Mercedes 207D, 208D, 210D, 307D, 308D Service Manual

Mercedes-Benz

2070,3070,2100,4100

208D,308D,310D,408D

'------------l

ADJUSTMENTS • TUNE-UP

REPAIRS • OVERHAULS SERVICING • FAULT FINDING

PETER

RUSS!\

MANUALS

'

----

-

------·-

POCKE I MECHANIC

Mercedes-Benz

207D, 307D, 210D,310D,

4100,2080,3080,4080

2.3, 2.4 and 2.9 Litre Diesel

COVERING:

GENERAL INFORMATION, DIMENSIONS, WEIGHTS,

CAPACITIES,

ENGINES .................................. ... ......

LUBRICATION SYSTEM ...................................... ......... ........

COOLING SYSTEM ...........

DIESEL FUEL INJECTION SYSTEM ....................................

CLUTC H ............................ ....................... ............................. 89

MANUAL

FRONT AXLE ..... ........................ ........

REAR AXLE AND PROPELLER SHAFT ............................. 110

FRONT

STEERING .......................................................................... 120

BRAKE SYSTEM .........

ELECTRICAL SYSTEM .... ................................................... 145

2.4

LITRE DIESEL ENGINE - TYPE 616 ............................ 153

SERVICING AND MAINTENANCE ............................

FAULT

WIRING DIAGRAMS ........ ...................... ............................. 188

TRANSMISSION .................................................. . 94

AND

FINDING SECTION ................................................. 179

GENERAL, SERVICING NOTES ....... .......... 4

.. .....

.............................. 9

.. .. ..

................................ .............

.. ............

REAR SUSPENSION .................................... 118

........................................................ 127

.................

.. .. ..

... 176

..

65 69 77

100

jay

PETER RUSSEK)

ORDER NO.: 445

Published by

Peter Russek Publications Ltd.

Floor, Block C

3rd

Commercial Square

ks

High Wycombe, Buc

Tel.: High Wycombe (01494) 440829

(01494)

(01494)473980

Fax:

E-mail: russek@globalnet.co.

'NWW

. russek-manual s.

ISBN. NO. 1-898780-45-5

WITH

FAULT

AT

FINDING SECTION

END OF

, HP11 2RH

526882

co.

MANUAL

uk

The publisher would like to thank Daimler Chrysler U. invaluable support

No part

transmitted in any form, electronic, mechanical, photocopying, recording, translati

No li ability can be accepted for any inaccuracies or Omissions in this workshop manual, complete and accurate as possible Every care has also been taken to prevent personal injury or damage to equipment when working on the vehicle We have tried to co ver un

dat

Re-published and re-printed J anuary

of

this publication may be reproduced , stored

ng

or other means without prior permissi

able to refer to all modifications and changes for certain markets or up-

ing of

models.

R.

D.Russek - 2000 P

in

producing this manual.

on

by the author.

although every possible care has been taken to make

all models produc

rin

ed

to the day

2006

ted in England

K.

Ltd. for their

in

a retrieval system or

of

publication, but are

it

as

2 3

PREFACE

Small though this Workshop Manual is in size, it

of

most models listed on the outside cover with 2 .3 and 2.9 601

Brief, easy-to-follow instructions are given, free from all necessary complications and repetitions, yet containing and information, and many diagrams and illustrations.

Compiled a helpful information, all

manufacturer's official service an d repa have derived from are required, these are identified not hesitate to advise you undertaken without the use

The readers own judgement must ultimately able to undertake, but there

there will cost

The manual pocket size with the aim that it should be kept in the travelling. Many garage mechanics their invaluable source

A general faultfinding (troubleshooting) section is included manual and the necessary remedies to correct

Important other 602 engine. Differences of

the servicing and repair

and 602) and th e earlier 2.4 litre engine (engine type 616).

nd

illustrated by experts, this manual provides a concise source

of

which has been c ross-checked for accu racy to the

actual practice to facilitate your work. Where specia l tools

be

many more occasions where the delay, inconvenience and the

of

having the van off the road can be avoided or minimised.

Is

called "Pocket Mechanic" and is produced

wor1<

and if you have the manual with you in the vehicle you will have an

of

reference which will quickly repay its modest Initial

all items listed are taken from actual experience, together with

Note: The

sections

engine,

associated

although

main

techn

for

the

manual

in

a separate

of

the Mercedes Van and Camper Diesel

ir

procedures, but many instructions

in

the text

if

we feel that the operation cannot be properly

of

such tools.

Is no doubt, that with this manual to assist him,

themselves use these pub lications in

faults and malfunctioning

text

of

the

with

the

engine, covers

ical

data

the

616

engine

section

.

Jacks

no detail in covering

litre engine (engine types

all the required technical detail

if

absolutely necessary and we do

de

cide just what

engine

are

also

are

described

wor1<

In

a handy glove

vehicle whil

at

the end

of

certain parts .

Section

the

given

for

at

he will feel

st

you are

cost

of

and

some

601

the the

and

end

the

616

of

0.

Our "Pocket Mechanics" are based on easy-to-follow step-by-step Instructions and advice, which enables you to carry out many, jobs yourself. Moreover, now you have the

means to avoid these frustrating delays and Inconveniences which so often result from not knowing the right approach to carry out repairs which are often of a comparatively simple nature.

Whilst special tools are required to carry out certain operations, we show you In this manual the essential design and construction of such equipment, whenever to enable you in many cases that

It Is advantageous to use only genuine parts since these give you the assurance a first class job. You will find that many parts are Identical In the range covered In this manual, but our advice spare

parts

0.

0. General

The manual covers the listed Mercedes-Benz commercial vehicles with 2.3 and 2 engine, but also refers to models with the earlier four-cylinder engine with 2.4 litre capacity. Models engine with a performance of remaining models are fitted with the

70

11M/

(95 HP)at

engine, with the additional cylinder added on. Models

2.4 litre engine, engine type

the Details

differences are Many different body versions and model numbers are used in the range of vehicles marketed. The following table shows some designation and referred to, mainly in the technical data sections and you should familiarise yourself

with the model number of your vehicle. We sold in any particular country.

All vehicles covered in the manual are fitted with a four-speed or five-speed

transmission. Model

MB MB MB MB MB

MB

2080 3080 4080 2100 3100 4100

of

the

INTRODUCTION

to

Improvise or use alternative tools. Experience shows

from

Is to find out before purchasing new parts - Always buy

an

officially

2080,

3080

appointed

lnfonn

and

58

ation

4080

IN'/ (78 HP) at

dealer.

are fitted with a

3800

2.3

rpm (engine type 601). The

2 .9 litre five-cylinder engine with a performance

3800

rpm (engine type 602). The engine Is similar

616

.

616

engine

such

that a new

fitted engine to the later model range. These numbers

are covered

Section Is necessary.

Model Number

under

of

should like to stress that not all vehicles are

601 .3

602.3 611 .3 601 .4

602.4

611.4

2070

and

separate h eadings, whenever

the models together with their type

Fitted engine

601.940

601.940 601 .

940

602.940

possible,

you

.9

litre

litre four-cylinder diesel

to

the four-cylinder

3070

are fitted with

are

sometlme5

of

r

of

0.1.

When your purchases the vehicle you all important vehicle as

well as identification

further

Instructions

No

.

601

possible that they are no longer available.

584

I

dentificatio

details, as for example chassis number and component numbers

of

optional equipment, etc. You Owner's Manual will give you

on

the use

36

96

, but you will have to check

n

will have received various data cards which have

of

these cards. Owner's Manuals were obtainable under

4

if

this number is still valid,

as

it

Is

Fig

.

