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Job No.
185
-0188-17
Caution!
Do not overfill.
Turbo engine:
Charge air pipe ......................... remove, install.
Cylinder head cover ..................... remove, install, 10 Nm.
Valve tappet (203) ...................... check with a mandrel, to do this first check on
the cylinder which is exactly on Ignition TDC
(cam tips for inlet and exhaust valve pornt
upwards).
Caution!
Unnecessary rotation of the engrne causes the
valve clearance compensating elements to sink.
05 10 211 1
EXIT
Note
Hydraulic valve clearance compensating
a
elements have been fitted with a larger oil
b
reservoir chamber since the start of production
9
on engines 602 and 603.
a Storage chamber
05.10 _ 211 2
EXIT
a Reservoirchamber
b Plunger
C Working chamber
1
not recorded
05 10 - 211 3
EXIT
not recorded
l
Tightening torque Nm
Hexagon bolts for cylinder head cover 10
05 10 - 211 4
EXIT
Special tools
Conventional tool
Dial gauge e. g. Mahr
D-7300 Esslingen
Part No. 810
Checking
Turbo engine:
3 Remove charge air pipe.
Caution!
Turning the engine unnecessarily causes valve
play compensating elements to sink.
The engine must not be turned by the camshaft
timing gear bolt.
0510 - 211 5
EXIT
Measuring pre-stroke
7 The basic setting of the dial gauge has to be
undertaken before measurement. To do this
insert the dial gauge in the measuring bridge
601 589 08 21 00 and push in until there is a
preload of approx. 1 mm. The probe in the
measuring bridge must be in the basic position
(lower stop).
Note
If required, measure dimension “X” on all valve
tappets.
0510 - 211 6
EXIT
Example:
’ \\J
^^_ ^^__+
.^
0510 - 211 7
EXIT
Reference value: 18 - 19 mm
PO5 2264 13
PO50189-13
05 10 - 211 8
EXIT
Note
If oil escapes, renew valve tappet.
tappet.
furbo engine:
26 Install charge air pipe.
05.10 - 211 9
EXIT
Preceding work:
Cylinder head cover removed.
InjectIon nozzles removed (07.1-230).
Charge air pipe removed (turbo engines).
Dial gauge holder 363 589 02 21 00 . . . . . . . . . . attach, remove at the No. 1 cylinder inlet valve.
Dial gauge with 3 mm preload on valve tappet.
Caution!
Engine must not be turned by the camshaft.
W ith 2 mm valve stroke ................... engine must be at 12” after TDC.
Timing
*) Not used.
3) With Ml 1 thread from 111'88.
“) On used camshafts.
5, Repalr camshafts with 0.5 mm larger bearing diameter and Ml0 thread.
6) Repair camshafts with 0.5 mm larger beanng diameter and Ml 1 !hread.
05 10 - 215 1
EXIT
Tightening torque Nm
Bolts for cylinder head cover 10
Special tool
363 589 02 21 00
00
Conventional tool
Dial gauge A 1 DIN 878 e. g. Mahr
D-7300 Esslingen
Part No. 810
Note
It is not possible to correct timing. The trming
chain should be checked for elongation if the
test values differ.
The timing chain is to be replaced with more
than 4” at the crankshaft.
Checking
Caution!
The engine must not be turned by the camshaft
timing gear bolt. Do not turn engine backwards
during measurement, otherwise measuring errors
result.
05.10 - 2152
EXIT
Caution!
The probe pin of the dial gauge must be exactly
vertical to the valve tappet.
05.10 215~3
EXIT
203
ws-m92-37
Turbo engine:
Charge air pipe . . ... .. ... ... . . ... ... . . . . remove, install.
Cylinder head cover (125) ................. remove, install, 10 Nm.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . position on ignition TDC of No. 1 cylinder.
Caution!
The engine must not be turned by the camshaft
timing gear bolt.
Chain tensioner (224) . . . . . . . . . . . . . . . . . . . . remove. install, replace sealing ring (237)
(05310).
With self-levelling suspension:
Drive of the pressure 011 pump (400) . . . . . . . . . remove, install (05437).
