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Instructions for use of service manual 00

1. 4 Introduce crankshaft into a suitable steel tube approx 165 mm dia x 420 mm long and place self made rivet support 2 underneath 1 Steel tube 165 mm dia x 420 mm long 2 Self made rivet support 3 Snap die 03 2 318 7 F3 5 Rivet countersunk rivet by means of a hydraulic press The additional weight should then rest fully against crankshaft cheek without leaving any inter mediate space 6 Then check crankshaft for runout of bearing journals and balance together with balancing disc and flywheel even if the former additional weight is used again t Crankshaft 2 Additional weight 110 031 05 01 3 Countersunk rivet 6 x 28 mm DIN 661 MUSt 34 Series production of riveted on additione weight starting December 1978 starting engine end no starting chassis end no 110 992 0 038 031 116 020 112 253 12 062 390 110 923 10 012 665 123 030 025 675 12 015 613 123 050 002 801 110 932 10 009 748 116 020 112 252 12 002 556 110 984 10 014 634 123 033 050 600 12 051 160 123 053 013 292 110 984 0 014 634 123 093 001 229 12 051 160 110 985 10 011 106 116 024 025 131 270 12 052 660 110 986 10 002 276 107 022 006 288 12 005 142 107 042 005 285 03 2 318 8 F3 03 320 Mounting of crankshaft Data Crankshaft Crankshaft Width of Crankpi Width of standard dimension bearing journal journal on dia crankpin and repair sta
2. Pressure test with air under water in bar gauge pressure Minimum distance A with new valves and new valve seats cylinder head parting surface not machined Intake 3 3 Valve retainer dia 37 mm 0 6 Exhaust l Valve retainer dia 39 mm 0 04 Max distance A with new valves and machined valve seats cylinder head parting surface not machined Intake 4 2 Valve retainer dia 37 mm 1 5 Exhaust Valve retainer dia 39 mm 0 94 93 9 94 0 93 1 0 08 in longitudinal direction in cross direction 0 0 0 1 0 010 Minimum distance A with new valves and new valve seats cylinder head parting surface 0 4 mm milled off 2 9 0 2 0 36 standout Max distance A with new valves and machined valve seats cylinder head parting surface 0 4 mm milled off 3 8 1 1 0 54 Max distance A is reduced by the same dimension by which the cylinder head parting surface has been machined down 01 2 418 1 F3 pee ee 1054 516771 Conventional tools Surface grinding machine with milling e g made by Ruaro u Fi Schio Italy equipment for light alloy surface scledum type RTY Knife edged straightedge approx 750 mm long Only 0 4 mm material can be machined off of the cyl inder head at the mating surfaces to the crankshaft and camshaft housing A distorted cylinder head must always be faced on both mating surfaces Machine valve seats until the permissible distance A between the valve head and cylinder head mating
3. 602 Permissible unbalance of crankshaft 15 cmg 1 When mounting crankshaft on outer crankshaft bearing journal and VII after one full turn 2 Boundary value should be available at min 2 3 of journal circumference Special tool Impact hardness tester Set ie 000 589 20 21 00 11CC04 6219 Self made tool Rivet support for riveting counterweight to crankshaft 0 015 10 0 006 p O m ae 3 3 ica 96 60 010 9015 50 4 2 Z 0 re a O mh wn S i 1032 8611 03 2 318 2 F3 ml 93 30 Note Since December 1978 the crankshaft of engine 110 is provided with an additional weight Remove additional weight when machining first crank pin After machining crank pin rivet additional weight on again Then check crankshaft for runout and balance together with flywheel and balancing disc also when re using the old additional weight The crankshaft with riveted on additional weight may be used only together with a modified oil pump which is provided with a recess arrow on housing shaft When checking and reconditioning crankshafts pro ceed in sequence of the following diagram and perti nent explanations For grinding crank pins a difference of only one re pair stage per crankshaft is permitted 03 2 318 3 F3 Visual checkup OS eo heavy damage y no Crack test Cracks showing up YES m V no elton COSC oa NO A
4. Knocking i If i AEE ee Pye 117 589 00 31 00 oil dipstick guide tube 110 589 02 15 00 11004 6194 Corventional tool Engine hoist Motordirigent size 1 5 e g made by B cker D 5630 Remscheid order no 3178 01 2 310 1 F3 Self made tools Gauges for cutting off radial sealing rings Radial sealing ring graphite grey Part no 000 997 65 41 Radial sealing ring yellow brown Note a 1 mm a 0 5 mm The modified oil pan 1 is installed on models 107 116 and 123 since October 1979 and model 126 since begin of series For this purpose the rear 3 fastening threads on cylinder crankcase have been changed on both sides from M 6 to M8 mm Begin of series October Model 107 022 107 042 116 020 116 020 116 024 025 123 030 123 033 123 050 123 053 123 093 Engine 110 986 110 922 110 932 110 985 110 923 110 984 110 923 110 984 1979 Engine end no automatic chassis manual transm 003225 040571 010337 014120 014163 020182 014163 020182 transm 007317 067591 002781 070947 017466 068009 017466 068009 end no 007709 006965 120830 152618 028051 065415 003470 017451 004597 This modified oil pan is screwed to cylinder crank case at the rear with 6 screws M 8 x 95 mm formerly 4 screws M 6 x 40 mm and 2 screws M 6 x 25 mm On model 126 the modified oil pan is screwed to cylinder crankcase together with supporting tray arrow by means of
5. conrod bolt to replace it Use third version conrod bolts for repairs Replacing 2 Knock out conrod bolts 3 Press new bolts into conrod with a pressure of about 45000 N or knock in with a hammer and mandrel 4 4 i Z 1006 4752 Place the connecting rod on a ground steel plate when S knocking in or pressing in conrod bolts 50 Distance between holes a 64 6 mm Bore b 11 mm Tightening 4 Lubricate nuts and threads 5 Tighten conrod nuts to a torque pressure of 40 50 Nm and a torque angle of 90 1000 Attention Tighten conrod bolts knocked in with a hammer to a torque pressure of 60 70 Nm and a torque angle of 90 100 for the first time 03 2 310 2 F3 Make sure that this instruction is observed since otherwise the nuts of the conrod bolts may become loose Note If no angle of rotation wrench is available the connecting rod nuts can also be tightened by means of anormal socket wrench with toggle in one step by an angle of 90 100 Estimate angle as accurately as possible To eliminate angle faults do not use a torque wrench for tightening according to angles of rotation 03 2 310 3 F3 03 313 Repairing and squaring connecting rods Data Center of conrod bearing bore to 131 950 center of conrod bushing bore 130 050 Width of conrod at conrod bearing bore 27 890 and conrod bushing bore 27 857 Basic bore for conrod bearing shells 51 619 51 600 l l 2
6. cylinder head covers of version A with oil protection ribs At idle speed and lower speed ranges the blow by gas will enter the combustion chamber via the vent valve and tntake manifold or idle air passage The vent valve spring works against the intake manifold vacuum pressure Depending on intake manifold vacuum pressure the valve cone will be pulled or pressed up by the valve spring and thus changes the through flow cross section opening Since the through flow capacity of the vent valve is larger than the amount of blow by gas from the crankcase fresh air is also drawn off from the air cleaner of a carburetor engine or from the throttle housing in front of the throttle valve via a pipe of an engine with fuel injection The additional fresh air is taken from an air cleaner of a carburetor engine via a hose When coasting the high intake manifold pressure will close the vent valve The very slight amounts of blow by gas in this case will now travel in reverse direction to the throttle housing via a pipe or the air cleaner via a hose and are drawn off at these points Note Carburetor engines with a vent valve can also be equipped with a vent jet 01 2 040 2 F3 101 9341 B Engine with vent jet This engine has a closed crankcase vent which does not require maintenance gis Ue Nore Ne A vent jet LYON Engine with twin two stage carburetors erke Lay Second version and USA version w
7. extent that it is still held to crankcase by 2 screws 8 Remove oil pan lower half 9 Remove oil pump 3 screws 10 Pull oil dipstick guide tube at top out of holder and knock out of oil pan upper half from below by means of a plastic hammer 11 On vehicles with refrigerant compressor remove lower strut 12 Disconnect regulating linkage 13 Unflange propeller shaft at transmission and push back 14 Unscrew engine shock absorber below 15 Unscrew screws for engine carrier on engine mount 16 Suspend engine at the front and rear on engine removing eyes and lift until oil pan can be removed 01 2 310 7 F3 Installation all models 1 Clean parting surface on cylinder crankcase and oil pan 2 Renew rear radial sealing ring in oil pan and work in Note Do not install radial sealing ring 000 997 90 41 yellow brown in engines which are provided with a new or refinished crankshaft and new crankshaft bearings in the event of repairs 3 To arrive at an overlap cut off radial sealing ring approx 0 5 or 1 0 mm above parting surface Use self made gauge for this purpose Radial sealing ring part no Dimension a mm 1 0 0 5 000 997 69 41 graphite grey 000 997 90 41 yellow brown 4 Provide radial sealing ring with engine oil 5 Coat parting surface of oil pan with sealing com pound 6 Install oil pan and screw on lightly at front and rear with 2 screws each Attention The oil p