0.2

-

type

plate

(1)

Identification

The

engine

the

injection

shown

in Fig.0.3,

the

cylinder

axle

and

number,

Always number model

quote

and/or

year, Important number, four

which

wheels

WHh

the

door

open with details of the codes.

number

pipes

on

can

at

the

block. Transmission,

steering

stamped

is

on

into

the

engine

when

also

will the

also

the

complete

number

ordering

the

indicate

you body

be

found

the

l.H.

have

housing

actual

the

etc.

Fig

. 0.1 - Identification ldentlfiCitlon plate

The

number

posHion

(2).

The type Identification plate with the vehicle Identification number can door entry

at

the position shown In Fig. Immediately next to it you will find additional plate, giving again the vehicle

number, the max. permissible vehicle weight and the basic setting headlamps. Details

will see a

and

pain

the paint the

work are given

LH.

door pillar, as shown In Fig. 0 .2.

near

position

side

of

rear

a serial

.

chassis and

the

parts.

model

construction

of

the

vehicle,

of

(1)

of

the body/number and

for

the

and

the type

be

found

In

a plate, fitted to

example

two

vehicle

on

the

01

an

of

the

or

.

Fig

.

0.3-

The

engine

number

can

be

found

at

(1

).

5

0.2 Fi

Fuel tank

- Optional Engi

Min

Cooling System:

..

. . . . . .

..........

ne

:

601

, four-cylinder, complete re-fill .

601

, oil change with fitter . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .

602, five-cylinder, complete re-fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 litres

602, oil change with fitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 litres

616,

four-cylinder, complete re-fill . . . . . . . . . . . . . . . .. . . . . . . . . . . . 7.

616, oil change with fitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 .5 litres

Oil Fill Capacity:

601

engine

602

engine

616 engine

601

engine 602 engine . 616 engine

lli

ng

Capacities

......

. .

....

. . .

.

........

.......................................

............

.............

..........

...............

.............

. .

........

....

...

. .

.......

... .........................

. . ....

..............•.............

. .

.............................

.... . . . .... . . .

.

........

. . . .

.......

....

...........................

....

.....

70

. . 2 x 651itres (131itres reserve)

... ..............

. . .

...........

(121itres reserve)

.....

.

.......

7.

3lltres

6.5 litres

511tres

5.0 litres

5.5 litres

3.5 litres

7.0 litres

7.51itres

11.7111res

Transmission Automatic transmission (fluid change) Power assisted steering . . Rear axle:

•

Axletype741.400and741.401 ..........

- Axle type Axle type lit res

0.3. General

The servicing and overhaul instructions in this Workshop Manual are laid out In easy-to-follow step-by-step fashion and no diffiCulty should and diagrams are followed carefully and methodically. The "Technical Data• sections form an important part work on the vehicle.

In order that we can Include generally repeat Again, to make the best use of the space the more obvious steps necessary the difficult or awkward procedures few of the more Important procedures and draw your attention to various points of

general interest that apply to all operations. Always use the torque settings given These are grouped together in separate sub-sections for convenient reference. Bolts and nuts should be assembled fa

ces and threads should always be inspected to make sure that they are free from

damage burrs or scoring. All

joint washers, gaskets, tabs and lock washers, split pins and replaced on assembly. the shaft and seal have been separatecj. Always lubricate the lip assembly and take care that the seal lip

........

741

.........

....

.404 and

741

.5 (twin wheels) .............

Servicing

of

the repair procedures and should always

In

the text the values already given under the technical data headings

DO

Seals will,

.

.........

. ....

.......................

.405 . . . . . .

................

.............

............

...

.....................

............

.

.......

.....

...........

.•

. . .

Notes

be

encountered, If the text

be

as

much data as possible , you will find that we

available, we do not repeat at each operation

- we feel it to be far more helpful In

greater detail. However, we summarise below a

In

the various main sections

in

a clean and very lightly oiled condition and

NOT

degrease bolts or nuts.

In

the majority of cases, also need

Is

facing the correct direction.

"0"

of

......

referred to during

to

...

2.3 lltres

5.9 litres

. . 1.6 lltres

1.61itres

.

..

1.81itres , , 1.8

an

do

nol

concentrate

of

the manual.

rings must be be replaced, If

the seal before

on

6

References to the left-hand and right-hand sides are always to observer is at the rear of the vehicle, facing forwards, unless otherwise stated.

Always make sure that the vehicle commencing any work on the underside of the car. A small jack or a make shift prop can

be

highly dangerous and proper axle stands are an essential requirement for your

safely.

own Dirt, grease and mineral oil will rapidly destroy the seals of the hydraulic system and even the smallest amounts must contact with the components. Use clean brake fluid or one of the proprietary cleaners to

wash the hydraulic system parts. An acceptable alternative cleaner Is methylated spirit, but It this parts for longer than necessary. removed

Always use genuine manufacturer's spares and replacements Since

the manufacturer uses metric units when building the cars that, these are used for these are not necessarily precise conversions, being rounded values.

Removal and away or put back the

·servicing", will cover the dismantling and repair from the vehicle

of all parts carried out needlessly. There are a number of variations Workshop Manual. model, and the year of manufacture, before obtaining any spares or replacement parts.

Std

.: To Indicate sizes and limits of components

manufacturer. Also

OIS

Paris supplied as Oversize or Undersize or recommended limits for such parts, to enable them to be

U/ S

0/S bushing or female part that

Max.: Where

anowable part

TIR: Indicates the Total Indicator Reading as shown

gauge).

TDC: Top Dead Centre (No. 1 piston on

MP:

Multi-Purpose grease.

Is

used, It should not

from the system before final assembly.

all precise units. Inch conversions are given in most cases but

installation Instructions,

unit or part

It

Is

pointed out that the major instructions cover a complete overhaul

but, obviously, this will not always be either necessary and should not be

We

strongly recommend that you take care to Identify the precise

Indicates a part that Is larger than Std. size U/S

gtven against a clearance or dimension Indicates the maximum

If

In

Is

excess

frtted.

Is adequately supported, and on firm ground, before

be

prevented from entering the system or coming Into

be

It Is also Important that all traces of the fluid should be

to

Indicate the production tolerances of new unused parts.

used with worn or re-machlned mating parts.

of

the value given It

allowed to remain In contact with the rubber

In

this Workshop Manual, cover the steps to take

In

question. Other Instructions, usually headed

In

unit parts on the range of vehicles covered in this

Is

smaller than Std.

of

the unit once it has been stripped

Is

recommended that the appropriate

tiring stroke).

by

a dial Indicator (dial

be

taken es

for

the best results.

It

Is

recommended

off for the unimportant

as

supplied by the

may

Indicate a bore

if

of

the

a

0.

4.

For small jobs, jack up the vehicle as described In the Owner's Manual, with the hydraulic jack supplied the weight of the vehicle. Additional weights should always be removed from the cargo room

To

Jack prevent the vehicle from rolling underneath the front axle. If the hydraulic vehicle jack Is used, place it underneath the

spring as shown In Fig. 04, Immediately

Jac

king

up

of the Vehicle

with the vehicle. If a mobile jack Is used, make sure it can take

of

the vehicle. up the vehicle completely, first jack

off the jack or apply the handbrake. Place a mobile

up

the front end . Chock the rear wheels to

In

front

of

the front axle .

jack

7

Fig. OA - vehicle,

t

he vehicle.

Jacking

using

the

up

the

hydraulic

front

Jack

end

supplied

of

the

with

Chassis stands should only be placed on the L.H. and R.H. Use

chassis

In

shown make

Fig

sure

carry the

the vehicle cannot

sides

stands

under the front axle.

of

the construction

. 0.5, should be used, but again

that they are strong enough to

weight

of

the vehicle.

slip

off

Make

the stands.

sure

Fig. 0.5safest work the

The rear with a

method

has

to

vehicle.

mobile

Three-legged

t o

support

be

carried

end

of

the vehicle Is jacked

jack

or

chassis

out

o n

with

the

stands

the

vehicle

the undersi

hydraulic

are th e

when

d e of

up

jack

shown In Fig .0.6. Chassis stands are placed underneath the axle beam, noting the points given above. Again make sure that

no

additional weights are left in

Note: It is always difficult to raise a vehicle first on one side

Fig.