0510 - 220 1
EXIT
Camshaft timing gear (188) . . . . . . . . . . . . . . . . mark at timing chain (210). Remove, install
camshaft timing gear. Different bolts (190) and
washers (189). Hexagon bolt, 65 Nm, bihexa-
gonal head bolt, 25 Nm 90” angle of rotation.
Caution!
When assembling the camshaft timing gear
ensure that the straight pin (187) is not pushed
out towards the rear.
Camshaft bearing cap (80, 81, 82) . . . . . . . . . . . remove, install, note sequence, hexagon bolts
(84) and washers (84a), 25 Nm.
Caution!
Note torquing diagram!
Camshaft (185) ........................ remove, install. Check for ease of movement.
Lock washer (186) . . . . . . . . . . . . . . . . . . . . . . check.
Valve tappet (203) . . . . . . . . . . . . . . . . . . . . . . remove, install, check.
Magnet lifter 102 589 03 40 00.
After installation . . . . . . . . . . . . . . . . . . . . . . . . allow engine to run, check for leaks.
05.10 _ 220 2
EXIT
Data
Bearing 602 603
position engine
Permitted eccentricity
of center bearing pin 2nd and 5th bearing
and camshaft gear seat
when accepting the
camshaft in the outer
bearing positions
2nd and 6th bearing - 0.030
position
135 10 - 220 3
EXIT
A
B
1 st Design
2nd Design
c9 @ PO50205-l 3
007763
* 1
008022
* l
033213 I
. not recorded
05 10 220 4
EXIT
Tightening torques
Hexagon bolt (A) 65 Nm
&hexagon necked down bolt (6)
Pre-torque 25 Nm
Torsion angle 90”
ql+y
_swl3_
Caution!
0
Note revised plain washer!
52 4
pf33oo213
05.10 - 2205
EXIT
transmission
000187 * 1
019336
201 014216 * *
004561
”
not recorded
Special tools
Removal
Turbo engine:
1 Remove, install charge air pipe.
05 10 - 2206
EXIT
Caution!
Do not turn engine by the camshaft timing gear
bolt. Do not turn engine backwards.
Note
The timing chain is prevented from twisting when
the timing case cover is assembled.
Caution!
Note different bolt and washer.
0510 2207
EXIT
Caution!
9 It is absolutely essential to observe the
following sequence during removal and
installation in order to avoid damage to the
camshaft:
Engine 602
Unscrew both hexagon bolts on camshaft
1 2 3 4 5 6
bearing caps 1, 2 and 6 (dark arrows).
PO5-0203-13
Engine 603
Unscrew both hexagon bolts on camshaft
bearing caps 1, 5 and 6 (dark arrows).
PO5-0204-13
05 10 - 220 8
EXIT
Caution!
Install valve tappet in the same position again.
Installation
0510 - 2209
EXIT
Turbo engine:
Install charge air pipe.
After installation:
22 Allow engine to run, check for leaks.
EXIT
203
202
201
05.10 - 250.1
EXIT
000016
* x
124.133 603.960 -
124.193 I I
001093 * *
126.125
015830 003949
* 215978
201.126 602.911
I I
. not recorded
05 10 - 250 2
EXIT
transmission
* *
124.133 603.960 - 018302
124.193 I I
013824
* t
201.126 067330
Note
Color markings of valve springs yellow green or
violet!green or yellow blue or violet blue.
05 10 - 253 3
EXIT
Special tools
601 589 02 43 00
05
Installation note
Lubricate valve tappets. Note sequence.
05.10. 2504
EXIT
Installation note
Install valve springs with the color marking
downwards.
Installation note
Lubncate valve tappets, note sequence.
05 10 250 5
EXIT
Installation note
Install valve springs with the color markings
downwards.
05 10 - 2506
EXIT
Preceding work:
Valve springs removed (05-250).
Conventional tool
Spring test scales e. g. Berco
Model CM130
05 10 - 26081
EXIT
Preceding work:
Valve springs removed (05-250).
PO5-0195-m
Valve stem seals (199, 200) . . . . . . . . . . . . . . . remove, install. Pliers 104 589 00 37 00,
mandrel 601 589 02 43 00. Note color marking.
