þ Low maintenance requirement
Þ Attractive power/weight ratio Þ Long maintenance intervals
Þ Low fuel consumption Þ Engine oil and fuel filter located at the front, for easy maintenance
Þ Maintenance-free belt drive
Þ Enormous potential: the V6 engines meet the requirements of the highly Þ Can run on FAME / RME (rape methyl ester) or biodiesel, and engine oil
popular 400 HP Class changes are halved
Þ High-pressure direct injection, pump-line-nozzle system with peak Þ High reliability and long runtime
pressures up to 1,800 bar. Þ Low number of component variants, as many parts are the same on both
6 and 8 cylinder engines
Þ Electronic engine control (MR) with electronic system fixed to the Þ Rear engine power take-off ex works
engine, and extensive engine protection functions
Þ Direct injection with centrally positioned 6-hole injection nozzle.
Þ 4-valve technology
Þ Useful engine brake rpm well over rated rpm, up to 2400 rpm
Þ Meets the emission legislation of EURO 3 and EUROMOT/EPA Level 2
Þ Turbocharger with charge air cooling
Þ V8 with 2 turbochargers

05/03 Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Technical features 64