8. or repairs or whether the marks are insignificant The following information will help in making an expert and correct decision With regard to marks on cylinder walls the first impor tant difference is between optical streaks and seizure streaks In most cases optical streaks are about 3 mm wide they are produced by the piston ring gaps and the honing structure will still be visible while seizure streaks will obliterate the honing structure Longitudinal streaks in piston pin direction are not the result of shaft scratches or seizure since there is no contact between piston skirt and cylinder wall 01 2 020 1 F3 01 025 Measuring oil consumption Special tools Oil dipstick with millimeter scale u 11004 7663 115 589 15 21 00 for engines with oil suction Oil dipstick with millimeter scale ai Rg 110 589 11 21 00 for engines without oil suction 11004 8082 Telethermometer 116 589 27 21 00 t i Bo eerie gh peat te sg amp 1004 7955 Valve for interrupting oil return 110 589 00 91 00 flow from oil cooler The oil consumption can be measured by means of oil dipstick with millimeter scale and the pertinent dia gram on back of data sheet 1033 7517 1 Data sheets Engine 110 Print Mo K Engines with oil suction 800 99 403 00 German English 800 99 403 01 French Spanish Engines without oil suction 800 99 227 00a Germa
9. sur face is reached The timing must be adjusted if a cylinder head mating surface is faced 05 215 01 2 418 2 F3 01 420 Pressure testing cylinder head Data Pressure test with air under water in bar gauge pressure 2 Special tools h FE T Pressure testing plate la A Ad Be a irs 110 589 00 25 00 4 9s vt f trode 8219 vv oe Vy 4 Suspension fixture 4 110 589 34 63 00 Conventional tool Electrically heated sink e g made by Otto Durr D 7123 Sachsenheim Ochsenbach Pressure testing r If the loss of water indicates cracks the cylinder head must be pressure tested 1 Bolt pressure testing plate to a cleaned cylinder head 2 Plug holes and connections 3 Connect compressed air hose 1 and regulate compressed air to 2 bar gauge pressure l R01 7506 01 2 420 1 F3 4 Attach cylinder head to suspension device and lower into heated water 80 C 5 Find location of leaks if air bubbles rise 01 2 420 2 F3 01 470 Removal and installation of camshaft housing Data Valve clearance Cold engine ca 20 C Warm engine 60 C 15 C Intake 0 10 0 15 Exhaust 0 25 0 30 i 0 05 mm more for consistent outside temperatures below 20 C Tightening torques Nm Cylinder asics M 12x 1 5 110 Bolts M 8 for camshaft housing to indet head 25 and crankcase EDansion boli ibi Emsi brocket i 80 Ball locating ring in chain tensioner l 25 Valve adjust
10. temperature switch and adaptor for extra fan air conditioner Core plug M 22 x 1 5 Plug M 14x 1 5 Coolant temperature gage sensor Core plug M 22 x 1 5 On LW ot asenet Measuring sensor box for fuel injection engine with air con ditioner 1 Coolant temperature sensor for control unit 2 1000C temperature switch and adaptor M 18 x 1 5 for extra fan air conditioner 3 Core plug M 22 x 1 5 4 Temperature timing switch for cold starts 5 Coolant temperature gage sensor 6 Core plug M 22 x 1 5 01 2 416 1 F3 Measuring sensor box for continuous fuel injection engine with air conditioner yahaw N 100 C temperature switch and adaptor M 18 x 1 5 for extra fan air conditioner Core plug M 22 x 1 5 Temperature timing switch for cold starts Coolant temperature gage sensor Core plug M 22 x 1 5 Measuring sensor box for carburetor engine USA with air conditioner NAU N 100 C temperature switch and adaptor M 18 x 1 5 for extra fan air conditioner and exhaust gas recirculation Core piug M 22 x 1 5 65 C temperature switch exhaust gas recirculation Coolant temperature gage sensor Core plug M 22 x 1 5 01 2 416 2 F3 01 418 Facing cylinder head mating surface Data Total cylinder head height Min height after machining Permissible unevenness of mating surfaces Permissible deviation in parallel of upper mating surface to lower mating surface in longitudinat direction Peak to valley height
11. to 0 06 0 01 to 0 04 torque pressure torque angle The piston version std 0 5 or 1 0 the group number 0 1 or 2 the piston code e g 40 and an arrow for forward direction are stamped in the piston crown The group number ts also stamped in the crankcase mating surface 03 2 316 2 F3 10g Wear limit 0 08 1 0 0 8 0 8 0 15 0 08 0 08 40 50 Nm 90 100 000 589 51 37 00 000 589 04 14 00 1034 5411 The group number of pistons e g 1 is the same as the group number of cylinder bores production This will guarantee the specified piston clearance When repairing the cylinder bores should be honed according to the sizes of the existing pistons plus the piston clearance Pistons and piston pins are matched The measuring point for nominal diameter of pistons is offset by 90 in relation to piston pin axis at level H On used pistons the measured value does not necessarily correspond with nominal diameter of a new piston since piston in range of measuring point and at shaft tab may recede already after a short operating period that is the nominal diameter may become smaller by up to 0 070 mm Piston normal compression dimension H 32 mm If used pistons are used again make sure that the oil drain bores in 3rd piston ring groove are cleaned Piston low compression and USA version dimension H 32 mm Removal 1 Take out connecting rod with pist
12. to ter minal 50 on cable connector Disconnect cable on ignition coil terminal 1 Attention On engines with CIS injection system pull off relay with code number 21 3 for fuel pump warm up compensator Model 126 Separate cable plug arrow terminal 16 so that the ignition coil and on engines with CIS the fuel pump cannot be activated Connect terminal 30 and 50 01 2 010 2 F3 105 9061 1 Rotate engine for several turns with ignition switched off and idle speed or selector lever position P so that residue and soot will be blown out 2 For testing rotate engine for eight turns while opening throttle valve 01 2 010 3 F3 01 015 Checking cylinders for leaks Data Total pressure loss max 25 On valves and cylinder head gasket max 10 On piston and piston rings max 20 Special tool Socket 27 mm for 001 589 65 09 00 rotating engine 1004 619 Conventional tool Cylinder leak tester e g made by Bosch EFAW 210A made by SUN CLT 228 1 Run engine up to operating temperature 2 Unscrew spark plugs 3 Remove radiator cap and add coolant 4 Remove oil filler plug 5 Remove air filter 6 Connect cylinder leak tester to a compressed air source Calibrate tester 7 Set piston of cylinder 1 to ignition TDC For this purpose turn engine on crankshaft by means of tool combination 8 Set throttle valve to fully open 01 2 015 1 F3 9 Screw connection hose into fir
13. with engine support while working underneath engine Model 116 1 Remove radiator 2 Remove vibration damper 03 340 01 2 310 4 F3 3 Detach control shaft 07 2 442 4 Detach both front engine mounts and engine dampers 5 Pull oil return line off of oil pan 18 030 6 Drain engine oil 7 Remove oil pan lower section and oil pump Remove fuel pump of carburetor engines 8 Remove oil lines for automatic transmission 9 Detach oil dipstick guide tube at cylinder head and drive it out from below with a 7 5 mm dia mandrel Knock out oil guide tube for drawing off oil with knocking out mandrel 9 mm USA version 10 Detach rear engine mount lift engine and place an approximately 40 mm thick piece of wood under neath 11 Lift front of engine and place approximately 60 mm thick pieces of wood on both sides between the engine carrier and engine mounts 12 Detach oi pan and remove forward 01 2 310 5 F3 Model 123 1 Remove engine 01 030 2 Remove oil filter complete with lines 3 Pull off oil return pipe arrow 4 Loosen strut for alternator bracket on oil pan 5 Remove oil pan USA version Model 126 1 Pull off oil return fine on oil pan 2 Remove supporting tray 3 Turn wheels completely to the left 4 Unscrew cover plate 5 Remove vibration damper 03 340 6 Unscrew lower holding bracket of alternator 01 2 310 6 F3 7 Unscrew oil pan upper half to the
14. 15 6 F3 15 Position 1st cylinder of engine at ignition TDC Marks on camshaft sprockets and camshaft housing must align 16 Remove both expansion bolts of camshaft sprock ets Counterhold camshaft with holder 17 Remove upper slide rail in camshaft housing 05 340 Knock out bearing pins with the impact extractor for this purpose 01 2 415 7 F3 18 Remove chain tensioner 05 310 19 Push both camshafts to the rear and remove camshaft sprockets 20 Remove guide wheel Knock out bearing pins with impact extractor M 10 bolts for this purpose 21 Remove guide rail in cylinder head Knock out bearing pins with impact extractor 6 x 150 mm bolt for this purpose 22 Loosen and remove cylinder head bolts in reverse sequence of tightening diagram Pull out the two M8 bolts in the timing case with a magnet 01 2 415 8 F3 70 3 5053 23 Pull up timing chain and press tensioning rail to center of engine Lift off cylinder head straight up with a cable attached to the suspension eyes Installation 24 Clean cylinder head and crankcase mating surfaces thoroughly 25 Install new cylinder head gasket Note Two dowel sleeves are press fit in the crankcase to locate the cylinder head 26 Place two locally manufactured wooden boards 15 x 35 x 240 mm on the cylinder head gasket front upright and rear flat 27 Place cylinder head on board guide in timing chain and tensioning rail 28 Lift f
