Page 1 EXIT Mercedes-Benz Mercedes-Benz of North America, Inc. Montvale, NJ 07645...
Page 2 Published by Mercedes-Benz of North America, Inc. Printed in U.S.A. Part number LZ S-2517-091...
Page 3 However, it is a general assumption that the reader is familiar with basic automotive repair procedures and Mercedes-Benz vehicles. You should not attempt to use this manual if this is not the case. 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.
Page 4 EXIT G r o u p General, Technical Data Crankcase and Cylinder head Crankshaft Assembly ngine Timing, Valvetrain System 07.1 Air Intake System Air Filter, Turbocharger elt Drive Intake and Exhaust Manifolds, mission Control System Electrical System, Preglow ngine Lubrication System ngine Cooling System Engine Suspension Accelerator Control...
Page 5: General, Technical Data
EXIT General, technical data 00...
Page 6 EXIT Job No........00 - 005 Instructions for use of service manual Engine and vehicle identification .
Page 7 Instructions for use of servic Location of specific repair instructions Complete Service Manual coverage for late model year Mercedes-Benz vehicles requires four individual manuals: First locate the Group No. in the Group Index. Individual groups are separated by an easily...
Page 8 EXIT Model 201.126 190 D 602.911 126.125 300 SDL Turbo (Federal) 603.961 126.125 300 SDL Turbo (California) 603.961 201.126 190 D 602.911 201.128 190 D 2.5 Turbo (Federal) 602.961 124.133 300 D Turbo 603.960 124.193 300TD Turbo 603.960 126.125 300 SDL Turbo 603.961...
Page 9 EXIT When ordering spare parts, please specify chassrs and engine numbers. 1 Certrfication Tag (left door pillar) 2 Identification Tag (left windshield post) 3 Vehicle Identificatron No. 4 Engine No. 5 Body No. and Paintwork No. 6 InformatIon Tag California version Vacuum line routing for emission control system 7 Emrsslon Control Tag...
Page 10 EXIT Vehicle identification number locations Model When ordering spare parts, please 1 Certrfication Tag (left door prllar) 2 ldentrftcatron Tag (left wrndshreld post) 3 Vehicle ldentifrcatron No. 5 Body No. and Paintwork No. 6 lnformatron Tag Vacuum line routing for emrssron control system 7 Emrssron Control Tag Model...
Page 11 EXIT Technical Diesel engines 4600 t 50 6 (multi-component, pump, thermosta pump, thermosta pump, thermosta pump, thermosta with bypass line, fan with bypass line, fan with bypass line, fan with bypass line, fan with visco fan clutch, with visco fan clutch, with visco fan clutch, 00 - 020/l...
Page 12 EXIT Technical Gasoline engines 126.125 1126.125 126.134 I.135 Model 4-cycle diesel, MB 4-cycle diesel, MB 4-cycle diesel, MB arranqemen Bore/stroke mm I 89.0192.4 Total effective piston displacement cc Compression ratio Engine output 11 O/4600 1071’ 4600 (SAE)kW/rpm 14814600 net bhp/rpm Maximum torque 27312400 3 1 o/2000...
Page 13: D Turbo
300 D 2.5 300 D Turbo 300 SDL Turbo Turbo Turbo 300 TD Turbo 602.962 Engine 602.911 602.961 603.961 Fuel tank/reserve aoorox. Engine oil initial filling approx. I During oil and filter change approx. I Marks on dipstick Oil-to-air cooler with 0.65...
Page 14: Sdl Turbo
124.193 (Federal) Sales designation 190 0 2.5 300 D 2.5 300 0 Turbo 300 SDL Turbo Turbo Turbo 300 TD Turbo 602.962 603.960 Engine 602.911 602.961 603.961 Battery Voltage 1 2 v 12 v 1 2 v 1 2 v...
Page 15: Crankcase And Cylinder Head
EXIT Crankcase and Cylinder Head 01...
Page 16 EXIT Crankcase and cylinder head Job No. Engine and model survey ..........01 - 001 Removal and installation of noise capsule at bottom of engine compartment .
Page 17 201.128 (12314600) (16812400) Federal 84.0 187.0 90 14600 2400 124.128 602.962 (164 2400) Federal 84.0 187.0 265 12400 124.133 603.960 (14314600) (195 2400) 124.193 300 TD Turbo 87.0 84.0 273 /2400 126.125 603.961 (148 /4600) (201 2400) Federal 87.0 184.0...
Page 18 EXIT Model Noise capsule, front and rear (1, 2) Remove sheet metal screws (arrows), reinstall and remove capsule, install. Note Install engine compartment capsule so that edges of side part of capsule engage in bottom part of capsule. 01.10...
Page 19 EXIT Opening setting vertical, warnings hood, There is risk of injury whenever the engine is running and the hood is open. Opening hood To unlock the hood, pull the lever (533) on the left below the instrument panel in the direction of the arrow.
Page 20 EXIT Close hood by pushing down forcibly. Model201 Model 124, 126, 201 Pull the handle (535) extending from the grille as far as the stop and open hood (it may be necessary to lift the hood slightly to release the handle). Note not attempt to lift the hood with handle (535).
Page 21 EXIT Model 126 Push hood down slightly. Push lock lever (538) on the left hood support (539) down in the direction of the arrow. Push hood up slightly to keep the lock lever (538) from reengaging. Repeat the preceding at the right hood support and set the hood in a vertical position.
Page 22 EXIT...
Page 23 EXIT 01-010 Testing compression pressure warm up to operating temperature Engine ,......(approx. 80 (item Note Check compression only with engine at operating temperature. remove, install (07-230). Nozzle holder (1) ..... . . for starter harness, disconnect, reconnect Plug connector (X27) (items 3 - 4).
Page 24 EXIT Contact handle for compression pressure recorder 001 589 78 21 00, connect, adapter line 124 589 36 63 00 (items 3 - 5). Engine ....... turn over a number of times to clean out;...
Page 25 EXIT Special tools 602 589 00 6300 Testing Warm engine up to operating temperature (approx. 80 “C). Note Check compression only with engine at operating temperature. Remove all nozzle holders (07-230). Models 124 and 126 Connect contact handle for compression pressure recorder 001 589 78 21 00;...
Page 26 EXIT Model 201 Connect contact handle of compression 78 21 00; pressure recorder 001 589 disconnect plug connector (X27) on left side of firewall and connect connection line (04) of contact handle to plug (Kl50) with adapter line 124 589 36 63 00. Connect second connection line from contact handle to positive pole (K130) on battery (arrow).
Page 27 EXIT Bolt compression pressure recorder into pre- chamber of cylinder to be tested with appropriate adapter (03) and flexible connector (02). Note On engines with angular injection use adapter 602 589 00 63 00. Crank engine at least 8 revolutions to test compression.
Page 28 EXIT Checking cylinders for leaks PO1 4224-57 warm up to operating temperature Engine ....... (approx.
Page 29 EXIT Engine ....... move piston of cylinder to be checked to TDC, ignition stroke, connect and calibrate cylinder leakage tester (items 7 - 9).
Page 30 EXIT Testing Warm engine up to operating temperature (approx. 80 “ C). Remove all nozzle holders (07-230). Open cap on coolant expansion tank only at coolant temperatures below 90 “ C. Remove cap on coolant expansion tank. Check coolant level in coolant expansion tank and add, if necessary.
Page 31 EXIT 10 Fill cylinder with compressed air and read off any pressure loss on tester. 11 If pressure is lost, determine cause; check by listening whether pressure is exhausted through cylinder head gasket, intake manifold, exhaust, oil filler cap or prechambers of adjacent cylinder(s) and check for formation of air bubbles in coolant in coolant expansion tank.
Page 32 EXIT 12 Perform test on other cylinders in engine ignition sequence. 13 Assemble in opposite order. 01.10 - 01515...
Page 33 EXIT...
Page 34 EXIT bores valuating cylinder removed Prechambers in cylinder to be tested, move to bottom dead Piston center. illuminate cylinder with illumination unit and Cylinder check visually for damage; for this purpose insert the probe (01) of the illumination unit through the precombustion chamber bore into the cylinder.
Page 35 EXIT Cylinder illumination unit Karl Storz Gmbt-i, e. g. D-7200 Tuttlingen Motoskop TW (cold light) with lens probes (570 103 26 CW mm) and 103 26 CT (210 mm) 01.10 - 020/2...
Page 36: Exhaust System
EXIT 01-030 Preliminary operations: removed (01-006). Exhaust system removed (49-l 00). disconnect positive and negative terminals, Battery (120) reconnect (items 1 - 4). Naturally aspirated engines: remove, attach (item 5). Air intake hose (5) remove together with filter cartridge, attach Air cleaner cover (4) (item 5.1).
Page 37 (items 10 - 11). Note On vehicles with viscodrive fan clutch Use screwdriver socket 103 589 01 09 99, torque wrench 001 589 72 21 00 and holding tool 603 589 00 40 00. Air conditioner: Poly-V-belts (13) remove, install (13-342).
Page 38 EXIT Vehicles with level control and/or ASD: (11) ... Oil pump (1) or tandem pump unbolt oil lines and hoses between engine and chassis, reinstall (item 23). Turbo-engines or naturally aspirated engines with exhaust gas recirculation: unbolt oil lines between cooler and engine, reinstall (item 24).
Page 39 EXIT Model 201 (up to 03185): Engine shock absorber remove, install, 10 Nm (item 27). Model 126: Engine shock absorbers (24), left and right ..remove, install, 10 Nm (item 28). Manual transmissions: Shift linkage (20) unhook, hook in (item 29).
Page 40 EXIT Following installation: Engine check engine oil, add, if required or fill engine with new oil. Cooling system fill up and perform pressure test (20-017), pressure tester 124 589 15 21 00. Engine ......start and check engine oil and cooling system for leakage.
Page 41 Hex. nuts, engine shock absorber Hex. head bolts, engine shock absorber mount Hex. nuts, drive shaft on transmission flange Hex. nuts, drive shaft on transmission flange, engine 603.96 Hex. head bolts, drive shaft intermediate bearing Clamping nut, drive shaft intermediate bearing 30 - 40 Hex.
Page 42: Models 124 And
EXIT Commercially available tools 7 mm socket on flexible shaft for hose e. g. Hazet, clamps with worm drive D-5630 Remscheid Order no. 426-7 Engine hoist no. 3188 Backer, (self-braking) D-5630 Remscheid, Self-made tools Guard plate for air conditioner condenser Dimensions: approx.
Page 43 EXIT Naturally aspirated engines: Remove air intake hose (arrow). 5.1 Open retaining clips on air cleaner cover and remove cleaner cover and filter cartridge. Turbo-engines: Remove intake hose to exhaust gas turbocharger. On vehicles with automatic transmission plug oil cooler lines with clamps 000 589 40 37 00 (arrow).
Page 44 10 Remove fan with viscodrive fan clutch; hold V-belt pulley with counterholder (01) 603 589 00 40 00 and remove Allen bolt with socket (03) 103 589 01 09 00 and torque wrench (02) 001 589 72 21 00. Remove fan.
Page 45 EXIT Models 124 and 201: Unhook engine control; press out guide (240) (208) piece on control lever and remove (230). control cable Model 126: Unhook engine control linkage; unhook connecting rod (arrow) on control shaft. Installation note Adjust control cable (30-300). 16 Disconnect all electrical lines between engine and chassis;...
