Mercedes-Benz

service

Mercedes-Benz of North America, Inc.

One Mercedes Drive Montvale, NJ 07645

Caution

Our service manuals contain descriptions of important assembly, adjustment and inspection jobs. Special tools required in performing certain service jobs are identified in the manual and recommended for use. Any part numbers given are only used for identification and easier differentiation between individual components, and are not intended for ordering purposes. All procedures, illustrations and specifications contained in these manuals were based on the latest information available at the time of publication. If your Mercedes-Benz model differs from the specifications contained in the manual you select, consult your authorized Mercedes-Benz dealer. Remember, the proper performance of services is essential for both the safety of the mechanic and the efficient operation of the vehicle. The procedures in these manuals are described in such a manner that the service may be performed safely and accurately. However, it is always assumed that the reader is familiar with basic automotive repair procedures and Mercedes-Benz vehicles.

0 Mercedes-Benz of North America, Inc., 1985 All rights reserved, Reproduction or translation in whole or parts is not permitted without written authorization from the publisher. Published by Mercedes-Benz of North America Inc. Printed in Germany 6510 1921 13 385 2.0 ru

Introduction
This Service Manual is the product of existing technical publications. Special care has been taken to provide accurate information on removal, disassembly, assembly, inspection, installation, and adjusting procedures, backed with the technical data necessary to do the job. The material in this manual is divided according to the Mercedes-Benz Component Group System as outlined on the GROUP INDEX page. This page will quickly direct the reader to the Major Component Group. Each Major Component Group begins with a JOB INDEX listing all jobs within that group. Mercedes-Benz of North America, Inc. recommends that repairs to, and maintenance of, Mercedes-Benz automobiles be performed only by MercedesBenz trained personnel at authorized Mercedes-Benz dealerships. The information contained in this special publication is ordinarily issued by Mercedes-Benz of North America, Inc., in conjunctionwith supplementary service literature and special tools supplied only to its authorized dealers. The repair and maintenance procedures outlined herein are procedures to be used by trained Mercedes-Benz service and dealership personnel. Supplementary service literature will not be provided with this publication, but may be contained in reprints of this Service Manual. Please note that this manual has been compiled from various sources, some of which cover models other than the subject of this book. Always refer to the engine and vehicle identification table for model and component information. The information contained in this manual was accurate to the best of our knowledge at the time the manual was approved for publication. However, the right is reserved to make production, design and specification changes at any time, without notice and without obligation to give notice. Any such changes will not be contained in this manual. Mercedes-Benz of North America, Inc. assumes no liability for any damage to person or property caused by the utilization of this publication to effect maintenance or repair work on Mercedes-Benz automobiles. MERCEDES-BENZ OF NORTH AMERICA, INC. Technical Publications

Group Index General, technical data 00

Crankcase and cylinder head

01

Crankshaft assembly

03

Engine timing, valves

05

Injection system

07.1.

Air cleaner

09

Belt drive

13

Intake manifold, exhaust manifold, emission control system

14

Electrical system, engine

15

Engine lubrication

18

Engine cooling

20

Engine suspension

22

Throttle control

30

Fuel system

47

Exhaust system

49

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

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General, technical data 00

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0 0 General,technical data

Job No.

............................................ 00-005 ............................................... 010 Vehicle identification number locations ...................................... ... 015 Technical data ................................. : ..................... .. 020
Instructions for use of service manual Engine and vehicle identification

00/l

. . . i. . . . . . . . . . . . . . . . . . . ._____.. .

1 . . . . . . . . _

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00

Instructions for use of service manual

Complete Service Manual coverage for late model year Mercedes-Benz vehicles requires four individual manuals: Service Manual, Engine Service Manual, Transmission Service Manual, Chassis and body Service Manual, Heating and air conditioning Throughout these manuals, the vehicles are identified by their chassis and engine numbers. These numbers are made up of the first six digits of the respective serial number. For the actual location of chassis and engine numbers, see page 00-015/l. In case where the repair instructions apply to all versions, only the first three digits of the respective number are referenced

Location of specific repair instructions First locate the Group No. in the Group Index. Individual groups are separated by an easily visible dividing page, which is followed by the job index page. Then check the job index for the exact job required. The first page of a typical job description looks like this: 03-320 Mounting of crankshaft Job Title appears on same line as Group No.

For example, engine 601 applies to all 601 engines. However, engine 601.921 would only apply to the engine used in model 190 D-2.2.

03.1 O-320/1

Technical data, tightening torques and tools are listed at the beginning of each job. All dimensions are in metric units, unless otherwise indicated. Any part numbers given are only used for identification and easier differentation between individual components, and are not intended for ordering purposes.

oo-005/l

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00 Engine and vehicle identification

This manual applies to the following passenger cars, starting model year 1984: Model USA Model Year From 1984 Chassis Type To 201.122 601.921 Engine Type

190 D-2.2

00-01 O/l

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Vehicle identification number locations 00

Certification Tag [left door pillar) Identification Tag (left window post) Chassis No. Engine No. Body No. and Paintwork No. Information Tag California version Vacuum line routing for emission control system Emission Control Tag Emission Control Tag Catalyst Information

00--015/1

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Technical data 00

Engine Model Engine Operation 201.122

! 601.921
4-cycle diesel, ME prechamber design

/
Number of cylinders Cylinder arrangement Bore/stroke Total effective piston displacement Compression ratio Firing order Maximum speed, no load rpm kW/rpm SAE net bhp/rpm Nm/rpm SAE net. Ibf-ft/rpm mm cc

4
In-line, 15 inclination 87192.4 2197 22 l-3-4-2 4900-5100 5414200 7214200 130/2800 96/2800 5 Overhead 1 overhead camshaft

Engine output

Maximum torque

Crankshaft bearings Valve arrangement Camshaft arrangement Oil cooler

Water circulating pump, thermostat with bypass line, finned tube radiator, fan with electromagnetic clutch Forced-feed lubrication via gear-type pump Combined main and bypass filter Dry air cleaner with paper cartridge

Cooling

Lubrication Oil filter Air cleaner

oo-020/l

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00 Technical data

Electrical system Voltage Capacity Bosch Bosch 12v 72 Ah EV 12 V 2.2 kW

Battery

Starter Alternator
1)

/ KI-14 V 55A 201)

As of model year 1985, a Bosch ahernator 980 W 114 V 70 A) is installed

Filling capacities Model Engine Fuel tank/reserve Initial filling During oil and filter change Engine Oil pan up to marks on oil dipstick Air-oil cooler Cooling system with heater Coolant pump Brake system Manual transmission Automatic transmission Brake fluid ATF ATF Initial filling! Oil change SAE 90 ATF or manual transmission oil approx. I approx. I Engine oil max./min. Engine oil approx. I approx. I 201.122 601.921

j 55f7.5 /
7.3

Engine oil

approx.

I I
I

6.5

5.Of3.0

Engine oil Coolant

approx. approx. I

8.5 maintenance-free 0.35 1.5 6.615.9

approx. I

Rear axle hypoid gear oil

approx. I

0.7

(
approx.

Power steering

0.6

oo-020/2

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Crankcase and cylinder head 01

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01 Crankcase and cylinder head

Job No. Engine Checking Checking

............... .................. Evaluating cylinder bores . . . . . . . . . . . . . . . . . . . Removal and installation of engine (oil capacity) . . . .
compression cylinder pressure. leaks for

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

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

Crankcase breather Operation

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

A. Standard version and @ Federal starting 1984 8. @ California starting 1984 Cylinder crankcase Measuring

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

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

040

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

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

.................... Renewing, boring and honing cylinder liners . . . . . . . . . . . . . . . . Facing cylinder crankcase parting surface . . . . . . . . . . . . . . . . . . Knocking out and inserting steel balls in main oil duct . . . . . . . . . Replacing core hole closing cover in cylinder crankcase . . . .
cylinder bores

110 115 120 130 140

Timing housing cover and cylinder crankcase cover Removal and installation of timing housing cover Removal and installation of end cover Oil pan Removal and installation of oil pan Cylinder head Cylinder head bolts and tightening cylinder head bolts Removal and installation of cylinder head

_...... ................

210 222

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

310

.............................. ...................................... Removal and installation of prechambers ....................................... Facing cylinder head parting surface .......................................... Pressure-testing cylinder head ..............................................

405 415 417 418 420

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01-010 Checking compression pressure

Test values with engine at operating temperature in bar gauge pressure Compression pressure, normal Minimum compression pressure Permissible difference between individual cylinders 24-30 approx. 15 max. 3

Tightening torques Coupling nuts of injection lines (reference value) Injection nozzles in prechambers

Nm 1 O-20 70+ 10

Special tools

Compression pressure recorder with accessories

001 5894721 00

Contact handle for rotating engine (component of compression pressure recorder 001 589 46 21 00) ,,oo.-M*l Box end wrench element, open, 14 mm, l/4 drive, for coupling nut of injection line . PP lWO4-10120,,

001 5894621 08

000 589 770300

Note
Check compression pressure at 80 C coolant temperature. Compression pressure can be checked only via prechambers. If minimum compression pressure is less than specified, check cylinders for leaks (01-015).

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Checking

1 Remove injection nozzles (07-230). 2 Connect contact handle for rotating engine to cable connector, terminal 30 and 50, on fire wall.

3 Rotate engine several times with transmission in idle position, so that residue and soot are thrown out. Attention! While rotating engine, push stop lever downwards by means of an extension, so that the injection pump is not injecting.

Compression pressure recorder, connected to prechamber 01 Compression pressure recorder 02 Connection

4 Screw adapter (component of compression pressure recorder) into prechamber. Connect compression pressure recorder.

Rotate engine 8 times for checking engine.

Attention! While rotating engine, push stop lever downwards by means of an extension, so that the injection pump is not injecting. 6 Install new nozzle reeds prior to installing injection nozzle.

Ol.lO-010/2

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01-015 Checking cylinders for leaks

Data Total pressure loss On valves and cylinder head gasket On pistons and piston rings max. 25 % max. 10 % max. 20 %

Tightening torques Coupling nuts of injection lines (reference value) Injection nozzles in prechambers

Nm 1 O-20 70+10

Conventional tools Cylinder leak tester e.g. Bosch, EFAW 210 A SUN, CLT 228 e.g. Bosch order no. 1 687 010 016

Couplings or connections

Checking

Run engine up to operating temperature.

2 Remove injection nozzles (07-230). 3 Remove air cleaner cover.

4 Remove oil filler cap. 5 Remove radiator closing cap and fill up with coolant.

6 Screw adapter (01) and angle piece (02) into prechamber of 1 st cylinder.

01 Connection 02 Angle piece 03 Connecting hose Ol.lO-015/l

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7 Set piston of 1st cylinder to ignition TDC.

8 Connect cylinder leak tester to a compressed air system, calibrate tester. 9 Screw connecting hose (03) of tester to screw-in member. Make sure that crankshaft is not rotating while screwing in hose.

10

Read pressure loss on tester.

11 Check by listening whether the pressure escapes via intake manifold, exhaust, oil filler cap, prechamber of adjacent cylinder or radiator cap.
12 Check all cylinders in ignition sequence.

?014-11623

Note: There is a possibility that the piston ring gaps of the individual pistons are directly one above the other, so that the test result will be misrepresented. When in doubt, continue running vehicle and check cylinders for leaks once again later on.

Ol.lO-015/2

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

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01-020

Evaluating cylinder bores

Tightening torques Coupling nuts for injection lines (reference value) Hex. head bolt for cylinder head cover Threaded ring for prechamber in cylinder head Injection nozzle in prechamber

Nm 1 O-20 10 lOOk 10 70 + 10

Special tools Box end wrench element, open, 14 mm, l/4 drive, for coupling nut of injection line P11004-1052on 000 589 77 03 00

Wrench element for threaded ring of prechamber

11004-636a

615589000700

Impact puller for prechamber

601 589 06 33 00

Conventional tool e.g. Karl Storz GmbH, D-7200 Tut-tlingen Motoskop TW (cold light) with lens probes 103 26 CW (570 mm) and 103 26 CT (210 mm)

Cylinder illuminating lamp

Note

The visual checkup can be made by means of a cylinder illuminating lamp with cylinder head mounted. Remove prechambers for this purpose (01-417).

Ol.lo-020/l

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When evaluating scored or streaky cylinder running surfaces, it is often hard for workshop to decide whether the damage is already significant and requires removal or repair of engine, or whether the marks are insignificant. The following information will help to make an expert and correct decision.

The first difference on cylinder running surfaces is between optical streaks and seizure streaks. In most cases, optical streaks are about 3 mm wide and are caused by ring gap, on which honing traces are still visible; with seizure streaks, however, the honing traces are no longer seen. With streaks in direction of land (in direction of piston pin) shaft streaks or seizures are not possible, since there is no contact between piston skirt and cylinder liner.

01.1 o-020/2

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01-030 Removal and installation of engine (oil capacity)

Specified viscosity classes according to SAE during lasting ambient temperatures

+oo tao

1) SAE 40 may be used during lasting outside temperatures above + 30 oC (+ 86 OF). 2) Do not use. 3) All-season oil. 4, For oils identified on sheets 226.1 and 227.1 of Specifications for service products with footnotel), the following applies: SAE 5 W-20 below + 10 OC SAE 10 W-30 in temperate zones all seasons

+77 +44 +SS +30 +41 +a2 +23 +14 +s - 4

+25 +20

+15 +10

+5

4 -10
-15 -24

Oil capacity in liters (for approved engine oils refer to Specifications for service products) Engine (total filling capacity during complete refill) 7.3

Tightening torques Oil drain plug to oil pan Nuts for oil filter cover Screws for engine carrier on engine mount, front

Nm 25 20-25 35 + 10

Special tools

Tester for cooling system and radiator cap

001 589 48 21 00

Radiator cap with hose for leak test

605 589 00 25 00

Syringe for removing oil

112589007200

Torque wrench, double-arm, 3/8 square, 8-32 Nm

001 589 51 21 00

Torque wrench, single-arm, emitting signal with plug-in ratchet, l/2 square, 25-130 Nm

001 589 66 21 00

01.1 o-030/l

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Conventional tools Socket wrench 7 mm on flexible shaft for hose clamps with worm drive e.g. Hazet, D-5630 Remscheid order no. 426-7 e.g. Backer, D-5630 Remscheid, HerderstraBe

Engine hoist no. 3180

Note

Remove and install engine with transmission.

Removal

1 Put engine hood in vertical position. For this purpose, the engine hood can be set vertically (90) by simply pushing hood up, In vertical position, the engine hood is secured by means of a detent lever.

Engine hood in vertical position

24161

2 Completely remove noise capsule below. For this purpose, unscrew sheet-metal screws (arrows).

3 Completely drain coolant (20-010).

12

Drain plug of cylinder crankcase

01.1 O-030/2

EXIT
To facilitate collection of coolant, plug an extension hose to drain connection of radiator.

Drain plug on radiator

4 Remove air hose (arrow).

Remove air cleaner cover (arrows).

6 Disconnect battery positive line. For this purpose, pull off rubber strip (1) above bulkhead. Remove clips (arrows). Swivel holder (2) in upward direction and place battery positive cable over engine.

01.1 o-030/3

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7 Remove radiator (20-420). 8 On vehicles with air-conditioning system, drain system (83-5161, disconnect refrigerant hoses (arrow) and close free ends of refrigerant hoses with plastic plugs.

9 On vehicles with level control, unscrew hex. socket screws (arrows) and put pressure oil pump with connected lines aside. Remove driver.

10 Draw oil from reservoir of power steering pump with syringe for oil removal and disconnect hoses. 11 Disconnect bowden wire (230) while pushing out slotted guide piece (240) on angle lever and remove bowden wire.

12 Disconnect all coolant, vacuum, oil, fuel and electric lines leading toward engine. 13 Unscrew engine shock absorber on cross member, while unscrewing fastening screws (arrows) for this purpose.

Ol.lo-030/4

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14 Remove engine stop. For this purpose, unscrew adjusting screw (2) as well as hex. head screws (1) and remove engine stop with holder.

15 Remove the lower of the two starter fastening screws (1) and put holder with tachometer shaft aside. Disconnect ground connecting line (2). On vehicles with rpm sensor, unscrew line on oil pan (arrow). 16 Unscrew exhaust system on flange of exhaust manifold.

17 Unscrew fastening screws for exhaust lateral support (1 ), loosen nuts (2) and swivel holder in downward direction. 18 Unscrew propeller shaft on transmission, loosen nut of slide piece as well as fastening screws for propeller shaft intermediate bearing and slide propeller shaft back as far as possible. Also unscrew heat guide plate on vehicle floor.

19 Unscrew drive shaft for tachometer on rear transmission cover. 20 Separate oil line from clutch master cylinder to slave cylinder (arrow). 21 Remove shift rods from transmission shift levers while removing clip locks for this purpose.

01.1 o-030/5

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22 Engage ropes of engine hoist on suspension eyes of engine (arrows). Tighten ropes.

Suspension eye front

Suspension eye rear

23 Remove rear engine carrier with engine mount. For this purpose, unscrew hex. nut (1) and screw out hex. head screws (3).

Rear engine carrier shown on S-speed transmission

24 Unscrew hex. socket screws for engine carrier on both front engine mounts from below (arrow).

Hex. socket screw for engine carrier left Ol.lO-030/6

EXIT

Hex. socket screw for engine mount right

25 Lift out engine with transmission in diagonal position of approx. 45.

Installation

26 Check engine mounts, engine shock absorbers, oil and fuel hoses and renew, if required. 27 Prior to flanging on manual transmission, check condition of radial ball bearing in crankshaft and of throw-out bearing of clutch; renew, if required. 28 To install engine, reverse removal procedure. Pay attention to specified torques of fastening screws and nuts. Check installation position of shielding plates on engine mounts. 29 Screw on propeller shaft and adjust (41-020).

30 Adjust engine stop (22-220). 31 Check oil level in engine and transmission and correct, if required. 32 On vehicles with air conditioning, fill system (83-514). 33 Check all drain plugs for specified tightening torque. 34 Clean air cleaner element and renew, if required. 35 Check for leaks with engine running.

01.1 o-030/7

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01-040 Crankcase breather - operation

A. Standard version and @ Federal starting 1984

Engine601.911 The closed engine breather requires no service. Depending on intake manifold vacuum, the engine blow-by gases are flowing through oil separator (126) in cylinder head cover and a hose line to distributing pipe (140) on intake manifold. From here they are uniformly distributed to all the cylinders and fed to the combustion chambers together with the intake air. The oil separated in oil separator (126) flows back to cylinder head through return pipe (127).

126 Oil separator 127 Return pipe 140 Distributing pipe C=I Fresh air Blow-by gases

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B. @ California starting 1984

Engine 601.921

Engine breather

The closed engine breather requires no service. Operation Depending on intake manifold vacuum, the engine blow-by gases are flowing through oil separator (126) in cylinder head cover and a hose line to distributing pipe (140) on intake manifold. From here they are uniformly distributed to all the cylinders and fed to the combustion chambers together with the intake air. The oil separated in oil separator (126) flows back to cylinder head through return pipe (127). Since on engine in California version the vacuums are considerably higher under influence of throttle valve in intake system, the oil separator (126) is provided with a pressure control valve (141, diagram valve). The valve prevents an excessive vacuum in cylinder crankcase and the resultant loss of oil (suction). To vent diaphragm chamber in pressure control valve, the cylinder head cover is provided with a bore (a). Make sure that this bore is not closed or will not be closed by dirt or preservation compound.

142 141a

143

125 126 127 141

Cylinder head cover Oil separator Return pipe Diaphragm housing

(preSSWe

control velvet

141a Diaphragm 142 Spring 143 Holder a Vent bore

01 .l O-040/2

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a
126 127

126 127 140 141 a

Oil separator Return pipe Distributing pipe Pressure control valve Bore 3 mm dia.

~1 Fresh air Blowby gases

01 .l o-040/3

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

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

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01-l 10

Measuring cylinder bores

Data Engine ) Version Group Code letter Cylinder 1 - 4 A X 8 601 Piston dia. Cylinder dia.

Std (standard)

86.970-86.976 above 86.975-86.983 above 86.982-86.988

87 .OOO-87.006 above 87.006-87.012 above 87.012-87.018 0.10

Max. wear limit in driving or transverse direction when new Permissible out-of-round and conicity wear limit Permissible deviation, vertically in relation to crankshaft axis, with reference to cylinder height Permissible roughness (J? 3 2) Permissible waviness
1) There are no repair stages for these engines.

0.014 0.05 0.05

0.003-0.006 50 % of roughness

Measu ri ng

Measure the cleaned cylinder bores with an internal measuring instrument at measuring points 1, 2 and 3 in longitudinal direction A (piston pin axis) and in transverse direction 8. With piston installed the measuring point 3 is barely above piston, which should be at BDC.

A B a b
C

Longitudinal direction Transverse direction Upper reversing point of 1st piston ring BDC of piston Lower reversing point of oil scraper ring

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01-l 15 Renewing, boring and honing cylinder liners

Data Engine ) Version Group Code letter Cylinder l - 4 A X B 601 Piston dia. Cylinder dia.

Std (standard)

86.980-86.976 above 86.975-86.983 above 86.982-86.988

87.000-87.006 above 87.006-87.012 above 87.012-87.018 90.000 90.035 0.01 0.01 0.003-0.006 50 % of roughness 25 0.006-0.016 refer to Fig.

Basic bore in cylinder crankcase for cylinder liner Permissible out-of-round of basic bore in cylinder crankcase Permissible out-of-round and conicity of cylinder bore Permissible roughness of cylinder bore (6 3 2) Permissible waviness of cylinder bore Honing angle Roughness of cylinder crankcase parting surface Chamfer of cylinder bores
1) There are no repair stages for these engines,

Self-made tool

Mandrel for pressing out or knocking out cylinder liners

Engine 601 a 89.7 mm b 86.9 mm
1033-535in

Ol.lO-115/l

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Only approved cylinder liners may be installed on principle (refer to replacement parts data).

Renewing

1 Press out cylinder liners with self-made mandrel and a press or knock out with a hammer. 2 Thoroughly clean basic bore.

Measure basic bore (D) in cylinder crankcase.

When boundary dimensions (refer to Table) are exceeded, do no longer use cylinder crankcase.

A 6 C D

4.3-4.6 mm 92.65-92.75 mm 0.25-0.35 mm 90.00-90.035 mm

4 Position new cylinder liners. Place a steel plate of pertinent size on liner flange and press in bushing by means of a press or knock in by meanf of a hammer. After pressing or knocking in, leave cylinder liner for an additional 7 seconds under press pressure (settling pressure) or apply a few settling blows with hammer.

0 1 . 1 0 - l 15/2

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5 Mill off or grind off the projecting flange of bushing. Remove as little as possible from cylinder crankcase parting surface. Guide milling cutter or grinding wheel centrally over cylinder bores.

6 Enlarge (bore) cylinder liners in two steps. For honing, leave an allowance of 0.03 mm in bores.

7 Chamfer cylinder liners.

8 Hone cylinder bores. 9 Measure cylinder bores and select matching pistons (01-l 10).

Ol.lO-115/3

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01-120 Facing cylinder crankcase parting surface

Data Height of cylinder crankcase when new Minimum height following a required material removal in longitudinal direction Permissible unevenness of parting surface in transverse direction Permissible roughness of upper parting surface Permissible deviation from parallel between upper and lower crankcase parting surface in longitudinal direction Pressing off pressure with air under water in bar gauge pressure Chamfer of cylinder bores Distance between piston crown and cylinder crankcase parting surface engine 601.911 engine 601.921 0.05 0.006-0.016 0.10 300-299.95

0.1

1.5 refer to Note + 0.65 to + 1.05 + 0.50 to + 0.90

Note

Prior to facing, check piston standout (projection). Do not exceed piston standout of 0.9 or 1.05 mm (03-316). Chamfer cylinder bores after facing. Check timing, if cylinder crankcase parting surface has been refinished (05-215).

Ol.lo-120/l

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01-130 Knocking out and inserting steel balls in main oil duct

Special tool Knocking-in mandrel for steel ball 601 589 08 15 00

Note

The main oil duct is closed with steel balls, 17 mm dia. at the front, 15 mm dia. at the rear. When reconditioning engine, the steel balls must be knocked out from the rear for cleaning main oil ducts. Undamaged steel balls can be used several times without refinishing of ball seat. Renew damaged steel balls.

10 Steel ball, front

In the event of leaks, reseat steel balls in cylinder crankcase with a knocking-in mandrel for approx. 1 mm (dimension is indicated on knocking-in mandrel 1. If the leaks are still not yet repaired, knock out both steel balls and close the respective main oil duct end with closing plug (front) M 18 x 1.5, part no. 000906 018000 or (rear) M 16 x 1.5, part no. 000906 0 16002.

9 Steel bail, rear Ol.lO-130/l

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For this purpose, cut threads M 18 x 1.5, 10 mm deep, at main duct front. Thoroughly remove chips from oil ducts. Coat closing plug M 18 x 1.5 with sealing glue Loctite 241, part no. 002 989 94 71 and screw in.

Cut threads M 16 x 1.5 mm approx. 14 mm deep into main oil duct on main oil duct rear. Thoroughly remove chips from oil duct. Coat closing plug M 16 x 1.5 with sealing glue Loctite 241, part no. 002 989 94 71 and screw in.

Main oil duct front and rear

Knocking out

1 2

Remove coolant pump with housing (20-230). Remove transmission and flywheel (03-410).

3 Knock out both steel balls from the rear to the front by means of a round steel bar (approx. 14 mm and approx. 550 mm long).

Knocking in

4 Thoroughly clean bore in pressing in range of steel ball. 5 Coat spherical indentation on knocking-in mandrel with grease and place steel ball into indentation.

Ol.lO-130/2

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6 Position steel balls and knock in up to stop on ma ndrel. 7 8 Mount all removed or disassembled parts. Run engine warm and check for leaks.

Knocking In steel ball, front

Knocking in steel bail, rear

Ol.lO-13013

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01-140 Replacing core hole cover in cylinder crankcase

Special tools Knocking-in mandrel for cover, 17 mm dia. Knocking-in mandrel for cover, 34 mm dia. +---_-.4.11745 601 589 07 15 00 102589001500

Note

Cylinder crankcase Driving direction, right

At the right (driving direction) a closing plug (6, M 38 x 1.5) is retained. A coolant preheater can be placed into this core hole.

Cylinder crankcase Driving direction, left

Cylinder crankcase Face, front 8a Core hole cover, front Ol.lo-140/l

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Cylinder crankcase Transmission side Arrow = core hole cover, rear

Renewing

Completely drain coolant (20-010).

2 Remove unit parts which prevent access (e.g. transmission, injection pump, etc.).

6 Closing plug 12 Drain plug on crankcase

3 Position a chisel with narrow blade or a screwdriver in deep-drawIn edge of closing cover.

4 Carefully knock in cover on one side until it has turned around its own longitudinal axis (approx. 90).

Ol.lO-140/2

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5 Position water pump pliers at flange of projecting part and pull out cover.

6 Thoroughly clean core hole from residue. Sealing surface must be free of grease (arrow). 7 Coat core hole with sealing glue Loctite 241, part no. 002 989 94 7 1.

8 Knock in new closing cover by means of pertinent knocking-in mandrel. 9 Attach removed unit parts. 10 Fill in coolant (20-010). Note: The sealing glue should cure approx. 45 minutes before filling in coolant.

11

Run engine warm and check for leaks.

Ol.lO-140/3

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01-210 Removal and installation of timing housing cover

Tightening torques Hex. head screw to crankshaft front Screws M 8 x 12 for pulley to hub Oil drain plug to oil pan M6 Oil pan to cylinder crankcase M8 Central screw for fan to coolant pump Adjusting screw for front engine stop Engine carrier to engine mount front Screws for cylinder head cover Cylinder head screws M 8 (reference value) M6 Screws for timing housing cover M8

Nm 370 + 40 25 25 10 25 25 130 35+10 10 25 10 25

Special tools

Torque wrench, double-arm, 318 square, 8-32 Nm

001 589 51 21 00

Torque wrench, single-arm, emitting signal with plug-in ratchet l/2 4 0 - 2 0 0 Nm square,

001 589 67 21 00

Torque wrench single-arm, with ratchet, 3/4 square, 150-800 Nm

001 589 74 21 00

Detent

601 589 02 40 00

Screwdriver with tommy handle for hex. socket screws 6 mm, 440 mm long

116589030700

Sleeve for pushing in radial sealing ring, front

601 589 03 14 00

Ol.lO-210/l

EXIT

Puller for flange on crankshaft

601 589 08 33 00

Box end-Allen wrench 13 x 14 mm

117589020700

Conventional tools Connection 3/4 square socket to l/2 square head e.g. Hazet, D-5630 Remscheid order no. 1058 R. 1 e.g. Backer, D-5630 Remscheid, HerderstraBe e.g. Hazet, D-5630 Remscheid order no. 426-7

Engine hoist no. 3180 Socket wrench 7 mm on flexible shaft for hose clamps with worm drive

Removal

1 Comprletely remove noise capsule. 2 Drain engine oil. 3 Comprletely drain coolant (20-010).

4 Remove air hose (arrow). 5 Remove radiator (20-420). 6 Disconnect negative terminal on battery.

_.;: : ..-

109-25525

EXIT
7 Unscrew collar screw (340) and remove fan.

8 Slacken V-belt and remove. For this purpose, unscrew flange nut (378). Insert a mandrel into spring tensioning lever (374) and releave hex. screw (375) against draw spring (380) until spring can be pushed back in direction of intake manifold. Release spring tensioning lever and remove V-belt.

9 Unscrew hex. socket screws (345) of coolant pump pulley and remove pulley (346).

10

Pull cable from magnetic body (arrow).

11 Unscrew magnetic body (347) from magnet carrier on fastening nuts (349). Note: The magnet carrier is glued to coolant pump housing and should not be pulled off.

Ol.lO-210/3

EXIT

355 356 357

Closing cover M 6 x 25 Hex. socket screw Lock washer

360 Tensioning lever 372 Hex. screw M 8 x 30 373 Holder

12 Completely remove V-belt tensioning device. Unscrew hex. screw (372) for this purpose. 13 Remove closing cover (355). Unscrew screw (356) and remove lock washer (357). Remove tensioning lever (360) together with shock absorber and draw spring from bearing bolt.