0.6 vehicle supplied.

the

cargo room.

Jacking with

up

the

the rear

hydraulic

end

of

the

jack

and

then on the other. Take care that the vehicle cannot tip-over when the first side is tiffed. Ask

a helper to support the vehicle from the other side . Never work

underneath the vehicle without adequate support.

8

[1

ENGINES

1.0. Technical Data

Fitted Engines:

-

208 0 (Model 601 .3)

-

308 0 (Model

- 408 0 (Model 611 .3)

-

210

0 (Model 601.4)

-

310 0 (Model602.4)

-

410 0 (Model611.4)

-

L2070

-

L2070,

L3070

602

.3)

601.940

602.940

616.017

616.934

Number

-

- 616 engine

Injection Order:

- Four cylinder

- Five

Arrangement Camshaft Arrangement Cylinder bore, 601, 602 engines

-

- Piston stroke,

-

- 616 engine

- 602 engine, with manual gearbox

-

- 616 engine

of 601 engine 602

616

Capacity:

601 602 engine

Compression Rallo:

601, 602 engines

-

- 616 engine

Max. B.H.P.

- 601 engine, with manual gearbox 601 engine, with

-

602 engine, with AfT

Cylinders:

engine

cylinder

engine

of

cylinders

of

valves

601 , 602, 616 engines

(DIN):

AfT

Four Five Four

1-3-4-2 1-2-4-5-3

In-line

Overhead camshaft, No. marked In end face

Overhead

89.00

mm

91.00

92.40

(3.4565 ln.)

mm

(3.6154 1n.)

mm

(3.6711 ln.)

2299ccm

2874

ocm

2404ccm

22 : 1 21

: 1

58

WI

at

WI

at 4000 rpm

WI

at 3800 rpm

WI

at 4000 rpm

WI

at 4200 rpm

3800 rpm 60 70

72

48

Max. Torque:

601

engine

-

602

engine

- 616 engine

15.7 kgm (113 rpm

19

.2 kgm (138 ft .lb.) at 2400 - 2600

rpm

13.7 kgm (99 ft.lb.) at

ft.lb

.) at 2000 -

2400 rpm

2800

9

Crankshaft bearings Cooling system

5 or 6 friction bearings Thermo system thermostat, clutch, tube-type radiator

with water pump,

cooling fan with fluid

Lubrication

Air cleaner

Valve

Timing-New

- Inlet valve opens 11" A.T.D.C

- Inlet valve

- Exhaust valve opens 28" B.B.D.C.

- Exhaust valve closes 15" B.T.D.C

Valve

- Inlet valve opens 12" A.T.D.C

- Inlet valve closes 18" A.B.D.

- Exhaust valve opens 27" B.B.D.C.

- Exhaust valve closes 14" B.T.D.C

Valve

- Inlet valve opens 11.5" A.T.D.C

- Inlet

- Exhaust valve opens 21" B.B.D.C.

-

Exhaust valve closes 19" B.T.D.C

Valve All valves 2" more

Valve

- Inlet valves 0.1 0 mm (0.004 ln.)

- Exhaust valves 0.

closes 17" A.B.D.C.

Timing-

valve closes 13.

Timing-

Clearances-

Timing

Chain-

Used

Timing

New

Timing

Used

Timing

616 Engine - Engine warm:

Chain

Chain-

Chain

(after

-616

601

818

Pressure-feed

oil pump, driven with chain from crankshaft. With

Dry paper element air cleaner

and

602

engines

12

000

miles)-

engine:

5"

A.B.D.C.

engine:

30

mm (0.012 in .)

lubrication with gear-type

:

601

and

C.

full-flow oil filter

802

engines:

Valve Clearances - 616 Engine - Engine cold:

valves

- Inlet

- Exhaust valves

1.1.

The engine and transmission Is removed from the vehicle as a complete unit after the parts shown in Fig. 1.1 are removed from the front end can then suitable hoist or crane is required to is more than refer to every possible variation and/or equipment that may be fitted

be

Place the bonnet Into the vertical.position until the lock engages. Remove the

ri

vers seat.

d

Engine

removed from the engine. Engine and transmission are a heavy unit and a

200 lbs. The following description Is a general guide line, as we cannot

- Removal and

lift

out the assembly, remembering that the weight

0.15 mm (0.0061n.)

0.35

mm (0.0181n.)

Installation

of

the vehicle. The transmission

to

your vehicle.

10

Fig.

1.1

- The engine Is removed

removed

• Disconnect the two battery cables . The battery can also be removed

• Remove the engine cover and the radiator grille.

• Open the expansion tank cap. It

• Remove the front bumper and the radiator crossmember (Fig . 1.1 ).

• Disconnect the propeller shaft from the transmission. Also disconnect the

from

the front

space

for other operations.

the cooling system as described

described

as

Remove the air Intake hose.

Separate the front exhaust pipe from the exhaust manifold and free the pipe from

the bracket on the transmission.

speedometer cable from the transmission.

Unscrew the clutch slave disconnecting the from hanging down on Its hose. Fig. 1.2 shows where the cylinder Is attached.

Unscrew the earth cable.

end

In

the same section.

hydraulic hose. Tie the cylinder

from

Cil

the

vehicle.

Is

assumed that the engine

In

Section "Cooling System". Remove the radiator

cylinder from the side

vehicle

after

the

Illustrated parts have bei!n

to

have more

Is

fairly cold . Drain

of

the transmission without

to

the vehicle floor to prevent

Fig. 1

.2-

The

clutch

slave

fltted

to

the

side

Cil

• Disconnect the electrical leads from the starter motor and the alternator. Free the cable harness from the engine (cut the cable binders) and push the harness to one side, where

during following operations.

• Disconnect the electrical lead from the glow

• Disconnect all vacuum hoses from the engine.

it cannot be in the way

plug relay.

cylinder

the

transmission.

{1) Is

it

-

11

• If a power-assisted steering is fitted, remove the drive belt and unscrew pulley from the pump shaft. Unscrew the complete steering pump and remove it together

Disconnect the fuel pipe from the

manner to prevent entry

• Remove the vacuum hose from

with the connected hoses.

of

dirt.

pre-filter. Close the open connections In suitable

the

vacuum pump

at

the

location shown

1.3.

Fig. 1

.3-

the

DlsconnKt the vacuum

brake

servo unit from the

pump (exhauster

pump).

hose

for

vacuum

• Unscrew the gear change lever knob, remove the rubber gaiter

and withdraw the lever after

removing the clamp bolt. During

Installation tighten the clamp

later

until the gap is 1.5 mm.

bolt

Slacken the heater hose behind

the thermostat housing and withdraw.

• Remove the starter motor.

the

In

Fig.

Fig. 1.4 -

removed In order to

The

ott

ntter

take

• Disconnect the oil pipes from the oil filter housing.

• Remove the pipe clamp from the oil sump.

the

oil

Remove

filler neck. Fig. 1.4

shows the location.

Remove the transmission

the

mounting from

bolt).

crossmember

Slacken the engine mounting

supports from the engine mounting.

Fig

.

1.5

-

The

crossmember underneath

Use a hand crane or suitable holst

• and with ropes

unit, utilising the lifting eyes.

power

place a mobile jack underneath

Also

the

or

chains attach the

the engine/transmission

attachment

of

vehicle.

unit

to support it from below. Before removing any of the engine and transmission mountings ensure that the weight of the assembly is

well

supported.

Disconnect the

throttle control.

