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1. 03 310 Reconditioning and squaring connecting rods seen eee tenes 313 Removal and installation of pistons 0 eee e 316 Checking and reconditioning of crankshaft cee ee ene tee 318 Mounting of crankshaft o error 320 Replacing front crankshaft radial sealing ring cee eevee o 324 Replacing rear crankshaft radial sealing ring ue e renee ven nae 327 Removal and installation of radial ball bearing in crankshaft TIEN 330 Removal and installation of crankshaft pulley at hub lt 0 T 341 Checking and correcting adjustment of TDC transmitter 345 Removal and installation of crankshaft timing gear 350 Flywheel of driven plate and ring gear Removal and installation of flywheel and driven plate 0 6 ee eee ee es 410 Refinishing of flywheel 0 0 0 ee ee ee ee ee ees 420 Renewing ring gear of flywheel 0 0 0 0 ee eee ee ee eee eee 430 03 1 03 3 10 Checking renewing and tightening connecting rod bolts Dimensions of connecting rod bolt Part no Thread dia Necked down shank dia c when new Fig item 1 601 038 01 71 MS x 1 7 4 0 1 Tightening connecting rod bolt Initial torque Angle of rotation torque Checking 1 Measure minimum necked down shank dia prior to re use Note If the minimum necked down shank dia of 7 1 mm is atta
2. 87 000 87 006 above 87 006 87 012 above 87 012 87 018 Piston standout Distance between piston crown and cylinder crankcase parting surface Test values Piston clearance Difference in weight of pistons in one engine Piston pin dia in connecting rod bushing Piston pin clearance in piston Connecting rod in piston end play groove 1 groove 2 groove 3 Gap clearance of piston rings groove 1 groove 2 groove 3 Side clearance of piston rings Tightening torque Connecting rod screws 03 10 316 1 when new 0 017 0 043 6g 26 995 27 000 0 018 0 029 0 004 0 015 0 083 0 314 0 20 0 40 0 20 0 40 0 20 0 40 0 090 O 120 0 050 0 080 0 030 0 065 initial torque angle of rotation torque standout max 0 96 standout min 0 73 wear limit 0 12 10g 1 5 1 0 1 0 0 20 0 15 0 1 30 5 Nm 90 1 00 Special tools Spreaders for piston rings 000 589 51 37 00 Clamping strap for piston rings 000 589 04 14 00 11094 6719 Note The group code letter A X or B the piston code number 05 or 06 and the driving direction arrow are punched into piston crown The group code letter is also punched into cylinder crankcase parting surface For repairs only pistons with group code letters X are available These pistons are also for installation in cylinder bores with group code letters A or B In the event of repairs hone cylinder bores according to dimensions
3. 7304 6208 601 589 03 43 00 001 589 51 21 00 001 589 66 21 00 R emoval 1 Remove transmission 26 020 or 27 600 2 Remove flywheel or driven plate 03 410 3 Unscrew fastening screws 21 and 55 and force off end cover on both lugs arrows 4 Clean sealing surfaces on cylinder crankcase and end cover 5 Check whether radial sealing ring is damaged Renew radial sealing ring Installation 6 Coat end cover on sealing surface uniformly with sealing compound Loctite 573 part no 001 989 45 20 7 Slip end cover with pressed in radial sealing ring over screwed on assembly sleeve Pay attention to oil pan gasket 01 1 0 222 2 8 Tighten fastening screws 21 and 55 to 10 Nm Tighten fastening screws 55 first 9 Run engine warm and check for leaks 10125572 01 10 222 3 01 310 Oil capacity in liters Oil pan Oil filter Tightening torques Oil drain plug to oil pan Oil pan to cylinder crankcase Adjusting screw for front engine stop Adjusting screw for rear engine mount Engine carrier to engine mount front Special tools Torque wrench with plug in ratchet 1 2 square 25 1 30 Nm Torque wrench with plug in ratchet 1 2 square 40 200 Nm Screwdriver with tommy handle for hex socket screws 5 mm 300 mm long Screwdriver with tommy handle for hex socket screws 6 mm 440 mm long Box end Allen wrench 13 x 14 mm 01 10 310 1 Removal and installat
4. 1033 8040 3 Install thrust washers of the same thickness on both sides on principle Regrinding of thrust washers is not permitted As replacement parts thrust washers are available in sets only One set comprises an upper and a lower thrust washer 148 and 148a Thrust washer sets Thickness in mm Set part no 2 15 601 030 00 62 2 20 601 030 01 62 2 25 601 0300262 2 35 6010300362 2 40 601 030 04 62 i 1 Association of crankshaft bearings installation of Y O crankshaft 1 Install crankshaft bearing cap Note All bearing caps are fitted laterally into crank case arrows and are fastened with 2 screws M 12 x 60 each O The pilot fit arrows is offset from center by 0 5 mm O so that the bearing caps can be mounted in one posi tion only E 1033 11466 54 5 53 5 The bearing caps are additionally identified from the front to the rear with the code numbers 1 2 3 4 and 5 arrows and should not be mixed up 03 1 0 320 4 2 Lubricate screws for crankshaft bearing caps and tighten to 90 Nm 3 Measure basic bore in direction A B and C on two levels conicity If the specified value of a basic bore is exceeded touch up bearing cap at its parting surface on a surface plate up to max 0 02 mm 4 Insert crankshaft bearing shells mount bearing caps tighten screws to 90 Nm Housings Caps 03 1 0 320 5 1032 116
5. 28 To install engine reverse removal procedure Pay attention to specified torques of fastening screws and nuts Check installation position of shielding plates on engine mounts 29 Screw on propeller shaft and adjust 41 020 30 Adjust engine stop 22 220 31 Check oil level in engine and transmission and correct if required 32 On vehicles with air conditioning fill system 83 514 33 Check all drain plugs for specified tightening torque 34 Clean air cleaner element and renew if required 35 Check for leaks with engine running 01 1 0 030 7 01 040 Crankcase breather operation A Standard version and Gs Federal starting 1984 Engine601 911 The closed engine breather requires no service Depending on intake manifold vacuum the engine blow by gases are flowing through oil separator 126 in cylinder head cover and a hose line to distributing pipe 140 on intake manifold From here they are uniformly distributed to all the cylinders and fed to the combustion chambers to gether with the intake air The oil separated in oil separator 126 flows back to cylinder head through return pipe 127 126 Oil separator 127 Return pipe 140 Distributing pipe lt a Fresh air fm Blow by gases 01 10 040 1 EBB 1004 11703 B sa California starting 1984 Engine 601 921 Engine breather The closed engine breather requires no service Operation Depending on intake manifold v
6. 4th stage 90 36 Tighten screws M 8 arrows by means of screw driver with tommy handle 101 258519 37 Install guide rail for timing chain For this pur pose insert slide rail bolts 221 and 222 into cylinder head 38 Install camshaft while paying attention to color mark Note The camshaft timing gear is centered by means of a cylindrical pin arrows 01 10 415 9 39 Position fastening screw of camshaft timing gear and tighten to 45 Nm For this purpose apply counterhold to camshaft timing gear with a screwdriver or steel pin 40 Install chain tensioner and tighten to 80 Nm 41 Rotate engine and set to ignition TDC of 1st cylinder Check adjusting marks The notch in flange of camshaft must be in alignment with cast on lug on cylinder head arrow 42 Mount electric lines for pencil element glow plugs 43 Mount pipe elbow 93 with new O ring 44 Install intake manifold 45 Install injection lines 01 10 415 10 120 26934 Ree RAR AR RRA RR RARE RRA RR RAR RR RARA RR ON 46 Screw exhaust system to exhaust manifold 47 On vehicles with EGR install pipe line 1 be tween EGR valve and exhaust manifold 48 Install fuel filter and fuel lines 49 Screw on holder for oil dipstick guide tube 50 On vehicles with level control mount pressure oil pump and driver 51 Mount tensioning device for V belt For this pur pose swivel spring tensioning lever 374 by means
7. A XN i Le AANNANAAAAASARARANS LUL LD ER N N 102 Gi A G4 EL La ey AS Y rn ES 1053 11648 105 26925 Sleeve 02 should be tight enough in grooves so that it will not slip out of grooves when loosening threaded ring Insert wrench at hexagon of sleeve 02 and unscrew threaded ring 01 Nut 02 Sleeve 7 Pull out prechamber with impact puller part no 601 589 06 33 00 8 Cover bore in cylinder head Installation Note If the removed prechambers are again installed check for perfect condition Ball pin should not be burnt or covered with scale In addition if the burner tops are showing burn marks or cracks are showing in prechamber lower half remove intake manifold and check inside for traces of oil If oil moistened spots are found check vacuum pump for damage or renew vacuum control unit on injec tion pump The vacuum lines blackened by oil are showing which of the two parts of the unit has failed 01 10 417 4 295 26936 A tt If a cylinder head is faced at parting surface the required distance c of 7 6 8 1 mm must be main tained For this purpose select appropriate sealing ring and insert between cylinder head and prechamber The following sealing rings are available N a X AY YY Ea Thickness Part no N N 4 N UIT KOSS We SS Y SS A 9 Position prechamber in such a manner that the l
8. a 001 589 74 2100 3 4 square 150 800 Nm S Torque wrench single arm emitting signal with plug in ratchet 1 2 square 25 130 Nm 001 589 66 21 00 Puller for crankshaft timing gear 601 589 07 33 00 Detent 601 589 02 40 00 Countersupport for internal puller 000589333300 Internal puller 14 5 18 5 mm 000589253300 for radial ball bearings Dial gauge holder for measuring 363589022100 end play 03 1 0 320 2 Note Engine removed and disassembled Main oil duct in cylinder crankcase open 01 130 Oil ducts in cylinder crankcase and in crankshaft carefully cleaned Check crankshaft for cracks dimensional accuracy hardness and concentricity 93 318 The 3rd crankshaft bearing is provided with thrust washers These thrust washers absorb the axial forces of crank shaft The thrust washers 148 and 148a installed in cylinder crankcase and in bearing cap on both sides are of different shape As a torsion lock and to prevent assembly faults the thrust washers in bearing cap are provided with two holding lugs of which the outer one is installed off center When reconditioning crankshafts regrind width of fitted bearing journals to one of the dimensions shown in Table section Data Associate thrust washers to respective journal or pin widths Table 2 Bearing cap 4 ScrewsM 12x60 145 Crankshaft 146 Bearing shell 148 Upper thrust washer 148a Lower thrust washer 03 1 0O 320 3
