CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
1. Using the serration wrench (4), remove the threaded ring
(1).
Serration Wrench 603 589 00 09 00
2. Install the sliding hammer into the prechamber.
Sliding Hammer 667 589 03 63 00
3. Remove the perchamber (2).
Notice
After removing the prechamber, cover over the bores with
clean rag.
4. Inspect the prechamber.
Notice
If the prechamber seats in the cylinder head are leaking or
if the prechambers are replaced, the sealing surfaces in
the cylinder head must be remachined.
Assembly Procedure
Notice
In case the prechambers are reused, inspect the
prechambers thoroughly, if the ball pin by heat and fire is
broken, it can not be used.
1. Clean the sealing surface of the prechamber.
2. Insert the prechamber into the cylinder head at the same
time aligning the cam on the collar of the prechambers with
the slots in the cylinder head.
Notice
If the spacer rings are fitted to the prechambers, the spacer
rings should be replaced with rings of the same thickness.
Thickness of Spacer Ring0.3, 0.6, 1.0 mm
3. Coat the threaded ring with oil and assemble the ring by
The prechamber sealing surface may only be remachined
once with the cylinder head fitted. It is essential to adhere
to the specified projection ‘C’ of the prechamber of 7.6 -
8.1mm.
This ensures that the required clearance exists between
prechamber and piston crown with the piston in TDC. For
this reason, spacer rings should be inserted on remachined
sealing surfaces.
If a spacer ring is already fitted, or a marking is made on the
cylinder head, the cylinder head must be removed and size
‘C’ measured if further remachining is necessary on a
prechamber sealing surface.
1. Remove the injection nozzle.
2. Remove the prechamber.
3. Cover the prechamber bore to avoid any chips dropping
into the combustion chamber.
4. Remove the protective sleeve from the countersink and
rotate the countersink into the prechamber bore to be
machined as far as the stop.
Counter Sink 601 589 00 66 00
5. Maintain size ‘X’ from the top edge of mandrel to the top
edge of the sleeve with the gauge.
Height Gauge 667 589 00 23 00
OM600 ENGINE MECHANICAL 1B3-33
6. Measure the ‘X’ by using a vernier caliper.
7. Mount the turning tool onto the countersink tool and rotate
to the right approx. 5 revolutions by applying slight pressure.
1B3-34 OM600 ENGINE MECHANICAL
8. Remeasure size ‘X’ and compare it with the first
measurement and determine the thickness of spacer ring.
Ex
Size before machining25.7 mm
Size after machining 25.5 mm
The spacer ring should be selected so that it is at least
0.1mm and not more than 0.3mm thicker than the
measured on the sealing surface. In this example, the
necessary thickness of spacer ring should be within
0.3 ~ 0.5mm and the thickness of spacer ring to be
installed is 0.3mm.
9. Remove the countersink tool and clean the chips.
Notice
If the sealing surface is not completely flat, remachine the
sealing surface.
10. emove rag from the prechamber bore and crank the engine
with starter motor to threw out any chips which may have
got into the combustion chamber.
11. Insert the proper spacer ring into the prechamber sealing
surface.
12. Punch a mark on the cylinder head above the prechamber
sealing surface which has been machined.
13. Install the prechambers.
Notice
If the cylinder head is removed, the projection ‘C’ is
measured in place of size ‘X’ and the appropriate size of
spacer ring selected.
Normal Projection (c)7.6 - 8.1mm
TDC (TDC SENSOR BRACKET) SETTING
Preceding Work : Removal of No.1 cylinder prechamber
The cylinder head may only be removed when the engine
has cooled down. The cylinder head is removed together
with the exhaust manifold. As the cylinder head bolts
undergo a permanent tightening. They require to be
replaced if they exceed the maximum lengthes indicated
in the table.
OM600 ENGINE MECHANICAL 1B3-39
Thread Dia.
M10
M10
M10
The twelve-sided socket head bolts are tightened with each
stages of torque and torque angle.
It is not necessary to retighten the cylinder head bolts at
the 1000~1500km inspection or after 1000~1500km of
repairs.
Length(L) When New
80mm
102mm
115mm
Max. Length(L)
82mm
104mm
117mm
1B3-40 OM600 ENGINE MECHANICAL
Disassembly Procedure
1. Completely drain the coolant from the radiator and cylinder
block.
