AR15.20-S-4111B Remove/install glow plugs 17.10.98 ENGINE 611.980 in MODEL 638

1 head cover 2 Connector

R13 Glow plug 1 R14 Glow plug 2 R15 Glow plug 3 R16 Glow plug 4

S15.20-2506-06 Modification notes

18.2.00 Figure modified from 14, 15 Nm to 12 Nm Figure in line BA15.20-P-1001-01A engine *BA15.20-P-1001-01A 611, 612, 613 modified e d Remove/Install a Danger! Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving. AS00.00-Z-0005-01A off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 1 Warm engine up to operating temperature 2 Ignition off 3 Remove trim panel of cover (1) AR01.20-S-5015A 4 Unplug connectors (2) at glow plugs (R13, l Pliers *611589003700 R14, R15, R16) a Danger! Risk of injury to skin and eyes from Wear safety gloves, protective clothing and AS00.00-Z-0002-01A handling hot or glowing objects. safety glasses, if necessary. 5 Unscrew glow plugs (R13, R14, R15, R16) p Only when cylinder head at operating temperature. i Installation: Grease stem of glow plugs (R13, R14, R15, R16) moderately with special grease. Do not grease sealing seat and thread. n Pay attention to part no. on glow plug. *BA15.20-P-1001-01A l Wrench socket *001589780900 Special grease *BR00.45-Z-1036-06A i Engine 611.980 engine @ If cylinder head removed: k heat up cylinder head to approx. 90° *WH58.30-Z-1001-28A k heat up cylinder head to approx. 90° *WH58.30-Z-1003-28A Cleaning

6 Clean glow plug bay k Cylinder brushes, Perlon Q 10mm *WH58.30-Z-1003-03A k Cylinder brushes, perlon Q 6mm *WH58.30-Z-1002-03A 7 Install in the reverse order n Preglow system

Copyright Daimler AG 12/25/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1 Number Designation Engine Engine 611.960/961/980/981/987, 611.980/981/987 612.961/963/981/983, with part no.

A 001 159 37 01 Engine Engine 611.980/981/983/987, 611.980/981/987, 612.981 with part no. 612.981 A 001 159 38 01, with part no. Engine A 001 159 42 01 611.962/963/965/966/967, 613.960/961

BA15.20-P-1001-01A Glow plug to cylinder head Nm 12 19

001 589 78 09 00 611 589 00 37 00

Wrench socket Pliers

Commercially available tools Number Designation WH58.30-Z-1002-03A Cylinder brush, Perlon, 6 mm dia. WH58.30-Z-1003-03A Cylindrical brush, Perlon, 10 mm dia. WH58.30-Z-1001-28A Recirculated air warming cabinet WH58.30-Z-1003-28A Heating oven

Repair materials

Number Designation Order number BR00.45-Z-1036-06A Special grease A 001 989 42 51 10

Copyright Daimler AG 12/25/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2 AF15.20-S-2000A Difficulties in removing glow plugs/ glow plugs break 30.7.01 ENGINE 611.980 in MODEL 638

Modification notes

30.7.01 Supercedes STIN 15.20V003 dated 26.07.2001

Damage code Cause Remedy

None i An increasing number of glow plug breaks have been occurring when glow plugs are removed. p To avoid breaking glow plugs, first warm up the engine to operating temperature before removing them. @ 1 Warm up engine to operating temperature. 2 Remove/install/replace glow plugs. AR15.20-S-4111B

Copyright Daimler AG 12/25/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1 AR09.20-S-1330A Removing and installing mixing housing with exhaust gas recirculation 15.10.98 ENGINE 611.980 in MODEL 638.094 /194 /294 with CODE (MQ4) Engine OM611 DE22 LA (75 kW) with CODE (MQ5) Engine OM611 DE22 LA (90 kW) ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