14 On vehicles with power steering, unscrew pulley for high pressure pump. 15 Unscrew both hex. screws for high pressure oil pump fastening (arrows) and put high pressure oil pumps with lines connected aside.

Ol.lO-210/4

EXIT
16 Unscrew the front screw of the ! fastening fuel filter (116).

two SC:rews for

17 Unscrew crankshaft pulley. 18 Unscrew hex. screw for flange. For th is purpose, mount detent, part no. 601 589 02 40 00, to oil pan.

19

Pull off crankshaft flange man1Jally.

If hard to move, pull off crankshafi t flange with puller, part no. 601 589 08 33.

20 On vehicles with TDC transmit :ter, unscrew hex. nut (39), pull TDC transmitter line out of holder (42) and put aside.

Ol.lO-210/5

EXIT
21 Unscrew vacuum pump (arrows).

22 Unscrew both fastening screws for engine carrier on engine mount (arrow).

23 Unscrew engine stop on frame cross member. For this purpose, unscrew adjusting screw (2) as well as hex. screws (1).

24 Attach rope of engine hoist at front suspei nsion eye (arrow) and lift engine with a crane. 25 Unscrew fastening screws for oil pan front : in range of timing housing cover. Loosen all remalining fastening screws. 26 Lower engine again into engine mounts.

Ol.lO-210/6

. . . . . .

EXIT

27 Remove

cylinder head cover.

28 Unscrew the two cylinder head screws M 8 (arrows) in chain box with Allen wrench 6 mm, 440 mm long.

29

Unscrew holder for oil dipstick guide tube (62).

30 Unscrew fastening screws (arrows) for injection pump. Remove square nuts on flange of injection pump.

31 Unscrew remaining fastening screws for timing housing cover (arrows). 32 Remove timing housing cover. Attention! Do not damage cylinder head gasket. Renew damaged cylinder head gasket.

Ol.lO-210,'7

EXIT
Installation

33 Clean parting surfaces. 34 Coat timing housing cover parting surface with sealing compound Curil T, part no. 001 98947 20. 35 Carefully position timing housing cover, while paying attention to cylinder head gasket,

36 Screw on timing housing cover. Pay attention to different screw lengths. 37 If the radial sealing ring has been removed, insert new radial sealing ring with sleeve, part no. 601 589 03 14 00. 38 For further installation proceed vice versa.

39 Adjust engine stop (22-220). 40 Check and correct oil level in engine. 41 Fill in coolant (20-010). 42 43 Pressure-test cooling system with tester. Run engine, check for leaks,

Ol.lO-210/8

EXIT
01-222 Removal and installation of end cover

Tightening torques Fastening screws for end cover Necked-down screws for flywheel and driven plate initial torque angle of rotation torque 10 Nm 30 + 10 Nm 90-100

Special tools Installation tool for rear crankshaft radial sealing ring and end cover

601 589 03 43 00

Torque wrench, double-arm, 318 square, 8 - 3 2 Nm

001 589 51 21 00

Torque wrench, single-arm, emitting signal, 2 5 - l 30 Nm with plug-in ratchet, l/2 square,

001 589 66 21 00

Note The central installation position for crankshaft center is located by means of two clamping sleeves (17). The end cover is sealed in relation to cylinder crankcase with sealing compound Loctite 573, part no. 001 989 45 20.
17 20 21 22 55 145 Clamping sleeve End cover Combination screw (M 6 x 22) Radial sealing ring Combination screw (M 6 x 85) Crankshaft

Ol.lO-222/l

EXIT
Removal
1 2 Remove transmission (26-020 or 27-600). Remove flywheel or driven plate (03-410).

3 Unscrew fastening screws (21 and 55) and force off end cover on both lugs (arrows).

4 Clean sealing surfaces on cylinder crankcase and end cover. 5 Check whether radial sealing ring is damaged. Renew radial sealing ring.

Installation

6 Coat end cover on sealing surface uniformly with sealing compound Loctite 573, part no. 001 989 45 20.

7 Slip end cover with pressed in radial sealing ring over screwed on assembly sleeve. Pay attention to oil pan gasket.

01.1 o-222/2

EXIT
8 Tighten fastening screws (21 and 55) to 10 Nm. Tighten fastening screws (55) first. 9 Run engine warm and check for leaks.

Ol.lO-222/J

EXIT
01-310 Removal and installation of oil pan

Oil capacity in liters Oil pan Oil filter 5 1.5

Tightening torques Oil drain plug to oil pan M6 Oil pan to cylinder crankcase M8 Adjusting screw for front engine stop Adjusting screw for rear engine mount Engine carrier to engine mount front

Nm 25 10 25 130 30 35+10

Special tools Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm Torque wrench with plug-in ratchet, l/2 square, 4 0 - 2 0 0 Nm Screwdriver with tommy handle for hex. socket screws 5 mm, 300 mm long Screwdriver with tommy handle for hex. socket screws 6 mm, 440 mm long r ,1oo..Wm 116589030700 001 589 66 21 00

001 5896721 00

116589020700

Box end-Allen wrench 13 x 14 mm

117589020700

Ol.lO-310/l

EXIT
Conventional tool Engine hoist no. 3180 e.g. Backer, D-5630 Remscheid, Herderstrat3e

Note

The engines are provided with a light alloy oil pan. The pan is sealed in relation to cylinder crankcase by means of a gasket.

At the rear left (arrow) is the rpm sensor for refrigerant compressor shutoff, EG R (California version) and revolution counter. To make sure that the oil pan floor in range of oil pump strainer is horizontal with engine installed (engine installation position tilted 15 to the right), the oil pan floor has also a tilt of 15 in relation to cylinder crankcase parting surface.

..

The oil drain plug (54, M 12 x 1.5) is attached at front left. The threaded bushing is sealed by an O-ring (59a) and is locked against rotation by means of a toothed collar (59b), which digs into oil pan when inserted.

53 Sealing ring Oil drain plug M 12 x 1.5 54 59 Threaded bushing 59a O-ring 59b Toothed collar

56 Closing cover b Fastening points for engine stop

101-26986

Ol.lO-310/2

._

EXIT

Removal

1 Remove noise capsule. 2 Drain engine oil.

3 Unscrew engine shock absorber on cross Imember. Unscrew fastening screws (arrows) for this PIu rpose.

4 Remove engine stop. For this purp ose, UIiscrew adjusting screw (2) as well as hex. scre WS (1) and engine stop with holder.

5 On vehicles with rpm sensor, discorinect I ine on oil pan (arrow). 6 Disconnect ground connecting line on tra nsmission.

Ol.lo-310/3

EXIT
7 Unscrew hex. socket screws for engine carrier on both front engine mounts from below (arrow).

Hex. socket screw for engine carrier right

8 Unscrew torsion bar on side members right and left.

9 Engage rope of engine hoist at front suspension eye of engine (arrow). Lift engine with a crane. Pay attention to fan and fan cover.

10 Unscrew oil pan. 11 Unscrew screw (259) on sprocket and remove sprocket from drive shaft. 12 Unscrew oil pump and remove. For this purpos e, unscrew fastening screws (260).

Ol.lO-310/4

EXIT
13 Remove oil pan in forward direction. Pull torsion bar down for this purpose. 14 Clean parting surfaces.

Installation

15 Place oil pan over bogie. 16 Install oil pump (18-210). 17 Mount oil pan with new gasket. engine carrier to engine

18 Lower engine mount.

19 Adjust engine stop (22-220). 20 Fill in engine oil. 21 22 Run engine warm and check for leaks, For further installation proceed vice versa.

Ol.lO-310/5

EXIT
01-405 Cylinder head screws and tightening cylinder head screws

Tightening torques and angles of rotation for cylinder head screws on cold engine 1st stage 2nd stage Setting interval 3rd stage 4th stage Tighten cylinder head screws M 8 with screwdriver with tommy handle. 25 Nm 40 Nm 10 min 9o 9o -

Double hex. socket cylinder head screws (necked-down cylinder head screws)

Dimensions of double hex socket cylinder head screws Thread dia. Length when new 80 102 115 Max. length (renew) 83.6 105.6 118.6

M 10 M 10 M 10

Special tools Screwdriver element l/2 square, 140 mm long for double hex. socket cylinder head screws M 10 on cylinder head

601 58900 1000

Screwdriver with tommy handle for hex. socket screws 6 mm, 440 mm long

116589030700

Torque wrench single-arm, emitting signal, with plug-in ratchet, l/2 square, 25-130 Nm

001 589 66 21 00

Ol.lo-405/l

EXIT
Note

To obtain a uniform and high screw pre-tensioning force, double hex. socket - necked-down - cylinder head screws are installed with a machined flange. They have a tapered-down shank and are mounted without washers.

Retightening of cylinder head screws during inspection at 1000-1500 km or in the event of repairs after 1000-l 500 km is no longer required.

The double hex. socket cylinder head screws are tightened to initial torque and angle of rotation torque (refer to Table). Since these cylinder head screws are subject to a lasting elongation after tightening, they must be renewed after the max. longitudinal dimensions named in Table shown below are exceeded.

Dimensions of cylinder head screws Thread dia. Lenghts when new (L) M 10 M 10 M 10 80 102 115 83.6 105.6 118.6 Max. length (L) (renew)

01.1 O-405/2

EXIT
Owing to the different lengths of cylinder head screws, attention must be paid to fit the bolts in the proper locations during assembly. Insert cylinder head screws according to the tightening diagram shown. MlOx80inbore3,5,11,13 M 10 x 102 In bore 2, 4, 6, 8, 10, 12, 14, 16, 18 M 10 x 115 in bore 1, 7, 9, 15, 17 M M 8 x 8 x 30 in bore a 80 in bore b

Tighten cylinder head screws to initial torque and angle of rotation torque. Estimate angle of rotation. For this purpose, place adjustable torque wrench in release position (locked) into plug-in ratchet. Position adjustable torque wrench with plug-in ratchet lengthwise in relation to engine and keep turning until it is transverse in relation to engine. Do not use torsion bar torque wrench for angle of rotation.

Tighten cylinder head screws in steps in sequence of tightening pattern shown. Do not release cylinder head screws after setting interval, but continue tightening.

After tightening according to tightening torque, a lo-minute setting interval must be maintained between the 2nd and the 3rd tightening step (refer to Table).

01.1 o-405/3

EXIT
01-415 Removal and installation of cylinder head

Timing at 2 mm valve lift Camshaft code number ) Intake valve opens after I-DC Exhaust valve opens before BDC

Engine

closes after BDC

closes before -l-DC

rox. 20 000 km

1) The camshaft code number is punched into flange of camshaft in range of TDC mark.

Tightening torques Screws for cylinder head cover initial torque 1st stage 2nd stage 10 min 3rd stage 4th stage

Nm 10 25 40

Double hex. socket cylinder head screws (with cold engine)

setting interval

angle of rotation torque

90 9o 25 45 80 1 O-20 10

Cylinder head screws M 8 (reference value) Screw for camshaft timing gear Chain tensioner Coupling nuts for injection lines (reference value) Hex. socket screws for intake manifold

Special tools Screwdriver element l/2 square, 140 mm long for double hex. socket screws M 10 on cylinder head

601 589 00 10 00

Screwdriver with tommy handle for hex. socket screws 6 mm, 440 mm long

116589030700

Impact puller for bearing bolts (basic unit)

116589203300

Ol.lO-415/l

EXIT
Threaded bolt for impact puller M 6, 50 mm long Threaded bolt for impact puller M 6, 150 mm long

116589013400

:W

116589023400

Contact handle for rotating engine (component of compression pressure recorder 001 589 46 21 00)

001 589 46 21 08

Torque wrench, double-arm, 3/8 square, 8-32 Nm

001 589 51 21 00

Torque wrench, single-arm, emitting signal, with plug-in ratchet l/2 square, 25-130 Nm Box end wrench element, open, 14 mm, l/4 drive for coupling nut of injection line

001 5896621 00

000589770300

Tester for cooling system and radiator cap

001 589 48 21 00

Radiator cap with hose for leak test

ip
605589002500

Conventional tool Socket wrench hexagon 7 mm on flexible shaft for hose clamps with worm drive e.g. Hazet, D-5630 Remscheid order no. 426-7

Note

Cylinder head should be removed with cooled down engine only. Remove together with exhaust manifold.

01.10415/2

EXIT
Removal

Set engine hood in vertical position. Completely drain coolant (20-010).

12

Drain plug on cylinder crankcase

Disconnect negative line on battery. Remove radiator (20-420). Completely remove air cleaner (09-410).

6 Slacken V-belt and remove. For this purpose, unscrew flange nut (378). insert a mandrel into spring tensioning lever (374) and relieve hex. screw (375) in relation to draw spring (380) until spring can be pushed back in direction of intake manifold. 7 Unscrew hex. screw (372) for fastening shock absorber.

8 On vehicles with level control, unscrew hex. socket screws (arrows), place pressure oil pump with connected lines aside. Remove driver.

Ol.lO-415/3

EXIT
3 Unscrew holder (62) for oil dipstick guide tube.

IO Disconnect coolant hoses (arrows) on coolant jutlet connection and pull cable from temperature witch.

t 1 Disengage bowden wire (230) for engine regula:ion. For this purpose, push out slotted guide piece 240) on angle lever and remove bowden wire,

12 Pinch fuel lines and unscrew at fuel filter :arrows).

N.lO-415/4

EXIT
13 Unscrew both fastening screws (116) and remove fuel filter.

14 On engines with EGR, remove pipe line (1) between EGR valve and exhaust manifold. 15 Unscrew exhaust flange from exhaust manifold.

16 Remove injection lines. 17 Remove intake manifold. 18 Remove cylinder head cover.

19 Pull off lock (91) for heater feed line (by means of a hook [Ol]. 20 Unscrew pipe elbow (93) on oil filter and pull from connection (89).

Ol.lO-415/5

EXIT
21 Unscrew electric lines on pencil element glow plugs. 22 Set engine to ignition TDC of 1st cylinder. Attention! Do not rotate engine at fastening screw of camshaft timing gear. Do not rotate engine in reverse.

23 Completely remove chain tensioner (224) (05-310).

24 Mark camshaft timing gear and timing chain in relation to each other.

25 Remove camshaft (05-220). For this purpose, unscrew fastening screw of camshaft timing gear. Apply counterhold to camshaft timing gear by mear 1S of a screwdriver or steel bolt Remove camshaft timing gear and lower timing chai n into chain box. Note: Uniformly loosen all camshaft bearing caps.

Ol.lO-415/6

EXIT
26 Knock out slide rail bolts (221 and 222) with impact puller and remove guide rail.

27 Unscrew both cylinder head screws M 8 (arrows) with screwdriver.

28 Loosen cylinder head screws in vice versa sequence of tightening diagram by means of screwdriver and unscrew.

EXIT
Installation

31

Mount new cylinder head gasket.

32 Mount cylinder head. Pay attention to clamping sleeve for locating cylinder head.

33 Measure length (L) of cylinder head screws. If the dimension named in Table is exceeded, use new cylinder head screws (01-405).

Thread dia.

Length (L) when new 80 102 115

Max. length (L)

M 10 M 10 M 10

83.6 105.6 118.6

34 Lubricate cylinder head screws on threads and on head contact surface and insert. 35 Tighten cylinder head screws in steps in sequence of tightening diagram, starting with screw 1.

Attention! Tighten cylinder head screws to initial torque and angle of rotation torque (01-405). Estimate angle of rotation. For this purpose, place adjustable torque wrench in release position (locked) into plug-in ratchet. Position adjustable torque wrench with plug-in ratchet lengthwise in relation to engine and keep turning until it is transverse in relation to engine.

Ol.lO-415/8

EXIT
Do not use torsion bar torque wrench. Tightening torques and angle of rotation torque of cylinder head screws 1st stage 2nd stage Setting interval 3rd stage 4th stage 25 Nm 40 Nm 10 min 90 9o

36 Tighten screws M 8 (arrows) by means of screwdriver with tommy handle.

lol- 25519

38 Install camshaft, while paying attention to color mark. Note: The camshaft timing gear is centered by means of a cylindrical pin (arrows).

Ol.lO-415/g

EXIT
39
Position fastening screw of camshaft timing gear and tighten to 45 Nm. For this purpose, apply counterhold to camshaft timi ng gear with a screwdriver or steel pin.

40

Install chain tensioner and tighten to 80 Nm.

41 Rotate engine and set to ignition TDC of 1st cylilnder. Check adjusting marks. The notch in flange of camshaft must be in alignment witt1 (cast-on) lug on cylinder head (arrow).

42

Mount electric lines for pencil element glow

plugIS. 43 Mount pipe elbow (93) with new O-ring.

44 Install intake manifold. 45 Install injection lines.

Ol.lO-415/10

EXIT
46 Screw exhaust system to exhaust manifold. 47 On vehicles with EGR, install pipe line (1) between EGR valve and exhaust manifold.

48 Install fuel filter and fuel lines, 49 Screw on holder for oil dipstick guide tube. 50 On vehicles with level control, mount pressure oil pump and driver.

51 Mount tensioning device for V-belt. For this purpose, swivel spring tensioning lever (374) by means of a mandrel against force of draw spring (380) to the left until screw (375) can be pushed through spring tensioning lever. Position collar nut and tighten.

52 Mount cylinder head cover. 53 Engage bowden wire for engine regulation and adjust, if required (30-300). 54 Plug on cable for temperature switch.

Ol.lO-415/11

EXIT
55 For further installation proceed vice versa.

5 6 Fill in coolant (20-010) and pressure-test cooling system. 57 Run engine and check for leaks.

Note: Retightening of cylinder head screws is not required.

Ol.lO-415/12

EXIT
01-417 Removal and installation of prechambers

hechamber standout on cylinder head dimension c 7.6-8.1 mm

Tightening torques Coupling nuts of injection lines (reference value) Screws for cylinder head cover Prechamber in cylinder head (threaded ring) Nozzle holder in prechamber

Nm 1 O-20 10 100 + 10 70 + 10

Special tools Box end wrench element, open, 14 mm, l/4 drive, for coupling nut of injection line

, tloo4.10520n ?IF

000589770300

Wrench element for threaded ring of prechamber

11004-6360

615 589 00 07 00

Socket wrench element 27 mm, l/2 square

-wU

001 589 65 09 00

Impact puller for prechamber

601 589 06 33 00

01.10417/1

EXIT
Note

The prechamber is identified at upper flange with code number 601/07.

6 burner bores of different diameter are located on prechamber lower half (burner neck) at different levels and angle positions. The firing duct (HI has a diameter of 7 mm and the burner neck (J) of 14 mm.

7.0 mm dia. H Firing duct 14.0 mm dia. J Burner neck K Burner bore 1.5 mm dia. 2.0 mm dia. L Burner bore 3.2 mm dia. M Burner bore 3.0 mm dia. N Burner bore 0 Bore for glow plug 10.0 mm dia.

In addition, the prechamber floor is designed as a spherical depression. This spherical shape provides uniform wall thicknesses in range of burner bores.

Ol.lO-417/2

EXIT
Removal

1 Unscrew injection lines from injection nozzles and loosen holder for injection lines on intake manifold. 2 Pull fuel return flow hoses from injection nozzles.

3 Unscrew holder for bowden wire of engine regulation and put aside.

4 Unscrew nozzle holder complete with socket wrench element (27 mm).

5 Remove pencil element glow plugs.

Cylinder crankcase Cylinder head gasket Pencil element glow plug 110 Prechamber 112 Threaded ring 113 Nozzle reed 114 Nozzle holder

5: 102

6 Unscrew threaded ring (112) with pin wrench. For this purpose, screw threaded member (03) into threaded ring, place sleeve (02) into grooves of threaded ring (arrows) and tighten with nut (01).

03 Threaded member Ol.lO-417/3

EXIT
Sleeve (02) should be tight enough in grooves, so that it will not slip out of grooves when loosening threaded ring. Insert wrench at hexagon of sleeve (02) and unscrew threaded ring.

01 Nut 02 Sleeve

7 Pull out prechamber with impact puller, part no. 601 589 06 33 00.

8 Cover bore in cylinder head.

Installation

Note: If the removed prechambers are again installed, check for perfect condition. Ball pin should not be burnt or covered with scale. In addition, if the burner tops are showing burn marks or cracks are showing in prechamber lower half, remove intake manifold and check inside for traces of oil. If oil moistened spots are found, check vacuum pump for damage or renew vacuum control unit on injection pump. The vacuum lines (blackened by oil) are showing which of the two parts of the unit has failed.

Ol.lO-417/4

EXIT
If a cylinder head is faced at parting surface, the required distance (c) of 7.6-8.1 mm must be maintained. For this purpose, select appropriate sealing ring and insert between cylinder head and prechamber. The following sealing rings are available: Thickness Part no.

9 Position prechamber in such a manner that the lug is pointing toward recess in cylinder head (arrows).

10 Lubricate threaded ring (112 in Fig. item 5) and tighten with pin wrench to specified tightening torque (90-l 10 Nm).

Ol.lO-417/5

EXIT
11 Screw in glow plugs (102) and connect.

12 Insert new nozzle reed (113). 13 Completely screw in nozzle holder (114) and tighten to 70-80 Nm. 14 Plug fuel return hoses on injection lines.

15 Mount injection lines. 16 Screw on holder for bowden wire of engine regulation and adjust bowden wire, if required (30-300).

70 71 102 110 112

Cylinder crankcase Cylinder head gasket Pencil element glow plug Prechamber Threaded ring 113 Nozzle feed 1 14 Nozzle holder

Ol.lO-417/6

EXIT
01-418 Facing cylinder head parting surface

Data Total height of cylinder head Minimum height after machining in longitudinal direction Permissible unevenness of parting surfaces in transverse direction Permissible deviation in parallel of upper parting surface in relation to lower surface in longitudinal direction Roughness Test pressure with air under water in bar gauge pressure Minimum distance a with new valves and new valve seats intake exhaust +0.17 to -0.23 +O. 12 to -0.28 0.0 0.08 142-144

0.1

0.016 2

Max. distance a (depth) on new valves and machined valve seats intake 1.0 exhaust

Facing

Face cylinder head parting surface.

2 Refinish valve seats until minimum distance a has been attained. 3 Check timing (05-215).

Ol.lO-418/l

EXIT
01-420 Pressure-testing cylinder head

Data Test pressure with air under water in bar gauge pressure 2

Special tools

Pressure plate

Suspension device

115589346300

Conventional tool Electrically heated water basin e.g. Otto Durr, D-71 23 Sachsenheim-Ochsenbach

Pressure-testing

Pressure-test cylinder head if cracks (coolant losses) are suspected. 1 Screw pressure plate on cleaned cylinder head.

2 Close bores and connections. 3 Connect compressed air hose (1) and regulate compressed air to 2 bar gauge pressure.
10 1-27240 $

01.1 O-420/1

EXIT
4 Fasten cylinder head on suspension device and immerse into heated water basin (80 Cl. 5 When air bubbles are rising, find leaking spot.

01.1 O-420/2

EXIT
Crankshaft assembly 03

EXIT
03 Crankshaft assembly

Job No. Crankshafts, connecting rods and pistons

...... ............. Removal and installation of pistons ................... Checking and reconditioning of crankshaft ............... Mounting of crankshaft ........................... Replacing front crankshaft radial sealing ring ............. Replacing rear crankshaft radial sealing ring .............. Removal and installation of radial ball bearing in crankshaft ... Removal and installation of crankshaft pulley at hub ........ Checking and correcting adjustment of TDC transmitter ...... Removal and installation of crankshaft timing gear. .........
Checking, renewing and tightening connecting rod bolts Reconditioning and squaring connecting rods Flywheel of driven plate and ring gear Removal and installation of flywheel and driven plate Refinishing of flywheel

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

03-310 313 316 318 320 324 327 330

. .

341 345 350

.............................. .................................................. Renewing ring gear of flywheel .............................................

410 420 430

03/l

EXIT
03-3 10 Checking, renewing and tightening connecting rod bolts

Dimensions of connecting rod bolt Part no. Thread dia. Necked-down shank dia. c when new (Fig. item 1) 7.4-o. 1 Minimum neckeddown shank dia. c 7.1

601 038 01 71

M9xl

Tightening connecting rod bolt Initial torque Angle of rotation torque 30+5Nm 90-l 00

Checking

+
I I

L-I

1 Measure minimum necked-down shank dia. prior to re-use. Note: If the minimum necked-down shank dia. of 7.1 mm is attained or less, renew connecting rod bolt.

Tightening

Lubricate threads and screw head contact area.

3 Tighten connecting rod bolt to 30 Nm initial torque and 90-100angle of rotation torque.

03.1 o-310/1

EXIT
Note: Estimate angle of rotation. For this purpose, place adjustable torque wrench in release position (locked) into plug-in ratchet. Position adjustable torque wrench with plug-in ratchet lengthwise in relation to engine and keep turning until it is transverse in relation to engine.

03.1 O-31012

EXIT
03-313 Reconditioning and squaring connecting rods

Data 148.97 149.03 144.97 145.03 Width of connecting rod (B) at connecting rod bearing bore and connecting rod bushing bore 23.835 24.165 5 1.600 51.619 29.500 29.521 Basic bore for connecting rod bushing repair stage

engine 601.911 Center of connecting rod bearing bore to center of connecting rod bushing bore engine 60 1.92 1

Basic bore for connecting rod bearing shells

standard dimension

standard dimension Connecting rod bushing OD repair stage

29.560 29.600

Connecting rod bushing ID

27.018 27.024

Roughness of connecting rod bushing, inside Permissible offset of connecting rod bearing bore in relation to connecting rod bushing bore with reference to 100 mm length Permissible deviation of parallel axle alignment: Connecting rod bearing bore in relation to connecting rod bushing bore with reference to 100 mm length Permissible difference in weight of complete connecting rods within one engine

0.004

0.1

0.045

59

Tightening torque initial torque Connecting rod bolts angle of rotation 90-l 00 30+5Nm

03.10-313/l

EXIT
Special tool Torque wrench, single-arm, emitting signal, with plug-in ratchet, l/2square, 25-130 Nm 001 589 66 21 00

Conventional tool Connecting rod straightener e.g. Hahn & Kolb, D-7000 Stuttgart model BC 503

Note

End play of connecting rods is not limited at crankshaft journals, but at piston pin eyes (piston-guided connecting rods). For this purpose, thrust surfaces (arrow) are cast onto piston pin eyes.

33-11458/Z

Connecting rod bearing and connecting rod bushing bores (B) are of similar width. A weight compensation is attached at left and right on connecting rod bearing cap. Only connecting rods of similar weight may be installed in one engine.

-168

!-6--j x)33-

11423

03.1 O-313/2

EXIT
Connecting rods, which have become overheated as a result of bearing damage (blue coloring), may no longer be used. Connecting rod and connecting rod bearing cap are marked together. There should be no transverse score marks and notches on connecting rod shaft. As a spare part, connecting rods with machined connecting rod bushing are available.

Reconditioning

1 Check connecting rod screws and renew, if required (03-310). 2 Mount connecting rod bearing caps. For this purpose, lubricate threads and screw head contact surface and tighten to 30 + 5 Nm.

3 Measure connecting rod bearing basic bore. At a basic bore which exceeds the value of 51.619 mm or is conical, touch up bearing cap at its contact surface on a surface plate up to max. 0.02 mm.

4 Press in new connecting rod bushing in such a manner that the oil bores are in alignment (arrow). Pressing-in pressure 2450 N. 5 Machine or ream connecting rod bushing. 6 Touch up lateral thrust surfaces of connecting rod on surface plate.

03.10-31313

EXIT
Squaring

7 Square connecting rod with a connecting rod tester. 8 Align connecting rod bearing bore in relation to connecting rod bushing bore (parallel alignment).

9 Check offset of connecting rod bearing bore in relation to connecting rod bushing bore and correct, if required.

03.1 O-31314

EXIT
03-316 Removal and installation of pistons

Association piston - cylinder

86.970-86.976 above 86.975-86.983 above 86.982-86.988

87 .OOO-87.006 above 87.006-87.012 above 87.012-87.018

Piston standout Distance between piston crown and cylinder crankcase parting surface standout max. 0.96 standout min. 0.73

Test values Piston clearance Difference in weight of pistons in one engine Piston pin dia. in connecting rod bushing Piston pin clearance in piston Connecting rod in piston (end play) groove 1 groove 2 groove 3 groove 1 groove 2 groove 3

when new 0.017-0.043 6g 26.995-27.000 0.018-0.029 0.004-0.015 0.083-0.314 0.20-0.40 0.20-0.40 0.20-0.40 0.090-O. 120 0.050-0.080 0.030-0.065

wear limit 0.12 109

Gap clearance of piston rings

1.5 1.0 1.0 0.20 0.15 0.1

Side clearance of piston rings

Tightening torque initial torque Connecting rod screws angle of rotation torque 90-l 00 30+5Nm

03.10-316/l

EXIT
Special tools

Spreaders for piston rings

000 589 51 37 00

Note

The group code letter A, X or B, the piston code number 05 or 06 and the driving direction arrow are punched into piston crown. The group code letter is also punched into cylinder crankcase parting surface.

For repairs, only pistons with group code letters X are available, These pistons are also for installation in cylinder bores with group code letters A or B . In the event of repairs, hone cylinder bores according to dimensions of available pistons X plus piston clearance.

Engine 601.911

Engine 601.921 03.1 O-31 6/2

EXIT
Removal

1 Remove connecting rod with piston in upward direction.

103-26983

Remove piston pin circlip and push out piston pin.

Recondition connecting rod and square (03-313).

Installation

4 Place piston on connecting rod in such a manner that arrow (1) points in driving direction and locking grooves (2) in connecting rod to lefthand engine side. Attention! Do not heat pistons.

03.1 O-31 6/3

EXIT
5 Push in piston pins provided with engine oil manually.

Insert piston pin circlip into groove.

Check piston rings for easy operation. When installing used pistons, check piston rings for gap and side clearance. 7 Lubricate cleaned cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons.

8 Distribute gaps of piston rings uniformly along piston circumference. 9 Mount piston ring clamping strap and introduce pistons. Arrow in piston crown should point in driving direction.

10 Mount connecting rod bearing caps with code numbers (arrow) in relation to each other on connecting rod. Lubricate threads and screw head contact surface of connecting rod screws and tighten to 30 Nm and 90-100angle of rotation torque. 11 Rotate crankshaft and check clearance between connecting rod and crankshaft. 12 Measure distance between piston crown and cylinder crankcase parting surface in TDC position of pistons (refer to Table).