Unscrew the crossmember underneath the transmission and also underneath engine. Figs. 1.5 and 1.6 show where the items are attached. Check once that the unit is supported.

out

neck

the

must

engine

the

more

12

belt

be

.

(1

Lift the engine/transmission assembly towards the front slightly to allow resting

on guide the power unit. transmission

disconnected parts until the engine and transmission are mountings and the engine

• Remove the engine mounts If their conditions require it. Keep oil or grease away from the rubber parts.

• Connect the propeller shaft in accordance with the Instructions

• Refill

• Check the air cleaner element before re-use. Dirty elements should

•

the temperatures to be expected. before filling

If overhaul work has been undertaken on the engine.

mainly

Check the oil levels

other operations have been carried out on the

After starting the engine and allowing It to warm up, check the cooling system for

leaks. Drive

the

a jack, remove the jack

cooling system with anti-freeze of the correct strength for

It in.

the

gearchange

If

required.

Finally lower the assembly to the ground. Remove the

In

engine and transmission and correct If necessary,

vehicle a few miles to check for exhaust pipe

to

clear the engine compartment. If the unit is

at

the same time. Helpers will be required to

Fig.

1.6 -

crossmember.

The

Installation procedure, but the following points should be

noted:

• Check the engine mountings and oil and fuel pipes (hoses) for damage and replace parts as necessary.

•

If

a manual transmission Is fitted, take the opportunity to check the bearing and replace

• Do not connect or refit any of the

Is

free from the ropes or chains.

If

the original anti/freeze is used, check

units.

The

attachment of

Is

a reversal

of

the

vehicle, turning

of

If necessary.

clu1ch

refitted to their

In

Section 4.

ratt1e

.

the

1st

be

replaced,

engine

removal

the

release

the

strength

If

no

it

1.2.

Diesel

eng make sure that no foreign matter can enter the pipes, connections, etc. during the dismantling operations.

Dismantling available. Otherwise place the engine/transmission on a work bench, supporting is adequately to prevent Before commencing dismantling, block up the inlet and exhaust openings exterior of the engine a thorough cleaning to remove

particular attention might

otherwise find Many of the parts are made of Aluminium use plastic

As a complete strip-down the operations can

Engine - Dismant l ing

ines are sensitive to dirt or other contamination. It

of the engine will be made much easier, If a swivelling engine stand Is

if

from

tanlng

over.

to

an

Joint

1st

or

rubber mallets to separate parts, If necessary.

be

carried out with the engine fitted, you will find in the following text

surfaces, brushing these to remove loose debris which

way Into the Interior of the engine.

of

the engine

alloy and must

Is

in most cases not necessary,

Is

therefor essential to

all

loose dirt and oil. Pay

be

treated accordingly. Only

and

many of

give the

13

a description of individual operations which can be carried out with the engine fitted and removed. Combining these,

will give you the complete dismantling

of

the engine.

II

II,

I)

1.3

.

1.3.0.

Cylinder

Cylinder head height:

- 616 engine Max. Distortion of

- Longitudinal direction:

- Across the face: Max. deviation

lower

Depth of valve head faces and cylinder head sealing face - Except 616:

- Inlet valves

- Exhaust valves

- With

Depth of valve head faces and cylinder head sealing face - 616:

Inlet valves +0.03 to 0.43 mm

-

- Exhaust valves - 0.

- With

Valves Valve Head Diameter (0" in Fig. 1.22):

Inlet valves

-

616 engine

- Exhaust valves

616 engine

Valve seat angle

Stem Diameter

Valve

- Inlet valves

- Exhaust valves

- 616 engine

Engine - Overhaul

Cylinder Head and

Head:

Cylinder Head Faces:

of

sealing faces (parallel

re-cut valve seats 1.0

re-cut valve seats 1.5 mm - all valves

faces between upper and

(01"

to

in

Fig.1.22):

Valves-

each other)

Technical Data

9-

143.1

142.

84.8-

0.08 mm O.OOmm

0.10

mm

+0

.17 to 0.23 mm

+0

.12 to 0.28 mm

mm

38

37.90-38.10 39

.70 - 39.90 mm

34.90-35.10 34

.10 - 34.30

45" + 15' (616 engine = 30")

7.

970-7

8.960-

9.

920-

mm

85.00

mm

- all valves

to 0. 78 mm

mm

mm mm

.955

mm

8.945

mm

9.940

mm

(min. 84.00 mm)

Valve Length

- Inlet valves

-

Exhaust valves 616 616 engine - Exhaust valves

Valve

- Inlet valves

- Exhaust valves

Valve Identification:

- Inlet valves

- Exhaust valves

("L" in Fig . 1.22):

engine-

Seat Width:

Inlet valves

14

106.

50-106

106.

50-

131 .

130.

2.5

3.5 mm (616

E A

106.30 mm 30-131.70 8-131.20

mm

(616 = 1.3 to 1.6 mm)

601

02 (616 = E 616 02)

601

02

(616

.30 mm

mm

= 2.

5-2

=A

616 05)

.9 mm)

Val

ve

Seats

Valve seat width:

- Inlet

valves

- Exhaust valves

Valve seat angles Upper correction angle Lower correction angle

Seat

Inserts

(only

601

and

602

Valve Insert outer diameter _ Inlet

valves-

_ Exhaust Insert inner diameter (01"

- Inlet

- Exhaust valves - Std. 30.

valves-

\D"

In

Std. 40.

Std. 33.

Fig. 1.20):

Std. 37.

In

Fig. 1.20):

given)

2.5

3.5 mm (616 = 2.

45"15"(616=60.) 60" (616 = N/A)

mm

(616 = 1.3 to 1.6 mm)

15' (616 = 30")

100-40 100-

400-

500-

5-

.084 mm

37.084 mm

33.600 mm

30.600 mm

2.9 mm)

Basic bore

- Inlet

Valve seat height, all valves

Upper edge

- Inlet valves 2.37 -2.

- Exhaust valves 2.

Valve Colour code Outer diameter Wire diameter Free length Length under load

- Wear

Valve Colour code

Outer diameter

Wire diameter

Free length Length under load of 58.9 kg

- Wearllmlt

Valve

Inlet valve Guides:

- Outer

In

cylinder head

valves-

Exhaust valves - Std.

Springs-

Springs

length

under load

Guides-

Inner diameter

Std.

of

valve seat

limit

-616

diameter diameter-

Except

of

72 to 77 kg

engine

of

46.3 to 53

Except

-Std Repair size

(D2"

In Fig. 1.20):

r1ngs

to cylinder head face:

616

engine

kg

618

.

40.000-

37.

000-

6.

97

- 7.00 mm

44-2.25

yellow-green

33.20 mm

4.

25

mm

50

.80 mm

27.

00

mm

27.

00

mm

green/green VloleVgreen

30.

20-30.5 mm

3.

80

mm

50.

50mm

29.

90

mm, min.

41.70

kg

14.

044-14.051

14

.214 -14.222 mm

8.000 - 8.015 mm

40.016 mm

37.016 mm

25

mm mm

or

purple-green

at

65

kg

or

mm

yellow/yellow

violet/yellow

30.

0-30

3.

90

mm

51.20mm

26.

00

mm

53.

00

kg

or

.7 mm

Baste bore

- Std.

-

Repair size

In

cylinder head:

14.030-14

14.198-14.203mm

.035 mm

15

I .

I!

Exhaust Valve Guides:

- Outer

- Outer diameter - Repair size

-

Basic bore in

- Std.

-

Interference

- Std.

-

Valve

Inlet Valve/Exhaust Valve Guides:

- Length:

CamshaftCamshaft Bearings:

- 4 cal. engine

diameter-

Inner diameter

Repair size

Guides-

Inlet valves Exhaust valves Outer

diameterOuter diameter- Repair size, all guides Inner diameter, all guides Max. inner diameter Basic bore in cylinder head:

Std.