Page 46 EXIT alternator. Completely remove engine wiring harness, for this purpose disconnect all clips and cable connectors. 21 Evacuate oil from supply reservoir for power steering pump or tandem pump using hand pump 112 589 00 72 00. 22 Unscrew oil lines for power steering on power steering pump (arrows) or on tandem Installation note Tightening torque 30 Nm.
Page 47 EXIT Turbo-engines or naturally aspirated engines with exhaust gas recirculation: 24 Unbolt oil lines and hoses (arrows) for air oil cooler in left wheelhouse between radiator and engine. Turbo-engines with automatic transmission and trailer hitch in combination with air conditioning: 25 Unbolt oil lines and hoses (arrows) for transmission air oil cooler in right wheelhouse between radiator and engine.
Page 48 EXIT Model 126: 28 Unbolt engine shock absorbers (24) on left and right; for this purpose unscrew hex. nut (50) and press shock absorber upward out of mount on frame cross member (49). Installation note Tightening torque 10 Nm. Vehicles with manual transmission: 29 Unhook shift linkage (21) on transmission.
Page 49 EXIT Vehicles with automatic transmission: Unhook shift linkage on transmission and disconnect connector for starter lockout, back-up light switch (S1611). 30.1 Disconnect connector for kickdown solenoid valve on right side of transmission. 31 Unbolt speedometer shaft or speedometer inductive sensor (arrow) and remove the two bottom hex.
Page 50 Installation note Replace self-locking hex. nuts. Tightening torque Engine 602, 603.91 40 Nm Engine 603.96 60 Nm. 36 Loosen hex. head bolts (494) on drive shaft intermediate flange.
Page 51 EXIT Caution! Attach guard plate on unit compartment firewall. 39 Fasten engine hoist cables to front and rear suspension eyes on engine. Align engine hoist so that engine is positioned horizontally. Suspension eye, front fear 01.10 - 030/17...
Page 52 EXIT Remove hex. head nuts (47) on mount for rear engine support. Remove hex. head bolts (48) and remove engine support with mount. Installation note Tightening torque Hex. nuts 70 Nm Hex. head bolts 45 Nm. Check adjustment bolt on rubber mounts, tightening torque 30 Nm.
Page 53 EXIT 42 Lift engine with transmission at angle out of engine compartment, continuously correct angle with engine hoist, maximum angle approx. 45” . When lifting engine pay attention to rear suspension eye on engine and engine oil filter. 43 Install in opposite order. After installation: Check engine oil, add, if required or refill engine oil and fill up cooling system.
Page 54 EXIT Crankcase ventilation - Function 01-040 A. Standard version Crankcase ventilation, naturally aspirated engine, standard version Engine 602 Return pipe Blow-by gasses Fresh am The crankcase ventilation on standard version naturally aspirated engines is a closed, maintenance-free system. 01.10 - 04011...
Page 55 The oil deposited in the oil separator runs back to the cylinder head through the return pipe (127). Crankcase ventilation, standard version turbo-engines Engines 602.96, 603.96, 603.97 To arr cleaner housmg Blow-by gasses Fresh air 0 1 . 1 0 - 04012...
Page 56 EXIT The crankcase ventilation for the standard version turbo-engines corresponds to that of the naturally aspirated engine. l-lowever on the turbo-engines, after removal of the engine oil, the blow-by gasses flow from the cylinder head cover to the intake hose. Naturally aspirated and turbo-engines with exhaust gas recirculation Crankcase ventilation on engines with exhaust gas recirculation Engine 602.91...
Page 57 EXIT Crankcase ventilation on engines with exhaust gas recirculation Engines 602.96, 603.96( 97 126 011 separator To air cleaner housmg Blow-by gasses Fresh am The crankcase ventilation on naturally aspirated engines with exhaust gas recirculation differs from that of the standard version by addition of a built-in pressure control valve (141).
Page 58 EXIT Pressure control valve Engines 602.91, 603.91 141a Diaphragm Oil separator Spring Holder Return pipe Pressure control valve Vent hole The pressure control valve is designed as a diaphragm-type valve and built into the oil separator in the cylinder head cover.
Page 59 EXIT 140b 140a Pressure control valve, engines 602.96, 603.96 Cylinder head cover Intermediate section Oil separator 141a Pressure control valve Return pipe Spring Angle fitting Vent hole Turbo-engines with exhaust gas recirculation are also equipped with a pressure control valve (141 a).
Page 60 EXIT 01-110 Measuring, boring and honing cylinder bores Preliminary operations: (03-316). Pistons removed Measuring ngines with and without cylinder sleeves Cylinder bores clean thoroughly. Cylinder bore Measure cylinder bore diameter with internal measuring instrument at 3 measuring points (c, d, e) in longitudinal direction (A) and transverse direction (B).
Page 61 EXIT Observe group ident. letters A, X or E3 stamped on the crankcase or piston crown. On used engines the difference between the diameter measured at point (c) and the original diameter is equal to the wear (max. permissible wear 0.2 mm).
Page 62 Measuring range “ a” (upper reversal point of 1st piston ring) in longitudinal 0.2 mm and/or transverse direction Standard and repair stage diameter “D” for cyl nder bores 603.970 602, 603 Cylinder dia. D in mm Version Cylinder dia. D in mm 1 - 4, 5, 6 87.000 - 87.006...
Page 63 Introduction of engines without cylinder sleeves Note Beginning in 1987 the cylinder sleeves were eliminated partially on engines 602/603 . The following tables show exactly when and on which model or engine the new version was introduced. Engine 603.970 was introduced into production without cylinder sleeves.
Page 64: Items
(see table) with internal measuring instrument (items 2 and 3). Note If the permissible values are exceeded, replace block. Cylinder sleeves press in and maintain pressure for approx. 7 seconds to seat sleeve, punch 603 589 00 15 00 (item 4). 01.10...
Page 65 “ D” and hone, Cylinder bores see Note in (01-l 10). Observe group code letters (A, X, B) (items 5 - 9). Diameter “D” for cylinder sleeves 602, 603 Cylinder dia. D in mm 87.000 - 87.006 Standard 1) over 87.006 - 87.012...
Page 66 EXIT Special tool 603 589 00 15 00 Commercially available tool e.g. Internal measuring instrument for 50 - 100 mm dia., D-5000 Koln with 0.01 mm increments and measuring point Sunnen Grm -2125 pressure relief Replacement Press out cylinder sleeves.
Page 67 EXIT Boring and honing Mill or grind off projecting collar on sleeve. Remove as little material as possible from the block parting surface. Guide milling cutter or grinding wheel carefully over cylinder bores. Bore out cylinder sleeves in two steps. Leave at least 0.03 mm additional material in the bores for honing.
Page 68 EXIT Planing crankcase parting surface Parting surface (1) plane according to operating instructions for planing tool used. Note Observe specified dimensions and machining data! Cylinder bores After reassembly check engine timing (05-215). 01.10 - 120/l...
Page 69 EXIT Data Height of block in new state from center of main 234.97 - 235.03 bearing bore Minimum height after required material removal from center 234.60 of main bearing bore in longitudial direction 0.06 Permissible unevenness of parting surface in transverse direction 0.06 Permissible roughness of upper parting surface 0.006 - 0.016...
Page 70 EXIT 01-130 Removal and installation of steel balls in main oil duct Coolant pump removed with housing (20-230). Flywheel removed (03-410). Steel ball, front, 17 mm dia. (10) Steel ball, rear, 15 mm dia. (9) knock out, insert. Steel balls Punch 601 589 08 15 00 (items 1 - 6).
Page 71 Plug M 18 x (front) 000 908 018 002 Plug M 16 x 1.5 (rear) 000 906 016 002 Gasket A 18 007 603 018 103 Sealant for replacement of rear steel ball Loctite 241 002 989 94 Special tool Knocking out Knock out both steel balls from rear toward front with suitable steel rod.
Page 72 EXIT Position steel balls on hole and drive in to specified stop on punch. After reassembling engine, warm up engine and check for leakage in area of steel balls. Note If one of the steel balls does not seal sufficiently after inserting or if leakage is present following leakage test, replace steel ball with plug.
Page 73 EXIT Preliminary operations: Coolant drained (20-010). Attachment parts In area of freeze plug removed. Freeze plug, right, 34 mm dia. (8b) Freeze plug, left, 34 mm dia. (8) (11) Freeze plug, rear, 34 mm dia. Freeze plug, front, 17 mm dia. (8a) remove, knock in.
Page 74 . Note The number of freeze plugs differs on the individual engine models. The figure shows engine model 603 as an example. Sealant 002 989 94 71 Loctite 241 Special tools...
Page 75 EXIT Carefully knock in freeze plug at one side until it rotates around its own longitudinal axis and can be gripped with a pair of pliers. Pull out freeze plug. Clean sealing surface; surface must be free of grease. Installation Coat sealing surface with sealant 002 989 94 71.
Page 76 EXIT 01-210 Removal and installation of thina cover Radiator removed (20-420). Magnetic or vlscodnve fan clutch removed (20-335, 20-312). Crankshaft pulley and hub removed (03-341). Poly-V-belt tensioning device removed Piston vacuum pump removed (43-618). Power steenng pump or tandem pump removed (46-710). (15-510).
Page 77 EXIT for fuel filter, remove, reinstall, 25 Nm Front hex. head bolt (116) (item 2). for oil dipstick tube, remove, reinstall, 25 Nm Holder (62) (item 3). Hex. head bolts (417) on mount (416) for alternator, remove, reinstall and remove mount, install, 45 or 25 Nm (item 4).
Page 78 EXIT Engine ....... lower back on engine mounts with engine hoist (item 14).
Page 79 EXIT Tightening torques Allen bolts, mount, engine stop, front Adjustment screw, engine stop, front Allen bolt, engine mount, front Allen bolt, engine mount, front, model 126 Hex. head bolts, cylinder head cover Cylinder head bolts in timing chain case Hex. head bolts, mount, alternator Hex.
Page 80 EXIT Commercially available tools e.g. Connection 314” square ratchet Hazet, D-5630 Remscheid square head Order no. 1058 R. 1 e.g. Backer, Engine hoist no. 3188 D-5630 Remscheid, (self-braking) _ -.____ mm socket on flexible shaft for hose e.g. Hazet, clamps with worm drive D-5630 Remscheid Order no.
Page 81 EXIT (116) Remove hex. head bolts at front of fuel filter. Unbolt holder (62) for oil dipstick tube, 25 Nm. Remove hex. head bolts (arrows) on mount for alternator and remove mount. Installation note Tightening torques 45 Nm Mounting bolts for mount Mounting bolt on timing 25 Nm.
Page 82 EXIT Model 201 (up to 03185): Remove Allen bolts (arrows) on mount for engine stop at front and remove mount. Installation note Tightening torque 25 Nm. Check engine stop with adjustment gauge 201 589 04 23 00 and adjust (22-220). Tightening torque for adjustment bolt 130 Nm.
Page 83 EXIT Attach engine hoist cable to front suspension eye (arrow). 10 Remove Allen bolts for front engine mount from frame cross member from bottom. Installation note Tightening torque Model 124 and 201 40 Nm Model 126 70 Nm Allen bolt, engine mount, left Allen bolt, engine mount, right 01.10 - 21018...
Page 84 EXIT 12 Hoist engine with engine hoist until hex. head bolts in oil pan are accessible in area of timing case cover. 13 Remove hex. head bolts in oil pan in area of timing case cover and loosen remaining bolts. Installation note Tightening torque M6 10 Nm,...