9. repair stages of thrust washers Normal dimension 1st repair stage 2nd repair stage 3rd repair stage 4th repair stage Basic bore and bearing play Associated thickness Crankshaft Crankpin Crankpin journal dia width widths 26 52 27 96 28 04 up to 28 30 46 950 46 965 Crankshaft bearings Connecting rod bearings 62 500 51 600 Basic bore dia 62 519 51 619 Basic bore width 22 00 on fitted bearing 91 97 Connecting rod width E 22 923 24 165 Permissible out of true of basic bore 0 01 Permissible conicity of basic bore 0 01 when new 0 03 1 0 073 Bearing play radial wear limit 0 08 when new 0 10 0 25 0 12 O 26 Bearing play axial wear limit 0 30 0 50 1 For radial clearance try for mean value 03 10 320 1 Bearing shells Wall thickness Width of Thickness of fitted Wall thickness crankshaft bearings bearing shells bearing thrust washers connecting rod bearings Normal dimension 2 25 17 30 17 60 2 15 or 2 20 1 80 1st repair stage 2 37 2 25 1 92 2nd repair stage 2 50 or 2 05 3rd repair stage 2 62 2 35 2 17 4th repair stage 2 75 or 2 30 2 40 Tightening torques Nm Crankshaft bearing bolts 90 initial torque 30 5 Connecting rod screws angle of rotation torque 90 100 Screw M 18 x 1 5 x 50 on crankshaft 370 40 Initial i Necked down screws for flywheel AA enor AO driven plate i p angle of rotation torque 90 1 00 Special tools Torque wrench singe arm with ratchet
10. 020 Removal and installation of engine oil capacity cee ee ee 030 Crankcase breather Operation eses trata eee AAA 040 A Standard version and Federal starting 1984 ee es 8 GS California starting 1984 cee eee ete eee Cylinder crankcase Measuring cylinder bores cece eee es ee ee ee 110 Renewing boring and honing cylinder liners 115 Facing cylinder crankcase parting surface 120 Knocking out and inserting steel balls in main oil duct 130 Replacing core hole closing cover in cylinder crankcase 140 Timing housing cover and cylinder crankcase cover Removal and installation of timing housing cover 210 Removal and installation of end cover 222 Oil pan Removal and installation of oil pan acia ara pales 310 Cylinder head Cylinder head bolts and tightening cylinder head bolts 405 Removal and installation of cylinder head 415 Removal and installation of prechambers o eee ee ee ee 417 Facing cylinder head parting surface 0 0 ce ee ee 418 Pressure testing cylinder head oo ooooo ees 420 01 1 01 010 Checking compression pressure Test values with engine at operating temperature in bar gauge press
11. ade 015 Technical data miei es E a Ae o e ds Bm Tee E Te ee ee ee ee E E 020 00 1 PARRA _EXIT Instructions for use of service manual 00 Complete Service Manual coverage for late model year Mercedes Benz vehicles requires four individual manuals Service Manual Engine Service Manual Transmission Service Manual Chassis and body Service Manual Heating and air conditioning Throughout these manuals the vehicles are identified by their chassis and engine numbers These numbers are made up of the first six digits of the respective serial number For the actual location of chassis and engine numbers see page 00 015 1 In case where the repair instructions apply to all versions only the first three digits of the respective number are refer enced For example engine 601 applies to all 601 engines However engine 601 921 would only apply to the engine used in model 190 D 2 2 Location of specific repair instructions First locate the Group No in the Group Index Individual groups are separated by an easily visible dividing page which is followed by the job index page Then check the job index for the exact job required The first page of a typical job description looks like this 03 320 Mounting of crankshaft Job Title appears on E same line as Group No Group No Sub Group No i Job No M Page No 03 1 0 320 1 Technical data tightening torques and tools are listed at the beginning
12. available on 2 3 of journal pin circumference Hardening y Pins without hardened fillets can be inductance hardened or flame hardened On the other hand journals and pins with hardened fillets arrows E should be inductance hardened on principle If this cannot be done scrap crankshaft ff a When hardening journals and pins without hardened fillets the distance A between hardened runout and rr per a fillets radius 5 6 mm must be maintained A 1032 11673 1 03 10 318 4 Checking the hardening results For perfect hardening check adjustment of hardening equipment by means of metallographic etching grinding These tests can be made with test hardenings on scrapped crankshafts Check hardening by etching surface of journals or pins with a 2 solution of alcoholic nitric acid HNO3 No dark spots should appear on journal or pin surface Unhardened fillets will become dark Hardened fillets on the other hand should be as bright as the surface of pin or journal A journal or pin which has already passed metallo graphic inspection may be used for comparison Then carefully wash off nitric acid with alcohol Protection against corrosion Crankshafts which are not immediately installed again should be lubricated with engine initial operation oil SAE 30 03 10 318 5 03 320 Mounting of crankshaft Crankshaft bearing journal dia Crankshaft standard Fitted bearing dimension and
13. iiitide itiiti TG 5 Mill off or grind off the projecting flange of bushing Remove as little as possible from cylinder crankcase parting surface Guide milling cutter or grinding wheel centrally over cylinder bores 6 Enlarge bore cylinder liners in two steps For honing leave an allowance of 0 03 mm in bores 7 Chamfer cylinder liners 4 PDP DIP ITO OOO ae TZ Ahh RR hbdibdhidhehhihdidhebahuhebabeehathateaharherler Y 1034 8233 Y 8 Hone cylinder bores 9 Measure cylinder bores and select matching pistons 01 1 10 01 10 115 3 01 120 Facing cylinder crankcase parting surface Data Height of cylinder crankcase when new 300 299 95 Minimum height following a required material removal in longitudinal direction 0 10 Permissible unevenness of parting surface in transverse direction 0 05 Permissible roughness of upper parting surface 0 006 0 016 Permissible deviation from parallel between upper and 0 1 lower crankcase parting surface in longitudinal direction l Pressing off pressure with air under water in bar gauge pressure 1 5 Chamfer of cylinder bores Distance between piston crown and cylinder crankcase parting surface engine 601 921 Note Prior to facing check piston standout projection Do not exceed piston standout of 0 9 or 1 05 mm 03 316 Chamfer cylinder bores after facing Check timing if cylinder crankcase parting surface has been refinished 05 215 01 10 120 1
14. of available pistons X plus piston clearance Engine 601 911 1034 11452 1 A SS Engine 601 921 1034 11641 1 03 1 0 31 6 2 Removal 1 Remove connecting rod with piston in upward direction 103 26983 2 Remove piston pin circlip and push out piston pin 103 25609 3 Recondition connecting rod and square 03 313 Installation 4 Place piston on connecting rod in such a manner that arrow 1 points in driving direction and locking grooves 2 in connecting rod to lefthand engine side Attention Do not heat pistons 103 26983 03 1 0 31 6 3 5 Push in piston pins provided with engine oil manually 6 Insert piston pin circlip into groove Check piston rings for easy operation When installing used pistons check piston rings for gap and side clearance 7 Lubricate cleaned cylinder bores connecting rod bearing journals connecting rod bearing shells and pistons 8 Distribute gaps of piston rings uniformly along piston circumference 9 Mount piston ring clamping strap and introduce pistons Arrow in piston crown should point in driving direc tion 10 Mount connecting rod bearing caps with code numbers arrow in relation to each other on con necting rod Lubricate threads and screw head con tact surface of connecting rod screws and tighten to 30 Nm and 90 100 angle of rotation torque 11 Rotate crankshaft and check clearance between connecting rod and c
15. oil duct Coat closing plug M 16 x 1 5 with sealing glue Loctite 241 part no 002 989 94 71 and screw in Main oil duct front and rear Knocking out 1 Remove coolant pump with housing 20 230 2 Remove transmission and flywheel 03 410 3 Knock out both steel balls from the rear to the front by means of a round steel bar approx 14 mm and approx 550 mm long Knocking in 4 Thoroughly clean bore in pressing in range of steel ball 5 Coat spherical indentation on knocking in mandrel with grease and place steel ball into indentation 01 10 130 3 03 3 405 6 Position steel balls and knock in up to stop on ma ndrel 7 Mount all removed or disassembled parts 8 Run engine warm and check for leaks Knocking n steel ball front Knocking in steel bail rear 01 10 130 3 III 01 140 Replacing core hole cover in cylinder crankcase Special tools Knocking in mandrel for cover 17 mm dia ee 601 589 07 15 00 11004 011745 Knocking in mandrel for cover 34 mm dia E xd 102589001500 Note The core holes in cylinder crankcase are closed with sheet metal covers 17 mm dia or 34 mm dia Be sure to replace leaking covers on principle Cylinder crankcase 101 25547 Driving direction right At the right driving direction a closing plug 6 M 38 x 1 5 is retained A coolant preheater can be placed into this core hole Cylinder crankcase Driving direction left
16. se quence of tightening diagram by means of screw driver and unscrew A 1014 11624 Note Cylinder head screws 2 8 10 16 and 18 are located in shafts of camshaft bearing brackets arrows 29 Lift off cylinder head 30 Clean cylinder crankcase and cylinder head part ing surfaces 01 10 415 7 Installation 31 Mount new cylinder head gasket 32 Mount cylinder head Pay attention to clamping sleeve for locating cylinder head 33 Measure length L of cylinder head screws If the dimension named in Table is exceeded use new cylinder head screws 01 405 Thread dia Length L Max length L when new M 10 80 83 6 M 10 102 105 6 115 118 6 34 Lubricate cylinder head screws on threads and on head contact surface and insert 35 Tighten cylinder head screws in steps in sequence of tightening diagram starting with screw 1 Attention Tighten cylinder head screws to initial torque and angle of rotation torque 01 405 Estimate angle of rotation For this purpose place adjustable torque wrench in release position locked into plug in ratchet Position adjustable torque wrench with plug in ratchet lengthwise in relation to engine and keep turning until it is transverse in relation to engine 01 10 415 8 Do not use torsion bar torque wrench Tightening torques and angle of rotation torque of cylinder head screws 1st stage 25 Nm 2nd stage 40 Nm Setting interval 10 min 3rd stage 90
17. 101 25546 Cylinder crankcase Face front 8a Core hole cover front 01 10 140 1 Cylinder crankcase Transmission side Arrow core hole cover rear Renewing 1 Completely drain coolant 20 010 2 Remove unit parts which prevent access e g trans mission injection pump etc 6 Closing plug 12 Drain plug on crankcase 3 Position a chisel with narrow blade or a screw driver in deep draw n edge of closing cover 4 Carefully knock in cover on one side until it has turned around its own longitudinal axis approx 90 01 10 140 2 5 Position water pump pliers at flange of projecting part and pull out cover 6 Thoroughly clean core hole from residue Sealing surface must be free of grease arrow 7 Coat core hole with sealing glue Loctite 241 part no 002 989 94 71 8 Knock in new closing cover by means of pertinent knocking in mandrel 9 Attach removed unit parts 10 Fill in coolant 20 010 Note The sealing glue should cure approx 45 minutes before filling in coolant 11 Run engine warm and check for leaks 01 10 140 3 01 210 Tightening torques Hex head screw to crankshaft front Screws M 8 x 12 for pulley to hub Oil drain plug to oil pan Oil pan to cylinder crankcase Central screw for fan to coolant pump Adjusting screw for front engine stop Engine carrier to engine mount front Screws for cylinder head cover Cylinder head screws M 8 reference val
