Mercedes 207,208,210,307,308,310,408,410D-service_manual_EN

8/7/2019 Mercedes 207,208,210,307,308,310,408,410D-service_manual_EN

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Mercedes-B~nz Transporter207'0,30'70, 21'00, 4,"OD-, -2080,3080,:3:1 O " D ; J . ! J - 0 8 0 : , ,601~,602an(l 6'fS:En~gine~~~,;/\"~_:, ,,:' ,

. . . , ' 1 ~ l i ~ ; ~ i ; : . ~ : i ' , , ~-. :. 'DETAILED DESCRIPTION- OF - ,_ REMOVAL,' '_-INSTALLATION, ADJUSTMENTS, REPAIRS,OVERHAUL AND SERVICING OF ALL THE iMAJORVEHICLE PARTS, (except body). ,INCL. -ENGINE,VALVES,DIES,EL '-FUEL INJECTION ,SY;STEM,CLUTCH,BRAKE:S; STEERING. TRANSMISSION(except overhaul). F'RONT AND Rr=AR- AXLESANbSUSPENSION, ENGINE ELECTRJCS -WITHEXPLODED VIEWS AND. COMPLEJE. TE_Cf-INICALDATA AND-WIRING- DIAGRAMS.

www.-russek-manuals,co.ukA NO TH ER B OO KP U BL IS H ED B Y :

PETER RUSSEKPUBLICATIONS LTD.Te lephone

0 14 9 4 4 4 08 29

Me: r -cedes : -Ben -z2070,3070,2100,4100208D, -308'0, 3100, 408D

2..3,,2.4 AND 2.9 LITREDIESEL ENGINESADJUSTMENTS. TUNE-UP P E T E RREPAIRS OVERHAULS f t IUSS! ! \SERVICING. FAULT FINDINGft

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I!II

POCKE I MECHANICMercedes-Benz2070,3070,2100,3100,4100,2080,3080,4080

2 .3 ,2 .4 a nd 2 .9 L it re Di es elCOVERING:GENERAL INFORMATION, DIMENSIONS, WEIGHTS,CAPACITIES, GENERAL, SERVICING NOTES 4ENGINES , , ' 9LUBRICATION SYSTEM ' ,.., 65COOLING SySTEM ' , , ' ,.. 69DIESEL FUEL INJECTION SYSTEM 77CLUTCH , , 89MANUAL TRANSMISSION , , ' 94FRONT AXLE , , , ,.,., 100REAR AXLE AND PROPELLER SHAFT ' 110FRONT AND REAR SUSPENSION 118STEER'ING , ' 120BRAKE SYSTEM , , , , 127ELECTRICAL SYSTEM ..,., 1452.4 LITRE DIESEL ENGINE - TYPE 616 153SERVICING AND MAINTENANCE , , 176FAULT FINDING SECTION 179WIRING DIAGRAMS, .., , ,., , 188

!II/-

IBY PETER RUSSEK )


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ORDER NO.: 445Published byPeter Russek Publications Ltd.3rd Floor, Block C

Commercial SquareHigh Wycombe, Bucks, HP11 2RHTel.: High Wycombe (01494) 440829(01494) 526882Fax: (01494)473980E-mail: [email protected]

ISBN. NO_ 1-89878045-5WITH FAULT FINDING SECTIONAT END OF MANUAL

The publisher would like to thank Daimler Chrysler U.K. Ltd. for theirinvaluable support in producing this manual.No par t of this publ icat ion may be reproduced, stored in a retrieval system ort ransmit ted in any form, e lectronic, mechanical , photocopying, recording,translating or other means without prior permission by the author.No liability can be accepted for any inaccuracies or Omissions in thisworkshop manual , al though every poss ible care has been taken to make it ascomplete and accurate as possible Every care has also been taken toprevent personal injury or damage to equ ipment when working on the vehic leWe have tried to cover all models produced to the day of publication, but areunable to refer to all modifications and changes for certain markets or up-dating of models.Re-publ ished and re-pr inted January 2006

Peter R.D_Russek - 2000 Printed in England

II!i_.!1l1 PREFACESmall though thIs Workshop Manual ls In size, it lacks no detail in coveringmost of the servicing and repalr of the Mercedes Van and Camper Dieselmodels listed on the outside cover with 2.3 and 2.9 l itre engine (engine types601 and 602) and the ear lier 2.4 l it re engine (engine type 616)_Brief, easy-to-foflow instructions are given, free from all necessarycomplications and repetit ions, yet containing all the required technical detai land information, and many diagrams and illustrations.Compiled and I llust rated by exper ts , this manual p rov ides a concise source ofhelpful informat ion , a ll o f which has been cross-checked for accuracy to themanufadurer's of fi cia l service and repa ir procedures, but many instructionshave derived from actual practice to facil itate your work Where special toolsare required, these are identif ied in the text if absolu tely necessary and we donot hesitate to advise you if we feel that the operation cannot be properlyundertaken without the use of such tools.The readers own judgement must ul timately decide just what work he wil l feelable to undertake, but there is no doubt, that with this manual to assist him,there will be many more occasions where the delay, inconvenience and thecost of having the van off the road can be avo ided orminimised.The manual Is called "Pocket Mechanic" and is produced in a handy glovepocket size with the aim that it should be kept In the vehicle whilst you aretravelling. Many garage mechanics themselves use these publications intheir work and if you have the manual with you in the vehicle you wi!! have aninvaluable source of reference which wiU quickly repay its modest ini tial cost.A genera! faul tf inding ( troubleshoot ing) section is inc luded at the end of themanual and all items listed are taken from actual experience, together withthe necessary remedies to correct faults and malfunctioning of certain parts.Important Note: The main text of the engine Section and someother sections associated with the engine, covers the 601 and602 engine, although technical data are also given for the 616engine. Differences for the 616 engine are described at the endof the manual ina separate section.

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o . INTRODUCTIONOur "Pocket Mechani cs" are based on easy-to-foll ow step-by-step Instruction s andadvi ce, which enables you to carry out many, Jobs yourself. Moreover, now you havethe means to avo id these frus tra ti ng del ays and Inconven iences whi ch so o ften resul tfrom not knowing the right approach to carry out repairs which are often of acomparatively simple nature.Wh ilst speci al tool s are requ ired to carry out certai n operati ons, we show you In thismanua l t he essen ti al des ign and const ruct ion o f such eqUipment , whenever possi bl e,to enabl e you In many cases to improvise or use alternative tool s. Experience showsthat i t i s advantageous to use only genu ine parts since Ihese give you the assurance ofa first class job. You will find tha i many parts are Identl calln the range covered in thismanual, but our advice Is to find out before purchasing new parts - Always buy yourspare parts from an offiCiall y appoi nted dealer.0 . 0 . General InformationThe manua l covers the Us tedMercedes-Benz commerc ia l veh ic les wi th 2 .3 and 2.9 l itr eengi ne, but also refers to models with the earli er four-cyll nder engi ne w~h 2.4 li trecapaci ty. Mode ls 2080, 308D and 4080 are fitted wi th a 2.3 l itre four-cyilnder dieselengine with a performance of 58 J < I N (78 HPJ at 3800 rpm (engine type 601). Theremain ing model s are fi tt ed wi th t he 2 .9 l itr e f ive- cy li nder eng ine wi th a perf ormance of70 kW (95 HPjat 3800 rpm (engi ne t ype 602). The eng ine I ss imi la r to the four-cyl lnderengine, wi th the addl tl onal cyli nder added on . Models 2070 and 307D are fi tted withthe 2.4 l it re engi ne,engine type 616.Details of the 616 engine are covered under separate headIngs, wheneverd ifferences are such that iInew Sed ion i s necessary .Many diffe rent body versions and model numbe rs are used in the range of vehiclesmarketed. The following table shows some of the models together with their typedes igna ti on and f it ted eng ine to the l at er mode l r ange . These numbers are sometimesre ferred to, mai nly in the technical data sections and you shoul d fami li ari se you rsel fwi th the model number o f your veh ic le . We shoul d l ike t o s tress tha t not aUvehIc les aresol d i n any particular country.A ll vehicles covered in the manual are fitted with a four-speed or five.speed

. . " _ '! .

Ij,I

transmission.ModelMB 208DM8308DMB 408DM8210DM B 3100M84100

Model Number Fitted engine601.3602.3611.3601.4602.4611.4

601.940601.940001.940602.940002.940602.940

0.1. IdentificationWhen your purchases the veh icl e you w il l have rece ived vari ous data. cards wh ich havea ll import an t veh ic le deta il s. as f or example chass is number and component numbersas we ll as identi fi cati on of optiona l equi pment, etc. You Owner' s Manual wi ll g ive youfurt her i ns tr uc ti ons on the use o f t hese cards . Owner 's Manual s were obtai nabl e underNo. 601 584 36 96, but you will have to check if this number is still valid, as it ispossible that they are no longer available.

4

Fig. 0.2- With the door openyou will see 8type phrte(1)with dl!taJJsof the body and painIdentlflclltlon codes.

Fig. 0.1 - Thl! Position of the vehicleIdentlflcatlon number (I) and the tYPI!Identification platl! (2).The type i dent if icat ion p la te wi th I he veh ic leIdentification number can be found on thedoor en try at the position shown In Fig. 01.Immediately next to It you will find anaddi ti onal p late, gIVing again the veh icleIdent if icat ion number, the max. permissiblevehicle weight and the basic setting of theheadl amps. Deta il s o f the body/number andIhe paint work are given In a plale, fitted tot he L .H . door p il la r, as shown In F ig . 0 .2 .

The engine number can be found nearthe Injection pipes at the positionshown in Flg.O.3, on the L.H. side ofthe cyl inder block. Transmission, rearaxle and steering also have a serialnumber, stamped into the housing.Always quote the complete chassisnumber andlor engine number and themodel year, when ordering parts.Important is also the actual modelnumber, which will indicate the construction of the vehic le, for example two orfour wheels on the rear etc,~ ~ . ; ;: - .; ,, '< : : "" ' "" " " " ' . . .. . ..=

Fig.0.3- Theenginenumber can be found at (1).5


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0,2 Filling CapacitiesFuel t ank. . . . . .. . ........................... 70 lit res (12li tres reserve)- Optional. . . . . , , , , 2 x 65litres (13 litres reserve)Engine:

601, four-cylinder, complete re-fill .............. , 7.3 IItres601 , oil change with filter. . . . . . . . . . . . . . . . .. . . . . . . . . . . .. 6.5 lit res602, f ive-cylinder, complete re-1111 . .. 7.511tres602, oil change wi1h filter ..... , . . . . . . . . . . . . . . . . . . . . . . . . .. 7.0 IIIres616, four-cytlnder, complete re-fill . . .. 7.5 I Itres616, o il change with f ilter , . . . . . . . . . . .. 6.5 lities

Min. Oil Fil l Capacity:601 engine .. , , 5.0 litres602 engine 5.5 Jitres616 engine .............................................. 3,5111res

Cooling System:601 engine .. , 7.011lres602 engine ...... , .................... , .. , 7.5 l itres616 engine ...... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11.7 litres

II

Transmission, .... , ......................................... 2.3 lilresAutomatic transmission (flUid change) ......................... 5.9 UtresPower assisted steering ........................................ 1.6 IllresRear axle:- Axle type 741.400 and 741.401 ................................ 1.6111res- Axle type 741.404 and 741,405 .......................... , 1.B litres

Axle type 741.5 (twin wheels) .................... , , ,1.8litres

0.3. General Servicing NotesThe servicing and overhaul instructions in Ihis Workshop Manual are laid out In aneasy-t o- fo ll ow s tep-by -s tep fashi on and no d if fi cu lty shoul d be encountered , I f t he tex tand d iagrams are fo ll owed careful ly and method ical ly , The "Techni ca l Data" sec ti onsform an import an t par t o f I he repai r p rocedures and shoul d a lways be refer red to duri ngwork on the vehic le.In order that we can Include as much data as possible, you will find thai we do notgeneral ly repeat In the tex t t he val ues a lready g iven under t he l echn ical dal a headi ngs.Aga in, to make the best use of the space ava il abl e, we do nol repea t al each operatio nthe more obvious steps necessary - we feel il to be far more help ful to concentra te onthe di ffi cult or awkward pro cedu re s In grea te r detai l. Howeve r, we summarise below afew of the more important procedures and draw your attention to various points ofgeneral interest that apply to all operations.Always use the torque settings given In the various main sections of the manual.These are grouped together in separate SUb-sections for convenient reference.Bolts and nuts should be assembled in a clean and very lightly oiled condition andfaces and threads should always be inspected to make sure that they are free fromdamage bu rrs o r scori ng. DO NOT degrease bol ts o r nuts.All joint washers,gaskets, labs and lock washers, splft pins and "0" rings must berepla ced on assembly . Sea ls wi ll , In the majori ty o f eases, al so need to be repl aced , ifthe shaft and seal have been separated. Always lubricate the lip of the seal beforeassembl y and take care that t he sea l Up 'i s f ac ing the cor rect d ir ec ti on .

