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Mercedes-Benz 201.024 Service Manual

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Mercedes-Benz
Mercedes-Benz of North America, Inc.
Montvale, NJ 07645

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Summary of Contents for Mercedes-Benz 201.024

  • 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 S-2347-93A...
  • Page 3 Mercedes-Benz vehicles. You should not attempt to use this manual if this 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 Group Index General, Technical Data Crankcase and cylinder head Crankshaft assembly Engine timing, valvetrain Continuous Fuel Injection System (CFI) 07.3 Air filter Belt drive Intake and exhaust manifolds, emission control system Electrical system, engine Engine lubrication system Engine cooling system Engine suspension Accelerator control, cruise control, electronic accelerator Fuel system...
  • Page 5 EXIT...
  • Page 6 EXIT technical General, Job No. Instructions for use of service manual ........00 - 005 Engine and vehicle identification .
  • Page 7 I n s t r u c t i o n s f o r u s e o f 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.
  • Page 8 EXIT This manual applies to the following passenger cars, starting model year 1984. Gasoline engines Model Year 1984 I 201.024 1985 I 201.024 I 201.028 I 190 E 2.3 1991 I 201.028 I 190 E 2.3 1992 190 E 2.3 102.985...
  • Page 9 EXIT I d e n t i f i c a t i o n n u m b e r l o c a t i o n s Model 201 When ordering spare parts, please specify chassis and engine numbers. Body No.
  • Page 10 EXIT T e c h n i c a l Gasoline engines Model 1.024 201.024 201.028 Sales 190 E 2.3 190 E 2.3 190 E 2.3 designation (Model year 1984) (Model years 1985 (Model years 1987-8, 1991-3) Engine 102.961 102.985 102.985...
  • Page 11 EXIT T e c h n i c a l Filling capacities Model 201.024 201.024 201.028 Sales designation 190 E 2.3 190 E 2.3 190 E 2.3 (Model Year 1984) (Model Years 1985 (Model Years 1987-8, 1991-3) Engine 102.985 102.961 Fuel tank/reserve approx.
  • Page 12 EXIT Crankcase and cylinder head...
  • Page 13 EXIT Crankcase and cylinder head Job No. Engine and model survey ..........01 - 001 Overview - Engines ............ 01 - 005 01 - 006 Removal and installation of bottom engine compartment cover Testing compression pressure Testing cylinder leaktightness ..........- 015 Illuminating cylinders Removal and installation of engine .
  • Page 14 EXIT 01-001 Engine and Model Survey Engine 102.961 201.024 1984 190 E 2.3 102.985 1190E2.3 102.985 1201.028 ll9OE2.3 01.1101 l-001/1...
  • Page 15 EXIT Overview - Engines, Models, Output and Compression Ratio 01-005 Sales Output in KW Compression designation at rpm ratio E : 1 net bhpirpm 201.024 190 E 2.3 190 E 2.3 12015000 190 E 2.3 01.0904 -...
  • Page 16 EXIT 01-006 Removal and installation of bottom engine compartment cover Model Self-tapping screws (arrows) remove, screw in and remove, install engine compartment cover. Note On Model 201.028 @ install engine compartment cover so that the edge of the side parts grips above the bottom part. 01.0904 .
  • Page 17 EXIT 01-010 Testing compression pressure Compression pressure recorder, special tool 001 589 76 ‘ 21 00 Adapter piece Sealing cone with check valve Test data with engine at normal operating temperature (80 “C) in bar Subject Compression ratio I aDDrox. 12 10.0 9 - 1 0 Permissible difference between individual cylinders max.
  • Page 18 EXIT Special tools 001 589 76 21 001 1 1 2 4 5 8 9 3 6 6 3 0 0 Notes Test compression pressure at normal operating temperature. If the minimum compression pressure is not reached, test cylinder leaktightness (01-015). Unscrew all the spark plugs for testing.
  • Page 19 EXIT Testing Switch off ignition. Detach connector from ignition distributor pickup (green cable on control module) (arrow). Caution! On injection engines, detach the fuel pump relay module (N1614) before turning the crankshaft to ensure that no fuel is injected. M o d e l 2 0 1 Connect compression pressure recorder.
  • Page 20 EXIT Crank engine several times with starter lever in position motor, in idle position, selector so that residues and soot are ejected. To test each cylinder, press the compression pressure recorder into the spark plug hole of the particular cylinder and, with the throttle valve fully opened, crank engine approx.
  • Page 21 EXIT 01-015 Testing cylinder leaktightness Data max. 25% Total pressure loss max. 10% At valves and cylinder head gasket At pistons and piston rings max. Tightening torque Spark plugs Special tools Commercial tool e. g. Bosch, EFAW 210 A Cylinder leaktightness tester Sun, CLT 228 Testlng Run engine until at normal operating...
  • Page 22 EXIT Top off coolant and leave filler opening at coolant expansion tank open. Remove oil filler cap. Remove air filter (09-400 or 09-410). Connect cylinder leaktightness tester to a compressed air system and calibrate tester. Position piston of No. 1 cylinder to ignition TDC.
  • Page 23 EXIT Notes It is possible that the piston ring gaps of individual pistons are directly above each other which falsifies the test result. In cases of doubt, allow vehicle to run and test cylinder leaktightness once again after some time. After spraying oil onto the piston crown, it is possible to determine whether the leak exists at the piston rings or at the valves or the cylinder...
  • Page 24 EXIT 01-020 Illuminating cylinders Preceding work: illuminate with cylinder inspection lamp (Ol), distinguish between “ optical rub marks and seizing rub marks” . “ Optical rub marks” may result from the ring gap. Traces of honing are still visible, engine in order.
  • Page 25 EXIT Removal and installation of englne 01-030 Preceding work: Removal and installation of bottom engine compartment Removal and installation of air filter (09-400 or 09-410). disconnect, connect. Battery positive cable remove, install, 25 Nm. Fan (75) ......detach (step 3).
  • Page 26 EXIT Fuel evaporation system detach, attach (step 19). Ground cable ......unbolt, bolt on at intake manifold (step 20). Accelerator control disconnect, connect Bowden cable, adjust (step 21). Fuel lines ......detach, attach (step 22). Coolant hose, heater supply line detach, attach (step 23).
  • Page 27 EXIT Engine with transmission lift out, insert (step 52). Lines, hoses and engine mounts examine for signs of wear, replace if necessary. Examine antifreeze protection, adjust to correct level if necessary. Test leaktightness. Viscosity grades for engine oils according to SAE Adhering to the SAE grades In accordance with ambient temperatures would result in frequent oil changes.
  • Page 28 EXIT Tightening torques Fan to engine coolant pump Exhaust pipe to exhaust manifold Exhaust bracket to transmission Hexagon bolt of belt pulley to power steering pump Bracket for A/C compressor to oil sump Bracket for AC compressor to AC compressor V bracket servo pump - engine supporting bracket - AC compressor Servo pump to supporting bracket Propeller shaft to transmission...
  • Page 29 EXIT Note Remove and install engine together with transmission. Disconnect battery negative terminal, connect. 2 Remove fan. install. Unplug cable connector (327) at alternator, plug in. Detach lines for pressure oil pump at cylinder head, connect (arrows). If equipped with air conditioning: install guard plate (arrow) to evaporator of air conditioning system.
  • Page 30 EXIT On Model 201, pull off rubber strip (1) above fire wall. Take out clips (arrows), fold fixture upwards. Model201 On Model 201, unplug cable connector (50) at the plug connection, plug in. Model201 10 Unbolt battery positive terminal. Disconnect terminal (30) at cable connector and pull cable through component compartment wall and place over engine.
  • Page 31 EXIT 11 Disconnect engine wiring harness at the individual connections and place over the component compartment wall. X 2 4 Engine wrnng harness, shown on Model 201 Volume air flow sensor posrtion Indicator Intake air temperature sensor, CFI qectron system Reference resistor, CFI Infectron system Connector, headlamp wrnng harness Throttle body switch connector...
  • Page 32 EXIT 13 Unplug start valve (Ye), plug in. Unplug electrohydraulic actuator plug in. Unplug idle air control valve (Y6), plug in. 14 Unplug deceleration shutoff microswitch 15 Unplug connector for crankshaft position sensor on ignition control module (N112), plug in. Unplug vacuum line (2) and 4-pin connector (3), plug in.
  • Page 33 EXIT cruise control, 17 On models equipped with unplug connector (arrow), plug in. 18 Unplug ignition cable 4 (arrow) at ignition distributor, plug in. 19 Detach vacuum lines (arrows) for fuel evaporative emission control system, attach. 20 Unbolt ground cable at intake manifold, screw on (arrow).
  • Page 34 EXIT 21 Detach Bowden cable (30) for accelerator control, attach. Press plastic guide (arrow) out of its seat in the fulcrum lever (13) to perform this step, and take Bowden cable (30) out of the slot in the fulcrum lever. Installation instruction Adjust Bowden cable (30) (30-325).
  • Page 35 EXIT 24 Disconnect vacuum line for brake booster at intake manifold (arrow), connect. 25 On models with AC compressor, disconnect electric lead at AC compressor, connect (arrow). 26 Disconnect piping group (170) at the cylinder head, connect (arrows). 27 Extract oil from the reservoir for power steering.
  • Page 36 EXIT Installation instruction Adjust oil level of power steering to correct level. When engine is running, top off oil to the marking. Turn steering several times from full left to full right lock. Oil level when oil at normal operating temperature (approx.
  • Page 37 EXIT 33 Unbolt high pressure oil pump, bolt on (arrows) and place to the side with the lines connected, tightening torque 25 Nm. 34 Unbolt AC compressor (425) at the supporting bracket, bolt on, and place to the side with lines connected. Bolts (149b), tightening torque 25 Nm.
  • Page 38 EXIT 38 Unbolt exhaust at the exhaust manifold, bolt on (arrows), tightening torque 25 Nm. 39 Unbolt exhaust holder (50 and 51) at the exhaust and transmission, bolt on, tightening torque 25 Nm. 40 Remove lambda sensor at exhaust pipe, install.
  • Page 39 EXIT 43 Unbolt shield, bolt on (arrows). 44 Unbolt drive shaft, bolt on. Loosen the bolts and nut (7a) to perform this step. Tightening torque 45 Nm. Note Flexible coupling remains on drive shaft. 45 Loosen clamping nut (2a), tighten (wrench Push drive shaft back as far as possible.
  • Page 40 EXIT 47 Unbolt ground cable (149) at transmission, bolt on. Tightening torque 45 Nm. 48 Detach shift rods at transmission, attach (arrows). Take the clip locks off the transmission shift levers to perform this step. 49 If equipped with automatic transmission, turn white plastic lock on starter lockout, backup light switch (53) approx.
  • Page 41 EXIT 51 Remove both bolts (22) for engine mounting. Tightening torque 40 Nm. 52 Lift out engine together with transmission at an angle of approx. 45” . 53 Install in the reverse order. 54 Check front and rear engine mounts. 55 Check fluid levels, adjust to correct levels necessary.
  • Page 42 EXIT 01-040 Crankcase Ventilation - Function Englne 102.985 (CFI system) 109 011 separator 202 Idle air distributor (bypass passage dia. 1.5 mm) Fresh air Function The engine blowby gases flow through the oil separator (109) at the cylinder head cover and through a pipeline to the idle air distributor (202) or to the air filter (clean air side).
  • Page 43 EXIT 01-l 10 Measuring, boring and honing cylinders Data Engine 1 st version code 102.985 letter 195.500 - 95.506 Standard 95.509 - 95.518 95.519 - 95.528 95.513 - 95.518 96.000 - 96.006 1st repair size 0 96.009 - 96.018 96.007 - 96.012 95.519 - 96.028 96.013 - 96.018 96.500 - 96.506...
  • Page 44 EXIT Note Since 04/88 the tolerance stages of piston and cylinder bore dia. have been identified with letters (hitherto figures, refer to data). As previously in the figures, the letters are also stamped in the mating face of the crankcase and in the piston crowns.
  • Page 45 EXIT Measuring Measure the cleaned cylinder bores with an internal measuring device at measuring points 2 and 3 in longitudinal direction A (piston pin axis) and in transverse direction B. With pistons installed, measuring point 3 is just above the piston, which must be at bottom dead center.
  • Page 46 EXIT 01-120 Facing crankcase parting surface Data Permissible variation of parallelism of top to bottom crankcase mating face in longitudinal direction Test pressure with air under water in bar gauge pressure 01.0904 - 120/l...
  • Page 47 EXIT Note Chamfer the cylinder bores after completing machine work. If the crankcase mating face has been remachined, the timing must be reset (05215). The timing case cover must be bolted tight to the crankcase and also be machined when machining the top or bottom crankcase mating faces.
  • Page 48 EXIT 01-130 Removal and installation of steel balls in main oil gallery Preceding work: Removal of engine coolant pump (20-210). Removal of flywheel (03-410). knock out together from back to front with a Both steel balls round steel bar (dia. 11 mm, approx. 500 mm long).
  • Page 49 EXIT Notes The main oil gallery is closed with steel balls, dia. 15 mm at the front, dia. 12 mm at the rear. When reconditioning the engine, the steel bails must be knocked out from the rear in order to clean the main oil galleries.
  • Page 50 EXIT This is done by tapping an Ml 6 X thread approx. 10 mm deep at the front of the main oil gallery. Thoroughly remove chips from the oil gallery. Coat Ml6 x 1.5 screw plug Part No. 000 906 016 002 with sealing adhesive 002 989 94 71 and screw in (arrow).
  • Page 51 EXIT 01-140 Replacing core plug in crankcase drain completely, pour in (20-010). Coolant ......Components which restrict access ...
  • Page 52 EXIT Special tools ~ 0 2 5 8 9 0 0 1 5 0 ~ Replacement Completely drain engine coolant (20-010). Remove components which restrict access. Position a chisel with narrow blade or a screwdriver into the deep-drawn edge of the Carefully knock in plug on one side far enough for it to turn through its own longitudinal axis (approx.
  • Page 53 EXIT Knock in new core plug with the matching mandrel. Special tool mm 0 102 589 00 15 00 102 589 03 15 00 8 Install removed components. Add engine coolant (20-010). 10 Run engine until warm and check leaktightness. 01.0904 - 14oi3...
  • Page 54 EXIT 01-210 Removal and installation of tlmlng case cover Preceding work: Removal of radtator (20-420). Removal of power steering pump (46-710). Removal of torsion bar (32-300). Removal of 011 sump (01-310). Removal of V-belt tensioning device (13345). Removal of vibration damper or hub and belt pulley (03-342) Removal of engine coolant pump (20-210).
