Mercedes-Benz 201.024, Service Manual

Page 1: ...Mercedes Benz Mercedes Benz of North America Inc Montvale NJ 07645 ...

Page 2: ...c tronic or mechanical including photocopying record ing or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from the publisher Published by Mercedes Benz of North America Inc Printed in U S A Part number S 2347 93A ...

Page 3: ...er to the engine and vehicle identification table for model and component information Special tools required in performing certain service jobs are identified in the manual and are recommended for use Any part numbers given are only used for identification and easier differentiation between individual components and are not intended for ordering purposes If your Mercedes Benz model differs from th...

Page 4: ...in 05 Continuous Fuel Injection System CFI 07 3 Air filter 09 Belt drive Intake and exhaust manifolds emission control system 14 Electrical system engine 15 Engine lubrication system Engine cooling system 20 Engine suspension 22 Accelerator control cruise control electronic accelerator 30 Fuel system Exhaust system ...

Page 5: ...General technical data 00 ...

Page 6: ...00 General technical Job No Instructions for use of service manual 00 005 Engine and vehicle identification 010 Vehicle identification number locations 015 Technical data 020 00 l ...

Page 7: ... the Group No in the Group Index Individual groups are separated by an easily visible dividing page which is followed by the job index page The exact job required is found in the job index The initial page of a typical job description appears as follows 03 324 Replacement of front crankshaft radial seal Job Title appears on same line as Group No Job No Page No Technical data tightening torques and...

Page 8: ...starting model year 1984 Gasoline engines Model Year 1 Model 1 Sales Designation IE 9 n ine 1984 I 201 024 I 190 E 2 3 I 102 961 1985 I 201 024 I 190 E 2 3 I 102 985 1991 I 201 028 I 190 E 2 3 I 102 985 1992 I 201 028 I 190 E 2 3 I 102 985 1993 I 201 028 I 190 E 2 3 I 102 985 00 010 l ...

Page 9: ...ne numbers 7 a Certrfication Tag left door plllar ldentlficatlon Tag left wlndow post Vehicle ldentlficatlon No Engine No Body No and Paintwork No lnformatron Tag California version Vacuum line routing for emission control system Emlsslon Control Tag Emlsslon Control Tag Catalyst Information from model year 1964 up to 1966 00 015 I1 ...

Page 10: ...us fuel injection system with airflow sensor CIS E Normal I Normal Aspiration Number of cylinders Cylinder arrangement Bore stroke mm In line 15 inclination I In line 15 inclination 95 5180 25 I 95 5 80 25 Total effective piston displacement cc Compression ratio l 3 4 2 l 3 4 2 Firing order Maximum speed rpm Engine output SAE kWrpm net bhp rpm 6200 A 50 6200 2 50 Maximum torque Nm rpm net lb fti r...

Page 11: ...del 1 201 024 1 201 024 1 201 028 Sales designation 190 E 2 3 190 E 2 3 190 E 2 3 Model Year 1984 Model Years 1985 6 Model Years 1987 8 1991 3 I I I Engine 1 102 961 I 102 985 1 102 985 Fuel tank reserve approx I Electrical system Starter Bosch 00 02012 ...

Page 12: ...Crankcase and cylinder head 01 ...

Page 13: ...e 120 Removal and installation of steel balls in main oil gallery 130 Replacing core plug in crankcase 140 Removal and installation of timing case cover 210 Removal and installation of end cover 222 Removal and installation of oil pan 310 Repair instructions for crankcase 403 Removal and installation of cylinder head cover 406 Reconditioning spark plug thread in cylinder head 407 Removal and insta...

Page 14: ...Engine 1 Model 1 y m l 1 Sales designation Power in kW at rprn z pression 102 961 201 024 1984 190 E 2 3 84 5000 8 O l 102 985 I 201 024 11985 86 1190E2 3 I 90 5000 I 9 0 1 102 985 1201 028 1 ll9OE2 3 197 5100 19 0 1 01 1101 l 001 1 ...

Page 15: ...utput and Compression Ratio 102 961 as of 1984 201 024 Sales designation 190 E 2 3 190 E 2 3 190 E 2 3 Output in KW at rpm net bhpirpm 84 5000 113i5000 90 5000 12015000 97 5100 130 5100 Compression ratio E 1 8 0 8 0 9 0 01 0904 005il ...

Page 16: ...e compartment cover Model 201 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 006 l ...

Page 17: ...21 00 02 Adapter piece 04 Sealing cone with check valve Test data with engine at normal operating temperature 80 C in bar Subject I When new 1 Limit value Compression ratio E 9 0 9 4 I 10 12 1 approx 8 5 E 10 0 113 5 15 5 I aDDrox 12 E 7 5 8 3 I 9 1 0 I approx 7 5 E 7 2 102 92 1 8 9 1 approx 6 5 Permissible difference between individual cylinders max 3 01 0904 010 l ...

Page 18: ...s are equipped with an ignition system with variable ignition characteristics EZL Because of high ignition voltage it is very dangerous to touch components of the ignition system ignition coil ignition cables spark plug connector plug on unit when l the engine is running l the engine is started l the key in the steering lock is in position 2 and the engine is cranked by hand Geftihrliche Hochspann...

Page 19: ...nkshaft to ensure that no fuel is injected Model 201 2 Connect compression pressure recorder This is done by clamping one of the two alligator clamps arrow of the compression pressure recorder Part No 001 589 76 21 00 to the positive terminal post of the battery 3 Detach connector X27 from plug connection terminal 50 4 Plug in connector of adapter cable 01 Part No 124 589 36 63 00 Model 201 01 090...

Page 20: ...t residues 6 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 8 revolutions Test all the cylinders in this way 7 Blow out spark plug recesses with compressed air Remove any residues on the tapered sealing seat 01 0904 01014 ...

Page 21: ... 10 At pistons and piston rings max 20 Tightening torque Nm Spark plugs Special tools Commercial tool Cylinder leaktightness tester e g Bosch EFAW 210 A Sun CLT 228 Testlng 1 Run engine until at normal operating temperature 2 Blow out spark plug recesses with compressed air 3 Remove spark plugs 01 0904 01511 ...

Page 22: ...aft Note The respective pistons are in the TDC position when the markings shown in the drawing opposite on the vibration damper or on the belt pulley are below the TDC pointer 9 Open throttle fully 10 Screw connection hose into the 1 st spark plug bore and attach to the connecting hose of the tester The crankshaft must not turn when performing this step 11 Read off pressure loss at tester 12 Deter...

Page 23: ...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 head gasket 01 0904 015 3 ...

Page 24: ... marks and seizing rub marks Optical rub marks may result from the ring gap Traces of honing are still visible engine in order Seizing rub marks honing marks no longer visible recondition engine Commercial tool Cylinder inspection lamp 8 g Karl Storz GmbH D 7200 Tuttlingen Motoskop TW cold light with lens probes 103 26 CW 570 mm and 103 26 CT 210 01 0904 02011 ...

Page 25: ...ector Lines for pressure oil pump Cover for evaporator Cover for engine wiring harness Starter wiring harness Terminal block terminal 50 Terminal 30 Engine wiring harness disconnect connect remove install 25 Nm detach step 3 detach attach step 4 insert step 5 remove at component partition wall steps 6 and 7 remove install step 8 disconnect connect step 9 disconnect connect at terminal block step 1...

Page 26: ...adjust step 21 detach attach step 22 detach attach step 23 detach attach step 24 Note On vehicles with air conditioning the AC compressor can be unbolted with the lines connected and without draining the system steps 25 to 34 attach to suspension lugs detach step 35 insert between component compartment and engine remove step 37 unbolt at exhaust manifold and transmission mount 51 bolt on steps 38 ...

Page 27: ... are merely guidelines which can be exceeded in the upper or lower limits for brief periods In moderate climatic zones SAE 30 may be used from the spring on for all engine models SAE low 40 or SAE low 50 may be used as an all seasons oil for all gasoline engines Refer to the most current Factory Approved Service Products for further information regarding specified viscosity grades and approved eng...

Page 28: ...mpressor 25 Servo pump to supporting bracket 25 AC compressor to supporting bracket 30 Propeller shaft to transmission 45 Clamping nut to spline end of propeller shaft 45 Ground cable to transmission 45 Engine mount to axle carrier 40 Special tools Commercial tool Engine hoist No 3188 self locking e g Messrs Backer HerderstraOe D 5630 Remscheid Shoe made tools Guard plate for radiator evaporator D...

Page 29: ...egative terminal connect 2 Remove fan install 3 Unplug cable connector 327 at alternator plug in 4 Detach lines for pressure oil pump at cylinder head connect arrows 5 If equipped with air conditioning install guard plate arrow to evaporator of air conditioning system 01 0904 030 5 ...

Page 30: ...xture upwards Model201 9 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 Model201termlnal30 01 0904 03016 ...

Page 31: ...ence resistor CFI Infectron system S27 2 Deceleration shutoff mrcroswrtch W1l Engine ground electric lead bolted on x11 Oragnosticconnector termrnal block terminal TD X24 Connector headlamp wrnng harness X56 Throttle body switch connector Yl Electrohydraukc actuator Y6 Idle air control valve ya Start valve 12 Detach twin connector B1112 for engine coolant temperature sensor CFI plug in Unbolt engi...

Page 32: ...itch S27 2 plug in 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 16 Unbolt terminal TD at terminal block of diagnostic connector Xl l bolt on Unscrew diagnostic connector Xl 1 and unplug on the bottom the grey cable for TDC pulse generator plug in 01 0904 03018 ...

Page 33: ...ug 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 I I 20 Unbolt ground cable at intake manifold screw on arrow 01 0904 03oi9 ...

Page 34: ... lever Installation instruction Adjust Bowden cable 30 30 325 22 Reduce fuel pressure in the fuel lines by briefly opening fuel tank cap Unbolt fuel lines 379 and 380 bolt on Note To prevent fuel flowing out of the disconnected fuel lines both fuel lines can be plugged with a fitting 01 shop made 23 Disconnect engine coolant hose 68 for heater supply line at the cylinder head connect 01 0904 03011...

Page 35: ... 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 28 Disconnect oil lines at power steering pump connect 01 0904 030111 ...

Page 36: ...80 C 18 26 mm below the top edge of reservoir Oil level when oil cold room temperature approx 20 C between Min and Max markings 29 On models with AC compressor remove poly V belt install 13 342 30 Remove and install tensioning device for V belt 13 345 31 Unbolt belt pulley for high pressure pump of power steering bolt on arrows 32 Unbolt strut 145 for high pressure oil pump and AC compressor arrow...

Page 37: ...h lines connected Bolts 149b tightening torque 25 Nm Unbolt bracket b bolt on 35 Attach engine hoist into the suspension lug of the engine Adjust engine hoist so that the engine can be raised horizontally 36 Disconnect all remaining lines e g vacuum oil fuel lines and electric cables running to the engine connect 37 Insert guard plate arrow between component compartment and engine remove 01 0904 _...

Page 38: ... and 51 at the exhaust and transmission bolt on tightening torque 25 Nm 40 Remove lambda sensor at exhaust pipe install Remove cover arrow to perform this step 41 Remove and install exhaust system 49 100 42 Unbolt engine supporting bracket 12 bolt on Tightening torques Bolt 1 25 Nm Nut 2 70 Nm 01 0904 030 14 ...

Page 39: ...rm this step Tightening torque 45 Nm Note 45 Loosen clamping nut 2a tighten wrench waf 41i46 Push drive shaft back as far as possible Tightening torque 45 Nm 46 Detach speedometer shaft at transmission attach Remove bolt 404 to perform this step Flexible coupling remains on drive shaft 01 0964 030 15 ...

Page 40: ...rows 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 45 to the right and unplug cable connector plug in 50 Unplug cable arrow at the kickdown solenoid valve plug in ol 0904 030116 ...