Ii

6

References to the left-hand and right-hand sides are always to be taken es If theobserver I sa t the rear o f t he veh ic le , faci ng fo rwards , unl ess o therwi se s ta ted.A lways make sure that t he veh ic le I sadequate ly support ed , and on fi rm ground, beforecommencing any work on the underside of the car. A small jack or a make shift propcan be h ighl y dangerous and proper axl e s tands are an essen ti al r equi rement f or yourown safety.Dirt, grease and mine ra l on wi ll ra pidl y destro y the sea ls of the hydraul ic system andeven the small es t amounts must be prevented from enter ing the sys tem or coming Int ocon tact w it h the component s. Use c lean brake f lu id or one o f the propr ie ta ry c teanersto wash the hydraul ic sys tem par ts . An accep tabl e a lt erna ti ve c leaner I s methyl at edspl r' ft , but I t this Is used, It should not be al lowed to rema in In con tac t w!l h the rubbe rpar ts for longer than necessary. It is al so Imporlant that a ll traces of the Ilu ld shoul d beremoved f rom the system before I1nal assembly,A lways use genuine manufacturer's spares and replacements for the best resul ts.Si nce the manufacturer uses me tri c units when bui ld ing the cars It is re commendedthat, these are used for al l prec ise units. Inch conversi ons are gi ven in most cases butt hese are not necessari ly p reci se convers ions , bei ng rounded off f or t he unimpor tantvalues.Removal and i ns ta ll at Ion Ins tr uc ti ons, I n th is Workshop Manua l, cover the s teps to l akeaway or put back the unit or part In question. Other Instructions, usually headed"Serv ic ing", w il l cover t he d ismant li ng and repai r o f t he uni t once it has been str ippedf rom the vehic le It I s poi nt ed out t ha t the major I ns tr uc ti ons cover a complete overhau lof a ll pa rts bu l, ob viously , this wil l no t a lways be ei the r necessa ry and shoul d no t becarried out needlessly.There are 8 number of va ri atio ns In unl l p arts on the range of vehi cles covered In thi sWork shop Manual . We strongl y recommend that you l ake care to Iden ti fy the pre cfs emodel , and the year o f manufi ll ct ure, befo re obtai ni ng any spares or rep lacement par ts .Std.: To Indicate sizes and limits of components as supplied by themanufac tu re r. A tso to Indi ca te t he product ion tol erances o f new unused par ts .015 Pari s suppli ed as Oversiz e or Unders ize o r recommended l imi ts fo r such parts,to enabl e t hem to be used wf lh wom or re-mach ined mat ing par ts .U/S als Indicates a part thai Is larger than Std. size UIS may Indlcale a bore of abushi ng or fema le part that I ssmal le r than S td .Max.: VVhere given against a clearance or dimension Indicates the maximum

allowable I f In excess of the vil ilue given It Is recommended that the appropr tatepart Is f it ted.TIR: Indicates the Total Indicator Reading as shown by a dial Indicator (dialgauge).TDC: Top Dead Centre (No, 1 piston on firing stroke).MP : Mul ti -Purpose g rease.

0.4. Jacking up of the VehicleFor small jobs, Jack up the vehicle as described in the Owner's Manual, with thehyd rauli c J ack suppl ie d Wi th the vehi cle . If a mobi le j ack is used, make sure It can takethe we lghl o f the veh ic le . Add it iona l we ight s shoul d a lways be removed from the cargoroom of the vehic le.To Jack up the veh icl e completel y, firs! Jack up the front end. Chock the rear Wheel s toprevent I he veh ic le f rom ro! li ng o ff t he Jack or app ly t he handbrake . P lace a mob il e JackUnderneath the f ronl axle. rr t he hydraul ic veh ic le Jack Is used, p lace II undernea th t hef ront spr ing as shown In F ig . 04, Immediat el y i n f ront o f the fr on t axl e.

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Fig.0.6 - Three.leggedchassis stands arethesafest method to support the vehIcle whenwork has 10be carriedout onthe undersIdeofthe vehicle.

Fig. 0.4 _ JackIng up the front end of thevehIcle,using the hydraulicJacksupplied withthe vehiCle.Chassis stands should only be placed onthe L .H. and R.H. s ides under the fr on t axl e.Use chassis stands of the constructionshown i n Fig. 0.5, should be used, but againmake sure that they are strong enough tocarry the weight of the vehicle. Make surethe vehic le cannot S lip off Ihe stands.

The rear end of Ihe vehicle is jacked upw tt h a mobi le j ack or w it h the hydraul ic j ackshown In Fig.0.6. Chassis stands arep laced underneath t he axl e beam, noti ng the poi nt s g iven above . Aga in make sure thaino add it iona l we ighl s are l eft i n t he cargo room.

FIg. 0.6 - Jacking up the rear end of thevehlcle with the hydraulic Jacksupplied.

Note: It is a/ways dffficult to raise B vehicle fir st on one side and then on theo ther. Take care that the vehicle cannot tip- over when the first side is lifted.Ask a helper to support the vehicle from the other side. Never workunderneath the vehicfe without adequate support.

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601.940601.940602.940602.940602.940602.940616.017616.934

ENGINES1.0. Technical DataFitted Engines:_ 2 08 D (Model 601.3)- 308 D (Model 602.3)_ 408 D (Model 611 .3 )- 210 0 (Model 601 .4) 310 D (Model 602.4)- 4100 (ModeI611.4)- l 207D- l207D, l 307DNumber of Cylinders:- 601 eng ine- 602 eng ine- 616 eng ineInjectlon Order:- Four cyl inder- Five cyl inderArrangement of cyl indersCamshaftArrangement of valvesCyl inder bore, 601 , 602 engines- 616 engIne- P is ton s tr oke. 601 , 602 , 616 eng inesCapacity: 601 eng ine- 602 eng ine- 616 eng ineCompression Ratio:- 601 , 602 eng ines- 616 eng ineMax. B.H.P. (DIN):- 601 eng ine, wi th manual gearbox- 601 eng ine, wi th A fT- 602 eng ine, wi th manual gearbox- 602 eng ine, wi th AJ T- 616 eng ine

Max. Torque:- 601 eng ine- 602 eng ine- 616 eng ine

FourFiveFour

1-3-4-21-2-4-5-3In-lineOverhead camshaft , No . marked In end faceOverhead89_00 mrn (3.4565 In. )91.00 mm (3.6154 In.)92.40 mm (3.6711 In .)

2299 cern2874 cern2404ccm

22: 121 : 1

58 kW at3800 rpm60 I N I J at4000 rpm70 kW al 3800 rpm72 kW at4000 rpm48 kW at4200 rpm

15.7 kgm (113 It.lb.) at 2000 - 2800rpm19.2 kgm (138 tUb.) at 2400 - 2600rpm13.7 kgm (99 It .l b.) a t 2400 rpm

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I'!I ~i Crankshaft bearingsCooling system 5 or 6 f rict ion bearingsThermo system with water pump,thermostat, cooling fan with fluidclutch, tube-type radiator

Lubrication Pressure-feed lubrication with gear-typeoil pump, driven wHh chain fromcrankshaf t. With ful l-now oil f il terDry paper element air c leanerircleaner

Va lve Timing - New Timing Cha in - 601 a nd 602 engines:- I nl et val ve opens 11 A.T.D.CInlet valve closes 17" A.B.D.C.- Exhaust val ve opens 28" B.B.D.C.- Exhaust valve closes 15" B.T.D.C

I II II!

Valve Timing - Used Timing Chain (afte r 12 000 miles) - 601 a nd 602 e ngines:- Inlet valve opens 12" A.T.D.C- I nl el val ve c loses 1SoA.B.D.C.- Exhaust valve opens 27 B.B.D.C.- Exhaust val ve c loses 14 B.T.D.C

Valve Timing - NewT iming Chain - 616 e ngine:- I nl et val ve opens 11.5' A.T.D.CInlel valve closes 13.5" A.B. D.C. Exhaust valve opens 21 B.B.D.C.- Exhaust val ve c loses 19" B.T.D.C

Valve Timing - Used Timing Chain - 616 e ngine:All valves 2' moreI ,Val ve Clearances - 616 Engine - Engine warm:Inlet valves 0.10 mm (0.004 In.)- Exhaust val ves 0.30 mm (0.012 ln.)

Val ve Clearances - 616 Engi ne - Engi ne cold:Inlet valves- Exhaus! val ves 0.15 mm (O.OOOn.)0.35 mm (0.018 In.)

1 . 1 . Engine - Removal and InstallationThe engine and transmissi on is removed from the vehi cle as a complete uni t after tnepar ts shown in F ig . 1 .1 are removed from the f ront end o f the veh ic le . The transmissi oncan !hen be removed from the engi ne. Engine and Iransmi ssionare a heavy uni t a nd asui tabl e hoi st o r c rane i s requi red to l ift out It le assembly , r emember ing tha t the weigh ti s more than 200 Ibs. The foll owi ng description is a general guide l ine, a s we cannolre fe r t o every possi bl e Vari ati on and /o r eqU ipment t ha t may be f it ted to your veh ic le . Place the bonnet Into the vertical. position until Ihe lock engages. Remove thedrivers seat.

10

Fig. 1.1- Th" I!nglne Is removed from the vl!hlcle anl !r thl ! l IIu5tr ", ted par ts have bl!enremoved from the front end of the vehIcle.Di sconnect the two batt ery cab les. The batt er y can a lso be removed to have morespace for other operal lons.

Remove Ihe engi ne cover and Ihe radiator gril le. Open the expansion tank cap. II Is assumed that Itle engine Is fairly cold. Drain

the cooling system as descr ibed InSect ion Coot ing System. Remove the radiatoras descr ibed InIhe same section.Remove the air Intake hose.Remove the f ront bumper a nd the radlalor crossmember (Fig. 1.1).Separate the fron l exhaust p ipe f rom the exhaust mani fo ld and f ree the p ipe fromthe bracket on Ihe transmission.Disconnect the propeller shaft from the transmission. Also disconnect thespeedometer cable from the transmission.Unscrew Ihe clutch slave cylinder from the side of the transmission withoutd isconnec ti ng Ihe hydraul ic hose. T ie t he cyl inder to t he veh ic le f loor t o prevent i tfr om hangi ng down on l is hose. F ig . 1.2 shows where the cyl inder is attached.Unscrew the ear th cable.