18. 2 6 when new 16 6 Distance b during repairs up to Permissible deviation from axial runout on 0 05 mm clutch surface or clutch flange on surface Note Flywheels for manual transmissions which are show ing burnt spots score marks or cracks on clutch surface must be refinished by precision turning If score marks or cracks are deeper than the max permissible material allowance replace flywheel YUN aa If the clutch surface A is refinished also refinish fastening surface B by the same dimension to main tain distance a SAXO In the event of repairs do not machine below dimen sion b For refinishing clamp flywheel well so that the permissible axial runout of 0 05 mm is not exceeded No cavities and chatter marks should be seen on clutch surface after refinishing 03 10 420 1 eee A to 03 430 Renewing ring gear of flywheel Data Axial runout on ring gear max 0 4 Centering flange dia for ring gear 275 00 275 05 Shrinking on temperature 220 C Annealing color yellow Conventional accessory Temperature measuring chalk e g AW Faber Castell color no 2815 220 white Thermochrom D 8504 Stein beiNurnberg Note The ring gear is hardened To protect hardness the temperature for heating up ring gear should not exceed 220 C at any point This can be done reliably only by means of a hot plate or a heating oven An open flame may be used as an exception only The flame should touch only
19. 4200 72 4200 130 2800 96 2800 Overhead 1 overhead camshaft Water circulating pump thermostat with bypass line finned tube radiator fan with electromagnetic clutch Forced feed lubrication via gear type pump Combined main and bypass filter Dry air cleaner with paper cartridge 00 020 1 00 Technical data Electrical system Batt Voltage 12v db Capacity 72 Ah Starter Bosch EV 12 V 2 2 kW Alternator Bosch KI 14 V 55A 203 1 As of model year 1985 a Bosch alternator 980 W 114 V 70 A is installed Filling capacities Model 201 122 Engine 601 921 Fuel tank reserve approx 55 75 Initial filling Engine oil approx 7 3 During oil and E l filter change ngine oi approx 6 5 Engine a pan up de MaRS Engine oil max min 5 0 3 0 on oil dipstick Air oil cooler Engine oil approx I Cooling system with heater Coolant approx 8 5 Coolant pump maintenance free Brake system Brake fluid approx 0 35 Manual transmission ATF approx 1 5 Automatic transmission ATF pee ee approx 6 6 5 9 Oil change Rear axle hypoid gear oil SAE 90 approx 0 7 ATF or manual Power steerin i g transmission oil 00 020 2 EN Crankcase and cylinder head 01 01 Crankcase and cylinder head Job No Engine Checking compression pressure o oo ee eee 01 010 Checking cylinder for leaks ce ee 015 Evaluating cylinder bores cece cee
20. 6589071500 116589030700 e g Hazet D 5630 Remscheid order no 1058 R l 161 158 157 160 159 162 Yil 31 28 155 156 155a 145 AO A o A SN A Pp ONA SS rea INN YU L In 8 x UE ti Y a HS S md Za SN El GAA SS ooo 22222222222 LAS Removal 1 Remove timing housing cover 01 210 2 Pull off clamp 262 and torsion spring 261 3 Unscrew fastening screw 259 and remove oil pump sprocket 257 4 Remove chain for oil pump drive 5 Mark timing chain and crankshaft timing gear in relation to each other 1403 26846 6 Mark timing chain and camshaft timing gear in relation to each other 7 Remove camshaft timing gear and let timing chain sag 8 Pull off crankshaft timing gear with puller 9 Check woodruff key in crankshaft for condition and renew if required 03 10 350 3 Installation 10 Transfer color mark from old to new crankshaft timing gear 11 Knock crankshaft timing gear with knocking in mandrel on crankshaft Pay attention to woodruff key Note For better location when knocking in crankshaft timing gear the front woodruff key for hub can be inserted 12 Mount camshaft timing gear and timing chain paying attention to marks 13 Keep turning crankshaft and check adjusting marks at TDC position of engine arrows 14 Mount chain for oil pump drive together with oil pump sprocket Note Mount sprocket in such a ma
21. 74 5 Measure bearing dia and write down 6 Measure crankshaft bearing journals find crank shaft bearing radial play Note The bearing play can be corrected by exchang ing bearing shells while trying for mean value of specified bearing play Crankshaft bearing shells with out color code are thicker than those with blue color code while taking into account that the thickness of walls without and with color code may overlap 7 Measure width of fitted bearing journal and asso ciate pertinent thrust washers refer to Table section Data 8 Lubricate bearing shells and crankshaft with engine oil and install crankshaft 03 1 0 320 6 9 Provide thrust washers with oil and slip into grooves on fitted bearing crankcase Attention Make sure that the two oil grooves arrows in thrust washers are pointing toward crankshaft webs 10 Mount crankshaft bearing caps 11 Tighten bearing caps to 90 Nm 12 Measure crankshaft end play 13 Rotate crankshaft manually and check for easy running 03 1 0 320 7 Association of connecting rod bearing and installation of connecting rod 14 Check connecting rod screws 03 310 1034 11459 15 Recondition connecting rod and square 03 313 16 Mount connecting rod bearing caps while paying attention to identification _ Lubricate connecting rod screws on threads and screw head contact surface and tighten to 30 40 Nm 17 Measure basic bore in
22. 9 0 00000000 AAA ARA ROA R NRO R RRO ar ceccecesescee A A IO 01 1 10 Measuring cylinder bores Data Engine 601 Version Group Piston dia Cylinder dia Code letter Std Cylinder 1 4 A 86 970 86 976 87 000 87 006 standard X above 86 975 86 983 above 87 006 87 012 8 above 86 982 86 988 above 87 012 87 018 Max wear limit in driving or transverse direction 0 10 when new 0 014 Permissible out of round and conicity wear limit 0 05 Permissible deviation vertically in relation to 0 05 crankshaft axis with reference to cylinder height Permissible roughness 4 3 Z 0 003 0 006 Permissible waviness 50 of roughness 1 There are no repair stages for these engines Measu ri ng Measure the cleaned cylinder bores with an internal measuring instrument at measuring points 1 2 and 3 in longitudinal direction A piston pin axis and in transverse direction 8 With piston installed the measuring point 3 is barely above piston which should be at BDC Longitudinal direction Transverse direction Upper reversing point of 1st piston ring BDC of piston Lower reversing point of oil scraper ring 1014 5696 1 0 5uw gt p 01 10 110 1 01 1 15 Renewing boring and honing cylinder liners Data Engine 601 Version Group Piston dia Code letter Std Cylinder 4 A 86 980 86 976 standard X above 86 975 86 983 B above 86 982 86 988 Basic bore in cylinder crankcase for cylinder liner Permissible out of roun
23. Double hex socket cylinder neag SCTEWS MECKEOOOWN Setting interval 10 min cylinder head screws 3rd stage 4th stage Tighten cylinder head screws M 8 with screwdriver with tommy handle Dimensions of double hex socket cylinder head screws Thread dia Length when Max length new renew M 10 80 83 6 M 10 102 105 6 M 10 115 118 6 Special tools 90 90 Screwdriver element 1 2 square 140 mm long for double hex socket cylinder head screws M 10 on cylinder head Screwdriver with tommy handle for hex socket screws 6 mm 440 mm long Torque wrench single arm emitting signal with plug in ratchet 1 2 square 25 130 Nm 01 10 405 1 601 58900 1000 116589030700 001 589 66 21 00 Note To obtain a uniform and high screw pre tensioning force double hex socket necked down cylinder head screws are installed with a machined flange They have a tapered down shank and are mounted without washers Retightening of cylinder head screws during inspec tion at 1000 1500 km or in the event of repairs after 1000 1 500 km is no longer required The double hex socket cylinder head screws are tightened to initial torque and angle of rotation torque refer to Table Since these cylinder head screws are subject to a lasting elongation after tightening they must be renewed after the max longitudinal dimensions named in Table shown below are exceeded Dimensions of cylinder head screws
24. Install noise capsule 03 10 341 3 03 345 Checking and correcting adjustment of TDC transmitter Tightening torques Nm Screws for cylinder head cover 10 Coupling nuts for injection lines reference value 1 0 20 Prechamber in cylinder head threaded ring 100 10 Nozzle holder in prechamber 70 10 Special tools Box end wrench element open 14 mm 1 4 drive pe 11004 105201 or coupling nut of injection line 000 589 77 03 00 Wrench element for threaded ring of prechamber armen 615589000700 11004 6360 Socket wrench element 27 mm 1 2 square 001 589 65 09 00 Impact puller for prechamber 601 589 06 33 00 Locating device for holder of TDC transmitter pe ONIS Measuring instrument for TDC and 20 after TDC 601 589 07 21 00 Dial gauge holder 3635890221 00 Pogue wrench double arm 8 square 8 32 Nm 001 589 51 21 00 Conventional tool e g Mahr D 7300 Esslingen Dial A 1 DIN 878 lal gauge order no 810 03 10 345 1 Note The TDC transmitter with holder is fastened to timing housing cover arrow The pin in crankshaft pulley must be accurately under TDC transmitter arrow in crankshaft position 20 after TDC Adjustment of adjusting slide must be checked and corrected if required a When renewing adjusting slide b When renewing crankshaft with hub or crankshaft pulley c When completing partial engines With cylinder head removed the measuring pin of the
25. Removal and installation of crankshaft timing gear Tightening torques Nm Screw M 18 x 1 5 x 50 to crankshaft 370 40 Screws for cylinder head cover 10 Screws M 8 x 12 for crankshaft pulley to hub 25 Oil drain plug to oil pan 30 M6 10 Oil pan to cylinder crankcase M8 25 Central screw for fan on coolant pump 25 Adjusting screw for front engine stop 130 Screws for engine carrier to engine mount 35 10 Cylinder head bolts M 8 25 M6 10 Screws for timing housing cover AAA M8 25 Special tools Torque wrench double arm 1 4 square 8 32 Nm Torque wrench single arm emitting signal with plug in ratchet 1 2 square 40 200 Nm Torque wrench single arm with ratchet 3 4 square 150 800 Nm Puller for hub 03 10 350 1 71004 6208 14734 11004 001 589 51 21 00 001 589 67 21 00 001 589 74 21 00 601 589 08 33 00 Puller for crankshaft timing gear Knocking in mandrel for crankshaft timing gear Screwdriver with tommy handle for hex socket screws 6 mm 440 mm long Conventional tool Adapter 3 4 square socket to 1 2 square head Layout crankshaft front 28 Timing housing cover 31 Radial sealing ring 145 Crankshaft 155 Woodruff key hub 1553 Woodruff key sprocket 156 Sprocket 157 Hub 03 1 0 350 2 158 Cylindrical pin 159 Cup spring 160 Screw M 18x 1 5 x 50 161 Crankshaft pulley 162 Combination screw M8 x 12 11004 6197 601 589 07 33 00 11