Page 85 EXIT 17 Remove all remaining hex. head bolts (arrows) in timing case cover and remove timing case cover. Caution! When removing timing case cover be careful of cylinder head gasket and oil pan gasket. Avoid damaging. Replace damaged gaskets. Installation note Clean gasket residues off of parting surface on timing case cover.
Page 86 EXIT Removal and installation of end cover (03-410). Flywheel removed Hex. head bolts (55) in oil pan, remove, reinstall, 25 Nm (item 1). Hex. head bolts (21) reinstall, 10 Nm (item 2). Note Coat threads of hex. head bolts with sealant 002 989 20 10.
Page 87 EXIT press out together with crankshaft radial cover (20) seal (22), press in, installation sleeve 601 589 03 43 00 (item 3). Note Avoid damaging oil pan gasket. Note Clean gasket residues off of parting surface on end cover and coat parting surface of cap with sealant 002 989 00 20 10.
Page 88 EXIT Removal, installation Remove the two hex. head bolts (55) in the oil pan. Installation note Tightening torque 25 Nm. Remove hex. head bolts (21) in end cover Installation note Coat threads on hex. head bolts with sealant 002 989 00 20 10. Tightening torque 10 Nm.
Page 89 EXIT...
Page 90 EXIT 01-310 Removal and installation of oil pan A. Model 124, 126 and 201 Preliminary operations: Bottom section of engine compartment noise capsule removed (01-006). Model 124 and 201: Torsion bar on front axle removed Models 124, 201 ,126 and 201 .128: Steer.
Page 91: Remove, Install, 25 Nm (Item
EXIT Model 201 (up to 03185): remove, install, 25 Nm (item 3). Mount, engine stop (6) . . Note Check engine stop, adjust, 130 Nm (22-220), adjustment gauge 201 589 04 23 00. Model 201 (up to 03185): Engine shock absorber remove, install, 10 Nm (item 4).
Page 92 EXIT remove from crankcase together with oil pan Oil pan (45) , ......gasket (45a), install (item 14). Note Remove oil pan toward front of vehicle while turning crankshaft slightly if required.
Page 93: Model 201 (Up To
EXIT Special tools 001 589 72 21 00 201 589 04 23 00 001 589 67 21 00 Commercially available tool 3188 e.g. Backer Engine hoist no. D-5630 Remscheid (self-braking) Removal, installation Disconnect negative cable from battery. 2 Drain engine oil. Installation note Tightening torque for oil drain plug M 12x1.5x13...
Page 94 EXIT Model 201 (up to 03185): Remove engine shock absorber, left; remove hex. head bolts (arrow) on mount and re- move engine shock absorber from frame cross member. Installation note Tightening torque 10 Nm. Model 126: Remove engine shock absorbers (24), left and right;...
Page 95 EXIT Disconnect plug from oil level sensor (arrow). Vehicles with automatic transmission: Clamp oil lines between transmission and oil cooler or transmission air/oil cooler, clamp 000 589 40 37 00, screw oil lines off of oil pan and radiator. Installation note Check transmission oil level, add if required.
Page 96 EXIT 10 Attach engine hoist cable to front suspension eye on engine (arrow). 11 Remove Allen bolts for front engine mount from frame cross member from below. Installation note Tightening torque Model 124 and 201 40 Nm Model 126 70 Nm. Allen bolt, engine mount, left Allen bolt, engine mount, right 12 Lift engine at front with engine hoist as far as...
Page 97 EXIT (19) Remove hex. head bolts of oil pan (45). Installation note Observe different lengths of hex. head bolts. M6 10 Nm, Tightening torque M 8 25 Nm. 14 Remove oil pan (45) from crankcase toge- ther with oil pan gasket (45a); remove oil pan toward front of vehicle, turn crankshaft slightly if required.
Page 98 Differentiation of cylinder heads for naturally aspirated and turbo-engines The cylinder heads for turbo-engines 602.96, 603.96 and 603.97 are reinforced at the water jacket due to the higher combustion pressures. On turbo-engines the diameter (d) of the pre- combustion chamber bore is 15 mm, on naturally aspirated engines 14 mm.
Page 99 EXIT The cylinder head gasket for the turbo-engines has stainless steel inserts around the combus- tion chambers (arrow). The combustion chamber inserts on the standard gaskets installed on naturally aspirated engines consist of normal sheet steel. Only the cylinder head gaskets with stainless steel inserts are available as replacement parts for both the naturally aspirated and turbo- engines.
Page 100 EXIT Modifications in area of timing chain case For production reasons the height of the bridge in the cylinder head in the area of the timing chain case was increased to 32 mm (previously mm). This modification made it necessary to change the dimensions of the two cylinder head bolts (arrow).
Page 101 EXIT Cylinder head gasket for improved sealing The cylinder head gasket has been equipped with circumferential silicone sealing strips (arrow) on both sides and a Viton sealing ring at the oil return passage at the rear right to better prevent water and oil leakage.
Page 102 EXIT Cylinder head gasket, engines 602, 603 (except for engine 603.970) The combustion chamber insert (dotted line) has been modified at the 1st cylinder on the cylinder block side. not avadable not avadable 01 10 - 40015...
Page 103 EXIT Cylinder head gasket, engine 603.970 Combustion chamber insert modified. Silicone sealing strip position changed on both sides. A. 1st version (Gotze) B. 2nd version not available Improvement to passage supports in water jacket The passage supports in the cylinder head water jacket were improved on the turbo-engines.
Page 104 Engine previous cast no. new cast no. 602 016 03 01 602 016 07 01 602 Turbo 602 016 06 01 602 016 08 01 603 Turbo 603 016 15 01 603 016 not avadable not avadable...
Page 105 EXIT Combustion chamber recess The size of the combustion chamber recess (d) was increased to reduce the thermal load in the cylinder head. Production breakpoint: 06/88 Model Engine Engine end no. Vehicle ident. end no. manual automatic transmission transmission 126.1 1603.970 If rom start of production 201.126...
Page 106 EXIT efinishing precharnber sealing surface 01410 Preliminary operations: l-4 17). Nozzle holder removed (0 Prechamber removed (01-417). plug or seal off toward combustion chamber Prechamber mounting bores (item 2). Countersinking tool bolt into precombustion chamber mounting bore 601 589006600(01,02,03) ....to be refinished down to stop (items 3 - 4).
Page 107 EXIT Prechamber sealing surface refinish, use countersinking tool 601 589 00 66 00 with tap wrench, turn clockwise approx. 5 revolutions while exerting slight pressure (item 6). Caution! Do not lift countersinking tool while refinishing. Interval “ X” measure again (item 7). Note The difference between the 1st and 2nd measurements corresponds to the material...
Page 108 EXIT Special tool 601 589 00 66 00 Refinishing Note Refinish prechamber sealing surface when damaged or leaking. The first refinishing operation on the prechamber sealing surface can be performed with the cylinder head removed or installed. If the sealing surfaces have already been refinished once before, this can be recognized by the markings (punch marks) in the area of the prechamber mounting bores or on...
Page 109 EXIT Cylinder head removed: When the cylinder head is removed the scope of work for refinishing is the same except for items 5 and 7. Instead of items 5 and 7 measure the projection dimension (c). Cylinder head installed: Plug or seal off prechamber mounting bores toward combustion chamber (e.g.
Page 110 EXIT Attach tap wrench to countersinking tool 601 589 00 66 00 and turn countersinking tool clockwise approx. 5 rotations while exerting light pressure. Caution! Do not lift countersinking tool while refinishing. Measure dimension “ X” again. The diffe- rence between the first and second measure- ments corresponds to the material removed.
Page 111 EXIT Remove rag from precombustion chamber bore and turn over engine with starter to throw out any chips which may have got into the combustion chamber. 10 Insert proper spacer ring. 11 Mark cylinder head with punch mark above each prechamber seat refinished (arrows). 12 Install in reverse order.
Page 112 EXIT 01415 Camshaft removed (05220). (01-417). Nozzle holders removed Radiator removed (20-420). Poly-V-belt tensioning device removed (13-345). Remove cylinder head only after engine has cooled off. Battery (120) disconnect negative cable, if not already disconnected (item 1). Naturally aspirated engines: (11) Air intake hose and air...
Page 113 EXIT Holder (62) for oil dipstick tube, remove, reinstall (items 6, 34). Engines with exhaust gas recirculation: Pipe between exhaust gas recirculation valve (13) and intake manifold or charging air manifold, remove, install (item 7). Exhaust gas recirculation valve (13) .
Page 114 EXIT Slide rail bolts (221, 222) on cylinder head, knock out, knock in, impact puller 116 589 20 33 00, threaded rod 116 589 02 34 00 and threaded insert 123 589 00 34 00 (items 14, 30). Note When installing coat collar on slide rail bolts with sealant.
Page 115 EXIT (17, 18, 19) ... . . Cylinder head bolts unbolt in opposite order of torquing diagram, check length of cylinder head bolts and replace if necessary. Bolt on according to torquing diagram, socket 601 589 00 10 00 (items 17, 20, 23 - 28).
Page 116 EXIT Cylinder head bolt dimensions and maximum permissible lengths (L) New state Max. permissible length (L) in mm M 10x80 M 10x102 1056 M 10x115 01.10 - 41%...
Page 117 EXIT Special tools 116589203300 116589023400 001 589 72 21 00 Commercially available tool 7 mm hex. socket on flexible shaft for hose e.g. Hazet, clamps with worm drive D-5630 Remscheid Order no. 426-7 Removal Remove cylinder head only when engine is cool. Disconnect negative cable on battery.
Page 118 EXIT Naturally aspirated engines: Remove air intake hose (arrow) and air cleaner cover together with filter cartridge, if not already removed. Turbo-engines: Remove intake hose to exhaust gas turbocharger. Disconnect fuel lines (arrows) from fuel filter and remove lines from fuel filter. (116) 5 Unbolt hex.
Page 119 EXIT Unbolt holder (62) for oil dipstick tube from cylinder head. Engines with exhaust gas recirculation (naturally aspirated engines): Remove line (arrow) from exhaust gas recirculation valve to air guide housing. Unbolt hex. head bolts for side exhaust support (5) from transmission. Loosen hex. nuts (2) on exhaust pipe.
Page 120 EXIT 10 Pull off retainer (91) for heater feed line with hook (01). 11 Unbolt pipe elbow (93) from oil filter and pull pipe elbow off of connection fitting (89). 12 Unbolt connection lines from glow plugs. 13 Remove intake manifold (naturally aspirated engines) or charge air manifold (turbo-engines) (14-180).
Page 121 EXIT 17 Unbolt cylinder head bolts in opposite order of torquing sequence using socket 601 589 00 10 00. 18 Remove cylinder head from cylinder block together with cylinder head gasket. 19 Clean parting surface on cylinder head and check for cracks. 20 Check length (L) of cylinder head bolts.
Page 122 1, 7, 9, 15, 17, 21 10x115 M 8x30 or a (Timing case area) M 8x50 b (Fuel filter) M 8X80 Engine 603 Bolt diagram Bolt size Hole 11, 13, 19, 21 10x80 20, 22, 24, 26 1, 7, 9, 15, 17, 23, 25...
Page 123 EXIT 25 Tighten cylinder head bolts in stages in specified in the torquing sequence, use socket 601 589 00 10 00. 26 Torque cylinder head bolts in specified tightening sequence. Tightening torques and rotation angles for cylinder head bolts Stage 1 15 Nm Stage 2 35 Nm...
Page 124 EXIT 29 Install pipe elbow (93) for heater feed line using new O-ring and slide onto connection fitting (89). Attach retainer (91) with hook (01). Note Dip O-ring in coolant to facilitate installation. 30 Install intake manifold (naturally aspirated engines) or charge air manifold (turbo-engines) (14-180).