F'g. f .2 - The cluteh S' IV I!cyl lnd" r (1) Isf it ted to the sid!! of the trlnsmlsslon. Disconnect the electrical leadsfrom the starter molar and thealternator. Free the cable harnessfrom the engine (cut the. cablebinders) and push the harness 10 oneside, where It canna! be in Ihe wayduring fol lowing operations.

Disconnect the elecl rl calleadf rom Ihe g low p lug rel ay . Disconnect all vacuum hosesfrom the engine.

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I I If a power-assisted steeri ng is fitled, remove the drive belt and unscrew the bel t

pul ley from the pump shaft. Unscrew the compl ete steeri ng pump and remove ittogether with the connected hoses. Disconnect the fuel pi pe from the pre-fi lte r. Close the open connecti ons i n suita blemanner t o prevent ent ry o f d ir t. Remove the vacuum hose from the vacuum pump at the l ocati on shown In F ig.1.3.Fig. 1.3- Disconnect the vacuum hose forIhe brake servo unit from the vacuumpump (exh;luster pump). Unscrew the gear change leverknob, remove the rubber gaiter

and withdraw the lever afterremoving the clamp bolt. Duringl at er i ns ta ll at ion ti gh ten the c lampbol t unli lth e gap Is 1.5mm.Slacken the heater hose behindthe thermostat housing andwithdraw.

Remove the starter motor.FIg. 1... - The oil nller neck must beremoved Inorder to take out the engine. Disconnect the 0 1 1 pipes from theoil f it ter housing. Remove the pipe clamp from theoil sump.

Remove the 0 11 f il ler neck. Fig. 1. 4shows Ihe location.Remove the transmission

mounti ng from the crossmember (1boil).Slacken the engine mountingsupports f rom the engine mount ing.

Fig. 1.5 - The attacnm . .nt of thecrossmember undernealh the vehlcte, Use a hand crane or suitable holst

and wi th ropes or chains attach thepower uni t, u ti li si ng the l ift ing eyes.A lso place a mobile jack underneaththe engineltransmlssion unit tosupport it from below. Beforeremoving any of the engine andtransmi ssi on mounti ngs ensure tha tthe weight of the assembly is wellsupported.

Disconnect the throttl e control .Unsc rew the c rossmember undernea th t he t ransmi ss ion and a lso underneath t heengine. Figs. 1.5 and 1.6 show where the i tems are attached. Check once morethat the uni t i s supported.

12

L if t t he eng lneft ransml ss lon assembl y t owards the fron t o f t he veh ic le , tu rn ing i tsl ightly to al low the gearchange to clear the engine compartment. If the unit i sresUng on a Jack, remove the jack al Ihe same time. Helpers wil l be requi red togui de Ihe power unit. Final ly lower the assembl y 10 the ground. Remove thetransmission if required.

FIg. 1.1 - Th ... attachm ...nt of the ...ngln...crossmember.The i nst al la ti on Is a reversal o f t he remova lprocedure, but the fol lowing points shouldbe noted: Check the engine mountings and the0 1 1 and fuel pipes (hoses) for damage andreplace parts as necessary. If a manual transmission Is f1tted, takethe opportuni ty to check the cl utch releasebearing and replace If necessary. Do not connect or rem any of thedisconnected parts until the engine and transmission are refitted to their

moun ll ngs and the eng ine Is f ree fr om Ihe ropes orchai ns . Remove the engine mounts if their conditions reqUire It. Keep oil or grease away

f rom the rubber par ts, Connect Ihe prope ll er sha ll I naccordance w ith t he Ins tr uc ti ons In Sec ti on 4.

Refill the cooling system with anti-freeze of the correct strength for thetemperatu res to be expec ted. I f t he ori gi na l anl i/ fr eeze i s used, check 1st s treng thbefore filling It in.

Check the air cl eaner element before re-use. Dirty elements shoul d be replaced,ma in ly i f overhaul work has been undert aken on the eng ine.Check the 0 11 l evels In eng ine and transmissi on and correct If necessary, If noo ther opera ll ons have been carr ied out on Ihe uni ts .

After starting the engine and allowing It to warm up, check the cooling system forl eaks . Dr ive the veh ic le a few mil es t o check for exhaust p ipe ra tt1e.

1.2. Engine - DismantlingDiesel eng ines are sensi ti ve to d ir t o r o ther con lamlna ti on . It is Iherefor essential 10make sure that no foreign matler can enter the pipes, connections, etc. during thedlsmantl!ng operations.Dlsmanllfng of the engine will be made much easler, If a swivelling engine stand Isavailab le. Otherwise place the engl ne"ransml sslon on a work bench, supporting Isadequately to prevent I f f rom fai ling over.Before commencIng d ismant li ng , b lock up Ihe In le t and exhaust openi ngs and g ive theexterior of the engine a thorough cleaning to remove all loose dirt and oil. Paypar ti cu la r a tl en tl on to a ll Joi nt sur faces, b rush ing these to remove l oose debri s whi chmight otherwise f ind 1stway Into the Inter ior of the engine.Many of the parts are made of Alumini um al loy and must be treated accordingl y. OnlyUse plast ic or rubber mal lets to separate par ts, I f necessary.As a compl ete strip -down of the engine is In most cases not necessary, and many oft he opera ti ons can be car ri ed out wi th t he eng ine f rl ted, you wi ll f ind i n the fo ll ow ing text

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a descri ption of individual operati ons whi ch can be carried out with the engine fittedand removed. Combini ng these , wi ll g ive you the comple te d ismantl ing o f t he eng ine.

\.\

1.3.1.3.0.

Engine OverhaulCylinder Head and Valves - Technical Data

Cylinder Head:Cylinder head height:- 616 engineMax. Distort ion of Cyl inder Head Faces:- Longitudinal direction:- Across the face:Max. dev ia ti on o f f aces between upper andlower sealing faces (parallel to each other)

142.9 - 143.1 mm84.8 - 85.00 mm (mi n. 84.00 mm)0.08 mm0.00 mm0.10 mm

Depth o f val ve head faces and cy li nder head sea li ng face - Excep t 616:_ Inlet valves +0.17 to 0.23 mm_ Exhaust valves +0.12 to 0.28 mm_ Wi th re -cu t val ve seat s 1.0mm - all valvesDepth o f val ve head faces and cy li nder head sea li ng face - 616 :Inlet valves +0.03 to 0.43 mm Exhaust valves 0.3810 0.78 mm With re-cut valve seats 1.5 mm - all valvesValvesVal ve Head Diameter ("D" i n F ig . 1. 22):- I nl et va lves616 engine Exhaus t va lves616 engineValve seat angleValve Stem Dtameter ( "Dl" in Fig.l .22) :Inlet valves- Exhaus t va lves 616 engine

I,Val ve l ength (" L" i n F ig . 1 .22):- Inlet val ves- Exhaus t val ves616 engi ne - In le t val ves616 engi ne - Exhaust val ves

I, Valve Seat Width:- In le t val ves- Exhaust val vesValve ldentiflcation:- Inlet valves Exhaust val ves

14

37.90 - 38,10 mm39.70 - 39.90 mm34.90 - 35.10 mm34.10 - 34.30 mm45 + 15' (616 engine = 30)

7.970 - 7.955 mm8.960 - 8.945 mm9.920 - 9,940 mm

106.50 - 106.30 mm106,50 - 106.30 mm131.30 -131.70 mm130.8 -131.20 mm

2.5 mm (616 = 1.3 to 1 .6 mm)3 .5 mm (616 = 2.5 - 2.9 mm)

E 601 02 (616 = E 616 02)A 60102 (616" A 61605)

Valve SeatsValve seal width: In le t va lves Exhaus t val vesValve seat anglesUpper correction angleLower correction angle

2 ,5 mm (616 = 1.3 t o 1.6 mm)3 .5 mm (616 = 2.5 - 2.9 mm)45 -15' (616 = 30)15 (616 = 60')60 (616 = N/A)

Val ve Seat Insert s (on ly 601 and 602 gi ven)Insert outer diameter rD" In Fig. 1.20): Inlet valves - Std. 40.100 - 40.084 mm_ Exhaust valves - Std. 37.100 - 37.084 mmInsert Inner diameter ("01 In Fig. 1.20): Inletvalves-Std. 33.400-33.600mm_ Exhaust valves - Std. 3O.S00 - 30,600 mmBasic bore In cyl inder head rOT In Fig. 1.20):_ Inl et valves - Std. E )(hausl val ves - S td .Valve seat height, all valves

40.000 - 40.016 mm37.000 - 37.016 mm6.97 -7.00 mmUpper edge of va lve seat ri ngs to cyl inder head face : Inlet valves 2.37 - 2.25 mm_ Exhaust valves 2.44 - 2.25 mmValve Springs - Except 616 engineColour codeouter diameterWire diameterFree lengthLength under l oad o f 72 1077 kg- Wear l imitVal ve Spri ngs -616 eng ineColour codeOuter diameterWire diameterFree lengthLength under l oad o f 46.3 t o 53 kgLength under l oad o f58.9 kg Wearl lmltVal ve Gui des - Except 616Inlet valve Guides: Outer di ameter - Std. Outer di ameter - Repair si ze- Inner diameterBasic bore Incylinder head:- Std. Repai r size

yellow-green or purple-green33.20mm4.25 mmSO.80 mm27,00 mm27.00 mm at 65 kg

green/green orViolet/green30.20 - 30.5 mm3,80 mmSO.SO mm29.90 mm, min,

yellowlyellow orviolet/yellow30.0 - 30,7 mm3.90mm51.20 mm28,00 mm53.00 kg1.70 kg

14.044-14,051 mm14.214 - 14.222 mm8.000 - 8,015 mm

14.030 - 14,035 mm14.198 - 14.203 mm

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I I ! IExhaust Valve Guides:- Outer diameter - Std.- Outer diameter - Repair size- i nner d iameterBas ic bore i n cyl inder head:- Std.- Repair sizeIn le rf erence fi t o f val ve gui des - A ll gui des:Std.- Repair size

, I

Valve Guides - 616Inlet ValvefExhaust Valve Guides:- Length:Inlet valvesExhaust valvesOuter d iameter - S td ., a ll gui desOuter d iameter - Repa ir s ize, a ll gui desInner diameter, all gUlde5Max. inner diameterBas ic bore i n cyl inder head:Std.Repair size

- Inte rference fi t of valv e gui des - A ll guides:Std.

II'

Camshaft - E xcept 616 EngineCamshaft Bearings:- 4 cal. engine- 5 cal. engineJournal diameterCamshaft Bearing Clearance:- New condi ti on- Wear limitCamshaf t End Float :- New condi ti on- Wear limitCamshaft - 616 EngineCamshaf t bearing running clearanceCamshaf t end f loat

1.3.0.1.

14.044-14.051 mm14.214 - 14.222 mm9.000 - 9.015 mm

14.030- 14.035 mm14.198 - 14.203 mm

0.009 - 0.021 mm0.011 - 0.024 mm

60.0 or 61.0 mm48.5 - 40.5 mm14.03 - 14.04 mm14.23-14.24 mm10 .00 - 10.015 mm10.025 mm14.000 - 14.020 mm14.200 - 14.220 mm0.01 - 0.04 mm

5630.944 - 30.950 mm0.050 - 0.091 mm0.11 mm0.07 - 0.15 mm0.18 mm

0.025 - 0.066 mm (max. 0.11 mm)0.05 - 0.128 mm (max. 0.18 mm)

Cylinder Head - Removal and InstallationThe fol lowi ng i nfo rmati on shoul d be noted when work Is carr ied out on a cyl inder head:

The cylinder head is made of light-alloy. Engine coolant, engine oil, Ihe airrequ ired to i gn ite t he fue l and the exhaust gases are d ir ec ted th rough the cyl inderhead. G low p lugs , i nj ec to rs , p re -combust ion chambers and val ve l appe ts are f it tedt o the cyl inder head. A lso In the cyl inder heads you w il l fi nd t he camshaft .