Page 41: ...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 56 Check leaktightness with engine running if 01 0904 030117 ...

Page 42: ... separator 109 flows back through a passage dia 3 mm to the cylinder head At a high intake manifold vacuum the blowby gases are drawn through the bypass passage dia 1 5 mm in the idle air distributor 202 and the idle air passage in the intake manifold and flow to the combustion chambers At the same time a small quantity of clean air from the air filter is drawn in as well through the bypass passag...

Page 43: ...96 498 96 508 96 509 96 518 96 519 96 528 195 500 95 506 95 507 95 512 95 513 95 518 96 000 96 006 96 007 96 012 96 013 96 018 96 500 96 506 96 507 96 512 96 513 96 518 Averaged peak to valley height Rz after ceramic finish honing I 0 002 0 004 Permissible height of unevenness Wt I 50 of PTV height Commercial tool Snap gauge for internal measurements 0 80 100 mm e g Hahn und Kolb BorsigstraRe 50 D...

Page 44: ...t Standard in mlementation 041 88 Model When performing repairs ensure that the tolerance stage identification of piston and cylinder bore agrees It is possible to install pistons with a code letter identification in cylinder bores with a digit identification if this tolerance stage identification agrees according to the table If when performing repairs no identical pairing is possible reference c...

Page 45: ...stons installed measuring point 3 is just above the piston which must be at bottom dead center Chamfer the cylinder bores after boring The material allowance for honing should be not more than 0 05 mm Measuring points 1 3 A Longltudmal direction B Transverse direction a Top reversal point of 1st piston nng b Bottom dead center of piston c Bottom reversal point of 011 scraper rmg 01 0904 1 lOi ...

Page 46: ...nkcase parting surface POl 0041 33 Data Permissible variation of parallelism of top to bottom crankcase mating face in 0 1 longitudinal direction I Test pressure with air under water in bar gauge pressure 01 0904 120 l ...

Page 47: ...chine 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 machining the faces and also be machined when top or bottom crankcase mating PO3 0060 13 01 0904 120 2 ...

Page 48: ...approx 500 mm long If the rear ball moves into the cross passage to the oil filter remove the oil filter to enable the ball to be removed Bores thoroughly clean in the area in which the steel balls are pressed in Cup on fitting mandrel coat with grease and install cup Steel ball I position with the installation in each at front and rear as the mandrel steel ball into the mandrel and knock far as t...

Page 49: ...damaged steel balls may be reused several times without machining the ball seat Replace damaged steel balls If a leak exists reset steel balls approx 1 mm size is fixed on installation mandrel Special tool 102 589 07 15 00 Should the leaks not be repaired after this knock out both steel balls and seal the main oil passage end in question with a screw plug 9 Front steel ball 0 15 mm 10 Rear steel b...

Page 50: ... Ml6 x 1 5 screw plug Part No 000 906 016 002 with sealing adhesive 002 989 94 71 and screw in arrow Tap an Ml 4 X 1 5 thread approx 12 mm deep into the rear of the main oil gallery Thoroughly remove chips from the main oil gallery Coat Ml 4 X 1 5 screw plug Part No 000 906 014 000 with sealing adhesive 002 989 94 71 and screw in arrow 01 0904 13013 ...

Page 51: ...l with narrow blade or a screwdriver in the deep drawn edge of the plug step 3 Carefully knock in plug on one side far enough for it to turn through its own longitudinal axis approx go and pull out with the pliers step 4 Thoroughly clean of residues The sealing surface must be free of grease install Coat sealing surface with the sealant Loctite 241 002 989 94 71 Note curing time of approx 45 minut...

Page 52: ...ep drawn edge of the plug 4 Carefully knock in plug on one side far enough for it to turn through its own longitudinal axis approx 90 and withdraw with pliers 5 Thoroughly clean sealing surface of residues The sealing surface must be free of grease 6 Coat sealing surface with sealant Loctite 241 002 989 94 71 Note The sealant must cure for approx 45 minutes before adding the engine coolant 0 1 0 9...

Page 53: ... new core plug with the matching mandrel mm 0 Special tool 102 589 00 15 00 102 589 03 15 00 8 Install removed components 9 Add engine coolant 20 010 10 Run engine until warm and check leaktightness 01 0904 14oi3 ...

Page 54: ...ine coolant pump 20 210 Removal of air filter 09 400 or 09 410 Removal of ignrtton distributor 15 l 10 Removal of pressure oil pump for level control 32640 Cylinder head cover 81 Hexagon socket bolts 77 Strut 145 A C compressor 425 remove install together with ignition cable and distributor cover 01 406 3 off remove and install 25 Nm reference value step 2 unbolt bolt on 25 Nm step 3 unscrew screw...

Page 55: ...s been replaced the TDC pulse generator bracket must be adjusted 03345 for oil pump strainer basket unbolt bolt on 25 Nm step 9 remove remaining bolts take off timing case cover steps 10 and 11 Do not damage cylinder head gasket replace cylinder head gasket if damaged clean step 12 coat with sealant 001 989 25 20 and install timing case cover steps 13 and 14 Use fitting tool 102 589 00 14 00 and s...

Page 56: ...73 Part No 001 989 25 20 The timing case cover also acts as a support or housing for the following components or component parts Engine coolant pump Ignition distributor Oil pump Oil overpressure valve Radial seal for sealing crankshaft at front Setting pointer TDC pulse generator Front side of timing case cover 45 Crankshaft radial seal 46 Setting pointer for TDC e Coolant pump chamber with inlet...

Page 57: ...t for sealing the timing case must not be installed on these engines with single belt drive The timing case cover was modified effective 11107 The contours on the rear side have been lowered This is detectible from the cast Part No 102 015 11 01 on the front side of the cover This timing case cover can also be installed on engines manufactured prior to this date A Previous version B Present versio...

Page 58: ...Remove cylinder head cover 01 406 2 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 3 Remove strut 145 for power steering pump and AC compressor arrows Tightening torque 45 Nm 01 0904 210 5 ...

Page 59: ...mpressor to the side with the pipe group connected 5 Unplug connector 327 at the alternator plug in 6 Remove bolts 49 and 51 bolt on remove alternator insert Tightening torque 30 Nm 7 Unbolt bracket 156 bolt on Tightening torque 25 Nm 6 Unbolt TDC pulse generator cable 1 at the holder 2 screw on 01 0904 21016 ...

Page 60: ...ase cover Caution Do not damage cylinder head gasket Replace cylinder head gasket if damaged Installation 12 Clean mating faces 13 Coat mating face of timing case cover with the sealant Part No 001 989 25 20 14 Carefully install timing case cover paying attention to the cylinder head gasket and bolt tight Note bolt lengths 01 0904 210 7 ...

Page 61: ...stall ring 01 spacer 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 16 The remaining parts are installed in the reverse order 17 Run engine and check for leaks 01 0904 _ 21018 ...

Page 62: ...600 Removal of flywheel 03 410 PO3 0002 35 3 4 End cover 19 remove install pay attention to instructions Clean mating face insert roll pins 17 Coat mating face and bolts 21 and 34 with sealant 001 989 45 20 10 10 Nm Radial seal 20 replace use special tool 601 589 03 43 00 Special tools 01 0904 222 1 ...

Page 63: ...shaft center is fixed with two roll pins 17 Press end cover off at both side plates arrows 17 Roll pin 21 Bolt washer assy M6 x 22 34 Bolt washer assy M6 x 65 Push end cover with radial seal installed in place over the bolted on assembly sleeve 01 0904 22212 ...

Page 64: ...ompartment cover 01 006 Removal of torsion bar 32 300 Engineoil drain add Unscrew oil drain plug 28 to perform this step screw in 25 Nm Replace sealing ring 29 Cable 351a unplug plug in Clips la pull off detach attach fan shroud l place over fan Exhaust pipes 48 unbolt at exhaust manifold bolt on 25 Nm step 4 01 0904 310 l ...

Page 65: ...ling surface Replace gasket 31 step 9 Tightening torque M6 10 Nm M8 25 Nm Oil capacity in litres Total capacity for oil and filter change Oil pan max min 5 5 4 8 12 8 Special tools 1e C 1165690307Ot 1 1 7 5 8 9 0 2 0 7 Commercial tool Engine hoist No 3180 e g Messrs Backer HerderstraOe D 5630 Remscheid Showmade tools Metal panel for component compartment wall Dimensions approx 320 X 380 X 1 Guard ...

Page 66: ...he diameter has been increased from 3 mm to 3 15 mm Color green previously black Standard implementation 09186 Model Engine ransmlsslon 201 024 I 102 985 In June 1987 the O ring of the oil level pickup was once again modified I Po1 0117 13 Modification dl I 40 20 I 37 20 d2 3 15 3 2 01 0904 31013 ...

Page 67: ...evel pickup plug in 3 Detach clips la for fan shroud detach attach fan shroud 1 place over fan 4 Unbolt exhaust pipes at exhaust manifold bolt on arrows 5 Unscrew pipe clip 53 at the front exhaust bracket to the transmission Replace nuts 50 Tightening torque 25 Nm 01 0904 31014 ...

Page 68: ...tom mounting fixture bolt on 45 Nm bolts 22 for engine Tightening torque Len side shown 8 Raise engine with the engine hoist 9 Remove remaining bolts 32 34 for attaching oil pan bolt on and remove oil pan Tightening torque M6 10 Nm M8 25 Nm 10 Carefully clean mating face at oil pan and on crankcase 01 0904 310 5 ...

Page 69: ...l 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 31 Oi6 ...

Page 70: ...d 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 It is sealed with a screw plug 5 and an O ring from engines 116 l 17 and 601 The crankshaft bearings in the crankcase have been modified size 5 Multi belt drive 24 mm Single belt drive 20 mm 01 0904 4031 ...

Page 71: ...drive 102 961 POl 0053 13 H 40 mm Fastening bolts of the crankshaft bearing covers converted to Ml 1 X 62 twelve side stretch bolts with collar Previously Ml 2 X 70 hexagon bolts A M 12 x 70 hexagon bolts B Mt 1 x 62 twelve side stretch bolt Bolt projections A 6 C on crankcase for fastening bolts of timing case cover lengthened 01 0904 40312 ...

Page 72: ...ng rib arrow Standard Implementation 06186 Engine End No 1 Vehicle ident End No transmission Cylinder head The same cylinder head is installed on engines 102 9221924 as on engines 102 962 982 985 Only one cylinder head version is supplied as a replacement part This cylinder head must not be installed on the previous engine 102 961 01 0904 4033 ...

Page 73: ...ngine 102 985 An oil pipe A is inserted in the oil feed passage at the rear of the cylinder head to prevent the oil passages running empty when the engine is off Since 071 87 the oil pipe A has a stop collar arrow This prevents the oil pipe migrating upward in the cylinder head At the same time the recess in the cylinder head has been modified I PO1 2077 13 POl 0097 5 PO1 0191 13 X I 9 0 mm I 9 5 ...

Page 74: ...s 102 985 Standard implementation Februarv March 1988 manufacturer Elrina Vehicle ldent End No I not covered The cylinder head gasket in the chain box area was modified with implementation of the double roller chain 6 arrow In addition sealing surfaces with modified coating and widened combustion chamber chamfered faces c as well as silicone strips d running all round the outer edge 01 0904 4035 ...

Page 75: ...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 B Double roller cham Standard implementation 01188 01 OW4 4036 ...

Page 76: ...nector d Vent line e Holder b Cap nut 96 or hexagon nut c Cylinder head cover 81 Gasket 93 unplug at distributor cover plug in unbolt at distributor bolt on detach from spark plugs fit on detach attach unbolt bolt on if equipped with automatic transmission unbolt bolt on 15 Nm remove with ignition cables refit Pay attention to instructions check replace if necessary 1 01 0904 406 l ...