Valve stem . . . . . . . . . , . . . . . . . . . . . . . . . . de-burr at groove.
-d-I -_d-1
PO5-0040-13A
05 10 2-o 1
EXIT
. not recorded
05 10 - 270 2
EXIT
Viton material
124.128 003020
124.133
124.193
126.135
201.126 016477
05 10 - 270!3
EXIT
124.128 602.962
124.133 603.960
124.193
126.135 603.970
201.126 602.911 017538
r
* *
201.128 602.961 002151 007954
.'1
from stal of production
not recoi led
601 589 02 43 00
0 5 1 0 270 4
EXIT
Preceding work:
Cylinder head removed(01-415).
Valve springs removed (05-250).
Valves removed.
PO50191.15
Valves
(Intake valve 195, exhaust valve 196) ......... clean, check visually.
Valve stem ............................ check for eccentricity (max. 0.03 mm).
Valve seat ............................ check for eccentricity (max. 0.03 mm), grind.
Dimensions and angles ................... check (table).
05 10 - 280 1
EXIT
Data
0 5 1 0 - 280,2
EXIT
Note
On turbo engines the surface of the inlet valve
head is ground (non-machined on naturally
aspirated engines).
AWarning
Unserviceable sodium-filled valves must be
neutralised before scrapping. They must
therefore be collected by the respective
departmental supervisor and dispatched to:
Mercedes-Benz AG
Werk Marienfelde
DaimlerstraOe 145
Anlieferstelle KST 3153
PO!%0196-15
Arbeitsvorbereitung TAI
Conventional tools
Valve grinder e. g. Krupp,
or D-5309 Meckenhelm
Valve poppet turning equipment Model VS
e. g. Hunger,
D-8000 Munchen 70
Model VKDR 1
Part No. 203.00.200
05 10 - 280 3
EXIT
POS-0035-13
05 10 - 280 4
EXIT
Preceding work:
Cylinder head removed (01-415).
Valve springs removed (05-250).
Valves removed.
204
206
Checking
Seat for valve stem seal (205) .............. check. Replace valve guide (204) if valve stem
seal is loose.
Valve guide .. . . . .. . . .. . . . . .. . . .. . .
(204) clean. Cylindrical brush 000 589 10 68 00.
Valve guide (204) inside 0 . . . . . . . . . . . . . . . . . . . . check. Plug gauge: 102 589 00 23 00 intake,
117 589 03 23 00 exhaust.
Replace valve guide, if reject pin of plug gauge
fits completely in the valve guide.
Replacement
Valve guide (204) . . . . . . . . . . . . . . . . . . . . . . . drive out, drive home.
Drift:
103 589 03 15 00 intake,
103 589 02 15 00 exhaust.
Punch:
601 589 06 15 00 intake,
601 589 02 15 00 exhaust.
Ream,
Reamers:
000 589 21 53 00 intake
000 589 10 53 00 exhaust
05.10 - 2851’1
EXIT
601 050 08 24
i-=+-D-l
POs-o187-15
05.10.285 2
EXIT
Special tools
.
?
I
I
I
II -
I
103 589 03 15 00
05
103 589 02 15 00
05
102589002300
05
117 589 03 23 00
05
_
J
000 589 21 53 00
05
-1
000 589 10 53 00 115 589 00 53 00
05
102 589 08 63 00
Conventional tool
e. g. Hunger,
Cylinder head clamping fixture D-8000 Mijnchen 70
Part No. 221.60.000
05 lO.c?853
EXIT
Note
The broach cutter must be cleaned before each
broaching operating.
Provide guide sleeve, basic bore and complete
broach with ample supplies of paraffin.
Note
Dnve the broach quickly through with an
aluminium mandrel, approx. 130 mm long, and a
plastic hammer of approx. 250 g.
1 Broach
2 Guide s l e e v e
3 Valve seat tnser-t PO50163-17
05.10 - 285 4
EXIT
r
Note
The high spot (arrow) on the intake valve seat
inserts is to be removed before inserting the
guide sleeve.