26. Thread dia Lenghts Max length L when new renew L M 10 80 83 6 M 10 102 105 6 M 10 115 118 6 01 1 0 405 2 1014 11394 Owing to the different lengths of cylinder head screws attention must be paid to fit the bolts in the proper locations during assembly Insert cylinder head screws according to the tightening diagram shown M 10 x 80 in bore 3 5 11 13 M 10 x 102 in bore 2 4 6 8 10 12 14 16 18 M 10 x 115 in bore 1 7 9 15 17 M 8x _ 30 in bore a M 8x 80 in bore b 1014 11624 Tighten cylinder head screws to initial torque and angle of rotation torque Estimate angle of rotation For this purpose place adjustable torque wrench in release position locked into plug in ratchet Position adjustable torque wrench with plug in ratchet lengthwise in relation to engine and keep turning until it is transverse in rela tion to engine Do not use torsion bar torque wrench for angle of rotation Tighten cylinder head screws in steps in sequence of tightening pattern shown Do not release cylinder head screws after setting interval but continue tightening 1014 11624 After tightening according to tightening torque a lo minute setting interval must be maintained be tween the 2nd and the 3rd tightening step refer to Table 01 10 405 3 01 415 Removal and installation of cylinder head Timing at 2 mm valve lift Exhaust valve opens before BDC Camshaft Intake va
27. acuum the engine blow by gases are flowing through oil separator 126 in cylinder head cover and a hose line to distributing pipe 140 on intake manifold From here they are uniformly distributed to all the cylinders and fed to the combustion chambers to gether with the intake air The oil separated in oil separator 126 flows back to cylinder head through return pipe 127 Since on engine in California version the vacuums are considerably higher under influence of throttle valve in intake system the oil separator 126 is provided with a pressure control valve 141 diagram valve The valve prevents an excessive vacuum in cylinder crankcase and the resultant loss of oil suction To vent diaphragm chamber in pressure control valve the cylinder head cover is provided with a bore a Make sure that this bore is not closed or will not be closed by dirt or preservation compound 125 141 142 iia 143 a a al del y Td ALLAN firs as o qa Lite dak Lars LE REL AA h ar Mac A d Le 73 4 IL nbrbrbtda A SOS Dese tas 1013 11937 127 126 125 Cylinder head cover 141a Diaphragm 126 Oil separator 142 Spring 127 Return pipe 143 Holder 141 Diaphragm housing pressure control valve a Vent bore 01 10 040 2 RT O RN 126 Oil separator 127 Return pipe 140 Distributing pipe 141 Pressure control valve a Bore 3 mm dia lt Fresh air QE Blow by gases 01 10 040 3 0 0 0 0 0 0 0 0 0
28. cover models other than the subject of this book Always refer to the engine and vehicle identification table for model and component infor mation The information contained in this manual was accurate to the best of our knowledge at the time the manual was approved for publication However the right is reserved to make production design and specification changes at any time without notice and without obligation to give notice Any such changes will not be contained in this manual Mercedes Benz of North America Inc assumes no liability for any damage to person or property caused by the utilization of this publication to effect maintenance or repair work on Mercedes Benz automobiles MERCEDES BENZ OF NORTH AMERICA INC Technical Publications a Tree rrr rere Sey See ee ee ee ee ee ee Group Index General technical data 00 Crankcase and cylinder head 01 Crankshaft assembly 03 Engine timing valves 05 Injection system 07 1 Air cleaner 09 Belt drive 13 Intake manifold exhaust manifold emission control system 14 Electrical system engine 15 Engine lubrication 18 Engine cooling 20 Engine suspension 22 Throttle control 30 Fuel system 47 Exhaust system 49 General technical data 00 00 General technical data Job No Instructions for use of service manual a 00 005 Engine and vehicle identification 0 0 o oo ee 010 Vehicle identification number locations sssaaa 0 ees
29. d of basic bore in cylinder crankcase Permissible out of round and conicity of cylinder bore Permissible roughness of cylinder bore QR 3 Z Permissible waviness of cylinder bore above above Cylinder dia 87 000 87 006 87 006 87 012 87 012 87 018 90 000 90 035 0 01 0 01 0 003 0 006 50 of roughness Honing angle 25 Roughness of cylinder crankcase parting surface 0 006 0 016 Chamfer of cylinder bores refer to Fig 1 There are no repair stages for these engines Self made tool Mandrel for pressing out or knocking out cylinder liners Engine 601 a 89 7 mm b 86 9 mm 01 10 115 1 1033 8351 Note Only approved cylinder liners may be installed on principle refer to replacement parts data Renewing 1 Press out cylinder liners with self made mandrel and a press or knock out with a hammer 2 Thoroughly clean basic bore 3 Measure basic bore D in cylinder crankcase When boundary dimensions refer to Table are exceeded do no longer use cylinder crankcase 4 Position new cylinder liners Place a steel plate of pertinent size on liner flange and press in bushing by means of a press or knock in by meanf of a hammer After pressing or knocking in leave cylinder liner for an additional 7 seconds under press pressure settling pressure or apply a few settling blows with hammer 01 10 1 15 2 1034 8234 NNN RNA EEN ERRE RR RRA RR RRA a EEE ETE TEE TEE ENN nw NE
30. dial gauge can be set directly on piston crown For this purpose place magnetic dial gauge holder on cylinder crankcase parting surface Checking 1 Remove radiator 20 420 2 Remove cylinder head cover 3 Set piston of 1st cylinder to ignition TDC of Ist cylinder 03 10 345 2 404 26920 4 Remove prechamber of 1st cylinder 01 417 5 Screw measuring instrument into prechamber duct 6 Place dial gauge at 2 mm preload on test mandrel 7 Slowly rotate crankshaft in direction of rotation of engine until large needle of dial gauge stops TDC position 8 Loosen dial gauge and place measuring arm under 5 mm preload into test mandrel Turn dial gauge scale until large needle points to zero 9 Slowly turn crankshaft in direction of rotation of engine until on engine 601 911 the dial gauge has moved back by 3 22 mm and on engine 601 921 by 3 65 mm 10 Place locating device into adjusting slide Pin in crankshaft pulley must engage in groove of locating device If pin is not engaging correct position of adjusting slide 03 10 34513 Correcting 11 Loosen adjusting slide 42 on screw 41 and displace until pin in pulley engages in groove of locat ing device 12 Screw down adjusting slide 13 Remove dial gauge and measuring instrument 14 Install prechamber 01 417 15 Install valve cover 16 Install radiator 17 Run engine check for leaks 03 10 345 4 03 350
31. druff key for sprocket 161 Crankshaft pulley 156 Sprocket 162 Combination N 157 Hub screw M 8 x 12 N 03 10 341 1 Removal Remove noise capsule below 2 Remove radiator 20 420 3 Slacken V belt and remove For this purpose unscrew collar nut 378 Insert a mandrel into spring tensioning lever 374 and releave hex screw 375 opposite to draw spring 380 until spring can be pushed back in direction of intake manifold Release spring tensioning lever and remove V belt 4 Remove crankshaft pulley 5 Unscrew screw 160 on crankshaft For this pur pose fasten detent part no 601 589 02 40 00 to oil pan 03 10 341 2 101 25526 10326847 6 Pull hub 157 from crankshaft journal Pull off hard to move hubs with puller 31 26 155 156 155a 145 Installation 7 Slip hub 157 on crankshaft journal and tighten screw 160 to 370 40 Nm a XI Make sure that woodruff key 155 and groove are in alignment Note Install the three cup springs 159 with crown toward screw head 1033 11646 8 Mount V belt pulley while paying attention to centering by means of cylindrical pin 158 9 Mount V belt and engage spring tensioning lever For this purpose swivel spring tensioning lever 374 with a mandrel against draw spring to the left until screw 375 can be slipped through spring tensioning lever Position collar nut and tighten 10 Install radiator 20 420 11
32. e For this purpose pull off rubber strip 1 above bulkhead Remove clips arrows Swivel holder 2 in upward direction and place battery positive cable over engine 01 1 0 030 3 7 Remove radiator 20 420 8 On vehicles with air conditioning system drain system 83 516 disconnect refrigerant hoses arrow and close free ends of refrigerant hoses with plastic plugs 9 On vehicles with level control unscrew hex socket screws arrows and put pressure oil pump with con nected lines aside Remove driver 10 Draw oil from reservoir of power steering pump with syringe for oil removal and disconnect hoses 11 Disconnect bowden wire 230 while pushing out slotted guide piece 240 on angle lever and remove bowden wire 12 Disconnect all coolant vacuum oil fuel and electric lines leading toward engine 13 Unscrew engine shock absorber on cross member while unscrewing fastening screws arrows for this purpose 01 10 030 4 122 26739 14 Remove engine stop For this purpose unscrew adjusting screw 2 as well as hex head screws 1 and remove engine stop with holder 15 Remove the lower of the two starter fastening screws 1 and put holder with tachometer shaft aside Disconnect ground connecting line 2 On vehicles with rpm sensor unscrew line on oil pan arrow 16 Unscrew exhaust system on flange of exhaust manifold 17 Unscrew fastening screws for exhaust lateral suppor
33. e sure that crankshaft journal and mount ing bore are not damaged 6 Check hub 157 for score marks of radial sealing ring renew hub if required Installation 7 Deburr mounting bore for radial sealing ring and clean 8 Moisten new radial sealing ring on sealing lip with oil and insert with inserting tool Attention The radial sealing ring should be accurately square in relation to crankshaft journal since otherwise no perfect sealing will be obtained 03 10 324 2 tir vi ee a INN ELA CN 31 ii 155 156 155a 145 SEXES Vast ROSY Va 1033 11848 9 Install hub and pulley 03 341 10 Mount V belt and engage spring tensioning lever For this purpose swivel spring tensioning lever 374 with a mandrel against draw spring to the left until screw 375 can be slipped through spring tensioning lever Position collar nut and tighten 11 Install radiator 20 420 12 Install noise capsule 03 1 0 32413 03 327 Replacing rear crankshaft radial sealing ring Tightening torques Nm initial torque 30 10 Necked down screw for flywheel Oven Pinte angle of rotation torque 90 1 00 Special tools gt Detent as 601589024000 11004 11737 Installation tool for rear 601589034300 crankshaft radial sealing ring Note The radial sealing ring 22 is seated in an end cover screwed to cylinder crankcase and oil pan and located by means of 2 clampi
34. ean parting surfaces 34 Coat timing housing cover parting surface with sealing compound Curil T part no 001 98947 20 35 Carefully position timing housing cover while paying attention to cylinder head gasket 36 Screw on timing housing cover Pay attention to different screw lengths 37 If the radial sealing ring has been removed insert new radial sealing ring with sleeve part no 601 589 03 14 00 38 For further installation proceed vice versa 39 Adjust engine stop 22 220 40 Check and correct oil level in engine 41 Fill in coolant 20 010 42 Pressure test cooling system with tester 43 Run engine check for leaks 01 10 210 8 01 222 Removal and installation of end cover Tightening torques Fastening screws for end cover Necked down screws for flywheel and driven plate Special tools Installation tool for rear crankshaft radial sealing ring and end cover 378 Square B32 Nm on i FABE TA emiting i9 um Note The central installation position for crankshaft center is located by means of two clamping sleeves 17 The end cover is sealed in relation to cylinder crank case with sealing compound Loctite 573 part no 001 989 45 20 17 Clamping sleeve 20 End cover 21 Combination screw M 6 x 22 22 Radial sealing ring 55 Combination screw M 6 x 85 145 Crankshaft 01 10 222 1 10 Nm initial torque 30 10 Nm angle of rotation torque 90 100