Page 77: ...which the ignition cables run is inserted in a longitudinal groove of the cylinder head cover In addition the ignition cables and the vent line at the face end of the cylinder head cover run through a plastic holder arrow On the inside the oil separator 109 and the r related outlet pipe are fixed in place with the hose piece arrow of the crankcase ventilation function description 01 140 0 1 0 9 0 ...

Page 78: ...vel control Distinguishing features l Collar bolt 151 l Hose connection for crankcase ventilation with larger OD The cylinder head gasket has wider plates arrows for sealing the bolt guides Caution1 If the cylinder head cover has to be replaced 8 g because of cracking install the previous magnesium cylinder head cover 152 A Cylinder head cover magnesium B Plasttc cylmder head cover 01 0904 406 3 ...

Page 79: ...el As of February March 1985 the oil separator is installed in the cylinder head cover with a vent pipe A 1 st verson B 2nd verson Standard implementation 02 85 On models with level control ransmisslon 0 1 0 9 0 4 406i4 ...

Page 80: ... 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 The modified cylinder head cover can also be installed on previous engines in the event of complaints Cylinder head cover 1 st version Cylinder head cover 2nd verson 0 1 0 9 0 4 406 5 ...

Page 81: ...ad 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 tool Recondltionina 1 Set piston at the cylinder in question to 20 30 before TDC 01 0904 _ 407 l ...

Page 82: ...bination tap after approx each five turns clean grooves of swarf and grease and again pack with grease 3 Check length of the HELI COIL thread insert 8 Use only the HELI COIL inset t with 9 1 mm block length 4 Install HELI COIL thread insert To perform this step insert HELI COIL insert 8 into the tool 2 ill note so that the bar arrow of the insert is facing the preload cartridge 16 Turn HELI COIL i...

Page 83: ... 3 ill note over the bar introducing the opened pliers 17 as far as the mark arrow into the sleeve and closing pliers The serrated tooth lock s must engage Turn sleeve to the left as far as the stop and hold tight Move pliers slightly up and down and break off bar Caution It is essential to remove a bar which may have dropped on the piston crown with a magnet 6 Caulk HELI COIL thread insert This i...

Page 84: ...drel the required milling depth is reached no further cutting resistance Once again thoroughly blow out spark plug recess before then removing the guide mandrel Turn crankshaft several times with starter motor and contact handle in order to remove any chips which may have dropped onto the piston crown 8 Place copper seal 7 into the milled mounting seat screw in spark plug and tighten to 30 Nm Note...

Page 85: ... remove install 25 Nm steps 1 and 2 Cylinder head cover 81 remove install with ignition cable and distributor cover 01 406 Exhaust pipes 48 unbolt at exhaust manifold bolt on 25 Nm step 4 Dipstick guide tube 40a unbolt bolt on step 5 Bowden cable 30 detach attach adjust 30 325 step 6 Intake manifold strut 160 and return spring 180 at intake manifold unbolt bolt on return spring detach attach steps...

Page 86: ...ain tensioner remove and install replace sealing ring 41 05310 step 21 mark relative to timing chain step 22 unbolt bolt on place to the side with lines connected step 23 unbolt bolt on 80 Nm check TDC marking steps 24 and 25 unbolt bolt on with pin wrench 116 589 03 07 00 25 Nm reference value step 26 unbolt bolt in check tighten steps 27 31 to 33 Refer to table for tightening torques remove refi...

Page 87: ...gine has cooled down Removal and installation 1 Detach fan shroud 1 and place over fan When installing ensure clearance to fan 2 Unbolt fan 79 remove together with fan shroud bolt on 3 Remove cylinder head cover together with spark plug connector and distributor cover 01 406 4 Unbolt exhaust pipes at exhaust manifold bolt on 001 589 7221 00 4 01 0904 41513 ...

Page 88: ...tep and take Bowden cable 30 out of the slot in the fulcrum lever Compress plastic clip 28 and push clip together with Bowden cable to the rear through the holder 16 Adjust Bowden cable 30 30 325 7 Unbolt strut at intake manifold To perform this step unbolt 2 hexagon socket bolts arrows on injection engine bolt on Detach return spring for throttle body assembly below intake manifold attach 01 0904...

Page 89: ...lug in 10 Detach cable from reference resistor R16 Model 201 only 11 Unbolt terminal TD at the diagnostic connector Xl 1 bolt on 12 Unbolt diagnostic connector Xl l unplug grey cable from the TDC pulse generator at the rear of the diagnostic connector plug in 13 Unplug all connectors and vacuum lines at therm0 valves and temperature switches plug in 01 0904 41515 ...

Page 90: ...pening fuel filler cap Unbolt fuel lines 379 380 bolt on When detaching the fuel line 380 hold connection to prevent it from turning 16 On models equipped with air conditioning unbolt bracket for pipe group 170 of AC compressor at cylinder head bolt on 17 Set engine to ignition TDC of No 1 cylinder 01 0904 41516 ...

Page 91: ...tor 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 21 Mark camshaft gear and timing chain relative to each other 22 Unbolt pressure oil pump place to the side with lines connected bolt on arrows 01 0904 41517 ...

Page 92: ...e 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 Tightening torque 25 Nm reference value 01 0904 4138 ...

Page 93: ...d Pal 0094 33 27 Remove cylinder head 51 28 Clean mating faces on cylinder head and crankcase 29 Replace cylinder head gasket 30 Check the shaft length of the cylinder head bolts If the maximum length L of 122 mm is exceeded the bolts should be replaced with new ones 31 Oil thread and head contact face of cylinder head bolts and insert 01 0904 41519 ...

Page 94: ...der of the tightening diagram beginning with 1 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 Pal 0094 33 33 Check for leaks with engine running 01 0904 415 10 ...

Page 95: ...hermovalves 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 C Temperature switch for magnetic fan coupling red 100 C 5 6 POl 0068 13 PO 0010 m 01 0904 416 l ...

Page 96: ...ensor for AX compressor blue Item 2 and 5 Screw plug Ml4 x 1 5 Item 3 Thermovalve for Ignition switchover Purge white 60 C red 50 C black 40 C Item 4 Temperature switch for intake manifold heater black 110 C 01 0904 416 2 ...

Page 97: ...ck 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: ...01 418 Facing cylinder head mating face POI oooe 54 Data mating face 01 0904 418il ...

Page 99: ...oaro u Fi Schioiltaly Knife edge straightedge approx 500 mm long e g Messrs Roaro u Fi Schioiltaly Note Only machine cylinder head mating face if there are porous or damaged areas Caution Clamp cylinder head absolutely flat for facing Failure to observe this instruction may result in the camshaft jamming when the cylinder head is reinstalled In this case the cylinder head must be replaced Facing 1...

Page 100: ...receding 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 D 01 0904 419 l ...

Page 101: ...herwise the bores for the rocker arm shafts will be distorted When machining the basic bores ensure that the half bores for mounting the cylinder head cover gasket or the sealing disc at front and rear on the cylinder head are not widened After widening the basic bores the edges at the mating face of the cylinder head bracket A or at the mating face of the cylinder head B on the camshaft bearings ...

Page 102: ...mber 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 01 0904 419 3 ...

Page 103: ...olt onto cleaned cylinder head plug connect and adjust compressed air to 2 bar gauge pressure Attach to suspension device and immerse into the heated water approx 80 C If air bubbles rise up determine leak point and mark Commercial tool Electrically heated water bath e g Messrs Otto Dtirr D 71 23 Sachsenheim Ochsenbach 010904 420 l ...

Page 104: ...Crankshaft assembly 03 ...

Page 105: ...g front crankshaft radial seal Replacing rear crankshaft radial seal Removal and installation of grooved bail bearing in crankshaft Removal and installation of vibration damper Checking and correcting setting of TDC pulse generator Removal and installation of crankshaft gear Removal and installation of flywheel or flex plate Remachining flywheel Replacing ring gear on flywheel 03 310 0 3 3 1 3 316...

Page 106: ...st bolt shaft dia If the dia reaches or is less than the minimum shaft dia of 7 1 mm replace the conrod bolt oil before installing initial torque 30 Nm Angle of rotation torque 90 1 OO use special tool 001 589 66 21 00 Pay attention to note Part No I Thread dia I Stretch shaft dia when new I Minimum stretch shaft dia c Torque of conrod bolt Initial tightening torque Angle of rotation torque 30 Nm ...

Page 107: ...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 6 2nd version L e 03 0905 31012 ...

Page 108: ...ission 027063 028449 I 076715 077418 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 To prevent any angular errors do not use a bending rod torque wrench for tightening according to angle degrees 030905 31013 ...

Page 109: ...out bearing shells 31 and 31a oil thread and bolt head contact surface 30 Nm measure if the value of 51 619 mm is exceeded or if it is conical dress bearing cover up to max 0 02 mm step 3 press in pay attention to oil holes Insertion pressure approx 2500 N Hollow out conrod bushing by turning or reaming Dress side contact surfaces on dressing plate steps 4 to 6 03 0905 313 l ...

Page 110: ...ith 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 Conrod aligning tool 8 g Hahn Kolb D 7000 Stuttgart Model BC 503 03 0905 313 2 ...

Page 111: ... OD Small end bushing ID D2 Fig para 4 Peak to valley height of small end bushing on inside Permissible axial twist of conrod bearing bore to small end bushing bore related to 100 mm length Permissible variation of axial parallelism conrod bearing bore to small end bushing bore related to 100 mm length 24 521 24 500 24 590 24 550 22 007 22 013 0 005 0 1 Permissible variation of conrod bearing bore...

Page 112: ...scolouration must not be reused Conrod and conrod bearing cover are marked together The conrod shaft must not show any cross scoring and notches Conrods are supplied as replacement parts with a machined small end bushing w AA PO3 2015 13 To reduce the distortion tendency conrods with a modified material were installed from June through September 1985 and are installed effective February 1987 03090...

Page 113: ...g in noises when the engine is operating at normal temperature Reconditioning 1 Check conrod bolts replace if necessary 03 310 2 Install conrod bearing cover To perform the step oil thread and bolt head contact surface and tighten to 30 5 Nm 3 Measure conrod bearing basic bore If the basic bore exceeds the value of 51 619 mm or is conical dress contact face of bearing cover on a surface plate to m...

Page 114: ... by turning or reaming 6 Dress side contact faces of conrod on the surface plate Checking angles 7 Check angles of bearing bores with a conrod tester 8 Align conrod bearing bore to small end bushing bore parallelism 9 Check axial relative to small necessary twist of conrod bearing bore end bushing bore and correct if 2 7 03 0905 3136 ...

Page 115: ...om bearing shells Pay attention to matching of conrod and bearing cap step 12 Conrod bolt 28 check 03 310 Piston 32 and conrod 25 push out of crankcase upwards Locking ring 37 remove step 3 and insert step 9 Piston pin 36 press out and press in by hand step 8 Installation lnstructlon Insert conrod into piston so that the chamfered splash bore in the small end bearing with the arrow in the piston c...

Page 116: ...ton install with tensioning strap 000 589 04 14 00 oil piston beforehand and clean cylinder bores steps 10 and 11 check in TDC position step 14 Special tools IO0 589 51 3700 I 0005890414001 I001 589 72 21 001 Matching pistons and cylinders 102 922 924 102 962963 I Standard normal size Repair size 1 0 0 5 L 89 468 L 89 482 89 478 89 492 89 488 L 89 502 89 498 89 508 89 509 89 518 89 519 89 528 A 89...

Page 117: ...9 992 90 009 90 018 89 988 9o 002 90 019 90 028 102 982i985 Standard normal size Repair size 1 0 5 95 969 95 981 95 998 96 008 A 95 979 95 991 9696 018 009 95 989 96 001 96 019 96 028 Repair size 2 1 O 96 469 96 481 96 498 96 508 96 479 96 491 96 509 96 518 03 0905 31613 ...

