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Introduction of the Sprinter LGT Model Series 906
Introduction into Service Manual
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Mercedes-Benz Service
Introduction of the Sprinter LGT Model Series 906
Introduction into Service Manual
Daimler AG · Technical Information and Workshop Equipment (GSP/OI) · D-70546 Stuttgart
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Information and copyright
Ordering workshop information All printed workshop information from GSP/OI, such as Introduction into Service Manuals, System Descriptions, Function Descriptions, Technology Guides, Technical Data Manuals and adhesive labels, can be ordered as follows: Within Germany Through our GSP/TI Shop on the Internet Link: http://gsp-ti-shop.de or alternatively from your distributor E-mail: customer.support@daimler.com Phone: +49-(0)18 05/0 10-79 79 Fax: +49-(0)18 05/0 10-79 78 Outside Germany Please get in touch with the contact person responsible for your market. Product Portfolio You can also find comprehensive information on our complete product portfolio in our internet portal. Link: http://open.aftersales.mercedes-benz.com Questions and suggestions If you have any questions or suggestions concerning this product, please write to us. E-mail: Fax: customer.support@daimler.com +49-(0)18 05/0 10-79 78
or alternatively Address: Daimler AG GSP/OIS HPC R822, W002 D-70546 Stuttgart © 2010 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: N00.00-3361-00
Order no. of this publication: 6517 1257 02
10/2010
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Contents
Preface
5
Overview Brief description Location of LPG cylinder Standard Sprinter versus Sprinter LGT Maintenance/repair/diagnosis Gas system inspection/training Safety information
6 7 8 9 11 13
Overall vehicle Selection switch and fill level indicator Mode changeover
14 15
Engine Technical data Engine management
16 19
Supply system Gas supply system
20
Body Function Gas rail/gas injection valves/evaporator Sensors/valves Safety
22 24 26 27
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Contents
Workshop equipment Parking areas/workshop rooms Tools List of abbreviations Index
28 29 30 31
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Preface
Dear reader, This Introduction into Service manual presents the principal changes and new features in the Sprinter LGT with engine M271 which can be operated with liquefied petroleum gas or gasoline. The purpose of this manual is to acquaint you with the technical highlights of the Sprinter LGT in advance of its market launch. This brochure is intended to provide information for people employed in service, maintenance and repair as well as for aftersales staff. It is assumed here that the reader is already familiar with the Mercedes-Benz model series currently on the market. The contents of this Introduction into Service manual focus on new features that have never been used in any other model series before. Features that already exist in other model series are not covered in this brochure. This Introduction into Service manual is not intended as an aid for repairs or for the diagnosis of technical problems. For such needs, more extensive information is available in the Workshop Information System (WIS) and via Xentry Diagnostics. WIS is updated continuously. Therefore, the information available there reflects the latest technical status of our vehicles. The Introduction into Service manual presents initial information relating to the Sprinter LGT and, as such, is not stored in WIS. The contents of this brochure are not updated. No provision is made for supplements. We will publicize modifications and new features as well as detailed descriptions of systems and their components in the relevant WIS documents. The information presented in this Introduction into Service Manual may therefore differ from the more up-to-date information found in WIS. All information relating to specifications, equipment and options is valid as of the copy deadline in August 2010 and may therefore differ from the series production configuration.
i Note Further information on workshop equipment, commercially available tools and special tools can be found on the internet at: http://gotis.aftersales.mercedes-benz.com This Introduction into Service manual is available in electronic form on Release 10/2010 of the Star Diagnosis CD in SDmedia.