03.10-316/4

EXIT
03-318 Checking and reconditioning of crankshaft

Data
I

Crankshaft normal dimension and repair stages

Crankshaft bearing journal dia.

Fitted bearing Associated thickness of thrust washers

Width of journal

Crankpin dia.

Crankpin width

27.96
Standard dimension

57.965
2.20

26.62 26.60

47.965

28.04

1st repair stage

57.700 -__---57.715 2.25 57.450 -.-=--57.465 57.200 -.=---57.215

26.72 26.70 or 26.92 2.35 26.90 or 2.40 27.02 27.00 47.200 47.215 up to 28.30

2nd repair stage

or

3rd repair stage

or

56.950
4th repair stage ~ 56.965

46.950
46.965 0.005 0.01 0.02 0.02 2.5 to 3.0 3.0 to 3.5

Permissible deviation of crankshaft journals and crankpins from true Permissible conicity of crankshaft journals and crankpins Permissible deviation of flywheel flange from true Permissible axial runout of fitted bearing on crankshaft bearing journals Fillets on crankpins Permissible deviation of crankshaft bearing journals from true when mounted in outer crankshaft bearing journals Scleroscope hardness of crankshaft journals and crankpins Permissible unbalance of crankshaft journal II, IV journal I I I

0.07 0.10 55-74 15cmg

Special tool Impact hardness tester 000 589 20 21 00

03.10-318/l

EXIT
Note

When testing and reconditioning crankshafts, proceed in sequence of diagram shown below.

Diagram

* Refer to section Explanations concerning diagram. V = scrap.

03.1 O-3 18/2

EXIT
Visual checkup Heavy damage? yes V

no

Crack test* Cracks showing?

yes -.

no

Hardness test* All bearing journals scleroscope hardness min. 60 on 2/3 of journal circumference

no

Measure pin (journal) Dimensions in order? = noI

yes
Lapping

Check whether regrinding is still possible within last specified repair stage 4

no no yes Hardening+

V V

Dimensional checkup Dimensions in order?

no

yes
Crankshaft, complete, balance, if possible

L yes
I I
Crankshaft, straighten Crankshaft, grind

Journal or pin with hardened fillets

Journal or pin without hardened fillets

I
Induction or flame hardening

Induction hardening facilities available?

I
no

I
yes

Crack test Cracks showing?

yes _..---- V

I nduction hardening

Check hardness by etching*

no

Relieve crankshaft at 80 C/176 OF for 2 hours

Refer to lapping Refer to crankshaft, straighten

03.10-318/3

EXIT
Explanations concerning diagram

Crack test

Clean crankshaft. Bearing journals should be free of oil and grease. Magnetize crankshaft and apply fluorescent powder (fluxing). A color penetration method may also be used (immersion in bath or using spray can). Agent: Paint or fluorescent powder, cleaning agent, developer

Hardness test

Test hardness with impact hardness tester (scleroscope hardness). Minimum hardness of 55 should be available on 2/3 of journal (pin) circumference.

Hardening

Pins without hardened fillets can be inductancehardened or flame-hardened. On the other hand, journals and pins with hardened fillets (arrows) should be inductance-hardened on principle. If this cannot be done, scrap crankshaft. When hardening journals and pins without hardened fillets, the distance A between hardened runout and fillets radius (5-6 mm) must be maintained.

L-Ic
-

03.10-318/4

EXIT
Checking the hardening results

For perfect hardening, check adjustment of hardening equipment by means of metallographic etching (grinding). These tests can be made with test hardenings on scrapped crankshafts.

Check hardening by etching surface of journals or pins with a 2 % solution of alcoholic nitric acid

WN03L
No dark spots should appear on journal or pin surface. Unhardened fillets will become dark.

Hardened fillets, on the other hand, should be as bright as the surface of pin or journal. A journal or pin which has already passed metallographic inspection may be used for comparison. Then carefully wash off nitric acid with alcohol.

Protection against corrosion

Crankshafts which are not immediately installed again should be lubricated with engine initial operation oil (SAE 30).

03.10-318/5

EXIT
03-320 Mounting of crankshaft

Data Crankpin width

27.96 28.04

1st repair stage

2nd repair stage up to 28.30 3rd repair stage

4th repair stage

Basic bore and bearing play

Crankshaft bearings 62.500 62.519

Connecting rod bearings 51.600 51.619

Basic bore dia.

Basic bore width on fitted bearing

22.00 21.97 23.835 24.165

Connecting rod width

Permissible out-of-true of basic bore Permissible conicity of basic bore when new Bearing play, radial wear limit when new Bearing play, axial wear limit
1 1 For radial clearance, try for mean value.

0.01 0.01 0.03 l-0.073 0.08 0.10-0.25 0.30 0.12-O-26 0.50

l)

03.10-320/l

EXIT
Bearing shells Wall thickness crankshaft bearings 2.25 2.37 2.50 2.62 2.75 Width of bearing shells 17.30-17.60 Thickness of fitted bearing thrust washers 2.15 or 2.20 2.25 or 2.35 or 2.40 Wall thickness connecting rod bearings 1.80 1.92 2.05 2.17 2.30

Normal dimension 1st repair stage 2nd repair stage 3rd repair stage 4th repair stage

Tightening torques Crankshaft bearing bolts initial torque Connecting rod screws angle of rotation torque Screw M 18 x 1.5 x 50 on crankshaft Initial torque angle of rotation torque

Nm 90 30 + 5 go-loo0 370 + 40 30-40 90-l 00

Necked-down screws for flywheel or driven plate

Special tools

Torque wrench, singe-arm, with ratchet, 3/4 square, 150-800 Nm

001 5897421

00

Torque wrench, single-arm, emitting signal, with plug-in ratchet, l/Z square, 25-130 Nm

001 589 66 21 00

Puller for crankshaft timing gear

601 589 07 33 00

Detent

601 589 02 40 00

Countersupport for internal puller

000589333300

Internal puller 14.5-18.5 mm for radial ball bearings Dial gauge holder for measuring end play

000589253300

363589022100

03.1 O-320/2

EXIT
Note

Engine removed and disassembled. Main oil duct in cylinder crankcase open (01-130). Oil ducts in cylinder crankcase and in crankshaft carefully cleaned. Check crankshaft for cracks, dimensional accuracy hardness and concentricity (93-318).

The 3rd crankshaft bearing is provided with thrust washers. These thrust washers absorb the axial forces of crankshaft.

The thrust washers (148 and 148a) installed in cylinder crankcase and in bearing cap on both sides are of different shape. As a torsion lock and to prevent assembly faults, the thrust washers in bearing cap are provided with two holding lugs, of which the outer one is installed off center. When reconditioning crankshafts, regrind width of fitted bearing journals to one of the dimensions shown in Table (section Data). Associate thrust washers to respective journal or pin widths (Table).

2 Bearing cap 4 ScrewsM 1 2 x 6 0 145 Crankshaft 146 Bearing shell 148 Urmer thrust washer 148a Lbwer thrust washer
03.1 O-320/3

EXIT
Install thrust washers of the same thickness on both sides on principle. Regrinding of thrust washers is not permitted. As replacement parts, thrust washers are available in sets only. One set comprises an upper and a lower thrust washer (148 and 148a).

Thrust washer sets Thickness in mm Set part no. 601 030 00 62 601 030 01 62 601 0300262 6010300362 601 030 04 62

2.15 2.20 2.25 2.35 2.40

Association of crankshaft bearings, installation of crankshaft

Install crankshaft bearing cap.

Note: All bearing caps are fitted laterally into crankcase (arrows) and are fastened with 2 screws M 12 x 60 each. The pilot fit (arrows) is offset from center by 0.5 mm, so that the bearing caps can be mounted in one position only.
1033-11466

03.1 O-320/4

EXIT
2 Lubricate screws for crankshaft bearing caps and tighten to 90 Nm. 3 Measure basic bore in direction A, B and C on two

levels (conicity).
If the specified value of a basic bore is exceeded, touch up bearing cap at its parting surface on a surface plate up to max. 0.02 mm.

4 Insert crankshaft bearing shells, mount bearing caps, tighten screws to 90 Nm.

Housings

Caps

03.1 O-320/5

EXIT
5 Measure bearing dia. and write down.

6 Measure crankshaft bearing journals, find crankshaft bearing radial play. Note: The bearing play can be corrected by exchanging bearing shells, while trying for mean value of specified bearing play. Crankshaft bearing shells without color code are thicker than those with blue color code, while taking into account that the thickness of walls without and with color code may overlap.

7 Measure width of fitted bearing journal and associate pertinent thrust washers (refer to Table, section Data).

8 Lubricate bearing shells and crankshaft with engine

oil and install crankshaft.

03.1 O-320/6

EXIT
9 Provide thrust washers with oil and slip into grooves on fitted bearing (crankcase). Attention! Make sure that the two oil grooves (arrows) in thrust washers are pointing toward crankshaft webs.

10 Mount crankshaft bearing caps. 11 Tighten bearing caps to 90 Nm.

12 Measure crankshaft end play. 13 Rotate crankshaft manually and check for easy running.

03.1 O-320/7

EXIT
Association of connecting rod bearing and installation of connecting rod

14 Check connecting rod screws (03-310). 15 Recondition connecting rod and square (03-313).

16 Mount connecting rod bearing caps, while paying attention to identification_ Lubricate connecting rod screws on threads and screw head contact surface and tighten to 30-40 Nm. 17 Measure basic bore in two directions. If one basic bore exceeds the specified value or if it is conical, touch up bearing cap at its parting surface on a surface plate up to 0.02 mm.

18 Insert connecting rod bearing shells, mount connecting rod bearing caps together with bearing shells and tighten connecting rod nuts to 30-35 Nm.

103 - 26742

19

Measure bearing dia. and write down.

20 Measure crankpins, find connecting rod bearing radial play. Note: The bearing play can be corrected by changing bearing shells, trying for medium value of specified bearing play. Crankshaft bearing shells without color coding are thicker than those with blue color coding, while taking into account that the thickness of wails without and with color coding may overlap.

03.1 O-320/8

EXIT
21 Attach piston to connecting rod (03-316).

22 Provide bearing shells, crankshaft, pistons and cylinder walls with engine oil, install connecting rod with piston (03-316). Pay attention to identification.

03-26983

23 Tighten connecting rod screws to 30 + 5 Nm initial torque and 90-100angle of rotation torque.

24 Measure connecting rod bearing end play, while displacing connecting rod directly at piston pin. Check clearance of connecting rods in relation to crankshaft. Attention! Disassemble oil pump and clean, renew, if required. Renew oil pressure relief valve. Disassemble oil filter and clean. Install initial operation oil filter element. Change engine oil and oil filter element after 1000-1500 km

03.10-320/g

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

EXIT

03-324

Replacing front crankshaft radial sealing ring

Tightening torques Screw M 18 x 1.5 x 50 on crankshaft Screws M 8 x 12 pulley to hub

Nm 370 + 40 25

Special tools Torque wrench, single-arm, with ratchet, 3/4 square, 150-800 Nm 001 5897421 00

t,
Puller for hub

: I
P

601 589 08 33 00

Detent

601589024000

Sleeve for pushing in radial sealing ring, front

601 589031400

Conventional tool Adapter 3/4 square socket to l/2 square head e.g. Hazet, D-5630 Remscheid order no. 1058 R-l

Removal

1 Remove noise capsule. 2 Remove radiator (20-420).

03.10-324/l

EXIT
3 Slacken V-belt and remove. Unscrew flange nut (378) for this purpose. Insert a mandrel into spring tensioning lever (374) and relieve hex. screw (375) in relation to draw spring (380) until spring can be pushed back in direction of intake manifold. Release spring tensioning lever and remove V-belt.

4 Unscrew pulley (161) and pull off flange (157) (03-341).

28 Timing housing cover Radial sealing ring 31 145 Crankshaft 155 W o o d r u f f k e y , hub 155a Woodruff key, sprocket Sprocket 156 Hub 157 Cylindrical pin 158

159 Cup spring 160 Screw M 18x1.5x50 Pulley 161 162 Combination screwM8x 12

5 Push out radial sealing ring by means of a screwdriver. Make sure that crankshaft journal and mounting bore are not damaged. 6 Check hub (157) for score marks of radial sealing ring, renew hub, if required.

Installation

7 Deburr mounting bore for radial sealing ring and clean. 8 Moisten new radial sealing ring on sealing lip with oil and insert with inserting tool. Attention! The radial sealing ring should be accurately square in relation to crankshaft journal, since otherwise no perfect sealing will be obtained.

03.10-324/2

EXIT
9 Install hub and pulley (03-341). 10 Mount V-belt and engage spring tensioning lever. For this purpose, swivel spring tensioning lever (374) with a mandrel against draw spring to the left until screw (375) can be slipped through spring tensioning lever. Position collar nut and tighten.

11 Install radiator (20-420). 12 Install noise capsule.

03.1 O-32413

EXIT
03-327 Replacing rear crankshaft radial sealing ring

Tightening torques initial torque angle of rotation torque

Nm 30+ 10 90-l 00

Necked-down screw for flywheel or driven plate

Special tools Detent 601589024000

Installation tool for rear crankshaft radial sealing ring

601589034300

Note
The radial sealing ring (22) is seated in an end cover screwed to cylinder crankcase and oil pan and located by means of 2 clamping sleeves ( 17).

The sealing lip of repair radial sealing ring is offset by 3 mm in inward direction, so that it cannot run in a groove which may have been generated by seriesradial sealing ring on crankshaft flange.

A Radial sealing ring (series) B Repair radial sealing ring

10X- 9402

03.10-327/l

EXIT
Renewing

1 2

Remove transmission (26-020 or 27-600). Remove flywheel or driven plate (03-410).

3 Push radial sealing ring out of end cover by means of a screwdriver. Make sure that the crankshaft flange and the end cover are not damaged. Cover crankshaft flange with a rag.

4 Check running surface for radial sealing ring on crankshaft flange for damage. 5 Clean mounting bore for radial sealing ring and deburr, if required. 6 Screw inner part of installation tool to crankshaft flange.

7 Fill new radial sealing ring between sealing and dust lip with 1 g or 1 cc longterm grease. Do not fill in more oil, since otherwise the presence of leaks might be simulated. 8 Slip radial sealing ring (arrow) over inner part of installation tool.

03.10-327/2

EXIT
9 Push radial sealing ring up to stop into end cover by means of outer part of installation tool. Attention! Radial sealing ring should be seated accurately square in end cover for perfect sealing.

10 11 12

install flywheel or driven plate (03-410). Check for leaks with engine running. install transmission (26-020 or 27-600).

03.10-32713

EXIT
03-330 Removal and installation of radial ball bearing in crankshaft

Special tools

Countersupport for internal puller

000589333300

Internal puller 14.5-18.5 mm

000589253300

Removal

Remove transmission (26-020 or 27-600).

2 Pull ball bearing out of crankshaft together with countersupport and internal puller.

Installation

3 Coat new ball bearing with glue Loctite 241, part no. 002 989 94 71 and knock into crankshaft on outer race by means of a suitable mandrel. 4 Install transmission (26-020 or 27-600).

03.10-330/l

EXIT
03-341 Removal and installation of crankshaft pulley and hub

Tightening torques Screw M 18 x 1.5 x 50 to crankshaft Screws M 8 x 12 crankshaft pulley to hub

Nm 370 + 40 25

Special tools

Torque wrench, single-arm, with ratchet, 3/4 square, 150-800 Nm

001 5897421 00

Detent

601 589 02 40 00

Puller for hub

601589083300

Conventional tool Adapter 314 square socket to l/2 square head e.g. Hazet, D-5630 Remscheid order no. 1058 R-l

Note

Engines 601 have no vibration damper and no balancing disk.

28 31 145 155 155a 156 157

Timing housing cover Radial sealing ring Crankshaft Woodruff key for hub Woodruff key for sprocket Sprocket Hub

158 Cylindrical pin 159 Cup spring 160 Screw M18x1.5~50 161 Crankshaft pulley 162 Combination screwM8x 12

03.10-341 /l

EXIT
Removal

Remove noise capsule below.

2 Remove radiator (20-420). 3 Slacken V-belt and remove. For this purpose, unscrew collar nut (378). Insert a mandrel into spring tensioning lever (374) and releave hex. screw (375) opposite to draw spring (380) until spring can be pushed back in direction of intake manifold. Release spring tensioning lever and remove V-belt.

4 Remove crankshaft pulley.

5 Unscrew screw ( 160) on crankshaft. For this purpose, fasten detent, part no. 601 589 02 40 00, t o oil pan.

EXIT
6 Pull hub (157) from crankshaft journal. Pull off hard-to-move hubs with puller.

31 26 15515615Sa 145

Installation
161 158 157 160 159 162

7 Slip hub (157) on crankshaft journal and tighten screw ( 160) to 370 + 40 Nm. Make sure that woodruff key alignment.

(155) and groove are in

Note: Install the three cup springs (159) with crown toward screw head.

8 Mount V-belt pulley, while paying attention to centering by means of cylindrical pin (158). 9 Mount V-belt and engage spring tensioning lever. For this purpose, swivel spring tensioning lever (374) with a mandrel against draw spring to the left until screw (375) can be slipped through spring tensioning lever. Position collar nut and tighten.

10 Install radiator (20-420). 11 Install noise capsule.

03.10-341/3

EXIT
03-345 Checking and correcting adjustment of TDC transmitter

Tightening torques Screws for cylinder head cover Coupling nuts for injection lines (reference value) Prechamber in cylinder head (threaded ring)

Nm 10 1 O-20 100 f 10

Special tools Box end wrench element, open, 14 mm, l/4 drive, for coupling nut of injection line

000 589 77 03 00

Wrench element for threaded ring of prechamber Socket wrench element 27 mm, l/2 square

615589000700

001 589 65 09 00

Impact puller for prechamber

601 589 06 33 00

Locating device for holder of TDC transmitter Measuring instrument for TDC and 20after TDC

601 589 06 21 00

601 589 07 21 00

Dial gauge holder

3635890221 00

Torque wrench, double-arm, 3/8 square, 8 - 3 2 Nm

001 589 51 21 00

Conventional tool e.g. Mahr, D-7300 Esslingen order no. 810

Dial gauge A 1 DIN 878

03.10-345/l

EXIT
Note

The TDC-transmitter with holder is fastened to timing housing cover (arrow).

The pin in crankshaft pulley must be accurately under TDC transmitter (arrow) in crankshaft position 20 after TDC.

Adjustment of adjusting slide must be checked and corrected, if required: a) When renewing adjusting slide. b) When renewing crankshaft with hub or crankshaft pulley. c) When completing partial engines. With cylinder head removed, the measuring pin of the dial gauge can be set directly on piston crown. For this purpose, place magnetic dial gauge holder on cylinder crankcase parting surface.

Checking

1 Remove radiator (20-420). 2 Remove cylinder head cover. 3 Set piston of 1st cylinder to ignition TDC of 1st cylinder.

03.10-345/2

EXIT
4 Remove prechamber of 1st cylinder (01-417). 5 Screw measuring instrument into prechamber duct. 6 Place dial gauge at 2 mm preload on test mandrel.

7 Slowly rotate crankshaft in direction of rotation of engine until large needle of dial gauge stops (TDC position).

8 Loosen dial gauge and place measuring arm under 5 mm preload into test mandrel. Turn dial gauge scale until large needle points to zero. 9 Slowly turn crankshaft in direction of rotation of engine until on engine 601.911 the dial gauge has moved back by 3.22 mm and on engine 601.921 by 3.65 mm.

10

Place locating device into adjusting slide.

Pin in crankshaft pulley must engage in groove of locating device. If pin is not engaging, correct position of adjusting slide.

03.10-34513

EXIT
Correcting

11 Loosen adjusting slide (42) on screw (41) and displace until pin in pulley engages in groove of locating device. 12 Screw down adjusting slide. 13 Remove dial gauge and measuring instrument.

14 Install prechamber (01-417). 15 Install valve cover. 16 Install radiator. 17 Run engine, check for leaks.

EXIT
03-350 Removal and installation of crankshaft timing gear

Tightening torques Screw M 18 x 1.5 x 50 to crankshaft Screws for cylinder head cover Screws M 8 x 12 for crankshaft pulley to hub Oil drain plug to oil pan M6 Oil pan to cylinder crankcase M8 Central screw for fan on coolant pump Adjusting screw for front engine stop Screws for engine carrier to engine mount Cylinder head bolts M 8 M6 Screws for timing housing cover M8

Nm 370 + 40 10 25 30 10 25 25 130 35+ 10 25 10 25

Special tools

Torque wrench, double-arm, l/4 square, 8-32 Nm

001 589 51 21 00

Torque wrench, single-arm, emitting signal, with plug-in ratchet, l/2 square, 40-200 Nm

001 589 67 21 00

Torque wrench, single-arm, with ratchet, 3/4 square, 150-800 Nm

0 0 1 5 8 9 7 4 2 10 0

Puller for hub

601 589 08 33 00

03.10-350/l

EXIT

Puller for crankshaft timing gear

601 589 07 33 00

Knocking-in mandrel for crankshaft timing gear

116589071500

Screwdriver with tommy handle for hex. socket screws 6 mm, 440 mm long

116589030700

Conventional tool Adapter 3/4 square socket to l/Zsquare head e.g. Hazet, D-5630 Remscheid order no. 1058 R-l

Layout crankshaft front

31 26 166156166a 145 I I

28 Timing housing cover Radial sealing ring 31 145 Crankshaft 155 Woodruff key, hub 155a Woodruff key, sprocket 156 Sprocket Hub 157 03.1 O-350/2

158 Cylindrical pin 159 Cup spring 160 Screw M 18x 1.5x50 161 Crankshaft pulley 162 Combination screw M8x12

EXIT
Removal

Remove timing housing cover (01-210). Pull off clamp (262) and torsion spring (261). Unscrew fastening screw (259) and remove oil pump sprocket (257). 4 Remove chain for oil pump drive.

6 Mark timing chain and calmshaft timing gear in relation to each other 7 Remove camshaft timing gear and let timing chain sag.

EXIT
Installation

10 Transfer color mark from old to new crankshaft timing gear.

11 Knock crankshaft timing gear with knocking-in mandrel on crankshaft. Pay attention to woodruff key.
Note: For better location when knocking in crankshaft timing gear, the front woodruff key for hub can be inserted.

12 Mount camshaft timing gear and timing chain, paying attention to marks. 13 Keep turning crankshaft and check adjusting marks at TDC position of engine (arrows).

14 Mount chain for oil pump drive together with oil pump sprocket. Note: Mount sprocket in such a manner that its crown is pointing toward oil pump and the three contact surfaces on the oil pump shaft coincide with those on the sprocket (arrows).

118 - 26004

15

Install clamp (262) and tensioning spring (261).

03.10-35014

EXIT
16 17 18 Install timing housing cover (01-210).
For further installation proceed vice versa.

Run engine and check for leaks.

03.1 o-350/5

EXIT
03-410 Removal and installation of flywheel and driven plate

Necked-down screw manual transmission Part no. Thread dia. D when new Necked-down dia. d min. dia. when new Length L max. length 22.5 26.5 22 F 0.2 8.1 26 + 0.2 1020320071 MlOxl 8.5-O-2 automatic transmission 601 03201 71

Tightening torque Initial torque Angle of rotation torque 30 + 10 Nm go- 100

Special tools 601 589 02 40 00

Detent

Torque wrench, single-arm, emitting signal, with plug-in ratchet, l/2 square, 25-l 30 Nm

001 589 66 21 00

Note

Weight and dimensions of flywheels of engines with manual transmission are similar. Flywheels and driven plates of engines with automatic transmissions are identical on all angines. Flywheels can be replaced without static or dynamic balancing.

Engine

601

D 254.5 mm Dl 223 mm H 57 m m 03.10410/1

EXIT
Fasten flywheel and driven plate to crankshaft in such a manner that the unused bores (arrow) on flywheel or on driven plate and spacing washer are in alignment with unused bore on crankshaft flange.

Vehicles with manual transmission

10%26320

Vehicles with automatic transmission

103-26665/2

Layout of flywheel for manual transmission 145 Crankshaft 150 Flywheel 151 Ring gear 152 Necked-down-screw 153 Ball bearing 154 Spacing ring .03.10410/2

1033-11671/l

EXIT

------15Oa

- 1 5 4 a

--

- 152 a __ 145

Layout of flywheel and driven plate for automatic transmission

145 Crankshaft 15Oa Driven plate 152a Necked-down screw 154a Spacing washer

Removal

Remove transmission (26-020 or 27-600).

Fasten detent (arrow)

to

oil pan below.

Flywheel manual transmission

103-26328

03.1 o-41 o/3

EXIT
Installation

4 Measure necked-down dia. of necked-down screws. If minimum dia. is attained, install new necked-down screws.

5 Position flywheel, driven plate and spacing washer on crankshaft journal in such a manner that the bores (arrow) are in alignment.

103-26665/2

6 Screw in necked-down screws and tighten to 30 Nm initial torque and 90-100 angle of rotation torque.

03.10-410/4

EXIT
03-420 Refinishing of flywheel

Data Engine Distance a when new Distance b during repairs Permissible deviation from axial runout on clutch surface or clutch flange-on surface up to 0.05 mm 601 22.4-22.6 16.6

Note

Flywheels for manual transmissions which are showing burnt spots, score marks or cracks on clutch surface, must be refinished by precision turning. If score marks or cracks are deeper than the max. permissible material allowance, replace flywheel.

If the clutch surface A is refinished, also refinish fastening surface B by the same dimension to maintain distance a. In the event of repairs, do not machine below dimension b. For refinishing, clamp flywheel well, so that the permissible axial runout of 0.05 mm is not exceeded. No cavities and chatter marks should be seen on clutch surface after refinishing.

03.10-420/l

EXIT
03-430 Renewing ring gear of flywheel

Data Axial runout on ring gear Centering flange dia. for ring gear Shrinking-on temperature Annealing color max. 0.4 275.00-275.05 220 c yellow

Conventional accessory Temperature measuring chalk color no. 2815/220 (white) Thermochrom e.g. AW Faber-Castell, D-8504 Stein bei Ntirnberg

Note

The ring gear is hardened. To protect hardness, the temperature for heating up ring gear should not C at any point. This can be done reliably exceed 220 only by means of a hot plate or a heating oven. An open flame may be used as an exception only. The flame should touch only the inside of the ring gear. Following renewal of ring gear, the flywheel need not be balanced.

Renewal

1 Drill into old ring gear and break up with a chisel, or heat quickly and immediately remove. 2 Clean mounting surface of ring gear on flywheel. 3 Uniformly heat new ring gear on a hot plate or in a heating oven. For this purpose, use temperature measuring chalk in accordance with instructions whenever possible. 4 Mount heated ring gear immediately on flywheel.

03.1 o-430/1

EXIT
Engine timing, valves 05

EXIT
05 Engine timing, valves

Job No. Camshaft and valves Checking and replacement of hydraulic valve clearance compensating elements Checking camshaft timing

... ...................................... Removal and installation of camshaft .............................. Removal and installation of valve springs ............................ Checking valve springs ........................................ Replacing valve stem seals ...................................... Checking and machining valves. ................................. Replacing valve seat rings ...................................... Machining valve seats .........................................

.......... 05-211 .......... 215 .......... 220 .......... 250 .......... 260 .......... 270 .......... 280 .......... 290 .......... 291

Timing chain, chain tensioner, tensioning and slide rails

........................ Replacing timing chain ...................................... Removal and installation of tensioning rail ........................ Removal and installation of slide rails ............................ A. Removal and installation of slide rail (220) in cylinder head ......... B. Removal and installation of guide rail (218) ....................
Removal and installation of chain tensioner Drive for hydraulic oil pump Removal and installation of drive for hydraulic oil pump.

. .

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

310 320 330 341

. .

.......

.......

.......

...........,.,..,...

.......

437

05/l

EXIT
05-211 Checking and replacement of hydraulic valve clearance compensating elements

Tightening torques Bolts for cylinder head cover Bolt for camshaft timing gear Bolts for camshaft bearing caps

Nm 10 45 25

Special tools

Torque wrench, double arm, 3/8 square, 8-32 Nm

001 589 51 21 00

Torque wrench with plug-in ratchet l/2 square, 25-l 30 Nm

001589662100

Measuring bridge for residual stroke

601 589 08 21 00

Vacuum lifter for valve tappet

601589053300

Note

Store valve tappet in upright position only (open

end up).

185 Install removed valve tappets again at the same spot. The basic position of valve tappets cannot be corrected . In the event of complaints about noise, perform the following test jobs: 203

185 Camshaft 203 Valve tappet 05.10-21 l/l

u 1053-11606

EXIT
Checking

Run engine for approx. 5 minutes at 3000/min.

2 Remove cylinder head cover. 3 Set cam of respective valve tappet on base circle (cam tip should point upwards).

4 Use a mandrel to push against valve tappet or try to move valve tappet manually. If, compared with others, the valve tappet drops quickly, or in the event of play in relation to base circle of cam, perform jobs item 6 and starting item 8. If a valve tappet has play, or if the sinking time is too short, check basic position (item 5-7).

5 Measure and write down dimension X (cylinder head parting surface to valve tappet). For this purpose, place measuring bridge over valve tappet about to be checked on cylinder head parting surface. Note: If required, measure dimension X on all valve tappets.

Remove fan and fan cover.

7 Remove camshaft (05-220). 8 Measure dimension Y (cylinder head parting surface to valve tappet). The difference between dimension X and Y is the initial stroke & installation position. Nominal value: Value when new 0.25-l .6 mm, value with used engine 0.25-2.5 mm.

05.10-21112

EXIT
9 If valve tappet sinks quickly or if the nominal dimension is not attained or exceeded, lift out valve tappet by means of vacuum lifter.

10 Measure dimension L on valve tappet and write down.

11

Measure dimension L 2 on valve tappet.

Dimension L I (difference between L and L 2) should be 18-19 mm.

12 If dimension L 1 is higher or lower, remove guide sleeve. For this purpose, pull guide sleeve (g) out of valve tappet (203) by means of rotary movements with pliers. Do not damage guide sleeve.

203 Valve tappet a Thrust pin with ball and cage Circlip b C Compression spring Guide sleeve 9 05.1 o-21 l/3

105-26706

EXIT
13 Pull thrust bolt (a) out of guide sleeve (g) and remove compression spring (c). 14 Blow out all components with compressed air.

Blow through valve tappet at oil feed bore (arrow).

