Regeneration of Setra and EvoBus injectors – Mercedes OM457, OM470, OM471 engines
Professional regeneration of Bosch Common Rail injectors for Setra S415, S516 HD, Setra ComfortClass and TopClass and EvoBus Travego coaches. OM457LA, OM470LA, OM471LA Euro 4–6 engines. Bosch numbers, EPS 815 table, report, warranty. Silesia and shipping to PL.
Setra and EvoBus – coaches with Mercedes-Benz engines and demanding CR systems
Setra is a brand of tourist and regional coaches belonging to EvoBus GmbH - a subsidiary of Daimler Truck AG. Setra coaches from theS 400 ComfortClass andS 500 TopClass series are some of the most advanced and exclusive passenger vehicles on European roads. Under the hood there are exactly the same engines that power the Mercedes-Benz Tourismo and Travego buses: OM457LA (Euro 3-5), OM470LA (Euro 6) and OM471LA (Euro 6, V6).
The high value of these vehicles and the costs of downtime make coach fleet owners particularly value efficient service with short lead times. A-Core Diesel Service offers injector regeneration for all generations of EvoBus/Setra engines with a confirmed test report on the Bosch EPS 815 bench.
Engine and injector part numbers – Setra ComfortClass and TopClass
| Setra / EvoBus model | Engine | Injector type | Bosch part number | Euro |
|---|---|---|---|---|
| S 415 / S 416 HDH (ComfortClass) | OM457LA Euro 4 | Bosch CRI2-18 | 0 445 120 123 / 0 445 120 125 | Euro 4 |
| S 415 / S 416 GT-HD (E5) | OM457LA Euro 5 | Bosch CRI2-18 | 0 445 120 124 / 0 445 120 126 | Euro 5 |
| S 516 HD / HDH (TopClass, E6) | OM470LA Euro 6 | Bosch CRI3-20 | 0 445 126 002 / 0 445 126 003 | Euro 6 |
| S 517 HDH / S 531 DT (E6) | OM471LA Euro 6 | Bosch CRI3-20 | 0 445 126 004 / 0 445 126 005 | Euro 6 |
| S 411 HD / S 412 HD (ComfortClass E6) | OM470LA Euro 6 | Bosch CRI3-20 | 0 445 126 002 / 0 445 126 006 | Euro 6 |
| EvoBus Tourismo RHD / SHD (E4/E5) | OM457LA | Bosch CRI2-18 | 0 445 120 123 / 0 445 120 124 | Euro 4–5 |
| EvoBus Tourismo RHD-2 (E6) | OM470LA | Bosch CRI3-20 | 0 445 126 002 / 0 445 126 007 | Euro 6 |
| Setra S 315 GT-HD (older) | OM457LA Euro 3 | Bosch CRI2-P | 0 445 120 078 / 0 445 120 079 | Euro 3 |
OM470LA and OM471LA engines used in Euro 6 buses are 6-cylinder units with the third generation Common Rail system (CRI3-20) operating at pressures up to 2,050 bar. The precision of CRI3 injector regeneration is demanding and directly translates into meeting the Euro 6 emission standard - necessary for entering clean transport zones in European cities.
The most common symptoms of injector damage in Setra coaches
Tour buses operate in different conditions than city buses - long routes, high speeds, variable loads in mountainous terrain. The first symptoms of injector wear usually appear after 500,000-800,000 km or after 6-9 years of intensive use.