Daimler AG Parts Technology and Technical Information (GSP/OI)
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Overview
Brief description
Vehicle concept
From November 2010 the Sprinter of model series 906 will be available with an engine which can be operated with either liquefied petroleum gas or gasoline. The following body variants are available in left-hand and right-hand drive versions: • Cab (FHS/FHL) • Panel van (FKA) • Crewbus (FKB) At present these body variants can only be combined with two wheelbases as 3.5 t versions: • 3665 mm (R2) • 4325 mm (R3) i Note The LGT (Liquefied Gas Technology) Sprinter is equipped with a liquefied petroleum gas system as per ECE-R 67. For this reason the vehicle may only be operated with liquefied petroleum gas or with gasoline, otherwise the engine will be damaged. Liquefied Gas Technology is a drive technology with an extremely low pollutant emission level on the basis of fossil fuels. • Reduced CO2 emissions • Compliance with the limits for pollutant emissions as per EURO 5 in gasoline and gas operation • Reduced noise emissions compared to diesel engines
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Location of LPG cylinder
The 95-liter LPG cylinder is mounted behind the rear axle in the vicinity of the spare wheel. 1 liter of gasoline (95 RON) corresponds to 1.25 liters of liquefied petroleum gas (95P:5B)
Payload reduction
The filled gas cylinder reduces the payload of the vehicle by approx. 85 kg. An additional 15 kg is required for the other LGT components.
Location of LPG cylinder
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Overview
7
Location of LPG cylinder
Overview
Standard Sprinter versus Sprinter LGT
Differences from the series production vehicle
• Mode changeover (gasoline or LPG operation) • Engine management • Fuel supply system
Additional components for LPG engine M271
• • • • • • • • • • • • • LGT interface control unit Gas rail Evaporator Gas injection valves Gas filter Engine compartment shutoff valve Combination valve LPG lines Filler valve Electrical wiring harness LPG cylinder Fill level sensor Gas reservoir shutoff valve
Resultant changes
• • • • Maintenance information Safety information Repair information Diagnosis information
Engine compartment of Sprinter LGT
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Notes on maintenance
The maintenance and service requirements of LPG vehicles are generally identical to those of gasolinefueled models. However, the maintenance and repair of gas systems for LPG operation require specially trained workshop staff. Various associations offer training courses in which expertise specific to the product and fuel system is taught. Maintenance service every 30,000 km, or every 15,000 km in heavy service • Oil Service Plus: Engine oil change (M 271 LGT) every 30,000 km with oils as per Sheets 229.5 and 229.51 • Replace gas filter element in gas filter every 30,000 km
Maintenance service every 60,000 km or every 2 years, or every 30,000 km in heavy service
• Engine oil change (M 271 LGT) every 30,000 km with oils as per Sheets 229.5 and 229.51 • Replace gas filter element in engine compartment shutoff valve every 60,000 km • Check LPG system and LPG cylinder for damage and corrosion • Check LPG cylinder for firm seating • Replace spark plugs All other service jobs are the same as for the series production vehicle.
i Note Work on components that do not form part of the LGT equipment may be carried out by any trained professional.
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Overview
9
Maintenance/repair/diagnosis
Overview
Engine management
Notes on diagnosis
• The LGT interface control unit can be diagnosed via DAS • The ME-SFI control unit is flashable • No additional external diagnostic tools are required • System access and diagnosis options are the same as for the Vaneo, Vito and Viano • The diagnosis software is available as of DVD 01/ 2011 • All electronic components can be actuated via diagnosis
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Notes on gas system inspection
National legislation may prescribe a regular inspection of the gas system by appropriately authorized persons and authorities. This inspection includes a visual inspection and a leak test of the gas system. Please comply with the national legal requirements applicable to you. In the Federal Republic of Germany this is the GAP gas system inspection according to Section 41a of the German vehicle licensing regulations (StVZO). For new vehicles the first gas system inspection (GAP) is performed after three years; after this the interval is shortened to two years. A gas system inspection (GAP) is necessary: • As part of the main inspection of the vehicle • After any work performed on parts and lines carrying gas, including parts of the tank system of the LPG system in the vehicle • After particular events, e.g. accident or fire After every repair to the liquefied petroleum gas system in the vehicle a leak test must be performed in accordance with the manufacturer's instructions. For countries with no national legislation we recommend a regular inspection of the gas system analogous to the German gas system inspection (GAP).
i Note A GAP gas system inspection may only be performed by a GAP inspector who has completed the examination course.