Repair size

Interference fit of valve guides

Std.

Except

Std.

cylinder head:

frt

of valve guides

616

Std., all guides

616 Engine

-All

- 5 cal. engine

Journal diameter Camshaft Bearing Clearance:

- New condition

-

Wearllmit

Camshaft End Float :

- New condition

-

Wearlimit

guides:

14.

044-14.051

14.

214

- 14.

9.

000-9.015

14.03014

.198 - 14.

0 .

009-

0.021

0.011 - 0.

60

.0 or 61.0 mm

48.5-40.5

14.03-14.

14.23-14.

10.00 -10.

10.025

mm

14.

000-

14.200-14

0.01 - 0 .

04

5

6

30.944-30.

0.

050

- 0 .091

0.11 mm

0.

07

- 0 .15 mm

0. 18 mm

222

14.035 203

024

mm

04 24

015

14.

020

.220 mm

mm

950

mm

mm mm

mm

CamshaftCamshaft bearing running clearance

Camshaft end noat

1.3

.0. 1.

The following information should be noted when work is carried out on a cylinder head:

required to Ignite the fuel and the exhaust gases are directed through the cylinder head. Glow plugs, injectors, pre-combustion chambers and valve tappets are fitted to

616

Engine

0.

025-0.066

0.

05

- 0 .128

mm (max. 0.

mm

(max. 0.

Cylinder Head - Removal and Installation

The cylinder head is made

the cylinder head. Also in the cylinder heads you will find the camshaft.

of

light-alloy. Engine coolant, engine oil, the air

18

11

mm)

16

The exhaust manifold and the Inlet manifold are bolted The fuel enters the head on one side and exits on the other side,

the well-known "crossnow" type.

• The cylinder head valves, responsible for certain functions of the temperature control.

• As the cylinder head the

order

of

the same reason never remove the

• A cylinder head cannot gasket will "blow", aflowing air Into the cooling system. A quick check is possible after opening the coolant reservoir cap (engine fairly cold). Allow the engine warm-up and observe the coolant. Visible air bubbles point in most cases to a "blown" gasket. Further evidence Is white exhaust smoke, oil in the coolant or coolant in the

grey emulsion on the dipsti ck gasket.

• If you are convinced that water has entered the engine and you want to get home or to the nearest garage, unscrew the injectors and crank the engine with the starter motor for a while to eject the water. Refit the injectors, start the engine drive to your destination without switching off the engine. This is the only method to

avoid serious engine damage (bent connecting rods for example).

The

cylinder head must only be removed when the engine Is cold . The head removed together with the exhaust manifold, but the Inlet manifold must from the

are wrapped

The cylinder head can

described below, but note that operations may vary, depending on the equipment frtted:

•

Remove the vlsco-clutch from the front end

assembly In vertical position.

Remove the

•

Cut

•

the cable binder securing the engine cable harness.

Remove

1

.8

and

1

:th

e eve the tension from the securing screw until the tensioning spring can

pushed

slackening or tightening of the cylinder head bolts Is not observed. For

cylinder head before the head can be lifted off. New cylinder head gaskets

In

plastic und must only be unwrapped just before the gasket

oil

the single poly V-belt from the front

slacken the nanged nut . Insert a drift of 12 mm diameter and 180

Into the spring-loaded lever and push the tensioning device towards the left.

In

direction Inlet manifold. Now remove the bolt (3) securing the mounting

Is

fitted with various sender units, sensors and switching

Is

made of light alloy, It

cylinder head from a hot engine.

be

checked

eng

ine oil. The latter can

be

removed with the engine frtted and these operations are

fifler elbow (Fig. 1.4).

In

Is

more or less a confirmation of a damaged cylinder

Is

frtted position. Sometimes the cylinder head

be

checked at the oil dipstick. A white,

of

the engine.

of

the engine. To do this, refer to Fig .

to

the outside

prone to distortion If, for example,

Fig

. 1.7 - Remove the shown slackening

disconnect the battery earth cable and remove the bonnet.

• Drain the cooling system (Section radiator.

•

lock It

• Disconnect the air intake hose shown in Fig . 1. 7.

by

the hose clamps.

Remove the driver's seat,

1.8.1.) und remove the

un

up

the radiator grill and

In

the raised position.

and

the coolant hose

Do

not store the clutch

of

the head .

I.

e. the head is of

and

be

separated

Is

frtted.

two

the arrows after

hoses

engine

mm

be

to

Is

In

17

I

I'

I

II

shock absorber (see also Fig. 1.9) and remove the tensioning device. Push down on the tensioning

Fig. 1

.8-

belt

2 Damper

3 Bracket for tensioner

•

Releasing

at

the

front

Tensioning spring

If a power-assisted steering is

remove the pulley for the drive belt.

Disconnect all coolant, fuel and vacuum hoses and the cables

connected to the cylinder head

or

any other unit on the cylinder head

which cannot be removed together

with the cylinder head (also see

below).

remove bracket and remove the Injection pipe of No. 4 cylinder without the bracket.

five-cylinder engine, the Injection pipes of Nos. 4 and 5

by means of a plastic clip. Also withdraw the leak-off hose

1 cylinder. Close off the hose end in suitable manner (a bolt

can be pushed into the hose end.

Remove the damper for the engine speed regulation from the

is the

the

Item shown in Fig. 1.1

pulley to loosen and remove the belt.

the

tenalon

of

the

end

of

the

engine.

Injection pipes

drive

frtted,

electrical

of

cylinder Nos. 1, 2 and 3 together with the pipe

0.

Fig. 1.1 - Unscrew

tensioning

• Separate the throttle control linkage at

the

• Disconnect the vacuum pipes from the exhauster (vacuum) pump. one union nut must be removed.

• Use suitable clamps and clamp-off the

fuel hoses and disconnect the fuel hoses at the bracket and

•

device

ball joint connection.

fuel pre-filter

In

the case of a four cylinder engine

the

demper

from

tM

cylinder

One

or

Ue

remove the fuel filter

it

up

with a piece

cylinder are held together

at

the Injector

of

suitable diameter

Inlet manifold. This

for

the

heed

hose and

of

wire.

On

of

the

belt

end

No

Fig. 1.10 - The regulation Is

• Disconnect the vacuum hose from the

Disconnect the electrical leads from

the glow

Remove the securing clip for the heater assembly feed pipe with a wire hook. Remove the connectors from the end.

Disconnect the exhaust pipe flange

damper

for

attached

thermo valve.

plugs.

oil filter and on the other

to

the

manifold.

engine

speed

18

from

the exhaust manifold and unscrew the exhaust pipe support bracket from the

transmission.

Remove the

•

Fig.

1.11-

Remove screws must located and two on engine. frtted,

Inlet (Intake) manifold .

Removal

of

an Injector.

the

cylinder

on

each long side of the cover

If

an automatic transmission Is

head

be

removed. Two are

the

timing side of

cover. Six

there Is a regulating rod frtted

the

across the cylinder head cover, which

must

be

ball joint. A stlcldng cylinder head G

separated

cover must not be freed by tapping with

a hammer. If difficult to remove, try to unstlck

Use

side.

a plastic mallet,

on

one side at the

lf

necessary.

It

by pushing It by hand to one

1

• 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 I.e. the

·cr

firing position.,

mark must be opposite the adjusting pin, as shown In

Fig. 1.12. A 27 mm socket can be applied to the crankshaft pulley

to

rotate the

In

the

crankshaft.

Fig.

1.12 - Dead

the

engine.

centre

position

of

Never attempt to rotate the

crankshaft by applying a socket to

camshaft liming wheel bolt.

the The crankshaft must

be

rotated

In

the direction of rotation.