  • Page 55 EXIT Connector (327) .... unplug at alternator, plug in (step 5). Alternator (G2) unscrew, screw on, 30 Nm (step 6). (156) Bracket for alternator, unbolt, bolt on, 25 Nm (step 7). TDC pulse generator cable (1) . unbolt, bolt on (step 8). If timing case cover has been replaced, the TDC pulse generator bracket must be adjusted (03345).
  • Page 56 EXIT Notes The timing case cover closes off the crankcase at the front. It is fixed in position with 2 straight pins 10 x 14 and attached to the crankcase with 15 hexagon bolts. The timing case cover is sealed to the crankcase with the sealant Loctite 573, Part No.
  • Page 57 EXIT To avoid any engine coolant mixing with the engine oil should a leak occur between crankcase and timing case cover, a groove (arrows) has been provided around the coolant inlet (h) to allow the coolant to flow to the outside.
  • Page 58 EXIT Standard imcblementation: Engine End No. Model 020073 201.028 Removal Remove cylinder head cover (01-406). Remove hexagon socket bolts (3 off MB, arrows) in the chain box with a stud wrench 116 589 03 07 00. Tightening torque 25 Nm (reference value).
  • Page 59 EXIT On models equipped with AC compressor, unbolt compressor. Unbolt bracket (b) to perform this step. Place A/C compressor to the side with the pipe group connected. Unplug connector (327) at the alternator, plug in. Remove bolts (49 and bolt on; remove alternator, insert.
  • Page 60 EXIT Unbolt bracket (8) for oil pump strainer basket, bolt on (arrows). 10 Remove remaining bolts (arrows) for timing case cover. 11 Remove timing case cover. Caution! Do not damage cylinder head gasket. Replace cylinder head gasket if damaged. Installation 12 Clean mating faces.
  • Page 61 EXIT 15 If the radial seal has been removed, insert new radial seal with the sleeve 102 589 00 14 00. Install spacer ring (01) 102 589 01 14 00 for the timing case cover with double roller chain. Note If the timing case cover has been replaced, the TDC pulse generator holder must be adjusted (03-345).
  • Page 62 EXIT 01-222 Removal and installation of end cover Preceding work: Removal of transmission (26-020 or 27-600). Removal of flywheel (03-410). - 3 4 End cover (19) ......remove, install (pay attention to instructions).
  • Page 63 EXIT Notes The center installation position relative to crankshaft center is fixed with two roll pins (17). Press end cover off at both side plates (arrows). 17 Roll pin Bolt-washer assy (M6 x 22) Bolt-washer assy (M6 x 65) Push end cover with radial seal installed in place over the bolted-on assembly sleeve.
  • Page 64 EXIT 01-310 Removal and installation of oil pan Preceding work: Removal of air filter (09-400 or 09-410). Removal of bottom engine compartment cover (01-006). Removal of torsion bar (32-300). Engineoil ......drain, add.
  • Page 65 EXIT Pipe clip (53) ..unbolt, bolt on, 25 Nm (step 5). Replace nuts 2 off MlO, unbolt, bolt on, 45 Nm (step 6). Bolts (22) ..unbolt, bolt on, 45 Nm, attach engine hoist to suspension lugs and raise (steps 7 and 8).
  • Page 66 In addition, the diameter has been increased from 3 mm to 3.15 mm. Color: green (previously black). Standard implementation: 09186 Engine Model 201.024 @ 102.985 In June 1987 the O-ring of the oil level pickup was once again modified. Modification 37.20 40.20...
  • Page 67 EXIT Removal and installation 1 Drain engine oil. Unplug cable (351a) at the oil level pickup, plug in. Detach clips (la) for fan shroud, detach, attach fan shroud (1) place over fan. Unbolt exhaust pipes at exhaust manifold, bolt on (arrows). Unscrew pipe clip (53) at the front exhaust bracket to the transmission.
  • Page 68 EXIT Remove two bolts at the transmission - engine joint (MlO, arrows), bolt on. Tightening torque 45 Nm. bolts (22) for engine Tightening torque mounting fixture, bolt on. 45 Nm. Len side shown Raise engine with the engine hoist. Remove remaining bolts (32, 34) for attaching oil pan, bolt on and remove oil pan.
  • Page 69 EXIT 11 install oil pan with new gasket. Pay attention to bolt lengths and tightening torques. 12 Lower engine and attach engine mounts. 13 Add engine oil and adjust to correct level. 14 Check for leaks with engine running. 01.0904 .
  • Page 70 EXIT 01-403 Repair instructions for crankcase, cylinder heads and cylinder head gaskets Crankcase The tapped hole for attaching the power steering pump carrier (compared to engines with multi- belt drive) have been converted from M8 to MlO. The M 38 X 1.5 tapped hole for mounting the coolant preheater on the left side is shorter.
  • Page 71 EXIT the same time, the crankshaft bearing covers are 8 mm lower (H = 40 mm). Engines with multi-belt drive (102.985) (102.961) Fastening bolts of the crankshaft bearing covers converted to Ml 62 twelve-side stretch bolts with collar. Previously, Ml 2 70 hexagon bolts.
  • Page 72 EXIT Because of the lengthened bolt extensions, the power steering pump carrier has been provided with a semi-circular cutout at the second reinforcing rib (arrow). Standard Implementation: 06186 Engine End No. transmission Cylinder head The same cylinder head is installed on engines 102.9221924 as on engines 102.962/982/985.
  • Page 73 EXIT A core plug, Part No. 000 443 025 003 should be inserted with MB sealant 002 989 94 71 and the installation mandrel 102 589 02 15 00 for engine 102.985. Caution! If the core hole is not closed (arrow), coolant may get into the cylinders on engine 102.985.
  • Page 74 EXIT No oil passage is provided at the 4th bearing point for camshaft lubrication (arrow). Cylinder head gasket Cylinder head gaskets of asbestos-free material were installed for a certain period on engines 102.985. Standard implementation: Vehicle ldent End No. not covered cylinder head gasket in the chain box area was modified with implementation of the double roller chain (6, arrow).
  • Page 75 EXIT Standard imDlementation: Model To achieve greater clearance for the double roller chain, the front wall at the cylinder head was lengthened. In addition, the bolt extensions were flattened off at the radius (f). A Single roller charn Standard implementation: 01188 01 .OW4...
  • Page 76 EXIT Removal and installation of cylinder head cover Preceding work: Removing air filter (09-400 or 09-410). PO1 - OOll- 37 Ignition cable (16) unplug at distributor cover, plug in. Ignition distributor cover (15) unbolt at distributor, bolt on. Spark plug connector (d) detach from spark plugs, fit on.
  • Page 77 EXIT Special tool Notes The cylinder head cover is manufactured from a magnesium alloy and is coated on the outside A two-part, glass fibre reinforced polyamide rectangular tube (107) in which the ignition cables run is inserted in a longitudinal groove of the cylinder head cover.
  • Page 78 EXIT The spacer sleeves (arrows) prevent the gasket being squeezed when tightened. In January 1986 a cylinder head cover made of plastic was fitted (on engines without pressure oil pump for level control). Distinguishing features: (151) Collar bolt Hose connection for crankcase ventilation with larger OD.
  • Page 79 EXIT Model affected Model As of February/March 1985 the oil separator is installed in the cylinder head cover with a vent pipe. A 1 st verson Standard implementation: 02/85 On models with level control 0 1 . 0 9 0 4...
  • Page 80 Standard implementation: Model Engine Engine End No. Manual transmission 201.024 @ 102.985 Since 12:88 cylinder head cover has been installed which has a recessed wall (arrows) in the area of the spark plug recesses. This prevents the valve spring or the valve spring plate rubbing the cylinder head cover and causing noises.
  • Page 81 EXIT Reconditioning spark plug thread In cylinder head 01-407 Special tool Note The spark plug threads in the cylinder head can be reconditioned on all gasoline engines with the HELI-COIL repair set. The cylinder head should only be removed for reconditioning the spark plug thread if the spark plug bore in question is not accessible for the Recondltionina...
  • Page 82 EXIT Pack grooves of the combination tap (9) of the tapping unit (1, ill. note) with grease and screw combination tap into the damaged thread. At the same time, press the guide bush (11) into the spark plug recess. Screw in combination tap far enough for the guide tube (12) to move up and be touching the stop ring (10).
  • Page 83 EXIT Install installation tool onto the tapped hole, hold jacket sleeve (15) tight and turn spindle for long enough until the stop ring (14) is touching the jacket sleeve. Note When installing the HELI-COIL thread insert, turn back jacket sleeve slightly (15) if it is jamming. Break off bar (arrow) of the HELI-COIL thread insert.
  • Page 84 EXIT Mill mounting seat for the copper seal (7). This is done by screwing in the guide mandrel (4) far enough for the stop collar (arrow) to be touching the tapped hole. Push milling cutter (5) over guide mandrel and mill the seat for the sealing ring.
  • Page 85 EXIT Removal and installation of cylinder head Preceding work: Removal of air filter (09-400). Draining engine coolant (20-010). Removal of guide rail in cylinder head (05340). Fan shroud (1) and fan (75) ....remove, install, 25 Nm (steps 1 and 2).
  • Page 86 EXIT Engine coolant hose (68) supply line for heater disconnect, connect (step 9). Engine wiring harness ....disconnect, connect (steps 10 to 14). Brake booster vacuum line disconnect, connect (step 15). Fuel lines ......disconnect, connect, dump overpressure (step 16). Air conditioning pipe group holder disconnect, connect (step 17).
  • Page 87 EXIT Special tools 001 589 7221 00 001 589 51 21 Ot 001 589 6621 00 Note Remove cylinder head together with camshaft, intake manifold and exhaust manifold once engine has cooled down. Removal and installation Detach fan shroud (1) and place over fan. When installing, ensure clearance to fan.
  • Page 88 EXIT Unscrew dipstick guide tube at exhaust manifold, screw in (arrow). Detach Bowden cable (30) for accelerator control, attach, press plastic guide (arrow) out of its seat in the fulcrum lever (13) to perform this step, and take Bowden cable (30) out of the slot in the fulcrum lever.
  • Page 89 EXIT Detach coolant hose (68) of supply line for heater, attach. Detach connector pickup of control cable (arrow) and 4-pin connector pickup (3) at ignition control module, plug in. 10 Detach cable from reference resistor (R16) (Model 201 only). 11 Unbolt terminal TD at the diagnostic connector (Xl 1) bolt on.
  • Page 90 EXIT 14 Disconnect vacuum line for brake booster, connect (arrow). 15 Lower fuel pressure in the fuel lines by briefly opening fuel filler cap. Unbolt fuel lines (379, 380), bolt on. When detaching the fuel line (380), hold connection to prevent it from turning.
  • Page 91 EXIT 18 Loosen bottom bolt (49) for alternator fixture, tighten. 19 Remove top bolt (51) swivel alternator out of the way to the outside (arrow). 20 Unscrew locking nut (40) of the chain tensioner, bolt on. Replace seal (41). Tightening torque 70 Nm.
  • Page 92 EXIT 23 Unbolt camshaft gear, remove and bolt on. Place timing chain in chain box. Tightening torque 80 Nm. Hold camshaft gear tight with an open-end wrench (waf 24 mm) for loosening or tightening the camshaft bolt. 24 Check setting marking on camshaft (arrow). 25 Unscrew hexagon socket bolts (arrows) with the pin wrench 116 589 03 07 00, screw on.
  • Page 93 EXIT 26 Remove cylinder head bolts in stages in the reverse order of the tightening diagram with the torque wrench insert 617 589 00 10 00 with engine cold. 27 Remove cylinder head (51). 28 Clean mating faces on cylinder head and crankcase.
  • Page 94 EXIT 32 Tighten cylinder head bolts in stages in the order of the tightening diagram, beginning with 1st tightening stage 55 Nm 2nd tightening stage 90” angle of rotation 3rd tightening stage 90” angle of rotation Hexagon socket bolts (a), 25 Nm. 33 Check for leaks with engine running.
  • Page 95 EXIT 01-416 Matching measuring sensors to cylinder head Note Different temperature switches, thermo-time switches or thermovalves are installed in the measuring sensor box on the cylinder head depending on the engine version. Items on cvlinder head Item 1 Temperature switch for magnetic fan coupling and 2nd stage auxiliary fan red 100 “...
  • Page 96 EXIT Item 2 Temperature sensor for AX compressor blue. and 5 Item 2 Screw plug Ml4 x 1.5 Item 3 Thermovalve for: 60 “ C Ignition switchover white Purge 50 “ C black 40 “ C Item Temperature switch for intake manifold heater black 110 “...
  • Page 97 EXIT Temperature sensor for: CFI control black Ignition control and CFI control module green Temperature sensor for CFI injection system black. Double temperature sensor for ON board, CFI control and ignition control black. Item 6 Temperature sensor for instrument cluster. 010904 _ 416:3...
  • Page 98 EXIT 01-418 Facing cylinder head mating face Data mating face 01.0904 - 418il...
  • Page 99 EXIT Valve clearance to cylinder head mating face 102.961 @ as of 1984 Engines Minimum clearance “ A” with new Inlet (172) valve seats and valves Exhaust (173) Inlet (172) Maximum clearance “ A” with machined valve seats and reground Exhaust (173) valves Commercial tools...
  • Page 100 EXIT 01-419 Enlarging camshaft bearing bores (repalr size) Preceding work: Removal and installation of cylinder head (01-415). Removal and installation of camshaft (05-220). Disassembling cylinder head. Camshaft bearing data Normal size Camshaft bearing dia. D Journal dia. Dl Repair size Camshaft bearing dia.
  • Page 101 EXIT Note If bearing seizure or severe scoring is present, the camshaft bearings in the cylinder head can be enlarged by 0.5 mm and camshafts with oversize bearing journals installed. These camshafts have different code numbers If the rocker arm bearing brackets are equipped for enlarging without the rocker arm shafts, the fastening bolts of the bearing brackets must be tightened to max.
  • Page 102 EXIT The bearing brackets differ. Each bearing bracket has a number stamped to identify it. This number must agree with the number stamped on the cylinder head (arrows). If correctly installed, the contact faces for the oil pump are facing to the rear and the code numbers are on the righthand side (direction of travel) (arrows).
  • Page 103 EXIT 01-420 Pressure-testing cylinder head Pressure-testing plate ....bolt onto cleaned cylinder head. Bores and connections Compressed air hose connect and adjust compressed air to 2 bar gauge pressure. Cylinder head ......Attach to suspension device and immerse into the heated water (approx. 80 “ C). If air bubbles rise up, determine leak point and mark.
  • Page 104 EXIT Crankshaft assembly 03...