16

The exhaust man ifold and the Inl et mani fo ld are bolted to the outs ida of the head.T he ruel en te rs the head on one s ide and exits on the other s ide , I.e. the head Is o fthe well-known "cross flow" type.

The eylinder head Is fitted with various sender units, sensors and switchingvalves, responsible for eer taln funet lons of the temperature contror .

As the cylinder head Is made of light alloy, H I s p rone to d is to rt ion If , f or example ,t he order o f s l aekenl ng or ti gh teni ng o f t he cyl inder head bol ts I s not observed. Fort he same reason never remove the cyl inder head from a hot eng ine.

A c yli nder head cannot be checked In fi tted pos ltlon . Some tlmes the cyl inder headgaske t w il l " bl ow" , a ll owi ng a ir In to t he coo li ng sys tem. A qul ck check Is possi bl eafter open ing the coolanl reservoi r cap (engi ne fai rly co ld). Al low the eng ine towarm-up and observe the coolant. Visible air bubbles point In m ost casesto a "blown" gaske t. Further evi dence Is wh ite exhaust smoke, oil i n the coo lan t orcoolant in the engine oil. The latter can be checked at the all dipstick. A white,g rey emuls ion on the d ipst ick Is more or l ess a con fl rmat ion o f a damaged cyl indergasket.

If you are convinced that water has entered the engine and you want to get homeor to the nearest garage, unscrew the Injectors and crank the engine with thes ta rt er motor f or a wh il e t o e ject the water. Re fi t t he i nj ec to rs , s ta rt the eng ine anddri ve to your des ti na ti on wi thou t swi tchi ng o ff t he eng ine. Thi s i s t he onl y methodto avo id ser ious eng ine damage (ben t connecti ng rods for example ).

The cylinder head must only be removed When the engine Is cold. The head Isremoved toge ther w ith the exhaust man if ol d, but the Inl el man ifo ld mus t be separatedfrom the cyli nder head befo re the head can be l in ed off. New cyl inder head gaske tsare wrapped In pla sti c und must only be unwrapped Jusl befo re the gaske t Is fi ll ed.The cylinder head can be removed with the engine filled and these operations aredescri bed bel ow, bul note that opera ti ons may vary, dependi ng on the equ ipment f il led:

Fig. 1.7 - Remove the two hosesshown by the arrows afterslackenng the hose clamps.

Remove the driver's seat,disconnect the battery earthcable and remove the enginebonnet. Drain the coating system(Section 1.8.1.) und remove theradiator. Lift up the radi ator g ri ll andlock it Inthe raised position. Disconnect the air intakehose and the coolant hoseshown in F ig . 1 .7 .Remove the vlsc o-clutch from the fron t end o f the eng ine . Do not s tore the cl utchassembly In vert ical posi1ion.

Remove the o il fi ll er e lbow (Fi g. 1 .4 ).Cut the cable binder secur ing the engine cable harness.~ emo ve the si ngl e pol y V -bel t from the front of th e eng ine . To do thi s, refer 10 Fig.I .8 and sl acken the fl anged nut. Insert a d ri ft 01 12 mm diameter and 180 mm In:~h In to the sp ri ngl oaded rever and push the tension ing devi ce towards the l eft.eheve the l ensl on from the securin g screw until the' te nsioning sprin g can bePUshedIn d ir ec ti on In le t mani fo ld . Now remove the bol t ( 3) secur ing the mounti ng

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I Ishock absorber (see also Fi g. 1.9) and remove the l enslonl ng device. Push downon t he tensi on ing pul ley to l oosen and remove the bel l.

Fig. 1.8 - R..Jus lng Ihe t .. ns lon o f t he dri vebelt at t he fr on t end o f the ..nglnl".Tension ing spring

2 Damper3 Brackel for tensioner

If a power-assi sted s teer ing i s f ltI ed ,r emove the pul ley f or t he dri ve bel t.

Disconnect all coolant, fuel andvacuum hoses and the electricalcab les connected to the cyl inder heador an y other uni t on the cyl inder headwhich cannot be removed togetherwith the cylinder head (also seebelow).

Ag. 1.9 - Unscrew the damp for Ihe belttensioning device f rom the cyl inder head end. Separate the throttle control linkage atthe ball joint connection. Disconnect the vacuum pipes from theexhauster (vacuum) pump. One hose andone uni on nut must be removed.

Use sui tabl e c lamps and c lam~of f thefuel hoses and disconnect the fuel hoses atthe fuel pre-fil ter or remove the fuel fi lterb racket and Ue I t up wi th a p iece o fw ire. In the case of a four cyl inder engineremove the Inje ction pi pes of cylinde r Nos. 1, 2 and 3 toge ther wi th the pipebracket and remove the InJect ron p ipe o f No. 4 cyl inder wi thout the bra cket. On af lve- cy li nder eng ine, the i nj ec ti on p ipes o f Nos . 4 and 5 cyl inder are held togetherby means o f a p last ic c li p. A lso wi thdraw the l eak-off hose a t the Inj ec to r o f t he No.

1 cylinder. Cl ose off the hose end In suitable manner (a bol t of suitable di ame tercan be pushed into the hose end.Remove the damper fo r t he eng ine speed regul at ion f rom the Inl et man if ol d. Thi si s t ne item shown in Fig. 1 .1 D .

Fig. 1,10 - The damper for th. .engine sf>eedregulation Is attached 10 the manifold. Disconnect the vacuum hose fromtne thermo valve. Disconnect the electrical leads fromthe glow plugs.

Remove tne securing clip for theheater assembly teed pipe with aw ire hook. Remove the connector sfrom the oil filter and on the otherend.

Disconnect the exhaust pipe flange

18

fr om the exhaust mani fo ld and unscrew the exhaust p ipe support b racket f rom Ihetransmission.Remove the Inlet (Intake) manifold.

Fig. 1.11 _Remova' of an Injector. Remove the cylinder head cover. Six

screws must be removed. Two arel ocated on each l ong s ide o f the coverand two on the timing side of theengine. I fan automat ic t ransmission Isfi tted, there Is a regul ati ng rod fltIedacross the cyl inder head cover , Whi chmust be separated on one si de at thebal l Joint . A stlcldng cylinder head .cover must not be freed by tappi ng It U!!!!!~I:i..:L.......!:::::'=:":':":__:'''''';;__---....Iwith a hammer . I f d if fi cu lt to remove, t ry t o uns tl ck I t by pushi ng it by hand to oneside. Use a plast ic mal let, I fnecessary.Unscrew the Injectors (Fig. 1.11) and remove the washers underneath.

Rotate the engine until the piston of No. 1 cylinder Is at top dead centre In thenr ing posil ion. , I .e. the ~O' " mark must be opposi te the adj usting pin, as shown InFig. 1.12 . A 27 mm socket can be applied to the cra n kshan pulley to rotate thecrankshan.

Fig. 1.12 - Dead centre posit ion ofthe engine.Never attempt to rotate thec rankshaft by app ly ing a socke t 10the camshaft timing wheel bolt.The crankshaft must be rotated Inthe direction of rotation. Remove the chain tensloneras describ ed In Section 1.3.5.0.The chai n tensloner pl ug must beunscrewed by app ly ing a spannerto the hexagon. The plug isl ocated above the water pump andthe thermostat cover, next to the

large tube. Mark the camshaft sprocket and the liming chain at opposite points, as shown In

F ig . 1 .13, usi ng a spo t o f pai ntFig. 1.13 - MarJl;the chain and sprocketwtth " spo t o f pai nt before remova l o fthe ~precket,

Unscrew the camshaf t sprocketbolt. To counterhold thecamshaft against rolat ion, Inserta strong screwdriVer brade orsteel bol t Into one or the hol esof the camshan sprocket.Remove the camshaf t sprocketfrom the shaft without

19


12/102

di sengaging the timing chai n from the crankshaft sprocket. Pul l the chai n ti ghtand use a p iece o f w ire to t ie cha in and sprocket toge ther .Remove the camshaf t as descr ibed under the relevant section.Remove the s li de rai l f rom the cyl inder head as descr ibed l at er on.

In the inside of the chain case remove two 8 mm socket head bolts wi th an Al lenkey . An extensi on and a socke t i s requi red to reach the bol ts ,Unscrew the cyl inder head bolts i n re ve rse order to the one shown;n Fig. 1.14 or1.15. A multi-spline bit must be used to slacken the bolts (Me Part No. 601 58900 10 0 0 . A normal Allen ke Is not suitable as It

o a

Fig. 1.14 - TIghtenIng sequence for the cylinder head boltl 'or the 601engine. The bolts "a" onthe L.H. s ide li fe the smlllle r bolts mentioned Inthetext. Slacken the bolts In reverse order.

I I

FIg. 1.15 - TIghtenIng sequence for the cylinder head boltl for the 601engine. The bolts "a" onthe L.H. Sideare the smalle r bolts mentioned Inthetext. Tighten the bolts Inreverse order.

will damage the bolt heads. Immediately after removal of the bolts measuretheir length. If the d imensi on from Ihe end o f the bolt to the underside of the bol thead is more than 83.6, 105.6 or 118.5 mm, depending where the bolts arel oca ted, rep lace the bol ts. New boll s have a l ength of 80 mm, 102.0 mm or 150.0mm. I .e . bol ts whi ch nearl y approach the max. l ength shou ld a lso be rep laced.

Note: Certai n bolts are frtted through the camshaft beari ngs. As the cyli nder headbol ts a re o f d iff erent l ength , mark them eefore remova l to assure refi tt ing i n t he ori gi na lpositions.

I I II[

20

l ift o ff t he cyl inder head. If a holst or othe r l ifti ng equi pment is avail able, hook arope to t he two l if ti ng eyes and l ift o ff t il e haad. Remove the cyl inder head gasketImmediately after removal, clean ti le cylinde r head and block surfaces of ol dgasket material.If necessary, overhaul He cyUnder head as descri bed In Section 1.3.0.2. afterdismantling.

PIt,!

Install the cyl inder head Int i le fol lowing manner:P lace a new cyl inder head gasket In Posit ion.Place the cyl inder head careful ly In posi tion , ta.ki ng care to engage the dowels leeves . Use a sof t- faced mal le t to tap the head In pos it ion.Coat the threads of the cylInder head bol ts and the underside of the bol! headswi th a ll . I t I s assumed tha t o ri gi na l bol ts have been measured fo r t hei r r e-use.Insert the cylinder head bolts as originally fitted (and hopefully marked) andl ighten them i n the sequence shown In Fi gs. 1.14 or 1.15 I n severa l s tage .s . Thet ightening Iscarr ied oul in stages as fol lows:

nghten all bolts In the correct order to I ,5 kgm (I I f t. I b.). Tighten all bolts In the correct order to 3.5kgm (30 f t.1b.) , Walt 10 m lnufes. Angie-tighten all bol ls In thei r correct tightening order. To do this, Insert ti le rnul t l -

spline bit with the socket Into each bolt and fit tile tommy bar so that It Is In linewi tl l th e longi tud inal axis of the engine. Ti ghten the bolt until the tommy bar Is atl ight angl e to the engine, I.e. th e bo lt has been ti ghtening by 90 (114 of a t urn).Do not use the torque wrench for this operation.