Page 125 EXIT 34 Bolt oil dipstick tube with holder (62) into cylinder head. 35 Install fuel filter, tighten hex. head bolts (116). 36 Connect fuel lines. 37 Bolt connection lines onto glow plugs. 38 After assembling engine check cooling and oil system for leakage after warming up engine. Note It is not necessary to retorque the cylinder head bolts.
Page 126 EXIT Mount for engine control removed (30-300) Nozzle holders removed (07.1-230). Angular Injection (example engine 601) (example engine 601) Glow plugs remove, reinstall, 20 + 2 Nm (item 1). Vertical injection: Threaded ring (112) remove, reinstall, 90 - 110 Nm, pin wrench 615 589 00 07 00 (item 2).
Page 127 EXIT Angular injection: Threaded ring (112a) remove, reinstall, 70 Nm, splined wrench 603 589 00 09 00 (item 3). Prechamber (110) knock out, install, impact puller 602 589 00 33 00 and check (items 4, 6). Note Install prechamber so that the lug on the collar of the prechamber is located in the recess in the cylinder head.
Page 128 EXIT Differentiation, vertical and angular injection A Prechamber, vertical injection B Prechamber angular injection, inclined 5” Code 601107, 601117, 601/09, 601123 Code 601/l 4, 601 05 C o n e y Recess 01.10 - 417/3...
Page 129 EXIT C Prechamber, angular injection Inclined 5” ) turned 180” Code 601125, 601 26, 601130 Cone y Recess Differentiation, combustion neck diameter The individual combustion neck diameters (d) differ on naturally aspirated engines and turbo- engines. mm naturally aspirated engines mm turbo-engines 01.10 - 4174...
Page 130 0 Bore for glow plug Tightening torques Glow plugs Threaded ring, vertical injection Threaded ring, angular injection Special tools 615 589 00 07 00 603 589 00 09 00 6 0 2 5 8 9 0 0 3 3 0 0 01.10 - 417/5...
Page 131 EXIT 001 589 66 21 00 Removal, installation Remove glow plugs (R9). Installation note Tightening torque 20 + 2 Nm. Vertical injection: Bolt threaded end (03) of pin wrench 615 589 00 07 00 into threaded ring of prechamber. 01.10 - 417/6...
Page 132 Oil threaded ring. Tightening torque 90 - 110 Nm. Angular injection: Remove threaded ring with splined wrench 603 589 00 09 00. Installation note Oil threaded ring. Tightening torque 70 Nm. Bolt impact puller 602 589 00 33 00 into prechamber and knock out prechamber.
Page 133 EXIT Installation note Insert prechamber into mounting bore so that lug on collar of prechamber fits in recess in cylinder head (arrows). Clean mounting bore for prechamber in cylinder head, check and cover. Note Refinish prechamber sealing surface if required (01-410).
Page 134 EXIT 0 1 4 1 8 Facing cylinder head mating surface Preliminary operations: Valves removed. Valve guides checked (05285). Prechambers removed (01-417). PO1 Xl246-57 plane according to operating instructions of tool Mating surface (1) manufacturer. Note Observe permissible minimum height (H) and machining data.
Page 135 EXIT Data 142.9 - 143.1 Total height of cylinder head in mm ‘ ) 142.4 Minimum height (H) after machining in mm Material removal per facing operation in mm 0.08 Permissible unevenness of mating surface in mm 0 . 0 Permissible deviation in parallel of upper mating surface in relation to lower surface in longitudinal direction in mm 0.004...
Page 136 EXIT Camshaft removed (05220). Valves removed. Camshaft bearing caps (1) ....remove, install, 25 Nm. Camshaft bearing basic bores (D) measure. Note bearing bores once to max. 0.5 mm oversize. Observe repair stage dimensions. Camshaft bearing basic bores (D) bore out according to operating instructions for tool used.
Page 137 EXIT After boring remove burrs on mating surfaces of camshaft bearing caps (1) and mating surfaces on cylinder head. Note Edges with burrs can lead to poor lubrication during engine operation resulting in bearing damage. with oversize bearing journals (Dl Install new camshaft (2) code for oversize camshaft (05215 or 05220).
Page 138 EXIT ressure-testing cylinder head Preliminary operations: l-4 15). Valves removed. Valve shaft seals removed (05-270). Cylinder head (1) clean. Pressure plate bolt onto cylinder head with rubber sealing plate 601 589 00 25 00, unbolt. Connection for cooling water return fitting and heater feed line on cylinder head, plug tightly.
Page 139 EXIT ..... . . Cylinder head check for air bubbles exiting. Note Air bubbles indicate a leak, locate exit point for air bubbles more precisely if possible.
Page 140 EXIT...
Page 141: Crankshaft Assembly
EXIT Crankshaft assembly Job No. 03 - 310 Checking, replacing and tightening connecting rod bolts 03 - 313 Reconditioning and squaring connecting rods ........Removal and installation of pistons Modifications to pistons - 3 1 7 Checking and reconditioning crankshaft ........Installation of crankshaft and connecting rod bearings ......
Page 142 EXIT 03-310 Checking, replacing and tightening connecting rod bolts = 7.1 measure, minimum dia, Stretch bolt dia. (dimension c) mm replace If shaft dia. is less than connecting rod bolts. oil. Threads on connecting rod bolts initially tighten to 30 Nm and then tighten to Connecting bolts 100”.
Page 143 EXIT Dimensions Part No. 102 038 00 M 9x1 Thread 7.4 - 0.1 Necked down shaft dia. (c) in new condition Minimum necked down shaft dia. (c) Length (L) in new condition 52 - 0.3 Tightening torques and rotation angles Initial tightening torque Rotation angle Special tool...
Page 144 EXIT 03-313 Reconditioning and squaririg connecting rods Pistons removed (03-316). oil. Connecting rod bolts (168) and sleeves (167) Connecting bearing attach without connecting rod bearing shells (165, 165a), remove, 30 Nm (item 1). measure, max. 51.619 mm, if dimension is Basic bore (D) exceeded, machine bearing cap down max.
Page 145 EXIT Data Engine 602 603.96 148.97 149.03 Center of connecting rod bearing bore to center of connecting rod bushing bore (L) 144.97 E n g i n e 6 0 3 . 9 7 0 145.03 23.974 st version 24.026...
Page 146 Replacement connecting rods are supplied with machined connecting rod bushings. Connecting rod width Connecting rod width (B) on engines 602 and 603 from start of production is 22 mm. 03.10 - 313/3...
Page 147 EXIT Engines 602.91, 603.91 starting 1 l/85 The connecting rods are heat treated before machining to reduce the tendency to warp. Production beakpoint: 1 l/85 registered Engine 603.960 starting 01188 On these engines there are 3 bores (arrows) with a dia. of 4.5 mm in the connecting rod eye for lubrication of the piston pin.
Page 148 EXIT Engines 602.961, 602.962, 603.970 and 602.96, 603.96 starting 09188 On these engines the connecting rod eye is now equipped with 2 bores (arrows) with a dia. of 4.5 mm. Engines 602.91, 603.91 Shaft cross section of piston rods reduced (stan-...
Page 149 EXIT Production breakpoint: W86 registered Tightening torque 30 Nm Initial tightening torque Connecting rod bolts 100" Rotation angle Special tool 001 589 66 21 00 Commercially available tools Hahn & Kolb, Connecting rod straightener e.g . D-7000 Stuttgart Model BC 503 e.g .
Page 150 EXIT Measure connecting rod bearing basic bore. If the basic bore diameter exceeds the value of 51.619 mm or if it is conical, touch up bearing cap at contact surface on surface plate up to max. 0.02 mm. Press in new connecting rod bushing (169) such that oil bores are aligned (arrow).
Page 151 EXIT Check offset of connecting rod bearing bore in relation to connecting rod bushing bore and correct, if required. 03.10 - 31318...
Page 152: Removal And Installation Of Pistons
EXIT 03-316 Removal and installation of pistons (01-030). (0 l-4 15). (01-310). pan removed Cylinder ......clean. (168) Connecting rod bolts remove, check (03-310), reinstall (items 2, 12). Caution Do not mix up upper and lower connecting rod bearing shells (165, 165a). Connecting rod bearing cap (166 a) remove, oil connecting rod bearing, position (166...
Page 153 (item 14). Projecting length max.: 0.965 mm Projecting length min.: 0.735 mm Cross reference, pistons - cylinders Group code Piston code Engine Piston dia. Cylinder dia. number letter 86.970-86.976 87.000-87.006 602.96, 603.96 upon 86.982-86.988 upon 87.012-87.018 03.10...
Page 154 Difference in weight between pistons in one engine 20 g Engines 26.995-27.000 Piston pin diameter 2nd version 602.91 Engines 27.995-28.000 602.961, 603.96 22.05-22.35 1 st version Distance, piston pin eye 24.1-24.3 2nd version Piston pin clearance in piston 1 st version 0.126-0.274...
Page 155 EXIT Special tools Standard tool e.g. Mahr, Dial gauge Al DIN 878 D-7300 Esslingen Order No. Removal Remove combustion residues in cylinder. Remove connecting rod bolts (168), re- move connecting rod bearing cap (166a) and remove connecting rod (166) together with piston (177) in upward direction.
Page 156 EXIT Installation Note The group code letters (arrows) are stamped on the crankcase mating surface. Only pistons with the group code letter “ X” are available for repair. These pistons should also be installed in cylinder bores with group code letters “ A” or ” 6” . When repairing hone cylinder bores according to dimensions of present pistons “...
Page 157 EXIT Insert piston pin retainer into groove (arrow). Check piston rings for easy motion. When installing used pistons check gap and side clearance of piston rings. Oil cleaned cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons. Turn piston rings so that gaps are distributed uniformly around circumference of piston.
Page 158 EXIT Modifications to pistons Piston pin bearings, engine 602 Piston pin bore provided with angular oil pockets (previously flat oil pockets) for improved lubrication. Production breakpoint: 08/85 "not reglstered Engine 602.91 The piston skirt has been provided with a larger recess (arrow) for better clearance on engines with oil injection nozzles or exhaust gas recirculation..
Page 159 EXIT Each piston is equipped with two compression rings and one oil scraper ring. The first piston ring groove is provided with a Niresit ring carrier. Taper face ring with InsIde bevel, 2 mm Rectangular ring, 2 mm thrck, runnrng surface chrome-plated Engine 602.91 starting 09189 The height of the ring groove for the rectangular...
Page 160 EXIT Production breakpoint: 03188 registered Production breakpoint: 04 - OW88 not regrstered Production breakpoint: 06188 (Piston code 14, KS co.) not reglstered Production breakpoint: 06/88 (Piston code 14, KS co.) not reglstered Production breakpoint: 1 l/88 (Piston code KS co.) Model Engine end No.
Page 161 (Piston code 14, KS co.) registered Production breakpoint: 1 l/88 (Piston code 14, KS co.) not reglstered Engines 602.961, 603.96/97 starting 12/87 (turbo) Piston pins The size of the piston pin has been increased to reduce the surface pressure. Engine 602.961, 603.96:...
Page 162 The required oil is supplied via injection nozzles located in the crankcase on the right side. The annular channel is deleted on engine 603.970. Only the piston crown is supplied with oil. located on the piston skirt (arrow) for recess is the oil injection nozzle.
