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Introduction of the Inline Engine Generation 4-Cylinder OM654

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Introduction of the Inline Engine Generation 4-Cylinder OM654 Introduction of the Inline Engine Generation 4-Cylinder OM654 Introduction into Service Manual Introduction of the Inline Engine Generation·Introduction of the 4-Cylinder OM654 – This printout will not be recorded by the update service. Status: 09/2015 – Mercedes-Benz Service Introduction of the Inline Engine Generation 4-Cylinder OM654 Daimler AG · GSP/OR · D-70546 Stuttgart – This printout will not be recorded by the update service. Status: 09/2015 – Contents Preface 4 Overview Brief description 5 Engine data 7 Performance graph 8 Engine views 9 Soundproofing 15 Mechanical system Basicengine 16 Crankassembly 17 Chaindrive 18 Cylinderhead 19 Beltdrive 21 Combustion Preheating 22 Intake air system 23 Forced induction 24 Fuel supply 26 Combustion chamber 32 Injection control 33 Exhaust gas recirculation 35 Exhausttreatment 41 Cooling and lubrication Engine cooling system 49 Thermal management 52 Charge air cooling 53 Engine lubrication 54 Electrical and electronic systems Engine management 55 Special tools Specialtools 61 Annex Abbreviations 68 Index 69 Notes 70 2 Introduction of the Inline Engine Generation | 4-Cylinder OM654 – This printout will not be recorded by the update service. Status: 09/2015 – Contents Product portfolio Youcanalsofindcomprehensiveinformationonourcom- plete product portfolio in our Internet portal: Link:http://aftersales.mercedes-benz.com Questions and suggestions If you have any questions or suggestions concerning this pro- duct, please write to us. E-mail: [email protected] ©2016byDaimlerAG 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/ OR,D-70546Stuttgart.Thisappliesinparticulartoreproduction,distribution,alteration,translation,microfilmingandstorageand/orprocessinginelectronicsystems, including databases and online services. Image no. of title image: P00.00-5670-00 Image no. of poster: P00.00-5669-00 Order no. of this publication: HLI 000 000 2582 Introduction of the Inline Engine Generation | 4-Cylinder OM654 3 – This printout will not be recorded by the update service. Status: 09/2015 – Preface Dear Reader, This Introduction into Service manual presents the new WIS is updated continuously. Therefore, the information avai- 4-cylinderdieselengineOM654inmodelseries 213.In labletherereflectsthelatesttechnicalstatusofourvehicles. terms of the contents, the emphasis in this Introduction into This Introduction into Service manual presents initial informa- ServiceManualisonpresentingnewandmodifiedcompo- tion relating to the new engine generation and, as such, is not nents and systems. stored in WIS. The contents of this brochure are not updated. No provision is made for supplements. The purpose of this brochure is to acquaint you with the technical highlights of this new engine in advance of its mar- Wewillpublicizemodificationsandnewfeaturesinthere- ket launch. This brochure is intended to provide information levant WIS documents. The information presented in this for people employed in service, maintenance and repair as IntroductionintoServicemanualmaythereforedifferfrom wellasforaftersalesstaff.Itisassumedherethatthereader the more up-to-date information found in WIS. All information isalreadyfamiliarwiththeMercedes-Benzmodelseriescur- relating to technical data is valid as of the copy deadline in rently on the market. September2015andmaythereforedifferfromthecurrent productionconfiguration. This Introduction into Service Manual is not intended as an aid for repairs or for the diagnosis of technical problems. Daimler AG For such needs, more extensive information is available Retail Operations (GSP/OR) in the Workshop Information System (WIS) and XENTRY Diagnostics. b Note b Note This and other printed products can be ordered from The printed documents are now available in WIS via the GLC by quoting the respective HLI number. WIS Service Media. 4 Introduction of the Inline Engine Generation | 4-Cylinder OM654 – This printout will not be recorded by the update service. Status: 09/2015 – Brief description Engine OM654 is a newly developed 4-cylinder diesel engine The following goals are achieved with the new OM654: Overview with common rail diesel injection system, multiway exhaust • Uniform concept of a single engine family gasrecirculation,single-stageturbocharging,exhaustafter- • Suitablefordifferentdriveconcepts treatment with the third generation SCR system and optimi- • Increased output zedthermalmanagement.EngineOM654willbeintroduced • Weight reduction in the new E-Class. • Reduced consumption • Compliance with future emissions limits • Potential for development with regard to reductions in consumption and emissions • Improved noise