PO5-0164-11
Intake
102 589 00 63 00 14.2 mm
Exhaust
Intake
601 589 15 63 00 14.4 mm
Exhaust
05 10 - 2855
EXIT
Precedmg work:
Valve guides checked (05-285).
PO50183-15
Valve seat insert . . . . . . . . . . . . . . . . . . . . . . . . turn out valve seat insert with the lathe tool.
Note operating instructions for the valve seat
turning equipment.
Basic bore (D2) . . . . . . . . . . . . . . . . . . . . . . . . check (table). Bore out to the repair stage, if
required.
Caution!
Machine basic bore for the valve seat insert if
minimum overlap is not achieved (Number 3).
Valve seat insert . . . . . . . . . . . . . . . . . . . . . . . . supercool with liquid nitrogen and insert
into basic bore.
AWarning
Do not touch supercooled valve seat inserts
with bare hands.
Valve seat insert must be square to the cylinder
head.
Valve seats , . . . , . . . . . . . . . . . . . . . . . . . . . . machine (05291).
05 10 - 290 1
EXIT
Data
I Intake I Exhaust
Overlap of valve seat inserts
in cylinder head
02
Dl 33.400 30.400
33.600 30.600
l-l
t (New value)
Note
Exhaust valve seat inserts are made from
centrifugally cast material on the naturally-
aspirated engines, and srntered metal on turbo
engines.
0510-2902
EXIT
PO5 -0164-11
Conventional tools
Cylinder head clamping fixture e. g. Hunger,
D-8000 Munchen 70
Part No. 221.60.000
05 10 - 290 3
EXIT
Replacement
05 10 290 4
EXIT
Preceding work:
Valve guides checked (05-285).
Note
Only loosen the pilot when eccentricity of the
valve seat has been checked.
Eccentricity of valve seat .................. check (Number 2).
Valve seat width (b) . . . . . . . . . . . . . . . . . . . . . measure, correct if required (Number 3).
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . insert and measure distance (A).
05.10 - 291il
EXIT
Data
Valve seat I Intake I Exhaust
Valve seat width (b) Il.2 - 1.7 Il.5 - 2.0
PO5-0133-13
I
Conventional tools
Cylinder head clamping fixture e. g. Hunger,
D-8000 Munchen 70
Part No. 211.60.000
05 10 2912
EXIT
Note
Clamp cylinder head in the clamp fixture for
dismantling and machining. Machine valve seats
with valve seat turning equipment, with valve
seat grinder or valve seat miller. The location of
the hydraulic valve clearance compensating
elements must be checked after machining the
valve seat Inserts and, if required corrected
(05211).
Caution!
Only loosen pilot (5) when eccentricity of the
valve seat has been checked.
6 Clamping fixture
8 Forward feed operation
PO5-0142-13
!
05 ‘0 231 3
EXIT
05.10 - 291 4
EXIT
244
215
PO5 0182 37
0510 - 3101
EXIT
Note
A revised valve disk (231) has been fitted in the
chain tensioner in order to avoid peak pressures
of the chain tensioner on the tensioner rail.
05 10 - 310 2
EXIT
dl 32 mm
d2 27 mm
A Previous design
B Rewsed design
. not recorded
05.10 - 3103
EXIT
Special tool
05 10 310 5
EXIT
244
215
PO50 1 8 2 3 7
Caution!
The trmlng chain must remain In engagement on
the camshaft and crankshaft gear as the engine
is turned.
0510-3201
EXIT
Timing chain . . . . . . . insert connecting link from behind and rivet the
link pins individually with assembly tool
000 589 58 43 00 (Numbers 6 - 10).
Tightening torque of spindle 30 - 35 Nm.
Link pin rivet . . . . . . . check (Number 11).
After installation . . . . . turn crankshaft, check adjustment marking at
TDC position (Number 13).
Note
Since 10 86 timtng chains from an additional
manufacturer have been fitted (Daido).
335707- 287778-
338278 291247
05 10 - 3202
EXIT
. not recorded
not recorded
”
G5 10 320 3
EXIT
Special tools
.-_A
0510 3204
EXIT
Renewal
Caution!