Re-tlghten each bolt In Ihe order given by a further 90' In the manner descr ibedabove. Fit the two socket head screws 10 the Inside of the timing chain chamber andt ighten them to 2 .5 kgm (18 ft. 1b.).

I

I1I

Cylinder heads are sometimes modified. When for example fitting a second headcyl inder head at some s tage , make sure It i s the correct one.

Refr t t he s li de rai l t o the head as desc ri bed l at er on (Sect ion 1.3.5.3.). Fit the camshaft sprocket log ether wfth the timing chain to the end of thecamshaft, making sure that the paint marks made duri ng removal are in li ne. The

sprocket must engage with I ts bore over tile dowel pin Inthe camshaf t. Fit the camshaft sprocket bolt and tighten the boll to 4.5 kgm (32.S rUb.).Counte rhol d t he camshaft by I nser ti ng a s trong screwdri ve r b lade or s teel bol ts

through one of the openings In the sprocket.Re fi t t he timi ng cha in tens loner and l ighten the p lug to 8 .0 kgm (58 .5 f t. lb .). Check the marking for top dead centre for the No. 1 cylinder In Ihe camshaft (see

FIg. 1.16). A notch is machined Into the camshaft which should be in li ne wi th amark machined into the cylinder head. The alignment can be seen by lookingfrom above and comparing it with Fig. 1.16.

I.j1

Note: Multi-spl ine head socket bolts require no re- tlghtening after they_have beenfitted as described above.

ii

Re-connect the glow plug cables.Ref it the inlet manifold. And the injectors and re-connect Ihe Injection pipes.

F~the tUbe e lbow wi th a new "0 sealing ring.21


13/102

Fig. 1.16 - Alignment of the notch In thecamshaf t f lange (1 ) and the lug on theNo.1 camshaft beari ng cap (2) assuresthe T.D.C. position at the engine.

Fit the exhaust pipe to theexhaust manifold. The remaining operations arecarried out In reverse order to theremoval procedure. Check and, Ifnecessary adj us t, the th ro tt le cabl eoperation.

1.3.0.2. Cylinder Head- DismantlingThe following descrlption assumes that the cylinder head Is to be replaced. If oolya top overhaul is asked for, Ignore the additional Instructions. The cylinder headmust be removed.The val ve stem 011seals can be replaced with the cyli nder head fitted. S igns of wornoi l seals are blue exhaust smoke when the vehicl e Is coasti ng (gear engaged), whenthe engine Is accelerated after Idli ng for a whi le or bl ue smoke when starti ng Ihe coldeng ine. I f t he o il consumpti on has reached 1 l itr e per 600 mil es , repl ace the val ve s tem01 1 seals as descr ibed under a separate heading.

Proceed as fol lows during dismantling:Remove all auxil iary par ts f rom the cyl inder head, Including the exhaust manifold.

Remove the camshaft. All camshaft bearing brackets must be removed and thecamshaft lifted out. Each bearing bracket is marked with a number. Acorresponding number i s marked i nto the cyl inder head. I.e. there i s no need tomark the bearing brackets.

A valve spr ing compressor i .s requ ir ed to remove the valves. Valves are held Inposi ti on by means of valve cotter halves. Compress the springs and remove thevalve cot te r hal ves wi th a pai r o f poi nted p li ers or a small magnet.

If a valve spring compressor Is not avail able, i t is possibl e to use a short pi ece of tubeto remove the valve cotter halves. To do this, place the tube over the upper valvespring collar and hit the tube with a blow of a hammer. The valve co tte r hal ves wi llcollect in the i nside of the tube and the components can be removed. The valve headmust be supported from the other side of the cyl inder head. Keep the hammer In cl osecon tact wi th the l ube to prevent t he cott er hal ves f rom f ly ing out. Remove the valve spri ng coi lar and the valve spring. The valve sprlngs (one

spri ng per valve) are i dentified with a paint spot and only a spring with a pai nt spotof the same colour must be rrtled. A thrust ring is fitted underneath each valvespring and can be removed. Fi gs. 1.17 and 1.18 show sectional views of the twovalve assemblies.Remove valve s tem oil sea ls care fu ll y w it h a screwdri ve r o r a pai r o f p li ers .

Remove the valves one after the other out of the valve gui des and p ie rce them in the irfitted order through a piece of cardboard. Write the cyHnder number against eachvalve if they are to be re-used.

22

Fig. 1.11- Sect iona l vi ew ofthe cylinder head and an Inletvalve.1. Cylinder head2. Inlet valve seat ring3. Inlet valve guide4 . 01 1 passage5. Welsh plug6. Beartng cap7. Bolt . Max 458. Washer 5


14/102

I, I

"

i '

1.3.0.3. Cylinder Head - OverhaulThe cylinder head must be thoroughly cleaned and remains of old gasket materialr emoved. The checks and i nspecti ons are to be carr ied out as requ ir ed .Valve Springs: If Ihe engine has a hi gh mil eage , al ways rep lace the valve sprin gs asa set. To che.ck a valve spring, place the old spring and a new spring end to end overa long boll (Wi th washer under bol t head ) and fit a nut (agai n wi th a washer). Ti ghtenIhe nut until the springs are under tension and measure the leng th of the two springs IfIhe o ld sp ri ng is shorte r by more than 10%, replace Ihe complete spring s~When a spring lesler is available, check the spring length when Ihe loads given I~Section 1.3.0. are appl ied.The sp~ngs must not be distorted . A spring placed w~h Its n a t con on a surface mustnot deVla le at the top by mo re than 2 mm (0.06 In. ).

18---0-21~1 9 /20

22

Fig. 1 .19 - Exploded view of the cyl inder headof a 602 engine.1 . Bol l in chain chamber2. Wave washer 12. Soeling ring13. Conneclor for lempemturn3. Bearing cap boll4. Plain washer5. Camshaft bearing cap6. Dowel pin7. CyUnder head boll8. Sealing ring9. Plug, oilgaUery10. Sealing ring11. Same as13

sender uni t14. Threaded Insert15. Healer connection16. StUd.exhaust manifold17. Welsh plug18. Sleel ball, oil gallery19. Bol l, f ue l f iUer20. Plan washer21. Steel ball, coolantclmuil22. eyl lnder head gaskel

24

Valve GuIdes: Valve guides for Inlet and exhaust valves are made of cast iron andhave d iff eren t d iameters , Gui des for exhaust val ves are short er and have a l arger i nnerdiameter.Clean the Insi de of the guides by pull ing a petrol -soaked cl oth through the guides.Valve stems can be cleaned best by means of a rotating wire brush. Measure theIns ide d iameter o f t he gui des. As an Insi de mic rometer I snecessary f or th is opera ti on ,whi ch Is not al ways avail able , you can Inserl the va lve Into its gui de and withdraw i tuntil the valve head Is approx. leve l wil h the cyli nder head fa ce. Rock the val ve to andfro and check fo r p lay_ A lthough no exact val ues are ava il ab le , if can be assumed thatthe p lay shoul d not exceed 1 .0 - 1.2 mm (0.04 -0.047 In.). Mercedes wo rkshops usegauges tocheck the gui des fo r wear.Guides are removed with a shoul dered mandre l fr om the combus ti on chamber s ide o fI he cyl lnde f head. I f gui des with nominal dimension 1 can be used, drtve them Inposition , until Ihe retain ing Is resting agai nst th e cyl inde r head. If repai r gui des arefitted, the locating bores In the cylinder head must be reamed out to take the newguIdes. A s dry Ice Is requi red to fH the new valve guides .we recommend 10 have thework camed out In a workshop.Before a val ve gui de I s repl aced , check the general condi ti on o f I he cyl inder head. Thegui des must be reamed aner Inst al la ti on , and aner the cyl inder head has coo led down,If applicable, to their correct Intemal diameter, given in Section 1.3.0, nollng thedif ferent diameters for Inlet and exhaust valves.V alves must al ways be repl aced If new val ve guides are rrtte d. The valve seats mustbe re-cut when a guide has been replaced. If II Is obvious that seats cannot be re-g round In t he present condi ti on , new val ve sea t I nser ts mus t be r rtt ed .A gai n thi s Is an operation for a specialist and the work should be carried out In aworkshop.Valve Seats: I f t he camshaft beari ngs are excessi ve ly wom, rrt a new or exchangecyl inder head. I n I hl s case there Is noneed to renovate the val ve sea ls .Check a ll val ve sea ts f or s igns o f p itt ing or wear. S li gh t Indenta ti ons can be removedwith a 45' cutter. If this operation Is carried oul properly, there shoul d be no needto grlnd"ln the valve s. Use correcti on cutters to bri ng the valv e seal ing area Into theFIg. 1.20. - Pri ncIpal dimensIons of a va lve seat(&011&021.

DfoscrlptlonD Oute r d iame te r o r s ea l ringD1 Innerdiameter of seat ringD2 Locating born In cylinder headH Height of valve seat r IngT Dimension be1ween head face and

upper race of valve seal ringDimensions

D 40.100.40.084 mm, inlet valveD1 33,400.33,600 mm,exhaust valves02 40.000_ 40.016 mm Inlet valvesH 6.97 - 7.0mm 'T 2.37- 2.25mm, Inletvalvo! ;

2.44- 2.25 mm.eidlau!;! valves

25


15/102

centre of the valv e sea l. Make sure tha t the val ve seat width, gi ven in S ectio n 1.3.0. Isobtained. This again is achieved by using cutters of different angles (for exampleISoand 60). Valve seat inserts can be fitted to the cylinder head. Replacement ofvalve seat inserts will require that the old seat Insert Is removed by machining. Themachi ni ng mus t not damage the bot tom face o f t he head recess .As Ihls is a critical operatlon,- we advise you to bring the cynnder head to yourMercedes Deal er who has the necessary equi pment and experi ence to do the Job . F ig .1 .20 shows a val ve sea l. It may be possible 10 obtai n a recond it ioned cyl inder head Inexchange for the old one to avoid Ume delay. In this case remove all ancillary partsfrom the o ld head and refit them to the new head .

A

I II

I IFig. 1.21 - The max imum dimension "A" between the valve face end cylinder head face Isshown on the L.H. side . Measure this d imension as shown onthe R.H. side.

If the valve seats have been re-cut, use the valve and measure the dimension ~A' inFig. 1.21. To do this, insert the valve inlo the respective bore and, using a depthgauge, measu re the gap between the cyli nde r head face and the valve face , a s shownon the R.H. side in Fig. 1.21. The dimension must be between 0.1 and 05 mm In thecase of new va lves. The wea r li mit i s 1.0 mm.Val ves can be ground Int o t he ir sea ts I n t he convent iona l manner.I IValves: The stems of inl et va lve s and exhaust v alve s have been speci all y treated,l.e. th e ends of the val ve stems must not be g round o ff.Va lve s can be cl eaned best WIth a rotating wi re brush. Check the vafve fa ces fo r wearo r groovi ng. If the wear is on ly sl igh t, va lves can be re-ground to thei r origi nal angl e i na valv e grind ing machi ne, but make su re tha t the re i s enough material le ft to have anedge on the valve head. The valve head thickness must be 0.5 - 0.7 mm in the case ofthe i nl et v alve s and 0,5 - 0.6 mm i n the case of the exhaust val ves.Measure the valve s in accordance wi th the values giv en In Sec ti on 1.3.0 and Fi g. 1.22and replace any valve which Is outside the limits given. Note Ihat the valves are notf il led w it h sod ium, as Is the case w it h o ther Mercedes eng ines .Check the valve stern diameters and In thls connection the Inside diameters of thevalve guides. If there Is a deviation from the nominal values, II may be necessary 10replace the valve guides (see above). Also check the end of the valve stems. Thereshoul d be no v is ib le wear I n I h is a rea.Always quote the model year and the engine number whe.n ordering new valves, asdifferent valves are used. These are marked by means of a number In the end of theval ve stem. The numbers can be found i n S ectio n 1.3.0.