15. 2 280 280 C 280 S 114 060 114 073 116 020 110 921 922 1976 1975 1974 1973 7 7 4 6 5 6 9 6 6 3 0 6 0 62 11 11 6 10 5 11 11 11 6 maintenance free 0 5 0 53 6 6 5 3 7 0 5 6 1 4 1 5 Engine Model Chassis Type Engine Type Year Operation Number of cylinders Arrangement of cylinders Bore stroke mm ins Total eff piston displacement cm cu ins Compression ratio Firing order Max engine rpm Engine output SAE net bhp rpm Max torque SAE net ft Ib rpm Crankshaft bearings Valve arrangement Camshaft arrangement Oil cooling Cooling Lubrication Oil filter Air filter 1 Federal California 280 E 280 CE 280 SE 123 033 123 053 116 024 110 984 985 1980 1981 1979 1978 1977 Four stroke gasoline engine mechanical CIS fuel injection with airflow sensor 6 upright in line 86 78 3 39 3 10 2746 167 6 8 0 4 1 8 1 1 5 3 6 2 4 6400 6500 142 5750 140 5500 137 5750 149 4600 Deion 142 46007 7 overhead DOHC None Water circulation pump thermostat with by pass line finned tube radiator fan with viscous coupling Forced oil circulation via gear type oil pump Full flow filter Air filter with paper cartridge 00 015 3 Filling Capacities Model Chassis Type Engine Type Year Initial filling Oil and filter change Oil pan up to max marking on oil dipstick Engine Oil filter Cooling s
16. 49 916 Bearing dia 52 5 na 49 950 51 400 52 900 53 900 49 900 49 850 51 340 52 840 53 840 49 850 Journal dia Te piri ae 49 834 51 321 52 821 53 821 49 834 Repair stage 1 0 25 mm Camshaft housing part no 110 010 21 36 Intake camshaft part no 110 051 7501 Exhaust camshaft part no 110051 79 01 49 816 51 269 52 769 53 769 49 765 Bearing dia 52 5 49 800 51 250 52 750 53 750 49 750 49 700 51 190 52 690 53 690 49 700 Journal dia 49 684 51 171 52 671 53 671 49 684 Repair stage 2 0 50 mm Camshaft housing part no 110 010 22 36 Intake camshaft part no 110 051 76 01 Exhaust camshaft part no 110 051 80 01 Bearing dia 49 566 51 019 52 5 52 519 53 519 49 516 49 550 51 000 52 500 53 500 49 500 49 450 50 940 52 440 53 440 49 450 Journal dia 49 434 50 921 52 421 53 421 49 434 On this camshaft housing bearing point 5 is without 1 2 4 5 6 8 oil bore and its ID is 1 mm larger than the respective camshaft bearing journal This camshaft housing can be used to install camshaft without changes on bearing journals 1053 8265 9 10 12 14 15 01 2 471 4 F3 This camshaft housing is attached together with cylinder head by means of 9 cylinder head bolts M 12 x 145 formerly M 12 x 150 since the bolt head contact surfaces in camshaft housing were counter sunk by 5 mm Attention On exchange engines starting unit number 496 861 approx starting October 1977 these 9 cylinder head bolts are installed wi
17. 5 12 599 2013 5050 27012 5049 19 Install right camshaft sprocket making sure that the adjustment marks of both camshafts align when the crankshaft is at TDC Attention When the vibration damper of an engine has a 0 0 mark for BDC in addition to TDC the TDC mark is next to the pin in the vibration damper 1 TDC mark 20 Install sliding rail so that the timing chain cannot jump 21 Install rigid chain tensioner and tighten by hand Attention if camshaft housing has been ground the timing must be adjusted 22 Lubricate spacers with engine oil and slide them into camshaft housing 01 2 470 7 F3 _h Spacer 2nd version without lubrication groove for pressure oil pump and vacuum pump 2nd version Washer Expansion bolt Dog for pressure oil pump and vacuum pump 2nd version Dog for vacuum pump 1st version Dog 1st version for oi pump Spacer 1st version with lubrication groove A 4 7 mm for vacuum pump 1st version A 8 3 mm for pressure oil pump and vacuum pump 2nd version Spring washers not valid Mounting bolt not valid WOO ht WN oO 23 Torque expansion bolt for camshaft sprocket to 80 Nm 8 kpm counterholding camshaft with the holding wrench Note Washer 2 with 30 mm OD is not fitting into spacing sleeve for vacuum pump on USA vehicles up to January 1973 In such a case machine OD of washer 2 down by approx 1 mm 24 Position chain t
18. 6 021 Basic bore for conrod bushing 76 000 Conrod bushing inside dia 23 013 23 007 Peak to valley height on inside of conrod bushing 0 004 Permissible stagger of conrod bore to conrod bushing bore 0 1 in reference to a length of 100 mm Permissible difference in paralle between axes conrod bearing bore to conrod bushing bore dia 0 015 in reference to a length of 100 mm Permissible deviation of conrod 0 020 bearing bore from true Permissible difference in weight of all 5 gr connecting rods of one engine gr Tightening torque Initial torque 40 50 Nm Conrod nuts p Torque angle 90 100 Conventional too Made by Krupp GmbH 5309 Meckenheim C hecki onnecting rod checking and straightening tool e g Model CL 6 03 2 313 1 F3 Note Connecting rods which are overheated blue discoloration due to bearing damage may not be re used The connecting rod and its cap are marked to fit together The connecting rod stem must not show cross scoring and notches Connecting rods with a machined conrod bushing are delivered as replacement parts When renewing conrods pay attention to different weights of rods 1 Check conrod bolts and replace if necessary 03 310 2 Check conrod bolt bores Place conrod cap on a conrod bolt If the conrod cap moves down by its own weight the connecting rod must be replaced 3 Mount connecting rod bearing cap and tighten to 40 50 Nm and 90 100 angle of
19. 6 screws M 8 x 110 mm 01 2 310 2 F3 11004 7708 20 If a modified oil pan is installed in the course of repairs the respective threaded bores in cylinder crankcase should be enlarged from M 6 to M 8 mm In the event of repairs use radial sealing ring 000 997 90 41 yellow brown with a projection of 0 5 mm on both sides except when a new or newly ground crankshaft with new crankshaft bearings is installed In such a case use radial sealing ring 000 997 69 41 graphite grey with a projection of 1 mm on both sides This will protect the rear bearing journal of crankshaft against being overheated under influence of a low crankshaft bearing play and excessive pressure against yellow brown radial sealing ring Removal Model 107 1 Remove front axle 33 100 2 Detach oil return pipe at cylinder head and pull off at oil pan 3 Detach oil dipstick guide tube at cylinder head 4 Detach steering rod at one side 5 Detach alternator holder strut at oil pan 6 Remove oil pan downward Note Hold engine with engine support when working underneath engine 01 2 310 3 F3 Model 114 1 Remove front axle 33 100 2 Remove exhaust gas recirculation line arrows for USA models 3 Remove oil lines for automatic transmission 4 Detach oil dipstick guide tube at cylinder head 5 Pull oil return line 1 off of oil pan 18 030 6 Drain engine oil 7 Remove oil pan Note Hold engine
20. 80 E 130 6000 110 984 123 053 280 CE 130 6000 110 984 123 093 280 TE 130 6000 110 985 116 024 280 SE 130 6000 110 985 116 025 280 SEL 130 6000 110 986 107 022 280 SLC 130 6000 110 986 107 042 280 SL 130 6000 110 987 126 022 280 SE 136 5800 110 987 126 023 280 SEL 136 5800 110 991 NV 114 062 280 E 125 6000 110 991 NV 114 072 280 CE 125 6000 110 992 NV 107 022 280 SLC 125 6000 110 992 NV 107 042 280 SL 125 6000 110 993 NV 116 024 280 SE 125 6000 110 993 NV 116 025 280 SEL 125 6000 1 for USA 2 Sweden only NV lowcompression SA 012 276 SA special equipment 01 2 001 1 F3 01 010 Checking compression Test values in bar for engine at operating temperature Compression Compression Engine ratio 1 Normal compression 9 0 Low compression Cs QD starting 1976 8 0 starting 1977 Special tool Compression recorder with attachments and contact grip normal 10 12 Check compression with coolant at temperature of 80 C Check cylinders for leaks if compression is less than the minimum specification 01 015 Unscrew all spark plugs for testing 01 2 010 1 F3 Min Compression Max difference approx 8 5 approx 7 5 between separate cylinders max 1 5 001 589 46 21 00 004 8207 Models 107 114 and 116 Connect contact handle to battery and terminal 50 on starter Disconnect cable on ignition coil terminal 1 Model 123 Connect contact handle to terminal 30 and
21. 906 01 2 040 5 F3 Data Group number Standard dimension 86 0 piston dia cylinder dia Repair stage 1 0 5 piston dia cylinder dia Repair stage 2 1 0 piston dia cylinder dia 0 85 970 85 982 85 998 86 008 86 470 86 482 86 498 86 508 86 970 86 982 86 998 86 008 Max wear limit in driving or transverse direction of cylinder 85 980 85 992 86 008 86 018 86 480 86 492 86 508 86 518 86 980 86 992 87 008 87 018 85 990 86 002 86 019 86 028 86 490 86 502 86 519 86 528 86 990 86 002 87 019 87 028 bores at upper reversing point of 1st piston ring 0 025 0 035 Piston clearance Machining tolerances Permissible deviation radia distance from cylinder shape Permissible deviation from square with reference to cylinder height Mean height of roughness Permissible height of waviness Chamfer of cylinder bores Conventional tools Inside measuring instrument for 50 150 mm dia with 0 01 mm readout and measuring point pressure relief In particular for a complaint concerning excessive oil consumption a measurement of the cylinder bores is essential in addition to a visual inspection 01 2 110 1 F3 0 10 When new Wear limit 0 08 When new 0 007 Wear limit 0 025 0 05 0 002 0 004 50 of roughness see fig point 2 e g made by Hommel Handel 5000 K ln 71 Sunnen GRM 2125 1 Measure the cleaned cylinder bores
22. Complete Service Manual coverage for late model year Mercedes Benz vehicles requires three individual manuals Service Manual Engine Service Manual Transmission Service Manual Chassis and Body 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 number and Engine number see page 00 010 1 In cases where the repair instructions apply to all versions of the engine only the first three digits of the respective number are referenced For example engine 110 applies to all 2 8 liter 6 cylinder engines with dual overhead camshafts See the engine and vehicle identification table on page OO 010 1 for the engine installed in your vehicle Location of specific repair instructions First locate the major component group in the Group ndex Individual groups are separated by an easily visible dividing page which ts 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 07 3 135 Checking Injection valves Job Title appears on same fine as Group No Major component group Sub component group Unit version Revision status of microfilm a Job No D No 07 3 2 11 135 1 Technical data tightening torques and tools are listed at the beginning of each Job All the dimensions a