Page 163 The piston skirt is graphitized. 00 Engine 602.96 / Piston codes: 13 Engine 603.96 surface chrome-plated Taper face ring wtth inside bevel, 2 mm thick, Rectangular nng with InsIde bevel, 2.5 mm thick, running surface molybdenum-coated 03.10...
Page 164: Checking And Reconditioning Crankshaft
EXIT Checking and reconditioning crankshaft Crankshaft removed. clean Crankshaft perform; apply fluorescent powder (magnaflux) Crack test or use penetration method. perform with impact hardness tester Hardness test (scleroscope hardness) 000 589 20 21 00. when hardening journals without hardened Distance (A = 5 - 6 mm) fillets, maintain distance A between hardened can be hardened inductively or with flame.
Page 165 EXIT Data Crankshaft Crankshaft Fitted bearing Connecting Connecting rod normal dimen- bearing journal Associated rod bearing bearing journal sions and repair dia. thickness of journal dia. width stages thrust washers Width of journal 2 6 . 5 2 ” 24.532’ 2.15 26.50 24.50...
Page 166 EXIT Special tool Note When testing and reconditioning crankshafts, proceed in sequence shown in diagram below. 03.10 - 31813...
Page 167 EXIT A. Testing, grinding Visual check Heavy damage Crack test ‘ ) Cracks present Hardness test ‘ ) All bearing journals Scleroscope hardness min. 55 on 213 of journal circumference...
Page 168 EXIT Measure journals Check whether regrinding is still possible within last specified repair stage 4. Scrap Grind crankshaft Crack test Cracks present Lapping Dimension check Dimensions okay 03.10 - 31815...
Page 169 EXIT Hardening Check whether regrinding is still possible within specified repair stage 4. Induction hardening Facilities available Check hardness by etching ‘ ) 03.10 - 31816...
Page 170 EXIT Crack test Clean crankshaft. Bearing journals should be free of oil and grease. Magnetize crankshaft and apply fluorescent powder (magnaflux). A fluorescent penetration method may also be used (immersion in bath or using spray can). Agent: Paint or fluorescent powder, cleaning agent, developer Hardness test...
Page 171 EXIT Checking hardening results To achieve perfect hardening check adjustment of hardening equipment using microsections. These can be obtained from scrapped crankshafts hardened for testing purposes. Check hardening by etching the journal surface with a 2% solution of alcoholic nitric acid Dark spots should not appear on the journal surface.
Page 172 EXIT Installation of crankshaft and connecting rod bearings Oil passages In crankcase and crankshaft cleaned. Crankshaft tested (03-318). Crankshaft bearing caps (2, 3) ....install without bearing shells, observe markings, tighten.
Page 173 EXIT Basic bores measure conicity in directions A, B and C, min. 62.500 mm, max. 62.519 mm (item 3). Crankshaft bearing caps (2, 3) ....remove (item 4). Crankshaft bearing shells (146, 147) ..insert (item 4). Caution! Do not mix up upper and lower crankshaft bearing shells.
Page 174 EXIT 165 - 166a Connecting rod bearing caps (166 a) install without bearing shells and tighten, 30 Nm. Observe marking. Basic bore for rod bearing ....measure (03-313).
Page 175 EXIT Pistons (177) and connecting rods (166) ..install (arrow on piston crown toward front of vehicle) (03-316). Connecting rod bearing end play measure, new value 0.12 to 0.26 mm; wear limit 0.50 mm (item 20). Oil pump and oil filter disassemble and clean, renew oil pressure valve and install initial operation oil filter cartridge.
Page 176 EXIT Crankshaft bearing Basic bore and bearing play in mm Connecting rod beartng Basic bore width on Engines 602 and 603 fitted bearing Engines 602 and 603 Connecting rod width 0.01 Permissible out-of-round of basic bore 0.01 Permissible conicity of basic bore 0.030 - 0.055’...
Page 177 Color code Dimension 1.804 to 1.808 mm Yellow 1.808 tol.812 Blue 1.812 to1.816 Engines 602.96, 603.96 and 603.96/97 Upper connecting rod bearing shells from Glyco with improved coating (cathode dust coating method). 03.10 - 32016...
Page 178 Dimension A: 3.2 mm for all engines Dimension B: 2.5 mm 602.96, 603.96197 3.5 mm 602.91 Production breakpoint: 05/86 Note The axial forces of the crankshaft are taken up by the thrust washers.
Page 179 EXIT The thrust washers (148 and 148a) installed in the crankcase and in the bearing caps have a different shape. The thrust washers in the crankshaft bearing caps each have two retaining lugs to prevent rotation and installation errors, whereby the lower retaining lugs are off-center.
Page 180 EXIT Association of crankshaft bearing shells and crankcases 2 punch marks 3 punch marks ‘ ) 1 punch mark Yellow Yellow Blue Yellow Yellow Yellow Color dots on crankshaft cheeks or counterwelghts next to crankshaft Journals. Punch marks on parting surface of crankcase on 011 pan side next to basic bore. The standard dimension crankshaft bearing shells with color codes blue, yellow and red are available as parts.
Page 181 EXIT Thrust washer sets Thickness in mm Part No. 2.15 601 030 00 62 2.20 601 030 01 62 2.25 601 030 02 62 2.35 601 030 03 62 2.40 601 030 04 62 Tightening torques and rotation angle M 12 90 Nm Crankshaft bearing bolts M 11...
Page 182 EXIT Installation of crankshaft and connecting rod bearings Attach crankshaft bearing cap. Note All bearing caps are fitted laterally into crankcase (arrows) and are fastened with two M 12 x 60 or M 11 x 60 bolts each. The pilot fit (arrows) is offset 0.5 mm from the center so that the bearing caps can be mounted in one position only.
Page 183 EXIT Remove crankshaft bearing bolts, insert crankshaft bearing shells, install crankshaft bearing caps and tighten. Tightening torque and rotation angle: 90 Nm Crankshaft bearing bolts M 12 Crankshaft bearing bolts M 11 100". Caution! Observe order of crankshaft bearing caps. Do not interchange upper and lower crankshaft bearing shells.
Page 184 EXIT Engine 603 A Upper bearing shells, crankcase Measure crankshaft bearings and note values. 03.10...
Page 185 EXIT Measure crankshaft bearing journals, deter- mine crankshaft bearing radial clearance. Note The bearing clearance can be corrected by exchanging bearing shells. Attempt to achieve the mean value of the specified bearing clearance. Caution! Observe different wall thicknesses. Measure width of fitted bearing journal and find proper thrust washers (see table, section Data).
Page 186 EXIT 10 Position crankshaft bearing caps in proper order. Note The crankshaft bearing caps are marked with code numbers at the marking points (arrows). Tightening torque and rotation angle: 90 Nm Crankshaft bearing bolts M 12 55 Nm, Crankshaft bearing bolts M 11 90 - 100”...
Page 187 The bore for lubrication of the piston pin has 3.2 m m engine 602 been eliminated. Due to higher loads in engine 603.970, the upper connecting rod bearing shells are made of a different material than the lower shells. To prevent misassembly, the upper locating groove is mm narrower.
Page 188 EXIT 19 Tighten connecting rod bolts to initial torque of 30 Nm and then turn 90 - 100” . 20 Measure connecting rod bearing end play while moving connecting rod directly at piston pin. Assure that connecting rod moves freely in relation to crankshaft.
Page 189 EXIT Modifications to crankshaft Increased displace- ment engine 603.970 The stroke was in- creased to 94.2 mm and the web width (b) reduced to 21.75 mm to increase the displacement (3.5 I) on the 603.970 engines. Engine 602.96 crankshaft webs On engine 602.96 starting 12187 the web width...
Page 190 EXIT Engine 602.91 flywheel locating pin Cylindrical pin in crankshaft for locating the flywheel and driven plate. Production breakooint: 01186 Vehicle ident end No. not registered 03.10 - 32112...
Page 191 EXIT This 03.10 - 32113...
Page 192 Replacing front crankshaft radial sealing ring 03-324 Radiator removed (20-420). Poly-V-belt removed (13-342). 161a 162b Engines 602, 603: Crankshaft pulley (161 a) with vibration damper (163) and Allen screws (162) and washers (162 b) remove, install (03-341) (item 2). Note The vibration damper for engine 602 is not Do not interchange during repairs.
Page 193 EXIT Crankshaft radial seal (31) replace. Deburr and clean mounting bore. Coat sealing lip with oil and press in with special tool 601 589 03 14 00 (item 4). Note The sealing ring for the repair crankshaft radial seal is offset 3 mm toward the inside so that it will not run in a groove left on the hub by the standard crankshaft radial seal.
Page 194 EXIT Replacement Engine 601.921 Remove crankshaft pulley (03-341). Engines 602, 603 Remove crankshaft pulley with vibration damper (03-341). Caution! Do not interchange vibration dampers. Remove crankshaft hub (03-341). Note The cylindrical pin centers the crankshaft pulley and vibration damper. Press out crankshaft radial seal with screw- driver.
Page 195 EXIT 150a Flywheel (149) and driven plate (150a) remove, install, (03-410) (items 1, 9). Crankshaft radial seal (600) remove, replace. Check running surface on crankshaft flange, clean mounting bore, coat sealing lip of crankshaft radial seal with oil and press in with special tool 601 589 03 43 00 (items 2 - 8).
Page 196 EXIT Note The sealing ring for the repair crankshaft radial seal is offset 3 mm toward the inside so that it will not run in a groove left on the hub by the standard crankshaft radial seal. Standard crankshaft radial seal Repair crankshaft radial seal Special tools Renewal...
Page 197 EXIT Check running surface for crankshaft radial seal on crankshaft flange for damage. Clean mounting hole for crankshaft radial seal, deburr, if required. Bolt inner part of installation tool 601 589 03 43 00 onto crankshaft flange. Coat sealing lip of crankshaft radial seal and opposite running surface lightly with oil, do not use grease.
Page 198 Spacer ring 102 031 01 33 Locking ring 115 980 01 15 Ball bearing Engines 602, 603 from start of production. For repair these parts can also be installed in engines produced earlier. Cement 002 989 94 71 Loctite 241 Special tools 03.10...
Page 199 EXIT Removal, installation Pull radial ball bearing out of crankshaft together with locking ring, use internal puller 000 589 25 33 00 and countersupport 000 589 33 33 00. Installation note Knock in spacer ring flush. Coat new ball bearing with cement 002 989 94 and knock into crankshaft with suitable punch on outer race.
Page 200 EXIT 03-341 Removal and installation of crankshaft pulley and hub 161a 162b Engines 602, 603: Crankshaft pulley (161 a) and vibration damper (163) remove, install, use washers (162 b) and Allen screws (162), 25 Nm. Use lock 601 589 02 40 00 (items 1, 3).
Page 201 Allen bolt M 8 x 28 Washer B 8 Engine 602 The vibration damper on engine 602 has a 35 mm wide machined recess (arrow) on the front and are therefore lighter. A Vrbratron damper, engine 602 B Vrbratton damper, engine 603 03.10...
Page 202 Caution! These vibration dampers cannot be installed on engine 602.91. Engine 603.96 The vibration damper of engine 603.96 is a single-mass vibration damper and identical with that of the naturally aspirated engine except for the resonant frequency. Do not interchange.
Page 203 EXIT Engines 602 and 603 Unbolt crankshaft pulley (161a) and vibration damper (163) and remove. 31 28 155 Screw out hex. head bolt (160). Installation note Install Belleville washers (159) with arch toward crankshaft pulley (161 a). The crankshaft pulley (161 a) and vibration damper (163) are centered with the cylindrical pin (158).