  • Page 105: Table Of Contents

    EXIT Crankshaft assembly Job No. 03 - 310 Checking, replacing and torquing conrod bolts Reconditioning and checking angles on bearing bores 0 3 - 3 1 3 Removal and installation of pistons -316 Checking and reconditioning crankshaft ........-318 Installation of crankshaft bearings Replacing front crankshaft radial seal Replacing rear crankshaft radial seal Removal and installation of grooved bail bearing in crankshaft...

  • Page 106: Checking, Replacing And Torquing Conrod Bolts

    EXIT 03-310 Checking, replacing and torquing conrod bolts shaft dia. If the dia. reaches or is less than the minimum shaft dia. of 7.1 mm, replace the conrod bolt. Thread and bolt head contact surface . torque 1 OO", Angle of rotation torque 90 - use special tool 001 589 66 21 00.
  • Page 107 EXIT Special tool Note In September 1988 conrod bolts with a longer thread were installed. These conrod bolts are not supplied as replacement parts. A 1st version...
  • Page 108 EXIT Standard imolementation: 09/86 Engine Engine End No. Model Manual Automatic transmission transmission 102.985 027063 - 028449 201.028 If no torque wrench is available, the conrod bolt can be tightened according to the specified torquing angle with a socket wrench in a single operation.
  • Page 109 EXIT 03-313 Reconditlonlng and checking angles of bearing bores bolt (28) check (03-310). install without bearing shells (31 and 31a), oil thread and bolt head contact surface, 30 Nm. Basic bore ....measure; if the value of 51.619 mm is exceeded, or if it is conical, dress bearing cover up to max.
  • Page 110 EXIT (25) check angles of bearing bores with conrod tester. Align conrod bearing bore to small end bushing bore (steps 7 and 8). Axial twist to small end bushing bore, check (step 9). Special tool Commercial tool Hahn & Kolb D-7000 Stuttgart Model BC 503 03.0905 - 313!2...
  • Page 111 EXIT Data Centre of conrod bearing bore to center of small end bushing bore 144 95 145.05 (L, Fig. para 4) Width of conrod at conrod bearing bore and at small end bushing bore 22 000 21.948 Basic bore for conrod bearing shells 51 600 51.619 Basic bore for small end bushing (Dl, Fig.
  • Page 112 EXIT Note The end play of the conrod is limited not at the crankshaft journals but at the piston pin bosses (piston-guided conrod, arrows). of a bearing damage (blue discolouration), must not be reused. together. The conrod shaft must not show any cross scoring and notches.
  • Page 113 Engine Engine End No. Vehicle ldent End No. transmission 201.024 102.961 201.024 @ 102.985 not covered Effective 09/89 all conrods are subject to additonal heat treatment to prevent conrod distortion resulting in noises when the engine is operating at normal temperature.
  • Page 114 EXIT Press in new small end bushing so that the Press-fitting pressure 2500 N. Hollow out small end bushing by turning or reaming. Dress side contact faces of conrod on the surface plate. Checking angles Check angles of bearing bores with a conrod tester.