The timing charn must remain engaged with the
camshaft and crankshaft gear while engine is
turned.
05 10 320 5
EXIT
PO5-2053 - 13
Caution!
Put clip on so that both rivet pins engage.
PO5-2056-13
05 10 3206
EXIT
Note
If adjustment markings do not align, the
camshaft timing (05215) and start of delivery of
the injection pump (07.1-l 11) must be checked.
II
L_LL,-,_
3 /p
I I
---., /-
PO6-2206-13 -
05 10 320 7
EXIT
Preceding work:
Cylinder head removed (01-4 15)
Tlmlng case cover removed (01-210)
Chain tensioner removed (05-310).
244
215
PO5 0182 37
Note
Plastic support of the tensioner rail cannot be
replaced.
05 10 330 1
EXIT
Note
Since 08 86 unhardened straight pins have been
fltted for the tensioner rail bearing.
05 10 330 2
EXIT
Data
Since 09 86 the lead-in tangent (abutment
surface) on the tensioner rail has been extended,
thus reducing linrng wear.
PO5 0215 15
0510 3303
EXIT
188
PO!!-01 99-35
Cylinder head cover (125) ................. remove, install, bolt (132) 10 Nm.
With self-levelling suspension:
Pressure oil pump drive . . . . . . . . . . . . . . . . . . . remove, rnstall (05437).
Camshaft timing gear (188) . . . . . . . . . . . . . . . . mark at timing chain. Remove, install camshaft
timing gear. Drfferent bolts (190) and washers
(189) with different tightening torques. Hexagon
bolt 65 Nm. Bihexagonal head bolt 25 Nm 90”
(05220) (Numbers 3 - 5).
05 10 - 341 1
EXIT
Caution!
The extractor 115 589 20 33 00 can be used
together with stud 115 589 01 34 00 If the
bearing pins have seized.
Special tools
L--
001 589 72 21 00
05 10 - 341 2
EXIT
Removal
Caution!
Note different bolt and washer (05220).
Caution!
Seized bearing bolts can also be pulled out with
puller 115 589 20 33 00 and stud
115 589 01 34 00.
PO5 2258 13
05 10 341 3
EXIT
Installation
PO5 2258 13
AWarning
Do not turn engrne by camshaft timing gear bolt.
0510 - 3414
EXIT
Preceding work,
Tlmlng case cover removed (01-210).
Chain tensioner removed (05-310).
POMrn 15
Guiding rail (218) ................,...... pull off from guiding blade bolt (222), put on.
Check guiding rail, renew If necessary.
Note
Since 09 86 unhardened straight pins have been
fitted for the guiding rail bearing.
05 10.341 5
EXIT
135 10 341 6
EXIT
406
PO5-019355
Cylinder head cover (125) . . . . . . . . . . . . . . . . . remove, Install, fixing bolt (132), 10 Nm.
Pressure oil pump (400) . . . . . . . . . . . . . . . . . . unbolt, reinstall, fixing bolt (408) wrth washers
(408a), 11 Nm, put pressure 011 pump to one
side with lines connected.
Note
Do not unbolt the upper and lower bolt with
continuous thread (vrsrble between housrng and
cover).
O-ring (404) ....................... . * . replace.
Carrier (403) ...................... . . . remove, install, check.
Bolt(407) ........................ . . . unbolt, reinstall. Note different bolt (05-220).
Tightening torque and angle of rotation
Hexagon bolt 25 Nm,
Bihexagonal necked down bolt 25 Nm, 90”.
Carrier sleeve (406) . . . . . . . . . . . . . . . . . . . . remove, install. Use grease when Installing.
Note different design (05220).
05 10 4371
EXIT
Note
Since 11 88 the camshaft timing gear has been
fitted with a blhexagonal necked down bolt Ml 1
(previously hexagon bolt MlO). The carrter has
been revised as a result of this change.
ul
t
_!I!!.& i_ _I !*10,4
A Prewcus Design
B Rewsed Design
124 000187 * 1
019336
. not recorded
Special tool
001 589 72 21 00
00
- ~_ I