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Overview
Gas system inspection/training
Overview
Gas system inspection/training
Notes on training
Available training courses can be found at http://gt.intra.mercedes-benz.com • Certificate of proficiency for motor vehicles with gas operation (prerequisite for the initial training course), code PNGG-MM237 • Initial training for the Sprinter LGT, code NGSLMG239 • Gas system inspection (GAP) on motor vehicles (examination course), code PGAP-MM240 • Other gas-specific training courses ... The certificate of proficiency in Germany merely entitles the holder to work on motor vehicles with gas operation. GAP inspectors in Germany must additionally be properly qualified automotive technicians or engineers. The examination course (GAP) must be repeated every three years with a final examination.
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General
• In most regions of German there are no restrictions on using LPG-fueled vehicles in multi-level car parks and tunnels. Instructions governed by civil law in multi-level car parks, underground garages, tunnels and ships must be observed. • The LPG cylinder, the lines, threaded connections and other fittings offer the greatest possible safety in the event of accidents. LPG-fueled vehicles therefore have no disadvantages in terms of accident behavior in comparison with conventionally powered vehicles. • The installation in the vehicle guarantees that the liquefied petroleum gas cannot enter the interior compartment of the vehicle. • The risk of fire in LPG-fueled vehicles is no higher than in gasoline or diesel vehicles. • Liquefied petroleum gas is heavier than air and therefore collects in depressions in the ground/ floor.
Welding and painting work
• When repair/welding work is to be carried out in the vicinity of gas-specific components, these must first be removed or protected against flying sparks with a fire-resistant cover. Gas cylinders that are damaged by flying sparks during welding work must be replaced. • The temperature in the spray booth may only exceed 60 °C for short periods. • The maximum drying temperature is 60 °C over a drying time of 30 min.
i Note • LPG cylinders must be protected against flying sparks during welding work. • LPG cylinders are not available as reconditioned parts. • Damaged LPG cylinders must be replaced. • Used LPG cylinders that have not been flushed out, as well as filled LPG cylinders, must always be identified as hazardous goods for transportation. • LPG cylinders are to be returned to the Mannheim plant (W20). LPG cylinders may only be replaced complete with valve.
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Overview
Safety information
Overall vehicle
Selection switch and fill level indicator
Gas/gasoline selection switch
The gas/gasoline selection switch is located on the left-hand side of the center console between the ignition lock and the ventilation controls. The operating mode is selected by a single press of the central pushbutton on the gas/gasoline selection switch, and is confirmed by means of an acoustic signal. Two operating modes can be selected: • Gasoline • Liquefied petroleum gas
LPG fill level indicator
The fill level of the liquefied petroleum gas in the gas cylinder is indicated by 4 LEDs arranged side by side on the gas/gasoline selection switch. When all four of the lower LEDs are lit, the cylinder is full. If only one of the four LEDs is still lit, then the gas supply is almost exhausted. Flashing of the last LED indicated that the reserve level has been reached and an automatic changeover to gasoline is imminent. The automatic changeover is signaled by a warning tone, which must be acknowledged by pressing the button. The combination valve on the LPG cylinder also features a sensor which indicates the fill level visually by means of a needle and a colored scale.
Gas/gasoline selection switch 1 2 3 4 Gas/gasoline selection switch Central pushbutton Mode LED Fill level LEDs
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Fill level indicator on LPG cylinder
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1 Combination valve 2 Fill level indicator 3 LPG cylinder
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Manual mode changeover
The gas/gasoline selection switch can be used to change between gasoline and LPG fuels at any time. The fully sequential, fully electronic changeover ensures that this occurs smoothly even under load.
Warnings
The following states are indicated by the mode LED in the gas/gasoline selection switch: LED lights up green • Vehicle in gas mode LED lights up yellow
Automatic changeover
The LGT system automatically detects when the engine fuel supply is no longer sufficient (empty LPG cylinder or system malfunction). In this case the gas system immediately switches to gasoline and emits a signal tone to indicate the automatic changeover.
• Changeover phase LED lights up red • Vehicle in gasoline mode
i Note Avoid manual changeovers at high rpms and loads in order not to subject the engine or the catalytic converter to unnecessary stress.
i Note The liquefied petroleum gas system switches back to gasoline automatically and fully sequentially only when the LPG cylinder is empty.