• Remove

a

.

as described

The

chain tensloner plug must unscrewed to the hexagon. The located the thermostat cover, next to

the

chain tensloner

In

Section 1.3.5.0.

be

by

applying a spanner

plug Is

above the water pump and

the

large tube.

Mark the camshaft sprocket and the timing chain at opposite points, as shown

Fig.

1.13, using a spot

of

paint.

In

Fig. 1.13-

With • the sprocket.

Mark

spot

the

of

paint before removal

chain and

Unscrew the camshaft sprocket

bolt.

To counterhold the camshaft against rotation, Insert a strong screwdriver blade or steel bolt Into one

of

of the camshaft sprocket.

Remove

the

camshaft sprocket

from the shan

sprocket

of

the holes

without

19

II

ij

I I

I

I I

disengaging the timing chain from the crankshaft sprocket. Pull the chain tight and use a piece of wire to tie chain and sprocket together.

Remove the camshaft as described under the relevant section. Remove the slide rail from the cylinder head as described later on . In the inside of the chain case remove two 8 mm socket head bolts with an Allen

key. An extension and a socket is required to reach the bolts.

Unscrew the cylinder head bolts in reverse order to the one shown in Fig. 1.14 or

1.15. A multi-spline bit must

00 10

00

. A normal Allen

@

be

used to slacken the bolts (MB Part No.

ke

is not suitable as It

601

589

:I

0 0

Fig.

1.14

engine.

text. Slilcken the bolts

Fig. 1.1 S - Tightening sequence tor the cylinder he•d bolts tor the engine. text. Tighten the bolts

will damage the bolt heads. Immediately after removal of the bolts measure their length. head is more than 83.6, located, replace the bolts. New bolts have a length of 80 mm, 102.0 mm. I.e. bolts which nearly approach the max. length should also

Note: Certain bolts are frtted through the camshaft bearings. As the cylinder head bolts are of positions.

- Tightening sequence

The

bolts

"•"

on the L.

In

reverse order.

The

bolts "a" on the L.

If

the dimension from the end of the bolt

different length, mark them before removal

In

reverse order.

105.6 or 118.5 mm, depending where the bolts are

H.

side

tor

the cylinder

•re

the smaller bolts mentioned In the

are

the smeller bolts mentioned

head

bolts for the

to

the underside

to

assure refitting in the original

In

mm

be

replaced.

801

801 the

of

or

the bolt

150

.0

20

Lift off the cylinder head . If a holst or other lifting equipment Is available, hook a

rope

to

the two lifting eyes and lift off the head . Remove the cylinder head gasket.

Immediately after removal, clean the cylinder head and block surfaces of old

gasket

material.

If

necessary, overhaul He cylinder head as described In Section 1.3.0 .2. after

•

dismantling.

Install the cylinder head

Place a new cylinder head gasket In Position. Place the cylinder head carefully In position, taking care

•

sleeves.

coat

•

with

Insert the cylinder head bolts as originally frtted (and hopefully marked) and

•

tighten them tightening

• Tighten all bolts

• Walt 10 minutes.

• Angle-tighten spline bit with the socket Into each bolt and fit the tommy bar so that It Is In with the longitudinal axis of the engine. Tighten the bolt until the tommy bar r1ght Do

• Re-tighten each bolt above.

• Fit the two socket head screws to the Inside tighten them

Note: Multi-spline head socket bolts require no re-tightening after they...llave been

fitted as described above.

Cylinder heads are sometimes modified. When for example fitting a second head cylinder head

Refrt

Fit the camshaft sprocket together with the timing chain to the end of the camshaft, making sure that the paint marks made during removal are sprocket must engage with

• Fit the camshaft sprocket bolt and tighten the bolt to 4.5 kgm (32.5 ft.lb.). Counterhold through one of the openings

•

Refrt

• Check Fig mark machined into the from above and comparing

Use a soft-faced mallet to tap the head in position.

the threads of the cylinder head bolts and the underside of the bolt heads

oil.

It Is assumed that original bolts have been measured for their re-use.

Is carried out

angle to the engine, I.

not use the torque wrench for this operation.

at

the slide rail

the timing chain tensloner and tighten the plug to 8.0 kgm (58.5 ft.lb.).

the marking for top dead centre for the No. 1 cylinder

. 1.16). A notch Is machined Into the camshaft which should be In line with a

In

the following manner:

to

engage the dowel

In

the sequence shown In Figs. 1.14 or 1.15 In several stages. The

In

stages

as

follows:

In

the correct order to 1 ,5 kgm

In

the correct order to 3.5 kgm (30 ft .1 b.).

all

bolts In their correct tightening order. To do this, Insert the multi-

e.

the bolt has been tightening by go• (1/4

In

the order given by a further go• In the manner described

to

2.5 kgm (18

some stage, make sure It Is the correct one.

to

the camshaft

ft.1

b.).

the head as described later on (Section 1.3.5.3.).

Its bore over the dowel pin in the camshaft.

by

Inserting a strong screwdriver blade or steel bolts

In

the sprocket.

cylinder head. The alignment can be seen by looking

it

with Fig . 1.16.

(11

ft .1 b.) .

of

the timing chain chamber and

In

the camshaft (see

fine

Is

a tum).

line. The

at

•

Re-connect the glow plug cables.

•

Refrt

•

the Inlet manifold. And the Injectors and re-connect the Injection pipes .

Fit the tube elbow with a new

"0"

sealing ring .

21

Fig. 1

.16 camshaft nange No. the

• exhaust

• carried removal procedure. Check and, necessary adjust, the throttle cable operation.

- Alignment

1 camshaft bearing cap

T.D.C. position

Fit the exhaust pipe

manifold.

The remaining operations are

out In reverse order to the

of

the notch In the

(1) and the lug on the

of

(2)

the engine.

assures

to

1.3.0.2. Cylinder Head - Dismantling

The following description assumes that

top

overhaul

a must be removed. The valve oil seals are blue exhaust smoke when the vehicle Is coasting (gear engaged), when

the engine

If

engine.

oil seals as described under a separate heading.

the oil consumption

Is

asked for, Ignore

stem

oil seals can be replaced with

Is accelerated after Idling for a while

has

reached 1 litre

the

cylinder head

additional Instructions.

the

cylinder head titled. Signs

or

blue smoke when starting

per

600

Is

to be replaced.

The

miles, replace the valve stem

If

of

the

only

worn

cold

cylinder head

Proceed as follows during

Remove all auxiliary parts from the cylinder head, Including the exhaust manifold.

•

Remove the camshaft. All camshaft bearing brackets must be removed camshaft lifted out. Each bearing bracket is marked with a number. A corresponding

mark the bearing brackets.

• A valve spring compressor position by means valve cotter halves with a pair

If

a valve spring comp!'essor is not available, it to remove the valve spring

collar

and

collect

in must be supported from the other side contact with the tube to prevent the cotter halves from

• Remove the valve spring collar and the valve spring. The valve springs (one

Remove fitted order through a piece

valve if they are to be re-used.

the

spring per valve) are identified with a paint spot and only a spring with a paint spot of

the

spring and can be removed. Figs. 1.17

valve assemblies.

Remove valve stem oil seals carefully with a

the

hit the tube with a blow

inside

same colour must be fitted. A thrust ring

valves one after the other out

dismantling:

number

of

is

marked Into the cylinder head, I.e. there

Is

of

valve cotter halves. Comp!'ess

cotter

the tube and the components

required to remove the valves. Valves

of

pointed pliers

halves. To do this, place

or

cardboard. Write the cylinder number against each

of a hammer

of

the cylinder head. Keep the hammer In close

and 1.18

of

the

or

a small magnet.