Page 118: ...d cylinder bores are arranged into three diameter groups within the tolerance and were previously identified with the figures 0 1 and 2 The identification is given as face of the crankcase and in As of April 1988 the tolerance stages are identified with the Group code letters A X and B before in the mating the piston crown previously I now 03 0905 31614 ...

Page 119: ...with Group numbers 0 1 and 2 namely piston x for Group No 0 and 1 Piston B for Group No 2 When performing repairs the cylinder bores should be honed according to the dimensions of the existing pistons plus piston play The piston crown is designed differently in the individual engines The piston crown of normal compression engines is either smooth or pro vided with a recess In addition there are tw...

Page 120: ...al size repair srzes All low compression engines have a step on the piston crown except 102 985 1985 additionally one valve niche 33 Rectangular ring wrth Internal chamfer runnrng surface chrome plated 34 Taper face 011 scraper ring running surface precksion turned 35 Chamferred 011 control nng wrth garter spring runnrng surfaces chrome plated T Herghtof size 2 0 mm PO3 0010 13 I j7 T 3 L PO3 0011...

Page 121: ...pression 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 102 982 as a noise reducing measure 03 0905 316 7 ...

Page 122: ...lon 0318 8 T 201 028 1102 985 Mahle Engine End No Manual transmission 023341 Vehicle ldent End No ransmrssron Standard Implementation 03188 KS 201 028 102 985 023788 070989 492527 The Group code numbers on the pistons and on the mating face of the crankcase have been replaced by Group code letters As a result the cylinder diameters and matching of pistons and cylinders have also been modified refe...

Page 123: ...are worn check the gap clearance and end play of the piston rings refer to table Check that the piston rings move easily Pay attention to installation position Top must be facing upwards Distribute the ring gaps evenly around the circumference of the piston 6 Oil piston pin and small end bushes 7 Install piston so that the chamfered splash bore in the small end bearing arrow and the arrow in the p...

Page 124: ...nsioning strap for piston rings and 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 of 30 Nm and angle of rotation torque of 90 13 Turn crankshaft and check clearance between piston pin boss and conrod 03 0905 316ilO ...

Page 125: ...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: ...03 318 Checking and reconditioning crankshaft Data Normal size II 4th repair size Crankpin width 28 000 28 084 up to 28 30 03 0905 31811 ...

Page 127: ...rom concentricity 0 02 flange from axial runout 0 012 Permissible variation of crankshaft journals from concentricity journal II IV journal Ill Scleroscopic hardness of crankshaft journals and crankpins 1 When crankshaft mounted on outer crankshaft journals I and V and one full rotation 2 If measurement performed when crankshaft installed eliminate radial beanng play by pressmgagainst crankshaft j...

Page 128: ...al tool jooo5892 1 OOJ Note Adhere to the sequence of operations of the diagram below when checking and reconditioning crankshafts Dianram Refer to Section Explanatory notes regarding diagram 03 0905 31 a 3 ...

Page 129: ...s present I Yes 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 I No 03 0905 31814 ...

Page 130: ...Grind crankshaft Dimensional inspection Refer to Checking Regrinding Fit parts to crankshaft End of inspection I 03 0905 31815 ...

Page 131: ...I I 1 Scrap Hardening Journal1 with radius hardening Journal without radius hardening Induction hardening System available Yes No 1 I y ction hardening 1 Induction or flame hardening Check hardening by etching lmenslons agree Journal1 with radius hardening I Journal without radius hardening 03 0905 318 6 ...

Page 132: ...test Test hardness with the drop hardness tester scleroscopic hardness The minimum hardness of 60 must exist at 2 3 of the circumference of the journal Hardening The journals without hardened radii may be hardened inductively or with a flame By contrast the journals with hardened radii arrows must always be hardened inductively If this is not possible scrap crankshaft When hardening the journals w...

Page 133: ...hardening operations on scrapped crankshafts Check hardening by etching the surface of the journal with a 2 alcoholic nitric acid HNOs No dark spots should appear on the surface of the journal Non hardened radii change to a dark colour By contrast the hardened radii must be just as bright as the surface of the journal As a comparison it is recommended to perform etching on a metallographically tes...

Page 134: ...ck crankshaft for cracks dimenslonal tolerance hardness and concentricity 03 318 27 4 25 I 31 QJ 31a QTI 26 28 3 a PQ3 0160 57 Crankshaft bearing covers 2 and 2 a install without bearing shells pay attention to markings tighten Hex bolt 90 Nm stretch bolt initial torque 55 Nm angle of rotation torque 90 steps 1 and 2 Basic bore measure conicity in direction A B and C step 3 03 0905 32011 ...

Page 135: ... 7 oil with engine oil and insert crankshaft step 8 oil and fit into grooves of thrust bearings pay attention to oil grooves step 9 oil together with thrust washers 23 a and install step 10 install hexagon bolt 90 Nm stretch bolt 3 a initial torque 55 Nm angle of rotation torque 90 steps 11 and 12 measure Check ease of movement of crankshaft steps 13 and 14 recondition and check angles 03 313 inse...

Page 136: ... dia 40 60 mm e g Hahn und Kolb BorsigstraOe 50 D 7000 Stuttgart 30 Order No G 222 K Quick caliper for internal measurements dia 60 80 mm Order No G 322 K Bow type measuring bolt 25 50 mm Order No 31346 025 Bow type measuring bolt 50 75 mm Order No 31346 050 03 0905 320 3 ...

Page 137: ... 4 15 or 4 20 4 25 1735 or 4 40 Crankshaft ournal width at thrust oearing 28 500 28 521 3r 78 600 L 28 621 38 700 L 28 721 3r 28 900 zzi 3r 29 000 29 021 vVrist pin dia 47 955 47 965 47 705 47 715 47 455 47 465 47 205 47 215 46 955 46 965 1 Colored dots on the crank webs or counterwelghts next to the crankshaft journals blue yellow red Basic bore and bearinadav Wrist pin width 28 000 28 084 up to ...

Page 138: ...on both sides are each identical The thrust washers each have two retaining lugs in the bearing cover as an anti twist lock and to avoid assembly errors the bottom lugs being fitted off center In addition all the thrust washers are chamfered at one end When repairing crankshafts the thrust bearing journals must be reground in the width to one of the dimensions stated in the table Section Data 1 Cr...

Page 139: ...th color coding blue blue I yellow I yellow yellow 1 blue I yellow red red yellow yellow red 1 Colored dots on the crank webs or counterwelghts next to the crankshaft journals 2 Chisel marks In mating face of crankcase at 011 sump end next to baste bore The normal size crankshaft bearing shells with the color coding blue yellow and red are supplied as replacement parts They should be matched accor...

Page 140: ...ng covers were converted to M 11 X 62 twelve sided stretch bolts with collar Previously Ml 2 x 70 hexagon bolts A Ml 2 x 70 hexagon bolts B Ml 1 x62 twelve sided stretch bolt In view of the narrower crankshaft bearings 4 15 mm thick thrust washers are installed on crankshaft bearing 3 thrust bearing A 2 15 mm thick thrust washers B 4 15 mm thick thrust washers IH I I PO1 0053 13 03 0905 32017 ...

Page 141: ...iod 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 PO3 0045 15 PO3 0046 13 03 0905 32018 ...

Page 142: ...ition In addition they are marked from front to rear with the code numbers 1 2 4 and 5 arrows with the exception of the thrust bearing covers and must not be interchanged or replaced 1 Install crankshaft bearing covers without bearing shells 2 Oil fastening bolts for crankshaft bearing covers and tighten to 90 Nm hexagon bolts or 55 Nm initial torque and 90 angle of rotation torque stretch bolts r...

Page 143: ... in fastening bolts and tighten to 90 Nm hexagon bolts or 55 Nm initial torque and 90 angle of rotation torque stretch bolts respectively PO32019 13 A Bearing shells in crankcase B Bearing shells in bearmg covers C Thrust bearings with thrust washers 03 0905 320110 ...

Page 144: ...ing the bearing shells refer to table for matching crankshaft bearing shells to crankcase 7 Measure width of thrust bearing journal and match appropriate thrust washers refer to table Section 11 Data 8 Oil bearing shells and crankshaft with engine oil and insert crankshaft 9 Oil thrust washers with engine oil and fit the grooves on the thrust bearing crankcase 03 0905 _ z 320 11 ...

Page 145: ...ves in the thrust washers must be facing the crankshaft webs When installing the thrust bearing cover hold both thrust washers tight 11 Install crankshaft bearing cover 12 Tighten fastening bolts of bearing covers to 90 Nm hexagon bolts or 55 Nm initial torque and 90 angle of rotation torque stretch bolts respectively 13 Measure end play of crankshaft bearings 14 Rotate crankshaft by hand and chec...

Page 146: ...shells are supplied only in the yellow version 17 Measure bearing diameter and note 18 Measure wrist pins determine radial play of conrod bearings Note If the conrod bearing play exceeds the specified value dress mating face of conrod bearing cover on a surface plate to max 0 02 mm 19 Fit pistons to conrod and install 03 316 Note The conrod must be installed on the pistons so that the chamfered sp...

Page 147: ...p 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 Remove oil filter 18 l lo disassemble and clean Install initial operation oil filter element After 1000 1500 km change engine oil and oil filter element 03 0905 320114 ...

Page 148: ...rain coolant 20 010 Remove radiator 20 420 Remove poly V Belt 13 342 Remove belt pulley and vlbratlon damper 03342 45 Radial seal 45 remove replace and install steps 1 3 and 4 Spacer ring 7 check replace if necessary step 2 Mounting hole clean check 03 0905 324 l ...

Page 149: ...entation of use of double roller chain a 4 mm narrower radial seal has been installed Size C 8 mm previously 12 mm For the same reason the mounting in the timing case cover D was made 3 4 mm flatter Size I D 9 8 mm previously 13 2 mm POl 0194 13 Standard implementation 08 86 radial seal 03 0905 32412 ...

Page 150: ... on the vibration damper is shorter Size E 0 8 mm previously 2 mm PO3 0141 13 Standard implementation 08 86 vibration damper transmwon 201 024 102 985 004202 039381 267452 A radial seal of a further manufacturer was installed for a certain period Identification outer ring black inner ring red 03 0905 32413 ...

Page 151: ... the timing case cover free of oil drying and spraying it with MB contrast spray white Part No 009 989 03 59 Run engine and pin point oil leak after 2 5 minutes 1 Pry radial seal 45 out of the timing case cover with a screwdriver When performing the step ensure that the crankshaft journal and the mounting hole in the timing case are not damaged Cover over crank shaft journal with a rag Deburr moun...

Page 152: ...ng 3 Oil the sealing lip of radial seal 45 Caution Do not use any grease Grease prevents the inclined webs on the sealing lip from positioning 4 Pull in radial seal with an installation tool Installation instruction Use special tool 102 589 00 14 00 on engines with single roller chain use additionally the spacer ring 102 589 01 14 00 01 on engines with double roller chain 03 0905 324el ...

Page 153: ...adial seal Preceding work Removing VansmIssIon 26 020 or 27 600 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: ... on the running surface on the crankshaft by the standard radial seal A Standard radial seal 6 Repalr radial seal 1 PO3 0078 15 _I 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: ... 2 Check running surface for radial seal on the crankshaft for signs of damage 3 Clean mounting hole in the end cover for the radial seal deburr if necessary 4 Screw inner part of installation tool onto crankshaft flange 5 Oil sealing lip of radial seal Caution Do not use any grease Grease prevents the inclined webs on the sealing lip from repositioning 6 Install radial seal arrow over the inner p...

Page 156: ... 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 8 Check for leaks with engine running 03 0905 32714 ...

Page 157: ...6 020 or 27 600 Removing clutch 25050 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 Knock in grooved ball bearing as far as the stop outer race flush 03 0905 330 l ...

Page 158: ...ng from the crankshaft special tool 000 589 33 33 00 and 000 589 25 33 00 2 Coat the new grooved ball bearing with the adhesive 002 989 94 71 and knock the outer race with a suitable drift to insert it into the crankshaft as far as the stop 3 Knock in locking ring 132 flush 03 0905 330 2 ...