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Overall vehicle
Mode changeover
Engine
Technical data
Engine data M 271.951 LGT Gasoline mode Rated output kW at rpm hp at rpm Nm at rpm 115 5000 156 5000 240 3000...4000 4 LPG mode
Rated output
Rated torque
No. of cylinders
Valves per cylinder
4
Total displacement
cm3
1796
Injection by
Gasoline injectors
Gas injection valves
Injection pressure
bar
3.8
2.5
Fuel type
Super 95 RON, unleaded; Super Plus 98 RON, unleaded
LPG 107 RON
Mean energy consumption as per NEDC with manual transmission with automatic transmission
100 km 12.2 l 13.2 l 15.2 l 16.5 l
Maximum speed
km/h
153
Acceleration
0...100 km/h
20.6 s
20.7 s
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System features Gasoline mode Exhaust system Engine
M 271.951 LGT LPG mode
Underfloor and firewall catalytic converters with oxygen sensor 4-cylinder inline engine with supercharging and Lanchester balancing, with 4 valves per cylinder and charge air cooling, port injection and internal exhaust gas recirculation
Mixture formation
Injection at 3.8 bar by one injection valve per cylinder in intake port upstream of intake valve
Supplemented by one gas injection valve per cylinder, gas rail with integrated PTS pressure/temperature sensor, system pressure 2.5 bar
Engine management
Motor Electronics (ME-SFI) gasoline injection and ignition system
Expanded by LGT interface control unit receiving signals via engine CAN
Fuel supply system
Fuel tank with filler neck and suction jet pump, fuel distributor
Expanded by a standardized filler connection in the combined tank recess behind the fuel filler door, gas cylinder with combination valve
System information
Via multifunction display in instrument cluster
Additional gas/gasoline selection switch with indicator
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Engine
Technical data
Engine
Technical data
LGT interface control unit
The LGT interface (Liquefied Gas Technology) control unit receives and processes the information from the following sensors: • Gas pressure/temperature sensor The LGT interface control unit is responsible for operating the following actuators: • • • • Combination valve Gas injection valves Evaporator Engine compartment shutoff valve with integrated filter
Location of control unit 1 LGT interface control unit
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ME-SFI control unit
The engine control system is supplied by Siemens. In combination with the LGT interface control unit, it allows either of the two operating modes to be used. The engine control unit (ME-SFI) calculates the opening times of the gasoline injection valves. These times are converted into injection times for LPG mode by the LGT interface control unit. The LGT interface control unit is responsible for actuating the gas injection valves in LPG mode.
Location of control unit 2 ME-SFI [ME] control unit
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Engine
Engine management
Supply system
Gas supply system
General
The tank system (gas) contains the following components: • LPG cylinder • Additional gas lines • Filler connection On the LPG cylinder is a combination valve which contains the following components: • Filler valve (with integrated check valve and 80 % fill shutoff via float) • Electromagnetically actuated gas sampling valve • Mechanical hand shutoff valve upstream of electromechanical gas sampling valve • Fill level indicator (readable mechanically/visually and electrically) • Overpressure safety valve (<30 bar gas-tight) • Flow limiter in pressure relief valve The gas system is inspected at regular intervals as part of the gas system inspection (GAP). The LPG cylinder is made of steel 3.5 mm thick and is accommodated in sturdy, crash-proof brackets. The combination valve ensures that there is no danger from the LPG cylinder, even in extreme situations. In addition, the LPG cylinder can be mechanically locked manually. The standard fuel tank for gasoline is preserved intact.
Combination valve 1 2 3 4 5 Gas sampling valve Fill level indicator Filler valve Overpressure safety valve Mechanical hand shutoff valve
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LPG cylinder with brackets
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Combined tank recess
The ACME refueling connection for Germany is the link between the gas refueling station connection and the vehicle system, and is located behind the fuel filler door. The vehicle can only be refueled at special gas filling stations. Adapters for other countries in the EU (e.g. Italy, Spain, Netherlands, UK) are included in the scope of supply.