  • Page 115: Removal And Installation Of Pistons

    EXIT Removal and installation of pistons 03-316 Preceding work: Removal of engine (01-030). Removal of cylinder head (01-415). Removal of oil pan (01-310). unbolt, bolt on, 30 Nm and 90” angle of rotation bearing cover (26) torque. Do not mix up top and bottom bearing shells.
  • Page 116 EXIT Piston (32) check condition, pay attention to installation position. check condition, pay attention to installation Piston rings (33, 34 and 35) . . position, “ Top” must face upwards. Position ring gaps evenly around circumference of piston. Piston (32) with conrod (25) . . . install with tensioning strap 000 589 04 14 00, oil piston beforehand and clean cylinder bores (steps 10 and 11).
  • Page 117 EXIT Engine Group No. Repair size 2 (+ 1.0) Standard (normal size) Repair size 1 95.991 Repair size 2 03.0905 - 31613...
  • Page 118 EXIT Test data When new Wear limit with Group No. 0, 1 or 2 Piston play with Group code letter A, X or B End gap of piston rings Note The pistons and cylinder bores are arranged into three diameter groups within the tolerance and were previously identified with the figures 0, 1 and 2.
  • Page 119 EXIT Only pistons with the Group code letter “ X” are supplied for repair purposes. These pistons should also be installed in the cylinder bores with the Group code letters “ A” or “ B” . Only pistons with Group code letters are also supplied for the previous engines with Group numbers 0, 1 and 2, namely piston “...
  • Page 120 EXIT Caution! A recess with a diameter of 50 mm appears on the piston crown of pistons in repair size version. Piston crown smooth, two valve niches Engine 102.985 Recess in piston crown, two valve niches dia. D 70 mm vanes according to piston (normal size, repair srzes) All low compression engines have a step on the...
  • Page 121 EXIT 102.985 @ As the design of the piston crown (flat, recess or step) has an influence on the compression, the pistons are not interchangeable. Two repair sizes (each step + 0.5 mm dia.) are approved for the pistons of all engines. The shape of the piston and the roughness of the grinding pattern of the pistons has been modified from 0.8 mm to 1.2 mm on Engine...
  • Page 122 EXIT On engine 102.985 @ the rectangular ring manufactured by Gotze is installed in groove I of the piston manufactured by Mahle and KS. The running surface of this piston ring is chrome-plated, asymmetrically crowned and sharp-edged at the bottom to reduce oil consumption.
  • Page 123 EXIT Removal and installation Unbolt conrod bearing cover and remove Check conrod bolts (03310). Remove piston pin locking element with screwdriver and press out piston pin. Recondition conrod and check angles of bearing bores, if necessary (03-313). If the pistons are worn, check the gap clearance and end play of the piston rings (refer to table).
  • Page 124 EXIT Press in piston pin by hand. Insert piston pin locking element into the groove. 10 Oil cleaned cylinder bores, conrod bearing journals, conrod bearing shells and pistons. install piston into cylinder bore with arrow facing in direction of travel. 12 Mount conrod bearing cover onto the conrod with the code marks (arrows) aligned with each other and torque conrod bolts to an initial torque...
  • Page 125 EXIT 14 Measure the distance between piston crown and crankcase mating face with the pistons in the TDC postion (refer to table). 03.0905 . 316111...

  • Page 126: Checking And Reconditioning Crankshaft

    EXIT Checking and reconditioning crankshaft Data width 28 000 28.084 Normal size II up to 28.30 4th repair size 03.0905 - 31811...
  • Page 127 EXIT Permissible out-of-roundness of crankshaft journals and crankpins 0.0025 crankpins Permissible conicity 0.010 crankshaft journals 0.010 Permissible axial runout of fit bearing 0.02 Fillet radii at the crankshaft bearing journals 2.0 - 2.2 crankpins 2.8 - 3.0 Bearing journals ground and fine-lapped, max peak-to-valley height R, (pm) 0.15 Crankshaft journal1 dia.
  • Page 128 EXIT Special tool Note Adhere to the sequence of operations of the diagram below when checking and reconditioning crankshafts. Dianram diagram” .
  • Page 129 EXIT A. Checking, grinding Severe damage Scrap Crack test ‘ ) Cracks present Hardness test ‘ ) All journals/crankpins Scleroscopic hardness at least 60 at 213 of circumference of journallcrankpin Measuring journals/crankpins Do dimensions agree Check whether regrinding still possible within the last specified repair size 4.
  • Page 130 EXIT Grind crankshaft Dimensional inspection Refer to Checking/Regrinding Fit parts to crankshaft End of inspection...
  • Page 131 EXIT Check whether regrinding is still possible within the last specified repair size Scrap Hardening ‘ ) Journal without radius hardening Induction hardening Induction or flame hardening System available Check hardening by etching ‘ ) Journal without radius hardening 03.0905 -...
  • Page 132 EXIT Explanatory notes regarding diagram Crack test Clean crankshaft. The bearing journals must be free of oil and grease. Magnetize crankshaft and apply fluorescent powder (flux). A dye penetration method (immersing in bath or with spray can) may also be used. Helpful tools: die, UV oil or fluorescent powder,...
  • Page 133 EXIT Corrosion protection Inspection of hardening Crankshafts which are not immediately re- To achieve proper hardening, check the setting installed, must be oiled with initial operation of the hardening system by metallographic engine oil (SAE 30). ground surfaces. These can be removed from test hardening operations on scrapped crankshafts.
  • Page 134 EXIT Installation of crankshafts bearings 03-320 Preceding work: Main oil passage in crankcase open (01-l 30). Clean 011 passages In crankcase and in crankshaft. Check crankshaft for cracks, dimenslonal tolerance, hardness and concentricity (03-318). install without bearing shells, pay attention to Crankshaft bearing covers (2 and 2 a) markings, tighten.
  • Page 135 EXIT Crankshaft bearing shells insert, adhere to tightening torques (step 4). measure and note values (step 5). Bearing diameters ....... Crankshaft (1) measure crankshaft bearing journals, determine bearing play (step 6). Thrust bearing journals measure width and match appropriate thrust washers (step 7).
  • Page 136 EXIT Special tools Commercial tools e. g. Hahn und Kolb Quick caliper for internal measurements, dia. 40 - 60 mm D-7000 Stuttgart 30 Order No. G 222 K Quick caliper for internal measurements, dia. 60 - 80 mm Order No. G 322 K Order No.
  • Page 137 EXIT Data Crankshaft Crankshaft Thrust bearings Crankshaft Wrist pin width ournal width dia. normal size and bearing journal Matched repair sizes dia. thickness of thrust washers 4.15 47 955 Normal size 28 500 28 000 28.521 47.965 57.965 28.084 4.20 28.621 57.960 Normal size I...
  • Page 138 EXIT Notes Engine removed and disassembled. Main oil passage in crankcase open (01-130). Oil passages in crankcase and in crankshaft carefully cleaned. Crankshaft checked for cracks, hardness, dimensional tolerance and concentricity (03-318). thrust washers Normal bearing shells and installed on the 3rd crankshaft bearing (thrust bearing).
  • Page 139 EXIT Thrust washers of the same thickness must always be installed on both sides. It is not permitted to regrind thrust washers. The thrust washers are available only as sets as replacement parts. A set consists of one top and one bottom thrust washer (23 and 23a).
  • Page 140 EXIT At the same time, the crankshaft bearing covers were reduced in height by 8 mm (H = 40 mm). H 48 mm B 2 4 m m B 2nd version H 4 0 m m B 20 mm Likewise, the bolts of the crankshaft bearing covers were converted to M 11 X 62 twelve-sided stretch bolts with collar.
  • Page 141 EXIT Standard implementation: 06186 During the period November through December 1987 and December 1987 through January 1988, single-section thrust washers from two different suppliers were installed. A Two-section thrust washers B Single-sectlon thrust washers 03.0905 . 32018...
  • Page 142 EXIT Matching crankshaft bearings, installing crankshaft Note These operations should be performed if the dimensions of the crankshaft journals or of the basic bearing bores in the crankcase and at the have been remachined. All the bearing covers fit into the side of the crankcase (arrows) and are attached each with 2 bolts.
  • Page 143 EXIT Insert crankshaft bearing shells, install bearing covers, screw in fastening bolts and tighten to 90 Nm (hexagon bolts) or 55 Nm initial torque and 90” angle of rotation torque (stretch bolts), respectively. Bearing shells in crankcase Thrust bearings with thrust washers 03.0905 .
  • Page 144 EXIT Measure and note bearing diameters. Measure crankshaft bearing journals, determine radial play of crankshaft bearings. Note Bearing play can be corrected by replacing the bearing shells (refer to table for matching crankshaft bearing shells to crankcase). Measure width of thrust bearing journal and match appropriate thrust washers (refer to table, Section 11 Data”...
  • Page 145 EXIT Caution! The two oil grooves (arrows) in the thrust washers must be facing the crankshaft webs. 10 Install thrust bearing cover. Caution! Oil thrust washers with engine oil and place into the grooves on the thrust bearing cover. The two oil grooves in the thrust washers must be facing the crankshaft webs.
  • Page 146 EXIT Matching conrod bearings and installing 15 Recondition conrod and check angles of bearing bores relative to each other 16 Insert conrod bearing shells. Install conrod bearing cover with bearing shell and tighten angle of rotation torque of 90” . Note yellow version.
  • Page 147 EXIT 20 Tighten conrod bolts to an initial torque of 30 Nm and angle of rotation torque of 90” . Caution! Remove oil pump, clean, replace, if necessary, oil pump gears and drive sleeve (18-210). Remove oil pressure relief valve and check ease of movement of pistons (18-215).

  • Page 148: Replacing Front Crankshaft Radial Seal

    EXIT 03-324 Replacing front crankshaft radial seal Preceding work: Drain coolant (20-010). Remove radiator (20-420). Remove poly V-Belt (13-342). Remove belt pulley and vlbratlon damper (03342). Radial seal (45) remove, replace and install (steps 1, 3 and 4) Spacer ring check, replace if necessary (step 2).
  • Page 149 EXIT Special tools 1 0 2 5 8 9 0 0 1 4 0 0 102 58901 14 00 102 58900 33 Notes Since August 1986 (implementation of use of double roller chain) a 4 mm narrower radial seal has been installed. Size “...
  • Page 150 Size “ E” 0.8 mm (previously 2 mm). Standard implementation: 08/86 vibration damper 267452 102.985 004202 039381 201.024 @ A radial seal of a further manufacturer was installed for a certain period. Identification: outer ring black inner ring...
  • Page 151 EXIT Removal and installation Note Before replacing the front crankshaft radial seal, it is necessary to determine whether the leak is occurring at the timing case cover itself (shrink holes, cracks). This is done by cleaning the bottom area of the timing case cover free of oil, drying and spraying it with “...
  • Page 152 EXIT Check whether the sealing lip of the radial seal has worn at the spacer ring (7) (groove). If necessary, remove spacer ring with the puller 102 589 00 33 00. If necessary, install new spacer ring. Oil the sealing lip of radial seal (45). Caution! Do not use any grease.