2. Remove the cooling fan shroud.
3. Hold the fan with counter holder and remove the bolt and
then remove the cooling fan.
Notice
Keep the fan in vertical position.
Counter Holder 603 589 00 40 00
4. Remove the bracket oil dipstick tube.
5. Remove the nut.
6. Remove the nut on the tensioning lever and insert the
rod(F12 ´ 180mm). By pushing the rod to the arrow direction,
pull back the bolt.
7. Push the tensioning lever to the opposite direction to release
the spring tension and remove the poly V-belt.
8. Remove the air cleaner cover and element and then
remove the air cleaner housing.
9. Remove the oil return hose and plug.
Notice
Cover them to prevent chips from coming into.
10 . Unscrew the EGR pipe mounting bolts onto the exhaust
manifold.
11. Remove the duct bracket from the cylinder head.
OM600 ENGINE MECHANICAL 1B3-41
12 . Unscrew the intake duct mounting bolts onto the intake
manifold.
13 . Separate the connecting rod from the control lever.
1B3-42 OM600 ENGINE MECHANICAL
14 . Pull out the accelerator control linkage.
15. Remove the fuel injection line(1) from the fuel injection
nozzle(12).
Box Wrench Inset 000 589 77 03 00
16. Remove the fuel injection line from the fuel injection pump.
Box Wrench Insert 000 589 77 03 00
17 . Remove the bracket mounting bolts and then remove the
fuel injection line(1).
18. Disconnect the booster hose connected to intake manifold.
19 . Remove the intake manifold and gasket.
OM600 ENGINE MECHANICAL 1B3-43
20. Remove the cylinder head cover and gasket with the blowby gas hose.
21 . Disconnect the glow plug cables.
1B3-44 OM600 ENGINE MECHANICAL
22 . Remove the cable channel.
23. Disconnect the cables from the glow plug sensor and
coolant temperature sensor.
24 . Remove the heater pipe bracket from the oil filter.
25. Pry off the clamp and push the heater feed pipe forward
and then pull out the pipe.
26 . Disconnect the fuel lines from the fuel filter.
27 . Disconnect the fuel lines from the injection pump.
OM600 ENGINE MECHANICAL 1B3-45
28 . Remove the fuel filter(35).
29. Remove the fuel injection nozzle(12) and nozzle
washer(11).
Socket Wrench Insert 001 589 65 09 00
1B3-46 OM600 ENGINE MECHANICAL
30 . Rotate the crankshaft and set the no.1 cylinder at TDC.
Notice
Do not rotate the crankshaft to the opposite direction of
engine revolution.
31 . Place alignment marks on the camshaft gear and timing
chain.
32. Ensure that the camshaft and the bearing cap marking
are aligned.
33. Remove the starter motor and install the engine lock onto
the flywheel ring gear.
Engine Lock 602 589 00 40 00
34 . Remove the turbocharger.
35. Remove the exhaust manifold and gasket.
OM600 ENGINE MECHANICAL 1B3-47
36 . Remove the chain tensioner and seal.
37 . Remove the bolt and separate the drive sprocket(21).
Notice
During removal, be careful not to drop the sprocket and
chain into the timing case.
Carefully pull off the chain and then pull out the sprocket.
1B3-48 OM600 ENGINE MECHANICAL
38 . Remove the camshaft bearing cap bolts according to the
numerical sequence.
Notice
Remove the No.1 bolts first and then remove the No. 2
bolts. Do not remove the bolts at a time completely but
remove them step by step evenly or camshaft can be
seriously damaged.
OM662LA
OM661LA
39. Remove the bearing caps and then pull out the
camshaft(20) upward.
Notice
Be careful not to miss the locking washer.
40. Remove the locking washer.
Notice
Check the locking washer and replace if necessary.
41 . Remove the bolt(32).
42 . Separate the spring and pull out the tensioning lever(31).
OM600 ENGINE MECHANICAL 1B3-49
43. Pry off the closing cover . Remove the bolt and then remove
the idle pulley.
44 . Using the sliding hammer(36) and the threaded pin(37),
pull out the sliding rail pins(25, 26) and remove the sliding
rail(24).
Sliding Hammer 116 589 20 33 00
Threaded Pin 1 16 589 02 34 00
1B3-50 OM600 ENGINE MECHANICAL
45. Remove the vacuum line from the vacuum pump.
46 . Disconnect the vacuum pipe from thermo valve.