23. ace 01 in relation to lower parting surface in longitudinal direction Permissible deviation from flatness 0 03 of upper parting surface Mean height of roughness of upper 0 005 0 020 parting surface Leak test with 1 5 bar air gauge pressure under water 10 Permissible leak rate in cc min see note Chamfer of cylinder bores Piston spacing in relation to parting surface Engines with normal compression USA version and low compression Standard size piston Below neo POED Distance between P max 0 70 below 0 15 piston crown and ae aa ee crankcase mating versizes min 1 min O 0 5 and 1 0 REIO max 1 5 pelew max 0 95 surface Conventional tools Surface grinding machine Knife edge straightedge approx 750 mm lon Note Chamfer cylinder bores after grinding Adjust valve timing 05 215 if crankcase mating surface has been machined 01 2 120 1 F3 e g made by Ruaro u Fi Schio Italy Scledum type RTY N N A 1034 6384 YY Tightening torques Nm Fastening bolts for intermediate flange 65 Closing plug for main oil duct 40 Pressure relief valve in main oil duct front 40 Closing plug pressure relief valve 50 Screw M 8 x 65 for vibration damper 35 Screw M 18 x 1 5 x 45 on crankshaft 400 450 Necked down screw for driven initial torque 40 plate and flywheel torque angle 90 100 Note Since October 1976 the 2 main oil ducts arrows in cylinder crankcase at transm
24. aft housing This re quires knocking out bearing pins with an impact extractor 12 Push back righthand camshaft and remove cam shaft sprocket 13 Guide camshaft into bearings again Unscrew M 8 bolts and cylinder head bolts in reverse sequence of tightening Do not loosen the 5 cylinder head bolts positioned deeper arrows and the 2 M 8 bolts arrows 14 Remove camshaft housing with camshafts 105 3003 01 2 470 5 F3 Installation 15 Clean mating surface on cylinder head and cam shaft housing to remove grease and install sheet metal foil part number 110 016 06 80 without a sealing compound 16 Install camshaft housing 17 Lubricate threads and cylinder head surfaces of cylinder head bolts before installation Attention Since July of 1974 the clearance on the camshaft housing for 22 mm dia washer of cylinder head bolt No 14 has been extended Use the former 20 mm dia washer arrow on former camshaft housings 18 Tighten cylinder head bolts in steps in the sequen ce of tightening Ist step to 70 Nm 7 kpm starting with bolt No 2 2nd step all cylinder head bolts to 110 Nm starting with bolt No 1 This requires first loosening the five cylinder head bolts 1 4 6 7 and 9 located deeper separately somewhat Tighten the M 8 bolts from inside to outside to 25 Nm Attention After tightening all bolts it must be possible to turn both camshafts by hand 01 2 470 6 F3 10
25. an should rest against or be screwed to inter mediate flange prior to tightening fastening screws for crankcase 7 For further installation proceed vice versa Attention Check regulating linkage for function 01 2 310 8 F3 7 32 AON ONORS Z033 4001 1 01 415 Removal and installation of cylinder head Timing at 2 mm valve lift Engine 110 Engine 110 California 1974 24 57 71 78 24 i Exhaust Camshaft code number Intake 25 67 74 25 74 opens after TDC 7 Intake valve Spee os ao tt closes after BDC 210 opens before BDC 30 Exhaust valve closes before TDC The camshaft code number is punched into rear end of camshaft Valve clearance on cold engine approx 20 C Intake 0 10 0 15 Exhaust 0 25 0 30 l 0 05 mm larger during lasting outside temperatures below 20 C Tightening torques Bolts and cap nuts for cylinder head cover Necked down screw for camshaft sprockets Cylinder head bolts M 12 x 1 5 on cold engine Bolts M 8 for cylinder head to crankcase Closing plug chain tensioner Threaded ring chain tensioner Ball seat ring in chain tensioner Special tools step 1 step 2 after 10 min setting time Remover and installer for rocker arm se J 01 2 415 1 F3 80 40 70 110 25 50 50 25 Engine 110 Federal 1973 and 1974 30 95 33 91 119 150 22 on warm engine 60 C 15 C 110 589 04 61 00 Rigid chain tensioner Chain
26. ate and flywheel expansion bolt Na Se a E E Torque angle 90 100 we Special tool Dial gage holder two required 121 589 00 21 00 Self made tool Threaded pin see fig point 3 Conventional tool Dial gauge A 1 DIN 878 e g made by Mahr 7300 Esslingen order no 810 Note A replaced intermediate flange must be centered The automatic transmission W4A040 requires the intermediate flange 1 with fitted pin and all around centering system which can be used as a replacement for the formerly used intermediate flange 2 with all around centering system 1 Modified intermediate flange 110 011 15 45 1 2 Former intermediate flange 11501111 45 i BR 01 2 220 1 F3 Series installation of intermediate flange 110 011 15 45 starting end of november 1979 Starting engine end no Starting chassis end no 110 923 10 014 453 123 030 028 448 12 017 710 123 050 003 543 110 94 19 021 092 123 033 067 904 12 070 620 123 053 018 127 12 067 894 416 020 121 410 110 932 10 010 365 12 002 796 110 985 10 014 287 116 024 025 154 967 12 073 060 110 996 10 003 392 107 042 007 301 12 007 701 107 022 007 921 Installing and centering 1 Place intermediate flange over dowel pins in crankcase 2 Tighten the four mounting bolts slightly 3 Screw threaded bolt self made into crankshaft and counterlock with hex nut 1 Hex nutM12x 1 5 2 Threaded bo
27. available at 2 3 of journal circumference Journals without hardened fillets can be hardened inductively or by flame hardening Journals with hardened fillets arrows should be inductance hardened on principle If this is not possible scrap crankshaft 1034 7993 When hardening journals without hardened fillets maintain distance A between runout of hardened surface and fillet 4 5 mm OOO LLL d ds 03 2 318 5 F2 For a good hardening job test adjustment of hardening plant by metallographic grinding tests These tests can be made by testing scrapped crank shafts Check hardening by etching surface of journal with a 2 alcoholic nitric acid HNO No dark spots should show up at surface of journal Non hardened fillets will become dark The hardened fillets on the other hand should be as bright as surface of journal For comparison perform an etching job on a metallo graphically controlled journal Then carefully wash off nitric acid by means of alcohol Corrosion protection Crankshafts which are not immediately installed again should be lubricated with engine initial operation oil SAE 30 03 2 318 6 F2 Riveting additional weight off and on 1 Punch mark countersunk rivet 6 x 28 mm accurate ly in center 2 Drill into rivet heads with a 6 5 mm dia drill and knock out 3 Slip on new or former undamaged additional weight together with 4 countersunk rivets
28. engine mounts engine shock absorbers coolant oil and fuel hoses and replace them if necessary 26 Prior to flanging on manual transmission check radial ball bearing in crankshaft and throw out of clutch and renew if required 01 2 030 6 F3 27 28 29 30 31 32 Install engine and connect Adjust rear engine mount free of tension 00 220 Connect propeller shaft Check all drain plugs for tight seat Add oil and coolant 20 010 Check cooling system for leaks with leak tester Note On vehicles with auxiliary heater bleed coolant circuit refer to repair instructions auxiliary heater 83 33 34 35 36 415 Check coolant for antifreeze Clean air filter and renew if required Check dwell angle and firing point Adjust idle speed and emission value 07 2 100 37 Check regulating shaft for function 01 2 030 7 F3 A Engine with vent valve This engine has a closed crankcase vent system which does not require maintenance Ee blow by gas lt gt fresh air 7003 5054 Engine with electronic fuel injection system _ _ i iD i ny j Engine with twin two stage carburetors First version with vent valve blow by gas gt fresh air 01 2 040 1 F3 The blow by gases flow via an oil separator in the cylinder head cover to the vent valve Attention Only use
29. engines eer eT 49 850 49 850 51 340 52 840 53 840 l 49 834 49 834 51 321 52 821 53 821 i f 49 816 49 765 51 269 52 769 53 769 bearing dia 49 800 49 750 51 250 52 750 53 750 Repair stage 1 0 25 mm 49 700 49 700 51 190 52 690 53 690 journal dia 49 684 49 684 51 171 52 671 53 671 49 566 49 516 51 019 52 519 53 519 bearing dia _ 49 550 49 500 51 000 52 500 53 500 Repair stage 2 ee 0 50 mm sumata 49 450 49 450 50 940 52 440 53 440 7 49 434 49434 50921 52421 53 421 radial 0 057 0 100 0 050 0 060 0 060 0 060 0 124 0 132 0 082 0 098 0 098 0 098 Camshaft bearing a a O U are play 0 050 axial a 0 120 Sleeve for bearing a OD 37 950 ID 24 013 37 925 24 000 01 2 471 1 F3 4 5 12 13 6 7 14 15 Combinations in the event of repairs a Camshaft housing with 15 bearing points intake camshaft code number 25 67 and 33 with 7 bearing journals Exhaust camshaft code number 24 30 57 and 71 with 8 bearing journals b Camshaft housing with 15 bearing points with bearing points 11 and 13 at intake end or 3 and 7 at exhaust end out of function Intake camshaft code number 74 and 91 with 5 bear ing journals and intermediate stage or repair cam shafts with reduced bearing dia Exhaust camshaft code no 78 and 95 with 6 bearing journals and intermediate stage or repair camshafts with reduced bearing dia I