  • Page 153: Replacing Rear Crankshaft Radial Seal

    EXIT 03-327 Replacing rear crankshaft radial seal Preceding work: Removing flywheel or driven member (03-410). Radial seal (20) remove, replace and install. Mounting hole clean, check. Sealing lip oil. Leaks when engine running ....check. 03.0905 - 327/l...
  • Page 154 The radial seal1 is installed into the end cover flush without any sealant. Oil leaks can be determined after spraying the cleaned and dried surrounding area with Mercedes-Benz contrast spray white, Part No. 000 989 03 59. 03.0905 - 32712...
  • Page 155 EXIT Removal and installation Press radial seal out of the end cover with a screwdriver. When performing this step, ensure that the crankshaft flange and the mounting hole in the end cover are not damaged. Cover over crank- shaft flange with a rag. Check running surface for radial seal on the crankshaft for signs of damage.
  • Page 156 EXIT Press the radial seal (arrow) into the end cover as far as the stop with the outer part of the installation tool. Caution! The radial seal must be positioned exactly at right angles to the crankshaft flange or inner part of the installation tool to ensure that it provides a proper seal.
  • Page 157 EXIT 03-330 Removal and installation of grooved ball bearlng in crankshaft Preceding work: Grooved ball bearing (19) and locking ring (21) withdraw, special tool 000 589 33 33 00 and 000 589 25 33 00. Before installation, coat outer race of grooved ball bearing with adhesive 002 989 94 71.
  • Page 158 EXIT Special tools Removal and installation Withdraw grooved ball bearing with locking ring from the crankshaft, special tool 000 589 33 33 00 and 000 589 25 33 00. Coat the new grooved ball bearing with the adhesive 002 989 94 and knock the outer race with a suitable drift to insert it into the crankshaft as far as the stop.
  • Page 159 EXIT Removal and installation of vibration damper or hub and belt pulley 03-342 Removing radiator (20-420). Retaining lock on starter ring gear remove and install, special tool 601 589 02 40 00. Belt pulley (13) ......unbolt, bolt on, 25 Nm. Hexagon bolt (8) ......
  • Page 160 EXIT Commercial tool e. g. Hazet D-5630 Remscheid Order No. 1058 R-l On vehicles with air conditioning/automatic climate control, the belt pulley (13) was installed with a hub with rubber part (38, damping part) with ball bearing (40) up to December 1984. The uneven running of the crankshaft, particularly at low engine speeds and during by the coupling so that the V-belt runs practically...
  • Page 161 EXIT In order to provide greater clearance for the top shock absorber of the poly V-belt tensioning device, the shape of the vibration damper has been modified. mm dia., previously Size “ a” = 133.1 145 mm dia. A 1st version Standard implementation: 102.985 201.028...
  • Page 162 EXIT (15) Remove bolts and take off belt pulley (13). Tightening torque 25 Nm. Remove bolt (8) and take off Eelleville spring washers (10). Installation Instruction Oil bolt threads and Belleville spring washers. Install Belleville spring washers with curved side facing bolt head.
  • Page 163 EXIT Pull off vibration damper (11) with the puller 103 589 00 33 00. Installation instruction When installing the vibration damper, check whether the groove in the hub is aligned with the Belleville spring washer in the crankshaft.

  • Page 164: Checking And Correcting Setting Of Tdc Pulse Generator

    EXIT 03-345 Checking and correcting setting of TDC pulse generator Preceding work: Removing poly V-belt (13-342). Removing cylilnder head cover (01-406). Removing spark plugs (15-016). remove and install (step 1). coupling No. 1 set to ignition TDC (step 2). cylinder piston ..... No.
  • Page 165 EXIT setting measure by attaching dial gauge holder 363 589 02 21 00 to cylinder head. Mount valve on piston crown. Turn back crankshaft to approx. 10” before TDC of No 1 cylinder. Inset-t dial gauge in holder. Fit tracer pin of dial gauge onto valve stem with preload of 2 mm.
  • Page 166 EXIT 363 589 02 21 00 001 589 51 21 001 1102589 01 61 001 104 58900 3700 Commercial tool Dial gauge A 1 DIN 878 Mahr D-7300 Esslingen Order No. 311000 Notes The TDS pulse generator with holder (1) is attached to the timing case cover.
  • Page 167 EXIT The crankshaft setting 20” after TDC is de- termined from the piston travel, starting from ignition TDC of No. 1 piston. The piston travel is measured either with the intake valve of No. 1 cylinder mounted on the piston crown and dial gauge or, if the cylinder head is removed, directly by mounting the dial gauge pin on the piston crown.
  • Page 168 EXIT Remove and install valve spring at No. 1 intake valve (05-250). Remove and install valve stem seal of No. 1 intake valve. Oil new valve stem seal and press on by hand. Mount assembly sleeve on the valve stem for performing this step (05-270). Mount valve on piston crown.
  • Page 169 EXIT Insert dial gauge with extension. 10 Mount dial gauge with 2 mm preload onto the valve stem or piston crown. 11 Slowly turn crankshaft in direction of rotattion of engine until the larger pointer of the dial gauge stops (TDC setting). 12 Unscrew hexagon nut (la) and withdraw TDC pulse generator (1).
  • Page 170 EXIT Adjustment 16 Loosen nut (2a) and move setting slide (2) far enough for the pin on the vibration damper to engage in the groove of the fixing device. 17 Tighten nut (2aj and withdraw fixina device. 18 Insert TDC pulse generator and bolt on. 19 Remove dial gauge and dial gauge holder.

  • Page 171: Removal And Installation Of Crankshaft Gear

    EXIT 03-350 Removal and installation of crankshaft gear Preceding work: Removing liming case cover (01-210). Removing chain tensioner (05-310). Timing chain (21) camshaft gear (4) and crankshaft gear (5 or 5a) ....mark relative to each other (steps 1 and 2). Camshaft gear (4) .......
  • Page 172 EXIT Crankshaft gear (5 or 5a) pull off with puller 102 589 05 33 00 together with oil pump drive sleeve. Transfer colour marking to new crankshaft gear. Knock in crankshaft gear, if necessary, with drift 116 589 07 15 00, pay attention to straight pin (6) (steps 5 through 8).
  • Page 173 EXIT Removal and installation Mark timing chain and camshaft gear rerlative to each other. Mark timing chain and crankshaft gear relative to each other. I /\ Unbolt camshaft gear and place timing chain in chain box. Pull tensioning rail (22) off bearing pin (26) . Note engines with double roller chain, knock out bearing pin of tensioning rail with the impact...
  • Page 174 EXIT Pull off crankshaft gear and oil pump drive sleeve with the puller 102 589 05 33 00. If the crankshaft gear is replaced, transfer color marking from the old to the new crankshaft gear. Install crankshaft gear onto crankshaft. If this proves difficult, knock in with the impact drift 116 589 07 15 00.

  • Page 175: Removal And Installation Of Flywheel Or Flex Plate

    EXIT Removal and Installation of flywheel or flex plate 03-410 Removing transmssion (26-020 or 27-600). Retaining lock on starter ring gear remove and install, special tool 601 589 02 40 00 (step 2). Stretch bolt (18) unbolt, bolt in, check length/stretch shaft dia., initial torque 30 Nm, angle of rotation torque rotation torque 90”...
  • Page 176 EXIT Stretch bolt 032 00 I 103 032 00 71 ‘ ) Part No. Thread dia. D when new 8.5 -0.2 Thread shaft dia. d minimum dia. when new 22 20.2 57 kO.2 Length L maximum length 22.5 Stretch bolt with two-mass flywheel Notes The engines 102.9221924i962/963 have the same flywheels (standard flywheel).
  • Page 177 EXIT The flex plate of the engines with automatic transmission is identical on all engines. Flywheel and flex plate with ring gear can be replaced without the need for static or dynamic balancing. Arrangement of flex plate on crankshaft of engines with automatic transmission.
  • Page 178 EXIT With the distributor ignition (DI - formerly EZL), the flywheel or the flex plate was provided with two segments (A) offset by 180“ . As the segments rotate past the position sensor this produces an alternating voltage as a result of induction.
  • Page 179 EXIT Check stretch bolts (see table). install flywheel or flex plate (43) with bonded disc and disc (44), pay attention to centering of installation pin. Bolt in stretch bolts (18) and tighten to an initial torque of 30 Nm or 50 Nm, respectively, for the two-mass flywheel.

  • Page 180: Remachining Flywheel

    EXIT 03-420 Remachining flywheel Preceding work: Removing flywheel (03410). up to for repairs Permissible axial runout at clutch face Notes The two-mass flywheel cannot be machined and is only available as a complete replacement part. Flywheels for manual transmissions which have scorch marks, scoring or cracks in the clutch face, should be machined by precision turning.
  • Page 181 EXIT If grooves or cracks are deeper than the maximum permissible material removal, the flywheel must be replaced. If the clutch face A is machined, the mounting face B must be machined by the same amount in order to maintain the distance a. The size b must be maintained as a minimum when performing repairs.