47 . Remove the socket bolts(13) of the chain box.
T T ype Socket Wrench 1 16 589 03 07 00
Magnetic Bar 102 589 03 40 00
48 . Remove the cylinder head bolts in numerical se-quence.
Cylinder Head Bolt Wrench 601 589 00 10 00
OM 662LA
49 . Remove the cylinder head(2) and gasket(3).
OM600 ENGINE MECHANICAL 1B3-51
OM 661LA
1B3-52 OM600 ENGINE MECHANICAL
Assembly Procedure
1. Replace the cylinder head gasket.
2. Install the cylinder head onto the crankcase.
Notice
Align the cylinder head holes with the guide pins.
3. Measure the length(L) of cylinder head bolts.
Notice
If the max. length is exceeded, replace the bolts.
4. Coat the head contact surface of bolts and thread with oil
and insert them as shown.
1. Remove the fan clutch and cooling fan belt pulley.
2. Drain the engine oil completely.
3. Remove the oil dipstick tube bracket bolts.
4. Remove the crankshaft pulley.
5. Loosen the bolt (1) and then remove the cylinder head cover
(2) and gasket.
6. Remove the vacuum pump.
7. Detach the closing cover (20). Remove the bolts(21) and
then remove the guide pulley (22).
8. Remove the guide pulley bracket (24).
9. Disconnect the pipes of power steering pump and remove
the belt pulley.
Notice
Be careful not to lose the key.
10. Remove the nut and pull out the bolt and then remove the
power steering pump.
OM600 ENGINE MECHANICAL 1B3-65
11. Remove the alternator bracket (16).
12 . Remove the fuel filter.
1B3-66 OM600 ENGINE MECHANICAL
13 . Remove the camshaft.
14. Remove the socket bolts(4) in the chain box.
Socket Wrench 1 15 589 03 07 00
15 . Remove the injection pump.
Notice
See the ‘Removal of fuel injection pump’.
16. Remove the oil pan bolts (8, 9) in the area of the timing
case cover (14).
17. Slightly loosen the remaining oil pan bolts.
18. Remove the timing case cover (19) bolts and then remove
the timing case cover (14).
Notice
Be careful not to damage the cylinder head gasket or oil
pan gasket.
Installation Procedure
1. Thoroughly clean the sealing surface and apply sealant.
2. Install the timing case cover.
Tightening Torque10 Nm
OM600 ENGINE MECHANICAL 1B3-67
Notice
Bolts arrangement
1.M6 x 60
2.M6 x 70
3.M6 x 40
3. Tighten the socket bolts in the chain box.
Tightening Torque23 Nm
4. Tighten the oil pan bolts.
Socket bolt
Tightening Torque
M6 bolt
M8 bolt
10 Nm
10 Nm
23 Nm
1B3-68 OM600 ENGINE MECHANICAL
5. Install the flange, vibration damper and crankshaft belt
pulley.
Notice
Replace front radial seal if necessary.
6. Install the alternator bracket.
Tightening Torque
7. Install the alternator
Tightening Torque
Front
Side
Upper - 25 Nm
Low - 25 Nm
25 Nm
25 Nm
8. Install the cylinder head cover.
Tightening Torque10 Nm
9. Tighten the injection pump mounting bolts.
Tightening Torque23 Nm
10 . Install the fuel filter.
Tightening Torque25 Nm
11. Install the vacuum pump.
Tightening Torque10 Nm
12. Install the power steering pump.
Tightening Torque23 Nm
OM600 ENGINE MECHANICAL 1B3-69
13. Install the power steering pump pulley.
Tightening Torque32 Nm
14 . Install the guide pulley bracket.
Tightening Torque9 Nm
1B3-70 OM600 ENGINE MECHANICAL
15 . Install the guide pulley (22) and fit the closing cover (20).
Tightening Torque23 Nm
16. Replace the gasket (3) and install the cylinder head cover
(2).
Tightening Torque10 Nm
17 . Install the cooling fan belt pulley and fan clutch.
18 . Install the belt tensioning device and then install the belt.
19 . Install the cooling fan.
20. Fill the engine oil and check oil leaks by running the engine.
CRANKSHAFT END COVER
Preceding Work : Removal of flywheel and driven plate.