S09.20-2510-09 1 Vacuum hose 7 Vacuum hose 13 Nut 2 Mixing housing 8 EGR valve 14 Bolt 3 Vacuum pump 9 flap valve 15 manifold 4 Bolt 10 16 Oil filler pipe 5 Vacuum hose 11 Bolt 17 Seal 6 Vacuum hose 12 Bolt 18 Screw clip

e d Removing, installing 1 Disconnect ground cable at battery AR54.10-S-0005A 2 Remove air cleaner crosspipe AR09.10-S-8031A 3 Take off screw clip (18) at charge air hose i Expose charge air hose (1) (1) to mixing housing (2) and detach charge air hose (1) k *WH58.30-Z-1001-06A 4 Remove vacuum hose at vacuum pump (3) 5 Unscrew bolt (4) at bracket of fuel filter (10) l *001589760900 to mixing housing (2) 6 Unscrew bolt (11) at rear bracket to mixing n *BA09.20-P-1008-01A housing (2) l *001589760900 7 Detach vacuum hoses (5, 6, 7) i Pay attention to installation position of vacuum hoses 8 Unscrew nut (13) at EGR valve (8) to i Installation: replace self-locking nuts exhaust gas heat exchanger (6) (13). Replace . n *BA14.20-N-1004-01C 9 Unscrew bolts (14) at mixing housing (2) to n *BA09.20-P-1007-01A intake manifold (15) l *001589760900 10 Remove intake manifold (15) together with p Ensure scrupulous cleanliness EGR valve (8) i Installation: replace seals (17) 11 Install in the reverse order n Intake manifold

Copyright Daimler AG 12/25/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1 Number Designation Engine 611.980

BA09.20-P-1007-01A Bolt of mixing housing to intake Nm 8 manifold

BA09.20-P-1008-01A Bolt of mixing housing to rear bracket Nm 8

n Exhaust gas recirculation

Number Designation Engine 611.980

BA14.20-N-1004-01C Nut of intermediate pipe to EGR valve Nm 8

001 589 76 09 00

External torx set

Commercially available tools Number Designation WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose clamps with worm drive

Copyright Daimler AG 12/25/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2 AR01.20-S-5015A Removing, installing trim panel of cylinder head cover 16.9.98 ENGINE 611.980 in MODEL 638.094 /194 /294 with CODE (MQ4) Engine OM611 DE22 LA (75 kW) with CODE (MQ5) Engine OM611 DE22 LA (90 kW) ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

1 Mixing housing with exhaust gas recirculation 2 Bolt 3 Bracket 4 Cylinder head cover 5 Bolt 6 Trim panel of cylinder head cover 7 ventilation hose

S01.20-2503-06 e d Removing, installing 1 Remove mixing housing with exhaust gas AR09.20-S-1330A recirculation (1) 2 Remove bolts (2) of bracket (3) at cylinder n *BA01.20-P-1004-01A head cover (4) l *001589760900 3 Remove bolts (5) of trim panel of cylinder n *BA01.20-P-1002-01A head cover (6) l *001589760900 4 Remove trim panel of cylinder head cover (6) i Installation: ensure that the crankcase ventilation hose (7) is correctly inserted 5 Install in the reverse order n Crankcase ventilation, cylinder head cover

Number Designation Engine 611.980

BA01.20-P-1002-01A Bolt of trim panel of cylinder head cover to Nm 10 cylinder head cover

BA01.20-P-1004-01A Bolt of bracket to cylinder head cover Nm 16

001 589 76 09 00

External torx set

Copyright Daimler AG 12/25/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1 AF15.20-S-6400B Preglow system does not operate 9.9.98 ENGINE 601.942, 601.970 ## up to 723680 in MODEL 638

Revisions 20.11.98 Validity and part number changed

Damage code Cause Remedy 15 305 93 Glow plug not sufficiently resistant to 1 Replace glow plug. AR15.20-S-4111A temperature Parts ordering notes

Part no. Designation Quantity 001 159 17 01 Glow plug 4

Copyright Daimler AG 12/25/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1 AF15.20-S-6400A Preglow system does not work 11.2.98 ENGINE 601 in MODEL 638.0## /1## /2## ## up to 106130

Revisions

17.11.98 Torque changed

Damage code Cause Remedy 54 011 74 Mounting screw on connection point X91 1 Clean corrosion and dirt on terminal comes loose point X91. 2 Replace mounting nut with self-locking nut and tighten to 10 Nm.