behavior P07.16-4185-00 OM654 D20 SCR Introduction of the Inline Engine Generation | 4-Cylinder OM654 5 – This printout will not be recorded by the update service. Status: 09/2015 – Brief description Overview The special features of engine OM654 in brief: • Commonraildieselinjectionsystemwith2050 bar • Cylinder head with 2-piece water jacket • 8-holepiezoinjectors • Near-engine mounted combination of diesel oxidation ca- • Aluminum crankcase with Nanoslide cylinder wall coating talyticconverter,dieselparticulatefilterandSCRcatalytic • Tandem oil pump integrated in the crankcase converter • Timingchainontheflywheelsidefordrivingthe • ExhaustaftertreatmentwithSCR high-pressurepump,theoilpumpandbothcamshafts • Load-controlled preinjections and post injections • Gearwheeldriveforthebalanceshafts • Twobalanceshafts(Lanchester) • Oilspraynozzleshutoffvalveforcontrollingtheoilspray • Compliance with the Euro 6 emissions standard nozzlesforpistoncrowncooling • ECO start/stop function • Aluminum cylinder head, four valves per cylinder, two • Quick-glow system with glow output stage overheadcamshafts • 1-stageturbocharging,variableturbinegeometrywithwa- • Multiway exhaust gas recirculation with cooled high-pres- ter-cooled bearing housing and E-actuator sure and low-pressure exhaust gas recirculation 6 Introduction of the Inline Engine Generation | 4-Cylinder OM654 – This printout will not be recorded by the update service. Status: 09/2015 – Engine data Overview Model series 213 Unit E 220 d Sedan Engine model designation OM654.920 Engine designation OM654 D20 SCR Emissions standard Euro 6 Cylinderconfiguration/number Inline/4 Displacement cm3 1950 Bore mm 82 Stroke mm 92.3 Valves per cylinder 4 Cylinder spacing mm 90 Compression ratio 15.5:1 Rated output kW 143 at engine speed rpm 3800 Rated torque Nm 400 at engine speed rpm 1600...2400 Fuel type Diesel Injection system Common rail Maximum injection pressure bar 2050 Boost pressure bar 1.8 Engine weight (dry) kg 168 Introduction of the Inline Engine Generation | 4-Cylinder OM654 7 – This printout will not be recorded by the update service. Status: 09/2015 – Performance graph Overview P01.00-3629-00 8 Introduction of the Inline Engine Generation | 4-Cylinder OM654 – This printout will not be recorded by the update service. Status: 09/2015 – Engine views Overview P07.16-4191-00 Front view of engine B5/1 Boostpressuresensor B60 Exhaust pressure sensor B11/4 Coolanttemperaturesensor Y85 EGR cooler bypass switchover valve B17/8 Chargeairtemperaturesensor Y133 Coolantpumpswitchovervalve Introduction of the Inline Engine Generation | 4-Cylinder OM654 9 – This printout will not be recorded by the update service. Status: 09/2015 – Engine views Overview P07.16-4188-00 Top view of engine B2/5 HotfilmMAFsensor B157/2 EGRtemperaturesensor,lowpressure B2/5b1 Intakeairtemperaturesensor N3/9 CDI control unit B6/1 CamshaftHallsensor N37/7b1 NOxsensorupstreamofdieseloxidationcatalyticconverter B19/7 Temperaturesensorupstreamofcatalyticconverter R39/1 Ventlineheatingelement B19/11 Temperaturesensorupstreamofturbocharger 10 Introduction of the Inline Engine Generation | 4-Cylinder OM654 – This printout will not be recorded by the update service. Status: 09/2015 – Engine views Overview P07.16-4184-00 Right side view of engine B19/9 Temperaturesensorupstreamofdieselparticulatefilter R48 Coolant thermostat heating element B28/18 EGRdifferentialpressuresensor,lowpressure Y77/1 Boostpressureregulator M1 Starter Introduction of the Inline Engine Generation | 4-Cylinder OM654 11 – This printout will not be recorded by the update service. Status: 09/2015 – Engine views Overview P07.16-4189-00 Left side view of engine B1 Engineoiltemperaturesensor R9/2 Cylinder 2 glow plug B4/6 Fuel pressure sensor, high pressure R9/3 Cylinder 3 glow plug B4/7 Fuel pressure sensor R9/4 Cylinder 4 glow plug B5/1 Boostpressuresensor Y74 Pressure regulating valve B42 Engine oil pressure sensor Y129 AdBlue®meteringvalve B50 Fuel temperature sensor Y130 Engineoilpumpvalve M16/6 Throttlevalveactuator Y131 Oilspraynozzlesshutoffvalve R9/1 Cylinder1glowplug 12 Introduction of the Inline Engine Generation | 4-Cylinder OM654 – This printout will not be recorded by the update service. Status: 09/2015 – Engine views Overview P07.16-4187-00 Rear view of engine B70 CrankshaftHallsensor N14/3 Glowoutputstage Introduction of the Inline Engine Generation | 4-Cylinder OM654 13 – This printout will not be recorded by the update service. Status: 09/2015 – Engine views Overview P07.16-4186-00 Bottom view of engine B40/6 Engineoilfilllevelsensor 14 Introduction of the Inline Engine Generation | 4-Cylinder OM654 – This printout will not be recorded by the update service. Status: 09/2015 – Soundproofing Overview P01.00-3625-00 View of noise reduction kit Introduction
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