OM600 ENGINE MECHANICAL 1B3-71
1 Crankshaft Flange
2 End Cover.............................. Clean, Loctite 573
1. Remove the bolts (3, 6) from end cover, By pulling out the
lugs (arrow), remove the cover.
Notice
Be careful not to damage the oil pan gasket.
2. Remove the radial seal (4) with care not to damage the
sealing surface.
Installation Procedure
1. Thoroughly clean the sealing surface of end cover and apply
Loctite 573.
2. Clean the groove of radial seal.
3. Apply Loctite 573 on the bolts and install the end cover.
Tightening Torque10 Nm
Notice
Be careful not to damage the oil pan gasket.
4. Install the inner oil seal assembler to the crankshaft flange.
Oil Seal Assembler 601 589 03 43 00
5. Coat a little oil on the sealing lip of new radial seal and
contacting surface.
Notice
Don’t use grease.
6. Insert the new radial seal (4) onto the oil seal assembler
(7).
Notice
The sealing lip of the repair radial seal is offset to the inside
by 3mm to ensure that it does not run in any groove which
the standard radial seal may have left on the crankshaft
flange.
A Standard Radial Seal
B Repair Radial Seal
OM600 ENGINE MECHANICAL 1B3-73
7. Install the outer oil seal assembler on he seal and by
tightening the bolts, press the radial seal into the end cover
as far as the stop.
Notice
The seal must be positioned exactly at right angles in the
end cover to ensure that it provides a proper seal.
11 Radial Seal
12 Timing Gear Case Cover
13 Key
14 Crankshaft Sprocket
16 Crankshaft
1B3-76 OM600 ENGINE MECHANICAL
Removal Procedure
1. Remove the starter motor and install the engine lock into
the wheel ring gear.
Engine Lock 602 589 00 40 00
2. Remove the poly V-belt.
3. Remove the cooling fan.
Notice
Keep the fan in vertical position.
4. Remove the cooling fan belt pulley (2).
5. Place alignment marks (arrow) on the vibration damper (5)
and crankshaft belt pulley (4).
6. Remove the timing sensor bracket.
Notice
Remove if necessary.
7. Remove the socket bolts (3) and then remove the belt
pulley (4) and vibration damper (5).
8. Remove the washer and bolt.
OM600 ENGINE MECHANICAL 1B3-77
9. Remove the hub by using a puller.
10. Replace the radial seal.
Puller 103 589 00 33 00
1B3-78 OM600 ENGINE MECHANICAL
Installation Procedure
1. Install the hub.
Notice
Exactly align the woodruff key and the groove of hub (arrow).
2. Install the washer (7) and tighten the bolt (6).
Washer (new) : 1 EA200 Nm + 90°
3. Install the vibration damper.
Notice
Exactly align and insert onto the straight pin.
4. Install the belt pulley.
Tightening Torque25 Nm
Notice
Align the alignment marks.
5. Install the timing sensor bracket.
Notice
See the ‘TDC setting’.
6. Install the cooling fan pulley.
Tightening Torque10 Nm
7. Install the cooling fan.
8. Install the fan belt.
OM600 ENGINE MECHANICAL 1B3-79
9. Remove the engine lock.
1B3-80 OM600 ENGINE MECHANICAL
CRANKSHAFT FRONT RADIAL SEAL
1 Radial Seal
2 Timing Case Cover
Tools Required
601 589 03 14 00 Sleeve
3 Woodruff Key
Notice
The sealing lip of the repair radial seal is offset to the inside
by 2mm to ensure that is does not run in any groove which
the standard radial seal may have left on the crankshaft
flange.
A Standard Radial Seal
B Repair Radial Seal
Replacement Procedure
1. Pull out the radial seal (1) and be careful not to damage the
sealing surface of timing case cover.
2. Thoroughly clean the mounting bore of the radial seal.
OM600 ENGINE MECHANICAL 1B3-81
3. Coat a little oil on the sealing lip of new radial (1) and contact
surface.
Notice
Don’t use grease.
4. Install the radial seal (1) by using a sleeve (4).
Notice
Align the groove of sleeve and woodruff key(arrow).
The gaps between the bearing shell and bore and
between the bearing shell and journal are different
each other. Refer to service data.