15 Remove circlip (b) from guide sleeve (g), slightly rebend at edges (arrows) and mount again on guide sleeve.

16 Assemble guide sleeve (g), compression spring (c) and thrust pin (a) in correct sequence. 17 Fill thrust pin with engine oil. Press on ball valve with a suitable pin and vent work chamber by pumping movements of thrust pin, close ball valve and add oil, if required. Then, no more oil should flow out at ball valve under slight pressure. If oil flows out, renew complete valve tappet.

18 Fill valve tappet (203) with engine oil and install vented thrust pin with guide sleeve into valve tappet. Push guide sleeve into valve tappet until circlip engages. 19 Check dimension L l, refer to item 9 and 10.

05.10-211/4

EXIT
20 Check oil supply in cylinder head. For this purpose, unscrew closing plug of oil duct on cylinder head rear. Blow with compressed air into oil duct, while checking outlet bore on seat for valve tappet for passage.

21 Lubricate valve tappet and install, pay attention to sequence. 22 Install camshaft (05-220). 23 Install cylinder head cover. 24 Install fan and fan cover.

25 Run engine at 3000/min.

05.10-211/5

EXIT
05-215 Checking camshaft timing

Timing at 2 mm valve lift

Engine

601

11

17O

28

15O

1
with used timing chain (after approx. 20 000 km)

) The camshaft code number is stamped into collar adjacent to TDC notch.

Tightening torque Bolts for cylinder head cover

Nm 10

Special tools

Dial gauge holder

363 589 02 21 00

Box-end wrench element, open 14 mm, l/4 drive for coupling nut on injection line

( .
1,004.1051011 W

000589 77 0300

Conventional tool Dial gauge A 1 DIN 878 e. g_ Mahr, D-7300 Esslingen Order No. 810

05.1 o-21 5/l

EXIT
Note

During assembly jobs alignment of marks (arrows) in ignition TDC position of 1st cylinder is adequate. In special cases, e. g. in the event of complaints about output, perform the following checkup with regard to begin of opening at intake valve of 1st cylinder. Timing is measured at 2 mm tappet travel. Corrections are not possible at the moment.

Checking

Remove cylinder head cover.

2 Remove injection nozzles (07.1-230). 3 Turn crankshaft until cam tip of 2nd cam is pointing upwards. Attention! Do not rotate engine on screw of camshaft timing gear. Do not rotate engine in reverse while measuring, since this would result in considerable measuring faults. 4 Tighten dial gauge holder on cylinder head (above 1st cylinder intake valve). 5 Position dial gauge with extension and fasten in such a manner that the sensor pin is seated on valve tappet (arrow) under a preload of 3 mm (small needle of dial gauge).

Turn dial of dial gauge until large needle points to 0. Attention! Sensor pin of dial gauge should be seated accurately vertical on valve tappet.

05.10-215/2

EXIT
6 Continue turning crankshaft in direction of rotation of engine until small needle of dial gauge has moved back by 2 mm (valve lift) to 1 mm. In this position, the value on balancing disk should be the same as the specified value intake valve opens. 7 Install injection nozzles (07 l-230). 8 Install cylinder head cover.

05.10-215/3

EXIT
05-220 Removal and installation of camshaft

Timing at 2 mm valve lift Exhaust valve

rox. 20 000 km)

) The camshaft code number is stamped into collar adjacent to TDC notch.

Data Permissible runout of center bearing journal and of camshaft timing gear seat when mounting camshaft in outer bearing points Camshaft code number Camshaft timing gear seat 2nd bearing point 3rd bearing point when new Scleroscope hardness of cams limit value Diameter of camshaft bearing journals 30,944-30,950 05 0.020 0.030 0.025 64-75

Tightening torques Bolts for cylinder head cover Bolt for camshaft timing gear on camshaft Bolts for camshaft bearing caps

Nm 10 45 25

Special tools Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm 001 589 66 21 00

Torque wrench, double arm, 3/8 square, 8-32 Nm

001 589 51 21 00

Vacuum lifter for valve tappet

601 589 05 33 00

05.1 O-220/1

EXIT
Note

The camshaft is a chill casting and mounted in five bearings. The diameter (D) of all five bearing points is 31 .O mm. Groove (A) serves to locate the camshaft axially by means of a circlip inserted in cylinder head. A cyl. pin on collar (6) serves to locate the camshaft timing gear.

A Groove for axial locating B Stop for camshaft timing gear and mounting of cyl. pin 0 Bearing points

z=
z P

BA

I :

The code number is stamped into flange adjacent to TDC notch (arrow).

TDC mark (arrow) and code number

Removal

Remove cylinder head cover.

2 Set crankshaft to ignition TDC of 1st cylinder. Attention! Do not rotate engine on fastening screw of camshaft timing gear. Do not rotate engine in reverse. TDC mark on pulley
05.1 o-220/2

EXIT
3 Remove chain tensioner (244) (05-340).

4 Mark camshaft timing gear and timing chain in relation to each other.

5 Remove camshaft timing gear. To loosen screws, apply counterhold on camshaft with a mandrel.

6 On vehicles with level control, the camshaft timing gear and the driver sleeve are fastened with a hex. socket screw. Remove driver sleeve. For this purpose, unscrew pressure oil pump and put aside with lines connected. 7 Uniformly loosen all camshaft bearing screws and remove camshaft bearing caps. Note: To prevent tilting of camshaft under influence of spring-loaded valve tappets, loosen camshaft bearing screws and unscrew uniformly.

l-

05.10-220/3

46

43

EXIT
8 Remove camshaft in upward direction. 188 84

187 190

ii: 185

186 187 188 Camshaft timing gear 189 Washer 190 ScrewMlOx50

Cylinder head Camshaft bearing bracket Camshaft ;ir;lg,,r axial locating

189q

9 Remove circlip for axial locating (186) camshaft longitudinal alignment and check for condition. 10 Pull out valve tappet by means of vacuum lifter 601 589 05 33 00. 11 Check valve tappet for condition (visual checkup) and renew, if required. Note: Install valve tappets at the same spot where they were installed before.

Installation

Note: If a new camshaft has been installed or if the cylinder head has been machined, check camshaft for easy operation.

12 Insert circlip for axial locating (arrow) in cylinder head. 13 Lubricate camshaft and place into cylinder head (without valve tappets). 14 Position camshaft bearing cap and tighten uniformly to 25 Nm. Pay attention to identification of bearing caps.

05.1 O-220/4

EXIT
15 When checking for easy operation, the camshaft can be rotated by means of a hex. socket screw M 10 x 30, which is screwed in through camshaft timing gear instead of fastening screw. If the camshaft can be rotated with an effort only, proceed as follows:

01

Hex. socket screw M 10 x 30

Loosen camshaft bearing caps individually. Then turn camshaft as required. Repeat until tight bearing point has been found. Remove camshaft and measure respective bearing point. Nominal 0.050-0.81 mm. Check camshaft for runout.

16 Lubricate valve tappets and insert. Pay attention to sequence. 17 Lubricate camshaft and place into cylinder head, pay attention to circlip (186).

1054 -13481

18 Install camshaft bearing caps. Note: Be sure to tighten camshaft bearing caps uniformly, so that the camshaft is not loaded on one side only under influence of valve tappet counterpressure.

05.1 o-22015

EXIT
19 Mount camshaft timing gear. Pay attention to color marks. Tighten fastening screw for camshaft timing gear to 45 Nm. For this purpose, apply counterhold to camshaft timing gear by means of a screwdriver or steel pin. 20 Install chain tensioner.

21 On vehicles with level control, mount pressure oil pump and driver. 22 Set engine to ignition TDC of 1 st cylinder and check marks (arrows).

23 Mount cylinder head cover. 24 Run engine, check for leaks.

05.10-220/6

EXIT
05-250 Removal and installation of valve springs

Tightening torques Bolts for cylinder head cover Screw for camshaft timing gear Screws for camshaft bearing caps

Nm 10 45 25

Special tools

Torque wrench, double arm, 3/8 square, 8-32 Nm

001 589 51 21 00

Torque wrench with plug-in ratchet, l/2 square, 2 5 - l 3 0 N m

001 5 8 9 6 6 21 0 0

Vacuum lifter for valve tappets

601589053300

Supporting bridge for valve spring depressor

601 589 02 59 00

Valve spring depressor for valve springs

601 5890261 00

Assembly board for clamping cylinder head Magnetic lifter for valve cone halves

601 589 01 59 00

116589066300

05.1 O-250/1

EXIT

185 203 202

Valve arrangement intake side Cylinder head Valve seat ring intake Valve guide intake Oil duct Core hole cap Camshaft bearing bracket Hex. screw M 8 x 45 :: Washer 84a 185 Camshaft intake valve 195 Thrust ring 197 197a Locking ring Valve spring 198 Valve stem seal intake 200 201 Valve spring retainer Valve key 202 203 Valve tappet 70 73 75 77a 78

1053-11524

Valve arrangement exhaust side Cylinder head Valve seat ring exhaust Valve guide exhaust Oil duct Camshaft bearing bracket ZI Hex. screw M 8 x 45 84a Washer Camshaft 185 196 Exhaust valve 197 Thrust ring 197a Locking ring 198 Valve spring 199 Valve stem seal exhaust Valve spring retainer 201 202 Valve key 203 Valve tappet ;: 77a
1053-1152311

70

Note

Each valve has a single progressively acting valve spring (198). For this reason, install spring only with color marks below. Color marks: yellow/green or purple/green

05.1 o-250/2

EXIT
A thrust ring (197) inserted under valve springs is supported at cylinder head via torsion lock naps. Similar to all engines, the counterbearing of the valve springs in upward direction are in the shape of valve spring retainers (201), which are fastened to the valves by means of valve cone halves (202).

With cylinder head removed, the valves can be removed as follows: Clamp cylinder head with 4 cylinder head screws on assembly board 601 589 01 59 00. Fasten supporting bridge 601 589 02 59 00 to cylinder head and remove valve springs by means of valve spring compressor and magnetic lifter. Note: Install valve tappets again at the same spot from which they were removed before.

Removal

1 Remove camshaft (05-220). 2 Remove chain tensioner (05-310). 3 4 Remove fan and fan cover. Lift out valve tappets with vacuum lifter.

5 Set piston of respective cylinder to ignition TDC. Note: For rotating engine, lift timing chain so that chain cannot be pulled in downward direction. The pistons are in TDC position when the following marks are under TDC indicator (arrow).

Mark TDC 180 (notch)

Piston at TDC 1 and 4 2 and 3

05.1 O-25013

EXIT
6 Fasten supporting bridge for valve spring depressor on cylinder head.

7 Push valve spring retainer down by means of valve spring depressor. 8 9 Remove valve cone halves with magnetic lifter. Remove vale springs and valve spring retainers.

10 Check valve spring (05-260).

Installation

11 Install valve spring with color dots in downward position.

12 Lubricate valve tappets and install, pay attention to sequence. 13 14 15 16 Install camshaft (05-220). Install chain tensioner (05-310). Mount cylinder head cover. Install fan and fan cover.

05.1 O-25014

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

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

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

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

EXIT

05--260

Checking valve springs

Valve spring data

Part No. Color code OD mm Wire dia. mm Length unloaded mm Spring force with preloaded when new limit value length N N

601 0 5 3 01 2 0

yellow/green or purple/green

33.2

4.25

50.8

27

720-770

648

Checking

1 Check valve springs with a valve spring tester or a spring test scale. 2 3 Check spring force at specified length. If less than limit value, renew valve springs.

05.1 o-260/1

EXIT
05-270 Replacing valve stem seals

Tightening torques Bolts for cylinder head cover Screw for camshaft timing gear Screws for camshaft bearing caps

NM 10 45 25

Special tools

Torque wrench, double arm, 318 square, 8-32 Nm

001 589 51 21 00

Torque wrench with plug-in ratchet l/2 square, 25-l 30 Nm

001 589 66 21 00

Vacuum lifter for valve tappets

601 589 05 33 00

Support bridge for valve spring depressor

601 589 02 59 00

Valve spring depressor for valve springs

601 589 02 61 00

Magnetic lifter for valve cone halves Assembly mandrel for valve stem seal intake and exhaust

116589066300

601 589024390

Valve sealing pliers

000 589 53 37 00

05.1 O-270/1

EXIT
Note

The valve stem seals are supplied as a repair kit. Different valve stem seals are installed during series production, refer to drawings. All versions are made of the same elastomere material. I D s are different according to valve stems.

199 Valve stem seal exhaust 200 Valve stem seal intake

Another version is externally the same for intake or exhaust valves. They differ at ID and on wire rings, which are phosphated (black) on the versions named above and high-polish galvanized (yellow) at exhaust valve.

Valve

stem seal

Renewing

Remove valve springs (05-250).

2 Pull off valve stem seals with pliers 000 589 53 37 00. Attention! Do not damage valve stem and valve guide.

05.1 O-270/2

EXIT
3 Deburr valve stem on groove (arrow).

4 Renew dented valve cone halves, spring retainers and thrust rings.

5 Lubricate valve stem seal and press on with assembly mandrel 601 589 02 43 00. For this purpose, be sure to place an assembly sleeve (included in repair kit) on valve stem.

6 Install valve springs (05-250).

05.1 O-270/3

EXIT
OS-280 Checking and machining valves

Data
Engine Adjusting Height h of valve disk angle ,,a for when new limit value machining valve

iTiedia.

1 z:,

1 %f~~~ 1

E$:h

Intake valve
601 37.90 38.10 0.5-0.7 45 + 15 7.970 7.955 with without 106 --L- 5 106.3

Exhaust valve

Conventional tools e. g. Krupp, D-5309 Meckenheim Model VS e. g. Hunger, D-6000 Miinchen 70 Type VKDR 1, order No. 203.00.200

Valve cone grinding machine or valve cone machining tool

Identification on stem end Engine 601 Intake valve E 601 02 Exhaust valve A 601 02

195 196 05.1 O-280/1

Intake valve Exhaust valve

EXIT
Checking and machining

Clean valves and check visually.

Renew valves with burnt valve disk, with insufficient height h of valve disk and with worn or scored valve stem.

2 Measure runout on valve stem. If runout exceeds 0.03 mm, renew valve.

3 Machine valve seat. Pay attention to operating instructions of machining unit and adjusting angle 45+ 15 . 4 Measure runout on valve seat and height h of valve disk. Renew valve, if limit values are not attained.

05.1 O-280/2

EXIT
05-290
Replacing valve seat rings

Data Intake Overlap of valve seat rings in cylinder head 40 .ooo dimension 40.016 Exhaust 0.068-O. 100 37 .ooo 37.016

Normal D 2

Repair stage max. up to 40.100 d i m e n s i o n ____ 40.084 37.100 37.084 ~Roughing dimension Repair stage 33.400 33.600 Normal dimension and repair stages 6.97 7.00 30.400 30.600 6 - .97 7.00

Normal D

Dl

t
2.37 2.25

9.35 9.25
2.44 2.25

t l

Special tools Check plug 8 m m dia. for intake valve guide Check plug 9 mm dia. for exhaust valve guide now-WV 102 5 8 9 0 0 2 3 0 0 117589032300

05.10-290/l

EXIT
Conventional tools Cylinder head clamping device e. g. Hunger, D-8000 Miinchen 70 Order No. 221.60.000 e. g. Hunger, D-8000 Miinchen 70 Order No. 220.03.110 e. g. Hunger, D-8000 Miinchen 70 Order No. 236.03.308 e. g. Hunger, D-8000 Miinchen 70 Order No. 2 16.93.300 e. g. Mahr, D-7300 Esslingen Order No. 844 e. g. Mahr, D-7300 Esslingen Order No. 40 S

Ring seat turning tool, size 2

Valve seat machining tool, type VDSNL l/45/30

Test set for valves Internal measuring instrument (measuring range 25-60 mm) External micrometer (measuring range 25-50 mm)

Note

For all valve seat ring versions each spare part is a repair valve seat ring with a larger OD.

Renewing

1 Unscrew old valve seat ring with ring seat turning tool. Pay attention to operating instructions of turning tool. 2 Check valve guides and renew, if required (05-285).

05.10-290/2

EXIT
3 Measure basic bore D 1. A new normal dimension valve seat ring can be used if the specified overlap is available. If the minimum overlap is not attained, machine basic bore for valve seat ring. 4 Machine basic bore D 1 with ring seat turning tool until the bore is just clean.

5 Measure machined basic bore. 6 Machine repair stage valve seat ring in such a manner that the specified overlap is obtained.

7 Heat cylinder head in water bath to approx. 80 C. 8 Undercool valve seat ring with liquid nitrogen.

9 Knock in valve seat ring with a suitable guide mandrel. 10 Machine valve seats (05-291).

05.1 O-290/3

EXIT
05-291
Machining valve seats

Data Intake Valve seat width b Valve seat angle Q Correction angle at top P Correction angle bottom y Permissible out-of-true of valve seat 45O 15O 60 Exhaust

\, 11
0.05

Valve distance to cylinder head parting surface Minimum distance a with new valves and new valve seats Max. distance a with refinished valve seats and reground valves -0.1 to -0.5

Intake/Exhaust

Intake Exhaust

The max. distance is reduced by the same dimension by which the cylinder head parting surface has been refinished.

a
Intake 38.10 Valve disk dia. Exhaust 34.90 35.10

Special

tools
102589002300 117589032300

Check plug 8 mm dia. for intake valve guide Check plug 9 mm dia. for exhaust valve guide

05.10-291/l

EXIT
Conventional tools e.g. Hunger, D-8000 Miinchen 70 Order No. 221.60.000 e. g. Hunger, D-8000 Miinchen 70 Order No. 236.03.308 e. g. Hunger, D-8000 Miinchen 70 Order No. 216.93.300 e. g, Hunger, D-8000 Miinchen 70 Order No. 216.64.622

Cylinder head clamping device

Valve seat machining tool, type VDSNL l/45/30

Test set for valve seats

60 correction bit No. 13 for correction angle, bottom

Note

Clamp cylinder head into clamping device for disassembly and machining. Machine valve seats with valve seat machining tool, with valve seat grinding machine or with valve seat milling cutter.

Machining valve seats

Check valve guides and renew, if required.

05.10-291/2

EXIT
2 Machine valve seat (45 15 ) (refer to operating instructions of tool manufacturer). Attention! Loosen pilot only after runout of valve seat has been checked (item 3).

3 Check runout of valve seat. For this purpose, slip fitted sleeve (19) with dial gauge holder (20) and dial gauge on pilot (5).

5 Pilot 18 Dial gauge 19 Fitted sleeve 20 Dial gauge holder

Measure valve seat width (b) and, if required,

correct at top (0) with 15 and below (y) with 60 .

Insert valves and measure distance a.

If required, renew valve seat ring (05-290).

1054-11629

05.10-291/3

EXIT
OS-31 0 Removal and installation of chain tensioner

Tightening torques Chain tensioner in cylinder head Closing plug for chain tensioner

Nm 80 60

Note

Install chain tensioner in filled condition on principle. Suitably, completely renew chain tensioner complained about.

The hydraulic chain tensioner is supplied with pressure oil through an oil duct in cylinder head. Check valve (227 and 228) and pressure limiting valve (227 and 231). together with compression spring (2301, will keep the contact pressure of thrust pin (233) on tensioning rail approximately constant, independent of engine oil pressure. The filling pin (233a) contributes to faster venting when filling in oil.

279 2yO 2p 2 3 3 225 226 227 228 229 230 231 232

2?2 277 2?6 234

Closing plug Aluminum seal

A 25 x 30 Ball dia. 5 mm Ball guide Compression spring Compression spring Valve disk O-ring

233 233a 234 235 236 a

b

Thrust pin Filling member Compression spring Housing Circlip B 16 Feed bore from cylinder head To oil pan

05.1 o-31 O/l

EXIT
Removal

1 Unscrew chain tensioner (224).

Installation

2 Fill chain tensioner. For this purpose, set chain tensioner with thrust pin in downward direction into engine oil SAE 10, with the oil extending over flange on hexagon. Press thrust bolt 7-10 times slowly down against stop with the assistance of a press or a column-type drill press. Upon filling, compression of chain tensioner should be possible very slowly and uniformly only, and under considerable force. 3 Install chain tensioner with new sealing ring.

Thrust pin of chain tensioner should rest against lug of tensioning rail.

224

215

156

215 Tensioning rail 224 Chain tensioner

05.1 o/31 o/2

EXIT
05-320 Replacing timing chain

Tightening torques Bolts for cylinder head cover Coupling nuts for injection lines (reference value) Injection nozzles in prechambers

Nm 10 1 O-20 70+ 10

Special tools

Pressing-on tool

000 589 57 43 00

Torque wrench, double arm, 3/8 square, 8-32 Nm

001 589 51 21 00

Box-end wrench element, open, 14 mm, l/4 drive for coupling nut on injection line

000 589 77 03 00

Note

A timing chain with connecting link is available for repairs. If only an endless timing chain is available, the chain can be opened prior to installation (refer to item 3). During an engine overhaul, an endless timing chain must be installed on principle. Check sprockets for score marks and pitting.

Replacement part (repair timing chain with connecting link) Designation Bushing chain with connecting link Connecting link Part No. 001 997 16 94 000997 11 98

05.1 o-32011

EXIT
Repair timing chain The connecting link is held in place by a locking spring. The outer flanges are dyed blue.

,
The outer flange of connecting link is pressed on by means of pressing-on tool 000 589 57 43 00.

Connecting link with locking spring

105-25310

Renewing

1 Remove injection nozzles (07.1-230). 2 Remove cylinder head cover. 3 Remove chain tensioner. 4 Remove fan and fan cover.

5 Cover chain box with a cleaning rag and cut through both chain bolts on one link of timing chain by means of a grinding wheel.

6 Connect new timing chain with connecting link to old timing chain, while pushing out opened link (Fig. item 6). 7 Slowly rotate crankshaft in rotating direction of engine, while simultaneously pulling up the old timing chain until the connecting link comes to rest against uppermost point of camshaft timing gear. Attention! Timing chain should remain in mesh while rotating camshaft and crankshaft timing gear.

8 Take off old timing chain and connect ends of new timing chain with a connecting link. For this purpose, secure chain ends with wire on camshaft timing gear. 9 Insert connecting link from the rear into timing chain (arrow).

Shown on engine 615 05.1 O-32012

EXIT
10 Put separately enclosed outer flange of connecting link (with punched in IWIS identification) into pressing-on tool (arrow). The outer flange is held magnetically.

11 Place pressing-on tool on connecting link and press on flange up to stop, while holding pressing-on tool on vertical lever.

12 Force locking spring in opposite direction of engine rotation into grooves of chain pins (arrow). 13 Install chain tensioner.

14 Rotate crankshaft and check adjusting mark in TDC position of engine.

Note: If the adjusting mark is not in order, check timing of crankshaft (05-215) and timing of injection pump (07.1-l 11).
15 Install cylinder head cover. 16 Install fan and fan cover.

05.1 O-320/3

I..,.

EXIT

05-330

Removal and installation of tensioning rail

Note

The plastic coating of tensioning rail is not exchangeable.

224 -

215 -

-18

- 218
156-

- 262

244 18

Injection

timer

156 Sprocket 188 Camshaft timing gear 215 Tensioning rail 218 Slide rail

220 224 244 262

Slide rail Chain tensioner Oil pump sprocket Tensioning clamp

Semoval

1 Remove cylinder head (01-415).

2 3 Remove timing housing cover (01-210). Remove tensioning rail from bearing bolts.

Installation

Place tensioning rail on bearing bolt. Install timing housing cover (01-210). Install cylinder head (01-415). Run engine and check for leaks.

05.1 o-330/1

EXIT
05-341 Removal and installation of slide rails

Tightening torques Cylinder head cover Screw for camshaft timing gear

Nm 10 45

Special tools

Impact puller for bearing bolt (basic unit)

116589203300

Threaded bolt M 6,50 mm long for impact puller

116589013400
llOOL-b3b8

Torque wrench, double arm, 3/8 square, 8-32 Nm

001 589 51 21 00

Torque wrench with plug-in ratchet, l/2 square, 25-130 Nm

001 589 66 21 00

Note

Remove timing housing cover for removal and installation of slide rail (218).

224

156

18 156 166 215 218

Injection timer Sprocket Camshaft timing gear Tensioning rail Slide rail

220 224 244 262

Slide rail Chain tensioner Oil pump sprocket Tensioning clamp

05.1 o-341 /l

EXIT
The longer bearing bolt (221), in cylinder head at top, serves for supporting slide rail as well as for spring tensioning lever of V-belt tensioning device.

A.

Removal and installation of slide rail (220) in cylinder head

Removal

1 Slacken V-belt and remove. For this purpose, unscrew collar nut (378). Insert a mandrel into spring tensioning lever (374) and relieve hex. screw (375) against force of draw spring (380) until screw can be pushed back in direction of intake manifold. Release spring tensioning lever. 2 Unscrew screw (372) and remove holder (373) as well as spring tensioning lever (374). 3 Remove cylinder head cover. 4 Mark timing chain and camshaft timing gear in relation to each other.

5 Unscrew camshaft timing gear and remove. For loosening hex. screw, apply counterhold to camshaft with a screwdriver or mandrel.

05.10-341/2

EXIT
6 Knock out both bearing bolts with impact puller and remove guide rail.

Installation

Coat bearing bolt on collar with sealing compound.

8 Insert slide rail and knock in bearing bolt with impact puller. Apply counterhold to slide rail with screwdriver.

9 Mount camshaft timing gear. Pay attention to color marks. For assembly of camshaft timing gear, push back thrust bolt of chain tensioner. Tighten fastening screw for camshaft timing gear to 45 Nm. For this purpose, apply counterhold to camshaft with a screwdriver or a mandrel.

10 Set engine to ignition TDC of 1st cylinder and check mark (arrows). 11 Mount cylinder head cover.

05.10-34113

EXIT
B.

Removal and installation of guide rail (218)

Remove timing housing cover (01-210).

2 Pull out slide rail (218). 3 For installation proceed vice versa.

14 OH nozzle 18 Injection timer 215 Tensioning rail

218 Slide rail 262 Tensioning clamp

?05-25877

05.1 o-341 I4

EXIT
05-437 Removal and installation of drive for hydraulic oil pump

Tightening torques Cylinder head cover Hex. socket screw for camshaft timing gear Hydraulic oil pump (level control) on fastening flange

Nm

45 15

Special tools

Torque wrench, double arm, 3/8 8 - 3 2 Nm square,

001 589 51 21 00

Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm

001 589 66 21 00

Note

Cylinder head Camshaft bearing cap Combination screw M 8 x 45 125 Cylinder head cover 129 Cylinder head cover gasket 185 Camshaft 186 Lockwasher 188 Camshaft timing gear 400 Hydraulic oil pump

IF 84

401 402 403 404 405 406 407

Cyl. pin Flange Driven plate O-ring Hex. socket screw Drive sleeve Hex. socket screw

4 0 3 4 0 2 4b5 4 0 4 4 0 6

The hydraulic oil pump (400) is directly driven by camshaft (185) via drive sleeve (406) and is fastened to cylinder head by means of a flange (4021. The installation position of flange on cylinder head is fixed by means of two cyl. pins (arrows).

05.10-437/l

EXIT
The camshaft timing gear (188) is fastened to camshaft together with drive sleeve (406) by means of a hex. socket screw 1405). The O-ring on flange (402) seals the half bore at front on cylinder head and in cylinder head cover.

Removal

Remove cylinder head cover. 2 Unscrew hex. socket screws (arrows) and put hydraulic oil pump aside with lines connected. Remove driven plate.

3 Unscrew hex. socket screw (405) for camshaft timing gear and drive sleeve and remove. For loosening hex. socket screw, apply counterhold to camshaft with holding wrench.

Installation

For installation proceed vice versa to removal.

Tighten hex. socket screw for camshaft timing gear and drive sleeve to 45 Nm. For this purpose, apply counterhold with a screwdriver or a mandrel.

05.10-437/2

EXIT
Injection system 07.1

EXIT
07.1 Injection system

Job No. Survey engine - injection pump - injection nozzle - nozzle holder Operation of injection system

. . . . . . . . . . . . . . . . . . . . . . . 07.1-001 010 ................................................ A. Lubrication of injection pump ............................................

B. Relief throttle in delivery valve holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Layout and operation of RSF governor

...................................... D. Pneumatic idle speed increase ............................................ E. Reference impulse verification ( RI V) ........................................ F.Fuelpump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Function diagram low pressure circuit ....................................... Operation of injection nozzles ................................................ A. Flat surface pintle nozzle (standard version) ................................... B. Hole-type pintle nozzle (a) ............................................ Operation of fuel preheater ..................................................
Testing and adjusting jobs Adjustment of idle speed Checking pneumatic idle speed increase

011

012

................................................. ........................................ Checking engine output and exhaust gas on chassis dynamometer ....................... Checking injection timing (high-pressure method) ...................... r. ......... Checking injection timing (position pickup-RIV-method) ............................ Checking injection timing with digital tester (RIV-method) ........................... Adjusting injection timing (high-pressure method) - following checkup. .................. Adjusting injection timing (position pickup-RIV-method) - following checkup .............. Adjusting injection timing with digital tester (RIV-method) - following checkup ............ Checking injection nozzles ................................................ A. Throttle pintle and flat surface pintle nozzle ................................ B. Hole-type pintle nozzle ..............................................
Disassembling, cleaning, assembling and adjusting injection nozzles Checking fuel pump

100 102 104 109 111 112 115 116 117 135

..................................................... ..................................................... Checking vacuum shutoff for leaks ...........................................

(following checkup)

137 145 150

Assembly jobs

..................................... ............................................... Renewing vacuum control unit ............................................. Removal and installation of injection nozzle ..................................... Removal and installation of fuel pump ........................................ Removal and installation of injection timer. ..................................... ..... ...... ..... . .. . . .. . . . . . . . . . . . . .. .. . .. ... .. ..... . Renewing fuel filter
Removal and installation of injection pump Renewing delivery valve seal

200 210 220 230 235 240 245

07.1/l

EXIT
07.1-001 Survey engine-injection pump-injection nozzle-nozzle holder

Standard version and @

Engine

601.911 standard version PES4M55C320RS152

601.921 @

Injection pump

Injection nozzle Nozzle holder

DN 0 SD 261/-

DN 0 SD 24-/ KCA 30 S 46

07.1.10-00111

EXIT
07.1-010 Operation of injection system

The injection system differs from that of engines 615, 616 and 617 as follows: Lubrication of injection pump. Relief throttle in delivery valve holder. Pneumatic idle speed increase. Reference impulse verification (RIV). Injection timing by means of adjusting device and injection pump flange. Injection system, self-venting. Fuel pump with higher delivery capacity, thereby eliminating hand pump. Overflow valve with throttle (orifice). Injection nozzle as flat surface pintle nozzle for standard version and as hole-type pintle nozzle for @. Injection timer mounted directly on injection pump shaft. Fastened by means of central bolt with lefthand threads. Fuel heater.