30. ensioner for installation and in stall Also install pressure spring 05 310 RRA eae Eat Kee CULLL K m 5 iiie B X s a Ss Sy WAA Ly SERRA DUIU 7053 5030 Chain tensioner in installation position 25 Install cover on front of camshaft housing and in stall level control pump or vacuum pump with gaskets 26 Install rocker arms 05 230 01 2 470 8 F3 27 Adjust valve clearance 05 210 28 Complete engine Note If the camshaft housing has been faced read just timing 05 215 01 2 470 9 F3 Note Exchange engines are in part supplied with camshaft bearing intermediate stages and repair stages In the event of repairs install pertinent camshafts with re duced bearing dia Also refer to table Camshaft housing with 11 bearing points Camshaft housings with repair stages are available for camshafts with reground bearing journals Also refer to table Camshaft housing with 11 bearing points Camshaft housing with 15 bearing points Bearing points 1 9 2 3 10 11 8 E ee 38 016 50 066 50 016 51 519 53 019 54 019 bearing dia 38 000 50 050 50 000 51 500 53 000 54 000 Standard dimension unada 23 993 49 950 49 950 51 440 52 940 53 940 23 980 49 934 49 934 51 421 52 921 53 921 l 49 966 49 916 51 419 52 919 53 919 bearing dia _ ee l 49 950 49 900 51 400 52 900 53 900 Intermediate stage 0 1 mm a ee eee ee B exchange
31. for the various repair stages varies Cylinder bore Combustion chamber frame 86 00 86 70 0 5 86 506 ane 87 00 87 20 0 5 mmo Removal 1 Remove compressor of models with an air condi tioner 2 Remove oil pump of models with a level control system and place it to one side without undoing the lines Only unscrew the boits marked with an arrow for this purpose 01 2 415 3 F3 3 Remove vacuum pump of models for USA 4 Drain coolant from radiator and engine Mode 123 5 Unscrew both covers at front of camshaft housing 6 Disconnect ali electric wires heater water fuel and vacuum lines which are connected to the cylinder head and intake manifold or carburetor 01 2 415 4 F3 7 Remove longitudinal regulating shaft 3 8 Disconnect oil return pipe at cylinder head 9 Remove hose between thermostat housing and water pump Disconnect bypass line at water pump 10 Disconnect oil dipstick guide tube from clamp on cylinder head and bend to one side 01 2 415 5 F3 11 Detach exhaust pipe at exhaust manifold and trans mission Unscrew pre heating cowl of models with car buretor engines 12 Press out all spring clamps with a wrench socket 13 Remove all rocker arms with the remover and installer 05 230 14 Turn crankshaft with combination tool Attention Don t turn engine on camshafts Don t turn engine in reverse direction of rotation 1100 6498 1 01 2 4
32. ges dia fitted bearing Standard dimension 28 084 28 000 Ist repair stage 2nd repair stage aes up to 29 60 up to 28 30 3rd repair stage 4th repair stage Basic bore and bearing play Crankshaft bearing Connecting rod bearing Basic bore dia 67 00 91 60 67 02 51 62 Perm out of round and _ 0 01 conicity of basic bore when new 0 031 to 0 053 0 025 to 0 065 Radial bearing play ota wear limit 0 08 when new 0 10 0 24 0 11 0 23 Axial bearing play iis wear limit 0 30 0 50 Try for mean value of radial play vertical runout Bearing shells Wall thickness Width of fitted Wall thickness crankshaft bearing bearing shells connecting rod bearing Standard dimension 3 500 3 513 28 78 28 90 1 804 1 814 Ist repair stage 3 625 3 638 1 929 1 939 2nd repair stage 3 750 3 763 2 054 2 064 3rd repair stage 3 875 3 888 29 4 29 6 2 179 2 189 4th repair stage 4 000 4 013 2 304 2 314 1 Measured at apex of bearing shell 2 The fitted bearing shelis for 1st to 4th repair stage are supplied in oversize width and should be refinished in accordance with ground crankshaft bearing journal 03 2 320 1 F3
33. haust camshaft sprocket 2 2b Sliding rail Intake camshaft sprocket Guide wheel Lock bolt Intermediate wheel Timing chain Crankshaft sprocket Tensioning rail bearing pin Tensioning rail Hydraulic chain tenstoner OOO MOAW 01 2 415 10 F3 J M 8 bolts 4 2a 11 2 10 6 9 7 8 2b 34 Install camshaft sprocket 6 of intake camshaft with spacer 5 Lubricate spacer 3 with engine oil and slide it into bearing 4 Intake EATR Expansion bolt Washer Spacer Bearing a Spacer f 4 Camshaft sprocket i Woodruff key Camshaft el Camshaft housing JE E Z052 5027 OCOMO AOOhWN med 35 Install camshaft sprocket 6 of exhaust camshaft 1234 6 7 910 with timing chain Lubricate spacer 3 with engine oil qA and slide it into bearing 4 Exhaust camshaft Expansion bolt Washer Spacer Bearing Camshaft sprocket Woodruff key Camshaft Camshaft housing Ds SNEG OONDQ AUN 36 During repair jobs mount necked down screw 3 with washer 2 only but do not yet tighten 1 Spacer 2nd version without lubricating groove for pressure oil pump and vacuum pump 2nd version Washer Expansion bolt Dog for pressure oil pump and vacuum pump 2nd version Dog for vacuum pump 1st version Dog 1st version with lubricating groove A 4 7 mm for vacuum pump 1st version A 8 3 mm for pressure oil pump and vacuum pump 2nd version Spring wa
34. ing screw 20 40 Cylinder head cover bolt and capped nuts 5 Level control pump to camshaft housing 9 Special tools Rocker arm removal and 110 589 04 61 00 installation tool Rigid chain tensioner 110 589 03 31 00 Chain tensioner holder 110 589 02 31 00 11004 7005 116 589 20 33 00 Bearing pin impact extractor basic unit M 6 x 50 bolt for impact extractor pera 116 589 01 34 00 Holding wrench for camshafts 116 589 01 01 00 01 2 470 1 F3 Valve adjusting wrench 17 mm 110 589 01 01 00 001 589 65 09 00 Socket 27 mm to turn engine 11004 619 10 mm wrench socket 1 2 square 140 mm long EEE a 000 589 05 07 00 Note Camshaft housing may only be removed after engine is cold The camshaft housing must be removed to remove the camshafts and valve springs or to replace the valve seals 105 8003 Attention On exchange engines starting unit no 496 861 start ing October 1977 9 cylinder head screws with a length of 150 mm are used instead of 145 mm in combination with camshaft housings which are countersunk by 5 mm at the 9 bolt head supporting points 2 3 5 8 10 11 12 13 and 14 These cylinder head bolts must be installed together with a washer part no 186 990 09 40 5 mm high since otherwise the thread lugs in cylinder crankcase may be forced off 7013 5050 For engines with CIS use camshaft housing with lug for attaching air cleaner arrow Camshaft housing
35. irclip Connecting rod with conrod cap Conrod bolt Nut Conrod bushing Conrod pin Conrod bearing upper half with oil bore Conrod bearing lower half WN OODNMDAA WN wd d ad 03 2 316 5 F3 03 318 Checking and reconditioning crankshaft Data Conrod bearing journal width Conrod bearing journal dia Width of journal at thrust bearing Crankshaft Standard size amp undersizes Crankshaft bearing journal dia Standard size 1st Undersize 2nd Undersize to 29 60 to 28 30 3rd Undersize 4th Undersize Crankshaft journal dia for mounting compensating weight Permissible deviation of crankshaft journal prior to mounting compensating weight fom trubi 0030 o Permissible deviation of crank pins and crankshaft 0 0025 bearing journals from true Permissible deviation of crank pin cyl 0 010 line from parallel Permissible deviation of running surfaces of fitted 0 020 bearing from parallel Permissible deviation of running surface of rear 0 015 radial sealing ring from concentric true Permissible deviation of flywheel flange 0 010 from axial true M a journal Il VI 0 070 Permissible deviation of crankshaft o _ bearing journal from concentric true journal 111 IV V 0 100 Fillets on crankshafts 25to3 and crank pins 03 2 318 1 F3 when new 74 84 Scleroscope hardness of crankshaft bearing journals and crank pins boundary value
36. ission end are closed by means of steel balls 15 mm dia VO DIN 5401 part no 005401 515001 For cleaning main oil ducts during engine repairs the steel balls must be knocked out from direction of front end of engine Undamaged steel balls can be used several times without refinishing ball seat in crankcase Damaged and rusty steel balls should be replaced 01 2 130 1 F3 Knocking out steel ball in upper main oi duct 1 Remove transmission 2 Remove flywheel 03 410 3 Remove radiator 20 420 4 Remove vibration damper O3 340 5 Unscrew closing plug 1 and screw oil pressure relief valve out of main oll duct 6 Knock out steel ball from direction of engine front end by means of a round steel bar 13 mm dia and approx 700 mm long Knocking out steel ball in lower main oil duct 1 Remove transmission 2 Remove flywheel 03 410 01 2 130 2 F3 3 Remove radiator 20 420 4 Remove vibration damper and compensating weight 03 340 103 8363 5 Remove complete oil pan 01 310 6 Remove oil pump 18 210 7 Remove slide rail 2b in crankcase 05 340 8 Knock out steel ball from direction of engine front end by means of a round steel bar 13 mm dia and approx 700 mm long 2052 5017 01 2 130 3 F3 Closing main oil duct 1 Thoroughly clean ball seat and bore in main oil duct 2 Coat up on self made knocking in mandrel with grease and place stee
37. ith vent jet ns ae l S i S gt blow by gas including model year 1979 at E AS fresh air RS NS Te Ae E S sa On i ANZ j p E 1 vent jet blow by gas fresh air Engine with continuous fuel injection Paget 01 2 040 3 F3 The blow by gases flow to the vent jet via an oil separator in the cylinder head cover Attention Only use cylinder head covers of version A with oil protection ribs 101 93 4 At idle speed and in low speed ranges the blow by gas will enter into the combustion chambers via the vent jet and intake manifold or idle air passage In lower and medium speed ranges the intake manifold vacuum will cause fresh air to be drawn in from the air cleaner via a hose in addition to the blow by gas In the upper speed range blow by gas will also flow from the fresh air side of the air cleaner depending on the blow by quantity This is drawn off to the combustion chambers via the carburetor or air flow sensor and intake manifold Models for USA Australia and Japan up to model year of 1977 have a flame guard arrow in the engine vent connection 01 2 040 4 F3 For 1975 and 1976 USA models 1976 Sweden model and 1976 Japan models the blow by gas is drawn off to the carburetor via an angle connector arrow On USA vehicles starting model year 1980 the vent nozzle is mounted with an overflow pipe 2 so that no engine oil is carried along in idle speed air duct 1004 8