Combined tank recess 1 LPG filler connection 2 Gasoline filler connection
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Supply system
Gas supply system
Body
Function
Function schematic
2 1 3 4 5 12 11 9 8 10 7 6
Function description 1 2 3 4 5 6 Filler valve Combination valve LPG cylinder Engine compartment shutoff valve Evaporator Gas filter 7 8 9 10 11 12 Gas injection valves Gas rail Pressure sensor Temperature sensor Low-pressure area (2.5 bar) High-pressure area (max. 30 bar)
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Components of the injection system
• Gas rail • Integrated pressure/temperature sensor (in gas rail) • Gas injection valves • Evaporator • LGT interface control unit • Gas filter • Electromagnetic shutoff valve The engine has been supplemented by gas injection valves on the top of the intake manifold. A near-engine mounted evaporator and an electromagnetic shutoff valve control the supply of liquefied gas. The expanded engine control for monitoring the LPG and gasoline functions is completely integrated into the vehicle and engine electronic systems. The fuel supply control allows the operating mode to be changed at any time. The changeover occurs by switching the cylinders from liquefied petroleum gas to gasoline and vice versa selectively, i.e. each cylinder is switched over individually according to the firing order. This results in a particularly soft transition from one fuel to the other.
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Body
Function
Body
Gas rail/gas injection valves/evaporator
Gas rail
The gas rail is made of aluminum and is fastened to the air filter box. The rail acts as the mounting for further components: • PTS pressure/temperature sensor • Gas injection valves
Evaporator
The evaporator is responsible for changing the aggregate state of the liquefied petroleum gas from a liquid into a gas with the aid of the coolant, so that the gas can then be injected into the cylinders and burned. The evaporator reduces the pressure prevailing in the LPG cylinder to the operating pressure of 2.5 bar required at the engine intake. The evaporator is equipped with a heating plate which is connected to the small cooling circuit. This prevents icing of the evaporator due to the liquefied petroleum gas.
i Note In both LPG and gasoline mode, the pollutant emissions limits of EURO 5 with EOBD (European OnBoard-Diagnosis) are complied with.
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Gas injection valves
When the solenoid coil is energized by the LGT interface control unit, the solenoid armature lifts the nozzle needle against the coil spring. The gas exits through the outlet hole and is injected into the intake manifold cylinder-selectively. The duration of actuation of the gas injection valves and of the gasoline injectors determines the injection quantity. The signal for actuation comes from the LGT interface control unit.
11 10 9 12 8 7 4
6 5 3 2C 2B 2A 2D 1
Gas injection valve 1 2A 2B 2C 2D 3 4 Gas outlet housing Flat spring Valve plate Nozzle needle Valve seat Injector housing Gas inlet housing 5 6 7 8 9 10 11 Solenoid Cover Air gap O-ring O-ring Thrust piece O-ring
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Body
Gas rail/gas injection valves/evaporator
Body
Sensors/valves
PTS pressure/temperature sensor
The PTS pressure/temperature sensor is located in the gas rail and forwards the current gas pressure and the current gas temperature to the LGT interface control unit. The PTS pressure/temperature sensor measures the temperature and pressure so that the correct injection quantity can be apportioned. If the pressure is > 2.5 bar (accelerating), a signal is given that the evaporator must deliver more gas, or in the opposite case, that the supply must be throttled. An NTC resistor installed in the PTS pressure/temperature sensor changes its electrical resistance according to the current gas temperature. The PTS pressure/temperature sensor measures the temperature so that the correct injection quantity can be apportioned.
Gasoline injectors and gas injection valves
The gasoline injectors and gas injection valves are actuated sequentially and cylinder-selectively by the switching output stages integrated in the LGT interface control unit. The length of the actuation dictates the gasoline or gas injection quantity depending on the operating mode. The signal for actuation of the gasoline injectors or gas injection valves comes from the ME-SFI control unit.
Engine compartment shutoff valve
The electromagnetic shutoff valve is located in the engine compartment upstream of the evaporator. The shutoff valve is actuated directly by the LGT interface control unit.
PTS pressure/temperature sensor 1 2 3 PTS pressure/temperature sensor Gas injection valves Gas rail
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Shutoff valve 1 2 Evaporator Engine compartment shutoff valve
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Manual gas cylinder shutoff valve
The LPG cylinder can be closed manually using the manual shutoff valve.
Overpressure safety valve
There is one overpressure safety valve on the gas cylinder and one upstream of the evaporator (engine compartment shutoff valve); both open at pressures in excess of 30 bar and allow the gas to escape into the atmosphere. When the pressure drops below 30 bar, the two valves automatically close again gas-tight.