Is

possible

can

Oying

screwdriver

valve guides and pierce

springs

to

use

the

. The valve cotter halves will

be removed. The valve head

is

rrtted underneath each valve

show sectional views

a short piece

tube

over the upper valve

out

.

or

a pair

and

of

is

pliers.

them

and

the

no

need to

are

held In

remove the

of

tube

of

the

two

in their

22

the

f

i

Fig.

1.11

the cylinder v

1. Cy1inder head

2

3:

4.

5. Welsh plug

6. Bearing

7.

8.

9.

If

10

11

12. Lock ring

13. Valve spring

14. Valve stem

15. Valve spring retainer

16. Valve coffer halves

11. Valve tappet with hydraulic

- Sectional head

alve

.

Inlet valve seat ring Inlet valve guide

011

passage

cap

Bolt,

M8X 45

Washer 5 Camshaft

. Inlet valve . Thrust ring

clearance compensating element

Otl

and

seal

view

an

of

Inlet

I

Flg. 1.18 - Sectional view

the cylinder

exhaust valve.

1. Cy1inder head

2. Exhaust valve seat ring

3. Exhaust valve guide

4. Oil passage

5. Bearing

6. Boll,

7. Washer

8. Camshaft

9.

10

. Thrust ring

11

. Lock ring

12

. Valve spring

13

. Valve stem oil seal

14

. Valve spring retainer

15

. Valve cotter halves

16. Hydraulic valve

A few words should be said about the camshaft (applicable to

The camshaft

engine has diameter

cylinder head. The camshaft Is located In axial direction

the ring, which of

the cylinder head.

The

camshaft nange

:!c,a

shaft

rrect camshaft for the engine in question.

of

a four-cylinder engine has five bearings, the shaft

six

bearing, the six cylinder

of

31.0 mm. The lower part

Is

secured to the cylinder head and engages Into a groove at

Is

is

replaced, only

marked with a line. Next to

rrt

a shaft with the same

has

of

the

bearing location

seven. All bearings have the same

the

line

number

Is

. The parts lists will have the

head

and an

cap

M8

X 45

Exhaust valve

lappet

601

and

602

engines).

of

a five-cylinder

Is

machined directly into

by

means

of

a retaining

the

front end

an Identification number.

of

-

23

1

1.3.0.3.

The cylinder head must be thoroughly cleaned and remains removed. The checks and inspections are to

Valve

Springs:

a set. To check a valve a

long bolt (with washer under boll head) and

the nut

until the springs are under tension and measure the length the old spring is shorter When a spring lester is available, check the

1.3.0. are applied.

Section The springs must not be distorted. A spring placed with Its

not deviate at the top

Cylinder

If

the engine

Head - Overhaul

be

carried out

has

spring, place the old spring and a new spring end to end over

by

a high mileage, always replace the valve springs as

frt

a nut (again with a washer). Tighten

more than

10%

, replace the complete spring set.

spring length when the loads given In

as

nat

by

more than 2 mm

(0.08

ln

.).

of

old gasket material

required.

of

the two springs.

coli on a surface must

1a--o

19/

20

9.

10.

11

24

-

Fig

1.

Bolt

In

2.

3.

4.

5.

6.

7.

8.

. Sameas13

chain

Wavo

washer

Bearing

Plain

washer Camshaft Dowel

Cylinder

Sealing Plug,

oil

Sealing

ring

. 1.

19-

chamber

cap

boll

bearing

head

gallery

EJ!ploded

cap

boll

view of the cylinder

12.

Sealing

13.

Connector

sender

14. Threaded

15. Heater

16.

Stud,

17.

Welsh

18.

Steel

19.

Bolt,

20.

Plan

21.

Steel

22.

Cylinder

he.d

ring

unit

insert

connection

exhaust

plug

ball,

fuel

filler

washer

ball,

coolanl

head

of

oil

gallery

gaskel

a 602

engine.

for

temperature

manifold

circuit

Valve

Guides:

have different diameters, Guides for exhaust valves are shorter and have a larger rnner diameter. .

Cl

n the Inside of the guides

v stems can be cleaned best

diameter of the guides. As

.

:ich

is not always available, you can Insert the valve into its guide and withdraw it

If

until the fro and check for the play should not exceed gauges

to

Guides

are

cylinder head. If guides with nominal dimension 1 can

the position, until the retaining

fitted the locating bores

As dry Ice Is required to

carried out

work

Before a valve guide guides must be reamed aner Installation, and aner the if

applicable, to their correct Internal diameter, given

different diameters for

Valve guides for Inlet and exhaust valves are made

by

pulling a petrol-soaked cloth through the gurdes.

by

means

of

an

Inside micrometer

valve head

Is

approx. level with the cylinder head face. Rock the valve to and

play. Although no exact values are available, it can be assumed that

1.0 - 1.2 mm (0.

check the guides for wear.

removed with a shouldered mandrel from the combustion chamber side of

a rotating wire brush. Measure the

Is

necessary for this operation,

04 -0.

047

ln.). Mercedes workshops use

be

Is

rHtlng

In

the cylinder head must be reamed out to take the new

In

a workshop.

Is

replaced, check the general condition of the cylinder head. The

Inlet and exhaust valves.

against the cylinder head.

fit

the new valve guides, we recommend to have the

cylinder head has cooled down,

In

Section 1.3.

of

cast and

used, drive them

If

repair guides are

0,

noting the

In

Valves must

be

re-QI! when a guide has been replaced. If it Is obvious that seats cannot be re-

ground

Aga

in this

workshop.

Valve Seats: If the camshan bearings are excessively wom,

cylinder head. Check all valve seats for signs with to

grind-In the valves. Use correction cullers to bring the valve seating area Into the

Flg.

1.20.

(6011602).

Outer

0

01

Inner

02 locating bore

H

Height

T

Dimension

UPJ>Or

Dlm@nslons 0 40.100-40. 01

33,400-

02 40.000-40.016

H 6.97T 2.37-

2.44- 2.

always be replaced

In

the present condition, new valve seat Inserts must be fitted.

Is

an

operation for a specialist and the work should

In this case there Is

a

45

" culler.

-Principal dimensions of a valve

Description

diameter

of

valve

face

33,600

7.0

2.25 25

of

In

seal

between

or

valve

084

mm

mm,

exhaust

If

this operation Is carried out properly, there should be no need

seat

ring

seal

ring

cylinder

head

ring

head

seal

ring

mm,lnlet mm,

exhausl

mm,

Inlet

valves

race

valve

valves

If

new valve guides are filled. The valve seats must

be

carried out

frt

no

need

lo

renovate the valve seats.

of

pitting or wear. Slight Indentations can be removed

seat

and

a new or exchange

In

a

-

25

centre

of obtained. This again is achieved by using cutters 15•and

valve seat inserts will require that the old seat Insert Is removed by machining. The machining must not damage the bottom face As this Mercedes Dealer who has the necessary equipment and experience to do the job. Fig.

1.20 shows a valve seat. exchange for the old one from

the valve seat. Make sure that the valve seat width, given in Section 1.3.

so•).

Valve seat inserts can be fitted to the cylinder head. Replacement

of

Is a critical operation,- we advise you to bring the cylinder head to your

It

may be possible to obtain a reconditioned cylinder head

to

the old head and refrt them to the new head.

avoid time delay.

of

different angles (for example

the head recess.

In

this case remove all ancillary parts

A

Fig.

1.21

-The

shown

on the

maximum

L.H.

side.

Measure

dimension "A"

this dimension as shown on the R.H.

between

the

valve

face

and

cylinder

side

.

head

face

If the valve seats have been re-cut, use the valve and measure Fig. 1.21 gauge, measure the gap between the cylinder head face and the valve face, as on case Valves can be ground Into their seats

Valves: The stems of

I.

e. the ends of the valve stems must not be ground off.