38. l ball into cup 103 13 405 ae OE E eas ce Se as ee Material C 45 oo 11003 7473 3 Position steel ball with knocking in mandrel and knock in up to stop on mandrel EE E EAE E x If the mandrel has no stop do not exceed dimension l Cat a ya ct r rn a max 3 mm to prevent cracking of crankcase max 3 mm dia 14 75 to 14 86 mm c oil ducts to crankshaft bearing Oo a i 37 w 01 2 130 4 F3 4 Mount all parts taken off or removed 5 Run engine warm and check for leaks Note If oil flows out as the result of a leaking ball seat knock out respective steel ball and close main oil duct with a closing plug after cutting the required threads into duct Closing main oil duct with closing plug 1 Cut threads M 16 x 1 5 mm approx 14 mm deep into respective main oil duct 2 Carefully clean main oil duct 3 Screw closing plug M 16 x 1 5 mm DIN 908 part no 000 908 016 001 with aluminum sealing ring A 16 x 22 mm DIN 7603 AL part no 007 603 016 102 and tighten to 40 Nm 01 2 130 5 F3 M16 x15 Mi6x15 4 1034 8638 1 01 220 Installation and centering of intermediate flange Data Radial runout of intermediate flange max 0 10 Permissible axial runout of intermediate flange when mounted in crankshaft bearing basic bore during 0 10 one full turn Tightening torques Nm Intermediate flange mounting bolts 65 Torque pressure 40 Drive pl
39. ll bearing journals scleroscope hardness min 60 at 2 3 of journal circum Crankshaft with additional weight ference If required bore out additional weight e g when hardening re yes grinding etc and rivet on again Measure journal Are dimensions prior to balancing Refer to job no 03 318 in order no Check whether NO ite N yes regrinding with no V in last Lap specified reapair yes stage 4 is still Harden Dimensional checkup possible Dimensions in order no Journal with Journal without hardened fillets hardened fillets yes yes Induction Balance crankshaft hardening system together with Crankshatt available Induction or compensating weight straighten flame hardening and flywheel Crankshaft ae grind Crack test Cracks showing I nduc Test hardness up os et yes V tion by etching hardening no Relieve crank shaft for 2 hours Refer to lap at 80 C 03 2 318 4 F3 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 flux A color penetration meth od insertion in bath or with spray can can also be applied Aids paint or fluorescent powder cleaning agent developer Hardness test Test hardness with impact hardness tester scleros cope hardness Scleroscope hardness of 60 should be
40. lt 10 mm dia 3 Hex nutM10 x 1 4 Attach dial gauge holder with dial gauge to threaded bolt 5 Position feeler pin at fitting point of centering surface Set dial gauge to O 01 2 220 2 F3 6 Rotate crankshaft for one full turn by means of tool combination Vertical runout should not exceed max 0 70 mm Note When rotating crankshaft make sure that the feeler pin of the dial gauge is not getting stuck 7 Correct vertical runout by light blows against intermediate flange 8 Tighten fastening screws Note If the vertical runout exceeds 0 10 mm remove intermediate flange 9 increase diameter of both fitted bores in inter mediate flange to 12 1 mm 10 Repeat item 1 8 01 2 220 3 F3 Ta BADRA 01 310 Complete removal and installation of oil pan Oil capacity in liters Oil dipstick color code wine red pink VE LOW green brown Oil pan 6 5 5 Oil filter 0 5 Model 107 114 116 0 7 Air oil cooler ee Model 123 126 0 40 1 model year 1975 76 Tightening torques Oi drain plug on oil pan Oil drain plug on air oil cooler 35 Filter lower section mounting bolt 45 Oil pan lower section to upper section 11 Special tools p p oe 6721 pA we 104 672 Stud ring wrench 13 x 14 mm 117 589 02 07 00 Stud wrench 5 mm 300 mm long 116 589 02 07 00 Stud wrench 6 mm 440 mm long 116 589 03 07 00 Engine support 107 589 02 61 00 11004 6200
41. n English 800 99 227 01 a French Spanish The measuring procedure is explained on front page of data sheet To avoid faulty measuring check engine oil for dilution by fuel prior to measuring Q Q oO O Q s6 oO N Oo N O v O n oO N Q 01 2 025 1 F3 01 030 Removal and installation of engine oil filling capacity 2 gt 35 Specified viscosity classes ee 2 according to SAE gt S during constant outside temperatures 2 1184 7659 During constant outside temperatures above 30 C 86 F SAE 40 may be used Oil filling capacity in liters for approved engine oil grades refer to specifications for service products Color code of total capacity when refilling oil dipstick engine Wine red pink 7 brown USA 1975 76 only yellow green 6 5 Tightening torques Nm Oil drain plug to oil pan 40 Fastening screw for oil filter lower half 40 l l M 12 70 Screws for engine carrier on engine mount front M 10 40 Special tools Tester for cooling system and l 001 589 48 21 00 radiator cap Double connection for radiator pee 000 589 73 63 00 cap test in combination with tester ee 11004 8326 Radiator cap with hose i for leak test dJ 8 fp 605 589 00 25 00 Conventional too Engine hoist e g made by Backer D 5630 Remscheid Motordirigent size 1 5 order no 3178 01 2 030 1 F3 Remove and install engine with transmis
42. n this case the oil bores of bearing points 11 and 13 or 3 and 7 on removed camshaft housing must be xX close oil bores closed For this purpose cut threads M 6 approx 10 mm deep from below into oil bores arrow and screw in threaded plug 000 913 006 110 with sealing compound c Camshaft housing with 15 bearing points with 1 2 3 4 5 6 7 8 bearing points 11 and 13 intake end or bearing points 3 5 and 7 exhaust end without oil supply Intake camshaft code number 25 67 and 33 with 7 bearing points of which bearing points 11 and 13 with 1 mm machined off Exhaust camshaft code number 24 57 71 and 30 of which bearing points 3 5 and 7 machined off by 1mm 9 10 11 12 13 14 15 1053 8264 01 2 471 2 F3 Exchange engines starting unit no 464 130 are supplied in this version c When installing an exhaust camshaft with code number 78 and 95 into camshaft housing version c machine 1 mm from bearing journal 5 arrow Camshaft housing with 15 bearing points of which 5 bearing points without oil bore Bearing points 1 9 2 3 11 4 12 5 13 6 14 15 7 8 10 Bearing dia 38 016 50 066 51 0 51 519 52 5 53 019 54 0 54 019 50 016 Bearing 38 000 50 050 51 500 53 000 54 000 50 000 points sats journaldia 23 993 49 950 B 49 950 M 52 940 B 53 940 49 950 23 980 49 934 49 934 52 921 53 921 49 934 This camshaft housing is not manufactured as an intermediate or repair stage On this camshaft housing
43. olts M 8 x 15 2 gaskets 2 covers 6 combination bolts Cover 7 combination bolts M 6 x 15 Gasket Cover with holder Gasket 2 nutsM 8 2 circlips 01 2 490 1 F3 Suspension eyes front 2 studs M 8 x 18 Camshaft housing Sheet metal foil for repairs Engine vent connecting hose Stud M 8 x 30 Cylinder head 2 dowel pins 8 x 16 5 bolts 5 washers Studs M 8 x 20 2 plugs for oil bores Plug AM 22 x 1 5 PlugM 18x 1 5 Seal A 22 x 27 2 combination bolts M 8 x 20 Plug M 10 x 1 for oil connecting bore Return flow oil jet Plug OM 30 x 1 5 Seal A 30 x 36 Connector for pre heating Connectors for carburetor heating 2 dowel pins 8 x 16 Stud M 8 x 35 Seal A 30 x 36 Cover for injection bore Heater connection Cylinder head gasket 03 310 eee epee and ey conrod bolts Conrod bolt sizes Distance Expansion stem Min Version Part Number aandb Thread dia d dia c when new Expansion ee se 1 fig point 1 stem dia Ist version 110 110 038 01 71 01 71 2nd version 110 038 03 71 3rd version 110 038 04 1100380471 Conrod bolt installation pressure 45000 N Conrod nut torque Initial torque 40 50 Torque angle 90 100 Self made tool Steel plate see e fig point 3 ee 1 Measure smallest expansion stem diameter before reusing 03 2 310 1 F3 Note If the minimum expansion stem diameter reaches or is less than 8 0 mm replace conrod bolt Only knock out a
44. on from above 2 Remove piston pin circlips and press out piston pin 3 Repair and square connecting rod 03 313 03 2 316 3 F3 1034 8929 1034 8928 Installation 4 Place piston on connecting rod that arrow 1 faces in forward direction and circlip grooves 2 in connecting rod face to left side of engine intake manifold Attention Don t heat piston 103 8914 1 5 Press in piston pin coated with engine oil by hand 6 Insert piston pin circlips in grooves When installing used pistons check piston ring gaps and clearances Check piston rings for easy movement 7 Lubricate cleaned cylinder bores conrod bearing journals conrod bearing shells and the pistons 8 Distribute gaps of piston rings around piston circumference evenly 9 Install piston ring compressor and guide in piston with arrow facing forward 03 2 316 4 F2 10 Place connecting rod bearing caps with code numbers facing each other on connecting rod and tighten connecting nuts to 40 50 Nm initial torque and to 90 100 angle of rotation torque 11 Turn crankshaft and check clearance between piston pin boss and connecting rod 12 Measure distance between piston crown and crankcase mating surface when piston is positioned at TDC see chart Pistons and connecting rods Plain compression ring Oil scraper ring Bevelled compression ring with hose lined spring Piston Piston USA and low compression C