A Brake fluid reservoir X91 Battery connection point in engine compartment

S15.20-0002-01 Parts ordering notes Part no. Designation Quantity N913 025 008 000 Self-locking nut M8 1

Copyright Daimler AG 12/25/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1 AR15.20-S-4312A Preglow and temperature indicator lamp sensor 7.2.95 ENGINE 601.942 in MODEL 638.0 /1 ENGINE 601.970 in MODEL 638.0 /1 /2

1 Connector B8 Preheating system sensor, temperature indicator

S15.20-1006-06 e d Remove/Install 1 Switch off ignition a Danger! Risk of injury to skin and eyes suffering Do not open cooling system unless coolant AS20.00-Z-0001-01A scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly Risk of poisoning from swallowing coolant. and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection. 2 Drain coolant *BF20.00-N-1001-01A 3 Remove intake manifold AR09.20-S-1310B 4 Disconnect connector (1) 5 Unscrew sensor (B8) i Replace sealing ring (arrow) if damaged. n *BA15.20-N-1003-01A 6 Install in the reverse order n Preglow system

Number Designation Engine 601.942, 601.970

BA15.20-N-1003-01A Preglow indicator lamp sensor NM 20

j Engine cooling system

Number Designation Engine 601.942/970

BF20.00-N-1001-01A Coolant Total capacityLiter 9.0

Anticorrosion/ agent Liter 4,5 down to -37 °C

Anticorrosion/antifreeze down to Liter 5,0 -45 °C

Specifications for Operating Shee Fluids t BB00.40-P-0310-01 A

Copyright Daimler AG 1/20/12 G/06/08. This WIS printout will not be recorded by the update service. Page 1 Shee t BB00.40-P-0325-00 A

Copyright Daimler AG 1/20/12 G/06/08. This WIS printout will not be recorded by the update service. Page 2 AR15.20-S-4330A Removing and installing the preheating timing relay 6.2.95 ENGINE 601.942 in MODEL 638.0 /1 ENGINE 601.970 in MODEL 638.0 /1 /2

1 Nut (circuit 30) 2 Nut 3 Protection cover D2 Preheater timing relay D2.1 Plug-in connection D2.2 Plug-in connection

S15.20-1004-06 e d Removing, installing p Notes on battery All models AH54.10-P-0001-01A 1 Disconnect ground cable at battery i Installation: encode radio set time 2 Pull off protective cover (3) at preglow time relay (D2) 3 Unplug connectors (D2.1, D2.2) 4 Unscrew nut (1) i Disconnect electric cable (circuit 30) 5 Unscrew nuts (2) and take off preheating timing relay (D2) 6 Install in the reverse order

Copyright Daimler AG 1/20/12 G/06/08. This WIS printout will not be recorded by the update service. Page 1 AR15.20-S-4330B Removing and installing the preheating timing relay 18.10.99 ENGINE 611.980 in MODEL 638

A15 Preheating timing relay A15.1 Plug connection of communication preheating timing relay A15.2 Plug connection of glow plugs preheating timing relay A15.3 Connection of preheating timing relay circuit 30

S15.20-4001-12 e d Removing, installing 1 Disconnect ground lead from battery i Installation: -Encode radio. AR54.10-S-0005A -Set clock. p Notes on battery AH54.10-P-0001-01A 2 Separate plug connections (A15.1, A15.2) 3 Unscrew nut of connection of preheating i Installation: Install protective cap. timing relay circuit 30 (A15.3) 4 Detach preheating timing relay (A15) at bracket 5 Install in the reverse order

Copyright Daimler AG 1/20/12 G/06/08. This WIS printout will not be recorded by the update service. Page 1