A. Lubrication of injection pump

The injection pump is connected to engine oil circuit by means of an oil bore (arrow). Oil return flow is by way of ring gap (x) between bearing and housing in cylinder crankcase. An O-ring (10) is installed on flange (la) for sealing the clutch space between injection pump flange and crankcase.

07.1.10-010/l

EXIT
B. Relief throttle in delivery valve holder

Relief throttles are installed in delivery valve holders of injection pump to reduce the hydro-carbon share in exhaust gas. An annular groove is located on delivery valve holder for identification (arrow). The relief throttle (7b) is a reed valve (74 with an orifice of 0.6 mm dia., which opens in direction of injection nozzle. The valve seat (7d) is riveted into delivery valve holder.

7 Delivery valve holder connection 7a Spring 7b Relief throttle 7c Reed valve 7d Valve seat 7e Delivery valve holder 7f Seal 7g Delivery valve

C. Layout and operation of RSF-governor

4a 4

The governor is an idle speed-maximum speed govern0 with its regulating spring (2 m) measured and adjusted in such a manner that the governor will not govern in partial load range, apart from adaptation (refer to ,,Regulation during start and full load ). In partial load and full load range the control rod (2t) of injection pump is operated by accelerator pedal only, which is connected to adjusting lever (29) of governor via regulating linkage. The vacuum control unit (4) preloads the idle speed spring and adjusts the idle speed.

07.1 .lO-010/2

.,

EXIT

2 6

4a 4

2 Governor 2a Guide lever 2b Stop screw for deltvery at idle 2c Transfer lever 2d Regulating lever 2e Spring capsule (adaptation) 2f Full load adjusting screw 2g Adjusting lever 2h Sliding sleeve 2i Flyweights (pump-governor-group) 2j Idle speed auxiliary spring-shutoff 2k Adjusting screw for idle speed auxiliary spring (tickler) 21 Tensioning lever 2m Governor spring 2n Idle speed spring 20 idle speed auxiliary spring (tickler) 2p Linkage lever 2r Stop lever 2s Emergency stop lever 2t Controi rod 4 Vacuum control unit idle speed increase 4a Adjusting nut for idle speed 6 Vacuum control unit (stop)

2a 2r -2b

-29

2h 2c 2e

2i

2f

1073-887911

2d

IL-I

Regulation during start and full load If, with the engine stopped, the adjusting lever (29) is placed against full load stop (fixed stop on governor housing), the transfer lever (2~) will swing around pivot ,,B and will take the regulating lever (2d) along in direction of start. In full load position of adjusting lever (29 ,,full throttle) the idle speed auxiliary spring (20, tickler) is forced away from guide lever under influence of idle speed auxiliary spring-shutoff (2j) A faster break away from starting position of governor will result.

a Start b Stop
07.1 .lO-010/3

c Idle speed stage d Adaptat ion

1073 - 8880/2

EXIT
After running through idle speed stage (c), the sliding sleeve (2h) rests against spring capsule (2e) As a result, the control rod of the injection pump will be moved into full load position via transfer lever (2~) and regulating lever (2d). When a given speed has been attained, excess pressure is applied to spring capsule (2e) for a given distance (d) (adaptation). If the engine speed is still increasing, the force of the flyweights is sufficient to apply excess pressure to regulating spring (2m) (maximum speed breakaway). Start of breakaway depends on preload of regualting spring {2m).

Regulation at idle speed Linkage lever (2~) rests against idle speed stop screw (2b). With increasing speed, the sliding sleeve (2h) runs through idle speed stage. Guide lever (2a) swivels around pivot ,,A and is thereby acting against idle speed spring (2n). At a given speed the guide lever (2a) rests against adjusting nut of idle speed auxiliary spring (20). The movement of the sliding sleeve (2h) is transmitted to control rod of injection pump via transfer lever (2~) and regulating lever (2d) in the same sense of direction. After running through idle speed stage, the sliding sleeve (2h) will rest against spring capsule (2e). If the engine speed continues to increase (e.g. under influence of deceleration), excess pressure will first be applied to spring capsule (2e) and then to regulating spring (2m) as from a given speed. This will move the control rod into ,,stop position .
4a 4

a Start b Stop 07.1 .lO-010/4

1073-888111

EXIT
Stop position of governor The vacuum control unit (6) is provided with a vacuum by means of vacuum pump via steering lock of vehicle. As a result, the diaphragm of the vacuum control unit is attracted against the pressure of the diaphragm spring. The vacuum control unit (6) is connected to a stop lever (2r). This lever will swivel around pivot ,,D and will thereby pull the control rod of the injection pump into ,,stop position. This will bridge the shunt spring of the regulating lever. Likewise, the control rod can be pulled from outer side of governor into ,,stop position via emergency stop lever (2s).
4a 4

1073-008212

D. Pneumatic idle speed increase

Idle speed increase for rpm stabilization is effected up to approx. 17 OC coolant temperature, as well as on vehicles with automatic transmission when the refrigerant compressor is additionally connected also above approx. 17 OC coolant temperature.

The vacuum control unit (4) attached to governor housing is activated via thermovalves (128 and 130) and switchover valve (127). If the vacuum control unit (4) is energized by a vacuum (approx. 500 mbar), the idle speed spring is attracted via plunger (4b) of vacuum control unit. The idle speed control characteristic is displaced and the idle speed is increased by approx. lOO/min.

07.1.10-010/5

EXIT
Coolant temperature < approx. 17 OC Thermovalve (128) is opened, thermovalve (130) is closed. On vehicles with automatic transmission the vacuum flows via switchover valve (1271, and on vehicles with manual transmission directly to vacuum control unit (4).

Coolant temperature > approx. 17 OC Thermovalve (128) is closed, thermovalve (130) is opened. The vacuum control unit is connected to atmosphere and the rpm increase is cancelled. When the refrigerant compressor is additionally connected (vehicles with automatic transmission only) the switchover valve is energized and will switch. The vacuum flows through upper connection of switchover valve to vacuum control unit (4).

07.1 .lO-010/6

EXIT

-----e

Function diagram Idle speed increase with manual transmission, standard version and @ Federal Injection pump a Vent line to vehicle interior Governor b Key shutoff Vacuum control unit idle speed increase c Remaining consumers ADA-capsule (altitude pressure compensator@ e Brake unit : Vacuum control unit (stop) 62 Vent filter 67 Vacuum pump 128 Thermovalve closes at approx. 17 C 130 Thermovalve opens at approx. 17 OC 140 Check valve brake unit : 1 bk bl br gr Pu re wh = = = = = = = black blue brown green purple red white

07.1 .lO-010/7

EXIT

Function diagram idle speed increase with automatic transmission, standard version a Vent line to vehicle interior 1 Injection pump b Key shutoff 2 Governor c Remaining consumers 4 Vacuum control unit idle speed increase ADA-capsule (altitude pressure compensator@ d Vacuum control unit automatic transmission e Brake unit : Vacuum control unit (stop) a Orifice (blue) :: Vent filter Vacuum control valve :75 Vacuum pump 72 Damper 128 Thermovalve closes at approx. 17 C 130 Thermovalve opens at approx. 17 C Check valve brake unit 140 bk = bl = br = gr = Pu = re = wh = black blue brown green purple red white

07.1.10-010/8

EXIT

Function diagram idle speed increase with automatic transmission,@ Federal 1 Injection pump 2 Governor 4 Vacuum control unit idle speed increase 5 ADA-capsule (altitude pressure compensator) 6 Vacuum control unit (stop) 61a Orifice (blue) 61 b Orifice 0.5 mm dia. oranae Vent filter Vacuum control valve 67 Vacuum pump 72 Damper 127 Switchover valve, electric 128 Thermovalve closes at approx. 17 OC 130 Thermovalve opens at approx. 17 C 140 Check valve brake unit a Vent +ine to vehicle interior b Key shutoff Remaining consumers : Vacuum control unit automatic transmission e Brake unit g To refrigerant compressor bk = black bl = blue br = brown gr = green Pu = purple re = red wh- white

07.1 .lO-010/g

EXIT

Function diagram idle speed increase with manual transmission, @ California 1 Injection pump 2 Governor 4 Vacuum control unit idle speed increase 5 ADA-capsule (altitude pressure compensator) 6 Vacuum control unit (stop) 60 EGR-valve 61 b Orif ice 0.5 mm dia. (orange) Vent filter Vacuum control valve Vacuum pump ii Pressure control flap 100 Vacuum control unit for (99) 105 Intake manifold 110 Exhaust manifold 120 EGR-line 123 Pressure converter 124 Adjusting screw for (123) 125 Switchover valve electric for EGR-valve 126 Switchover valve electric for pressure control flap C 128 Thermovalve closes at approx. 17 130 Thermovalve opens at approx. 17 C 140 Check valve brake unit a Vent line to vehicle interior b Key shutoff c Remaining consumers d Vacuum control unit automatic transmission e Brake unit f To refrigerant compressor-control unit bk = black bl = blue br = brown gr = green pu = purple re = red ve ,- = vellow I- ;-

07.1.10--010/10

EXIT

Function diagram idle speed increase with automatic transmission, @ California 1 Injection pump 2 Governor 4 Vacuum control unit idle speed increase 5 ADA-capsule (altitude pressure compensator) 6 Vacuum control unit (stop) 60 EGR-valve 61 a Orifice 61 b Orifice 0.5 mm dia. (orancte) Vent filter 8 Vacuum control valve 67 Vacuum pump Damper ;: Pressure control flap 100 Vacuum control unit for (99) 105 Intake manifold 110 Exhaust manifold 120 EGA-line 123 Pressure converter 124 Adjusting screw for (123) 125 Switchover valve electric for EGR-valve 126 Switchover valve electric for pressure control flap 127 Switchover valve electric for rpm increase C 128 Thermovalve closes at approx. 17 130 Thermovalve opens at approx. 17 C 140 Check valve brake unit a Vent line to vehicle interior b Key shutoff c Remaining consumers d Vacuum control unit automatic transmission e Brake unit f To refrigerant compressor-control unit bk = black bl = blue br = brown gr = green pu = purple re = red ye = yellow

07.1.10-010/11

EXIT
E. Reference impulse verification (RI V)

Measuring the association of injection pump in relation to engine requires two signals:
l

TDC-impulse from crankshaft. Regulating impulse from injection pump.

Both impulses are supplied by impulse transmitters. To obtain a measuring signal, the sensor pins must be moved past the impulse transmitters at a minimum speed (idle speed). A measuring instrument measures the chronological distance between the two impulses and converts the result into an angle value, which is then indicated.

001 Digital tester 2 Governor 2i Flyweight with sensor pin 015 Test cable

016 017 021 059

Socket Reference impulse transmitter TDC-impulse transmitter Sensor pin

07.1 .lO-010/12

EXIT
F. Fuel pump

An increased delivery capacity of fuel pump makes the fuel system self-venting. The manual delivery pump is no longer installed.

E Delivery end D Suction end

Venting of injection pump requires an orifice in overflow valve.

Overflow valve with 1.5 mm dia. orifice The overflow valve prevents unfiltered fuel from entering injection pump.

a Housing
b Ball

c Spring
d Slide e Inlet

07.1.10-010/13

EXIT
G. Function diagram low pressure circuit

148

Injection pump Fuel pump Overflow valve with orifice 1.5 mm dia. Injection nozzles Fuel prefilter Leak oil hose Injection line cylinder 1 Fuel tank Fuel filter top a Orifice in fuel filter top 0.8 mm dia. Fuel thermostat open, position up to +8 C, fuel is preheated Supply line - cold fuel a Return line - preheated fuel Heater feed line with fuel heat exchanger

07.1.10--010/14

EXIT

3 :; 42 43 50 73 :: 77 78 79

Injection pump Fuel pump Overflow valve with orifice 1.5 mm dia. Hollow screw Fuel filter Fuel prefilter Leak oil hose Fuel filter top Hollow screw fuel filter O-ring Sealing ring fuel filter Sealing ring Rung-type fitting

80 Return line 81 Expanding screw 82 Inlet fuel filter 83 Inlet injection pump 84 Hose clamp 86 Fuel thermostat 87 Supply line fuel-heat exchanger 87a Return line fuel-heat exchanger 88 Supply line fuel thermostat 89 Suction line fuel pump 148 Heater feed pipe with fuel heat exchanger

07.1.10-010/15

EXIT
70 xf@ 69 F

%64b

55----1 25

- 5 6 1

.J

>J

..-

ai 71

-I

/I

11 23

3 Fuel pump 4 Vacuum control unit idle speed increase ,,PLA 5 ADA-capsule (altitude pressure compensator) 6 Vacuum control unit (stop) 8 Injection timing-adjusting device 10 O-ring (seal) 11 Closing plug - RIV 13 Fastening screw front 13a Fastening screw rear 13b Screw for assembly basket 14 Cage nut 15 Overflow orifice 1.5 mm dia. injection pump 16 Damper 18 Injection timer 18a Injection timer-assembly basket 19 Center fastening screw ,,lefthand threads 20 Washer 23 Pressure connection-delivery pump 24 Holder, injection pump rear 25 Spring

26 Adjusting lever 30 Injection nozzle, complete 50 Leak oil hose 51 Hose clamp 52 Closing plug 53 Nozzle reed 54 Injection line 1 55 Injection line 2 56 Injection line 3 57 Injection line 4 64 Holder, cylinder 4, nozzle end 64a Holder, cylinder 4, pump end 64b Screw 66 Holder, lines 68 Plastic clip 68a Plastic clip 69 Rubber base 70 Plastic holder for 3 lines 71 Plastic holder for 2 lines

07.1 .lO-010/16

EXIT
07.1-011 Operation of injection nozzles

A. Fiat surface pintle nozzle (standard version)

Bosch designation DN 0 SD 261/Differs from pintle nozzle fy a flat surface (arrow) on throttle pintle (41). This will improve throttle effect.

30 Injection nozzle, complete 32 Nozzle body 37 Nozzle holder top 41 Throttle pintle 44 Injection pintle

B. Hole-type pintle nozzle USA

Bosch designation DN 0 SD 240/ Differs from pintle nozzle by a transverse and lengthwise bore (46 and 47) in throttle pintle. A service-free bar filter (filter cartridge) (45) is inserted in nozzle holder top (37).

3045--

30 37 45 46 47

Injection nozzle, complete Nozzle holder top Bar filter (filter cartridge) Transverse bore Lengthwise bore

07.1.10-01 l/l

EXIT
07.1-012
Operation of fuel preheater

A fuel heat exchanger (148) is installed in feed line of heater to preheat the fuel.

Full preheating up to +8 OC. The required fuel is guided through fuel heat exchanger.

Fuel heat exchanger c SUPPlY D Return flow E Heater feed

Mixed operation from +8 OC to +25 OC. The required fuel flows partially via fuel heat exchanger. Above +25 OC the fuel heat exchanger is shorted by a thermostat. No more fuel will flow through fuel heat exchanger.

A Supply from fuel tank B Suction line to fuel pump C Supply to heat exchanger D Return flow to fuel heat exchanger

07.1.10-012/l

EXIT

Function diagram fuel preheating up to +8 C lniection cumc 3 F;el pumb 15 Overflow valve with orifice 1.5 mm dia. 30 Injection nozzle 42 Fuel filter 42a Orifice in fuel filter top 0.8 mm dia. 43 Fuel prefilter 50 Leak oil hose 54 Injection line cylinder1 63 Fuel tank 86 Fuel thermostat 87 Supply line (cold fuel) 87a Return line (preheated fuel) 148 Fuel heat exchanger

07.1.10-012/2

EXIT

148

Function diagram fuel preheating above +25 C 1 Injection pump 3 Fuel pump 15 Overflow valve with orifice 1.5 mm dia. 30 Injection nozzles 42 Fuel filter 42a Orifice in fuel filter top 0.8 mm dia. 43 Fuel prefilter 50 Leak oil hose 54 Injection line cylinder 1 63 Fuel tank 86 Fuel thermostat closed 87 Supply line (cold fuel) 87a Return line (preheated fuel) 148 Fuel heat exchanger

07.1 .lO-012/3

EXIT
07.1-100 Adjustment of idle speed

Job no. of work units or standard texts and flat rates data 07-2053

Test value Idle speed 750 + 50/min

Special tool

TDC-impulse transmitter

601 589 04 21 00

Conventional tool e.g. Bosch, MOT 001.03 Digital tester e.g. Sun, DIT 9000

1 Connect digital tester (001) and impulse transmitter (021).

2 3

Check regulation for easy operation and condition. Run engine to 60-80 OC coolant temperature.

07.1.10-100/l

EXIT
4 Disengage connecting rod (204) on transfer lever (214)

5 Check idle speed 750 4 5O/min, adjust by turning vat:uum control unit (41, if required, loosen counternult (4a) for this purpose.

Engage connecting rod (204) free of tension.

7 Switch on all auxiliary units and check engine for smooth running.

07.1.10-100/2

EXIT
07.1-102 Checking pneumatic idle speed increase

Job no. of work units or standard texts and flat rates data 07-2009.

Test values Idle speed increase min lOO/min at approx. 500 mbar from 500 to 400 mbar approx. 1 min

Permissible pressure drop of system

Special tool

Test unit O-1000 mbar for vacuum

\ 1 i \J

116589252100

Note

Prior to performing this job, check idle speed adjustment. Renewing of vacuum control unit on injection pump can be made at a Bosch service station only, since renewal of vacuum control unit requires disassembly of governor and subsequent adjustment on a Bosch injection pump test bench.

Engine at idle. Connect vacuum tester to straight connection of thermovalve (130) and energize with 500 mbar. Engine speed increases by approx. 1 OO/min.

Check thermovalves (128 and 130). Make sure that thermovalve (128) has no passage. Thermovalve (130) must have passage. Renew thermovalve, if required. Check vacuum lines according to function diagram.

07.1.10--102/l

EXIT
Engine stopped. Check vacuum control unit (4) for leaks. Energize vacuum tester, connection as above, with approx. 500 mbar. Vacuum value may drop approx. 100 mbar in 1 minute.

Check vacuum lines and connections for damage, renew vacuum control unit, if required.

Check vent line for passage. Engine stops. Pull vacuum line from straight connection of thermovalve (130) and connect with vacuum tester. Operate hand pump, but do not build up a vacuum. Vent line in order

vacuum line. End of test

07.1.10-102/2

EXIT
07.1-104 Checking engine output and exhaust gas on chassis dynamometer

Job no. of work units or standard texts and flat rates data 07-1200.

Scope Fill in data sheet. Check fluid levels in engine, radiator and automatic transmission. Remove and install air cleaner cover. Connect digital tester according to connection diagram. Check regulating system for easy operation and for condition and lubricate. Check full throttle stop of accelerator pedal and adjust. Run engine oil temperature under partial load to 75-85 OC. Check idle speed, adjust. Check pneumatic idle speed increase. Check max. speed under no load condition. Check tire pressure of rear wheels. Cool engine with blower. Check performance - perform tachometer checkup. Exhaust gas (emission) test under load.

Test values Performance reference values and exhaust gas (emission) value

transmission

Note: During performance measurements be sure to include the different influencing factors. 1 The test values are minimum performances; the permissible losses for power steering of approx. 1.5 kW (2 HP) are already deducted.

Injection timing at 750 2 50/min Idle speed Idle speed increase min. lOO/min * 1 RI-value - indirect injection timing.

15O f lo after TDC*) 750 f 50/min at approx. 500 mbar

07.1.10-104/l

EXIT
Special tools

Oil telethermometer

116589272100

TDC-impulse transmitter

601 589 04 21 00

_-d -\

Exhaust gas probe, flexible

126 589 11 63 00

R l-transmitter

617 589 1021 00

Adapter (for available digital testers)

617

5890921 00

Conventional testers CO-measuring instrument e.g. Bosch, ETD 019.00 Digital testers e.g. Sun, DIT 900 e.g. AVL, Diesel-Tester 875

07.1.10-104/2

...............,

__________________.._.

EXIT

Connection diagram for test instruments without adapter, e.g. Bosch ETD 019.00, Sun DIT 9000, AVL Diesel-Tester 875 001 Digital tester 2 Governor 2i RI-transmitter pin 015 Test cable with plug 016 Diagnosis socket 017 R l-transmitter 021 TDC-impulse transmitter 59 TDC-transmitter pin

07.1.10-104/3

EXIT

Connection diagram for available testers with adapter, e.g. Bosch 001.03, Hartmann & Braun EOMT 3 001 Digital tester 2 Governor 2i R l-transmitter pin 010 Adapter 011 Trigger clamp 015 016 017 021 59 Test cable with plug Diagnosis socket RI-transmitter TDC-impulse transmitter TDC-transmitter pin

07.1 .lO-104/4

EXIT
Checking

1 Fill in data sheet. 2 Check fluid levels: in engine, radiator and automatic transmission and correct, if required. 3 Remove and install air cleaner cover.

4 Connect digital tester according to connection diagram. 5 Check ragulating system for easy operation and condition and lubricate. 6 Check full throttle stop from direction of accelerator pedal, adjust by means of adjusting screw (2291, if required. 7 Run engine oil temperature under partial load to 75-85 OC. 8 Disengage connecting rod (204) on transfer lever (214).

9 Check idle speed 750 + 50/min, adjust by turning vacuum control unit (41, if required, loosen counternut (4a) for this purpose. Engage connecting rod (204) free of tension. Switch on all auxiliary units and check engine speed.

10 Check pneumatic idle speed increase: Attention! Prior to performing this job, check idle speed adjustment. The vacuum control unit for idle speed increase on injection pump can be renewed only with injection pump removed.

07.1.10-104/5

EXIT
Engine at idle. Connect vacuum tester to straight connection of thermovalve (130) and energize with 500 mbar. Engine speed increases by approx. lOO/min, check pneumatic idle speed increase, if required (07.1-102). Note: The vacuum control unit idle speed increase on injection pump can be renewed only with injection pump removed.

11 Secure front wheels. For this purpose, place chocks at a distance of approx. 100 mm in front of front wheels. 12 Check tire pressure of rear wheels and correct, if required. 13 Check trunk contents, remove heat-sensitive items.

14 Cool engine with blower.

15 Check full load performance. Attention! Run at full load only as long as required for reading the instruments. 16 Check exhaust gas (emission) value under load.

If the specified exhaust gas values under load cannot be attained in spite of fully including idle speed emission value tolerance, set injection pump on pump test bench to upper tolerance limit.

07.1.10-104/6

EXIT
07.1-109 Checking injection timing (high-pressure method)

Job no. of work units or standard texts and flat rates data 07-8234.

Test value Injection timing In compression stroke 24O before TDC

Attention! While measuring, move regulating lever of injection pump to full load and pull off vacuum hose at vacuum control unit ,,Stop.

Tightening torque (reference value) Injection line

Nm 1 O-20

Special tools

Pump unit, complete

617589007100

Connecting parts with storage case

617589009100

Quick lock e 3 &ao+U)102 Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm Box wrench element, open, 14 mm, l/4 square for injection lines Socket wrench element 27 mm, l/2 square

617589029100

001589662100

000589770300

001589650900

07.1 .lO-109/l

EXIT
Testing

1 Clean injection lines in range of coupling nuts on injection pump as well as on fuel filter. 2 Set control rod of injection pump to full load.

Adjusting lever on full load stop

3 Completely remove air cleaner. 4 Pull off vacuum line on stop capsule.

5 Unscrew injection line from cylinder 1. Screw test line with sight glass to injection pump and install return flow line to fuel tank of pump unit.

6 Close fuel return line from injection pump to fuel filter. Insert O-ring into ring fitting (79) of return flow line and firmly press in quick lock (arrow).

07.1 .lO-109/2

EXIT
7 Connect supply line from pump unit to injection pump supply (arrow).

8 Connect connecting cable of pump unit to vehicle battery (red terminal positive, black terminal nagative). 9 Rotate crankshaft in direction of rotation of engine up to approx. 35O before TDC in compression stroke of first cylinder. Engage pump unit. Attention! Engage pump unit for measuring only. If an injection nozzle is leaking, fuel may enter combustion chamber.

10 Rotate crankshaft slowly in direction of rotation of engine while watching fuel jet in sight glass. If fuel jet changes to chain-like drops, start of delivery (injection timing) has been attained. In this position, read begin of delivery (injection timing) on graduated scale on belt tension. Nominal value: 24O before TDC.

A Fuel jet, full B Fuel jet, restricted

twior to besin of delivery

bhain-like &ops begin oi delivery

07.1 .lO-109/3

EXIT
11 Disconnect pump unit. Assemble injection system. Mount air cleaner. Note: When engine is started, the injection system will vent itself automatically. 12 Run engine and check all connections for leaks.

63

107%1028711

Connection diagram high-pressure overflow method w

Return flow line

ZZZ High-pressure approx. 34 bar

1 Injection pump 03 Sight glass 04 Pump unit 06 Pressure limiting valves (not required) 42 Fuel filter 63 Fuel tank

A B

Hollow screw, fuel supply from pump unit Fuel return flow line closed with quick lock or clamp

07.1 .lO-109/4

EXIT
07.1-111 Checking injection timing (position pickup-RIV-method)

Job no. of work units or standard texts and flat rates data 07-8240.

Test values Test value RI-value (indirect injection timing) 15 + lo after TDC Adjusting value 15O after TDC

Tightening torques (reference values) Closing plug on governor (measuring point) Injection lines Injection pump flange

Nm 30-35 1 O-20 20-25

Special tools Torque wrench with plug-in ratchet, l/2 square, 25-130 Nm 001 5896621 00

Position indicator

617 589 08 21 00

Socket wrench element 27 mm, l/2 square

001 589 65 09 00

Checking

Remove air cleaner top (arrows).

07.1.10-111/l

EXIT
2 Remove closing plug (11). Attention! Attach emerging oil.

3 Screw position indicator into governor housing. Make sure that the guide pin of positioning indicator (arrow) is extending in upward direction. Tighten coupling nut manually.

4 Connect position indicator according to connection diagram.

07 Position indicator 0 8 Indicator 09 Battery terminal (battery positive)

7073-no08

07.1.10-l 1 l/2

EXIT
5 Rotate crankshaft with tool manually (in direction of rotation only), until lamp ,,A lights up. Carefully continue rotating crankshaft until both lamps are lighting up ,,A + B . In this position, read RI-value (indirect injection timing) on graduated disk. Nominal value: 15O after TDC If only lamp ,,B ist lighting up, repeat test.

6 Remove position indicator. 7 Screw in closing plug. 8 Mount air cleaner top. 9 10 Perform leak test with engine running. Check engine oil level and correct, if required.

07.1.10-111/3

EXIT
07.1-l 12 Checking injection timing with digital tester

( RIV-method)

Job no. of work units or standard texts and flat rates data 07-8244.

Test values

Mm
RI-adjusting value R l-test value
1 Indirect injection timing.

750 f 50/min

15O after TDC 15O + lo after TDC

Tightening torques (reference values) Closing plug on governor (measuring point) Injection pump flange

Nm 30-35 20-25

Special tools

TDC-impulse transmitter

601 I

589042100

di

R l-transmitter

617589102100

Adapter (for available digital testers)

617689092100

Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm

001 589 66 21 00

Conventional tools Application with adapter e.g. Bosch, MOT 001.03 e.g. Hartmann & Braun, EOMT 3

Digital testers

07.1.10-l 12/l

EXIT
Application without adapter e.g. Bosch, ETD 019.00 Digital testers e.g. Sun, DIT 900 e.g. AVL, Diesel-Tester 875

Connection diagram for available testers with adapter, e.g. Bosch MOT 001.03, Hartmann & Braun EOMT 3

001 010 011 015 016

Digital tester Adapter Trigger clamp Test cable with plug Diagnosis socket

017 RI-transmitter 021 TDC-impulse transmitter Reaulator 5i RI-transmitter pin 59 TDC-transmitter pin

07.1.10-112/2

EXIT
Connection diagram for testers without adapter, e.g. Bosch ETC 019.00, Sun DIT 9000, AVL Diesel-Tester 875

2 Regulator 2i RI-transmitter pin 001 Digital tester 015 Test cable with plug

016 017 021 59

Diagnosis socket R l-transmitter TDC-impulse transmitter TDC-transmitter pin

Checking

Remove air cleaner cover (arrows),

07.1.10-l 12/3

EXIT
2 Remove closing plug from regulator.

Attention! Catch emerging oil.

3 Connect digital tester accord ing to connection diagram.

017 RI-transmitter on regulator (injection pump)

021

TDC-impulse transmitter on holder (engine)

4 Engine at idle. Read TI-value (indirect injection timing) at idle speed 750 k 50/min on digital tester. RI-nominal value: 15O after TDC at 750 + 50/min.

07.1.10-l

12/4

EXIT
Stop engine. Disconnect digital tester. Screw in closing plug on regulator. Mount air cleaner top. Perform leak test with engine running. 10 Check engine oil level, and correct, if required.

07.1.10-112/5

EXIT
07.1-l 15 Adjusting injection timing (high-pressure method) - following checkup

Job no. of work units or standard texts and f tat rates data 07-8300.

Note

Prior to adjustment, check injection timing on cylinder 1 (07.1-109).

Adjusting

1 Set crankshaft in direction of roation to 24O before TDC in compression stroke of 1st cylinder.

2 Loosen fastening screws (arrows) on injection pump flange and on supporting holder (arrow).

Fastening of supporting holde

07.1.10-l 15/l

EXIT
3 Engage pump unit. 4 Swivel injection pump by turning adjusting screw on adjusting device, while watching fuel jet. If the fuel jet changes to chain-like drops, begin of delivery (injection timing) has been attained. Nominal value: 24O before TDC.

Direction of rotation of adjusting screw Clockwise = injection timing retarded Counterclockwise= injection timing advanced

Note: If adjustment cannot be made any further, displace injection pump. Removal and installation of injection pump (07.1-200).