45. re in metric units provided no other unit of measure is used The indicated part numbers are serving exclusively for identification and better differentiation of individual versions When odering spare parts always use part numbers from the latest parts literature 00 005 1 Installation Survey Engines with CIS Continuous Injection System 6 Cylinder in line engine with dual two stage carbu retor Model Chassis ype Engine type Model Chassis type Engine type 280 E 123 033 110 984 QR T E ace ere ee Oe ere 280 CE 123 053 110 984 280 114 060 110 921 280 SE 116 024 110 985 280 C 114 073 110 921 280 S 116 020 110 922 Identification of Vehicle When ordering spare parts please quote chassis and engine numbers With your MERCEDES BENZ you receive two vehi cle data cards listing all major vehicle data Engine No stamped on left front of cylinder block arrow BP 1074 9957 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 OORUN o N 00 010 1 Engine Model Chassis Type Engine Type Year Operation Number of cylinders Arrangement of cylinders Bore stroke Total eff piston displacement Compression ratio Firing order Max engine rpm Engine output Max to
46. ression I PP ee gE re rere 110 921 110 922 110 923 110 924 110 931 110 932 Installed in engine 110 984 110 985 110 986 and 110 987 as standard equipment Not available as repair stages Use only together 110 984 110 985 110 991 110 992 110 993 Compression ratio 1 9 0 0 2 8 7 0 2 8 0 0 4 with piston of same piston code number 03 2 316 1 F3 Std 0 5 1 0 Std 0 5 1 0 Piston code number 37 40 50 60 64 69 80 83 86 89 38 41 51 67 70 84 90 39 42 52 68 71 85 91 28 54 72 75 29 55 73 76 30 56 74 77 Distance between piston crown and cylinder crankcase parting surface 2 85 990 86 002 86 019 86 028 86 490 86 502 86 519 86 528 86 990 86 002 87 019 87 028 Standback 0 20 to 0 70 Standback 1 0 to 1 50 0 25 standout up to 0 15 standback Standback 0 55 to 0 95 Test values Piston clearance Difference in weight of pistons in one engine Piston pin dia Piston pin clearance Piston ring gap Piston ring clearance Tightening torque Connecting rod nuts Special tools Piston ring pliers Piston ring compressor Note in conrod bushing in piston groove 1 groove 2 groove 3 groove 1 groove 2 groove 3 New Installation tolerance 0 016 to 0 040 4g 22 996 to 23 00 0 007 to 0 017 0 002 to 0 011 0 30 to 0 45 0 30 to 0 45 0 25 to 0 40 0 05 to 0 08 0 03
47. ront of cylinder head and pull out front wooden board toward exhaust side Lower cylinder head until it fits on the dowel sleeve 29 Lift rear of cylinder head slightly and pull out wooden board toward exhaust side Lower cylinder head until it fits over rear dowel sleeve Note If possible connect cylinder head with cam shaft housing to eyes for engine removal carefully lower with a crane and set down 01 2 415 9 F3 30 Lubricate threads and head surface of cylinder head bolts before installation Attention Since July of 1974 the clearance on the camshaft housing for the 22 mm dia washer of cylinder head bolt number 14 has been extended The former 20 mm dia washer must be installed on older camshaft hous ings arrow 31 Tighten cylinder head bolts in steps in sequence of tightening diagram beginning with screw 1 refer to job no 01 415 removal and installation of cylinder head Tighten screws M 8 to 25 Nm 2 5 kpm Attention After all bolts have been tightened it must be possible to turn both camshafts by hand 32 Install slide rail 2a For this purpose pull up timing chain while introducting slide rail with pliers and knocking in bearing bolts with impact puller Align slide rail laterally equalize 33 Pull up timing chain position guide wheel 4 with left hand and knock in lubricated bearing bolt by means of impact puller Screw in screw connection with sealing ring Chain drive 1 Ex
48. rotation torque 4 Measure conrod bearing basic bore If a basic bore exceeds the value of 51 62 mm or shows conicity hone bearing surface of bearing cap on a surface plate up to max 0 02 mm 03 2 313 2 F3 W3 FIFE 103 9232 5 Press in new conrad bushing that oil bores match DA AVIDI DA Installation pressure 2500 Nm 6 Mill or ream out conrod bushing 7 Hone side bearing surfaces of connecting rod on a surface plate 1034 7657 Squaring 8 Square connecting rod with a conrod tester 9 Align parallel of conrod bore to conrod bushing bore sq 103 11174 10 Correct stagger of conrod bore to conrod bushing bore 03 2 313 3 F3 03 316 Removal and installation of piston Association piston cylinder Group number Standard dimension Ist repair stage 0 5 2nd repair stage 1 0 Piston dia Cylinder dia Piston dia Cylinder dia Piston dia Cylinder dia 0 85 970 85 982 85 998 86 008 86 470 86 482 86 498 86 508 86 970 86 982 86 998 86 008 1 85 980 85 992 86 009 86 018 86 480 86 492 86 509 86 518 86 980 86 992 87 009 87 018 The smallest measured cylinder dia and the largest measured piston dia are decisive for association Piston code number and piston distance Engine Normal compression 110 921 110 922 110 923 110 924 110 981 110 982 110 983 110 984 110 985 110 986 110 987 Low comp
49. rque Crankshaft bearings Valve arrangement Camshaft arrangement Oil cooling Cooling Lubrication Oil filter Air filter mm ins cm cu ins SAE net bhp rpm Air filter with paper cartridge Technical data 00 280 280 C 280 S 114 060 114 073 116 020 E 110 921 922 1976 1975 1974 1973 Four stroke gasoline engine with carburetor 6 upright in line 86 78 3 39 3 10 2746 167 6 9 1 8 1 9 1 8 1 1 5 3 6 2 4 6500 160 5500 145 5500 160 5500 130 5000 SAE net ft Ib rpm 165 4000 154 4000 165 4000 150 3500 7 overhead DOHC None Water circulation pump thermostat with by pass line finned tube radiator fan with viscous coupling Forced oil circulation via gear type oil pump Full flow filter 00 015 1 Filling Capacities Model Chassis Type Engine Type Year Initial filling Oil and filter change Engine Oil pan up to max marking on oil dipstick Oil filter Cooling system with heater Water pump Brake system Autom Initial Trans filling mission fluid change Power steering Engine oil approx Itr US qt Engine oil approx Itr US qt Engine oil max Itr US gt Engine oll approx Itr US qt Coolant approx Itr US qt Brake fluid approx Itr US qt Autom transmission fluid ATF approx Itr US qt Autom transmission fluid ATF approx Itr US qt 110 922 280 S 11 Itr 11 6 qt 00 015
50. s with repair stages are available for camshaft with reground bearing journals 01 471 Exchange engines are in part supplied with camshaft bearing intermediate stages and repair stages 01 471 Also refer to 01 471 association camshaft housing and camshafts 01 2 470 2 F3 Removal 1 Remove pressure oil pump of models with level control and place to one side without disconnecting the lines This requires loosening only those bolts marked with an arrow 2 Remove compressor of models with an air condition er 3 Remove vacuum pump of models in USA version 4 Drain coolant from radiator and remove upper water hose from engine to radiator Remove cylinder head cover Radiator drain plug of type 123 5 Unscrew right cover arrow on front of camshaft housing 01 2 470 3 F3 6 Remove all spring clamps with a wrench socket 7 Remove all rocker arms with removal and installa tion tool 8 Counterhold only the right camshaft exhaust with the holding wrench and loosen the camshaft sprocket mounting expansion bolt 9 Position piston 1 at ignition TDC and both camshafts at marks This requires turning the crankshaft with the combination tool Attention Do not turn engine at the mounting bolts of the cam shaft sprockets Don t turn engine in reverse direction of rotation 01 2 470 4 F3 10 Remove chain tensioner and pressure spring 05 310 11 Remove sliding rail in camsh
51. shers not valid Mounting bolt not valid Ooo AUN oa 3 7 When 1st cylinder is at ignition TDC the adjust ment marks on both camshaft sprockets and camshaft housing must align 01 2 415 11 F3 Attention If the vibration damper of an engine has a 00 mark for BDC in addition to TDC the TDC mark is next to pin 2 in the vibration damper 1 TDC mark 38 Install sliding rail in camshaft housing so that the timing chain cannot jump 39 Install rigid chain tensioner and tighten by hand 40 Turn crankshaft with combination tool and ad just to ignition TDC Check adjustment marks fig of point 37 Check timing if cylinder head or camshaft housing surfaces have been faced 05 215 41 Tighten necked down screw for camshaft sprocket to 80 Nm 8 kpm while applying counterhold to camshaft by means of holding wrench 42 Install rocker arms and spring clamps 05 230 01 2 415 12 F3 A ay 43 Position chain tensioner for insallation and install ac 05 310 i ane saaaaane L 44 Adjust valve clearance 05 210 Further installation instructions in reverse sequence of removal 01 2 415 13 F3 01 416 Cylinder head measuring sensor box The measuring sensor box must be equipped to agree with the engine version Note screwed depth and use seals of sufficient thick ness 1054 7443 Measuring sensor box for carburator engine with air con ditioner 2 100 C
52. sion by means of an engine hoist in diagonal position If removal and installation is performed on a lifting platform the engine of model 126 can be placed on cross yoke center piece at the rear during installation Removal 1 On model 123 and 126 move engine hood into 90 position and let left hand locking lever arrow engage On other models remove engine hood 2 Disconnect battery cable 3 Drain coolant arrow 4 Disconnect and close lines for air oil cooler and transmission oil cooler on radiator and close so that no oil will run out 5 Remove radiator together with air oil cooler while suspending fan cover over fan 01 2 030 2 F3 6 Remove fan For this purpose loosen screw arrow on magnetic fan 7 On vehicles with air conditioning unscrew refri gerant compressor and put aside with lines connected When removing refrigerant compressor drain air condi tioning system 83 516 8 Disconnect lines at oil pressure pump Only loosen bolts arrows to detach oil pressure pump 9 Draw oil out of power steering pump tank 10 Disconnect hoses at power steering pump 01 2 030 3 F 3 11 Disconnect electric harness for starter motor and alternator 12 Disconnect all electric connections on engine 13 Remove longitudinal control shaft 14 Disconnect all coolant vacuum oi and electric lines leading to the engine 15 Pull off TDC transmitter wires at test socket This requires