35. ecorder 5 Rotate engine 8 times for checking engine Attention While rotating engine push stop lever downwards by means of an extension so that the injection pump is not injecting 6 Install new nozzle reeds prior to installing injec tion nozzle 01 10 010 2 101 26132 107 26792 01 015 Checking cylinders for leaks Data Total pressure loss max 25 On valves and cylinder head gasket max 10 On pistons and piston rings max 20 Tightening torques Nm Coupling nuts of injection lines reference value 1 O 20 Injection nozzles in prechambers 70 10 Conventional tools e g Bosch EFAW 210 A Cylinder leak tester SUN CLT 228 Soui ii e g Bosch a eee order no 1 687 010 016 Checking 1 Run engine up to operating temperature 2 Remove injection nozzles 07 230 3 Remove air cleaner cover 4 Remove oil filler cap 5 Remove radiator closing cap and fill up with coolant 6 Screw adapter 01 and angle piece 02 into prechamber of 1 st cylinder 01 Connection 02 Angle piece 03 Connecting hose 01 10 015 1 7 Set piston of 1st cylinder to ignition TDC 8 Connect cylinder leak tester to a compressed air system calibrate tester 9 Screw connecting hose 03 of tester to screw in member Make sure that crankshaft is not rotating while screwing in hose 10 Read pressure loss on tester 11 Check by listening whether the pressure escapes via intake manifold exhaust oil fil
36. engine 601 911 refer to Note T o o PIPATITIAIIII VOI TITAIIIIAIITIAAIID Y 1034 8233 0 65 to 1 05 0 50 to 0 90 Y 01 130 Knocking out and inserting steel balls in main oil duct Special tool Knocking in mandrel for steel ball 601 589 08 15 00 14004 11746 Note The main oil duct is closed with steel balls 17 mm dia at the front 15 mm dia at the rear When reconditioning engine the steel balls must be knocked out from the rear for cleaning main oil ducts Undamaged steel balls can be used several times with out refinishing of ball seat Renew damaged steel balls 10 Steel ball front A a 1013 11403 In the event of leaks reseat steel balls in cylinder crankcase with a knocking in mandrel for approx 1 mm dimension is indicated on knocking in mandrel If the leaks are still not yet repaired knock out both steel balls and close the respective main oil duct end with closing plug front M 18 x 1 5 part no 000906 018000 or rear M 16 x 1 5 part no 000906 0 16002 9 Steel bail rear gt O LOZ 7 y 1013 11404 01 10 130 1 For this purpose cut threads M 18 x 1 5 10 mm deep at main duct front Thoroughly remove chips from oil ducts Coat closing plug M 18 x 1 5 with sealing glue Loctite 241 part no 002 989 94 71 and screw in Cut threads M 16 x 1 5 mm approx 14 mm deep into main oil duct on main oil duct rear Thoroughly remove chips from
37. il drain plug to oil pan 25 Nuts for oil filter cover 20 25 Screws for engine carrier on engine mount front 35 10 Special tools Tester for cooling system and radiator cap 001 589 48 21 00 Radiator cap with hose for leak test 605 589 00 25 00 Syringe for removing oil 112589007200 Torque wrench double arm 3 8 square 8 32 Nm Torque wrench single arm emitting signal with plug in gue 001 589 66 21 00 ratchet 1 2 square 25 130 Nm 01 1 0 030 1 001 589 51 21 00 Conventional tools Socket wrench 7 mm on flexible shaft for hose clamps with worm drive Engine hoist no 3180 Note Remove and install engine with transmission Removal 1 Put engine hood in vertical position For this purpose the engine hood can be set vertically 90 by simply pushing hood up In vertical position the engine hood is secured by means of a detent lever Engine hood in vertical position 2 Completely remove noise capsule below For this purpose unscrew sheet metal screws arrows 3 Completely drain coolant 20 010 12 Drain plug of cylinder crankcase 01 1 0 030 2 e g Hazet D 5630 Remscheid order no 426 7 e g Backer D 5630 Remscheid Herderstra e 188 24161 To facilitate collection of coolant plug an extension hose to drain connection of radiator Drain plug on radiator 4 Remove air hose arrow 5 Remove air cleaner cover arrows 6 Disconnect battery positive lin
38. in weight of complete connecting rods within one engine Tightening torque initial torque Connecting rod bolts angle of rotation 03 10 313 1 148 97 149 03 144 97 145 03 23 835 24 165 5 1 600 51 619 29 500 29 521 29 560 29 600 27 018 27 024 0 004 0 1 0 045 5g 30 5 Nm 90 1 00 Special tool Torque wrench single arm emitting signal ee Ain ESO BIOS with plug in ratchet 1 2 square 25 130 Nm ee jai Conventional tool e g Hahn amp Kolb D 7000 Stuttgart model BC 503 Connecting rod straightener Note End play of connecting rods is not limited at crank shaft journals but at piston pin eyes piston guided connecting rods For this purpose thrust surfaces arrow are cast onto piston pin eyes SONIC y SS NS ANAL RIR RRRA RARR RART ARNASA RRR i Y S pi A Z Z A ZN NS E Ahhh hh AR Connecting rod bearing and connecting rod bushing bores B are of similar width A weight compensation is attached at left and right on connecting rod bearing cap Only connecting rods of similar weight may be installed in one engine e Be 1033 11423 03 1 0 313 2 Connecting rods which have become overheated as a result of bearing damage blue coloring may no longer be used Connecting rod and connecting rod bearing cap are marked together There should be no transverse score marks and
39. ined or less renew connecting rod bolt Tightening 2 Lubricate threads and screw head contact area 3 Tighten connecting rod bolt to 30 Nm initial torque and 90 100 angle of rotation torque 03 1 0 310 1 Minimum necked down shank dia c 7 1 30 5 Nm 90 1 00 1034 11459 03 26348 Note Estimate angle of rotation For this purpose place adjustable torque wrench in release position locked into plug in ratchet Position adjustable torque wrench with plug in ratchet lengthwise in relation to engine and keep turning until it is trans verse in relation to engine 03 1 0 31012 03 313 Reconditioning and squaring connecting rods Data engine 601 911 Center of connecting rod bearing bore to center of connecting rod bushing bore engine 60 1 92 1 Width of connecting rod B at connecting rod bearing bore and connecting rod bushing bore Basic bore for connecting rod bearing shells standard dimension Basic bore for connecting rod bushing repair stage standard dimension Connecting rod bushing OD repair stage Connecting rod bushing ID Roughness of connecting rod bushing inside Permissible offset of connecting rod bearing bore in relation to connecting rod bushing bore with reference to 100 mm length Permissible deviation of parallel axle alignment Connecting rod bearing bore in relation to connecting rod bushing bore with reference to 100 mm length Permissible difference
40. ion of oil pan M6 M8 pq A _ SE 11004 6187 11004 9929 1 5 Nm 25 10 25 130 30 35 10 001 589 66 21 00 001 5896721 00 116589020700 116589030700 117589020700 Conventional tool e g Backer D 5630 Remscheid HerderstraBe Engine hoist no 3180 Note The engines are provided with a light alloy oil pan The pan is sealed in relation to cylinder crankcase by means of a gasket At the rear left arrow is the rpm sensor for refri gerant compressor shutoff EG R California version and revolution counter To make sure that the oil pan floor in range of oil pump strainer is horizontal with engine installed engine installation position tilted 15 to the right the oil pan floor has also a tilt of 15 in relation to cylinder crankcase parting surface 101 26985 The oil drain plug 54 M 12 x 1 5 is attached at front left 59 59a 59b 53 54 The threaded bushing is sealed by an O ring 59a and is locked against rotation by means of a toothed collar 59b which digs into oil pan when inserted 1014 9280 53 Sealing ring 54 Oil drain plug M 12 x 1 5 59 Threaded bushing 59a O ring 59b Toothed collar 56 Closing cover b Fastening points for engine stop 301 26986 01 10 310 2 Removal 1 Remove noise capsule 2 Drain engine oil 3 Unscrew engine shock absorber on crossimember Unscrew fastening screws arrows for this purpo
41. jection line 11004 105201 Tester for cooling system and radiator cap 001 58948 21 00 11004 8325 Radiator cap with hose 605589002500 for leak test Conventional tool Socket wrench hexagon 7 mm on flexible shaft e g Hazet D 5630 Remscheid for hose clamps with worm drive order no 426 7 Note Cylinder head should be removed with cooled down engine only Remove together with exhaust manifold 01 10 415 2 Removal 1 Set engine hood in vertical position 2 Completely drain coolant 20 010 12 Drain plug on cylinder crankcase 3 Disconnect negative line on battery 4 Remove radiator 20 420 5 Completely remove air cleaner 09 410 6 Slacken V belt and remove For this purpose unscrew flange nut 378 insert a mandrel into spring tensioning lever 374 and relieve hex screw 375 in relation to draw spring 380 until spring can be pushed back in direction of intake manifold 7 Unscrew hex screw 372 for fastening shock absorber 8 On vehicles with level control unscrew hex socket screws arrows place pressure oil pump with connect ed lines aside Remove driver 01 10 415 3 10125526 101 25935 Unscrew holder 62 for oil dipstick guide tube lO Disconnect coolant hoses arrows on coolant xutiet connection and pull cable from temperature witch 11 Disengage bowden wire 230 for engine regula ion For this purpose push out slotted guide piece 240 on angle lever and rem
42. ler cap pre chamber of adjacent cylinder or radiator cap 12 Check all cylinders in ignition sequence Note There is a possibility that the piston ring gaps of the individual pistons are directly one above the other so that the test result will be misrepresented When in doubt continue running vehicle and check cylinders for leaks once again later on 01 10 015 2 AS AAA AAA ANO AAA A gt gt PPAAAAAAAAAAAAAAAAAADAAAAAAAAAAAAAAAAAAAAAAAAAAAAAPAE rr rr 01 020 Evaluating cylinder bores Tightening torques Nm Coupling nuts for injection lines reference value 1 0 20 Hex head bolt for cylinder head cover 10 Threaded ring for prechamber in cylinder head 100 10 Injection nozzle in prechamber 70 10 Special tools B h el 14 V A E line F oaos 000 589 77 03 00 Wrench element for threaded ring of prechamber es gt pS 615589000700 11004 6360 A 601 589 06 33 00 11004 11774 Impact puller for prechamber Conventional tool e g Karl Storz GmbH D 7200 Tuttlingen Motoskop TW cold light with lens probes 103 26 CW 570 mm and 103 26 CT 210 mm Cylinder illuminating lamp Note The visual checkup can be made by means of a cylinder illuminating lamp with cylinder head mount ed Remove prechambers for this purpose 01 417 01 10 020 1 When evaluating scored or streaky cylinder running surfaces it is often hard for workshop to decide whether the damage is already significa