Page 159: ...ly V belt 13 340 PO3 0029 55 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 unscrew bolt on 300 Nm Shock absorber 28 Unbolt at bottom bolt on step 4 and press up 25 Nm Vibration damper 11 pull off special tool 601 589 08 33 00 fit on Special tools 03 0905 342 l ...

Page 160: ...urges of the AC compressor are damped by the coupling so that the V belt runs practically slip free on the belt pulley 1 KW Crankshaft 1ZK 2 5 6 7 8a 9 10 1OP 11 13 15b 22 26 38 Crankcase Oil pump outer gear Crankshaft gear Strarght pm 3 x 5 mm Spacer ring M 18 x 1 5 x 75 stretch bolt Woodruff key Bellevrlle spnng washer Oil pump Inner gear Vibratron damper Belt pulley M6 x 13 bolts 011 pump dnve ...

Page 161: ...dified Size a 133 1 mm dia previously145 mm dia A 1st version B 2nd version Standard implementation 1 O 87 201 028 I 102 985 The spacer ring on the crankshaft was made 3 65 mm narrower with implementation of the double roller chain Removal and installation 1 Attach retaining lock 601 589 02 40 00 with two bolts to the oil pan arrows 03 0905 3421 3 ...

Page 162: ...eville spring washers 10 Installation Instruction Oil bolt threads and Belleville spring washers Install Belleville spring washers with curved side facing bolt head 4 Remove bolt 34 for bottom shock absorber mounting and swing shock abosrber 28 upwards Tightening torque 25 Nm PO3 0064 13 03 0905 _ 342J4 ...

Page 163: ...on 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 03 0905 34215 ...

Page 164: ...oving spark plugs 15 016 PO3 0025 36 Fan and fan coupling remove and install step 1 No 1 No 1 Valve Valve cylinder piston set to ignition TDC step 2 cylinder rocker arm bearing bracket remove and install 20 Nm step 3 spring remove from 1st intake valve install 05 250 stem seal remove from 1st intake valve install step 5 and 05 270 03 0905 34511 ...

Page 165: ...direction of rotation of engine until the large pointer stops TDC setting steps 6 through 11 unbolt at TDC pulse generator withdraw TDC pulse generator step 12 loosen and set preload of 5 mm position scale of gauge to 0 step 13 until dial gauge has moved back by 2 85 mm or 3 07 mm respectively step 14 Insert special tool 119 589 00 21 00 into setting slide The pin in the vibration damper must enga...

Page 166: ...ith holder 1 is attached to the timing case cover The pin in the vibration damper or on the belt pulley must be positioned exactly below the TDC pulse generator at a crankshaft setting of 20 after TDC The adjustment of the TDC pulse generator must be checked or corrected l When replacing the crankshaft or the vibration damper l When replacing the timing case cover l When installing parts to recond...

Page 167: ... 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 Checking 1 Remove and install fan shroud 1 and fan 75 tightening torque of bolt SO 25 Nm 2 Set engine to ignition TDC of No 1 cylinder 3 Remove and install rocker arm bearing bracket 61 by unscrewing oil pipe Tightening torque of bolts 63 21 Nm PO3 2026 13 03 0905 3451...

Page 168: ...bly sleeve on the valve stem for performing this step 05 270 6 Mount valve on piston crown 7 Turn back crankshaft to approx 10 before TDC of No 1 cylinder 8 Bolt dial gauge holder 363 589 02 21 00 with threaded sleeve onto cylinder head set bolt at front left Note With cylinder head removed mount a magnetic dial gauge holder onto the mating face of the crankcase 03 0905 34515 ...

Page 169: ...13 Loosen dial gauge and mount extension with 5 mm preload onto the valve stem or piston crown Turn scale of gauge until the large pointer is at zero 14 Turn on crankshaft in direction of rotation until the dial gauge has moved back by the appropriate value data in table 15 Position fixing device 119 589 00 21 00 into the setting slide 2 The pin on the vibration damper must engage in the groove of...

Page 170: ...g 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 03 0905 3497 ...

Page 171: ...ensioning rail 22 mark relative to each other steps 1 and 2 remove and place timing chain in chain box step 3 Install step lo 80 Nm pull off and insert Note Drill bearing pin 26 of engines with double roller chain tap M6 thread and knock out with impact extractor 115 589 12 33 00 and extension 100 589 00 43 00 When installing tensioning rail insert new bearing pin together with tensioning rail ste...

Page 172: ...e 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 Special tools 116 589 07 15 O I I 1165890034Ot Note As of January 1988 a double roller timing chain has been installed 03 0905 35012 ...

Page 173: ...aft gear and place timing chain in chain box 4 Pull tensioning rail 22 off bearing pin 26 Note On engines with double roller chain knock out bearing pin of tensioning rail with the impact extractor 115 589 12 33 00 and the extension 100 589 00 43 00 To perform the step tap an M6 thread approx 10 mm deep into the bearing pin I PO3 2056 13 PO3 2054 13A 03 0905 350 3 ...

Page 174: ...proves difficult knock in with the impact drift 116 589 07 15 00 Pay attention to the straight pin for locating when performing this step 8 Insert drive sleeve 9 Insert tensioning rail On engines with double roller chain insert tensioning rail and knock in new bearing pin as far as the stop 10 Install camshaft gear pay attention to color marking tightening torque 80 Nm 11 Check for leaks with engi...

Page 175: ... 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 90 with two mass flywheel 50 Nm angle of rotation torque 90 steps 6 and 7 Flywheel 16 or flex plate 43 with spacer disc 44 detach attach step 5 Special tools 001 569 66 21001 601 569 02 40 00 1 03 0905 41011 ...

Page 176: ...221924i962 963 have the same flywheels standard flywheel Compared to this standard flywheel the flywheel of engine 102 985 is lighter and the hole circle for the tapped holes for mounting the clutch are larger The flywheels must not be interchanged and can be replaced without the need for static or dynamic balancing I i H 4 I H 1 f 60 PO3 0026 15 A Engines 102 922 924 962 963 D 253 mm Dl 223 mm H ...

Page 177: ...he need for static or dynamic balancing Arrangement of flex plate on crankshaft of engines with automatic transmission 17 Ring gear ia Ml0 x 1 x22 stretch bolt 43 Flex plate 44 Spacer disc 44a Spacer disc bonded on Arrangement of flywheel on crankshaft of engines with manual transmission 16 Flywheel 17 Ring gear la MlOxl x22 stretch bolt 1 6 1 8 030905 4100 ...

Page 178: ...late Flywheel of manual transmission Flex plate of automatic transmission Removal and installation 1 Remove end cover 30 from the rear of the oil pan Remove bolts arrows bolt in tightening torque 10 Nm Press off end cover with screwdriver fit on 2 Attach retaining lock 601 589 02 40 00 with both bolts arrows The pins on the retaining lock must mesh into the ring gear teeth 3 Unscrew stretch bolts ...

Page 179: ... and disc 44 pay attention to centering of installation pin 6 Bolt in stretch bolts 18 and tighten to an initial torque of 30 Nm or 50 Nm respectively for the two mass flywheel 7 Torque stretch bolts 18 in a single operation by the specified angle of rotation torque of 90 03 0905 410 5 ...

Page 180: ...airs 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 03 0905 42011 ...

Page 181: ...e 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 The flywheel must be properly clamped for machining to ensure that the permissible axial runout of 0 05 mm is not exceeded After machining the clutch face must not show any shrink holes or chatter marks 03 0905 42012 ...

Page 182: ... onto the flywheel immediately Pay attention to instruction Lateral runout at ring gear max 0 4 mm Centering collar dia a for ring gear 275 31 27539 mm Clean contact surface of ring gear at flywheel before installation on ring gear This ring gear is welded on and cannot be replaced Replace driven member complete Commercial accessories Temperature measuring chalk Colour No 2815 220 white Thermochro...

Page 183: ...ossible Only use a flame in exceptional cases Coat only the inside of the ring gear for this purpose After replacing a ring gear the flywheel does not need to be balanced To avoid damage to the ring gear a ring gear with axially chamferred teeth was installed for a brief period to vehicles with automatic transmission Standard implementation April July 1986 standard Model Engine Engine End No Manua...

Page 184: ...ngine timing valvetrain 05 ...

Page 185: ... arm bearing supports 240 Removal and installation of valve springs 250 Checking valve springs 260 Replacement of valve stem seals 270 Checking and machining valves 280 Checking and replacing valve guides 285 Replacing valve seat ring 290 Machining valve seats 291 Removal and installation of chain tensioner 310 Replacement of timing chain 320 Installation of oil spray nozzle retroactively 328 Remo...

Page 186: ...raulic element under test on the base circle Load hydraulic element for approx 5 to 10 seconds If the element drops remove it To do this remove corresponding rocker arm bearing support OS 235 If a leaking hydraulic element is not found check fitting position OS 214 Note When pressure testing the compensating elements do not press valves against the piston crown Numbers 1 and 2 05 0906 211il ...

Page 187: ...isfactory check oil bores in cylinder head rocker shaft and rocker arm for passage and clean if required If several compensating elements are soft replace oil pipe in cylinder head 01 415 for this purpose remove cylinder head Ol 415 Replacement Valve clearance compensating element 58 With oil reservoir chamber full and original washer 57 push into the rocker arm up to the stop on the snap ring 56 ...

Page 188: ...ap Oil reservoir chamber Working chamber Return and venting bores Valve adjustment Is no longer required when equipped with hydraulic valve clearance adjusters The maintenance free hydraulic valve clearance compensating elements located in the rocker arms eliminate valve clearance i e dimensional changes in the valve train due to thermal expan sion and wear are compensated by the ele ments Valve t...

Page 189: ... built in clearance between guide sleeve and set bolt to the reservoir chamber a When the cam tip moves away from the rocker arm the set bolt 64 is relieved of load and the compression spring 60 presses the set bolt upwards until the rocker arm contacts the cam The vacuum arising from the upward movement of the set bolt opens the ball valve and oil flows out of the reservoir chamber a into the wor...

Page 190: ...ves in the washer 57 and from there via the annular gap between washer and rocker arm and the joint gap of the snap ring 56 In order that the hydraulic valve clearance compensating elements can be supplied with oil pressure corresponding to the respective engine speed oil flows unrestricted via nozzle A into the longitudinal channel a in the cylinder head pressure orientated oil feed The nozzle si...

Page 191: ... carefully out of the rocker arm with an aluminium or brass mandrel If a leaking compensating element cannot be detected try to move the rocker arm by hand If play is detected when doing this check and correct fitting position of the hydraulic valve clearance compensating elements 05 214 Caution When testing compensating elements do not press valves against the piston crown 3 Fill reservoir chambe...

Page 192: ... arm for free passage and clean if required To do this remove rocker arm 05240 If several compensating elements are loud or soft the oil nozzle in the cylinder head should be checked for firm seating and replaced if required Replacement 4 Slide new valve clearance compensating element 58 with the original washer 57 into the rocker arm 51 as far as the stop on the snap ring 56 Note Install new comp...

Page 193: ...riginal ball socket 55 Note Use ball socket Part No 103 055 00 24 if a new ball socket is installed PO5 2016 13 6 Check the installation position of the new valve clearance compensating element correct if necessary 05 2 14 7 Install in the reverse sequence 05 0906 211 8 ...

Page 194: ...s Preceding work Air cleaner removed 09 400 and 09 410 Cylinder head cover removed 01 406 PO5 0026 39 Camshaft 1 position the cylinder under test so that rocker arm 51 contacts the cam base circle Number 1 Measuring fixture mount set dial gauge with 5 mm pretension set dial gauge pointer to 0 050906 214 l ...