  • Page 182: Replacing Ring Gear On Flywheel

    EXIT 03-430 Replacing ring gear on flywheel Preceding work: Removing flywheel (03-410). Ring gear (17) .., ..Drill old ring gear and snap open with a chisel or heat rapidly and then remove immediately.
  • Page 183 EXIT Notes The ring gear is hardened. For this reason, do not exceed temperature of 220 “ C (yellow annealing colour) at any point when heating. This is only reliably possible by using a heating plate or heating oven. Use a temperature measuring chalk corresponding to the instructions if possible.
  • Page 184 EXIT...
  • Page 185 EXIT ngine timing, valvetrain Job No. 05 - 211 Checking and replacement of hydraulic valve clearance compensating element ..Checking and correcting the installation position of hydraulic valve clearance -215 Checking and adjusting camshaft timing -220 Removal and installation of camshaft .........
  • Page 186 EXIT Checking and replacement of hydraulic valve clearance Preceding work: Cylinder head cover removed (01-406). Check ....... . position hydraulic element under test on the base circle.
  • Page 187 EXIT Fill up reservoir chamber of valve clearance Valve clearance compensating element (58) compensating element on test with engine oil. Press on ball valve with a suitable pin and vent working chamber by pumping set bolt up and down. Close ball valve, if necessary replenish oil.
  • Page 188 EXIT Special tool 102 589 04 21 00 Hydraulic valve clearance compensation Valve Valve spring retainer Rocker arm Ball socket Snap ring Washer Guide sleeve Compression spring Telescopic type ball Compression spnng Ball mm 0) Set bolt Sealing cap Oil reservoir chamber Working chamber Return and venting bores Valve adjustment Is no longer required when...
  • Page 189 EXIT The hydraulic valve clearance compensating elements consist of the following components: Set bolt (64) with oil reservoir chamber (a) 5 8 - as well as return and venting bores (c) and a ball valve, consisting of a 5 mm 0 ball (63), 5 5 - (61) telescopic type ball bearing traveler...
  • Page 190 EXIT The oil needed for operating the hydraulic valve clearance compensating elements, flows from the longitudinal channel and the transverse bores in the cylinder head to the rocker arm bearing points. From here it reaches the ring channel (f) through the bore (h) in the rocker arm and the reservoir chamber (a) via grooves in the washer Any air in the reservoir chamber can separate from the oil (solid oil), with the result that, if...
  • Page 191 EXIT Checking Position camshaft on the hydraulic element under test so that the rocker arms contact the cam base circle. Press on the rocker arm with a hammer butt or similar above the hydraulic valve clearance compensating element for 5 - 10 seconds. If one compensating element drops noticeably compared to others, compensating element should be removed.
  • Page 192 EXIT After this, press compensating element setbolt heavily downwards for about 5 - 10 seconds with hammer butt or similar. If the setbolt drops noticeably when doing this, replace the compen- sating element. Note Compensating element must be vertical when filling the working chamber as well as during the test.
  • Page 193 EXIT Install rocker arm bearing support (05235). In so doing install the original ball socket (55). Note Use ball socket Part No. 103 055 00 24 if a new ball socket is installed. Check the installation position of the new valve clearance compensating element, correct if necessary (05-2 14).
  • Page 194 EXIT Checking and correcting the installation position of hydraulic valve clearance compensating elements Air cleaner removed (09-400 and 09-410). Cylinder head cover removed (01-406). Camshaft (1) ......position the cylinder under test so that rocker arm (51) contacts the cam base circle (Number 1).
  • Page 195 EXIT Turn pressure pad (06) to the right until a Checking detectable pressure point is reached. Read setting range (residual stroke) on the dial gauge. Reference value 0.5 - 2.4 mm. Correct the fitting position if the residual stroke is larger or smaller (Number 2).
  • Page 196 EXIT Washer Ball socket Conventional tool Mahr, D-7300 Esslingen Part No. 311000 05.0906 - 21413...
  • Page 197 EXIT Note The fitting position of the hydraulic valve clearance compensating elements must be checked If there have been complaints of valve train noise and no malfunctions have been established when checking the compens- ating element in accordance with 05211. If valve timing parts, which are installed or mounted on the cylinder head (apart from the camshaft timing gear, valve guides, valve...
  • Page 198 EXIT After the test, position camshaft so that in- dentation on the collar agrees with the edge on the cylinder head (arrow). In order to determine the specified fitting position of the hydraulic valve clearance compensating element, the residual stroke “ Z” of the compensating elements must be measured.
  • Page 199 EXIT Checking Position camshaft by turning the crankshaft so that the rocker arms contact the cam base circle on cylinder under test. Place measuring fixture 102 589 04 21 00 so that the claws of the claw sleeve (03) contact the ring shaped area around the hemispherical mushroom pad of the guide sleeve (59).
  • Page 200 EXIT Turn the pressure pad (06) by hand to the right sufficiently until it contacts the washer (57, previous picture), and a clearly detectable pressure point is reached. Note The pressure pad must contact the washer and not the rocker arm. Insert measuring pin adapter (04) in the central bore of the pressure pad (06), set dial gauge measuring pin on the measuring pin...
  • Page 201 EXIT Corrections Remove rocker arm bearing support (05235). Press hydraulic valve clearance compens- ating element (58), together with the washer aluminum or brass mandrel, and finally slide into the rocker arm up to the snap ring stop (56) again. Use a thinner washer (residual stroke too small) or a thicker washer (residual stroke too large).
  • Page 202 EXIT Checking and ad)usting camsbft timing Preceding work: (01-406). Checking Position the No. cylinder camshaft so that the rocker arm @la) contacts the cam base circle. Remove No. 1 cylinder rocker arm bearing support (05235). Remove rocker arm and hydraulic valve clearance compensating element and adjustable rocker arm 102 055 00 01 together with adjusting screw 102 050 0220 (164)
  • Page 203 EXIT Dial gauge (01) Insert and put tip vertically on valve spring retainer with 3 mm pretension (small pointer) (Number 6). Crankshaft Turn in the direction of rotation of the engine until the small pointer on the dial gauge has travelled back by 2 mm (valve stroke).
  • Page 204 EXIT with 2 mm valve stroke camshaft stamped at the rear of the camshaft before TDC 11” 17” 32” 35 3)/36 ‘ )/444) Value for used c WI In brackets. . Special tools 001 589 66 21 00 001 589 67 21 00 363 589 02 21 00 Conventional tool e.g.
  • Page 205 EXIT Checking Turn crankshaft until cam tips of No. 1 cylinder intake valve point downwards (valve closed). Caution! The engine must not be turned at the camshaft timing gear fixing bolt. Under no circumstances turn engine backwards during the measurement, otherwise considerable measuring errors result, and chain tensioner lock Remove rocker arm bearing support of No.
  • Page 206 EXIT Turn crankshaft in direction of rotation of the engine until dial gauge small pointer has returned by 2 mm (valve stroke). In this positic? t?~ value on the vibration damper must agree Nrth the value “ intake valve opens after TDC” in the valve timing table.
  • Page 207 EXIT Unscrew hexagon cap nut (40) for chain tensioner and remove sealing ring (41) as well as compression spring (39) (see 05310). Caution! The chain tensioner hexagon cap nut is under pressure from the compression spring. 10 Unscrew oil pressure pump (arrows) and set to one side with the lines connected.
  • Page 208 EXIT To do this hold in position with a fork wrench (24 mm) on flats at the rear end of the camshaft. Note On vehicles with self-levelling suspension the camshaft timing gear and driving sleeve are attached by a bolt with hexagon recessed hole. Take out the driving sleeve.
  • Page 209 EXIT 19 Insert compression spring (39), replace sealing ring (41), bolt in screw plug (40) and tighten to 70 Nm. 20 Unbolt rocker arm bearing support from No.1 cylinder and withdraw rocker arm (51a) for hydraulic valve clearance compensation. 21 Install rocker arm bearing support, tightening torque 20 Nm (05- 235).
  • Page 210 EXIT camshaft Preceding work: Air cleaner removed (09-400 and 09-410). Cylinder head cover removed (01-406). Piston of No. 1 cylinder position on ignition TDC, note markings (Numbers 1 and 2). of the chain tensioner, unbolt, bolt in, Screw plug (40) 70 Nm.
  • Page 211 EXIT All rocker arm bearing supports (61) with unbolt, bolt on, 20 Nm. Note oil pipe designs rocker arms and oil pipe (67) (Number 9)......Camshaft remove, replace, oil bearing points with engine oil.
  • Page 212 EXIT Exhaust valve Intake valve Engine Camshaft identification number stamped at rear of camshaft 102.96 32” 27128 ‘ ) 102.985 35 3)/6 ‘ )/444) Value for used chains in brackets. mm) and tin-plated. Note The camshaft supported on 5 bearings is drilled hollow.
  • Page 213 EXIT The marking for the ignition TDC position of the piston is placed on this collar. It must match up with the edge on the cylinder head (arrow). The camshaft can be removed from above. The rocker arm bearing supports and the camshaft timing gear have to be removed for this.
  • Page 214 EXIT The running in and wear characteristics have been improved by short- stroke honed camshafts (formerly tin-plated). Introduced in Droduction: Januarv 1986 Engine end number Vehicle identification end Since October 1987 camshafts have been fitted with 19 mm wide tinplated cams (formerly 18 mm).
  • Page 215 EXIT Since 1988, in order to avoid camshaft wear, chilled cast iron camshafts and rocker arms with soldered on hard metal pads have been equipped. If the chilled cast iron camshaft has been installed on previous engines, rocker arms with hard metal cam follower must also be installed.
  • Page 216 EXIT In order to improve camshaft lubrication the oil feed bore in the cylinder head has been enlarged from 3 mm to 4 mm (arrow). The oil groove in the rocker arm bearing support has also been widened from 4 mm to 5.5 mm (arrow).
  • Page 217 EXIT Introduced in Droduction: Januarv 1988 Engine end number Engine end number Model Engine Manual transmission Automatic transmission 201.028 022013 Removal and installation Position piston of No. 1 cylinder on ignition TDC. Marking on camshaft collar must align with the edge on the cylinder head (arrow). Before turning the crankshaft, switch off the ignition and remove the plug for the inductive sensor at the switching unit.
  • Page 218 EXIT Unscrew the chain tensioner hexagon cap nut (40) and remove sealing ring (41) as well as compression spring, tightening torque 70 Nm (05-310). Caution! The chain tensioner hexagon cap nut is pressurized by the compression spring. Unbolt, bolt on oil pressure pump (68) (arrows) and put to one side with the lines connected.
  • Page 219 EXIT Remove camshaft timing gear, remove timing chain and place in the timing case, tightening torque 80 Nm. Remove and install Woodruff key (6) and spacer washer (7). Installation note Note color markings on camshaft timing gear and timing chain. Assemble camshaft timing gear so that on the single roller chain the wide collar points to the camshaft and on the dual roller chain the...
  • Page 220 EXIT 11 Install hexagon cap nut (40) and compres- sion spring (39) with new sealing ring tightening torque 70 Nm. 12 The installation proceeds in reverse sequence. 13 Check for leaks when engine is running. 05.0906 - 220111...
  • Page 221 EXIT Removal and installation of rocker arm bearing supports with rocker arms Preceding work: Cylinder head cover removed (01-406). 0 5 - 0 0 4 6 - 3 5 Engine turn, so that rocker arm of bearing support being removed is on base circle of cam (cam tips pointing downwards).