43. lve Engine code number opens after TDC closes before TDC closes after BDC Tightening torques Nm Screws for cylinder head cover 10 initial torque 1st stage 25 2nd stage 40 Double hex socket cylinder head o setting interval 10 min screws with cold engine 3rd stage 90 angle of rotation torque g q 4th stage 90 Cylinder head screws M 8 reference value 25 Screw for camshaft timing gear 45 Chain tensioner 80 Coupling nuts for injection lines reference value 1 0 20 Hex socket screws for intake manifold 10 Special tools Screwdriver element 1 2 square 140 mm long for double hex socket screws M 10 on cylinder head 601 589 00 10 00 49004 11731 Screwdriver with tommy handle for hex socket 11 7 screws 6 mm 440 mm long 6589030700 116589203300 Impact puller for bearing bolts basic unit 19006 6220 01 10 415 1 Threaded bolt for impact puller M 6 Breit 50 mm long 11004 6368 116589013400 Threaded bolt for impact puller M 6 Gas 150 mm long neocons 116589023400 Contact handle for rotating engine component of compression pressure recorder 001 589 46 21 00 001 589 46 21 08 Torque wrench double arm 001 589 51 21 00 3 8 square 8 32 Nm Torque HEN single arm emitting signal pe 001 5896621 00 with plug in ratchet 1 2 square 25 130 Nm y Box end wrench element open Je mim pe 000589770300 1 4 drive for coupling nut of in
44. nd oil filter element after 1000 1500 km 03 10 320 9 7103 26983 03 26843 03 324 Tightening torques Screw M 18 x 1 5 x 50 on crankshaft Screws M 8 x 12 pulley to hub Special tools Torque wrench single arm with ratchet 3 4 square 150 800 Nm E Puller for hub Detent Sleeve for pushing in radial sealing ring front Conventional tool Adapter 3 4 square socket to 1 2 square head Removal 1 Remove noise capsule 2 Remove radiator 20 420 03 10 324 1 Replacing front crankshaft radial sealing ring ers aes AAA I 11004 11732 Nm 370 40 25 001 5897421 00 601 589 08 33 00 1734 11004 601589024000 601 589031400 e g Hazet D 5630 Remscheid order no 1058 R I 3 Slacken V belt and remove Unscrew flange nut 378 for this purpose Insert a mandrel into spring tensioning lever 374 and relieve hex screw 375 in relation to draw spring 380 until spring can be pushed back in direction of intake manifold Release spring tensioning lever and remove V belt 4 Unscrew pulley 161 and pull off flange 157 03 341 28 Timing housing cover 31 Radial sealing ring 145 Crankshaft 155 Woodruff key hub 155a Woodruff key sprocket 156 Sprocket 159 Cup spring 160 Screw M 18x 1 5 x 50 161 Pulley 162 Combination screw M8 x 12 157 Hub 158 Cylindrical pin 5 Push out radial sealing ring by means of a screw driver Mak
45. ne running 12 install transmission 26 020 or 27 600 03 10 327 3 03 330 Removal and installation of radial ball bearing in crankshaft Special tools Countersupport for internal puller 000589333300 000589253300 Internal puller 14 5 18 5 mm Removal 1 Remove transmission 26 020 or 27 600 2 Pull ball bearing out of crankshaft together with countersupport and internal puller Installation 3 Coat new ball bearing with glue Loctite 241 part no 002 989 94 71 and knock into crankshaft on outer race by means of a suitable mandrel 4 Install transmission 26 020 or 27 600 03 10 330 1 03 341 Removal and installation of crankshaft pulley and hub Tightening torques Nm Screw M 18 x 1 5 x 50 to crankshaft 370 40 Screws M 8 x 12 crankshaft pulley to hub 25 Special tools Torque wrench single arm with ratchet 3 4 square 150 800 Nm Perret OE Detent 601 589 02 40 00 Puller for hub 601589083300 11734 11004 Conventional tool Adapter e g Hazet D 5630 Remscheid 3 4 square socket to 1 2 square head order no 1058 R I Note Engines 601 have no vibration damper and no balanc ing disk 31 28 155 156 155a 145 161 A j ANNENS EN PA 5 IMA ES Sa 28 Timing housing cover 158 Cylindrical pin A 31 Radial sealing ring 159 Cup spring Ki ES eas 145 Crankshaft 160 Screw N 155 Woodruff key for hub M 18 x 1 5 x 50 N 155a Woo
46. ng sleeves 17 The sealing lip of repair radial sealing ring is offset by 3 mm in inward direction so that it cannot run in a groove which may have been generated by series radial sealing ring on crankshaft flange wees LY TZ 1 A Radial sealing ring series B Repair radial sealing ring 03 10 327 1 Renewing 1 Remove transmission 26 020 or 27 600 2 Remove flywheel or driven plate 03 410 3 Push radial sealing ring out of end cover by means of a screwdriver Make sure that the crankshaft flange and the end cover are not damaged Cover crankshaft flange with a rag 4 Check running surface for radial sealing ring on crankshaft flange for damage 5 Clean mounting bore for radial sealing ring and deburr if required 6 Screw inner part of installation tool to crankshaft flange 7 Fill new radial sealing ring between sealing and dust lip with 1 g or 1 cc longterm grease Do not fill in more oil since otherwise the presence of leaks might be simulated 8 Slip radial sealing ring arrow over inner part of installation tool 03 10 327 2 SS O O O O Gs Syste tees A a aa aao ae e e a ey anata a e alatat 9 Push radial sealing ring up to stop into end cover by means of outer part of installation tool Attention Radial sealing ring should be seated accurately square in end cover for perfect sealing 10 install flywheel or driven plate 03 410 11 Check for leaks with engi
47. nner that its crown is pointing toward oil pump and the three contact surfaces on the oil pump shaft coincide with those on the sprocket arrows 15 Install clamp 262 and tensioning spring 261 03 10 350 4 1039 26843 118 26004 IN II eta AETA a a aaa aaa a atata a aa 16 Install timing housing cover 01 210 17 For further installation proceed vice versa 18 Run engine and check for leaks 03 1 0 350 5 03 410 Necked down screw Part no Thread dia D when new Necked down dia d min dia when new Length L max length Tightening torque Initial torque Angle of rotation torque Special tools Removal and installation of flywheel and driven plate manual transmission 1020320071 M 10 x 1 8 5 0 2 8 1 22 0 2 26 0 2 22 5 26 5 automatic transmission 601 03201 71 H 219 30 10 Nm 90 100 Detent Torque wrench single arm emitting signal with plug in ratchet 1 2 square 25 1 30 Nm Note Weight and dimensions of flywheels of engines with manual transmission are similar Flywheels and driven plates of engines with automatic transmissions are identical on all angines Flywheels can be replaced without static or dynamic balancing 03 10 410 1 Engine 601 D 254 5 mm D1 223 mm H 57 mm 601 589 02 40 00 001 589 66 21 00 N L A Fasten flywheel and driven plate to crankshaft in such a manner
48. notches on connecting rod shaft As a spare part connecting rods with machined con necting rod bushing are available Reconditioning 1 Check connecting rod screws and renew if re quired 03 310 2 Mount connecting rod bearing caps For this pur pose lubricate threads and screw head contact surface and tighten to 30 5 Nm 3 Measure connecting rod bearing basic bore At a basic bore which exceeds the value of 51 619 mm or is conical touch up bearing cap at its contact surface on a surface plate up to max 0 02 mm 4 Press in new connecting rod bushing in such a manner that the oil bores are in alignment arrow Pressing in pressure 2450 N 5 Machine or ream connecting rod bushing 6 Touch up lateral thrust surfaces of connecting rod on surface plate 03 10 313 3 103 26488 Squaring 7 Square connecting rod with a connecting rod tester 8 Align connecting rod bearing bore in relation to connecting rod bushing bore parallel alignment 103 1174 9 Check offset of connecting rod bearing bore in relation to connecting rod bushing bore and correct if required 03 1 0 31314 03 316 Removal and installation of pistons Association piston cylinder Group code letter Piston Engine code number 601 911 601 921 Norma dimension std standard piston dia above 86 975 86 983 above 86 982 86 988 86 970 86 976 cylinder dia
49. nsert a mandrel into spring tensioning lever 374 and releave hex screw 375 against draw spring 380 until spring can be pushed back in direction of intake manifold Release spring tensioning lever and remove V belt 01 25526 9 Unscrew hex socket screws 345 of coolant pump pulley and remove pulley 346 10 Pull cable from magnetic body arrow 11 Unscrew magnetic body 347 from magnet carrier on fastening nuts 349 Note The magnet carrier is glued to coolant pump housing and should not be pulled off 01 10 210 3 ZZ mn E Zy 3 Cr A 2 j WS 355 355 Closing cover M 6 x 25 360 Tensioning lever 356 Hex socket screw 372 Hex screw M8 x 30 357 Lock washer 373 Holder 12 Completely remove V belt tensioning device Unscrew hex screw 372 for this purpose 13 Remove closing cover 355 Unscrew screw 356 and remove lock washer 357 Remove ten sioning lever 360 together with shock absorber and draw spring from bearing bolt 14 On vehicles with power steering unscrew pulley for high pressure pump 15 Unscrew both hex screws for high pressure oil pump fastening arrows and put high pressure oil pumps with lines connected aside 01 10 210 4 28 358 357 356 360 SAUNA a 103 26916 16 Unscrew the front screw of the two screws for fastening fuel filter 116 17 Unscrew crankshaft pulley 18 Unscrew hex screw for flange For this purpose moun
50. nt and requires removal or repair of engine or whether the marks are insignificant The following information will help to make an expert and correct decision The first difference on cylinder running surfaces is between optical streaks and seizure streaks In most cases optical streaks are about 3 mm wide and are caused by ring gap on which honing traces are still visible with seizure streaks however the honing traces are no longer seen With streaks in direction of land in direction of piston pin shaft streaks or seizures are not possible since there is no contact between piston skirt and cylinder liner 01 1 0 020 2 01 030 Removal and installation of engine oil capacity Specified viscosity classes according to SAE during lasting ambient temperatures oF C 6 a e is s l 11 4 lalala 1 SAE 40 may be used during lasting outside temperatures ot o cranes above 30 C 86 OF 50 10 2 Do not use re pes mani 3 All season oil 23 5 nel 4 For oils identified on sheets 226 1 and 227 1 of Specifica Me v Ea In tions for service products with footnote the following cd 24 bet Sia aa nanan ae chal Tala applies SAE 5 W 20 below 10 C SAE 10 W 30 in temperate zones all seasons Oil capacity in liters for approved engine oils refer to Specifications for service products Engine total filling capacity during complete refill 7 3 Tightening torques Nm O
51. of a mandrel against force of draw spring 380 to the left until screw 375 can be pushed through spring tensioning lever Position collar nut and tighten 52 Mount cylinder head cover 53 Engage bowden wire for engine regulation and adjust if required 30 300 54 Plug on cable for temperature switch 01 10 415 11 55 For further installation proceed vice versa 56 Fill in coolant 20 010 and pressure test cooling system 57 Run engine and check for leaks Note Retightening of cylinder head screws is not required 01 10 415 12 01 417 Data hechamber standout on cylinder head dimension c 7 6 8 1 mm Tightening torques Coupling nuts of injection lines reference value Screws for cylinder head cover Prechamber in cylinder head threaded ring Nozzle holder in prechamber Special tools Box end wrench element open 14 mm 1 4 drive for coupling nut of injection line Wrench element for threaded ring of prechamber Socket wrench element 27 mm 1 2 square Impact puller for prechamber 01 10 417 1 Removal and installation of prechambers a NY N N N as o NAS ANS NT ty 1053 11649 PS 11004 10520n TIGO 0703 1100411774 Y La boy ELSA DD LAA N Nm 1 O 20 10 100 10 70 10 000589770300 615 589 00 07 00 001 589 65 09 00 601 589 06 33 00 Note The prechamber is identified at upper flange