Page 204 EXIT Checking and correcting adjustment of TDC sensor Holder for TDC sensor, engines 602 and 603 from start of Cylinder 1 ......
Page 205 (TDC position), set dial gauge scale to zero (item 3). Engine turn until dial gauge moves back 3.22 mm on engines 602 and 603 or until dial gauge moves back 3.65 mm on engines 601.921, 603.97 (item 4). Note Corresponds to crankshaft position of 20”...
Page 206 EXIT Special tools 603 589 01 21 00 Commercially available tool e.g. Mahr, Dial gauge A DIN 878 D-7300 Esslingen Order No. 870 Testing Note The holder for the TDC sensor is fastened to the timing case cover. TDC sensor, engines 602 and...
Page 207 EXIT Position piston in cylinder 1 to approx. BTDC, ignition stroke. Holder for TDC sensor, engines 602 and 603 from start of productlon Bolt gauge 601 589 07 21 00 up to precombustion chamber bore and attach dial gauge to gauge with 5 mm pretension (small pointer on dial gauge).
Page 208 Gauge 177 Plston crown Turn crankshaft in normal direction of rotation slowly until the gauge moves back 3.22 mm on engines 602 and 603 or 3.65 mm on engine 603.97. Note After the dial gauge has moved back (crankshaft position 20” ATDC) the pin in the crankshaft pulley or in the vibration damper should be located exactly below the TDC sensor (arrow).
Page 209 Loosen holder (42 or 44) with screw (41) and move until pin on crankshaft pulley or on vibration damper catches in the groove in the locating device 603 589 01 21 00. Holder for TDC sensor, engine 601.921 Screw holder for TDC sensor down tight.
Page 210 EXIT 03-350 Removal and installation of crankshaft sprocket pan removed (01-310). for 011 pump removed (05-437). Tensioning bracket (262) remove together with torsion spring (261), install (items 1, 17). Oil pump sprocket (257) unbolt hex. head bolt (259) and remove together with washer (258) (item 2).
Page 211 Bolt for camshaft sprocket Starting 1 l/88 the bolt for mounting the camshaft sprocket was changed from an M 10 bolt to an M 11 stretch bolt on engines 602.91/96; 603.91196 and 603.970 (see 05-220). 0 3 . 1 0 - 35012...
Page 212 EXIT Tightening torques and rotation angles Hex. head bolt for camshaft sprocket 90” Hex. head bolt for oil pump sprocket Special tools 116 589 07 15 00 001 589 66 21 00 Removal Remove clamping bracket (262) and torsion spring (261). Remove hex.
Page 213 EXIT Mark position of timing chain and camshaft sprocket in relation to one another. unbolt hex head bolt and remove with washer. Remove camshaft sprocket and allow timing chain to sag. Pull off crankshaft sprocket with puller 601 589 07 33 00. 10 Check condition of retaining wedge in crankshaft, replace, if required.
Page 214 EXIT 13 Install camshaft sprocket and timing chain making note of marking and tighten. Tightening torque and rotation angle 65 Nm, Wex. head bolt 25 Nm, 90” . 14 Install chain tensioner and replace sealing ring (05-3 10). 15 Continue to turn crankshaft and check adjustment marking at TDC (arrows).
Page 215 601 589 02 40 00 in flywheel ring gear and remove flywheel together with driven plate (items 1, 2). Driven plate (153) engine 603.970 unbolt, reinstall. Position lock 601 589 02 40 00 in teeth on driven plate and remove driven plate and spacer disc (150b) (items 1, 2).
Page 216 EXIT Stretch bolts (152, 152a) check, max. length, 1 st version (152a) 26.5 mm, 2nd version (152) 22.5 mm, necked down shank diameter min. 8 mm, replace stretch bolts if required (item 2). Initial torque 35 Nm, rotation angle 90 - 100” . Stretch bolts (152~) on two-mass flywheel (149b) engine 602.91,...
Page 217 EXIT Flywheels for manual transmissions Engine 602 223.00-223.07 mm 57 mm 03.10 - 41013...
Page 218 EXIT Engine 602.96 Engine 602.96 has a lighter flywheel than engine 602.91 with automatic transmission. Flywheel, engine 602.91 Flywheel, engme 602.96 Crankshaft Flywheel 152a Stretch bolt 152b Engine 603.96 Crankshaft Flywheel 150a Stretch bolt 03.10...
Page 219 Stop damper Primary flywheel weight Radial ball bearing Stretch bolt M 10 x 1 x Spacer bolt Torsion damper Secondary flywheel weight Spacer bolt Ring gear Flywheels with automatic transmissions A Flywheel, engine 602 B Flywheel, engine 603 03.10 -...
Page 220 EXIT Tightening torques and rotation angles Stretch bolts for flywheel 90 - 100” Stretch bolts for two-mass flywheel 90 - 100” Special tools 589024000 Removal, installation Remove hex. head bolts (55) and insert lock 601 589 02 40 00 into ring gear on flywheel and tighten with hex.
Page 221 Tightening torque and rotation angle Initial torque 35 Nm, rotation angle 90 - 100” . Driven plate (engine 603.97) Screw out stretch bolts remove spacer disc (150b) and driven plate (153). Installation note Check stretch bolts, max. length 22.5 mm, necked down shank dia.
Page 222 EXIT Two-mass flywheel with manual transmission, engine 602.91 Remove stretch bolts and remove two-mass flywheel. Installation note Check stretch bolts, max. length 57.2 mm, necked down shank dia. min. mm, replace stretch bolts if required. Tightening torque and rotation angle 40 Nm, Initial torque rotation angle...
Page 223 If material removal causes dimension (a) to exceed max. causing dimension (b) to be less than 15.6 mm, replace flywheel. Dimension (a) ......measure, engine 602: 22.5 mm, engine 603: 19.4 mm. Maximum material removal if material removal is greater than replace flywheel.
Page 224 EXIT refinish Flywheel Caution! The two-mass flywheel cannot be refinished. Clamp flywheel in lathe so that permissible deviation from flat = 0.05 mm is not exceeded. Data Engine Distance a 22.5 2 0.1 in new state 16.6 + 0.4 Distance b for repair up to 15.6 + 0.4 Permissible deviation from flat on clutch...
Page 225 EXIT Preliminary jobs: Flywheel and driven plate removed (03-410). (149) ......Flywheel check, centering flange dia. (a) for ring gear 275.00 + 0.05 mm. Clean mounting surface for ring gear on flywheel before installing ring gear. (151) ......drill hole into old ring gear and break up with a Ring gear chisel or heat quickly and then remove immediately.
Page 226 EXIT Caution! The ring gear is hardened. For this reason do not exceed 220 “ C at any point while heating with hot plate or heating furnace. Use temperature measuring chalk in accordance with directions. Use open flame only In exceptional cases. Apply flame to inside of ring gear only.
Page 227 EXIT...
Page 228 EXIT Job No... . . 05 - 211 Checking and renewal of hydraulic valve clearance compensating elements Checking camshaft timing Removal and installation of camshaft ......... Removal and installation of valve springs ........Checking valve springs Renewal of valve stem seals Checking and machining valves...
Page 229 EXIT 05-211 Checking and renewal of hydraulic valve clearance compensating elements Engine ......bring to operating temperature (80°...
Page 230 Guide sleeve “ g” dimens. f-4 1 (mm) Note Hydraulic valve clearance compensating elements have been fitted with a larger oil reservoir chamber since the start of production on engines 602 and 603. a Storage chamber Break date: 08184 05.10 _ 211 2...
Page 231 EXIT From 09/87 valve tappets have been installed with a ventilation bore (d = 0.2 mm), in order to prevent tappet rattle during short distance operation. Plunger Production breakpoint: 09187 not recorded 211 3 10 -...
Page 232 EXIT From 01,90 revised valve clearance compensating elements have been installed. These compensating elements have a reduced residual stroke, i.e. the stroke of the plunger (b) and the working chamber (c) have been reduced and the reservoir chamber (a) enlarged. Less oil is needed in the working chamber due to the reduced stroke.
Page 233 EXIT Special tools 001 589 66 21 00 001 589 72 21 00 601 589 08 21 00 102 589 03 40 00 Conventional tool Dial gauge e. g. Mahr D-7300 Esslingen Part No. 810 Checking Run engine to operating temperature (80° C). Check engine oil level, making absolutely sure it is not overfilled.
Page 234 EXIT In order to check with a mandrel press lightly on the valve clearance compensating element and thus check the clearance. Continue turning the engine until the next cylinder in the firing order can be checked. A valve clearance compensating element must only be replaced when a clearance of >0.4 mm is established between cam and element.
Page 235 EXIT 9 Remove camshaft (05220). 10 Measure dimension “ Y” (cylinder head mating surface to valve tappet). The difference between the dimension “ X” and Reference value: 0.25 - 2.0 Example: No. 1 Cylinder A (exhaust) E (Inlet) 2.82 2.98 Dimension “...
Page 236 EXIT 12 Measure dimension “ L” on valve tappet. 13 Measure dimension “ L2” on valve tappet. The dimension Ll is the difference between L and L2. 18 - 19 mm Reference value: 14 If the dimension "Ll" is outside the reference value remove guide sleeve.
Page 237 EXIT 19 Fill plunger with engine oil. Press off ball valve with a suitable pin and then ventilate the working chamber by pumping the plunger, close ball valve and possibly replenish oil. Then no oil should escape from the ball valve when it is gently compressed.
Page 238 EXIT Preceding work: Cylinder head cover removed. Charge air pipe removed (turbo engines). Dial gauge holder 363 589 02 21 00 attach, remove at the No. cylinder inlet valve. Dial gauge with 3 mm preload on valve tappet. Engine ....... turn in direction of rotation.
Page 239 EXIT Tightening torque Bolts for cylinder head cover Special tool 363 589 02 21 00 Conventional tool Dial gauge A 1 DIN 878 e. g. Mahr D-7300 Esslingen Part No. 810 Note is not possible to correct timing. The trming chain should be checked for elongation if the test values differ.
Page 240 EXIT Fasten dial gauge holder 363 589 02 21 00 on the cylinder head (above the No. 1 cylinder inlet valve). Insert dial gauge and extension and fasten so that probe pin sits on the valve tappet with a preload of 3 mm (small dial gauge pointer). Turn dial gauge scale until the large pointer is on “...
Page 241 EXIT Removal installation of camshaft 2 0 3 Turbo engine: Charge pipe remove, install. Cylinder head cover (125) remove, install, 10 Nm. Engine position on ignition TDC of No. 1 cylinder. Caution! The engine must not be turned by the camshaft Chain tensioner (224) remove.
Page 242 EXIT Camshaft timing gear (188) mark at timing chain (210). Remove, install camshaft timing gear. Different bolts (190) and washers (189). Hexagon bolt, 65 Nm, bihexa- gonal head bolt, 25 Nm 90” angle of rotation. Caution! When assembling the camshaft timing gear ensure that the straight pin (187) is not pushed out towards the rear.
Page 243 EXIT Data Bearing position engine Camshaft timing 0.025 0.025 gear seat Permitted eccentricity of center bearing pin 2nd and 5th bearing and camshaft gear seat when accepting the camshaft in the outer bearing positions 2nd and 6th bearing 0.030 position 3rd and 5th beanng 0.045 position...
Page 244 Engine Thread for Camshaft sprocket code number wheel 602, 603 M l 0 07, OS’ ) 11, 13’ ) Washer for camshaft timing gear bolt A revised washer with a larger outer diameter (c) has been fitted in order to prevent the camshaft timing gear bolt loosening.