26

rIig. 1.22. - Pr1nclpal valve dimensions.o = Valve head diameter. 01 = Stem diameterL = Length

Somet imes I I I s onl y requi red to repl ace the exhaustvalves, If these for example are burnt out at theirvalve head edges.Cylinder Head: Thoroughl y c lean the cyl inder headand cyli nde r b lock surfa ces of o ld gasket materia land check Ihe faces for di sto rtio n. To do this, p lace asteel rule r wi th a sharp edge over the cyl in der headface and measure the gap belween ruler and facewith feeler gauges. Checks must be carried out inlo ngitud ina l and diagona l directi on and across theface. If a feeler gauge of more than 0,10 mm (0.004In.) c an be I nse rted, when the rule r Is pl aced along oracross the cyl inder head, have Ihe cyl inder head facere-ground. The dimension between the face of thevalve heads and the cytlnder head face fA' In Fig.1 .21) w il l change aft er r egr l nd lng, but the workshop

wil l correct II accordingly.A further check must be carried out on the pre-combustion chambers for the fuelInJection. These must protrude by 7.6 - 8.1 mm. Mercedes workshops correct thisdimension by f it ting sealing washers of dif ferent thicknesses, to correct the protrusion.

..J

Fig. 1.23- Checking acamshaft for run-out.Camshaft: Place thecamshaf t wi th both end Journal s I nt o~V' blocks or clamp the shaftbetween the centres of a lathe andapply a dial gauge to the centreJournal, as shown In FIg. 1.23.Slowl y rola te the shaft 10 check fo rexceeds 0.01 mm, fit a new shaft.The following points must beobserved when replacing thecamshaft:run-out. If the dial gauge reading

Make sure to f it the cor rect sha ft I f t he sha ft Is t o be rep laced. Check the i denti fi ca ti onnumber when order1ng a new shaft .ReplaCing Valve Stem Off Seals (Cyflnder Head mted): Valve stem oil seals areava il ab le I n repai r kHs . I nc luded In t he repa ir k it s a re pro tecti ve s leeves wh ich mus t bepUshed over t he val ves dur ing Ins ta ll at ion o f t he sea ls . Val ve s tem sea ls are d if fe rentI nd iameter and can a lso be Iden ti fi ed by thei r shape (Fi g. 1 .24) .Normil ilya special 1001 Is u sed to fit the seal s, but a wel l fitting p iece of tube of s uitabl edi ameter can be used. Take care no t to damage the seal in g li p and the spr1ng.The va lve co tter hal ves and the va lve sprin gs must be removed to repla ce the sea ls.To prevent Ihe val ves f rom dropp ing In to t he combusti on chambers, the p is tons mus t

27


16/102

be at the top dead centre position. This Is easy in the case of a four-cylinder engine,as two pi stons are a lways at lop dead cent re. The opera ti on is more di ff icult on a f ive -cyl inder eng ine , as the cranksha ft mus t be ro tated bya cer tai n angle to move the nex tpiston to TD.C. Only attempt this operation If you are competent. Start by setllng thepiston of the No.1 cylinder to the top dead centre position. Valve stems seals ofcyl inders Nos. 1 and 4 can be replaced In this pos it ion.

I III'

Fig. 1 ,24 - Sectional v iew of the valve stem all semll, On the lentor the exhaust valves; on the r,lghtfor the Inlel valves. Remove the camshaft (see descripUon later on).

Remove the valve coller halves of the first cylinder as described In Section1.3.0.2. Remove the valve springs in the case of a four-cylinderengine. Use a pair of pliers or a screwdriver to remove the valve stem seals, withoutdamaging the valve stems. Coat the new seals wjth engine all and carefully push them over the valve stems.The protective sleeve must be used for the Inlet valves. Push the seals over the

valve guides until properly In position. Fit the valve springs with the paint spot towards the bollom, m the upper spr ing

cup and compress the spr ings unt il t he val ve cot ter ha lves can be Inser ted. Makeabsolutely sure that the cot ter halves have property engaged before the crankshaf tis rolated.Replace the val ve s tem seal s of cyl inder No .4 In the same manner .Li ft t he camshaf t sp rocket sl ight ly to prevent d isengagement of the t iming Chainand' ro ta te the c ranksha ft o f a fou r-cyl inder eng ine by half a tum. The valve stemseals of cylinders Nos. 2 and 3 can be replaced In the same manner, In the caseof a f ive-cy linder engine, rotate the crankshaf t unt il both valves of the next cyl inderare closed. This wjll be in the order 24-5-3. As already mentioned, take carewhen rota,ting the crankshaft. Both valves ofa cylinder must be at the sameheight, before the valve col ter halves are removed.Ref it the camshaft and assoc iated parts .

II

I Note: Operate the valve spring compressor very slowly, as valve cotter halvessomet imes st ick to the val ve stems. Observe the val ve spnng duri ng compress ion .Only the sp.ring should move, not the valve. Prevent by alf means that the valve canpress against the piston.

1.3.0.4. Cylinder Head - AssemblyThe assembly of the cylinder head Is a reversal of the dismantling procedure. Notethe foilow,ing' points:

Lubricate the valve stems with engine oil and insert the valves into the correctvalve guides.

28

V ive stem seals are dlfferen! for Inlel and exhaust valves. Make sure to orderIh : cor rect seals . The repa ir ki t con ta ins f itt ing sleeves and these must be used tor n the seals (see lasl Section).The s leeves are f it ted over the valve s lem before the seal Ispushed In pos it ionFit t he va lve spr ing and va lve spr ing col la r over the val ve and use the val ve li ~erto compress the spnng. Insert the valVe col ter halves and release the valve spnnglifter. Make sure Ihat fhe cotler halves ale in position by tapping the end of thevalve slem wi th a plasti c mal let . P lace a rag ove r the va lve end - Just In case.Fit the camshaft as descr ibed later on and carry out a ll o ther operations In reverseorder to the dlsmant!lng procedure.

1.3.0.6, Hydraulic Valve Clearance CompensationThe funct ion of the hydra.u llc valve c learance compensat lng elements Is , to eliminatevalve clearance, I.e. the dlmanslonal changes In Ihe valve train (valve lash) due toheat expansion and wear are compensated by the elements. The rocker arm Is Ina

12

FIg. 1...5- Secllonal view of _ valve clearance compensating element1 Rockerlever 7 Ball guide 13 Valve2 lock ring 8 Thrusl sJK'lng 0 011chamberJ Was!>er 9 8011 ,.4 mm b Work ,,!>\lmber4 Closing cep 10 TIlnr.;t apr!ng c RB1umbores5 Til rust pin 11 Ball socket IRing groove6 Guide sleeve 12 Valve spring retainer h 01 1 bores

COns tan tcontact w lth the cam. The compensati ng elements cannot be repaired , butcan be checked for cor rect functi oning as desc ri bed be low. Figs. 1.25 and 1.26 show:,:cllonal views of a valve w~h clearance. compensation. We will give a shortescripl lon of the operation. All references refer to Fig. 1.25.

29


17/102

The hydraul ic val ve compensa tj ng e lement a re fi tt ed I nt o the rocker l evers and opera tethe val ves d ir ec tl y v ia a .bal l socke t (11). Each e lement consi sts o f t he fol lowi ngcomponents:

76

Fig. 1.26 - Sectional v iew ora valve and acompensating element,1 Thrust pin2 Lock ring3 Thrust spring4 Ball guide5 Ball6 Thrusl spring-t~~~~~2~3 The thrus t p in (5) w it h a ll suppl y chamber5 and the retu rn bores and the bal l val ve ( checkval ve), I .e . i tems (9), (7 ) and (10) . The bal lval ve separa tes t he suppl y chamber f rom thework chamber. The guide sleeve (6) with the workchamber (b) , t he th rust spr ing (8 ) and theclosing cap (4) .When the engine Is stopped and the tappet ishel d under load from the cam, the element cancomple tel y retract. The all displ aced from thework chamber (b ) fl ows th rough an annul ar gap ,l .e . the c learance between the gui de s leeve andthe thrust pin 10 the all supply chamber (a) .When the cam lobe has moved past the valvetappet, the thrust pin (5) will be without load.The thrust spri ng (8 ) forces the thru st p in upwards until the valve tappet rests agai nst

the cam.The vacuum resulting from the upward movement of the thrust pin In the workchamber (b) opens the ball valve and the all can fl ow from the supply chamber (h) i ntothe work chamber (b). The ba ll val ve closes when the val ve tappet presses against thecam and puts the thrust pin under load. The ol l in the work chamber acts as a"hydraulic rigid connection" and opens the valve in quest ion.When the engine i s runn ing and depending on the engi ne speed and the cam position,t he th rust p in i s onl y pushed down s li gh tl y.The oi l contai ned In the 01 1 supply chamber (a) Is suf fi cient 1 0 f il l th e work chamber (b)under a ll opera ti ng condi ti ons o f the eng ine. all or l eak all whi ch is not requ ired, aswell as air are able 10 escape via the annul ar gap between the washer (3) and therocker l ever. The o il e ject ed from the work chamber f lows v ia the annul ar gap betweenthe guide Sleeve and the thrust pin and the two return bores (c) Into the oil supplychamber.I f the l appe ts are removed, note the fol lowi ng poi nt s:

A lways keep the tappe ts i n an upr ight pos iti on , i .e . t he open side towards the top.After removal of a tappet (see below), mark the cylinder number and thecompensating element in su itable manner. Always fi t orig inal parts i n thei r samelocations.

Checking a hydraulic compensating element: As the e lement s are i n con ti nuouscontact with the camshaft, you wil l rar~ly hear noi ses from the area o f the hydrauli celements. Jf noi ses can be heard , check the e lement s as fol lows :

30

S tart the eng ine and run I I approx. 5 m inutes a l 3000 rpm.Remove the cyl inder head cover .Rotate the crankshaft unlll the cam for the tappet to be checked is pointingver tically towards the top.

I11

Fig. 1.27 - Checking of II hy-draullccompensating elem...nt. Use a drift, as shown In Fig.1.27 and push the tappet t owardsthe Ins ide, o r try t o move the tappetwith the fingers. If the tappet cannot bedepressed or excessl ve c learancecan be fell between the tappet andthe back of the cam, replace Ihetappet. The tappet is suppliedtogether with the hydrauliccompensati ng e lement . Mercedesworkshops can reset the tappet toits original position, but this

operation Isbeyond Ihe scope of Ihe home mechanic.TBppet RemovBI and Installatton: Remove the camshaft as described later on. Use a suc ti on too l to remove the tappe ts . Mark t hem, I r t hey are to be re fi tt ed . F it t he tappe ts In to t he ir o ri gi na l bores , If re -used. Refi t the camshaft as desc ri bed

and carry out all other operations In reverse order to the removal procedure.

1.3.1.1.3.1.0.