52. of each job All dimensions are in metric units unless otherwise indicated Any part numbers given are only used for identification and easier differentation between individual components and are not intended for ordering purposes 00 005 1 00 Engine and vehicle identification This manual applies to the following passenger cars starting model year 1984 Model USA Model Year Chassis Type From To 190 D 2 2 1984 201 122 00 01 0 1 Engine Type 601 921 ttl A Se EEE AAA Vehicle identification number locations 00 Om a WH J Certification Tag left door pillar Identification Tag left window post Chassis No Engine No Body No and Paintwork No Information Tag California version Vacuum line routing for emission control system Emission Control Tag Emission Control Tag Catalyst Information 00 015 1 Engine Model Engine Operation Number of cylinders Cylinder arrangement Bore stroke mm Total effective piston displacement cc Compression ratio Firing order Maximum speed no load rpm kW rpm Engine output SAE net bhp rpm Nm rpm SAE net bf ft rpm Maximum torque Crankshaft bearings Valve arrangement Camshaft arrangement Oil cooler Cooling Lubrication Oil filter Air cleaner _EXIT Technical data 00 201 122 601 921 4 cycle diesel ME prechamber design 4 In line 15 inclination 87192 4 2197 22 1 3 4 2 4900 5100 54
53. one ete a a eg a a a aa a aa a eee ee eee eee aa aan AAA ra Service Manual Eng ine 601 Mercedes Benz service Mercedes Benz of North America Inc One Mercedes Drive Montvale NJ 07645 Caution Our service manuals contain descriptions of important assembly adjustment and inspection jobs Special tools required in performing certain service jobs are identified in the manual and recom mended for use Any part numbers given are only used for identification and easier differentia tion between individual components and are not intended for ordering purposes All procedures illustrations and specifications contained in these manuals were based on the latest information available at the time of publication If your Mercedes Benz model differs from the specifications contained in the manual you select consult your authorized Mercedes Benz dealer Remember the proper performance of services is essential for both the safety of the mechanic and the efficient operation of the vehicle The procedures in these manuals are described in such a manner that the service may be performed safely and accurately However it is always assumed that the reader is familiar with basic automotive repair procedures and Mercedes Benz vehicles Mercedes Benz of North America Inc 1985 All rights reserved Reproduction or translation in whole or parts is not permitted without written authorization from the publisher Published by Mercedes Benz of N
54. orth America Inc Printed in Germany 6510 1921 13 385 2 0 ru rr ii A OOOO Oe m mnta n rr rr Introduction This Service Manual is the product of existing technical publications Special care has been taken to provide accurate information on removal disassembly assembly inspection installation and adjusting procedures backed with the technical data necessary to do the job The material in this manual is divided according to the Mercedes Benz Component Group System as outlined on the GROUP INDEX page This page will quickly direct the reader to the Major Component Group Each Major Component Group begins with a JOB INDEX listing all jobs within that group Mercedes Benz of North America Inc recommends that repairs to and maintenance of Mercedes Benz automobiles be performed only by Mercedes Benz trained personnel at authorized Mercedes Benz dealerships The information contained in this special publication is ordinarily issued by Mercedes Benz of North America Inc in conjunctionwith supplementary service literature and special tools supplied only to its authorized dealers The repair and maintenance procedures outlined herein are procedures to be used by trained Mercedes Benz service and dealership personnel Supple mentary service literature will not be provided with this publication but may be contained in reprints of this Service Manual Please note that this manual has been compiled from various sources some of which
55. ove bowden wire 12 Pinch fuel lines and unscrew at fuel filter arrows 1 10 415 4 13 Unscrew both fastening screws 116 and remove fuel filter 14 On engines with EGR remove pipe line 1 be tween EGR valve and exhaust manifold 15 Unscrew exhaust flange from exhaust manifold 16 Remove injection lines 17 Remove intake manifold 18 Remove cylinder head cover 19 Pull off lock 91 for heater feed line by means of a hook 01 20 Unscrew pipe elbow 93 on oil filter and pull from connection 89 01 10 415 5 21 Unscrew electric lines on pencil element glow plugs 22 Set engine to ignition TDC of 1st cylinder Attention Do not rotate engine at fastening screw of camshaft timing gear Do not rotate engine in reverse 23 Completely remove chain tensioner 224 05 310 24 Mark camshaft timing gear and timing chain in relation to each other 25 Remove camshaft 05 220 For this purpose unscrew fastening screw of camshaft timing gear Apply counterhold to camshaft timing gear by mears of a screwdriver or steel bolt Remove camshaft timing gear and lower timing chain into chain box Note Uniformly loosen all camshaft bearing caps 01 10 415 6 AA 20022 26 Knock out slide rail bolts 221 and 222 with impact puller and remove guide rail 27 Unscrew both cylinder head screws M 8 arrows with screwdriver 101 25519 28 Loosen cylinder head screws in vice versa
56. p Heavy damage _____ yes no Crack test Cracks showing _______________ yes no Hardness test t______________khno All bearing journals scleroscope hardness min 60 on 2 3 of journal circumference yes Measure pin journal Dimensions in order no Check whether regrinding is still yes possible within last specified repair stage 4 Lapping Dimensional checkup Dimensions in order no yes L yes Crankshaft Crankshaft complete straighten balance if possible Crankshaft grind Crack test Cracks showing no Refer to lapping 03 10 318 3 V V no y yes Hardening TT Journal or pin Journal or pin without hardened with hardened fillets fillets Induction Induction hardening or flame facilities available hardening no yes I nduc Check hardness yes V tion by etching hardening Relieve crankshaft at 80 C 176 F for 2 hours Refer to crank shaft straighten Explanations concerning diagram Crack test Clean crankshaft Bearing journals should be free of oil and grease Magnetize crankshaft and apply fluorescent powder fluxing A color penetration method may also be used im mersionin bath or using spraycan Agent Paint or fluorescent powder cleaning agent developer Hardness test Test hardness with impact hardness tester scleros cope hardness Minimum hardness of 55 should be
57. rankshaft 12 Measure distance between piston crown and cylinder crankcase parting surface in TDC position of pistons refer to Table 03 10 316 4 103 25608 103 26488 03 318 Checking and reconditioning of crankshaft Data Crankshaft normal Crankshaft Fitted bearing Crankpin Crankpin dimension and bearing Associated thickness Width dia width repair stages journal dia of thrust washers 27 96 Standard dimension 28 04 1st repair stage 2nd repair stage ee up to 28 30 3rd repair stage 4th repair stage Permissible deviation of crankshaft journals and crankpins from true Permissible conicity of crankshaft journals and crankpins Permissible deviation of flywheel flange from true Permissible axial runout of fitted bearing on crankshaft bearing journals Fillets on crankpins Permissible deviation of crankshaft bearing journals from true when mounted in outer crankshaft bearing journals journal Scleroscope hardness of crankshaft journals and crankpins Permissible unbalance of crankshaft Special tool Impact hardness tester 03 10 318 1 0 02 0 02 2 5 to 3 0 3 0 to 3 5 0 07 journal Il IV 0 10 55 74 15cmg 000 589 20 21 00 Note When testing and reconditioning crankshafts proceed in sequence of diagram shown below Diagram Refer to section Explanations concerning diagram V scrap 03 1 O 3 18 2 Visual checku
58. se 4 Remove engine stop For this purpose unscrew adjusting screw 2 as well as hex screws 1 and engine stop with holder 5 On vehicles with rpm sensor disconnect line on oil pan arrow 6 Disconnect ground connecting line on transmission 01 10 310 3 7 Unscrew hex socket screws for engine carrier on both front engine mounts from below arrow Hex socket screw for engine carrier right 122 26111 4 8 Unscrew torsion bar on side members right and left 9 Engage rope of engine hoist at front suspension eye of engine arrow Lift engine with a crane Pay attention to fan and fan cover 10 Unscrew oil pan 11 Unscrew screw 259 on sprocket and remove sprocket from drive shaft 12 Unscrew oil pump and remove For this purpose unscrew fastening screws 260 01 10 310 4 13 Remove oil pan in forward direction Pull torsion bar down for this purpose 14 Clean parting surfaces Installation 15 Place oil pan over bogie 16 Install oil pump 18 210 17 Mount oil pan with new gasket 18 Lower engine and screw engine carrier to engine mount 19 Adjust engine stop 22 220 20 Fill in engine oil 21 Run engine warm and check for leaks 22 For further installation proceed vice versa 01 10 310 5 01 405 Cylinder head screws and tightening cylinder head screws Tightening torques and angles of rotation for cylinder head screws on cold engine 1st stage 25 Nm i 2nd stage 40 Nm
59. t 1 loosen nuts 2 and swivel holder in downward direction 18 Unscrew propeller shaft on transmission loosen nut of slide piece as well as fastening screws for pro peller shaft intermediate bearing and slide propeller shaft back as far as possible Also unscrew heat guide plate on vehicle floor 19 Unscrew drive shaft for tachometer on rear trans mission cover 20 Separate oil line from clutch master cylinder to slave cylinder arrow 21 Remove shift rods from transmission shift levers while removing clip locks for this purpose 01 10 030 5 191 26109 ER 22 Engage ropes of engine hoist on suspension eyes of engine arrows Tighten ropes Suspension eye front 101 25968 Suspension eye rear 23 Remove rear engine carrier with engine mount For this purpose unscrew hex nut 1 and screw out hex head screws 3 Rear engine carrier shown on S speed transmission 24 Unscrew hex socket screws for engine carrier on both front engine mounts from below arrow Hex socket screw for engine carrier left 01 10 030 6 Hex socket screw for engine mount right 25 Lift out engine with transmission in diagonal position of approx 45 Installation 26 Check engine mounts engine shock absorbers oil and fuel hoses and renew if required 27 Prior to flanging on manual transmission check condition of radial ball bearing in crankshaft and of throw out bearing of clutch renew if required