Page 195: ... be fitted Numbers 3 to 6 if necessary Note Before installation of the hydraulic valve clearance compensating element fill reservoir chamber with engine oil Rocker arm bearing support Install repeat test Numbers 7 and 8 Prior to this turn the engine with the starter and contact handle a few times 1 Production 2 Production install in the case of repatr when valve timing parts rocker arm beanng supp...

Page 196: ...Washer PO6 0087 1s Ball socket PO5 0025 13 Conventional tool Oial gauge Al DIN 878 0 g Mahr D 7300 Esslingen Part No 311000 05 0906 21413 ...

Page 197: ...ng gear valve guides valve stem seals have been renewed or when valves and or valve seat inserts have been machined For testing all timing parts located on the cylinder head must be installed correctly and working chamber of valve clearance compens ating elements must be filled with engine oil The tests can also be carried out when the cylinder head is removed To do this clamp cylinder head with f...

Page 198: ...ating element the residual stroke Z of the compensating elements must be measured The permitted residual stroke is 0 5 to 2 4 mm If a residual stroke smaller than 0 5 mm or larger than 2 0 mm is measured despite installing a washer and a ball socket in accordance with the installation specification table compensation is to be carried out with the next thinnest or thickest washer or ball socket 05 ...

Page 199: ...aft so that the rocker arms contact the cam base circle on cylinder under test 2 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 05 0906 2146 ...

Page 200: ...measuring pin adapter with 5 mm pretension small pointer and attach the dial gauge to claw sleeve bracket arrow Position large dial gauge pointer on zero by turning the dial gauge scale 4 Turn pressure pad 06 slowly to the right with a fork wrench 17 mm on the hexagon until a clearly detectable pressure point is reached Read off setting range residual stroke on dial gauge It must be 0 5 2 4 rnolp ...

Page 201: ...esidual stroke measured use a thinner or thicker ball socket 55 see note on the washer and ball socket tables Caution Before carrying out the installation fill reservoir chamber of the hydraulic valve clearance com pensating element with engine oil 05 211 Number 3 The grooves in the washer 57 must point in the direction of the compensating element setbolt 7 Install rocker arm bearing support 05 23...

Page 202: ...he 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 and fit locknut 163 Eliminate valve clearance by turning the adjustment screw 164 Numbers 1 to 4 Dial gauge bracket 02 Screw onto stud bolt at front left part of cylinder ...

Page 203: ...Intake valve open Number 7 Put engine on ignition TDC of No 1 cylinder Number 8 Unbolt and bolt up replace sealing ring 41 70 Nm Numbers 9 and 19 Unbolt set to one side with lines connected Number 10 Align with timing chain Unbolt camshaft timing gear Numbers 11 to 13 and 15 Select from table and insert Numbers 14 and 15 Assemble note color marking only install set bolt Repeat tests Numbers 6 and ...

Page 204: ...00 Closes before TDC Conventional tool Dial gauge A 1 DIN 878 e g Mahr D 7300 Esslingen Bestell Nr 311000 Note It is sufficient during assembly work if the marking on the camshaft agrees with the cylinder head edge in the ignition TDC position of the No 1 cylinder arrow In special cases for example when there are performance problems the start of opening of No 1 cylinder intake valve is to be chec...

Page 205: ...f No 1 cylinder 05235 3 Install intake valve rocker arm against the rigid rocker arm la Part No 102 055 00 01 together with the adjustment bolt 164 Part No 102 050 02 20 and the locknut 163 Part No 000936 008009 05 240 4 Install rocker arm bearing support 21 Nm 5 Install the dial gauge bracket with threaded sleeve onto the stud on the front left part of the cylinder head 6 Insert dial gauge and at...

Page 206: ...iming settings have to be corrected an offset Woodruff key has to be installed and a Offset mm Part No for a correction of approx 0 9 0 7 621 621 991 04 67 991 02 6 C K A 67 8 CKA 1 1 621 991 01 67 9 5 CKA 1 3 621 991 00 67 11 5 CKA An offset of one tooth on the camshaft timing gear produces approx 20 at the crankshaft Offsetting the Woodruff keys to the right in direction of travel A causes the v...

Page 207: ...sion 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 11 Align camshaft timing gear and timing chain 12 Remove camshaft timing gear set bolt 05 0906 2156 ...

Page 208: ...mshaft timing gear 14 Place cleaning rag over the timing case and remove Woodruff key 6 15 Insert selected Woodruff key 16 Put on camshaft timing gear In the process note that the colour markings on the camshaft timing gear and the timing chain align Do not torque the set bolt 9 yet 17 Repeat test Numbers 6 and 7 18 Torque camshaft timing gear set bolt 9 to 80 Nm For this hold in position with a f...

Page 209: ... 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 22 Remove dial gauge and dial gauge bracket 23 The remaining installation takes place in the reverse sequence PO5 2021 13 24 Check for leaks when engine is running 05 0906 21518 ...

Page 210: ...ings Numbers 1 and 2 Screw plug 40 of the chain tensioner unbolt bolt in 70 Nm Warning Screw plug is under pressure Remove compression spring 39 replace sealing ring 41 Numbers 3 and 11 Oil pressure pump 68 unbolt bolt in set to one side with lines connected Number 4 Camshaft timing gear 4 and timing chain align When installing note markings Screw 9 and 9a 80 Nm Numbers 5 to 8 05 0906 220 l ...

Page 211: ...ration damper Number 10 Special tools 001 589 66 21 00 Test values 001 589 72 21 00 I New value I Wear limit Permitted deviation from true running At the seat of 0 025 when locating camshaft in bearing camshaft timing gear positions 1 and 5 At the bearing points I 0 030 I 2 3 and 4 I I Camshaft bearing play radial I 0 050 0 091 I 0 11 axial I 0 070 0 150 I 0 18 Camshaft journals 0 Normal dimension...

Page 212: ...lied with oil via the longitudinal bore 10 5 mm which is sealed at the front with the camshaft timing gear set bolt and at the rear with a pressed cover arrow The oil feed takes place via a groove 360 and a transverse bore 3 5 mm 0 in the rear journals The diameter D of all 5 bearing points is 32 mm repair stage 32 5 mm A fork wrench can be put on flats A 24 mm at the rear end of the camshaft for ...

Page 213: ...arm bearing supports and the camshaft timing gear have to be removed for this If the camshaft is to be replaced all the rocker arms have to be replaced as well In the event of scored bearings or pronounced striation the camshaft bearings in the cylinder head and in the rocker arm bearing supports can be bored out by 0 5 mm and a camshaft with over dimensioned bearing spigots installed 01 419 05 09...

Page 214: ...number Vehicle identification end Since October 1987 camshafts have been fitted with 19 mm wide tinplated cams formerly 18 mm Identification number 39 Note As a temporary measure this camshaft has been given the identification number 3 Model Engine Engine end number Vehicle identification end 201 028 I 102 985 I 019320 I 062484 I 416851 I 435608 05 0906 220 5 ...

Page 215: ...installed As a temporary measure this camshaft has been given the identification number 5 Introduced in woduction October 1988 Model Engine Engine end number Manual transmission Engine end number Automatic transmission 201 028 I 102 985 I 027671 I 077053 From 09189 a chilled cast iron camshaft with crowned cams has been installed This camshaft is also supplied as a replacement part Identification ...

Page 216: ... oil groove in the rocker arm bearing support has also been widened from 4 mm to 5 5 mm arrow The injection bores in the oil pipe for camshaft lubrication have a different diameter depending on position A Oil pipe first design B Oil pipe second design PO 2207 1s A 01 8 4x 01 3 4x 03 5 1 2 3 4 B 0 4 3 4 POS 0162 13 05 0906 22017 ...

Page 217: ...n ignition TDC 2 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 Caution Do not turn the engine by the camshaft timing gear set bolt Do not turn the crankshaft backwards Engine end number Automatic transmission 05 0906 220 8 ...

Page 218: ...s compression spring tightening torque 70 Nm 05 310 Caution The chain tensioner hexagon cap nut is pressurized by the compression spring 4 Unbolt bolt on oil pressure pump 68 arrows and put to one side with the lines connected 5 Align camshaft timing gear and timing chain 05 0906 22019 ...

Page 219: ...r chain the curvature points to the camshaft 8 In order to loosen or tighten up camshaft timing gear hold in position with flats at the rear of camshaft with a fork wrench 24 mm 9 Remove and install rocker arm bearing supports 61 05 235 tightening torque 20 Nm 10 Remove camshaft Before installing lubricate all bearing points with engine oil Check whether the marking on set collar aligns with edge ...

Page 220: ...stall hexagon cap nut 40 and compres sion spring 39 with new sealing ring 41 tightening torque 70 Nm 12 The installation proceeds in reverse sequence 13 Check for leaks when engine is running 05 0906 220111 ...

Page 221: ...46 35 Engine turn so that rocker arm of bearing support being removed is on base circle of cam cam tips pointing downwards Oil pipe 67 remove install Number 2 Rocker arm bearing support 61 remove install 20 Nm Number 3 Installation note Install ball socket 55 in original position Note identification number on cylinder head and camshaft bearing cap Special tool 05 0906 235 l ...

Page 222: ...63 and with two installation sleeves 60 Each bearing support simultaneously acts as a rocker arm carrier The rocker arm bearing supports can be distinguished by the following features Front bearing support Code No 1 Two bearing positions arrows Center bearing supports Code No 2 and 3 These two bearing supports are the same apart from the identification numbers Rear bearing support Code No 4 Connec...

Page 223: ...be confused with each other They are therefore identified on the right hand side with the Numbers 1 2 3 and 4 from the front to the back The identification of the bearing support must agree with the number which is cast in the cylinder head arrows In the replacement parts area the bearing supports are made individually and without code numbers stamped on The corresponding code number is to be appl...

Page 224: ...ow 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 head and a feed bore in the bearing support which is also the set bolt bore 1 Camshaft 50 Rocker shaft 51 Rocker arm 55 Ball socket 58 Hydraulic valve clearance compensating element 68 Oil pipe I I PO6 207 ...

Page 225: ... pipe 67 to do this unbolt bolt up the two bolts 63 on the pipe clamps tightening torque 20 Nm 3 Remove install relevant rocker arm bearing support tightening torque 20 Nm Note Loosen seized bearing supports using light blows with a plastic hammer The ball sockets 55 on the hydraulic elements can stick or fall down when removing the bearing support Install ball sockets in their original positions ...

Page 226: ...circle of the cam Number 1 Oil pipe 67 remove install Number 2 Bearing support 61 remove Rocker shaft 50 pull out with impact extractor 116 589 20 33 00 and extension 616 589 00 34 00 Lubricate new rocker arm and rocker shaft and install Prior to this rebuild hydraulic valve clearance compensating element 05 211 Numbers 4 and 5 New bearing support 61 install with rocker shaft without rocker arm 20...

Page 227: ...bers 9 and lo 20 Nm Special tools 7 001 589 66 21 00 116 589 20 33 00 Threaded pm M8 116589203300 Data Rocker arm bore 18 016 18 027 __ Rocker shaft diameter 17 089 TKEB Radial clearance between rocker arm and rocker shaft 0 016 0 038 Rocker arm bearing support bore i 8 000 i 8 01 Note Only one bearing support can be replaced on an engine otherwise camshaft binding will result 05 0906 2402 ...

Page 228: ...ation the camshaft bearings can be bored out by 0 5 mm and a camshaft with oversized journals installed 01 419 These camshafts have different code numbers 05215 and 05 220 If the bearing supports are put together without rocker shafts tighten the set bolts to max 15 Nm otherwise the shaft bores distort The radius on the rocker arm has been changed in order to increase the clearance between the roc...

Page 229: ...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 PO5 2038 13 05 0906 24014 ...

Page 230: ...er shaft with the impact extractor 116 589 20 33 00 and extension 616 589 00 34 00 or with an M8 bolt 5 Lubricate new rocker arm and rocker shaft and install b Bearing suppoft 6 Lubricate new rocker shaft and install without rocker arm in the new bearing support Note Insert the arrow is rocker shaft so that the half bore located in one half of the screw shaft 7 Put on bearing support tighten set b...