A Radial Bearings
B Radial and Axial Bearings (Thrust Bearing)
1B3-86 OM600 ENGINE MECHANICAL
Crankshaft Standard and Repair Sizes
Crankshaft bearing
journal diameter
Standard size50.950 - 57.965
Repair size 1
Repair size 2
Repair size 3
Repair size 4
57.500 - 57.715
57.450 - 57.465
57.200 - 57.215
56.950 - 56.965
Bearing Clearances
Radial clearances
New
Limit
Axial clearances
New
Limit
Matching Fit Bearing Journal Width to Thrust Bearings
Thrust bearing
journal width
Thrust bearing
journal diameter
24.500 - 24.533
24.600 - 24.633
24.700 - 24.733
24.900 - 24.933
25.000 - 25.033
-
47.950 - 47.965
47.700 - 47.715
47.450 - 47.650
47.200 - 47.215
46.950 - 46.965
Thrust bearingCrankshaft bearing
0.027 - 0.051
Max. 0.070
0.100 - 0.254
Max. 0.300
0.026 - 0.068
Max. 0.080
-
-
mm
mm
mm
Fit bearing journal width Thrust bearings thickness
24.500 - 24.533
24.600 - 24.633
24.700 - 24.733
24.900 - 24.933
25.000 - 25.033
Notice
l Measure crankshaft axial clearance and adjust with proper thrust Bearing.
l The same thickness of washer must be installed on both sides of the fit bearing.
2.15
2.20
2.25
2.35
2.40
OM600 ENGINE MECHANICAL 1B3-87
Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft
Marking of basic bearing bore in lowerColor code of relevant crankshaft
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft
Marking of bearing journals on crank webs
parting surface
1 punch mark or blue
2 punch marks or yellow
3 punch marks or red
Blue or white-blue
Yellow or white-blue
Red or white-blue
bearing shell
Blue or white-blue
Y ellow or white-yellow
Red or white-red
Color code of relevant crankshaft
bearing shell
Blue or white-blue
Y ellow or white-yellow
Red or white-red
1B3-88 OM600 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the bearing cab bolt.
2. Remove the bearing caps (8).
Notice
The crankshaft bearing caps are marked with stamped
numbers. Remove the bearing cap from the vibration
damper side.
3. Remove the crankshaft bearing caps (9) and lower thrust
bearings (7).
4. Remove the lower thrust bearings (6) from the bearing cap
(9).
5. Remove the crankshaft (5).
6. Remove the upper thrust bearings(4).
7. Remove the upper bearing shells (3) from crankcase.
8. Thoroughly clean the oil gallery.
9. Select a proper new bearing shells with reference to table.
10 . Coat the new bearing shells with oil and insert into the
crankcase and into the crankshaft bearing caps.
Notice
Do not mix up upper and lower crankshaft bearing shells.
11. Install the bearing caps according to marking and tighten
the 12-sided stretch bolts.
Tightening Torque35 - 40 Nm
Notice
No. 1 is vibration damper side.
12. Measure crankshaft bearing diameters (E).
Extension 366 589 00 21 05
OM600 ENGINE MECHANICAL 1B3-89
13. Measure at 3 points (A, B and C) and if the average value
of B and C is less than A’ s value, the average value of B
and C is the mean value and if more than A’ s value, A’ s
value is the mean value.
If the length ‘L’ of bolts exceeds 22.5mm, replace the bolts.
3. Remove the flywheel (3), if equipped with manual
transmission.
Installation Notice
Correctly align the position of dowel pin (2).
1B3-96 OM600 ENGINE MECHANICAL
4. Remove the flywheel (6) and driven plate (5), if equipped
with automatic transmission.
Installation Notice
Correctly align the position of dowel pin (2).
5. Installation should follow the removal procedure in the
reverse order.
MACHINING OF FLYWHEEL
OM600 ENGINE MECHANICAL 1B3-97
1 Flywheel
Machining of Flywheel
Notice
Flywheels which have scorch marks, scoring or cracks in
the clutch surface should be machined by grinding or
precision-turning. If the scores or cracks are severe than
permissible specifications, replace the flywheel.
Distance ‘a’
Distance ‘b’
Repair up to
Max. axial runout
l When machining the clutch surface ‘A’, the mounting
surface (B) for the clutch pressure plate should also be
machined in accordance with ‘A’ to keep the distance ‘a’.
l Do not machine under ‘b’ value.
l When machining, fix the flywheel exactly not to exceed the