  • Page 222 EXIT Note The five bearing bores for camshaft support are each located half in the cylinder head and on top in the four rocker arm bearing supports. The front rocker arm bearing support has two half bearing bores. Each of the four bearing supports is attached with four bolts (63) and with two installation sleeves (60).
  • Page 223 EXIT The two oil grooves (arrows) act as oil supply to the hydraulic valve clearance compensating elements. The oil pipe for camshaft lubrication is supplied with oil via the groove (arrow) on the rocker arm bearing support. The rocker arm bearing supports should not be confused with each other.
  • Page 224 EXIT The rocker arms for operating the valves are supported individually on a rocker shaft fitted in a bearing support on both sides (arrows). Rocker arms with soldered on cemented carbide tips have been installed since October 1988 (arrow). The oil required for lubricating the rocker arm bearings reaches the rocker arm bearing shaft (50) and hydraulic valve clearance compensating element via a longitudinal channel in the cylinder...
  • Page 225 EXIT The rocker shaft is secured in the axial and rotary direction by a bearing support set bolt. For this a half bore is attached to the shaft, in which one half of the screw shaft is located (arrow). An M8 thread (D) has been incorporated in the front face for installation and removal of the rocker shaft.
  • Page 226 EXIT Preceding work: Air cleaner removed (09-400 and 09-410) Cylinder head cover removed (01-406). Camshaft position so that rocker arms of bearing support being removed is on base circle of the cam (Number 1). remove, install (Number 2) pipe (67) Bearing support (61)
  • Page 227 EXIT Camshaft turn and check for smooth running, possibly fit new bearing support (Number 8). Bearing support (61) ..remove, complete with rocker arm (51) and install rocker shaft (50) and bearing support (Numbers 9 and lo), 20 Nm. Special tools Threaded pm M8, 116589203300...
  • Page 228 EXIT Only rocker arm bearing supports where camshaft bearing half bore is 0.05 mm larger than on production parts are supplied as spare parts. This prevents the camshaft binding when replacing a bearing support. In the event of bearing seizure or pronounced striation the camshaft bearings can be bored out by 0.5 mm and a camshaft with oversized journals installed (01-419).
  • Page 229 EXIT In order to avoid camshaft wear, rocker arms with soldered on cemented carbide tips have been installed (arrow). Only this rocker arm is still supplied as a replacement part. These rocker arms may only be installed together with the chilled cast iron camshaft. 0 5 .
  • Page 230 EXIT Replacement a) Rocker arms and rocker shafts Turn the engine so that the cam tips of the bearing support being removed point downwards and the rocker arms are on the base circle. Remove, install oil pipe (67). 3 Remove bearing support. Pull out rocker shaft with the impact extractor 116 589 20 33 00 and extension 616 589 00 34 00 or with an M8 bolt.
  • Page 231 EXIT Turn camshaft by the fiats with a fork wrench (24 mm) and check for ease of move- ment. If binding occurs, remove the bearing support again and replace with another. Remove new rocker arm bearing support and pull out rocker shafts (Figure Number 4). 10 Lubricate rocker arms and rocker shafts and install in bearing support.
  • Page 232 EXIT Preceding work: (01-406). Cylinder head cover removed (15-018). Spark plugs removed 5 - 0 0 4 8 - 3 7 A. Cylinder head removed Cylinder head clamp on assembly board 102 589 00 59 00. Remove, install rocker arm bearing supports. Attach support bridge 102 589 01 59 00 to cylinder head.
  • Page 233 EXIT (61) ... . Rocker arm bearing support remove, install, 20 Nm (Number 3). Repair note Lubricate camshaft journals. Ball sockets (55) must be installed in the same position again. Note installation position of the rocker arm bearing bolt.
  • Page 234 EXIT Conventional tool e. g. Bosch, E F A W 210 A Cylinder leakage tester Sun, CLT 228 Note Valve springs and valve spring retainers with scoring on the mounting surfaces must be replaced. - 4 0 - 5 4 The valve springs act progressively and must be installed so that the color marking (narrow coil) points towards the thrust collar (47).
  • Page 235 EXIT A. Cylinder head removed When the cylinder head is removed the valve springs can be removed as follows: Clamp cylinder head with four cylinder head bolts (arrows) on assembly board 102 589 00 59 00 (1). Remove rocker arm bearing supports with rocker arms and camshaft.
  • Page 236 EXIT Cylinder headl installed Removal, installation Put piston of the relevant cylinder on ignition TDC. Note The respective pistons are in the ignition TDC position, when the markings on vibration damper shown in the adjacent drawing are beneath the TDC pointer. I 180”...
  • Page 237 EXIT Bolt up, unbolt support for lever compressor, Connect cylinder leakage tester and pres- sur ,ize cylinder. Mount lever compressor on the support and install the valve spring retainer. Compress valve spring and take out valve cone halves with the magnetic lever. Caution! not remove the valve springs without compressed air in the cylinder, otherwise...
  • Page 238 EXIT Checking valve springs Data Valve spring Colour Wire Free Spring force at the identification side length pre-loaded length Part no. violet-red 102 053 11 20 violet-yellow orange yellow-yellow orange Note When carrying out repairs valve springs are to be checked for corrosion before reuse and to be replaced as necessary.
  • Page 239 EXIT Checking Check valve springs with a valve spring tester or with a spring test scale. Check spring force at the specified length. If the limit value is not achieved, replace valve springs. 05.0906 - 260/2...
  • Page 240 EXIT Replacement valve stem seals Preceding work: Air cleaner removed (09-400 and 09-410). Cylinder head cover removed (01-406). Spark plugs removed (1 S-01 8). Valve springs removed (05-250). Valve stem seal (48 and 49) extract with special tool 104 589 00 37 00. hammered valve cone halves, spring seats and thrust collars.
  • Page 241 EXIT Note The valve stem seals including assembly sleeves are supplied in the repair set. Since September 1988 standardized valve stem seals in Viton (formerly Polyacrylic) are installed for intake and exhaust valves. The valve stem seals must not be interchanged due to the different inside 0. Distinguishing features: Intake valve stem seal (48) Chamfer (arrow) relieved...
  • Page 242 Introduced inproduction: January to Februarv 1986 Model Engine Engine end number Engine end number Manual transmission Automatic transmission 201.024 I 029482 - 031994 Exhaust valve stem seal Introduction of Viton valve stem seal Color identification: brown Introduced in production: June 1988...
  • Page 243 EXIT...
  • Page 244 EXIT Checking and machining valves Checking clean valves. Visual inspection: Valves with burnt valve heads, insufficent val\ head height (h) worn or grooved valve stem must be replaced (Number Checking Measure valve stem eccentricity. Replace va when eccentricity is more than 0.03 mm (Number 2).
  • Page 245 EXIT Conventional tools Valve cone grinding machine e.g. D-5309 Meckenheim VS Model e.g. Hunger, Valve cone turning equipment D-8000 Miinchen 70 Type VKDRl, Part Number 203.00.200 Data Valve head @ D the valve head Identification on end of stem Engine A 102 03 27 102.985 E 102 08...
  • Page 246 EXIT -0043 42 Intake valve Note The exhaust valve stem is chrome-plated on these engines and filled with sodium due to high temperatures in the combustion chamber. Warning! Unserviceable sodium filled valves must be neutralised before scrapping. They must therefore be collected and sent to: Mercedes Benz AG Werk Marienfelde 3153...
  • Page 247 EXIT Checking and machining Clean valves and carry out visual inspection. Valves with burnt valve heads with insufficient valve head height “ h” and with worn or scored valve stem are to be replaced. 2 Measure valve stem eccentricity. Replace valve when an eccentricity of more than 0.03 mm is measured.
  • Page 248 EXIT Checking and replacing valve guides Valve stem seal seat (3) check for wear. If the valve stem seal is no longer firmly seated, replace valve guide, 00, 103 589 03 15 special tools 103 589 02 Valve guide (54 and. 56) ....clean, check, special tools 000 589 10 68 00, 102 589 00 23 00 and 117 589 03 23 00.
  • Page 249 EXIT Base bore for valve guide check before inserting a valve guide. in the cylinder head (1) Special tool 117 589 05 23 00. If normal dimension valve guide can be used; Ream base bore with reamer 14.035 mm 0, 1105890300 When the checking pin can be inserted to the full extent, broach base bore to 14.2 mm 0.
  • Page 250 EXIT Conventional tool Cylinder head clamping fixture e.g. f-lunger, D-8000 Munchen 70 Part Number 221.60.000 Exhaust valve Normal Repair stage Normal Repair stage dimension dimension Part Number 1 1 0 2 0 5 0 1 7 2 4 1 1 0 2 0 5 0 1 0 2 4 1 1 0 2 0 5 0 1 8 2 4 1 1 0 2 0 5 0 1 3 2 4 114.044 - 14.051 114.214 - 14.222 114.044 - 14.051...
  • Page 251 EXIT Vehicle identification end Engine end number Model Engine Broach base bore in cylinder head (repair stage) Remove rust and clean the cylinder head seat thoroughly, particularly the inside of valve rings. Select correct guide sleeve (2) and remove stiff plastic brush or similar. Note The broaching tool cutting edges must be cleaned before every broaching process.
  • Page 252 EXIT Inserting valve guide Drive in the valve guides with impact mandrel and hammer, when the valve guides are not super cooled and cylinder head is not heated up. Coat valve guides with wax or oil before driving Guide sleeve - valve seat allocation to enaine Valve seat Engine Guide sleeve...
  • Page 253 EXIT Valve seat ring (52 and 53) unscrew with seat ring turning tool Note turning tool operating instructions. Valve guides (54 and 56) check, replace if necessary (05-285). Base bore (D2) measure. Note A new valve seat ring with normal dimensions can be used, when specified overlap is present.
  • Page 254 EXIT Special tools 102 589 00 23 00 1 1 7 5 8 9 0 3 2 3 0 0 Conventional tools Cylinder head clamping fixture e.g. Hunger, D-8000 Munchen 70 Part No. 221.60.000 Ring seat turning tool e.g. Hunger, D-8000 Munchen 70 Size 2, Part No.
  • Page 255 EXIT Data Intake Exhaust 05.0906 - 29013...
  • Page 256 EXIT Intake Note The valve seat rings are sintered metal on account of lead free fuel. These hardened valve seat rings temporarily had a step (arrow) on the inside of the ring. PO5 -0164 -11 This step must be turned off in order to machine the valve seat ring.
  • Page 257 EXIT Machining valve seats check (05285). Valve guides (56) Valve seats (53) machine in accordance with manufacturer’ s operating instructions. See data for adjustment. Note Only loosen pilot, when eccentricity of valve seat ring has been checked. check (Number 3). Valve seat eccentricity measure, correct if required (Number 4).
  • Page 258 EXIT Conventional tools Cylinder head clamping fixture e.g. Hunger, D-8000 Munchen 70 Part No. 221.60.000 Valve seat turning equipment e.g. Hunger, D-8000 Munchen 70 Type VDSN l/45/30, Part No. 236.03.308 Test set for valve seats e.g. Hunger, D-8000 Munchen 70 Part No.
  • Page 259 EXIT Valve distance to cylinder head parting surface Engines 102.9621963 Minimum distance A with new valve seats and new valves Largest distance A with reworked valve seats and reground valves Largest distance A reduces by the same dimension, by which the cylinder head parting surface has been reworked. Note Clamp cylinder head in clamping fixture for stripping down and machining.
  • Page 260 EXIT Machining valve seats Check valve guide, replace if necessary (05-285). Machine valve seats (see manufacturer’ s operating instructions). Caution! Only loosen pilot, when eccentricity of valve seat has been checked (Number 3). Check valve seat eccentricity. For this push test sleeve (19) with dial gauge bracket (20) and dial gauge on the pilot (5).
  • Page 261 EXIT Insert valves and measure distance A. 05 0906 -...