Typical symptoms of damaged injectors
- Smoke on cold start – white or gray smoke for the first 30-60 seconds of engine operation
- Increase in fuel consumption - especially visible on highway routes above 120 km/h
- Uneven engine operation – vibrations when parked in parking lots or on crowded routes
- DTCs in Mercedes XENTRY – indication of a specific cylinder OM457 or OM470
- Metallic clatter from the head – characteristic of a damaged CRI3 solenoid valve
- DPF / SCR alarm – a damaged injector causes incorrect combustion affecting DPF regeneration and AdBlue operation
- Jerks when revving - uneven dosage between cylinders
DTCs for OM470 / OM471 (Mercedes XENTRY / STAR) engines
| DTC | Description | Engine |
|---|---|---|
| P0201–P0206 | Cylinder injector circuit. 1–6 – open or short circuit | OM457 / OM470 / OM471 |
| P0261–P0272 | Low / high signal of injector coil - cyl. 1–6 | all |
| P0087 | CR bus pressure too low - below threshold | all |
| P0093 | System leakage - excessive fuel return | all |
| P2146 | Power supply for injector bank 1 - break | OM470 / OM471 (6-cyl.) |
| P2149 | Power supply for bank 2 injectors - break | OM470 / OM471 (6-cyl.) |
| P0191 | Rail pressure sensor – range / result | OM470 E6 CR |
Setra injector regeneration – full procedure
Pre-test and serial number identification
Each Setra coach injector is identified by a number engraved on the body. In the case of CRI3-20 with OM470/OM471, the serial number is crucial for selecting the appropriate calibration parameters from the EPS 815 database. The input test records the complete set of parameters at 5 operating points.
Disassembly and precision inspection
CRI3-20 injectors have a more complex structure than CRI2 - a two-stage control valve and a piezoelectric or solenoid actuator. Disassembly requires specialized Bosch wrenches and a clean station. We check: needle and seat clearance (≤1 μm), second stage control valve, solenoid valve coil or the condition of piezo crystals, seals and inlet filters.
Replacement of elements and calibration 1 μm
We only use Bosch F 00V C99 005 and F 00V C99 006 repair kits for CRI3-20, and for older CRI2-18 - F 00V C99 003 and F 00V C99 004. Calibration of spacer washers with an accuracy of 1 μm is crucial to meet Euro 6 emission requirements in OM470 and OM471 engines.
Post-test, report and guarantee
Acceptance of results only with a tolerance of ±2% from the Bosch/Daimler value. The client (coach company, fleet manager, partner service) receives a printout of the pre/post report with a serial number, which can be attached to the vehicle documentation. Warranty: 12 months for each regeneration.
Setra and EvoBus models supported
- Setra S 415 / S 416 HDH / GT-HD – ComfortClass, OM457LA Euro 4–5
- Setra S 511 / S 515 / S 516 HD / HDH – TopClass, OM470LA Euro 6
- Setra S 517 HDH – TopClass 500, OM471LA Euro 6
- Setra S 315 GT-HD / NF – older ComfortClass, OM457LA Euro 3
- EvoBus Tourismo RHD / SHD / RHD-2 – OM457LA, OM470LA
- EvoBus Travego O580 – OM457LA, OM471LA
Service for coach companies and tour operators
Coach fleet owners can count on a flexible service schedule - we plan the implementation in advance so that it does not interfere with the tourist season (April-October). The shipping service operates all year round. For fleets of more than 5 coaches - individual contact regarding the terms of permanent cooperation: +48 504 511 170.
FAQ
Can CRI3 injectors from OM470 and OM471 be regenerated without replacing the piezo?
Most CRI3-20 injectors used in the OM470 and OM471 are solenoid (electromagnetic) versions, not piezoelectric. Regeneration of solenoid CRI3 is fully possible. Piezo versions (used less often in these engines) require specialized tools to assess the condition of the crystals - we inform about this during the initial assessment.
How quickly can a set of 6 OM470 injectors be regenerated?
Standard delivery time is 3-5 business days. In case of prior arrangement and urgent order (coach out of service), we offer express delivery within 2 business days - please contact us before shipping.
Is servicing at XENTRY required after regeneration of OM470 injectors?
Bosch CRI3 injectors in OM470 Euro 6 do not have individual calibration codes requiring reprogramming of the controller. However, we recommend performing the adaptation procedure (resetting the injector adaptation) in XENTRY after installation, which allows the OM470 controller to optimize operation after regeneration.
Do you service leased or imported Setra coaches?
Yes - we accept vehicles regardless of service history and country of registration. The only requirement is to provide the model, engine number and year of production when ordering, which allows us to prepare appropriate calibration parameters.
Contact
A-Core Diesel Serwis, Knurów (Silesia)
Tel.: +48 504 511 170 – Mon–Fri 8:00–16:00
Free quote after initial diagnostics. Shipping service – all over Poland.
Having a problem with your injection pump?
Contact us – we respond during working hours (Mon–Fri 8:00–16:00).