53. st spark plug bore and couple to connecting hose of tester Crankshaft should not rotate 10 Read pressure loss on tester 11 Check by listening whether pressure escapes via intake pipe exhaust oil filler cap spark plug bore of adjacent cylinder or radiator cap 12 Check all cylinders in ignition sequence Note The respective pistons are in TDC position when the markings on vibration damper as shown in adjacent drawing are below TDC indicator TDC position of pistons TDC Piston 1 and 6 a Piston 3 and 4 b Piston 2 and 5 Note There is the possibility that the piston ring gaps of 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 2 015 2 F3 1033 7670 T Exhaust T Intake Conventional tool e g made by Karl Storz GmbH 7200 Tuttlingen Cylinder illuminating lamp Motoskop TW cold light with lens attach ment 210 mm long Note Visual inspections can be made with a cylinder illumi nating lamp on mounted cylinder head When illuminating because of oi consumption or blue smoke run engine warm shut off and illuminate cold or immediately following deceleration coasting 103 15713 When evaluating scored or streaky cylinder walls it is often no easy job for a workshop to decide whether the respective damage is bad enough to require removal of engine
54. tensioner holder Bearing pin impact extractor basic unit M 6 x 50 bolt for impact extractor M6 x 150 bolt for impact extractor M 10 x 100 bolt for impact extractor Camshaft wrench 17 mm valve adjusting wrench 27 mm socket to turn engine 1 2 square Socket 10 mm 1 2 square 140 mm long SHOE EE A 11004 7006 N 11004 7005 oo S i 1004 7003 Conventional tools Engine director size 1 9 Note 110 589 03 31 00 110 589 02 31 00 116 589 20 33 00 116 589 01 34 00 116 589 02 34 00 116 589 03 34 00 116 589 01 01 00 110 589 01 01 00 001 589 65 09 00 000 589 05 07 00 e g made by Backer D 5630 Remscheid Order No 3178 A cylinder head may only be removed after the engine is cold Removal is together with the camshaft housing exhaust manifold and intake manifold 01 2 415 2 F3 There is only one type of cylinder head as a replace ment part for carburetor and fuel injection engines If the cylinder head is used on a carburetor engine the fuel iniector bores must be plugged with 6 covers part number 000 443 01 80 OO Starting April 1978 exhaust valve seat rings 42 mm OD and valve guides 9 mm ID are installed in cylinder head Exception engines national version Cylinder heads for engines with air injection are attached to exhaust ducts by means of threaded bores for air injection The diameter of the combustion chamber frame on cylinder head gaskets
55. th a length of 150 mm Washers 5 mm thick part no 186 990 09 40 are fitted to make sure that the thread lugs in cylinder crankcase are not forced off 01 2 471 5 F3 01 472 Facing camshaft housing Data Total height of new camshaft housing 104 8 105 0 Min height after machining 104 0 Permissible deviation from parallel between upper and 0 1 lower parting surface in longitudinal direction Note The camshaft housing may only be faced if mechanical damage is visible on the mating surfaces A distorted camshaft housing will align with the cyl inder head when tightened Only 0 4 mm may be machined off of the camshaft housing mating surfaces to the cylinder head or cyl inder head cover The same amount of material must be removed from the bearing surfaces for the gaskets at the spark plugs 2 as was machined from the mating surface to the cylinder head cover 1 if the camshaft housing was faced the timing must be adjusted 05 215 01 2 472 1 F3 Cylinder head and camshaft housing illustrated table Q P wA gt d NAWNH OOMNODUOBAWN Filler plug 3 bolts M 8 x 55 3 sealsC 8x 13 Valve cover Capped nuts Cylinder head cover gasket 2 bolts M 8 x 135 Plain washers 38 x 15 3 threaded inserts M 8 x 16 5 cylinder head cover gaskets Vent valve Vent jet 12 studs M 8 x 18 9 bolts 9 washers 21 combination bolts M 8 x 40 2 suspension eyes rear Circlip 4 b
56. the bearing points 3 5 7 1 2 3 4 5 6 7 8 11 and 13 are without oil bore and their ID is 1 mm larger than the respective camshaft bearing journals This camshaft housing can be used to install all cam shafts with normal dimension 1053 8 9 10 11 12 13 14 15 This camshaft housing is attached together with cylinder head by means of 9 cylinder head bolts M 12 x 145 mm formerly M 12 x 150 mm since the bolt head contact surfaces in camshaft housing were countersunk by 5 mm Attention On exchange engines starting unit number 496 861 approx starting October 1977 these 9 cylinder head bolts are installed with a length of 150 mm Washers 5 mm thick part no 186 990 09 40 are fitted to make sure that the thread lugs in cylinder crankcase are not forced off 7013 5050 01 2 471 3 F3 Camshaft housing with 11 bearing points of which 1 bearing point without oil bore Bearing points 1 9 2 4 12 5 6 14 15 8 10 Benada 38 016 50 066 51 519 53 019 54 019 50 016 r i ERPE 38 000 50 050 51 500 53 000 54 000 50 000 Bearing points Jumade 23 993 49 950 51 440 52 940 53 940 49 950 23 980 49 934 51 421 52 921 53 921 49 934 Intermediate stage 0 1 mm exchange engines only Camshaft housing part no 110 010 20 36 Intake camshaft part no 110 051 77 01 Exhaust camshaft part no 110 051 98 01 49 966 51 419 52 919 53 919
57. unscrewing test socket at holder 16 Detach exhaust pipes at exhaust manifold and exhaust strut at transmission 01 2 030 4 F3 17 Unscrew engine shock absorbers left and right 00 240 Model 123 18 Remove engine mounting bolts from engine mount Model 114 from above Models 107 116 123 and 126 from bottom of vehicle arrow 1000 11491 19 Remove rear engine carrier with engine mount 20 Disconnect tachometer shaft on transmission Models with inductance transmitter arrow Disconnect inductance transmitter for tachometer For this purpose unscrew screw M 6 and pull out inductance transmitter 01 2 030 5 F3 21 Disconnect propeller shaft on transmission and slide back Support propeller shaft so that shaft will not abut against transmission flange when installing engine 22 Loosen all connections and shift rods on trans mission 23 Attach engine at rear and front to suspension eyes 24 Lift engine with transmission by means of engine hoist in an approx 459 diagonal position Make sure that the partition for unit compartment model 126 is not damaged since its damping effects will be lost by absorbed splash water Attention On vehicles with air conditioning cover condenser with a hard fiber board arrow Installation Attention When installing an engine because of previous bearing damage flush out the oil cooler and oil hoses Clean oil filter housing 25 Check
58. with an internal tester at measuring points 1 2 and 3 in longitudinal direction A piston pin axis and in cross direction B When the pistons are installed measuring point 3 will be just barely above the piston which must be at BDC a top reversing point of first piston ring b BDC of piston c bottom reversing point of oil scraper ring The group number punched into crankcase arrow matches the group number of the pistons installed as standard equipment On used engines the original cylinder dia shows up after thorough cleaning of top land zone The difference in diameter of dimension shown on top land zone and the dimension at measuring point 1 generally indicates the respective max wear In the event of repairs hone cylinder bores according to dimensions of available pistons plus piston clearance The processing machines used for boring pre honing finish honing and polishing should be set in accordance with respective operating instructions Upon boring the cylinder bores should be chamfered at upper cylinder end according to drawing The lower cylinder end should remain sharp edged without burr 01 2 110 2 F3 NJ i032 ESBL longitudinal direction cross direction measuring point 01 120 Grinding crankcase mating surface Data Height of new crankcase 213 1 213 2 Min height after removal of necessary material 212 8 Permissible deviation from parallel of upper parting surf
59. ystem with heater Water pump Brake system Autom Initial Trans filling fluid change mission Power steering Engine oll approx Itr US qt Engine oil approx Itr US qt Engine oil max Itr US qt Engine oil approx Itr US qt Coolant approx Itr US qt Brake fluid approx Itr US qt Autom transmission fluid ATF approx Itr US qt Autom transmission fluid ATF approx Itr US qt 110 985 280 SE 11 Itr 11 6 qt 280 E 280 CE 280 SE 123 033 123 053 116 024 110 984 985 6 5 6 9 7 7 4 6 6 3 6 5 6 9 5 4 5 7 6 6 3 0 6 0 62 10 10 6 maintenance free 0 5 0 53 6 6 5 3 7 0 5 6 1 4 1 5 00 015 4 01 001 Engine and model survey Engine Model Sales designation kW at 1 min 110 921 114 060 280 118 5500 110 921 114 073 280 C 118 5500 110 922 116 020 280 S 118 5500 110 923 123 030 280 115 5500 110 923 NV 123 030 280 105 5500 110 923 123 050 280 C 115 5500 110 923 NV 123 050 280 C 105 5500 110 924 126 021 280 S 115 5500 110 924 NV 126 021 280 S 115 5500 110 931 NV 114 060 280 107 5500 110 931 NV 114 073 280 C 107 5500 110 932 NV 116 020 280 S 107 5500 110 981 114 062 280 E 136 6000 110 981 114 072 280 CE 136 6000 110 982 107 022 280 SLC 136 6000 110 982 107 042 280 SL 136 6000 110 983 116 024 280 SE 136 6000 110 983 116 025 280 SEL 136 6000 110 984 123 0077 280 E Special body long 130 6000 110 984 123 033 2

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