  • Page 262 EXIT...
  • Page 263 EXIT detach, assemble (13-342). V-ribbed belt loosen (Number 2). Bolt (49) unbolt (Number 3). Bolt (51) swing outwards. Alternator unbolt. Sealing plug (40) Note The sealing plug is under pressure (Number 4). Sealing ring (41) ......replace. remove, install. Compression spring (39) ....Chain tensioner casing (36) unbolt (Number 5).
  • Page 264 EXIT press out of chain tensioning casing in the direction of pressure. Check individual parts for wear (Number 6). Chain tensioner casing (36) ..screw into cylinder crankcase, 15 Nm (Number 7). push in (Number 8). Sealing plug (40) with compression spring (39) and new sealing ring (41) screw in, 70 Nm (Number 9).
  • Page 265 (dimension “ a” = 0.1 mm, was 0.5 mm) Improved material Dimension “ b” = 3.5 mm, was 4.0 mm. Introduced in production: December 1985 Model Engine Engine end number Engine end number Manual transmission Automatic transmission I 029429 201.024 @ 050906 - 310/3...
  • Page 266 EXIT Removal and installation Removal and installation of Poly V- belt (13-342). Loosen lower bolt (49) for alternator positioning. Remove upper bolt swing alternator outwards (arrow). Unscrew sealing plug (40) and sealing ring (41) and remove compression spring (39). Caution! Sealing plug is pressurized by the compression spring.
  • Page 267 EXIT Bolt chain tensioner casing (36) onto crankcase, tightening torque Push setbolt (37) and locking spring (38) into the assembled chain tensioner casing. Mount compression spring (39) and sealing plug (40) with new sealing ring (41), tightening torque 70 Nm. 10 Mount alternator, tightening torque of the bolts (49 and 51), 25 Nm.
  • Page 268 EXIT Preceding work: Cylinder head cover removed (01-406). Spark plugs (15) remove, install (15318). Chain tensioner (36 to 41) remove and install (05310). Chain bolt ......grind off (Number 3).
  • Page 269 EXIT Special tools 102 589 01 09OC 000 589 58 43 00 103 589 01 63 OC Note An open timing chain with connector link is supplied for repairs. The sprockets are to be checked for scores and pitting as well as the chain tensioner for perfect function before installing a new timing chain.
  • Page 270 2 0 1 . 0 2 4 @ ( 1 0 2 . 9 8 5 1003057-003893 I 027366-036001 Engine end No. Automatic transmission Not recorded 036289 201.024 @ 102.985 312513 003925 Double roller timing chains have been installed since January 1988. 05.0906 - 32013...
  • Page 271 EXIT The former connector link with locking devices (A) has been deleted. Only the connector link (B) is still supplied for riveting. Former connecting link with locking devices Modified connecting link can be Replacement Remove, install spark plugs (15018). Remove, install chain tensioner (05-310). Cover the open part of the chain casing with a rag, grind off both chain bolts (arrows) at a double link in the timing chain.
  • Page 272 EXIT Pull out the released end of the old timing chain evenly, to correspond with drawing on the new timing chain. Caution! The timing chain must remain engaged while turning the camshaft timing gear and crankshaft gear. Secure the ends of the chain to the camshaft timing gear with wire.
  • Page 273 EXIT 11 Remove assembly tool and turn punch (02) so that the notch (arrow) points forward. 12 Install assembly tool exactly over the center bolt. Rivet bolts of the connector links individually, tightening up spindle to approx. 30 - 35 Nm (reference value). Check riveting (arrows), re-rivet if required.
  • Page 274 EXIT 15 Turn crankshaft and check adjustment markings at engine TDC position. Note If the adjustment markings do not align, the valve timing settings of the camshaft must be checked (05215). 16 Assembly is completed in the reverse order. 0 5 . 0 9 0 6 - 32017...
  • Page 275 EXIT Installation of oil spray nozzle retroactively 05328 Preceding work: case (01-210). cover removed (05-412). idler gear shaft removed remove (Numbers 1 and 2). Sealing plug (13) Part No. 102 589 14 15 00 bolt up, unbolt Joggle plate (Number 3). drive home up to stop (Number 4).
  • Page 276 EXIT Note In order to achieve better lubrication of the timing chain, an additional oil spray nozzle (66) has been fitted in the front face of the main oil channel. This oil spray nozzle, can be installed retroactively. The retroactive installation should only be carried out, when for example the timing case cover has already been removed for other work.
  • Page 277 (Injection engines 1st design) 2 0 1 . 0 2 4 @ 1 1 0 2 . 9 8 5 1003626-003670 Production breakpoint: May 1986 (Injection engines 1 st design) 201.024 @ Production breakpoint: November 1986 (Injection engines 2nd Design) Model 201.028...
  • Page 278 EXIT Installation Remove sealing plug to do this drill a core hole (5 mm 0, 10 mm deep). Note Carefully cover oil channel (a), bearing bore (A) and window (arrow). Unscrew sealing plug with impact extractor 116 589 20 33 00 and stud 116 589 00 34 00 15 00 Attach joggle plate (AP) 102 589 14 with two hexagon bolts M8 x 15 (48).
  • Page 279 EXIT Select correct oil spray nozzle (carburettor or injection engine) and drive home the cylinder crankcase up to the stop. The correct fitting position of the oil spray nozzle is achieved when this is laid on the joggle plate, as shown in Figure (Number 3).
  • Page 280 EXIT...
  • Page 281 EXIT Timing case cover removed (01-210). (21) Timing chain and crankshaft gear mark (Number 1). Timing chain and camshaft timing gear (4) mark (Number 2). Chain tensioner (36 to 41) remove, install (05310). Oil pressure pump (69) unbolt, bolt up, put to one side with lines connected (Number 4).
  • Page 282 EXIT Special tools 001 589 72 21 00 116 589 03 34 00 Note order to achieve better guidance of the timing chain, the plastic support has lateral guide bars (arrows). The plastic support is also fixed differently; way the support is prevented in this from slipping off the tensioner blade.
  • Page 283 EXIT Removal and installation Align timing chain and crankshaft gear. Align timing chain and camshaft timing gear. Remove chain tensioner (05-310). Unbolt oil pressure pump with lines connected (arrows) and put to one side. 05.0906 - 330~3...
  • Page 284 EXIT Unbolt, bolt up camshaft timing gear, bolt markings on camshaft timing gear and crankshaft gear. Note On vehicles with oil pressure pump remove driving disc sleeve (70). Swing tensioner blade (22) for single roller chain inwards and remove from bearing pin (26), install.
  • Page 285 EXIT Insert new tensioner blade and drive home bearing pin up to stop. 10 Install chain tensioner (05310). 11 Turn crankshaft and check adjusting marking at TDC position of engine. 12 The installation proceeds in the reverse sequenceas removal. Run engine, check for leaks. 05.0906 - 3306...
  • Page 286 EXIT Removal and installation of guide rails A. Guide rail (24) in cylinder heacd Preceding work: Air cleaner removed (09-400 and 09-410). Cylinder head cover removed (01-460). Chain tensioner (39 to 41) remove, install 70 Nm (Number (75) ....Fan shroud (1) and fan remove, install, bolt (80), 25 Nm (Number 2).
  • Page 287 EXIT pressure pump (69) unbolt, bolt up, put to one side with lines connected (Number 4). Timing chain and camshaft timing gear (4) align and unbolt, bolt (9 and 9a), 80 Nm (Number 5). Guide rail bolt (26) extract, with impact extractor 589 20 33 00 and stud 100 589 00 34 00, drive home Note...
  • Page 288 EXIT Note The guide rails have been changed with the introduction of the double roller chain. A Guide rail for single roller chain Removal and installation Removal and installation of chain tensioner (05310). Tightening torque of hexagon cap nut (40) 70 Nm. Remove fan shroud (1) and fan (75).
  • Page 289 EXIT Unbolt oil pressure pump with lines connected (arrows) and set to one side. Align timing chain and camshaft timing gear. Unbolt camshaft timing gear and remove sprocket. Note When installing the sprocket note color markings. Tightening torque of set bolt 80 Nm.
  • Page 290 EXIT Install guide rail (24) so that the locating lug (arrow) engages in the groove of the upper guide rail bolt. Note Apply sealant 001 989 25 20 at collar of guide rail bolts. Check for leaks when engine is running. 05.0906 - 340/5...
  • Page 291 EXIT Preceding work: a. With single roller chain Guide rail (25a, single roller chain) ... remove, put on (Number 1). b. With double roller chain position on ignition TDC (Number 2). Piston of No.
  • Page 292 EXIT align and unbolt, (9 and 9a), 80 Nm (Number 5). Timing chain and camshaft timing gear (4) align (Number 6). Timing chain and crankshaft gear ... . (19) unscrew, remove clip and idler gear shaft Bolt (20) (18) (Numbers 7 and 8).
  • Page 293 EXIT Note The guide rails have changed with the introduction of the double roller chain. A Guide rail for single roller chain Removal and installation a. With single roller chain Pull off guide rail (23, install. b. With double roller chain Position piston of No.
  • Page 294 EXIT Remove chain tensioner (05310). Align timing chain and camshaft timing gear and unbolt camshaft timing gear. Put timing chain in timing case. Align timing chain and crankshaft gear. Unscrew bolt (20) and remove retaining clip (19). 05.0906 - 340/9...
  • Page 295 EXIT Pull out idler gear shaft (18) and remove timing chain. Remove, install, pull timing chain and crankshaft gear forward as far as possible and remove guide rail (25b). Put on timing chain and push back crankshaft gear together with timing chain.
  • Page 296 EXIT 11 Install timing chain and camshaft timing gear, note marking. Tightening torque of camshaft timing gear set bolt 80 Nm. 12 Install chain tensioner (05310). Tightening torque of sealing plug (40), 70 Nm. Check adjustment marking of camshaft (arrow) at ignition TDC position of engine, correct if necessary.
  • Page 297 EXIT Preceding work: Timing case cover removed (01-210). Fuel pump removed (07.2-212, only carburettor engines). remove, install (05-310)....Chain tensioner (36 to 41) unbolt, bolt up, set to one side with lines pressure pump (69)
  • Page 298 EXIT unbolt, bolt up, 5 Nm. Remove, install retaining Hexagon socket bolt (20) clip (19) (Number 7). withdraw from rear bearing and remove from Idler gear shaft (18) timing chain, insert (Numbers 8 and 9). check for leaks. When engine is running Special tool 001 589 66 21 O( Note...
  • Page 299 EXIT Removal and installation Remove chain tensioner (05-310). Unbolt, bolt up oil pressure pump (arrows) and put to one side with lines connected. Align camshaft timing gear and timing chain. Align crankshaft gear and timing chain. Unbolt camshaft timing gear and remove, put timing chain in timing case.
  • Page 300 EXIT Remove guide rail (25a) (only on single roller chain). Unbolt hexagon socket bolt (20) and remove (19). retaining clip Remove idler gear shaft (18), install, in so doing raise timing chain somewhat. Install retaining clip (19) and secure with bolt Install guide rail (25a).
  • Page 301 EXIT Preceding work: Cylinder head cover removed (01-406). unbolt, bolt up, Nm (Numbers 1 and 2). bolts (68) remove together with driving disc (76). On Oil pressure pump (69) Model 201 set oil pressure pump with lines connected to one side. renew.
  • Page 302 EXIT Special tools 72 21 OC 21 00 001 589 001 589 66 Camshaft timing gear Woodruff key Oil pressure pump Driving disc sleeve Flange Gasket Driving disc Cylinder head cover gasket Note The oil pressure pump (69) is driven directly by the camshaft (1) via the driving disc sleeve (70) and the driving disc (76) and is attached to the cylinder head by a flange (71).
  • Page 303 EXIT Removal and installation On Model 201 remove bolts (68), remove oil pressure pump and set to one side with lines connected. Remove, install driver (76). Replace gasket (75). Unbolt, bolt up flange (71) together with the attachment eye (22), renew O-Ring (73). Tightening torque of bolts (72) 25 Nm.
  • Page 304 EXIT Unscrew hexagon socket bolt (9a) and remove, insert driver sleeve (70), tightening torque 80 Nm.

This manual is also suitable for:

201.028

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