A Fuel jet full B Fuel jet restricted shortly before begin of delivery (injection timing) C Chain-like drops begin of delivery (injection timing)

5 Disconnect pump unit. 6 Assemble injection system and check regulating linkage, adjust, if required (30-300). Note: When the engine is started, the injection system will automatically vent itself. 7 Run engine and check all connections for leaks.

07.1.10-l 15/2

EXIT
07.1-l 16 Adjusting injection timing (position pickup-RIV-method) - following checkup

Job no. of work units or standard texts and flat rates data 07-8300.

Note

Prior to making adjustments, check begin of delivery

(injection timing) (07.1-l 11).

Adjustment

1 Set crankshaft in directi on of rotation to 15O after TDC of first CY !linder.

2 L o o s e n fasteni

screws (arrows) on injection

pump flange and ( 3n suppro lting holder (arrow).

Screw on supporting hol der

07.1.10-l 16/l

EXIT
3 Swivel injection pump by turning adjusting screw on injection timing-adjusting device until both lamps are lighting up.

Direction of rotation of adjusting screw Clockwise = injection timing retarded Counterclockwise = injection timing advanced RI-nominal value 15O after TDC.

Note: If adjustment cannot be made any further, displace injection pump. Removal and installation of injection pump (07.1-200).

4 Tighten fastening screws on injection and on supporting holder.

pump

flange

5 Remove position indicator (position pickup). 6 Screw in closing plug. 7 Mount air cleaner top.

8 Check control linkage and adjust, if required (30400). 9 10 Perform leak test with engine running. Check engine oil level and correct, if required.

07.1.10-116/2

EXIT
07.1-l 17 Adjusting injection timing with digital tester(R IV-method) - following checkup

Job no. of work units or standard texts and flat rates data 07-8300.

Note

Prior to making adjustments, check begin of delivery (injection timing) (07.1-l 12).

Adjusting

1 Loosen fastening screws (arrows) on injection pump flange as well as on supporting holder (arrow).

Screw on supporting holder

Run engine at 750 f 50/min at idle.

3 Adjust RI-value (indirect injection timing) by turning adjusting screw on injection timing-adjusting device. RI-nominal value: 15O after TDC at 750 2 50/min.

Direction of rotation of adjusting screw Clockwise = injection timing retarded Counterclockwise = injection timing advanced

07.1.10-l 17/l

EXIT
Note: If adjustments cannot be made any further, displace injection pump. Removal and installation of injection pump (07.1-200). 4 Stop engine. 5 Disconnect tester. 6 Screw in closing plug on regulator. 7 Mount air cleaner. 8 Check control linkage and adjust, if required (30-300). 9 10 Perform leak test with engine running. Check engine oil level and correct, if required.

07.1.10-117/2

EXIT
07.1-135 Checking injection nozzles

Job no. of work units or standard texts and flat rates data 07-6712.

Injection nozzles removed (07.1-230).

Test values Injection nozzle Opening pressure in bar new 115-125 used min. 100

Special tool

Cleaning unit

Conventional tools Tester EFEP 80 H e.g. Bosch, D-7000 Stuttgart order no. 0 881 200 502 e.g. Bosch, D-7000 Stuttgart order no. KDEP 2900/4

Cleaning needle 0.18 mm dia.

Note

For testing, use clean test oil or filtered diesel oil only. When checking a nozzle, never place hand in jet of a nozzle. The jet will enter deeply and destroy the tissue. Fuel entering the blood may cause blood poisoning.

A. Throttle pintle and flat surface pintle nozzle

1 Energetically pump 5 times through injection nozzle on tester. Then test buzzing of nozzle, slowly actuating hand lever for this purpose (approx. 1 stroke per second).

07.1.10-135/l

EXIT
2 Test jet: During short, fast partial strokes (at least 2 strokes per second) the jet should be rather closed and tear off well.

A Jet pattern closed and well atomized B Jet pattern torn up, too wide and spreading

3 Check opening pressure: Nominal value 115-125 bar with new nozzle, min. 100 bar with used nozzles. Move hand lever slowly downward (at least 1 stroke per second) and read opening pressure on pressure gauge. For this test, shutoff valve mut be open.

B. tiole-type pintle nozzle

1 Prior to testing: Check longitudinal bore (151 with cleaning needle of 0.18 mm dia. for passage.

2 Energetically pump 5 times through injection nozzle on tester. Then test buzzing of nozzle, slowly actuating hand lever for this purpose (approx. 1 stroke per second).

07.1 .lO-135/2

EXIT
3 Test jet During short, fast partial strokes (at least 2 strokes per second) the jet should be rather closed and tear off well.

A _ Jet pattern closed and well atomized

B

Jet pattern torn up, too wide and spreading

I I,I#;I;

4 Generate initial jet by moving hand lever slowly in downward direction (4-6 s/stroke). A vertical cord-like jet should come out of center bore (15). Note: On new nozzles it is rather difficult to generate the initial jet, for this reason check longitudinal bore with cleaning needle of 0.18 mm dia. for passage.

5 Check opening pressure. Nominal value: 115-l 25 bar with new nozzle, at least 100 bar with used nozzle. Move hand lever slowly in downward direction (approx. 1 stroke per second) and read opening pressure on pressure gauge. Shutoff valve must be open during test.

07.1.10-135/3

EXIT
07.1-137 Disassembling, cleaning, assembling and adjusting injection nozzles (following checkup)

Job no. of work units or standard texts and flat rates data 07-6750.

31 32 33 34 35 36 37 40

Nozzleneedle.. . . . . . . . . . . . . . . . . . . . . . . . Visual and slide test; on hole-type pintle nozzle clean center and longitudinal bore Nozzle body . . . . . . . . . . . . . . . . . . . . . . . . . . Remove combustion residue Nozzle holder element ................... Touch up on surface plate Thrustpin . . . . . . . . . . . . . . . . . . . . . . . . . . . Tip should point toward upper part Nozzle holder lower part .................. 70-80 Nm Compression spring Nozzle holder upper part. ................. Clamp in protective jaws Steel disk ............................ Adjust for opening pressure. Nominal value 115-125 bar with new nozzle or nozzle to be newly adjusted, min. 100 bar with used nozzle. Opening pressure will be higher or lower depending on thickness of disk, 0.05 mm provide approx. 3 bar difference in pressure

07.1.10-137/l

EXIT
Special tools Torque wrench with plug-in ratchet, l/2 square, 25-130 Nm Socket wrench element 27 mm, l/2 square 001 589 66 21 00

001 589 65 09 00

Cleaning unit

Conventional tool Cleaning needles 0.18 mm dia. e.g. Bosch, D-7000 Stuttgart order no. KDEP 2900/4

Note

During disassembly, make sure that the nozzle body, the nozzle needle and the individual parts are not mixed up among each other.

Disassembly

1 Clamp injection nozzle holder upper part (37) with protective jaws into vice in such a manner that the leak oil line connections are not damaged.

07.1.10-137/2

EXIT
2 Disassemble injection nozzle.

36 +!? 34

E933

Nozzle needle Nozzle body Nozzle holder element Pressure pin Injection nozzle holder lower part Compression spring injection nozzle holder upper part Steel disk for making adjustments

32

35

Cleaning and testing

3 Remove combustion residue on nozzle needle seat with cleaning cutter.

4 Clean nozzle needle and nozzle body with brass brush.

07.1 .lO-137/3

EXIT
5 Visual and slide check. Immerse nozzle into filtered diesel fuel. With nozzle body held vertically, the nozzle needle should slide under its own weight in direction of nozzle seat.

6 Touch up nozzle holder element (33) on surface plate.

7 With hole-type pintle nozzle, additionally clean longitudinal and transverse bore with cleaning needle 0.18 mm dia.
.,

2*

-,

: I, /

Longitudinal bore

Transverse bore

07.1 .lO-137/4

2..

A..

EXIT

Assembly

8 Assemble injection nozzle. Tightening torque for iniection nozzle holder 70-80 Nm. 9 Check injection nozzle for function (07.1-135) and adjust, if required (07.1-137).

Nozzle needle Nozzle body Nozzle holder element Pressure pin Injection nozzle holder lower part Compression spring Injection nozzle holder upper part Steel disk for making adjustment

Adjusting

10 Add thicker or thinner disks depending on opening pressure. Thicker disk = increases opening pressure
Thinner disk = reduces opening pressure

Disks are available from 1 .O to 1.8 mm thick, in steps of 0.05 to 0.05 mm. An increase of preload by 0.05 mm increases opening pressure by approx. 3.0 bar.

07.1 .lO-137/5

EXIT
07.1-145 Checking fuel pump

Job no. of work units or standard texts and flat rates data 07-5700.

Test value Delivery at min. 200 rpm (stop lever pushed) min. 200 ml/30 s

Special tools

TDC-impulse transmitter

601 589 04 21 00

Contact handle (for starting)

001 58946 21 08

Conventional tools Digital tester Measuring glass or measuring cup (min. 1 liter) Stop watch e.g. Bosch, MOT 001.03

Testing

1 Connect digital tester (001) according to connection diagram.

001 Digital tester 021 TDC-impulse transmitter

07.1.10-145/l

EXIT
2 Di isconnect return 1flow Iline (E) and hold into
measrJring cup.

3 Move ignition lock into position ,,O , injection pump will then be at ,,zero delivery. 4 Start motor for 30 seconds with separate starting cable, with battery intact (10.0 V when starting) a delivery quantity of min. 200 ml must be attained. Renew delivery pump, if required.

07.1.10-14512

EXIT
07.1-150 Checking vacuum shutoff for leaks

Job no. of work units or standard texts and flat rates data 07-8222.

Special tool

Vacuum tester

116 589 25 21 00

Function diagram

-61~

-6ld

Injection pump Vacuum control unit (stop) 6:b Orif ice 0.5 mm dia. 61 c Valve ignition starter switch 61d Cam disk ignition starter switch 67 Vacuum pump

A Intermediate wall c Remaining consumers e To brake unit

bl = blue br = brown

07.1.10-150/l

EXIT
Testing

Set ignition key on steering lock to position ,,2.

2 Pull suction line (brown) out of connection (arrow).

Connect tester and activate with vacuum.

If readout on pressure gauge is not changing, the valve for key starting system is tightly sealed. If pressure gauge shows a vacuum drop, valve (61~) on steering lock is leaking. Attention! Prior to exchanging valve for key-starting system and the vacuum control unit of injection pump, check hose lines and their connections.

4 Renew valve for key-starting system on steering lock.

5 Turn ignition key on steering lock back to . PCbsition ,,O If pressure gauge shows a vacuum drop, the vacuum control unit or the valve may be leaking. 6 In such a case, disconnect tester on suction line.

07.1.10-150/2

EXIT
7 Pull control line (brown/blue) from connection (arrow).

Layout standard version and @

@California

version

8 Connect tester to connection and activate with vacuum. If pressure gauge shows a vacuum drop, the vacuum control unit of injection pump is leaking. Attention! Prior to exchanging vacuum control unit, check hose lines and their connections. 9 Renew vacuum control unit (07.1-220).

07.1 .lO-1!50/3

EXIT
07.1-200 Removal and installation of injection pump

Job no. of work units or standard texts and flat rates data 07-8410.

Test value injection timing (indirect), position of engine 15O after TDC cylinder 1

Tightening torques (reference values) Closing plug on regulator (measuring point) Injection line Injection pump flange Central fastening bolt on injection timer (lefthand threads)

Nm 30-35 1 O-20 20-25 40-50

Special tools Torque wrench with plug-in ratchet, 1/2square, 25-l 30 Nm Locking screw Socket wrench element 27 mm, l/2 square d&Z.-W73 001 589 66 21 00

601 589 05 21 00 001 589 65 09 00

Box wrench element open, 14 mm, l/2 square for injection lines Serration wrench for rotating injection pump

000 589 77 03 00

601 589 09 08 00

Removal and installation

Remove radiator shell and fan (20-335).

2 Completely remove air cleaner (09-400).

07.1 .lO-200/l

EXIT
3 Rotate crankshaft in direction of rotation to 15O after TDC of 1st cylinder.

4 Disengage belt tensioner (13-340). 5 Remove chain tensioner (05-310). 6 Connect injection and fuel lines to injection pump. 7 Pull vacuum lines from vacuum control unit for idle speed increase, stop unit and vacuum control valve, if required. 8 Disengage regulating linkage on adjusting lever.

9 Remove vacuum pump (43-610).

10 Loosen central fastening scr ew (19) (lefthand thread), apply counterhold to CI rankshaft for this purpose. Attention! LEFTHAND T H R E A D S

07.1.10-200/2

EXIT
11 Unscrew fastening screws (arr*ows) and screw on supporting holder.

12

Pull out injection pump toward the rear.

Installation notes

13 Check whether engine is at 15O after TDC of first cylinder.

14 Remove closing plug (11).

07.1.10-200/3

EXIT
15 Rotate injection pump with serration wrench (027) on injection pump camshaft until lug of regulator shows up on bore, slip in locking gauge (023) in this position until gauge is noticeably engaging. Attention! Risk of damaging injection pump! As soon as the injection pump is installed and tightened, remove locking gauge.

16 Assemble engine. Note: When the engine is started, the injection system will automatically vent itself.

07.1 JO-200/4

EXIT
07.1-210 Renewing delivery valve seal

Job no. of work units or standard texts and flat rates data 07-8627

Removal and installation of air cleaner (09-400).

7h 7i 7k
7f 79
1074-500612

7 Delivery valve holder . . . . . . . . 7f Copper seal , . . . . . . . . . . . . . . . . 79 Delivery valve carrier . . . . . . . . . . 7h O-ring. . . . . . . . . . . . . . . . . . . 7i Compression spring 7k Delivery valve

. . . . . . . . . . . . . 35 Nm . . . . . . . . . . . Renew . . . . . . . . . . . Note installation position . . . . . . . . . . . . Lubricate prior to installation.

Special tool Socket wrench element notched tooth 17 x 20, l/2 square 617 589 01 09 00 VOW-8541

07.1 .lO-210/l

EXIT
07.1-220 Renewing vacuum control unit

Job no. of work units or standard texts and flat rates data 07-8618

Removal and installation of air cleaner (09-400).

t ~ 6b W6a 6c

1 Injection pump 6 Vacuum control 6a 6b 6c 25 O-ring Screw Holder Emergency

unit

(stop).

. . . . . . . . . . . . . . . Slightly lift during removal, tilt rearward toward engine

end and pull out

stop

lever.

. . . . . . . . . . . . . . . . . . . During installation, push and let connecting rod of

vacuum control unit engage in rocker of emergency stop lever

07.1.10-220/l

EXIT
07.1-230 Removal and installation of injection nozzle

Job no. of work units or standard texts and flat rates data 07-6810.

30 Injection nozzle ...,. 50 Leak oil hose 51 Hose clamp (aonly) 52 Closing plug 53 Nozzle reed. . . . . . . . . . 54 Injection lines cylinder 1

. . . . . . . . . . . . . . . . . . . 70-80 Nm, use special tool 001 589 65 09 00

. . . . . . . . . . . . . . . . . Renew . . . . . . . . . . . . . . . . . . lo-20 Nm (reference value)

07.1.10-230/l

EXIT
07.1-235 Removal and installation of fuel pump

Job no. of work units or standard texts and flat rates data 07-5710.

Remove air cleaner cover (09-400).

1 Injection pump 3 Fuel pump. . . . 3a Gasket 3b Circlip, 2 each 3c Nut, 2 each 23 Pressure connection 82 Fuel filter inlet 84 Clamp 89 Suction line

. . . . . . . . . . . . . . . . . . . . . . . During removal, catch emerging engine oil

07.1.10-235/l

EXIT
07.1-240 Removal and installation of injection timer

Job no. of work units or standard texts and flat rates data 07-8014.

Tightening torque Central fastening screw on injection timer (lefthand threads)

Nm 40-50

Special tools Socket wrench element 27 mm, l/2 square 001 589 65 09 00

Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm

001 589 66 21 00

Impact puller

116589203300

Threaded bolt M 6

Sii$Q
moL-6368

11658901 3400

Note

Injection pump removed, remove and install injection pump (07.1-200).

Removal and installation

1 Remove assembly basket. 2 Remove camshaft timing gear for slackening chain.

3 Pull out locking pin (arrow).

07.1.10-24011

EXIT
4 Push timing chain in outward direction, slip in sheet metal strip of approx. 0.2 mm for this purpose, and pull out injection timer. 5 Install injection pump. 6 Check injection timing with digital tester (07.1-l 12). adjust, if required (07.1-l 17).

07.1 .lO-240/2

._

._

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

EXIT

07.1-245

Renewing fuel filter

Job no. of work units or standard texts and flat rates data 07-5513.

Note

Fuel system will vent itself automatically when starting, owing to higher delivery capacity of fuel pump and throttles (orifices) in filter top, as well as on injection pump. Function diagram, refer to 07.1-010 section ,,G .

Removal and installation

tit 74
1 Disengage vacuum line on holder.

t.3

2 Loosen fastening screw (74) and remove filter (42) in downward direction.

42 Filter 73 Fuel filter top 74 Screw 76 O-ring 77 Sealing ring (aluminum)

42

07.1.10-245/l

EXIT
Air cleaner 09

EXIT
09 Air cleaner

Job No. Removal and installation of air cleaner A. Standard version and @ Federal B. @California . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-400

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

09/l

EXIT
09-400 Removal and installation of air cleaner

A. Standard version and 6%) Federal

95 96 @

33 95a

CP
95c

90 Air cleaner cover 91 Air cleaner element 92 Closing clip, 6 each 93 Sealing sleeve, 4 each 94 Air guide housing

\ a
102a % Q; / 102

92
98 intake line 102 Intake scoop 102a Bolt

95 Holder. 2 each iga Nut 95b Washer 95c Screw 96 Rubber, 4 each

09.10-400/l

EXIT
E3. @California

102a

92
Air cleaner cover Air cleaner element Closing clip, 6 each Sealing sleeve, 4 each Air guide housing 95 Holder, 2 each 95a Nut 95b Washer 95c Screw 96 Rubber, 4 each 98 Intake line 99 Pressure control flap 100 Vacuum control unit 101 Linkage pressure control flap 102 Intake scoop 102a Bolt 119 Clamp

09.10-400/2

EXIT
Belt drive 13

EXIT
13 Belt drive

Job No. Removal and installation of V-belt

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

13-340

13/l

EXIT
13-340 Removal and installation of V-belt

V-belt dimensions A Basic drive Version B with power steering pump C with power steering pump and refrigerant compressor 2120 0079978492

Length (mm) Part number

1015 0079979092

2050 601 9970292

Belt tension (test value KG scale on measuring instrument)

Tightening torque Screw for fan

Nm 25

Special tools Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm Measuring instrument (Krikit)

001 58967 2100

L-z -.- nr ,>IY-

001 589 69 21 00

Contact handle for rotating engine (component of compression pressure recorder 001 589 46 21 00)

001 589 46 21 08

Note

The V-belt is tensioned by means of a draw spring (380) via tensioning roller (6). A shock absorber (370) prevents vibrations in belt drive.

: 370 374 380

Crankshaft pulley Pulley, alternator Pulley, coolant pump Pulley, hydraulic oil pump for power steering Pulley, refrigerant compressor Tensioning roller Shock absorber Tensioning lever Tensioning spring

13.10-340/l

EXIT
The tensioning roller for belt drive version A has grooves on circumference in accordance with V-belt. For belt drive versions B and C the circumference of tensioning roller is flat.

1134-11621

Checking

Mark belt at a well visible spot with chalk. Connect contact handle to cable connector (terminal 30) and to coupling (terminal 50) (arrows). Rotate engine step by step while checking belt for damage. Complete inspection when identification shows up
again (one rotation of engine).

Renew cracked, burnt or worn out belts.

Version A (standard version) 1 2 3 6 Crankshaft Alternator Coolant pump Tensioning roller

Version 6 1 Crankshaft 2 Alternator 3 Coolant pump 4 Power steering pump 6 Tensioning roller 13.1 O-340/2

EXIT

Version C Crankshaft Alternator Coolant pump Power steering pump Refrigerant compressor Tensioning roller

Removal

1 2 3

Disconnect vent line on fan cover. Disengage fan cover and place over fan. Unscrew center bolt (340) for fan and remove fan.

4 Remove fan cover.

5 Slacken V-belt and remove. For this purpose, unscrew collar nut (378). Insert a mandrel (12-l 3 mm dia., approx. 300 mm long) or wheel nut wrench from vehicle tools into spring tensioning lever (374) and relieve hex. head screw (375) opposite to force of draw spring (380) to the extent that the screw can be pushed back in direction of intake manifold. Release spring tensioning lever, push back tensioning roller and remove V-belt.

Installation

6 Check pulley profiles and tensioning device for damage and contamination (e. g. worn out bearing points of tensioning device, dents in pulleys etc.) and renew, if required.

346 Pulley 385 V-belt

13.1 o-340/3

EXIT
7 Mount V-belt. Start at tensioning roller and finish at coolant pump. Do not use belt wax or similar products. Swivel spring tensioning lever (374) by means of a mandrel against force of draw spring (380) to the left until the screw (375) can be slipped through spring tensioning lever and cylinder head. Position collar nut (378) and tighten.

Insert fan cover prior to mounting fan.

Tighten fan fastening screw to 25 Nm.

9 Mount fan cover. 10 Attach vent line. 11 Check belt alignment and tension.

Note: Measure tension with Krikit instrument 001 589 69 21 00. Test value (KG scale on measuring instrument).

13.10-340/4

EXIT
Intake manifold, exhaust manifold, emission control system 14

EXIT
14 Intake manifold, exhaust manifold, emission control system

Job No. Operation of emission control system .................. A. General .................................. 8. Components and operation . . . . . . . . . . . . . . . . . . . . .

............................ Checking emission control system .................... Removal and installation of intake manifold .............. Removal and installation of exhaust manifold ............. A. Standard version and @ Federal ................. B. @California. .............................
C. Overall operation

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

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

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

100 180 350

14/l

EXIT

14-050

Operation of emission control system

A. General

Starting model year 1984, engine 601.92 is provided with a pneumatically/electronically controlled EGRsystem for California. Engines in Federal version vehicles are not provided with EGR.

14.10-050/l

USA

EXIT

1341

61b

Function diagram with automatic transmission 1 Injection pump 2 Regulator 4 Vacuum control unit idle speed increase 5 ADA-capsule (altitude pressure compensation) 6 Vacuum control unit (stop) 60 EG R-valve 61 a Orifice 61 b Orifice 0.5 mm dia. Vent filter Vacuum control valve 67 Vacuum pump Damper :: Pressure control flap 100 Vacuum control unit for (99) 105 Intake manifold 110 Exhaust manifold 120 EGA-line 121 Control unit 123 Pressure converter 124 Adjusting screw for (123) 125 Switchover valve, electric for EGR-line 126 Switchover valve, electric, for pressure control flap 127 Switchover valve, electric, for rpm increase 128 Thermovalve closes at approx. 17 OC 129 Temperature sensor coolant 100 C C 130 Thermovalve opens at approx. 17 132 Rpm sensor, engine 134/l Microswitch 134/l I Microswitch 136 Starter ring gear 139 Orifice 140 Check valve brake unit a Vent line to vehicle interior b Key shutoff c Remaining consumers d Automatic transmission e Brake unit f To refrigerant compressor - control unit bk = black bl = blue br = brown gr = green pu = purple re = red ye = yellow

s6:

14.10-050/2 U S A

EXIT

i
I

Function diagram with manual transmission 1 Injection pump 2 Regulator 4 Vacuum control unit idle speed increase 5 ADA-capsule (altitude pressure compensation) 6 Vacuum control unit (stop) 60 EGR-valve 61 b Orifice 0.5 mm dia. 62 Vent filter 65 Vacuum control valve 67 Vacuum pump 99 Pressure control flap 100 Vacuum control unit for (99) 105 Intake manifold 110 Exhaust manifold 120 EG R-line 121 Control unit 123 Pressure converter 124 Adjusting screw for (123) 125 Switchover valve, electric, for EGR-valve 126 Switchover valve, electric, for pressure control flap 128 Thermovalve closes at approx. 17 C 129 Temperature sensor coolant 100 C 130 Thermovalve opens at approx. 17 C 131 Rpm sensor, tachometer 132 Rpm sensor, engine 134/l Microswitch 134/l I Microswitch 136 Starter ring gear 139 Orifice 140 Check valve brake unit a Vent line to vehicle interior b Key shutoff c Remaining consumers d Automatic transmission e Brake unit f To refrigerant compressor - control unit bk = black bl = blue br = brown gr = green pu = purple re = red ye = yellow

14.10-050/3

USA

EXIT
B. Components and operation

Vacuum control valve The vacuum control valve is attached to injection pump and connected to adjusting lever by means of a driver. With supply vacuum connected (central connection) the valve modulates under increasing load a pressure with dropping characteristic. This modulated pressure is processed still further by pressure converter (also refer to group 27).

La tout automatic transmission 65 72 A B Vacuum control valve Vacuum damper Control line Suction line

La yout manual transmissio 65 A B Vacuum control valve Control line Suction line

Pressure converter The pressure modulated by pressure control valve is converted for EGR-system in pressure converter. The EG R-valve is activated via switchover valve (125). The modulated pressure can be continuously changed by means of adjusting screw (124) - under red protective cap - by approx. 100 mbar.

14.1 o-050/4

EXIT
Air guide housing with pressure control flap A pneumatically operated pressure control flap is located in air guide housing to increase the vacuum in intake manifold. When the engine is running in EGR-mode, the pressure control flap closes the fresh air duct. In closed condition, a minimum opening (arrow) remains between pressure control flap and air guide housing.

Pressure control flap closed

Note

Do not operate linkage on vacuum control unit for pressure control flap manually.

Control unit Installed behind battery. After switching on ignition, the control unit is connected to battery voltage. Minimum working voltage approx. 11 Volts.

Electric switchover valve (125) Valve releases the vacuum for EGR-valve under given operating conditions. Activation is by means of control unit in dependence of coolant temperature and engine speed, as well as speed and load-dependent on microswitch (134/l).

14.10-050/5

EXIT
Electric switchover valve (126) Releases vacuum for pressure control flap under given operating conditions. Activation is by means of control unit in dependence of coolant temperature and engine speed, as well as speed and load-dependent on microswitch ( 134/l I).

Microswitch ( 134/l 1 Switches off EGR and refrigerant compressor prior to full load (refrigerant compressor only if air conditioning-comfort circuit is operating).

Microswitch (134/l

I)

Switches off pressure control flap prior to full load.

Temperature switch coolant 100 OC (129) For thermic protection of engine, EG R is switched off as from 100 OC coolant temperature by temperature switch (129) via control unit.

Rpm sensor engine (132) Installed on flange toward transmission. The rpm sensor (132) comprises a magnetic core and a coil. It senses the engine speed and transmits that speed in the shape of an AC-voltage to control unit for refrigerant compressor. The transformed signal is then transmitted to control unit.

14.10-OW6

EXIT
Rpm sensor on tachometer (manual transmission only). The vehicle speed is sensed by rpm sensor (arrow) on tachometer. At a speed above 78 5 8 km/h (48 mph) the switching unit will switch off EGR.

C. Overall function

EGR proceeds when the following items have been met: Engine speed > 1200 f 50/min < 2950 f 50/min Coolant temperature < 100 OC Load-dependent shutoff via microswitches shortly before full load. 134/l EG R-valve 134/l I Pressure control flap Speed-dependent < 78 + 8 km/h (48 mph) (on vehicles with manual transmission only)

Central connection (A) of vacuum control valve (65) is connected to vacuum from vacuum pump (67). The modulated pressure from vacuum control valve outlet (6) is adapted to EGR-valve (60) in pressure converter ( 123).

14.10-050/7

EXIT
The pressure converter (123) regulates the pressure modulated by vacuum control valve (67) according to load condition (accelerator pedal position). The pressure control flap (99) is pneumatically operated and activated by control unit (121) via switchover valve (126). The full vacuum of vacuum pump (67) is then resting against vacuum control unit (100). The pressure control flap (99) will then close. With pressure control valve closed, the vacuum in intake manifold increases. As a result, more exhaust gas will be recirculated. Engine rpm and speed are picked up by rpm sensor and processed by control unit. The pressure control valve and the EGR-valve will be opened or closed, depending on operating condition of engine, via magnetic switchover valves (125 and 126). When exhaust gas is recirculated, a part of the exhaust gases is guided into intake manifold via EGR-pipe and EGR-valve and sucked up again.

14.10-050/8

EXIT
14-100 Checking emission control system

Special tools

Tester O-1000 mbar for vacuum

; f

116589252100

TDC-impulse transmitter

601 5890421 00

Conventional tools e.g. Bosch, MOT 001.03 Digital tester e.g. Sun, DIT 9000 Multimeter e.g. Sun, DMM-5

Distributor

14.10-100/l

EXIT

Function diagram automatic transmission 1 Injection pump 2 Regulator 4 Vacuum control unit idle speed increase 5 ADA-capsule (altitude pressure compensation) 6 Vacuum control unit (stop) 60 EGR-valve 61a Orifice 61 b Orif ice 0.5 mm dia. 62 Vent filter 65 Vacuum control valve 67 Vacuum pump 72 Damper 99 Pressure control flap 100 Vacuum control unit for (99) 105 Intake manifold 110 Exhaust manifold 120 EGR-line 121 Control unit Pressure converter Adjusting screw for (123) Switchover valve, electric, for EGR-valve Switchover valve, electric, for pressure control flap 127 Switchover valve, electric, for rpm increase C 128 Thermovalve closes at approx. 17 129 Temperature sensor coolant 100 C C 130 Thermovalve opens at approx. 17 132 Rpm sensor, engine 134/l Microswitch 134/l I Microswitch 136 Starter ring gear 139 Orifice 140 Check valve brake unit 123 124 125 126 a Vent line to vehicle interior b Key shutoff c Remaining consumers d Automatic transmission e Brake unit f To refrigerant compressor bk = black bl = blue br = brown gr = green pu = purple re = red ye = yellow

14.10-100/2

EXIT

Function diagram manual transmission

:
4 5 6: 61b :: :z 100 105 110 120

Injection pump Regulator Vacuum control unit idle speed increase ADA-capsule (altitude pressure compensation) Vacuum control unit (stop) EG R-valve Orifice 0.5 mm dia. Vent filter Vacuum control valve Vacuum pump Pressure control flap Vacuum control unit for (99) Intake manifold Exhaust manifold EGR-line

121 123 124 125 126 128 129 130 131 132 134/l 134/l 136 139 140

Control unit Pressure converter Adjusting screw for (123) Switchover valve, electric, for EGR-valve Switchover valve, electric, for pressure control flap Thermovalve closes at approx 17 oC Temperature sensor coolant 100 oC Thermovalve opens at approx. 17 oC Rpm sensor, tachometer Rpm sensor, engine Microswitch I Microswitch Starter ring gear Orifice Check valve brake unit

a b : e f bC bl br gr Pu re ye

Vent line to vehicle interior Key shutoff Remaining consumers Automatic transmission Brake unit To refrigerant compressor = black = blue = brown = green = purple = red = yellow

14.10-100/3

EXIT

br0,75 b0,75ws

C.75 bl/gn -

-.-.-.-

1142-11782/l

Electric wiring diagram EGR 121 Control unit = EGR 125 Switchover valve EG R-valve 126 Switchover valve pressure control flap 127 Switchover valve refrigerating system 129 Temperature sensor coolant 100 oC Rpm sensor, engine 132 134/l Microswitch EGR 134/l I Microswitch pressure control flap Control unit refrigerant compressor 141 142 Plug connection auxiliary fan Electromagnetic clutch refrigerant 143 compressor Rpm sensor refrigerant compressor 144 145 Relay kickdown switch 146 Plug connection interior 147 Central electrics, coupling E = plug connection &point W = plug connection 4-point 150 Plug connection a b c d ; To electromaanetic clutch To plug conn&tion revolution counter To kickdown switch (automatic transmission only) Relay auxiliary fan Pressure switch air conditioning Terminal 15 x preglow switch bl = blue br = brown el = ivory ye = yellow gn = green gr = gray na = natural pi = pink re = red bl = black pu = purple wh = white (bl) (se) I;; [nr/ .r (rt) I:? (ws)

Ground connection points M5 Ground, engine M 10 Ground, battery

14.10-100/4

. . . . . .