Page 245 EXIT Camshaft timing gear bolt From 11,‘ 88 the camshaft timing gear fixing has been revised from a Ml 0 hexagon bolt to a Ml 1 bihexagon necked down bolt on all engines. Tightening torques Hexagon bolt (A) 65 Nm Pre-torque 25 Nm Torsion angle 90”...
Page 246 EXIT Production breakpoint: 1 l/88 transmission 000187 019336 014216 004561 not recorded Tightening torques and angles of rotation Hexagon bolts on cylinder head cover Hexagon bolts on camshaft timing gear 90” Bihexagonal head bolt on camshaft timing gear Hexagon bolts on camshaft bearing cap Special tools 102 589 03 40 00 001 589 72 21 00...
Page 247 EXIT Position engine on ignition TDC of No. cylinder (arrow). Caution! Do not turn engine by the camshaft timing gear bolt. Do not turn engine backwards. Remove chain tensioner (05310). With self-levelling suspension Remove pressure oil pump (05437). Align camshaft timing gear and timing chain. Unscrew hexagon bolt or bihexagonal head bolt on camshaft timing gear, whilst holding the camshaft with a mandrel.
Page 248 Loosen both hexagon bolts on camshaft bearing caps 3, 4 and 5 in increments of one turn respectively, until counterpressure is reduced (light arrows). Engine 603 Unscrew both hexagon bolts on camshaft bearing caps 5 and 6 (dark arrows). Loosen both hexagon bolts on camshaft bearing...
Page 249 EXIT Remove lock washer for axial fixing (arrow) and check condition. 12 Pull out valve tappet with magnetic lifter 102 589 03 40 00. 13 Check valve tappet for condition (visual inspection), replace if necessary. Caution! Install valve tappet in the same position again. Installation 14 Insert lock washer for axial fixing (arrow) in cylinder head.
Page 250 9. Engine 602; camshaft bearing caps 3, 4 and 5 Engine 603; camshaft bearing caps 2, 3, 4 and 7 The remaining camshaft bearing caps (dark arrows) can then be assembled at random.
Page 251 EXIT Removal and installation of valve springs Camshaft removed (05-220) A. Cylinder head removed Cylinder head (70) clamp. Assembly table 601 589 01 59 00, support bridge 601 589 02 59 00. Valve tappet (203) remove, rnstall. Magnetic lifter 102 589 03 40 00. Valve springs (198) remove, install, check (05-260).
Page 252 EXIT Valve tappet (203) remove, install. Magnetic lifter 102 589 03 04 00. position on TDC. Piston of cylinder concerned Retaining gear 601 589 01 40 00. Valve springs (198) remove, install, check (05260). Support bridge 601 589 02 59 00, lever press Magnetic lifter 116 589 06 63 00.
Page 253 EXIT Since 08/88 the valve spring retainers are in bath nitrided material (previously case hardened). Standardization with engines 102 and 103. Production breakpoint: 08188 transmission 124.133 6 0 3 . 9 6 0 - 018302 124.193 201.126 067330 013824 6 0 2 . 9 6 1 - 003806 201.128 not recorded...
Page 254 EXIT Special tools 601 589 02 59 00 104 589 00 37 t 102 589 03 40 00 116 589 06 63 00 601 589 02 43 00 A. Cylinder head removed Removal and installation Clamp cylinder head on assembly table 601 589 01 59 00 wtth 4 cylinder head bolts.
Page 255 102 589 03 40 00. Installation note Place piston of the cylinder concerned on TDC. Use retaining gear 603 589 01 40 00 instead of camshaft timing gear or camshaft in order to turn the engine. 05 10 250 5...
Page 256 EXIT Attach support bridge 601 589 02 59 00 for lever press on cylinder head. Press valve spring retainers downwards with lever press 601 589 02 61 00. Remove valve totters with magnetic lifter 116 589 06 63 00. Remove valve springs and valve spring retainers.
Page 257 EXIT Checking valve springs Valve springs removed (05-250). check at specified length. If limit is not Spring force achieved, replace valve spring. Valve spring data New value Limit Spring force Part No. Color at preloaded marking length yellow/green 710 - 790 601 053 01 20 (1 st design) violet/green...
Page 258 EXIT Replacing of valve stem seals Preceding work: Valve springs removed (05-250). Valve stem seals (199, 200) remove, install. Pliers 104 589 00 37 00, mandrel 601 589 02 43 00. Note color marking. Valve stem de-burr at groove. Valve stem seal designs Distinguishing features: Intake valve stem seal (199) Exhaust valve stem seal (200)
Page 259 EXIT Valve stem seals with standardized exterior dimensions are installed due to automatic cylinder head assembly. Production breakpoint: 1 l/85 not recorded Inlet valve stem seals without gas lip have been fitted since 09 89 and exh,aust valve stem seals without gas lip since 04 90.
Page 260 EXIT Viton material Intake valve stem seal Exhaust valve stem seal Production breakpoint: 09/89 (Inlet) Vehicle identification end No. Model Engine Engine end No. Manual Automatic transmission transmission 124.128 003020 124.133 124.193 126.135 201.126 016477 201.128 602.961 000177 007086 from st, of productlon not reel 05 10...
Page 261 EXIT (Exhaust) Vehicle identification end No. Engine Model 602.962 124.128 124.133 603.960 124.193 126.135 603.970 201.126 602.911 017538 201.128 602.961 002151 007954 from stal of production not recoi 601 589 02 43 00 0 5 1 0 270 4...
Page 262 EXIT OS-280 Checking and machining valves (01-415). Cylinder head removed Valve springs removed (05-250). Valves removed. Valves clean, check visually. (Intake valve 195, exhaust valve 196) check for eccentricity (max. 0.03 mm). Valve stem check for eccentricity (max. 0.03 mm), grind. Valve seat check (table).
Page 263 EXIT Data 602.96 602.91 602.91 Engine 602.96 603.96 603.96 Valve head Q (D) 38.10 38.10 35.10 35.10 New value 1.75-2.05 Height (h) of valve head Limit Setting angle (a) for 45” + 15’ machining the valve 8.960 8.960 Valve stem 0 (D 1) 7.955...
Page 264 Unserviceable sodium-filled valves must be neutralised before scrapping. They must therefore be collected by the respective departmental supervisor and dispatched to: Mercedes-Benz AG Werk Marienfelde Arbeitsvorbereitung TAI 196 Exhaust valve The locatron of the hydraulic valve clearance...
Page 265 EXIT Checking and machining Clean valves and carry out visual inspection. Valves with a burnt valve head, with insufficient valve head height (h) and with worn or scored valve stem should be replaced. Measure eccentricity on valve stem. Replace valve if eccentricity exceeds 0.03 mm. 3 Machine valve seat.
Page 266 EXIT Checking and replacing valve guides Cylinder head removed (01-415). Valve springs removed (05-250). Valves removed. Checking check. Replace valve guide (204) if valve stem Seat for valve stem seal (205) seal is loose. clean. Cylindrical brush 000 589 68 00. Valve guide (204)
Page 267 EXIT Basic bore of valve guide cylinder head (70) check. If required bore out to next repair stage. Broach (14.20 mm) 115 589 00 53 00. Guide sleeves: 102 589 00 63 00 intake, 102 589 08 63 00 exhaust. Broach (14.40 mm) 115 589 01 53 00 Guide sleeve 601 589 15 63 00.
Page 268 EXIT Special tools 103 589 03 15 00 103 589 02 15 00 000 589 21 53 00 000 589 10 53 00 117 589 03 23 00 102589002300 115 589 00 53 00 102 589 08 63 00 Conventional tool e.
Page 269 EXIT Broach base bore in cylinder head (Repair stage) Decarbonize and clean cylinder head carefully, particularly the inside of the valve seat inserts. Select correct guide sleeve (2) and remove swarf from the tip of the broach (1) with a stiff plastic brush or srmilar tool.
Page 270 EXIT Note The high spot (arrow) on the intake valve seat inserts is to be removed before inserting the guide sleeve. Inserting valve guide Drive home valve guides with punch and hammer, when the valve guides are not super- cooled and the cylinder head is not heated up. Coat valve guides with wax or 011 before driving home.
Page 271 EXIT Replacing valve seat inserts Valve guides checked (05-285). Valve seat insert turn out valve seat insert with the lathe tool. Note operating instructions for the valve seat turning equipment. Basic bore (D2) check (table). Bore out to the repair stage, if required.
Page 272 EXIT Data Intake Exhaust Overlap of valve seat inserts in cylinder head 33.400 30.400 33.600 30.600 (New value) 133.4 133.4 (Thrs dimension is valid up to the upper edge of cylinder head on reworked cylinder head parting surface) 37” 30’ 37”...
Page 273 EXIT The hardened valve seat inserts (sintered metal) had a high spot (arrow) on inside of the insert for a short time. This high spot must be turned off in order to machine the valve seat insert. There is a repair valve seat insert with larger outside diameter as a replacement part for all valve seat insert designs.
Page 274 EXIT Replacement Turn out old valve seat insert with lathe tool. Note operating instructions for the tool. Check valve guides, replace if required (05285). 3 Measure basic bore 02. A new valve seat insert standard dimension can be used, when the specified overlap exists. If the minimum overlap is not achieved, machine basic bore for valve seat insert.
Page 275 EXIT Machining valve seats Preceding work: Valve guides checked (05-285). machine in accordance with tool manufacturer’ s Valve seats (53) operating instructions. Refer to data for adjustments. Note Only loosen the pilot when eccentricity of the valve seat has been checked. check (Number 2).
Page 276 EXIT Data Valve seat Intake Exhaust Valve seat width (b) Valve seat angle (a) 45” 45” Upper correction angle Lower correction angle Permitted concentricity deviation of valve seat Minimum gap (a) on 0.1 - 0.5 0.1 - 0.5 new valves and new valve seats Gap (a) on reworked valve seats and...
Page 277 EXIT Note Clamp cylinder head in the clamp fixture for dismantling and machining. Machine valve seats with valve seat turning equipment, with valve seat grinder or valve seat miller. The location of the hydraulic valve clearance compensating elements must be checked after machining the valve seat Inserts and, if required corrected (05211).
Page 278 EXIT Insert valves and measure distance (a). Distance (a) 0.1 - 0.5 mm. outside tolerance, replace valve seat insert (05290). 05.10 - 291 4...
Page 279 EXIT Removing and installing chain tensioner OS-31 0 PO5 0182 37 Chain tensioner (224) remove, install, 65 Nm. Replace sealing ring and install chain tensioner filled with SAE 10 engine oil. 0510 3101...
Page 280 EXIT Filling chain tensioner with engine oil: Place chain tensioner with the plunger bolt downwards in SAE engine oil until over the collar on the hexagon. Press plunger up to the stop 10 times slowly with the aid of a press or power drill.
Page 281 EXIT The outside diameter of the sealing surface on the chain tensioner housrng has been enlarged by 2 mm. This necessitates a sealing ring (237) having dimensions of 27 x 32 mm (previously 25 x 30). This revision prevents the formation of burrs on the sealing ring (picture, circular cut-out) when tightening the chain tenstoner.
Page 282 EXIT Special tool...
Page 283 EXIT Renewal of timing chain Preceding work: Operation No. of Operatron Texts and Work Units, Cylinder head cover removed. Standard Texts and Flat Rates Fan and fan shroud removed (20-312 or 20-335). PO50 1 8 2 3 7 Chain tensioner (244) .