60. t detent part no 601 589 02 40 00 to oil pan 19 Pull off crankshaft flange manually If hard to move pull off crankshaft flange with puller part no 601 589 08 33 20 On vehicles with TDC transmit ter unscrew hex nut 39 pull TDC transmitter line out of holder 42 and put aside 01 10 210 5 21 Unscrew vacuum pump arrows 22 Unscrew both fastening screws for engine carrier on engine mount arrow 122 26098 lt 3 23 Unscrew engine stop on frame cross member For this purpose unscrew adjusting screw 2 as well as hex screws 1 24 Attach rope of engine hoist at front suspeinsion eye arrow and lift engine with a crane 25 Unscrew fastening screws for oil pan front in range of timing housing cover Loosen all remalining fastening screws 26 Lower engine again into engine mounts p 101 25526 1 01 10 210 6 27 Remove cylinder head cover 28 Unscrew the two cylinder head screws M 8 arrows in chain box with Allen wrench 6 mm 440 mm long 101 25519 29 Unscrew holder for oil dipstick guide tube 62 30 Unscrew fastening screws arrows for injection pump Remove square nuts on flange of injection pump 31 Unscrew remaining fastening screws for timing housing cover arrows cs a ee 32 Remove timing housing cover Attention Do not damage cylinder head gasket Renew damaged cylinder head gasket 01 26976 01 10 210 7 Installation 33 Cl
61. that the unused bores arrow on fly wheel or on driven plate and spacing washer are in alignment with unused bore on crankshaft flange Vehicles with manual transmission 103 26308 150a Vehicles with automatic transmission 103 26665 2 151 Y i50 We 134 145 i Q 4 1 3 EN Layout of flywheel for N manual transmission 145 Crankshaft Y en 150 Flywheel 151 Ring gear ES 152 Necked down screw AS 153 Ball bearing YEN 154 Spacing A 1033 11671 1 03 10 410 2 ON ELE TEENIE II owen ees A AAA eee Layoutof flywheel and driven plate for automatic transmission 145 Crankshaft 150a Driven plate 152a Necked down screw 154a Spacing washer 1033 11799 1 Removal 1 Remove transmission 26 020 or 27 600 2 Fasten detent arrow tO oil pan below 3 Unscrew necked down screws 152 and remove flywheel driven plate and spacing washer Flywheel manual transmission 103 26328 03 1 0 41 0 3 Installation 4 Measure necked down dia of necked down screws If minimum dia is attained install new necked down screws 5 Position flywheel driven plate and spacing washer on crankshaft journal in such a manner that the bores arrow are in alignment 150a 103 2666 5 2 6 Screw in necked down screws and tighten to 30 Nm initial torque and 90 100 angle of rotation torque 03 10 410 4 03 420 Refinishing of flywheel Data Engine 601 Distance a 22 4 2
62. the inside of the ring gear Following renewal of ring gear the flywheel need not be balanced Renewal 1 Drill into old ring gear and break up with a chisel or heat quickly and immediately remove 2 Clean mounting surface of ring gear on flywheel 3 Uniformly heat new ring gear on a hot plate or in a heating oven For this purpose use temperature measuring chalk in accordance with instructions whenever possible 4 Mount heated ring gear immediately on flywheel 03 1 0 430 1
63. two directions If one basic bore exceeds the specified value or if it is conical touch up bearing cap at its parting surface on a surface plate up to 0 02 mm 103 27245 18 Insert connecting rod bearing shells mount connecting rod bearing caps together with bearing shells and tighten connecting rod nuts to 30 35 Nm 103 26742 19 Measure bearing dia and write down 20 Measure crankpins find connecting rod bearing radial play Note The bearing play can be corrected by changing bearing shells trying for medium value of specified bearing play Crankshaft bearing shells without color coding are thicker than those with blue color coding while taking into account that the thickness of wails without and with color coding may overlap 03 1 0 320 8 21 Attach piston to connecting rod 03 316 22 Provide bearing shells crankshaft pistons and cylinder walls with engine oil install connecting rod with piston 03 316 Pay attention to identification 23 Tighten connecting rod screws to 30 5 Nm initial torque and 90 100 angle of rotation torque 24 Measure connecting rod bearing end play while displacing connecting rod directly at piston pin Check clearance of connecting rods in relation to crankshaft Attention Disassemble oil pump and clean renew if required Renew oil pressure relief valve Disassemble oil filter and clean Install initial operation oil filter element Change engine oil a
64. ue Screws for timing housing cover Special tools Torque wrench double arm 3 8 square 8 32 Nm TAAR SGA HOPA SING A ym sq rque wrench single arm with ratchet 3 A quare 150 800 Nm Detent Screwdriver with tommy handle for hex socket screws 6 mm 440 mm long Removal and installation of timing housing cover M8 M6 M8 17004 6206 Sleeve for pushing in radial sealing ring front 01 10 210 1 2 Nm 370 40 25 10 25 25 130 35 10 10 25 10 25 001 589 51 21 00 001 589 67 21 00 001 589 74 21 00 601 589 02 40 00 116589030700 601 589 03 14 00 Puller for flange on crankshaft Box end Allen wrench 13 x 14 mm Conventional tools Connection 3 4 square socket to 1 2 square head Engine hoist no 3180 Socket wrench 7 mm on flexible shaft for hose clamps with worm drive Removal 1 Completely remove noise capsule 2 Drain engine oil 3 Completely drain coolant 20 010 4 Remove air hose arrow 5 Remove radiator 20 420 6 Disconnect negative terminal on battery f14 an 3410 9 601 589 08 33 00 11734 11004 117589020700 e g Hazet D 5630 Remscheid order no 1058 R 1 e g Backer D 5630 Remscheid HerderstraBe e g Hazet D 5630 Remscheid order no 426 7 7 Unscrew collar screw 340 and remove fan 8 Slacken V belt and remove For this purpose unscrew flange nut 378 I
65. ug is pointing toward recess in cylinder head arrows A 26665 10 Lubricate threaded ring 112 in Fig item 5 and tighten with pin wrench to specified tightening tor que 90 1 10 Nm 01 10 417 5 11 Screw in glow plugs 102 and connect 12 Insert new nozzle reed 113 13 Completely screw in nozzle holder 114 and tighten to 70 80 Nm 14 Plug fuel return hoses on injection lines 15 Mount injection lines 16 Screw on holder for bowden wire of engine regu lation and adjust bowden wire if required 30 300 70 Cylinder crankcase 71 Cylinder head gasket 102 Pencil element glow plug 110 Prechamber 112 Threaded ring 113 Nozzle feed 114 Nozzle holder 01 10 417 6 N 14 RA TFT me EOS a LN 110 SY ROLE SAY Sa 413 LLL KOO SS dll ANA gt AP tee N NON gt gt N W AN S V4 S a K snl TC ay NA y 3053 1848 01 418 Facing cylinder head parting surface Data Total height of cylinder head Minimum height after machining in longitudinal direction Permissible unevenness of parting surfaces in transverse direction Permissible deviation in parallel of upper parting surface in relation to lower surface in longitudinal direction Roughness Test pressure with air under water in bar gauge pressure 142 144 0 08 0 0 0 1 0 016 Minimum distance a with new valves and new valve seats intake 0 17 to 0 23 e
66. ure Compression pressure normal 24 30 Minimum compression pressure approx 15 Permissible difference between individual cylinders max 3 Tightening torques Nm Coupling nuts of injection lines reference value 1 0 20 Injection nozzles in prechambers 70 10 Special tools Compression pressure recorder with accessories 001 5894721 00 Contact handle for rotating engine component of compression pressure recorder 001 589 46 21 00 001 5894621 08 2 11004 8487 Box end wrench element open 14 mm 1 4 drive for coupling nut la 000 589 770300 u 11004 10520 of injection line N ote Check compression pressure at 80 C coolant tem perature Compression pressure can be checked only via prechambers If minimum compression pressure is less than specified check cylinders for leaks 01 015 01 10 010 1 Checking 1 Remove injection nozzles 07 230 2 Connect contact handle for rotating engine to cable connector terminal 30 and 50 on fire wall 3 Rotate engine several times with transmission in idle position so that residue and soot are thrown out Attention While rotating engine push stop lever downwards by means of an extension so that the injection pump is not injecting Compression pressure recorder connected to prechamber 01 Compression pressure recorder 02 Connection 4 Screw adapter component of compression pressure recorder into prechamber Connect compression pres sure r
67. with code number 601 07 6 burner bores of different diameter are located on prechamber lower half burner neck at different levels and angle positions The firing duct H has a diameter of 7 mm and the burner neck J of 14 mm H Firing duct 7 0 mm dia J Burner neck 14 0 mm dia K Burner bore 1 5 mm dia L Burner bore 2 0 mm dia M Burner bore 3 2 mm dia N Burner bore 3 0 mm dia 0 Bore for glow plug 10 0 mm dia In addition the prechamber floor is designed as a spherical depression This spherical shape provides uniform wall thick nesses in range of burner bores 01 10 417 2 1014 11350 Removal Unscrew injection lines from injection nozzles and loosen holder for injection lines on intake manifold 2 Pull fuel return flow hoses from injection nozzles 3 Unscrew holder for bowden wire of engine regula tion and put aside 4 Unscrew nozzle holder complete with socket wrench element 27 mm 5 Remove pencil element glow plugs 70 Cylinder crankcase 71 Cylinder head gasket 102 Pencil element glow plug 110 Prechamber 112 Threaded ring 113 Nozzle reed 114 Nozzle holder 6 Unscrew threaded ring 112 with pin wrench For this purpose screw threaded member 03 into threaded ring place sleeve 02 into grooves of threaded ring arrows and tighten with nut 01 03 Threaded member 01 10 417 3 i ll gt J Wee 114 AK BANS 113 ZX gt a an U i eeke AF
68. xhaust 0 12 to 0 28 Max distance a depth on new valves and machined valve seats intake 1 0 exhaust Facing l Face cylinder head parting surface 2 Refinish valve seats until minimum distance a has been attained 3 Check timing 05 215 01 10 418 1 AAANAAARN 1054 11629 105 26929 l 01 420 Pressure testing cylinder head Data Test pressure with air under water in bar gauge pressure 2 Special tools 601 589 00 25 00 Pressure plate oe See Oj Ao e z PTE Oe o6 EPES IT EF EP E rt rf rt oe 11004 11684 y 7 Suspension device a E 115589346300 Cal A A F g lt m al 1004 6209 nS A Conventional tool e g Otto D rr D 71 23 Sachsenheim Ochsenbach Electrically heated water basin Pressure testing Pressure test cylinder head if cracks coolant losses are suspected 1 Screw pressure plate on cleaned cylinder head 2 Close bores and connections 3 Connect compressed air hose 1 and regulate compressed air to 2 bar gauge pressure j 101 27240 i 01 1 0O 420 1 4 Fasten cylinder head on suspension device and immerse into heated water basin 80 C 5 When air bubbles are rising find leaking spot 01 1 0 420 2 SRO OOO SOS Oa Oh Sti he aia Crankshaft assembly 03 03 Crankshaft assembly Job No Crankshafts connecting rods and pistons Checking renewing and tightening connecting rod bolts

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