PISTON AND CONNECTING RODSTechnical Data

All dimensions are given In metric uni ts.P is tons - 601 lind 802 EngfnesPiston Diameter - Std.:

Class A : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.97088 .976 mmClass X : . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . More than 88.975 - 88.983 mmClass B: . ............................... More than 88.982 - 88.988 mm

Piston Running Clearance:- New , ......... 0_017-0.043mm- Wear limit 0.12 mmMa)(. weight difference within engine:- New , , .4 grams- Wear Ilmit 10 gramsPiston Pins:~:~t~~a~~t~~~i~.g.~i~.a.~~~~~: _ 26.995 - 27000 mm

31

~,


18/102

_ In small end bush , , , , , , 0.018 - 0,029 mm_ In piston 0.004 - 0.015 mmPiston Rings:Piston Ring Gaps:- ~ ~ : : ;I ? ~ ~ : : :: : :: : :: : ::: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : . ~ . . ~ ~ . ~ . ~ 1 ~ ~~_ Centre rings 0.30 - OA O mm_ Wear l imit .. . 1 , 0mm_ lower rings 0.20 - 0.40 mm- Wear li mi t 1.0 mm

II

Side Clearance in Grooves:- _ U ~ : ~ ; i I 7 ~ ~ L : : : : : :: : : : : : :: : : : : : :: : : : : :: : : : : : :: : : : : : :: : : : : :: : : : : : :: : : : : : :: : : : : :: : : : : : :: : : : : : :: : : : : :. O . ' . ~ . ~. ~ . ~ ~ . ~ ; ;_ Centre rings 0.050 - 0.080 mm- Wear limit , 0.15 mm_ lower rings ' ' ' ,,., .., , 0.030 0,065 mm_ Wear limit: , , 0.10 mm

Connecting RodsDis tance f rom centre small end bore tocentre big end bore 145.0 mmWidth of con rod at big end bore 24.000 mmBasic bore diameter of big end bore 47.95 mmBasic bore diameter of small e nd bore 29.500 mm

II", ,,

Small End Bush:~ Outer diameter.. ............ 29.50 mm_ Inner diameter. . , ......................................... 27.000 mmMax, twist o f connecting rods. . . . 0.10 mm per 100 mmMax. bend of c onnecting rods ......................... 0.045 mm per 100 mmMax. weight difference in same engine: 5 gram (per set)Connect ing Rod Bot ts:_ Thread: , , , ,..................... M9 x 1- Diameter of stretch neck 7,4 mm- Min. diameter of stretch neck: 7.1 mmConnecting rod bearing details: See under "Crankshaft"

, ,,I '

P istons - 616 Engi nePiston Diameter - Std. - Piston No. 03, 38:Class a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9O.g8mmClass 1 , , .......................... , .. 90.99 mmClass 2... . , , , ,.. .. 91,00 mm

Piston Diameter - Std. - Piston No, 35, 44:Class 0 , ' , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90.88 mmClass 1 , , ..................................... 90.69 mmClass 2 .................................. , . , . . . . . . . . . 90,90 mm

Piston Running Clearance:- New.. . , . . . . , . : : ...... 0.02 - 0.03 mm-Wearlimit., .......... , " " .. 0.12mm

32

j

Max. weight difference within engine: 4 ram- ~ee~~ii;;;it::::::::::::::: :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::'1'0 ~ram:

Piston Pins: 25.995 _ 26.000 mmPin dlameter .piston pin running olearance:_ In smail end bush " ~:~~~ = ~ : ~ ~ ~ ~ ~- In piston . tIIPiston Rings:Piston R!ng Gaps: 0 30 _ 0 45 mm: f { ~ . . . ~ ! 5 ~ . ~ ~~Connecting RodsDist ance f rom centre small end bore tocentre big end bore 149.05 mmBasic bore diameter 01 big end bOfe , 55.60 - 55.62 mmBaSic bore diameter of small end bore 29.000 - 29.02 mmSmall End Bush:_ Outer dtameter.. ." .. ,................ 29.096 - 29.058 mm_ Inner diameter. . . . . . . . . . . . . . . . . . . . . . . . .. . ......... 26.012 - 26.018 mmMax. twist of connecting rods. .. . ................ ' 0.10 mm per 100 mmMax, bend of connecting rods. . .. . 0.045 mm per 100 mmMax. weight difference In same engine: 5 gram (per set)Connecting Rod Bolts:_ Thread: ,............ Ml0 x 1- Diameter of stretch neck 8.4 mm- Min. diameter of stretch neck .. 6.0 mmConnecting rod bearing details: See under "Crankshaft"

1.3.1.1. Piston and Connecting Rods - RemovalThe pistons are made of IIght.alloy. Each piston has a star-shaped cavity, a pre-combUstion chamber and two round recesses for the valve heads. The exit of theI)re.combusl ion chamber Is connected with the combustion cavity. Fi g. 1.26 shows aview of the piston.

33


19/102

Fig. 1.28 - VIew of the piston, showfng thecombustion chamber with (1). The tw o recesses'or the valves prevent contact between the valveheads and the piston crown.Three piston rings are filled to each piston.The two upper rings are the compressionri ngs, I. e. t hey prevent t he pressure above thepiston crown to return to the crankcase. Thelower ring is the o il scraper ring . Its functi on i sto remove excessive 01 1 fr om the cyl inder bore ,thereby preventing the entry of 01 1 Into thecombustio n chamber. The three ri ngs a re no tthe same in shape. The upper ring has arectangul ar section , the centre ring has achamfer on the Inside and the lower ring Ischrome-p la ted on i ts out si de . Onl y t he correc tf it ti ng o f t he p is ton r ings wi ll assure the proper opera ti on o f t he p is ton sea li ng .

Pistons and connecting rods are pushed out towards the top of the cylinder boresUsing a hammer handle alter connecting rod bearing caps and shells have beanr emoved. Befo re remova l o f t he assembl ies note the fol lowi ng poi nt s:P is tons and cyl inder bores are graded In th ree d iameter c lasses w it hi n speci fi edtolerance groups and marked with the letters A, X and B or 0, 1 and 2 (616engi ne). The cl ass number is stamped into the upper face of the cyl inder bl ock,nex t to t he par ti cu la r cyl inder bore, as shown In F ig . 1.29.

Fig. 1.29 - Ident ifi cat ion (marking) of piston crown and cylinderblock race with th e g [0UP code Ietters.

Fig. 1.30 - Connecting rods andbearing caps can be marked with IIcentre punch as shown.

The class number of thepi ston must al ways be Identica lwith the letter stamped next tothe cylinder bore. Piston

L ~ ~ ~ f : ~ ~ ~ ; b e i r i i re s t a i i n D i ;a - " " T i T t o ~ e l di ameter, the cl ass number il ndthe two l as t numbers o f t he p is tonspare number are piston crown. An arrow with thei nscri pti on ' "Vorn" (f ront) , Indi ca ti ng the f it ti ng d irecti on Is a lso s tamped i nt o t hepiston crown.For repai rs , onl y p is tons wi th group code l e.t le r_: : X' are ava il ab le . These p is tonscan also be used If the code lette rs "A ' or "B" are stamped Into the cylin der blo ck.

34

If the cyl inder bores are re-bored, thei r s ize wi ll be Increased to t ake the group -X'pistons. plus the allowance for the piston running clearance.Mark each p is ton and the connect ing rod befo re remova l w it h the cyl inder number .This can be carried out by wri ti ng the cyl inder numbe r with pai nt onto the pistoncrown. Also mark an arrow, facing towards the front of the engine (the arrow inthe plslon crown will be covered by the carbon deposits), When removing theconnecting rod, note the correct Installailon of the big end bearing cap.Immedia tel y after removal mark the connecti ng rod and the big end beari ng capon the same side. This Is best done with a centre punch (cylinder No. 1 onepunch mark, etc., see Fig. 1.30).Mark the b ig end beari ng she lls with the cyli nder number. The upper shel ls havean all dri ll ing ( to lubricate the piston pin).The bi g end bearing shell s can be o f two different d lamete rs. At the l ower end ofthe connecting rod bearing cap, at the position shown i n F ig. 1.31, you wil l seeone or two punch marks. If one pun


20/102

Fig . 1.33 - Removal or Install ation o f pi stonrIngs with a pair of piston ring pliers. NeVerexpand r ings more than necessary t o preventbreakage.

36

Cylinder bores must be measured Inl ong itudi nal and transverse di re cti on and atthree positions down the bore, I.e. 10 mm(O.4 In.) from the upper bore edge, 10 mmfrom the lower bore e d g e ,lind once In the

centre, total l ing 6 measurements. The wonst measurement must be taken whendec id ing on the s ize for t he p is tons to be f rl ted (Fi g. 1.34).

EJS;L.~a

I 1 1Iii2 b 233

Fig. 1.34. - Measuri ng dIagram for the cyli nde r bores.Numbers 1, 2 and 3 Indicate the three levels Wheremeasurements should take place.A = Measurement parallel to b ore b" Boltom dead cenlre of p islonB ~'Measurement across bore c - Lower returnpointof alla QUpper return point of cantrol r ing

upper piston ring 1-3 = Measuring pointsNote that al l cyli nde r bores must be re -bo rad, even If onl y one of the bo re s is outsidethe diameter l imit . A to le rance o f 0 .20 mm Is permissible. If the wear Is outside Ihellmits, It is possible to have new cylinder liners frlted to the block. Your dealer willadv ise you Whatcan be done.The fi na l cyl inder bore d iameter i s determined a ft er measuri ng the p is ton d iameter. Tomeasure the d iameter, appl y an ou tsi de mi crometer 10 mm (0.4 In.) from the bottomedge and at righ t ang le to the pi ston pin bore. A dd the pis ton runni ng cl earance to th isdimension and 0.03 mm for the honi ng of the cyl in ders. The pi ston runni ng cl earancemust not exceed 0.12 mm.To measure the runn ing clea rance, de termine the p iston and cyl inder bore diamete rsas descri bed above and cal cu la te the d if fe rence between the d imens ions .If t he d iff erence i s more than 0.12 mm, have the cyl inder bores re-bored to frt oversizepistons.

1.3.1.3. Checking Pistons and Connecting RodsA ll pa rts shou ld be thoroughly i nspected. S igns of se izu re, grooves or exeessl ve wearrequi re the part t o be rep laced. Check the p is tons and connect lnq rods as fol lows :

h ld clearance of each piston ring In its groove by inserting the ringCheck t e Sl e . . t bwith a feeler gauge, as. shown in Fig. 1.35. The grooves mu_s eIOgelherhl leaned before the check. If the wear limit exceed the values In thethoroug Y c .t echn ical data I s reached, e it her t he nngs or t he p is ton are worn .Fig. 1.35 - Checking the side clearance ofpiston rings. Check Ihe pi ston rin g gap by In serti ngthe r ing f rom the bott om into t he cyl inderbore. Use a piston and carefully pushthe plslon ring approx , 1 In. fur ther Intothe bore. This will square II up. Insert af ee le r gauge between the two p is ton r ingends to check the ring gap, as shown inFig. 1.36. Refer t o Sec ti on 1.3.1.0. for

the wea r li mi ts. Ri ngs mus t be repla ced, If th ese are sxceeded . New rings shoul dalso be checked in the manner descr ibed.