Valves can be cleaned best with a rotating wire brush. Check the valve faces for wear

or grooving. a valve grinding machine, but make sure that there Is enough material left to edge on the valve head. The valve he the inlet valves and 0 ,5-0.6 mm in the case of the exhaust valves .

Measure the valves in accordance with the values given and replace any valve which filled with sodium, as

Check the valve guides.

replace the

should be no visible wear

Always quote the different

val

. To do this, insert the valve into the respective bore and, using a depth

the

R.H. side in Fig.

of

new valves. The wear limit Is 1.0 mm.

If the wear Is only slight, valves can be re-ground to their original angle In

valve stem diameters and

If there Is a deviation from the nominal values, It may

1.21

. The dimension must be between 0. 1 and 05 mm

In

the conventional manner.

Inlet valves and exhaust valves have been specially treated,

ad

thickness must be

Is

Is the case with other Mercedes engines.

outside the limits given . Note that the valves are not

In

this connection the Inside diameters

In Section 1.3.0

valve guides (see above). Also check the end of the valve stems. There

In

this area.

model year and the engine number whe.n ordering new valves, as

valves are used. These are marked by means of a number

ve stem. The numbers can be found

In

Section 1.3.0.

0.5-

the

dimension "A' in

0.7

mm

in the case

and

be

necessary to

In

the end

shown

In

have

Fig. 1.

of

26

0.

Is

of

In

Fig.

1.22.-

Principal valve dimensions.

D "' Valve head diameter

01

Stem diameter

.

l

=length

Sometimes it Is only required to replace the exhaust valves,

If these for example are burnt out

at

their

valve head edges.

the

an

of

22

Cyflnder Head: Thoroughly

clean

the

cylinder head and cylinder block surfaces of old gasket material and check the faces for distortion. To do this,

steel ruler with a sharp edge over the face and measure the gap between with feeler gauges. Checks must longitudinal face.

and

diagonal direction and across the

If a feeler gauge of more than 0,10 mm (0.004

be

place a

cylinder head

ruler and face

carried out in

ln.) can be Inserted, when the ruler Is placed along or across the cylinder head, have the cylinder head face re-ground. The dimension between the face of the valve heads and the

1.21)

will change after regrinding , but

will correct A further check must be

Is

Injection. These must protrude by 7.6 dimension by fitting

it

accordingly.

carried out on the pre-<:ombustion chambers for

8.1

mm. Mercedes workshops correct this

sealing washers of different thicknesses,

cylinder head face I A'

to

correct

Fig.

1.

23-

ou1.

Checking a

the

camshaft

In

the

workshop

the

protrusion.

for run-

Fig.

fuel

Camshaft: Place the camshaft with both end journals Into

"V'

blocks or clamp the shaft between the centres of a lathe and apply a journal, as shown

dial gauge to the centre

In

Fig. 1.23.

Slowly rotate the shaft to check for

0.

01

mm,

frt

exceeds

a new shaft. The following points must be observed when replacing the camshaft:

Make sure to number when

frt

the correct shaft If the shaft

ordering a new shaft.

run-out.

Is

to be replaced. Check

If

the dial gauge reading

the

identification

the

Replaci

ng Valve Stem

available In repair kits. Included pushed over In

diameter and can also be Identified by their shape (Fig . 1 .24).

the

a special tool Is used to dtameter can The

valve cotter halves and the valve springs must be removed to replace the seals.

To

prevent

be

the

valves from dropping Into the combustion chambers,

011

Seals (Cyflnder

In

the repair kits are protective sleeves which must be

Head

f1tted): Valve stem oil seals are

valves during Installation of the seals. Valve stem seals are different

frt

used. Take care not to damage the sealing lip and

the seals, but a well fitting piece

of

tube of suitable

the

spring.

the

pistons must

27

be at the top dead centre position. This is as two pistons are always

cylinder

engine, as the crankshaft must

at

top dead centre . The operation Is more difficult on a five-

easy

in the case of a four-cylinder engine,

be

rotated by a certain angle to move the next piston to TO.C. Only attempt this operation If you are competent. Start by setting the piston of the No. 1

cylinder to the top dead centre positlon. Valve stems seals of

cylinders Nos. 1 and 4 can be replaced in this position.

Fig.

1.2A

tor

the

exhaust valves; on the right t

•

Remove

the

camshaft (see description later on).

• Remove the valve cotter halves of the first cylinder

1.3.0.2. Remove the valve springs

- Sectional view

• Use a pair

of

pliers or a screwdriver to remove the valve stem seals, without

of

the valve

In

the case of a four-cylinder engine.

stem

oil

or

the Inlet valves.

Hal

s . On the

as

described

left

In

Section

damaging the valve stems.

• Coat the new seals with engine oil and carefully push them over the valve stems. The protective sleeve must be used for the

valve guides until properly

In position.

Inlet valves. Push the seals over the

• Fit the valve springs with the paint spot towards the bottom, fit the upper spring

cup and compress the springs until the valve cotter halves can be Inserted. Make

have

absolutely sure that the cotter halves

properly engaged before the crankshaft

Is rotated.

Replace

• Lift the camshaft sprocket slightly to prevent disengagement

and rotate the crankshaft of a four-cylinder engine by seals of a are closed. This will

when rotating the crankshaft. Both valves

the

valve stem seals

of

cylinder

No. 4 In

the same manner.

of

the timing chain

half a tum. The valve stem

of

cylinders Nos. 2 and 3 can be replaced in the same manner. In the case

five-cylinder engine, rotate the crankshaft until both valves of the next cylinder

be

in the order 2-4-5-3. As already mentioned, take care

of

a cylinder must be

at

the same height, before the valve cotter halves are removed. Refrt the camshaft and associated parts.

Note: Operate

the

valve spring compressor very slowly, as valve cotter halves sometimes stick to the valve stems. Observe the valve spring during compression. Only the spring should move, not the valve. Prevent by all means that the valve can press against the piston.

1.3.0.4. Cylinder Head - Assembly

The

assembly

of

the cylinder head is a reversal of the dismantling procedure.

Note

the following points:

Lubricate the valve stems with engine oil and insert the valves Into

the

correct

valve guides.

28

Valve

stem seals are different for Inlet and exhaust valves. Make sure to order

the

correct seals. The repair kit contains fitting sleeves

rrt

the

seals (see last Section).

The sleeves are frtted over the valve stem before the seal

•

Fit the valve

•

to compress the sprtng. Insert the valve cotter halves and release the valve spnng

lifter. Make sure that the cotter halves are valve stem with a plastic mallet. Place a rag over the valve

Fit the camshaft as described later on and carry out

•

order to the dismantling procedure.

spring and valve spring collar over the valve

In

and

these must be used to

Is

pushed

In

position

and

use the valve

position by tapping the end of the

end

- In case.

all

other operations

In

reverse

1.3.0.6. Hydraulic Valve Clearance Compensation

The

function of the hydraulic valve clearance compensating elements

valve clearance,

heat expansion and wear are compensated by the elements. The rocker arm is

I.e. the dimensional changes

In

the valve train (valve lash) due to

Is

to eliminate

a

In

-

12

Fig.

1.25-

Sectiona

Rocker lever 7 Ball guide 13 Valve

2

lock

ring 8 Thrust spring •

3 Washer 9 Ball,

<4

Closlng cap 10 Thrust spring o Retum bores Thrust pln

5 6 Guide sleeve 12 Valve spring re1ainer h

constant can

contact with the cam . The compensating elements cannot be repaired, but

be

checked for correct functioning as described below. Figs. 1.25 and 1.26 show

e&crlptlon

views of a valve with clearance compensation. We will give a short

of the operation. All references refer to Fig. 1.25.

l view of 1 valve

11

Ball socket f Ring groove

o4

mm

clearance

compensating ele

on

chamber

b Work chamber

011

bores

ment

29