EXIT

Quick test

Test EGR-valve (60) with engine stopped Activate EG R-valve with approx. 300 mbar vacuum. Pull off vacuum line.

Renew EG R-valve. End of test

Test pressure converter (123) and pressure adjustment Connect vacuum tester with Y-distributor to connection A and read vacuum value at idle speed. Nominal values in mbar with: manual transmission 320 ? 5 automatic transmission 350 f 5 If the vacuum is above or below nominal value, adjust vacuum. For this purpose, pull protective cap (arrow) from pressure converter (123) and adjust by means of adjusting screw (124) with socket wrench element (4 mm) to specified nominal value.

Check supply pressure on connection C, renew pressure converter, if required. Check vacuum lines according to function diagram. Check vacuum pump (43-660). End of test

14.10-100/5

EXIT

Checking vacuum control Connect vacuum tester with Y-distributor to EGRvalve (60). Check vacuum values and position of pressure control flap (99). Read vacuum values at the following speeds: l/min 750+50 1200 f 50 mbar 0 150-350 Pressure control flap Basic position Fully attracting Basic position Test values not in order.

3 0 0 0 250 0 Test values in order.

Check pressure supply as well as individual parts. End of test

Testing microswitch

(134/l and 134/l I)

Connection vacuum tester as above. At 1200 + 50/min, operate microswitch (134/l), pressure on EGR-valve (60) drops to 0 mbar. Pressure control flap (99) moves into basic position. Actuate microswitch (134/l I), pressure control flap (99) moves into basic position. Function in order. Function not in order.

Check individual parts.

14.10-100/6

EXIT
Testing individual parts

Testing vacuum control valve (65) Connect vacuum tester with Y-distributor to connection 6 of pressure converter ( 123) and check vacuum at idle speed. Nominal values: At 750 f 50: approx. 360-410 mbar With engine stopped and regulating linkage on full load stop 0 mbar.

Check vacuum lines according to function diagram. Check vacuum pump (43-6601, adjust vacuum control valve and renew, if required (27-037). End of test

14.10-100/7

EXIT

Testing switchover valves (125 and 126)

Connect voltmeter to plug connection of switchover valves and measure voltage at 1200 f 50/min. Nominal value: approx. 12 V.

Check electric activation according to wiring diagram, renew control unit, if required. End of test

Connect vacuum tester with Y-distributor to connection C and check vacuum at 1200 + 50/min, with 12 V connected.

C
Switchover valve (125): approx. 350 +- 10 mbar Switchover valve (126) : approx. 700 f 10 mbar Vacuum value in order. Vacuum value not in order.

Check vacuum pump (43-660), renew switchover valve, if required. Check vacuum lines according to function diagram. End of test

14.10-100/8

EXIT

Checking rpm sensor for engine (132) Engine stopped. Separate coupling (1441 and test resistance with multimeter.

Renew rpm sensor. End of test

Connection as above. Push button V- . Read test values at the following engine speeds: l/min 700-800 V>49

I
End of test

Renew rpm sensor.

) With increasing speed, increasing

voltage.

14.10--100/g

EXIT

Testing TD-signal On jack 2 of 4-point plug connection (146) test TD-signal with multimeter button V at idle speed: l/min 750 f 50 Test values in order. Volt approx. 0.35

Check electric activation according to wiring diagram, check rpm sensor for engine, if required. End of test

Testing EGR-protective circuit 100 OC Connect vacuum tester with Y-distributor to EGR valve. Run engine to 120/min, pull off plug on temperature switch (129) and hold against ground. Vacuum 0 mbar on EGR-valve, fan clutch audibly attracting. Function in order. Function not in order.

Test electric activation, renew control unit, if required. End of test

14.10-100/10

EXIT

Testing rnicroswitch (134/l and 134/11) Engine stopped. Pull coupling from microswitch and test for passage with ohmmeter on terminal 2 and 4 or 1 and 3. At idle: 0 SI At full throttle: 00 52

Renew microswitch End of test

Testing full throttle contact on microswitch (134/l) Engine stopped: Coupling on microswitch pulled off. Test with ohmmeter on terminal 1 and 5 for passage. At idle: 00 52 At full throttle: 0 52

Renew microswitch. End of test

14.10-lOO/ll

EXIT
Vehicles with manual transmission

Testing speed shutoff Connect vacuum tester with Y distributor to EG R. valve. Operate vehicle on test bench or on road in 5th gear at partial load. Read vacuum. Readout Speed < 78 * 8 km/h: approx. 300 mbar > 78 ? 8 km/h: approx. 0 mbar Vacuum values In order. Not in order.

Test electrical activation of switchover valve (125). For this purpose, connect multimeter to plug (arrow) of switchover valve and take vehicle again on test run. If there is voltage (approx. 12 VI at a speed of > 78 * 8 km/h, test electric activation of switchover valve according to wiring diagram. Renew defective parts, if required. If there is no voltage, renew switchover valve. End of test

14.10-100/12

EXIT
14-180 Removal and installation of intake manifold

105 Intake manifold 106 Gasket

107 Engine breathing 108 Combination screw

14.10-180/l

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

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

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

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

EXIT

14-350

Removal and installation of exhaust manifold

A.Standard version and @ Federal

110 Exhaust manifold 111 Stud 112 Washer

113 114

Nut M 8, Cu Gasket

B. @ California

60 EG R-valve 61 Corrugated tube 110 Exhaust manifold 111 Stud in cylinder head, 8 each 112 Washer, 8 each

113 114 119 120

NutM8,Cu,8each Gasket Clamp, 2 each EGR-line

14.10-350/l

EXIT
Engine lubrication 18

EXIT
18 Engine lubrication

Job No. Oil circuit, oil consumption

Oil

circuit,oil pressure, pressure relief and bypass valve, oil filter . . . . . . . . . . . . . . . . . . . . . .

18-005

Oil filter Removal and installation of oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pump Removal Removal and and installation installation of of oil oil pump pressure 110

. . .. .. . . . . . . . .. . . . . . .. . . . . . . . . . . .. . .. ... . relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 215

18/l

EXIT
18 -005
Oil circuit, oil pressure, pressure relief and bypass valve, oil filter

Oil circuit

14

185

203

275

52

I -h A+

I
240

1183-11835

18

oil circuit diagram 14 18 52 185 Oil spray nozzle Injection (spray) timer Oil pressure gauge Camshaft 203 Valve tappet 240 Oil pump 275 Oil filter A Injection pump

18.10-005/l

EXIT
Oil pressure

At operating pressure, the oil pressure at idle may drop to 0.3 bar gauge pressure. Upon acceleration, the oil pressure should immediately rise again and attain at least 3 bar gauge pressure at 3000/min.

Opening pressures of valves Bypass valve filter element (differential pressure) Return flow non-retun valve Oil pressure relief valve in oil pump

bar gauge pressure

0.2

4.7-5.3

Oil pressure relief valve

The oil pressure relief valve is integrated in oil pump. The oil is drawn from lowest spot in oil pan via strainer to suction chamber (B). From here, the oil flows through gearwheels to pressure chamber (A) into main oil duct toward filter. Pressure and suction chamber are connected to each other by means of pressure relief valve. Starting from an oil gauge pressure of 4.7-5.3 bar the piston (252) is displaced against force of compression spring (251) and clears the de-activation (shutoff) hole (arrows) to suction chamber (B). Simultaneously, oil flows across two flats on collar (a1 into damping chamber (Cl. This oil opposes the piston movements set up by the pulsating oil pressure and will thereby dampen the piston. C A B

249 Closing plug 250 Guide bolt 251 Compression spring 252 Oil pressure relief valve A Pressure chamber B Suction chamber C Damping chamber a Collar

lB.lO-005/2

EXIT
Bypass valve in oil filter

The bypass valve (285) opens when the differential pressure between contaminated and clean side of filter exceeds 2 bar. This will happen when the filter element is heavily contaminated. The oil will then flow in uncleaned condition to engine.

- 275 - 285 _ 203

275 283 285 286 287 290 b
C

Oil filter housing Spring retainer Valve cone bypass valve Valve seat return flow no-return valve Valve cone return flow no-return valve Ball 8 mm dia. To bearing points Finely filtered oil toward oil pan
118*-n!

- 286 -207

Oil filter

The main flow and the bypass flow filter element are combined in a cartridge. During inspection (1000-l 500 km) the initial operation oil filter element (A) must be replaced by combination oil filter element (B). The combination oil filter element should then be cleaned every 10 000 km. Attention! Do not mix up the oil filter element and the O-ring of oil filter cap of engine 601 with those of engines 615,616 and 617. The oil filter cap is fastened by means of two nuts. The return flow pipe (276) is pressed into cap and has a check valve (277). Unscrew cap (273) when changing oil filter elements and pull up a bit. As a result, the return pipe (276) fastened to cap clears a bore which connects ducts (b) and (4 with each other. The oil in oil filter will flow through duct (c) into oil pan.

ia.io-005/3

EXIT
Operation The oil filter comprises the following main components: a) Oil filter housing with bypass and return flow no-return valve. b) Cap with return flow pipe, check valve and O-rings. c) Combination oil filter element. Coming from supply duct (a) the oil flows in through return flow no-return valve (286 and 287) in oil filter housing and from there directly to combination filter element. After flowing through combination filter element the oil cleaned in main flow filter element (280a) flows through riser (281) and duct (b) to main oil duct and on to bearing points.
On the other hand, the oil finely filtered in bypass filter element (280) flows through return flow pipe (276) and duct (c) to oil pan.

To keep main flow and bypass flow separate, the combination filter element is provided with a rubber seal.

271 Nut M 8 272 Stud M 8 273 Cap 274 O-ring 275 Housing 276 Return flow pipe 277 Check valve 278 O-ring 279 O-ring 280 Oil filter element 280a Main flow filter section 281 Riser 282 Locking ring 283 Spring retainer 284 Spring 285 Valve cone bypass valve 286 Valve seat return flow no-return valve 287 Valve cone return flow no-return valve 288 Compression spring 289 Spring retainer a To oil filter b To bearing points c To oil pan

18.1 O-005/4

EXIT
Complaints about oil filter If following a filter element change an oil pressure below 0.3 bar gauge pressure shows up at idle, observe the following: Forcible pushing-in of return flow pipe (276) during oil filter change may, under certain circumstances, force the sealing ring of oil filter element out of its holder into a position in front of riser (281). The oil supply proceeds then through bypass valve (2851, which will lead to an oil pressure drop. To prevent knocking out of sealing ring, introduce return flow pipe (276) into oil filter without using force.

18.1 O-005/5

EXIT
18-110 Removal and installation of oil filter

Tightening torques Nuts for oil filter cap Screws for oil filter to cylinder crankcase

Nm 20-25 25

Special tools

Torque wrench, double arm, 3/8 square, 8 - 3 2 Nm

001 589 51 21 00

Box-end wrench element, open,

12 mm, 3/8 square

fs+
-400.~as62

61758901 0300

Note

When removing oil filter it is quite possible that remains of gasket will stick to flange surface of cylinder crankcase. To make sure that during their removal (e. g. by scraping) no such remains of gasket will enter the clean-oil duct (arrow) of cylinder crankcase, be sure to cover or close bore beforehand.

Removal

Completely remove air cleaner (09-400).

2 Unscrew holder (a) for starter cable, (b) for return flow line of heating system and (c) clamp for vacuum lines. 3 On vehicles with EGR, remove EGR line (1).

18.10-l 10/l

EXIT
4 Unscrew oil filter cap and pull up a bi t, so that the oil flows back toward oil pan.

Unscrew line for oil pressure gauge (arrow).

6 Unscrew filter and remove. 7 Clean sealing surfaces on oil filter and cylinder crankcase. For this purpose, close bores on cylinder crankcase.

Line for oil pressure gauge engine 601.91 1

Installation

8 Position oil filter with new gasket and screw down. 9 Connect line for oil pressure gauge to oil filter. 10 If required, insert new oil filter element.

Line for oil pressure gauge engine 601.921

18.10-l 10/2

EXIT
11 Mount oil filter cap and tighten nuts to 20-25 Nm.

12 On vehicles with EG R, install EGR line (1). 13 Mount holder (a) for starting line, (b) for return flow line of heating system and (cl clamp for vacuum lines. 14 Run engine at idle and check for leaks.

18.10-11013

EXIT
18-210 Removal and installation of oil pump

Tightening torques Oil drain plug on oil pan Nuts for oil filter cap M6 Screws for oil pan on cylinder crankcase Screw for drive sprocket on oil pump Screws for oil pump on cylinder crankcase M8

Nm 30 20-25 10 25 25 25

Special tool

Torque wrench, double arm, 318 square, 8-32 Nm

001 589 51 21 00

Removal

1 Remove engine (01-030). 2 Remove oil pan (01-310). 3 Unscrew screw (259) on sprocket and remove sprocket from drive shaft.

Unscrew screws (260) and remove oil pump.

18.10-210/l

EXIT
Installation

5 Install oil pump and tighten hex. socket screws to 25 Nm. 6 Engage sprocket in chain and set on drive shaft.

Note: Mount sprocket in such a manner that crown is facing oil pump and that the trochoid shape corresponds with that on oil pump shaft (arrows).

118 - 26004

7 Install oil pan (01-340). 8 Install engine (01-030). 9 Run engine, check for leaks.

18.10-210/2

EXIT
18-215 Removal and installation of oil pressure relief valve

Tightening torques Closing plug for oil pressure relief valve

Nm 50 + 5

Opening pressure Oil pressure relief valve in oil pump

bar gauge pressure 4.7-5.3

Removal

1 Remove engine (01-030). 2 Remove oil pan (01-310). 3 Unscrew closing plug (249) and remove compression spring (251) with guide pin (250) and piston (252). Note. Closing plug is under pressure.

240 Oil pump 242 Dowel sleeve 249 Clostng plug 250 Guide pin 251 Compression spring 252 Piston 257 Sprocket

ll%- 2cmo6

Installation

4 For installation proceed vice versa. 5 Run engine and check for leaks.

18.10-215/l

EXIT
Engine cooling 20

EXIT
20 Engine cooling

Job No. Cooling system Coolant circuit and engine cooling Cleaning cooling system

........................................... 2 0 - 0 0 5
010 015

Draining and filling in coolant - antifreeze table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

A.De-oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Decalcification, derusting Coolant thermostat Removal Coolant pump Removal Removal Fan coupling Magnetic Removal Radiator fan and coupling. installation of and and installation installation of of coolant coolant pump pump housing and installation of thermostat

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

110

..............................,....... ...............................

210 230

. .. . . . . . .. .. ..... .... ... . . . . . . .. . . . . . . . . . , . , . , . . . , magnetic fan coupling _ . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . .

330 335

.......................................... ...................................................... Checking expansion tank closing cap ..........................................

Removal and installation of radiator Repairing radiator

420 425 430

20/l

EXIT
20-005 Coolant circuit and engine cooling

Coolant circuit

F G

1203-11838

From radiator to coolant thermostat From outlet connection to radiator Inlet to heater (heat exchanger) Return flow from heater (heat exchanger

F Filling hose G Vent line H Expansion tank I Overflow pipe

20.1 O-005/1

EXIT
Thermostat Thermostat begins to open 85

Engine

fully opened 100

601

Note

These engines are provided with a thermostat which begins to open at 85 C.

Operation

Warm-up period - coolant temperature up to approx. 85 C. Up to a coolant temperature of approx. 85 C the main valve is closed and the bypass disk is fully open. Inflow (B) from radiator is therefore interrupted. The coolant flows via bypass line (C) directly through coolant pump into cylinder crankcase (D).

1204 -11855

D From crankcase (bypass line) D To crankcase

Partial load operation - coolant temperature approx. 85 C to max. 100 C At coolant temperatures from approx. 85-100 C the main valve as well as the bypass section are more or less opened depending on engine load. The coolant flows from radiator (B) and via bypass line (C) through coolant pump into cylinder crankcase (D).

B From radiator C From crankcase (bypass line) D To crankcase

1204-M 854

20.1 o-005/2

EXIT
Full load operation - high outside temperature (above 100 C) At coolant temperatures above approx. 100 C the main valve is completely opened. The bypass line (Cl is closed by bypass disk. All the coolant will flow through radia;or.

The cooling system is automatically vented by ball valve in coolant thermostat when refilling while engine is operating.

20.1 O-00513

EXIT
20-010 Draining and filling in coolant - Antifreeze table

Total filling capacities of cooling system with heater and mixing ratio Antifreeze)/water2) in liters Total filling capacity of cooling system with heater Mixing ratio antifreeze/water for antifreeze protection up to - 3 0 Oc -40 Oc 3.7514.75 4.514.0

8.5

) Refer to Specifications for Serwce Products sheet 325. ) Refer to Specifications for Service Products sheet 310 and 311.

Tightening torques Radiator Drain plug Cylinder crankcase 30 1.5

Special tools

Tester for

Radiator cap with hose for leak test

605 589 00 25 00

Conventional tool

Antifreeze tester Prestone-VU-Check (Union Cabride) e. g. Philipp Gather, D-4020 Mettmann 2

R -A789

20.10-010/l

EXIT
Note

To prevent corrosion in cooling system, the concentration of the antifreeze should not drop below -20 C antifreeze (30 % by volume). If no antifreeze is available and if only water is filled in, be sure to add 1 % refining agent (anticorrosion oil, 10 cc/l water).

Attention! To prevent corrosion damage on light alloy components, use only approved antifreeze compounds (Specifications for Service Products sheet 325) and refining agents (Specifications for Service Products sheet 311).

Draining

Open cap on expansion tank in steps.

Attention! Open cap only at coolant temperatures below 90 C. 2 Completely remove noise capsule.

3 Open drain plug on radiator. Note: For catching coolant, a pertinent extension hose may be plugged on drain connection.

Drain plug on vehicles without air conditioning system

20.10-010/2

EXIT
On vehicles with air conditioning, open flap for towing eye at front right in front skirt.

Drain plug on vehicles with air conditioning

Note: On vehicles with air conditioning, remove closing plug under righthand wheelhouse on noise capsule. An extension hose can be inserted through this opening and plugged on drain connection of radiator.

Extension hose, plugged on

4 Unscrew drain plug (12) on cylinder crankcase.

12

Drain plug on cylinder crankcase

Filling in

5 Set both heater switches on vehicles with and without air conditioning to max. heating capacity. 6 Slowly fill in coolant up to mark on expansion rank.

Mark on expansion tank

20.10-010/3

EXIT
7 Run engine at intermittent acceleration until coolant thermostat opens (coolant temperature approx. 90-100 C). Note: Close filler neck on expansion tank starting at a coolant temperature of approx. 60-70 C. 8 Check coolant level and fill up to specified mark, if required.

Pressure-test cooling system with tester.

10 Install noise capsule.

20.10-010/4

EXIT
20-015 Cleaning cooling system

A. De-oiling (required only if anti-corrosion oil had been filled in)

1 2

Completely drain coolant (20-010). Remove coolant thermostat (20-l 10).

3 On vehicles with and without air condit,ioning, set heater control to full capacity. 4 Fill cooling system with a 5 % solution of water and a neutral cleaning agent or with a mildly alcaline cleaner, such as P 3-Croni (supplier: Henkel) or Grisiron 7220 (supplier: Farbwerke Hoechst). Attention! On these vehicles (light alloy radiator) do not use heavily alcaline cleaning agents such as P 3-Standard (supplier: Henkel). 5 Run engine warm at medium speed up to approx. 80 C (176 OF) and hold at this temperature for approx. 5 minutes. 6 Stop engine and let cooling system cool down to approx. 50 C (122 F). 7 Completely drain solution. 8 Immediately thereafter, fill cooling system twice with fresh water, run warm (approx. 5 minutes) and drain.

8. Decalcification, derusting

Prior to decalcification and if anti-corrosion oil has been filled in, de-oil even if there is no visible oiling UP.

20.10-015/l

EXIT
1 Fill cooling system with a 10 % (100 g/l) solution of citric acid (available from the chemical trade). 2 Run engine warm at medium speed up to approx. 80 C (176 OF) and hold for approx. 10 minutes at this temperature, while proceeding according to item 3 section A De-oiling. 3 Stop engine and let cool down to approx. 50 C (122 OF). 4 Completely drain decalcification solution. 5 Flush cooling system at least 3 times with fresh water while running engine for at least 5 minutes with each flushing charge. Badly calcified cooling system may require a repetition of the treatment. Always prepare a fresh decalcification solution and repeat flushing steps. 6 Install coolant thermostat with new sealing ring (20-l 10). 7 Fill in coolant (20-010).

20.10-015/2

EXIT
20-l 10 Removal and installation of thermostat

Tightening torques Screws for thermostat housing cover Radiator Drain plug

Nm 10 1.5

Cylinder crankcase 30

Special tools

Tester for cooling system

001 589 48 21 00

Radiator cap with hose for leak test

PT
$\

A-_

,,004-7l2.

---&

605589002500

Removal

Open closing cap on expansion tank in steps.

Attention! Open closing cap only at coolant temperatures below 90 c. 2 Remove noise capsule. 3 Drain coolant (20-010).

4 Unscrew thermostat housing cover and remove thermostat (arrows).

20.10-110/l

EXIT
Installation

5 When installing a new thermostat, place new seal on thermostat housing. 6 Insert thermostat with sealing ring into cover in such a manner that the recess on thermostat corresponds with cast-on rib in cover (arrows). 7 Screw on cover and tighten to 10 Nm.

IX)-26839

8 Fill in coolant (20-010). 9 Pressure-test cooling system with tester.

10 Install noise capsule.

20.10-l 10/2

EXIT
20-210 Removal and installation of coolant pump

Tightening torques Radiator Drain plug

Nm 1.5

Cylinder crankcase 30 Fan on coolant pump shaft (central bolt) Pulley on coolant pump Coolant pump on coolant pump housing 25 10 10

Special tools Torque wrench, double arm, l/4 square, 4-16 Nm Torque wrench, double arm, 3/8 square, 8-32 Nm

000 589 67 21 00

001 589 51 21 00

Tester for cooling system

001 5894821 00

Radiator cap with hose for leak test

605 589 00 25 00

344b. 343309340306

Layout of magnetic fan coupling and coolant pump

301 Coolant pump housing 302 Flange 303 304 Shaft Bearing 305 306 309 340 241 Cassette seal Impeller Washer Collar srew Disk 343 Ball bearing 344 Fan 344a Armature 344b Leaf spring 345 346 347 348 349 ScrewM6x 12 Pulley Magnet, body Magnet carrier Hex. nut

341345302 -

20.10-210/l

EXIT
Removal

1 2 3

Completely. drain coolant (20-010). Disengage overflow hose on fan cover (arrow). Disengage fan cover and place over fan.

4 Unscrew collar screw (340) for fan and remove fan. 5 Remove fan cover.

6 Slacken V-belt and remove. For this purpose, unscrew collar nut (378). Insert a mandrel into spring tensioning lever (374) and relieve hex. screw (375) against force of draw spring (380) until screw can be pushed back in direction of intake manifold. Release spring tensioning lever and remove V-belt.

7 Unscrew fastening screws (345) and remove pulley (346).

Pull cable from body of magnet (arrow).

9 Unscrew hex. nuts (349) and remove magnet carrier (347).

20.10-210/2

EXIT
Note: Magnet carrier (348) is glued to coolant pump housing and may not be pulled off.

10 Unscrew coolant pump housing. 11 Clean sealing surfaces.

Installation

12 Insert coolant pump with new gasket and tighten combination screws to 10 Nm. 13 Mount magnetic body and plug on cable.

14 Mount pulley and tighten fastening screws to 10 Nm.

15 Mount V-belt and engage spring tensioning lever. For this purpose, swivel spring tensioning lever (374) with a mandrel against force of draw spring to the left until the screw (375) can be slipped through spring tensioning lever. Screw on collar nut and tighten.

20.10-210/3

EXIT
16 17 18 Place fan cover over coolant pump. Mount fan and tighten center screw to 25 Nm. Fasten fan cover and attach overflow hose.

19 Fill in coolant (20-010). 20 Pressure-test cooling system with tester. 21 Install noise capsule.

20.10-210/4

EXIT
20-230 Removal and installation of coolant pump

Tightening torques Radiator Drain plug

Nm I,5

Cylinder crankcase 30 Fan to coolant pump (collar screw) Pulley to coolant pump Coolant pump to coolant pump housing Coolant pump housing to cylinder crankcase Alternator to carrier Carrier for alternator to cylinder crankcase 25 16 10 10 45 25

Special tools Torque wrench, double arm, l/4 square, 4-16 Nm Torque wrench, double arm, 3/8 square, 8-32 Nm Torque wrench with plug-in ratchet, l/2 square, 2 5 - l 30 Nm

000589 67 2100

001 589 51 21 00

001 589 66 21 00

Tester for cooling system

001 589 48 21 00

Radiator cap with hose for leak test

605589002500

Conventional tool 7 mm socket wrench hex. head on flexible shaft for hose clamps with worm drive e. g. Hazet, D-5630 Remscheid Order No. 426-7

2 0 - l O-230/1

EXIT
Removal

1 Remove coolant pump (20-210). 2 Disconnc set negative terminal on batte w 3 Unscrew alternator (arrows) and put aIside.

Unscrew carrier for alternator (arrows).

5 Unscrew return line (326) on cylinde!r crankc:as;e and pull auf: of coolant pump housing.

6 Unscrew coolant pump housing. 7 Clean sealing surfaces.

20.1 O-230/2

EXIT
Installation

8 Renew O-ring on return line (326). 9 Plug coolant pump housing on return line, screw with a seal to cylinder crankcase and tighten to 10 Nm. 10 Screw return line (326) to cylinder crankcase.

11 Mount carrier for alternator and tighten screws to 25 Nm. 12 Mount alternator and tighten screws to 45 Nm. Connect negative terminal to battery. 13 Install coolant pump (20-210). 14 Fill in coolant (20-010). 15 Pressure-test cooling system with tester.

20.10-230/3

............................,

EXIT

20- -330

Magnetic fan coupling

General

The engines are provided with an electromagnetic fan coupling which is controlled in dependence on temperature. The coupling is switched on or off by means of a 100 C temperature switch, which is screwed into outlet connection (a). The electromagnetic fan coupling is service-free.

Fan

The fan (344) is seated on a shank on coolant pump bearing and is fastened by means of a collar screw M8x 18. Fan (A) has 6 blades and a diameter of 380 mm. On vehicies with air conditioning the fan (B) has 5 blades and a diameter of 430 mm.

The armature (344a) and the ball bearing (343) are attached to or in fan, respectively. The ball bearing is sealed on both sides with covering disks.

20.10-330/l

EXIT
Body of electromagnetic fan coupling The body of the magnet (347) is fastened to magnet carrier with 3 nuts (349). The magnet carrier is glued to coolant pump housing.

344

344a

306

341 301 302 303 Fr;;;t pump housing 344 344a 344b 345 346 347 348 349 Fan Armature Leaf spring Hex. socket screw M6x12 Pulley Magnet, body Magnet carrier Hex. nut 305 345 302

Shaft Bearing :K Cassette seal 306 impeller 309 Washer 340 Collar screw 341 Disk 343 Bearing

The electric line is connected to body of magnet by meaIns of a coupling (arrow).

Pulley (346) is seated on coolant pump shaft (303) in front of magnet body. The pulley (346) is screwed to flange of coolant pump by means of 4 hex. socket screws (345).

20.1 O-330/2

EXIT
Operation

The fan is switched on only with the ignition engaged and at a coolant temperature of above 98-102 C. The body of the magnet (347) is constantly connected to positive via fuse No. 10 terminal 15. Below 98-102 C coolant temperature the fan is switched off and will run along only under influence of headwind or bearing friction. At the latest, starting from 102 C coolant temperature, negative is connected via temperature switch (1) in runout socket (330). The armature (344a) is attracted by magnet body (347) and presses against face of pulley (3461. The fan is now rigidly connected to pulley and runs along in accordance with coolant pump speed. If the coolant temperature drops below 98-93 C, the temperature switch opens and the armature (344a) is lifted from pulley (346) by leaf springs (344b). On vehicles with air conditioning, the fan and the electric auxiliary fan is switched on by way of a double contact relay which is activated by the temperature switch 52 C on receiver dehydrator. When the air conditioning system is switched off, a temperature switch 100 C in runout connection will again switch fan on or off.

20.10-330/3

EXIT
20-335 Removal and installation of magnetic fan coupling

Tightening torques Fan to coolant pump (collar screw) Pulley to coolant pump Magnet body to magnet carrier (reference value)

Nm 25 10 10

Special tool Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm 001 589 66 21 00

Removal

1 2

Disconnect vent line on fan cover. Disconnect fan cover and place over fan.