Page 284 EXIT insert connecting link from behind and rivet the Timing chain link pins individually with assembly tool 000 589 58 43 00 (Numbers 6 - 10). Tightening torque of spindle 30 35 Nm. Link pin rivet check (Number 11). After installation turn crankshaft, check adjustment marking at TDC position (Number 13).
Page 285 EXIT Since 02 89 timing chains have increased clearance sleeves (Iwis Company). Production breakpoint: not recorded Since 09 89 timing chains (Daido Company) have been installed again. Production breakpoint: 09/89 122989 023241 066158 124.133 124.193 126.135 488196 016428 533524 666204 201.126 1602.911 1082936 not recorded...
Page 286 EXIT Repair timing chain Only a riveted design of connecting link (A) is to be used. The outer clips of connecting link (A) are colored blue and its link pins have no grooves. The outer clip of revised connecting link (A) must be pressed on and riveted with assembly tool 000 589 58 43 00.
Page 287 EXIT Renewal Remove chain tensioner (05310) Check camshaft timing gear for scores and pitting. Cover chain case with a cloth and grand off both link pins at a timing chain link. Mount new timing chain with connecting link on the old timing chain. Slowly turn crankshaft in the direction of rotation of the engine, while simultaneously raising the old timing chain until the connecting...
Page 288 EXIT Place loose enclosed outer clip of the connecting link (with the IWIS marking stamped on) in assembly tool 000 589 58 43 00 (arrow). The outer clip is retained magnetically. Put assembly tool 000 589 58 43 00 on connecting link and press on clip up to the stop.
Page 289 EXIT 11 Check link pin rivet, If necessary re-rivet (arrows). 12 Install chain tensioner (05-310). 13 Turn crankshaft and check adjustment marking at TDC posltton of engine. Note If adjustment markings do not align, the camshaft timing (05215) and start of delivery of the injection pump (07.1-l 11) must be checked.
Page 290 EXIT Removal and installation of tensloner rail Preceding work: Cylinder head removed (01-4 15) 2 4 4 PO5 0182 37 Tensioner rail (215) pull off, reinstall. Note Plastic support of the tensioner rail cannot be replaced. 05 10 330...
Page 291 EXIT Note Since 08 86 unhardened straight pins have been Production breakpoint: 08186 Model Engine end No. Manual transmission transmission 124.133 003526 313431 019062 124.193 1 2 6 . 1 2 5 1 6 0 3 . 9 6 1 (- 004997 201.126 602.911...
Page 292 Dotted line shows former desrgn. Production breakpoint: 09/86 Engine end No. Vehicle identrficatron Model end No. Manual Automatic transmission 004863 342586 023347 124.133 I 603.960 124.193 389319 126.125 6 0 3 . 9 6 1 - 006205 333489 286635 201.126 028504 006859...
Page 293 EXIT Removal and installation of guide rail Preceding work: Charge air pipe removed (turbo engines). A. Removal and installation of guide rail in cylinder head Cylinder head cover (125) remove, install, bolt (132) 10 Nm. With self-levelling suspension: Pressure pump drive remove, rnstall (05437).
Page 294 EXIT Bearing pins (221, 222) remove, install. Special tools 589 20 33 00 and 116 589 01 34 00. Check guide blade (220), replace If necessary. (Number 6). Caution! The extractor 115 589 20 33 00 can be used together with stud 115 589 01 34 00 If the bearing pins have seized.
Page 295 EXIT Removal Remove cylinder head cover. With self-levelling suspension: Remove pressure 011 pump drive (05437). Align timing chain and camshaft timing gear. Remove hexagon bolt or blhexagonal head bolt on camshaft timing gear, while holding camshaft with a mandrel. Remove camshaft timing gear and allow Caution! Note different bolt and washer (05220).
Page 296 EXIT Installation Coat bearing pin collar with sealing compound. Insert guide rail and drive home bearing pin 589 20 33 00 and 116 589 01 34 00. PO5 2258 13 Install camshaft timing gear according to the marking and tighten, noting the color markings. Tightening torque and angle of rotation Hexagon bolt 65 Nm,...
Page 297 EXIT Preceding work, Guiding rail (218) ...., ..off from guiding blade bolt (222), put on. pull Check guiding rail, renew If necessary. Note Since 09 86 unhardened straight pins have been fitted for the guiding rail bearing.
Page 298 EXIT Production breakpoint: 08186 Model Engine Engine end No. Vehicle identlficatlon Manual Automatic end No. transmission 124.133 003526 313431 019062 124.193 126.125 6 0 3 . 9 6 1 - 004997 278305 201.126 602.911 025293 006190 332559 266086...
Page 299 EXIT Removal and installation of pressure oil pump drive Preceding work: Charge air pipe removed (turbo engines). 4 0 6 Cylinder head cover ....remove, Install, fixing bolt (132), 10 Nm.
Page 300 EXIT Note Since 11 88 the camshaft timing gear has been fitted with a blhexagonal necked down bolt Ml 1 (previously hexagon bolt MlO). The carrter has been revised as a result of this change. A Prewcus Design Production breakpoint: 1 l/88 Model Engine end No.
Page 301 EXIT r, Turbocharger - 09...
Page 302 EXIT System - Air Filter, Turbocharger Intake Job No. Function of turbocharger ..........09 - 050 Testing turbocharger boost pressure .
Page 303 For Callfornla with air recirculation valve. Engine 602.961, Garrett TB 025 Boost pressure control Turbine housing valve Fresh air Inlet Compressed air Bypass passage Exhaust Inlet Exhaust outlet Engine 603.96, Garrett TB 03 Boost pressure control valve Compressor housing Turbine housing 09.10 III -...
Page 304 EXIT Garrett TB 03 with air recirculation valve Boost pressure control Compressor houslng KKK-K24 with air recirculation valve Boost pressure control valve Compressor houslng General The exhaust gas turbocharger (EGT) is a flow machine. The energy of the engine exhaust gas is used for driving a turbine, which in turn drives a compressor through a shaft.
Page 305 (d) turbine wheel (i) rotating. This causes the is compressed and sent to the engine. compressor wheel (d) which is connected Functional diagram turbocharger KKK K24 (Engine 603.96) Boost pressure control valve Charge housing Shaft...
Page 306 EXIT Function diagram Boost pressure control valve ALDA unit Compressor wheel Exhaust manifold Control line Turbocharger Charge air pipe Turbine wheel Pressure switch, engine overload protection Compressor Inlet (fresh air) Switch-over valve, engme overload protectlon Compressor outlet (compressed arr) Exhaust gases to turbine wheel Exhaust outlet 09.10 III -...
Page 307 EXIT Air Recirculation Valve characteristic map. (refer also to EDS Operation No. 07.1-010) After the closing operation, a residual vacuum of In order to create more favorable combustion approx. 30 mbar is retained at the air circulation conditions for the trap oxidizer, the air recirculation valve is continuously opened or valve.
Page 308 EXIT Boost pressure Control Valve (KKK) To prevent the boost pressure from rising above a certain level, a boost pressure control valve (a) is attached to the turbine housing (h). The boost pressure is taken from the compressor housing (14) and passed through the connecting hose the boost pressure control valve.
Page 309 EXIT Idle and Lower Part Load No boost pressure occurs during idling and in the lower part load range; therefore, the engine operates as a naturally aspirated engine. Upper Part Load and Full Load As the engine load and speed increase, e.g. with an increase in the exhaust gas flow, the turbine wheel (i) is accelerated producing a boost pressure up to a certain value via the...
Page 310 EXIT 09-l Testing turbocharger boost pressure Tester (001) connect, disconnect. connect, disconnect. Pulse generator (021) connect to measuring point “ A” and test boost Tester (020) with Y distributor pressure. Tester (020) with Y distributor connect to measuring point “ B” and test boost pressure.
Page 311 If all components are in working order, replace turbocharger. Test data Boost pressure at full load in drive position “ 3” at n = 4000 rpm Special tool 603 589 03 21 00 Commercial tester e.g. Bosch, MOT 002.01 Sun, DIT 9000 Sun, FMT-101 S/Master 3,...
Page 312 EXIT Vehicle ......drive onto the platform or inspection pit. Bottom section of noise encapsulation detach, attach.
Page 313 EXIT Corrugated pipe (61) ..... remove, install. Exhaust gas recirculation valve (60) remove, install. Tightening torque 25 Nm. Trap oxidizer (139) on exhaust manifold unbolt, bolt on. Tightening torque 45 Nm. Supporting bracket unbolt, bolt on and remove at the same time with trap oxidizer.
Page 314 EXIT Remove partition wall “ A” (9 bolts), of which 6 (WAFlO) are accessible from above, 2 (WAF8) and 1 (WAFIO) accessible from below. Detach vacuum lines red/violet/brown on EGR valve and red/violet/blue on air recirculation valve. Loosen clips “ B” on corrugated pipe, and remove corrugated pipe.
Page 315 EXIT Detach engine breather hose. 10 Detach mixing pipe (135) with exhaust gas recirculation valve from cylinder head. 11 Unbolt oil feed line (141) from turbocharger (replace seal). 12 Loosen both mounting brackets (134) on the exhaust manifold and turbocharger. 13 Loosen bolts of exhaust pipe - accessible from above (arrows).
Page 316 EXIT 20 Install new trap oxidizer, insert supporting bracket at the same time and install. Tightening torque 21 Install EGR valve together with corrugated pipe. 22 Install partition panel. 23 Connect vacuum line red/violetbrown to EGR valve and vacuum line red/violetblue to air recirculation valve.
Page 317 EXIT Function of engine overload protectiom - Turbodiesel A pressure switch is installed in the charge air pipe as an overload protection for the mechanical parts of the engine. In the event that the boost pressure rises above 1 .l k 0.15 bar gauge pressure, air is admitted to the ALDA unit through the switchover valve and the fuel quantity is limited to that of a naturally aspirated...
Page 318 EXIT Pressure, vacuum diagrams (refer to 07.1-500). Wiring diagrams (refer to 07.1-400). 09.10 III - 2001’ 2...
Page 319 EXIT Testing engine overload protection Turbodiesel Injection pump Boost pressure control valve ALDA unit Compressor wheel Exhaust mantfold Control line Turbocharger Charge air pipe Turbine wheel Compressor Inlet (fresh air) Pressure switch, engine overload protection Compressor outlet (precompressed air) Exhaust gases to turbine wheel Exhaust outlet 09.10 III - 250/l...
Page 320 EXIT 2-pin connector on swrtchover valve (Y30) detach and briefly energize with voltage. The switchover valve must audibly actuate; replace if necessary. l-pin connector on pressure switch (S66) ..detach and test for continuity with ohmmeter. The pressure switch (S66) is open in the off position.
Page 321 EXIT A. Standard version and Federal as of 1984 102a Suction line (98) ..installation position. Closing catch, 6 off (92) open, close. Air cleaner cover (90) . remove, reinstall. (91) ....Air cleaner filter element remove, reinstall.
Page 322 EXIT Engine 602.91 Air cleaner cover (90) and filter element (91) of revised material. Production breakpoint: December 1989 Engine end no. Engine Engine end no. Model Manual transmission Automatic transmission 016956 201.126 602.911 086698 09.10 II - 40012...
Page 323 EXIT Model Air cleaner element (91) remove, install. Ensure correct position during installation. Air cleaner cover (90) remove, install. Air guide housing (94) ....remove, install. Air guide housing (94 a) remove, install. Cup seal (142) ......remove, install.
Page 324 EXIT Repair Instruction When the engine is running, the fender cover (right) must be removed, otherwise the fresh air intake (arrow) is blocked.

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