Flg.1.36- Chklng piston r ing gaps. Piston pins and small end bushesmust be checked fO f wear or

seizure. One Indiv idual connect ingrod can be repl aced , p rovi ded Iha t arod of the same weight group Isf i t ted. Connect ing rods are markedwi th ei the r one or two punch marks(ar row, Fig. 1.30) and only a rodw ith t he same mark must be f rtt ed .Before re-uslng the connect ing rodbolts check their diameter at thepos it ion shown in F ig . 1.37. IfI hl s I ssmall er th an gi ven fo r the engi ne In questio n, repla ce the bolt. A second check Iscarried out by placing the connecting rod bearing on one of the connecting rodbolts. If t he beari ng cap I smovi ng under rts own weight, renew bol t.

fig. 1.37 _ Connecting rod baHs can stretch In thei r l eng th " LA . Bymeasuring the stretch neck "c" , you wil l know If the bol ts can bere-used. Connectin g rods shoul d be checked for bend or twist, pa rti cula rl y when the engi ne

has covered a h igh mil eage . A speci al J ig I s necessary fo r t hi s opera ti on and Ihe. Job _ should be carried out by an engine shop. The max. values are given InSection 1 . 3 . 1 . 0 . - .-

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21/102

Fi g. 1.38 - Sectional view of aconnecting rod (601 and 602engines). 6Upper bearingshen2 Lower bearing shell r -Cannacling rod4 Spring pins(roll pins)5 Connecting rodboll6 Small end bushL 145.0 mmB 24.00 mm0 47.95mm 3

I I I 01 29.50mm.J

02 27.00 mm or 28.00 mm l _he fol lowi ng i nf ormat ionconcern the connect ing rods: 1 Connecting rods whichwere over-heated due to 4bearing fai lure (bluefishcolour) must not berefitted.

II'1

I.

Connectin g and beari ngcaps are matched to eachother and must be fittedaccordingly.New connec ti ng rods are suppli ed toge ther with the smal l end beari ng bush andcan be f it ted as suppl ied.F it the bearing cap with the i nserted bearin g shel ls and clamp the connecti ng rodinto a vi ce. Ti ghten the bolts 10 the speci fied torque, using an Internal micrometer,measure the b ig end bore d iameter a t vari ous poi nts . Ir th e value of 51.119 mm isexceeded, o r the bore i s out o f r ound , rep lace Ihe complet e connecti ng rod.If the piston pin has excessive clearance in the small end bush, fit a new bush .When pressi ng in the new bush, al ign the 01 1 bore In the bush wi th the 01 1 bore Inthe connectin g rod. The smal l end bush must be reamed to the di amete r -02" InFig. 1.38 to obtain the correct piston pin running clearance and again Werecommend to have the j ob carri ed out b y an engi ne shop.

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II'II

1.3.1.4. Checking the Big End Bearing ClearanceThese operations are descr ibed In connect ion with the crankshaf t (Sect ion 13.3.2.).1.3.1.5. Piston and Connecting Rods - Assembly

1If new p is tons are f it ted, check the p is ton c rown marki ngs to ensure the cor rect p is tonsare f it ted. i f t he ori gi na l p is tons are fi tt ed , a rrange them In accordance wi th the cyl indernumber markings.

If connecting rods have been repl aced check the bottom of the bi g end bearingcaps. Either one or Iwo punch marks are stamped Into the centre of the cap, asshown in F ig . 1.31. These numbers refer to the bearin g shel ls to be fitte d. She ll swith bl ue co lour code (marked a t t he si de of the she lls) must be fi tted 11one punchmark i ss tamped i nt o t he cap ,Insert the connecti ng rod into the piston and ali gn the two bores. Make sure thatthe arrow i n the pi ston crown and l ocating l ugs for the bea ri ng shel l loca ti on a refaci ng the L .H. side o f t he engi ne, a s shown in Fig. 1.39.

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F1g. 1.39 - The arrow In the p is ton c rown (1) must 'ace thefront end of the engine when the 1CX:lII tlngugs 'or the bell i ringshells (21l11reon the LH. side 0 ' the cyl inder block. Generousl y lu bri cate the pi ston pi n with eng ine 01 1 andInsert It Inl o the pi ston and connecti ng rod, u sing thumbpressure only. Neve r heat the p iston to fi t the piston p in.F it the cl rcl ip s to both sides of the pi ston, making sure o ftheir engagement around the groove . Move the p iston upand down tocheck fo r f ree movement. Using a pair of piston ring pliers, fit the piston ringsfrom the top of the piston, starting with the bottom ring .The two compressi on ri ngs coul d be mi xed up and Fi gs.1.40 shOUld be referred to avoid mistakes. Under noc ircumstances mix -up the upper and l ower compressi onrlngs.

1IiiI

IFIg. 1....0- Sectional of a piston, concentrating on the piston rings.SloHedcontrol ringwith J Squarecompression ring.expender ring, chrome plated contact face a symmetrically2 Ghamfered compression ring ground and chrome-plated

ModtfJcatlons - PIstons and Connecting RodsModilled pistons and connecting rods have been fitted to 601 engines with theInt roduct ion of model year 1985 The width of the connecti ng rods has been reducedfrom 24 mm to 22 mm. A t the same time the p is ton p in d iameter ('OZ' In Fig. 1.38) hasbeen reduced f rom 27 to 2S mm and Is 1.0 mm l onger. The new connecting rods canbe f il led to ear lier engines, but on ly together with the new p istons and pis ton pi ns. It IsObV ious tha t t he new p is tons can onl y be n tt ed together w it h t he mod ifi ed connectf ngrods.If the eng ine ope rates with an EGR system, the pi stons are cool ed by all spl ash jets (Ifapplicable, Int roduced for model year 1991 on 601{602 engines).1.3.1.6. Pistons and Connecting Rods - InstallationGene rously lubri cate the cy lin der bore s wi th oU. Markings on connecting rods andbearing caps mus t be opposi te each other. The a rrows in the pi ston crowns must facetowards the f ront of the engine.

3 9


22/102

A rrange the p iston ring s a t equa l s paci ngs of 120 a round the ci rcumference of thepiston skirt and use a piston ring compressor to push the rings into their grooves.Check that aU ri ngs are fu ll y pushed i n.Insert t he second beari ng she ll i nt o the connect ing rod beari ng cap , w it h I he l ocat inglab on the L.H. side and fit the assembly over the connecting rod. Check thatconnect ing rod/ cap marks are fac ing each o ther .Coat the contact areas for the cap bol ts wi th eng ine oil a nd rr t and t ighten the bol ts to3 .0 kgm (22 ft.l b.) in several sl ages. From th is posltlon t ight en each bol t by a fu rt her90 - 100' (app ro x. 1/4 of a l ur n) wi thou t usi ng the to rque wrench. It I s assumed tha tt he s tre tch bol ts have been measured as previ ousl y descr ibed .Rotate the cranksha ft unti l th e two remai ni ng crankpln s are at bottom dead centreand fit the two other p is ton/ connec ti ng rod assembl ies I n t he same manner.Check Ihe pistons and connecti ng rods once more for correct Install atio n and Ihaleach p is ton I s f i ll ed t o i ts o ri gi na l bore, i f t he same part s are re fi ll ed .With a feeler gauge measure the side clearance of each big end bearing cap on thecrankpin . The wea r l imi t i s 0.50 mm.

1,3,2.1.3.2.0.

CYLINDER BLOCKTechnical Data

Cyl inder Bore Diameter (601/602 engines):Nominal diameter - Group A: 89.000 - 89.006 mm- Group X: More than 89.000 - 89.01 2 mm- Group B: more than 89.01289.018 mmMax. wear, longitudinal and across: 0.1 0 mm (0.004 in.)Ma.x. out -of- round or taper of bores:New condition: 0.014 mmWear limit: 0.05 mmMeasuring point for bores: Upper edge, centre and lower edge,in longitudinal and transversedirection

Cyl inder Bo re Di ameter (616 engi ne) - V ersion 1:Nominal diameter - Group 0 - Cylinder No.1....... 91 .009 - 91. Of 8 mm- Group 1: 91.019 - 91.028 mm

- Group 2: 91.029 - 91.038 mmNominal diameter - G roup 0 - Cylinder No.2 to 4 90.998 - 91.008 mm- Group 1: 91.009 - 91.018 mm- Group 2: 91.019 - 91.028 mm

Cy li nder Bore D iameter (616 eng ine) - Versi on 2 :Nominal d iameter - G roup 0 - Cyl inder No. 1 .. .. ... .. ... ... .. ... .. 90. 908 - 90.918 mm- Group 1: 90.918 - 90.928 mm- Group 2: 91 .029 - 91.038 mmNomina l d iame ter - Group 0 - Cyl in der No.2 to 4.............. 90 .898 - 90 .908 mm

. Group 1: 90.909 - 90.918 mm- Group 2: 90.918 - 90.928 romNote : Repa ir s izes are not ava il ab le f or t hi s eng ine, as cyl inder l iner s are suppl ied wi thnominal diameter.Max. wear, longitudinal and across: : 0.10 mm (0.004 in.)

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r*1tj1Max out-of -round or t aper o f bores:~e:arcl~~~~.'.~"..:.:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::.::::::::::.~~6;.~~Measuring point for bores: - , . . . . . . . . . . As for other enginesCrankcasePermissible unevenness of:~~!:;:~~::::~:::::::::::::::::::::::::.::::::::::::::::::::.::::::::::::::::::::::::::: 6~~Difference tJetween upper and lower sealing face: 0.10 mm (0.004 ln.)

1.3.2.1. ServicingSpecia l a ttentio n shoul d be g iven to the cyl inderblo ck each time the crankshaft hasbeen removed, Ir respec ti ve whether t he bores are to be re-mach ined or not.

1.)IFig. 1.41 - View of the rear end of thecylinder b lock, showing the ~eel ball1 (1) tor the man 011galler y and thewelsh plug (2).Thoroughly clean all cavities andpassages and remove al l traces offore ign ma tter from the Joi nt fa ces. Ifany machin ing or honi ng of the borestakes place, it Is essential that allswarf Is removed before assembl y ofthe eng ine ta kes pl ace . The mai n 01 1gallery Is closed off steel balls of 17mm diameter at the front and 15 mmdiameter at the rear. The steel balls

must be removed In o rder to cl ean the maJn on gal lery. The stee l ball s can be refitte dunl ess they show deep g rooves. F igs. 1.41 and 1.42 show whe re these s tee l bal ls a rel ocated . F ig . 1 .42 a lso shows other part s o f t he cyt lnder b lock o f a f our- cy ll nder eng ine,which should also be checked for wear. A five-cytlnder engine Is similar. We mustpoint out that the special drift 601 589 06 15 00 Is used to drive the steel balls Inposition to ensure their correct seating. If possible always clean all galleries withcompressed air.The fol lowing Instructions epp/y to the IJdVlJnoed engineer.If all l eaks can be detected at the fron t Of r ear o f t he cyl inder b lock and the ment ionedspeci al d ri ft canno t be obtai ned, I tw l ll be possi bl e t o c lose o ff t he bores w it h t hreadedplugs. AI the front an M 18 x 15 mm plug (Part No. 000906 0 18 000), at the rear anM16 x 15 mr n p lug (P art No. 000906 016002) i s u sed. Correspondi ng threads mustbe cut into the cytlnder block. The thread depth at the fronlls 10 mm, allhe rear 14mm. Remove a ll meta! chi ps and f it t he p lugs w it h "Loc tl te " t hread l ocki ng agent beforeInstallationI f the specf~ ' d ri ft can be obtai ned, rep lace the s teel bal ls as f ol lows ( it i s assurned thatthe engine is f lf ted}: Remove Ihe 0 1 1 pump. Remove the transmis sion and the fl ywheel . Use a s teel rod of 14 mm diameter and 550 mm ;n length and drive out the steel

bal ls fr om the rear towards the'1' ront , as shown In F ig . 1

Mercedes 207,208,210,307,308,310,408,410D-service_manual_EN

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Transcript of Mercedes 207,208,210,307,308,310,408,410D-service_manual_EN