Page 231: ...ding occurs remove the bearing support again and replace with another 9 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 11 The installation proceeds in the reverse sequence 05 0906 24016 ...

Page 232: ...der 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 Remove install valve springs with the lever compressor 601 589 02 61 00 Cylinder head Installed Piston of the relevant cylinder position on ignition TDC Number 1 Oil pipe 67 remove install Number 2 05 0906 250 l ...

Page 233: ...umber 4 Cylinder leakage tester Disconnect connect to the relevant cylinder Number 5 Pressurize cylinder Valve totters 45 remove and install with the lever compressor 601 589 02 61 00 and magnet 116 589 06 63 00 Remove insert valve springs Numbers 7 to 9 Installation note Install valve spring so that the color marking and the narrower coil point downwards Special tools I 001 589 72 21 00 116 58906...

Page 234: ...y and must be installed so that the color marking narrow coil points towards the thrust collar 47 Color marking yellow red or violet red A thrust collar 47 is inserted under the valve springs which is supported on the cylinder head via anti rotation lugs As on all other engines the valve spring thrust bearing at the top forms valve spring retainers 46 which are attached to the valves with valve co...

Page 235: ...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 Attach support bridge 102 589 01 59 00 to the cylinder head and remove the valve springs with the lever compressor 05 0906 250 4 ...

Page 236: ...linder 1 and 4 I I 2 and 3 2 Removal and installation of oil pipe 67 3 Remove and install the required rocker arm bearing support 61 tightening torque 20 Nm Installation note Before installing rocker arm bearing support lubricate camshaft journals Install the rocker arm bearing support so that the support area for the oil pipe points rearwards and the code number is on the right in the direction o...

Page 237: ...spring and take out valve cone halves with the magnetic lever Caution Do not remove the valve springs without compressed air in the cylinder otherwise damage can occur due to contact between the valves and the piston 8 Remove install valve spring retainers and valve spring 9 Check valve spring 05260 and valve spring retainers replace as necessary 10 Installation is the reverse of removal 050906 25...

Page 238: ...53 02 20 yellow red or violet red 102 053 11 20 violet yellow orange or yellow yellow orange Note Out side 0 mm Wire 0 mm Free length Spring force at the pre loaded length When carrying out repairs valve springs are to be checked for corrosion before reuse and to be replaced as necessary 05 0906 260 1 ...

Page 239: ...ng 1 Check valve springs with a valve spring tester or with a spring test scale 2 Check spring force at the specified length 3 If the limit value is not achieved replace valve springs PO5 2129 1 05 0906 260 2 ...

Page 240: ...01 8 Valve springs removed 05 250 48 PO5 0047 34 Valve stem seal 48 and 49 extract with special tool 104 589 00 37 00 Debut r valve stem at the groove Replace hammered valve cone halves spring seats and thrust collars Lubricate valve stem seal and insert Special tool 601 589 02 43 00 Note color marking use assembly sleeve Special tools 05 0906 270 l ...

Page 241: ...d d 7 3 mm Wire ring phosphated black Color brown Exhaust valve stem seal 49 Chamfer arrow inclined d 8 2 mm Wire ring bright galvanized yellow Color brown Valve guides which are opened out at the retaining groove for the valve stem seal must be replaced When installing the valve stem seal on the intake valves it is absolutely essential that the plastic sleeve which is enclosed in the repair set i...

Page 242: ...on January to Februarv 1986 Model Engine Engine end number Manual transmission Engine end number Automatic transmission 201 024 I 102 985 I 003217 003513 I 029482 031994 Exhaust valve stem seal Introduction of Viton valve stem seal Color identification brown Introduced in production June 1988 PO5 0169 13 Model Engine Engine end number Manual transmission Engine end number Automatic transmission 20...

Page 243: ......

Page 244: ...alve heads insufficent val head height h worn or grooved valve stem must be replaced Number 1 Measure valve stem eccentricity Replace va when eccentricity is more than 0 03 mm Number 2 Note operating instructions for machining equipment Note adjustment angle a 45 15 Weplac valve when maximum tolerances are reached Numbers 3 and 4 Ive 8 05 0906 280 l ...

Page 245: ...urning equipment e g Krupp D 5309 Meckenheim VS Model e g Hunger D 8000 Miinchen 70 Type VKDRl Part Number 203 00 200 Data Valve head D the valve head Identification on end of stem Engine I Inlet valve I Exhaust valve 102 985 I E 102 08 IA 102 03 27 05 0906 280 2 ...

Page 246: ...must be neutralised before scrapping They must therefore be collected and sent to Mercedes Benz AG Werk Marienfelde DaimlerstraOe 145 Anlieferstelle KST 3153 Arbeitsvorbereitung TAI 43 Exhaust valve 42 PO5 0043 15 POS 0042 15 After machining or replacing valves the installed length of hydraulic valve clearance compensating elements must be checked and corrected if necessary 05214 05 0906 28013 ...

Page 247: ...lve stem are to be replaced 2 Measure valve stem eccentricity Replace valve when an eccentricity of more than 0 03 mm is measured 3 Machine valve seat Note operating instructions of the machining equipment and adjustment angle a 45 15 4 Measure valve seat eccentricity and valve head height h Replace valve if the limit values are reached h PO50035 l 3 05 0906 28014 ...

Page 248: ...89 03 23 00 If the pin of the no go checking mandrel can be slid in longitudinally or laterally to the full extent 6 5 mm replace valve guide Special tools 103 589 02 15 00 and 103 589 03 15 00 Insert Super cool in liquid nitrogen approx 3 minutes special tools 102 589 04 15 00 and 102 589 05 15 00 See repair note After insertion check inside 0 with testing mandrel special tools 102 589 00 23 00 a...

Page 249: ...ach base bore to 14 2 mm 0 Special tools 115 589 00 53 00 102 589 00 63 00 102 589 01 63 00 and 102 589 02 63 00 See repair note Valve seat ring 53 and 54 after installing a new valve guide check for eccentricity if necessary machine 05 291 Special tools 000 589 10 68 00 1 1 7 5 8 9 0 3 2 3 0 0 102589016300 117589052300 115589005300 103589031500 110589035300 102 589 05 1500 103 589 02 15 00 102 58...

Page 250: ... grey brown red Base bore in cylinder head 114 030 14 035 114 198 14 203 114 030 14 035 114 198 14 203 Overlap I 0 009 0 021 IO 01 1 0 024 1 0 009 0 021 0 011 0 024 Valve guide inside A 8 000 8 015 8 000 8 015 9 000 9 015 9 000 9 015 Length L I 46 0 I 46 0 I 51 0 I 51 0 Note Valve guides are made of different materials on the intake and exhaust side Intake valve guide 54 copper olours Exhaust valv...

Page 251: ...g process Provide guide sleeve base bore and complete broach with ample supply of kerosene Slide broaching tool in direction of broaching into the guide sleeve so that when putting the guide sleeve on the valve seat ring 3 the first broach cutter is inserted in the base bore When doing this note that the correct side A or B of the guide sleeve is placed on the valve seat Center guide sleeve by rot...

Page 252: ...inder head is not heated up Coat valve guides with wax or oil before driving in Guide sleeve valve seat allocation to enaine Valve seat Engine Guide sleeve Part No Base bore 0 in cylinder head Intake 102 922 924 102 589 01 63 00 14 2mm 102 962 963 I 102 985 I 102 589 02 63 00 I Exhaust I 102 985 I 102 589 00 63 00 I 05 0906 285 5 ...

Page 253: ...te A new valve seat ring with normal dimensions can be used when specified overlap is present If minimum overlap is not achieved machine base bore for valve seat ring Machined base bore measure Valve seat ring repair stage skim so that the specified overlap is achieved Cylinder head 1 heat up in water bath Valve seat ring Super cool with liquid nitrogen and stamp with a suitable mandrel Machine va...

Page 254: ...00 Munchen 70 Size 2 Part No 220 03 110 Valve seat turning device e g Hunger D 8000 Munchen 70 Type VDSN l 45 30 Part No 236 03308 Test set for valve seats e g l iunger D 8000 Munchen 70 Part No 216 93 300 Internal measuring instrument measuring range 35 100 mm e g Mahr D 7300 Esslingen Part No 844 N External micrometer measuring range 25 50 mm e g Mahr D 7300 Esslingen Part No 40 S l f 05 0906 29...

Page 255: ...I Intake I Exhaust I Data PO6 0064 N Exhaust 05 0906 29013 ...

Page 256: ...PO5 0164 11 This step must be turned off in order to machine the valve seat ring There is a repair valve seat ring with larger outside diameter as a replace ment part for all valve seat ring designs After renewing valve seat rings the fitting condition of the hydraulic valve clearance compensating elements must be checked and corrected if necessary 05214 05 0906 29014 ...

Page 257: ...instructions See data for adjustment Note Only loosen pilot when eccentricity of valve seat ring has been checked Valve seat eccentricity check Number 3 Valve seat width b measure correct if required Number 4 Valves insert and measure stand off A PO5 006 Valve guides 56 check 05285 05 0906 29l l ...

Page 258: ...eat 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 216 93 300 60 correction steel No 13 for correction angle below y e g Hunger D 8000 Munchen 70 Part No 216 64 622 Data Inlet Exhaust PO50060 13 05 0906 291 2 ...

Page 259: ...same dimension by which the cylinder head parting surface has been reworked Note Clamp cylinder head in clamping fixture for stripping down and machining Machine valve seats with valve seat turning equipment with valve seat grinding machine or with valve seat miller After machining the valve seat rings the installation position of the hydraulic valve clearance compensating elements must be checked...

Page 260: ...ilot when eccentricity of valve seat has been checked Number 3 3 Check valve seat eccentricity For this push test sleeve 19 with dial gauge bracket 20 and dial gauge on the pilot 5 5 Pilot 18 Dial gauge 19 Test sleeve 20 Dial gauge bracket 4 Measure valve seat width b and if required correct top P 15 angle and the bottom y 60 angle PO 0060 l 05 0906 29114 ...

Page 261: ...5 Insert valves and measure distance A 05 0906 291i5 ...

Page 262: ......

Page 263: ... 13 342 Bolt 49 loosen Number 2 Bolt 51 unbolt Number 3 Alternator swing outwards Sealing plug 40 unbolt Note The sealing plug is under pressure Number 4 Sealing ring 41 replace Compression spring 39 remove install Chain tensioner casing 36 with setbolt 37 unbolt Number 5 050906 3101 ...

Page 264: ... 6 screw into cylinder crankcase 15 Nm Number 7 push in Number 8 screw in 70 Nm Number 9 mount Number 10 assemble 13 342 check for leakage Stud driver insert 17 mm l 2 square e g Hazet D 5630 Remscheid Part No 985 l 7 Note The housing 36 of valveless hydraulic lock chain tensioner is bolted to the crank case 1 The application force required to tension the chain is comprised of the force from compr...

Page 265: ...fied in order to improve the function of the chain tensioner Changes l Ends free from burrs l Smaller twist dimension a 0 1 mm was 0 5 mm l Improved material l Dimension b 3 5 mm was 4 0 mm Introduced in production December 1985 Model Engine 38 PO52052 13 36 Chain tensioner casing 37 Setbolt 38 Locking spring 39 Compression spring 40 Cap nut 41 Sealing ring 38 37 36 POS 0170 13 Engine end number M...

Page 266: ...g 41 and remove compression spring 39 Caution Sealing plug is pressurized by the compression spring 5 Unbolt chain tensioner case 36 from the cylinder crankcase with the stud driver insert 6 The chain tensioner must be stripped down before assembly To do this press the setbolt 37 and locking spring 38 out of chain tensioner casing 36 in the direction of the arrow Clean parts and check for wear POS...