3 Unscrew collar screw for fan and remove fan. 4 Remove fan cover.

5 Slacken V-belt and remove. For this purpose, unscrew collar nut (378). Insert a mandrel into spring tensioning lever (374) and relieve hex. screw (375) against force of draw spring (380) until screw can be pushed back in direction of intake manifold. Release spring tensioning lever and remove V-belt.

20.10-335/l

EXIT
6 Unscrew fastening screws (345) and remove pulle Y (3146).

Pull coupling of electric line from magnet body

(ar row). 8 Unscrew magnet body (347) from magnet carrier on fastening screws (349).

NCbte: Magnet carrier (348) is glued to coolant pump ho using and may not be pulled off.

Installation

9 Mount magnet body and plug on cable. 10 Mount pulley and tighten fastening screws to 10 Nm.

20.10-33512

EXIT
11 Mount V-belt. Pay attention to layout of unit.

Swivel spring tensioning lever (374) with a mandrel (arrow). against force of draw spring to the left until the screw (375) can be slipped through spring tensioning lever. Screw on collar nut and tighten.

12 13 14

Insert fan cover and place over coolant pump. Mount fan and tighten collar screw to 25 Nm. Fasten fan cover and attach vent line.

20.10-335/3

EXIT
20-420 Removal and installation of radiator

Installation dimensions for radiator, fan and fan cover Fan distance a to radiator, approx. mm 90 Fan distance to fan cover, approx. mm B A 25 20

Radiator/Fan

Fan cover/Fan

Radiator and expansion tank

These vehicles are provided with an expansion tank which is attached to wheelhouse at the right. Different radiators are installed depending on vehicle equipment (without or with air conditioning).

20.10420/l

EXIT
Tightening torques Radiator Drain plug Cylinder crankcase 30 Nm 1.5

Special tools Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm 001 589 66 21 00

Clamp for hose lines

P 9 J g

000589403700

Tester for cooling system

001 589 48 21 00

Radiator cap with hose for leak test

605589002500

Conventional tool 7 mm socket wrench hex. head on flexible shaft for hose clamps with worm drive e. g. Hazet, D-5630 Remscheid Order No. 426-7

Note

Vehicles without air conditioning are provided with a cross flow radiator with a core depth of 34 mm and a height of 373 mm. The drain plug is accessible from below (enlarged cutout).

Radiator for vehicles without air conditioning

20.1 o-420/2

EXIT
Vehicles with air conditioning are also provided with a cross flow radiator, the radiator has a core depth of 42 mm and is 29 mm higher. The cooling capacity is thereby increased. The drain plug is accessible from the front via flap in front-end skirt (enlarged cutout).

Radiator for vehicles with air conditioning

Fan cover

There are two fan cover versions in accordance with different radiators.

Version A On vehicles without air conditioning

(low radiator).

Version 6 120 - 26740 On vehicles with air conditioning (high radiator). The fan covers are plugged below into one or two holding lugs on radiator (arrows) and are fastened to radiator at top or laterally with holding clamps.

Removal

1 Drain coolant (20-010). 2 On vehicles with automatic transmission, disconnect oil lines from or to transmission and unscrew on radiator.

20.10 42013

EXIT
3 Disconnect coolant hoses on radiator.

4 Pull out flat contour springs (1) for fan cover, slightly lift fan cover and place over fan. 5 Pull out flat contour springs (2) for radiator and lift out radiator.

Installation

For installation proceed vice versa to removal.

Note that the fastening mounts of the radiator are correctly introduced into rubber grommets of lower holder and the holders of the fan cover into holding lugs on radiator (arrows). 7 Fill in coolant (20-0101, pressure-test cooling system with tester and check for leaks.

20.10-420/4

EXIT
20-425 Repairing radiator

Special tools

Tester for cooling system

001

589482100

004-8325

Radiator cap with hose for leak test

605 589 00 25 00

Conventional tool 7 mm socket wrench hex. head with flexible shaft for hose clamps with worm drive e. g. Hazet, D-5630 Remscheid Order No. 426-7

Note

Since light alloy radiators with plastic water tanks cannot be repaired by soldering, a sealing compound has been developed and approved. The compound can also be used to seal radiators made of heavy-metal (nonferrous metal radiator). The sealing compound is a product on a silicone rubber base, which remains permanently elastic in its final condition. Temperature stability extends from -50 OC to +200 OC. Owing to different accessibility on radiator (e. g. more difficult in core than on water tank) the sealing compound is available in a diluted and an undiluted shape. The different sealing compound versions and the priming fluid are included in a repair kit, part No. 123 989 00 20.

20.10425/l

EXIT
Designation Priming fluid Purpose Preparation of wash primer. For sealing easily accessible areas. For sealing poorly accessible areas (e. g. laterally on cooling pipes).

Sealing compound, undiluted Sealing compound, diluted

Sealing compound and priming fluid have a shelf life of approx. 1 year, provided they are always closed airtight. Cloudy priming fluid should no longer be used.

Individually, the sealing compound serves to seal the following parts or areas in coolant circuit: a) Plastic water tanks (3 and 4). b) Heavy-metal water tanks (holes up to 1.5 mm dia.). c) Light and heavy-metal cooling pipes (6). d) Pipe plate (2). e) Beaded flange (connection between radiator core and water tank). f) Heat exchanger of heating system.

1 Radiator core 2 Pipe plate 3 Water box, top 4 Water box, bottom

5 Gasket 6 Cooling pipes 7 Ribs

20.1 O-42512

EXIT
Damages spots on water tanks, which are exposed to increased stress caused by e. g. torn or broken fastening lugs, cracks in fillets of connections, fractures and very long or wide cracks on top should not be repaired, since the sealing compound can accept very light loads only.

Plastic water tanks of radiators made by Behr can be exchanged by means of special tools or fixtures in Behr radiator repair shops or Inter-Radia service stations. If required, consult the nearest Behr repair shop or Inter-Radia service station for such a possibility and if such a repair can be made. If there is no such a possibility, renew radiator.

On heavy-metal radiators with plastic water tanks, soldering on core may be performed only at a distance of 20 mm from water tank, since otherwise the high soldering temperature will damage the gasket (5) and the water tank (3 or 4). Seal leaks which are closer to water tank with sealing compound only.

If the leaking spot can be clearly located in installed condition, the radiator need not be removed. In such a case, it will be enough to drain the coolant and, after sealing, to pressure-test the cooling system with tester (1.0-l .2 bar gauge pressure).

20.10-425/3

EXIT
When handling priming fluid and sealing compound observe the following: The priming fluid is easily inflammable (adhere to safety rules, dangerous materials class A 1). Up to complete interlacing (bonding) of sealing compound, acetic acid will be released. For this reason, avoid skin contact. Clean affected parts immediately with water and soap. Rinse eyes with water, see a doctor, if required.

Sealing

1 If the leaking point cannot be accurately localized in installed condition, remove radiator (20-420). 2 Clean radiator. 3 Close hose connections with self-made closing

caps.

15 Required parts for upper hose connection: 15 16 17 A 5

C

16

15

17

2 clamps L 36-46, part No. 976026 036000 Length of hose, part No. 201 501 38 82 Reduction piece made of two lengths of pipe 35 mm dia. 39 mm dia.
12 mm dia.

18

19

18

29

Required parts for lower hose connection.

18

19 20 z

clamps L 36-46, part No. 916026 036000 Length of hose, part No. 201 501 38 82 Cap made of length of pipe 35 mm dia. 39 mm dia.
2

1204-8463

4 Close connections of gear oil cooler with plastic caps or plugs made of old oil cooler lines. For this purpose, saw off oil cooler lines directly behind nipple and close with solder.
20.1 O-42514

EXIT
5 Connect tester to radiator. 6 Place radiator into a water bath.

7 Pressurize radiator with tester and watch where air bubbles are rising. 8 Mark leaking point. 9 Remove radiator and reduce pressure.

10

Blow radiator dry with compressed air.

11 Clean spot to be sealed with a conventional cleaning agent (e. g. Tri or bentine). Always clean a spot slightly larger than the area to be sealed (e. g. clean cracks approx. 20-30 mm beyond ends of cracks).

There is no need to remove paint. Then blow respective radiator area dry with compressed air. There should be no more dust and grease residue.

12 Apply priming fluid with a brush uniformly and very thinly. Similar to cleaning, apply priming fluid slightly beyond area to be sealed. To make sure that the priming fluid is not soiled in tank, pour the quantity required for repair into a separate vessel. Attention! Pay attention to safety rules!

20.10-42515

EXIT
13 Let priming fluid dry at ambient temperature for approx. 10 minutes. 14 Position radiator in such a manner that the sealing compound cannot flow away from area to be sealed. 15 Depending on accessibility, apply sealing compound diluted or undiluted. Use brush, spatula or the like for distributing sealing compound.

Attention! During application and distribution make sure that no air pockets will occur. Similar to cleaning and priming, apply sealing compound beyon area to be sealed. If there are several leaking spots on beaded flange (arrows), it is recommended to seal the beaded flange all-around. Seal leaks in core from both sides.

At end of sealing procedure, close tube immediately. Up to complete interlacing (bonding) of sealing compound, acetic acid will be released. For this reason, avoid skin contact. Clean affected parts immediately with water and soap. Rinse eyes with water, see a doctor, if required.

16 Leave radiator alone for at least 3 hours to permit drying of sealing compound. Depending on quantity of applied sealing compound and size of spot to be sealed, complete interlacing (bonding) of sealing compound into a lasting elastic connection will be completed after max. 24 hours at ambient temperature.

20.1 O-425/6

EXIT
17 Pressure-test radiator in water bath for approx. 5 minutes at 1.5 bar gauge pressure. If leaks are still showing up, repeat pressure test as from item 7. 18 Remove tester and closing plugs.

19 Upon re-installation of radiator, pressure-test cooling system with tester.

20.10-425/7

EXIT
20-430 Checking expansion tank closing cap

Closing cap new radiator closing cap Open pressure relief valve at 1.2 Tt:5 bar gauge pressure used radiator closing cap 1 .O-0.2 bar gauge pressure 0.1 bar gauge vacuum

Vacuum valve opens at

Special tools

Tester for cooling system and radiator cap

001 589 48 21 00

Double connection for closing cap

000589736300

Checking pressure relief valve

1 Fasten double connection to leak tester by means of holding clips. 2 Place expansion tank closing cap on double connection. 3 Check opening pressure by pumping.

Checking vacuum valve

Vacuum valve (arrow) should rest against rubber seal, which should permit easy lifting and should then snap back upon release. Note: Replace corroded (slightly rusted) expansion tank closing caps.

20.1 O-430/1

EXIT
Engine suspension 22

EXIT
22 Engine suspension

Job No. Engine mounting

................................. 22-211 212 ................................... 215 Removal and installation of front engine stop .................................... 220 Adjusting engine stop .................................................... 240 Removal and installation of engine shock absorber .................................
Removal and installation of front engine mounts Removal and installation of rear engine mount

22/l

EXIT
22-211 Removal and installation of front engine mounts

Tightening torques Screws for engine carrier on engine mount front Screws for engine mount on front axle carrier Screws for engine shock absorber on front axle carrier Adjusting screw on front engine stop

Nm 40 25 10 130

Special tools Torque wrench with plug-in ratchet, l/2 square, 25-130 Nm Torque wrench with plug-in ratchet, l/2 square, 40-200 Nm Gauge for adjusting front engine stop

001 589662100

001 589 67 21 00

201589042300

Note

Shore hardness of engine mounts is alike. Shielding plates are inserted between engine carriers and engine mounts.

Removal

Remove noise capsule below.

2 Unscrew hex. socket screws for engine carrier on engine mount from below (arrow).

Hex. socket screw for engine carrier, right

22.10-211 /l

EXIT

Hex. socket screw for engine carrier, left

1223-fl993

Engine carrier, right 22 25 30 41 42 43 Shielding plate Engine mount Engine carrier Screw M 8 x 30 Combination screw M 8 x 18 ScrewMlOx30

Unscrew engine shock absorber below.

Engine carrier, left 22 Shielding plate 25 Engine mount 30 Engine carrier 31 Hex. nut M 6 32 Washer 33 Lower rubber mount 34 Engine shock absorber 35 Upper rubber mount 38 Hex. head screw M 6 x 18 48 Cross member

1223-11992

33 48 32 31

22.10-211/2

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

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

... .

EXIT

4 Unscrew hex. socket screws (1) for engine stop and remove holder.

Remove adapter on air cleaner (arrow).

6 Attach ropes of engine hoist to front suspension eye (arrow) and lift engine with a crane. When lifting, make sure that fan is not wiping against fan cover. 7 8 Remove both engine mount shielding plates. Unscrew screws (42) and remove engine mounts.

Installation

Install new engine mounts and screw down.

10 insert both shielding plates. 17 Lower engine and tighten hex. socket screws for engine carrier on engine mount to 70 Nm.

22.10-211/3

EXIT
12 Screw engine shock absorber to front axle carrier and tighten screws to 10 Nm.

13 Mount holder for engine stop and adjust engine stop (22-220).

14

Install noise capsule.

1 5 Mount adapter for air cleaner. 16 Disengage engine hoist.

22.10 211/4

EXIT
22-212 Removal and installation of rear engine mounts

Tightening torques Screws for engine mounts on engine carrier Adjusting screw for engine mounts Nut for engine mount on transmission (reference value)

Nm 25 30 70

Special tool Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm

001 589 66 21 00

Note

An engine mount with stop is installed with all transmission versions.

The engine carriers are of different width (dimension A) depending on transmission version.

22.10-212/l

EXIT
Removal

1 Remove noise capsule. 2 Unscrew nut (1). 3 Unscrew adjusting screw (11). 4 Unscrew screws 5

(14).

Lift transmission with a pit lift and remove engine

mount (4).

Vehicles with manual 4-speed or automatic transmission : 3 3a

4 8

Lockwasher Nut M 12 x 1.5 B 12 Nut M8 Washer 0.4 Engine mount

Cage nut

10 11 12 13
14 17

Washer Adjusting B 8.4 screw Engine carrier Washer B 8.4

ScrewM 8 x 1 8 C o m b i n a t i o n screw M 10 x 2 2
1224-11906/l

Vehicles with 5-speed transmission 1 NutM12x1.5 2 Lockwasher B 12 4 Engine mount 6 Threaded plate 7 Holder 8 Cage nut 10 11 12 13 14 17 Washer B 8.4 Adjusting screw Engine carrier Washers B 8.4 8crewsM8x 18 Combination screw M 10 x 22

22.1 o-21 212

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

I..

EXIT

Installation

6 On vehicles with manual 4-speed or automatic transmission, place engine mount in carrier (12) and lower transmission. 7 On vehicles with 5-speed transmission, place engine mount into holder (7). 8 Screw down engine mount with screws (14). 9 Screw on nut (1 I. Torque reference value 70 Nm. 10 Adjust engine stop (22-220). 11 Mount adjusting screw (11) and tighten to 130 Nm. 12

Install noise capsule.

22.10-212/3

EXIT
22-215 Removal and installation of front engine stop

Tightening torques Adjusting screw (1) Hex. socket screws for holder on oil pan

Nm 130 25

Special tools

Torque wrench, double arm, 3/8square, 8 -32 Nm

001 589 51 21 00

Torque wrench with plug-in ratchet, l/2 square, 40-200 Nm Gauge for adjusting front engine stop

001 589 67 21 00

201 589 04 23 00

k
/------

I
I

1223-1097911

2
1 ScrewM12x1.5~90 2 Stop clamp 3 Screws M 8 x 20 4 Clamp

Removal

1 Unscrew noise capsule. 2 Unscrew adjusting screw

(1).

3 Unscrew hex. socket screws (3) and remove clamp (4) together with engine stop.

22.10-215/l

EXIT
Installation

For installation proceed vice versa to removal.

5 Adjust engine stop (22-220). 6 Tighten hex. socket screws (3) to 25 Nm and adjusting screw (1) to 130 Nm. 7 Install noise capsule.

22.10-215/2

EXIT
22-220 Adjusting engine stop

Tightening torques Adjusting screw for front engine stop

Nm 130

Special tools Torque wrench with plug-in ratchet, l/2 square, 25-l 30 Nm Torque wrench with plug-in ratchet, l/2 square, 40-200 Nm Gauge for adjusting front engine stop 001 589 66 21 00

001 589 67 21 00

201 589 04 23 00

Vehicle should rest on its wheels ready-to-drive. Do not use grease or oil for engine stop.

1
1 ScrewM12x1.5x90 2 Stop clamp

2
3 ScrewsM8x20 4 Clamp

,
22.1 O-220/1

EXIT
Installation

1 Unscrew noise capsule. 2 Completely loosen adjusting screw engine stop. 3 4

(1) on front

Loosen adjusting screw (11) on rear engine stop. Insert adjusting gauge (02) on front engine stop.

5 Move engine by lightly shaking crosswise manually. 6 Tghten adjusting screw (11) on rear engine mount to 30 Nm. 7 Tighten adjusting screw (1) on front engine stop to 130 Nm. 8 Remove adjusting gauge (02). 9 Install noise capsule.

-02
1224-11025

22.10-220/2

EXIT
Z-240 Removal and installation of engine shock absorber

Note

An engine shock absorber (45) is installed at the left on engine and side member above one rubber mount (49) each.

43a Engine carrier 45 Engine shock absorber 48 Side member Rubber mount 49

Removal

Unscrew front noise capsule below (arrows).

2 Unscrew the two upper and lower hex. screws and remove engine shock absorber.

Installation

For installation proceed vice versa to removal.

22.1 O-240/1

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Throttle control 30

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30 Throttle control

Job No. Adjusting control linkage

................................................... 30-300 315 Removal and installation of front wall bearing for accelerator lever ........................ Removal, installation and adjustment of bowden cable ................................ 325 330 Removal and installation of accelerator pedal ...................................... Lubrication of control linkage and control shafts. ................................... 335

30/l

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30-300 Adjusting accelerator linkage

Adjusting value Length of connecting rod (204) from injection pump to transfer lever (214) )
1 For automatic transmission only.

146 + 8 mm

Note

Grease bearing points as well as ball sockets of linkage with Molykote Longterm 2.

Adjusting

1 Check accelerator linkage for distortion, bowden cable for easy operation. Renew linkage or bowden cable, if required. 2 Disengage bowden cable (230). For this purpose, force out slotted guide piece (240) on angle lever and remove bowden cable.

3 Vehicles with automatic transmission Disengage connecting rod (204, adjustable) on transfer lever (214). Check whether adjusting lever of injection pump rests noticeably against idle speed stop. Engage connecting rod (204) free of tension. Make sure that roller (215) in guide block rests free of tension against end stop (arrow) and adjust, if required.

30.1 o-300/1

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4 Pull to full load on angle lever (208). with adjusting lever of injection pump resting against full load stop. If required, displace adjustable ball head (206) in slot of transfer lever (214) and counterlock.

5 Vehicles with manual transmission Check whether adjusting lever of injection pump rests noticeably against idle speed stop, disengage connecting rod (201) on cruise control/tempomat for this purpose. 6 Re-engage bowden cable (230).

7 Adjusting cruise control/tempomat For this purpose, disengage connecting rod (201) on actuator (arrow). Push linkage into idle speed position. Adjust connecting rod (201) in such a manner that it is 1 mm shorter than the actual max. distance. Engage connecting rod (201) and counterlock.

8 Checking full throttle stop With engine stopped, step on accelerator pedal from inside vehicle down to full throttle stop or with automatic transmission down to stop on kickdown switch. Adjusting lever (arrow) should then noticeably rest against full load stop. Check by applying excess pressure to connecting rod (204). Readjsut adjusting screw (229) on bowden cable, if required.

30.1 O-300/2

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9 In idle position, nipple (226) of bowden cable (230) should rest free of tension against compression spring (227). If required, adjust bowden cable (230) from inside vehicle by means of adjusting nut (232).

Attention! Apply full throttle and let accelerator pedal slowly return to idle speed position. In this position, the roller in slotted lever should rest free of tension -against end stop. Correct adjustment from inside vehicle with adjusting nut (2321, if required.

10 Adjust control pressure cable, pushing off ball socket (212) for this purpose. Pull idle travel rod (202) apart up to stop. Pull control pressure cable (211) forward until slight resistance is felt. In this position, hold ball socket (212) above ball head and engage free of tension, adjusting idle travel rod (arrow), if required.

30.10-300/3

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225
1302-1,873

201 202 203 204 204a 205 5za 207 208 210 211 212 213 214 214a

Connecting rod idle travel rod Connecting rod Connecting rod (automatic transmission) Connecting rod (manual transmission) Lock Ball head Nut Holder Regulating lever Antichaf ing hose Control pressure cable for automatic transmission Ball socket Slotted lever Transfer lever Transfer lever (automatic transmission)

215 216 216a 217 217a 218 219 220 221 222 223 224 225 226 227 228

Roller Holder automatic transmission Holder (manual transmission) Lock Lock Screw Spring Lock Washer Nut Holder Accelerator pedal Clip Nipple Compression spring Plastic clip

229 Adjusting screw 230 Bowden cable 231 Rubber grommet 232 Adjusting nut 233 Accelerator lever 234 Front wall bearing 235 Return spring 236 Full throttle stop 237 Washer 238 Kickdown switch 239 Adjusting nut 240 Guide piece 242 Sealing sleeve 243 Screw

30.1 o-300/4

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30-315 Removal and installation of front wall bearing for accelerator lever

Removal and installation

1 Remove accelerator pedal (30-330). 2 Unscrew cover.

3 Remove bowden cable (230). Pull off lock (arrow) for this purpose. 4 Unscrew front wall bearing (234) and remove together with accelerator lever (233).

5 Disengage return spring (235). 6 Remove front wall bearing (234) from accelerator lever (233). Pull off lock (arrow) for this purpose.

Installation note

Make sure that the lug (arrow) of front wall bearing (234) engages in bore on front wall (241). Check regulating linkage and adjust, if required (30-300).

30.10-315/l

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30-325 Removal, installation and adjustment of bowden cable

Removal and installation

1 Disengage bowden cable (230) on control lever (213). Compress and push out guide piece (arrow) for this purpose.

2 Slightly lift angle lever (208) and remove slotted guide piece (240) on angle lever. 3 Compress black plastic clip (228) and remove bowden cable.

4 Remove lock (arrow) for bowden cable (230) inside vehicle. 5 Push bowden cable (230) in outward direction. Make sure that the rubber buffer (231) is not pushed out. 6 Remove complete bowden cable from outside between front wall and accessories compartment wall.

Adjusting

7 Check whether transfer lever (214) rests noticeably against inner idle speed stop of injection pump and adjust control linkage, if required (30-300).

30.10-325/l

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8 With engine stopped, step on accelerator pedal from inside vehicle down to full load stop or with automatic transmission down to stop on kickdown switch. Adjusting lever should then rest against full load stop of injection pump. Readjust adjusting screw (229) on bowden cable, if required.

9 Let accelerator pedal slowly return to idle speed position. In this position, roller in slotted lever should rest free of tension against end stop. If required, adjust bowden cable (230) with adjusting nut (232) from inside vehicle. There should be no idle travel between nipple and spring following adjustment.

30.1 O-32512

EXIT

205 203 204 206 215 207

213

210

242

241

240 231 232

1302-11656

201 Connecting rod 202 Idle travel rod 203 Connecting rod 204 Connecting rod 205 Lock 206 Ball head 207 Holder 208 Angle lever 210 Anti-chafing hose

Control pressure cable control for automatic transmission 213 Slotted lever ga;tyatic transmission only) 215 224 Accelerator pedal 229 Adjusting screw 230 Bowden cable

211

231 232 233 234 235 240 241 242

Rubber grommet Adjusting nut Accelerator pedal Front wall bearing Return spring Front wall Unit compartment wall Sealing sleeve

30.1 O-32513

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30-330 Removal and installation of accelerator pedal

Removal

1 Compress expanding clip (arrow) behind accelerator pedal and pull out.

2 Slide accelerator pedal in upward direction and rotate by 18OO. 3 Pull accelerator pedal down, lug (arrow) on accelerator lever should be in alignment with groove in accelerator pedal.

Installation

4 For installation proceed vice versa, making sure that the expanding clip is reliably engaging. The connection from accelerator lever to accelerator pedal requires no service and need not be lubricated.

30.10-330/l

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30-335 Lubrication of control linkage and control shafts

Lubricating

Following each engine wash and preservation of engine compartment, lubricate all bearing points, all control levers and joints of control linkage with an oil can. On USA version vehicles, use the following hydraulic oils only for this purpose. BP-Aero-Hydraulik 1 Castro1 DB Hydraulik Fluid Esso Univers J-13 Mobil Aero HFA Shell Aero Fluid 4 The bowden cable requires no service and need not be lubricated.

Layout manual transmission

Layout automatic transmission

30.1 o-335/1

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Fuel system 47

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47 Fuel system

Job No. Operation of immersion tube transmitter for fuel readout Operation of fuel tank positive and negative venting Removal and installation of fuel tank

.............................. 4 7 - 0 2 0 .................................. 030

100 120

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

Removal and installation of immersion tube transmitter ...............................

47/I

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47-020
Operation of immersion tube transmitter for fuel readout

When fuel level drops, the slide contact (1) on float (2) of immersion tube transmitter increases the resistance value, voltage is reduced and the indicating needle in instrument will therefore move back. When fuel level drops still further, the reserve warning contact (5) in immersion tube transmitter, which switches to reserve warning lamp, is closed.

1 Slide contact 2 Float 3 Contact plate 4 Guide and contact rod 5 Reserve warning contact

The reserve warning contact lights up with ignition switched on (control function). Lamp will go out the moment the engine starts, provided there is more fuel in fuel tank than the reserve. Note: During control function, the reserve warning lam; lights weaker, for reserve stronger. Check fuel readout (54-269).
1 2 4 a b 47.1 O-020/1 Immersion tube transmitter Fuel gauge Cable connector To terminal 15 To terminal 61

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47-030 Operation of fuel tank positive and negative venting

Closing cap At a gauge pressure of 100-300 mbar the fuel evaporation vapors can escape through closing cap.

1 2 3 4 5

Closing cap Sealing ring Closing clip Compression spring Filler neck

Vent system The vent system comprises a central tube (54) with one check vessel (54a) each at ends. The vent line (64) runs from central tube downward through fuel tank. The vent valve is plugged on at end of vent line (64). The steadying bowl (67) is installed on vehicles with gasoline injection engines only.

W7 - 23938

51 69 70 71 47.1 o-030/l

Vent valve Suction hose Return hose Gasket

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The vent valve permits establishing a pressure of 30-50 mbar in fuel tank. With a vacuum in fuel tank, the vent opens at l-l 6 mbar vacuum.

Vent valve opened at overpressure (gauge pressure) 1 2 3 4 5 6 7 Compression spring Valve housing Spring retainer Negative vent valve Valve plate Positive vent valve Connection

Vent valve opened at underpressure (vacuum)

.8280/l

47.10-030/2

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47-l 00 Removal and installation of fuel tank

62a 60a 60

Fuel tank . . . . . . . . . . . 50 50a Washer, 4 each. . . . . . . . 50b Nut, 4 each . . . . . . . . . . Vent valve 51 Filler neck 60 60a Sealing sleeve. . . . . . . . . 62 Closing cap 62a Sealing ring 64 Vent line Immersion tube transmitter 65 flange ....................... 65a Sealing rings ........................ 6 5 b Sealing Fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . 68 ........................ 68a Sealing ring. Feed line . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Return line . . . . . . . . . . . . . . . . . . . . . . . . . 70 71 Gasket ............................ Damping shim . . . . . . . . . . . . . . . . . . . . . . . 74 190 + 5 mm a Filling capacities in liters Full readout Warning lamp - reserve

Pump off fuel (item 2) Use large washers (risk of tearing) 21 Nm

Pay attention to correct seat

39 Nm Renew Clean, check for re-use, 39 Nm Renew Check for reuse, 28 Nm Check for re-use Pay attention to correct seat on rear floor Item 9a

approx. 55 approx. 7.5

47.10-100/l

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Attention! When removing fuel tank, pay attention to safety rules.

Removal

Disconnect ground connecting line on battery.

2 Drain fuel tank. Carefully pump off fuel, so that no residue remains in fuel tank. 3 Loosen or disengage lining for fuel tank first below, then laterally and then on top (arrows). Remove trunk mat for this purpose. 4 Pull coupling (66) for fuel gauge from immersion tube transmitter. Disengage cable harness on holding clamps (arrows).

5 Loosen all connections on fuel tank and pull gasket (71) from pipe connection and fuel filter. Note: Catch residual fuel, close lines and connections.

64 68 70 71

Vent line Fuel filter Return line Gasket

6 Slide back drain hose (arrow) for approx. 5 cm.

47.10-100/2

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7 Unscrew fastening nuts for fuel tank and pull out drain hose (arrows) in upward direction in such a manner that hose can be installed behind edge of fuel tank. Slightly lift fuel tank for this purpose.

8 Lift fuel tank over side panelling (arrows) at the left.

Installation

9 Install fuel tank in vice versa sequence, paying attention to the following: a) Check whether damping shims (74) are well fastened on fuel tank. Glue down with MB-Universal Glue, part no. 000 989 92 71, if required.

a 190+5 mm

b) Plug on coupling for fuel gauge and check for function. Engage cable harness in holding clamps provided. c) Check for leaks.

47.10-100/3

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47-120

Removal and installation of immersion tube transmitter

Tightening torque Immersion tube transmitter

Nm 35-43

Note

Prior to removing immersion tube transmitter, pump off approx. 8 liters fuel from full fuel tank.

Removal

1 Loosen or disconnect lining for fuel tank at first below, then laterally and on top. 2 Pull coupling (66) for fuel gauge from immersion tube transmitter. 3 Unscrew sealing flange (65a). 4 Pull out immersion tube transmitter first in upward direction, then toward the rear. Let immersion tube transmitter run empty, if required.

Installation

5 For installation proceed vice versa, paying attention to the following: a) Renew both sealing rings (arrows). b) Prior to installation of immersion tube transmitter, remove locking pin. c) Plug on coupling and check fuel gauge for function. d) Insert immersion tube transmitter with lug (arrow) in downward direction into fuel tank. e) Tighten sealing flange to 35-43 Nm. f) Check for leaks.

747-23633

47.10-120/l