Check valve
The filler connection and the combination valve on the gas cylinder each contain a check valve. The check valve in the filler connection prevents the LPG in the filler line (high pressure) escaping from the filler connection after refueling.
Flow limiter
The contents of the LPG cylinder can escape into the atmosphere in a controlled manner via the flow limiter. The flow limiter prevents any sudden escape of liquefied petroleum gas.
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Body
Safety
Workshop equipment
Parking areas/workshop rooms
Parking areas for gaseous fuel vehicles
Gaseous fuel vehicles on the workshop premises must be marked as such in an easily visible location. As long as the systems are leaktight, no further requirements apply. If there are indications of leakage, gaseous fuel vehicle must always be parked out of doors. If this is not possible and the gaseous fuel vehicle has to be left in a closed room, then only in the following state: • Gas sampling valve (hand valve) CLOSED • Operating mode "Gasoline" • Ignition OFF
Working on gaseous fuel vehicles in closed workshop rooms
In the case of general maintenance and servicing work (on parts not carrying gas), no particular measures need to be observed. Special gas workplaces must exist for work on the gas system. The floor and pit areas of the special gas workplace must be adequately ventilated. This can be achieved by means of: • Fans at the gas workplace itself • Technical ventilation with an air cycle rate of ≥ 3/h All applicable national legal requirements must be complied with!
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Commercially available tools
PEAKER 3000 flex multiple-range gas trace instrument Use Multiple-range gas trace instrument for methane, propane and hydrogen UST Umweltsensortechnik GmbH
Supplier
Special tools
Open-end wrench, double W271 589 02 01 00 Use For removing/installing the 3/4" gas hoses on the cylinder of the intake manifold e.g. Hahn
Supplier
No further special tools are required for the Sprinter LGT compared with the series production vehicle.
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Workshop equipment
Tools
List of abbreviations
EOBD European On-Board-Diagnosis EURO 5 European emissions standard, valid from 2005 FHS Cab FKA Panel van FKB Crewbus GAP Gas system inspection
ME Motor Electronics (ME-SFI) LGT Liquefied Gas Technology NTC Negative temperature coefficient ROZ Research octane number (RON) SA Special equipment
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Index
A
Additional components for LPG engine . . . . 8
Manual gas cylinder shutoff valve . . . . . . Mode changeover
Automatic . . . . . . . . . . . . . . . Manual . . . . . . . . . . . . . . . .
27 15 15
C
Check valve . . . . . . . . . . . . . . . . 27 Combined tank recess . . . . . . . . . . . 21 Control unit
LGT interface . . . . . . . . . . . . . . 18 ME-SFI . . . . . . . . . . . . . . . . . 18
O
Overpressure safety valve . . . . . . . . .
27
P
Parking areas for gaseous fuel vehicles . . . 28 Payload reduction . . . . . . . . . . . . . 7 PTS pressure/temperature sensor . . . . . 26
D
Diagnosis . . . . . . . . . . . . . . . . . 10 Differences from the series production vehicle . 8
R
Repairs . . . . . . . . . . . . . . . . . . 9
E
Engine compartment shutoff valve . . . . . . 26 Engine data . . . . . . . . . . . . . . . . 16 Evaporator . . . . . . . . . . . . . . . . 24
S
Safety . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . System features . . . . . . . . . . . . .
13 29 17
G
Gas injection valves . Gas level indicator . . Gas rail . . . . . . . Gas system inspection Gasoline injectors . .
. . . . . . . . . 25, 26 . . . . . . . . . . . 14 . . . . . . . . . . . 24 . . . . . . . . . 11, 20 . . . . . . . . . . . 26
T
Tank system . . . . . . . . . . . . . . . Training courses . . . . . . . . . . . . .
20 12
V
Vehicle concept . . . . . . . . . . . . . . 6
L
LPG cylinder . . . . . . . . . . . . . . . . 20
W
Warnings . . . . . . . . . . . . . . . . Working on gaseous fuel vehicles . . . . . .
15 28
M
Maintenance
...............9
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Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart 6517 1257 02 – Printed in Germany – 10/10
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