Page 267: ...spring 38 into the assembled chain tensioner casing 9 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 11 Install Poly V belt 13 342 12 Check for leaks when engine is running 05 0906 31015 ...

Page 268: ...with old timing chain 21 Exterior bracket Riveting tool Connector link bolt remove install 15318 remove and install 05310 grind off Number 3 connect pull in Numbers 4 to 7 press on with riveting tool 000 589 58 43 00 rivet set 103 589 01 63 00 for single roller chain conversion set 000 589 53 43 for double roller chain Numbers 8 to 10 remove convert Number 11 rivet individually Numbers 12 and 13 0...

Page 269: ...ockets are to be checked for scores and pitting as well as the chain tensioner for perfect function before installing a new timing chain Improved timing chains have been installed since November 1985 Changes Sleeves 2 with recesses notches arrow and A f lence improved oil supply to bolts 3 and sleeves 2 3 2 I A i A A PO5 0165 13 050906 32012 ...

Page 270: ...ual transmission Engine end number Automatic transmission 2 0 1 0 2 4 1 0 2 9 8 5 1003057 003893 I 027366 036001 201 024 102 985 I I 003925 Engine end No Automatic transmission 036289 312513 Not recorded Double roller timing chains have been installed since January 1988 05 0906 32013 ...

Page 271: ... tensioner 05 310 3 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 4 Attach new timing chain and the connector link onto the old timing chain To do this press out ground off double link 5 Put the new timing chain connected with the old timing chain onto the camshaft timing gear Rotate crankshaft POS 2057 13 Caution The timi...

Page 272: ...ends of the new timing chain with the repair connector link Note Connector link must be inserted from behind 8 Fit riveting set 103 589 01 63 00 to the basic tool 000 589 43 00 corresponding to the timing chain design single or double roller chain 9 Put loosely attached exterior bracket of the connector link in the press tool arrow The exterior bracket is held magnetically 10 Put press tool on the...

Page 273: ...s 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 13 Check riveting arrows re rivet if required 14 Install chain tensioner 05310 PO 2056 13 05 0906 32016 ...

Page 274: ...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 05 0906 32017 ...

Page 275: ...OS 0076 35 Sealing plug 13 remove Numbers 1 and 2 Joggle plate Part No 102 589 14 15 00 bolt up unbolt Number 3 Oil spray nozzle 66b and 66 drive home up to stop Number 4 Idler gear shaft install 05 412 Timing case cover install 01 210 On engine change oil and filter When engine is running check for leaks Special tools 05 0906 3281 1 ...

Page 276: ... 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 Production breakpoint of the various designs Injection engines 66a 1st design March to April and May 1986 66b 2nd design November 1986 to July 1987 66c 3rd design July 1987 05 0906 328 2 ...

Page 277: ...ection engines 1 st design 201 024 1 102 985 I00381 l 003828 I 03521 o 035424 Production breakpoint November 1986 Injection engines 2nd Design Model I Engine I Engine end No Man transm I Engine end No Autom transm 201 028 I 102 985 I 007099 I 045782 Production breakpoint July 1987 Injection engines 3rd Design 201 028 I 102 985 I 015733 I 057671 05 0906 3281 3 ...

Page 278: ... A and window arrow 2 Unscrew sealing plug with impact extractor 116 589 20 33 00 and stud 116 589 00 34 00 3 Attach joggle plate AP 102 589 14 15 00 with two hexagon bolts M8 x 15 48 4 8 5 0 P18 0009 13 1 Cylinder crankcase 48 Fixing bolts 50 Straight pin guide for timing case cover 66 011 spray nozzle AP JOQQle plate 05 0906 32814 ...

Page 279: ...tach joggle plate 6 Install idler gear shaft 05412 7 Install timing case cover 01 210 8 Change engine oil and filter 9 Check for leaks when engine is running POS 0013 13 Parts required Part No Oil spray nozzle 102 180 09 43 Carburettor engine 102 180 08 43 Injection engine Standard Text and flat rates Install oil spray nozzle for timing chain Idler gear shaft removed 02 0367 01 Related work 5 flat...

Page 280: ......

Page 281: ...il pressure pump 69 unbolt bolt up put to one side with lines connected Number 4 Camshaft timing gear 4 unbolt bolt up 80 Nm Number 5 Tensioner blade 22 remove from bearing bolt put on Note Plastic support 23 check possibly renew Number 8 Camshaft adjustment check Number 11 On double roller chain spot drill bearing pin 26 and drive out with the impact extractor 115 589 12 33 00 Install new tension...

Page 282: ...support has lateral guide bars arrows The plastic support is also fixed differently in this way the support is prevented from slipping off the tensioner blade A Former design B Current design Production breakooint Auaust 1986 Model Engine Engine end No Engine end No Man transmission Auto transmission 325157 05 0906 33012 ...

Page 283: ...n 1 Align timing chain and crankshaft gear 2 Align timing chain and camshaft timing gear 3 Remove chain tensioner 05 310 4 Unbolt oil pressure pump with lines connected arrows and put to one side 2 B Pck5 2056 13 05 0906 330 3 ...

Page 284: ...nsioner blade 22 for single roller chain inwards and remove from bearing pin 26 install 7 On engines with double roller chain drive out bearing pin 26 of the tensioner blade with the impact extractor 116 589 20 33 00 and extension 116 589 03 34 00 To do this cut an M6 thread approx 10 mm deep on the bearing pin Remove tensioner blade 8 Check plastic support for wear replace if necessary PO5 2032 1...

Page 285: ... 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 13 Run engine check for leaks 05 0906 3306 ...

Page 286: ...eceding work Air cleaner removed 09 400 and 09 410 Cylinder head cover removed 01 460 PO5 0078 57 Chain tensioner 39 to 41 remove install 70 Nm Number 1 Fan shroud 1 and fan 75 remove install bolt 80 25 Nm Number 2 Piston of No 1 cylinder position on ignition TDC Number 3 050906 340 l ...

Page 287: ... 0 0 001 589 72 21 00 100 58900 34 00 connected Number 4 align and unbolt bolt 9 and 9a 80 Nm Number 5 extract with impact extractor 116 589 20 33 00 and stud 100 589 00 34 00 drive home Note Insert guide rail bolt with sealant 001 989 25 20 Note that the fixing nose on the guide rail engages in the guide rail bolt Numbers 6 and 7 check for leaks 001 589 66 21 OC 05 0906 34012 ...

Page 288: ...hain B Guide rail for double roller chain Removal and installation 1 Removal and installation of chain tensioner 05310 Tightening torque of hexagon cap nut 40 70 Nm 2 Remove fan shroud 1 and fan 75 Tightening torque of bolt 80 25 Nm 3 Position piston of No 1 cylinder on ignition l DC POS 0079 13 P20 0006 13 05 0906 34013 ...

Page 289: ...ve sprocket Note When installing the sprocket note color markings Tightening torque of set bolt 80 Nm 6 Withdraw both guide rail bolts 26 with impact extractor 116 589 20 33 00 and stud 100 589 00 34 00 Note If the guide rail bolts are too tight the extractor 115 589 20 33 00 with stud 115 589 00 34 00 can also be used Impact extractor in place 050906 340 4 ...

Page 290: ...uide 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 8 Check for leaks when engine is running 05 0906 340 5 ...

Page 291: ...ith single roller chain Guide rail 25a single roller chain remove put on Number 1 b With double roller chain Piston of No 1 cylinder position on ignition TDC Number 2 Oil pressure pump 69 unbolt bolt up put to one side with lines connected Number 3 Chain tensioner remove install 05310 05 0906 340 6 ...

Page 292: ...rankshaft gear pull forward as far as possible remove and fit guide rail 25b Number 9 Note When pushing back the crankshaft gear and the timing chain note the positioning pin in the camshaft flange and alignment of timing chain to tension lever Idler gear shaft 18 install bolt 20 5 Nm Number 10 Further installation in reverse sequence When engine is running check for leaks Special tool 1 001 589 6...

Page 293: ... chain B Guide rarl for double roller chain Removal and installation a With single roller chain 1 Pull off guide rail 23 install b With double roller chain 2 Position piston of No 1 cylinder on ignition TDC 3 Unbolt bolt up oil pressure pump arrows and put to one side with lines connected POS 0075 13 05 0906 340 8 ...

Page 294: ...5310 5 Align timing chain and camshaft timing gear and unbolt camshaft timing gear Put timing chain in timing case 6 Align timing chain and crankshaft gear 7 Unscrew bolt 20 and remove retaining clip 19 Po5 2056 13 05 0906 340 9 ...

Page 295: ...de rail 25b Put on timing chain and push back crankshaft gear together with timing chain Note When pushing back the crankshaft gear note the positioning pin in the camshaft timing gear flange and the color marking 10 Install idler gear shaft tightening torque of the hexagonal socket screw 20 5 Nm reference value POS 2085 13 PO5 2085 13 05 0906 340 10 ...

Page 296: ... chain tensioner 05310 Tightening torque of sealing plug 40 70 Nm 13 Check adjustment marking of camshaft arrow at ignition TDC position of engine correct if necessary 14 Install oil pressure pump in so doing note driving disc 15 The installation is the reverse of removal 16 Check for leaks when engine is running 05 0906 34Ot ll ...

Page 297: ...1 remove install 05 310 Oil pressure pump 69 unbolt bolt up set to one side with lines connected Number 2 Camshaft timing gear 4 align with timing chain Number 3 Crankshaft gear align with timing chain Number 4 Bolt 9 and 9a unbolt bolt up and remove camshaft timing gear 80 Nm Note marking Number 5 Guide rail 25a remove install only on single roller chain Number 6 05 0906 412 l ...

Page 298: ...cover and cylinder crankcase It is fixed axially by a retaining clip 19 bolted on the cylinder crankcase which engages in a groove on the idler gear shaft The teeth for driving the ignition distributor 18 are located behind the front bearing position Arrangement of idler gear shaft Engines 102 985 I Cylinder crankcase 6 Beanng bush in timing case cover 17 Bearing bush In cylinder crankcase 18 Idle...

Page 299: ...olt bolt up oil pressure pump arrows and put to one side with lines connected 3 Align camshaft timing gear and timing chain 4 Align crankshaft gear and timing chain 5 Unbolt camshaft timing gear and remove put timing chain in timing case PO3 2056 13 05 0906 41213 ...

Page 300: ...secure with bolt 20 tightening torque 5 Nm reference value 10 11 Install guide rail 25a Assemble camshaft timing gear at the same time noting colored markings tightening torque 80 Nm 12 Check adjustment marking of the camshaft arrow at ignition TDC position of engine correct if necessary 13 Install chain tensioner 05310 14 The installation is the reverse of removal 15 Check for leaks when engine i...

Page 301: ... pressure pump 69 remove together with driving disc 76 On Model 201 set oil pressure pump with lines connected to one side Gasket 75 renew Driving disc 76 remove install Flange 71 unbolt bolt up with attachment eye 22 25 Nm Number 4 O Ring 73 replace Hexagon socket bolt 9a unbolt bolt up 80 Nm Remove install driving disc sleeve 70 Number 5 05 0906 43711 ...

Page 302: ... 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 The fitting position of the flange on the cylinder head is fixed by two straight pins arrows The cam shaft timing gear 4 is attached to the camshaft with the driving disc sleeve 70 and the hexagon socket screw 9a The O Ring 73 on the flan...

Page 303: ...pump and set to one side with lines connected Model 201 2 Remove install driver 76 Replace gasket 75 75 69 PO5 0081 13 3 Unbolt bolt up flange 71 together with the attachment eye 22 renew O Ring 73 Tightening torque of bolts 72 25 Nm Note both dowels 70 POS 0083 13 05 0906 43713 ...

Page 304: ...4 Unscrew hexagon socket bolt 9a and remove insert driver sleeve 70 tightening torque 80 Nm 70 9a 6P I a 05 0906 43714 ...