Telephone: Fax: VAT Registration No.

: Name: Address: Tel - Private: Tel - Business: Tel - Mobile

Notes

fdsgtfr

Manufacturer: Model: Year: Registration: Mileage: Job number: Date

Mercedes-Benz 124 250d 1993

Specified value No. of cylinders Capacity Compression ratio Type 5/OHC cc 2497 :1 22 Make Bosch Type PES 5M RS 173 Part No. 0 400 075 939 Part No. 0 400 075 940 Part No. 0 400 075 941 In-Line 1-2-4-5-3 Make Bosch Part No. 0 432 217 169 bar 115-145/104-112 BTDC 18 Engine/Pump Pointer / Overflow v = BTDC, n = ATDC v /rpm 17/670 /rpm 141/70050 rpm 70050 rpm AT=68020 rpm 5150150 C 70 rpm 610-800 rpm 4900-5400 secs 1,0 A/B B 1/2 1 m-1 (%) 2,50 (66) m-1 (%) 2,10 (60) V/RC(Ah) 12/130 (72) Make Bosch Type 0 001 218 108 A 194-238

Measured value

Vehicle identification

Injection system
Fuel/injection pump assembly Fuel/injection pump assembly Fuel/injection pump assembly Fuel/injection pump assembly Fuel/injection pump assembly Pump type Injection sequence Injector nozzle Nozzle and holder assembly Nozzle opening pressure - new/used

Tuning and emissions

Crankshaft position (n = ATDC) Adjusting method Dynamic timing - Time Trac Stanadyne, Snap-on - Tecnotest Idle speed Idle speed - alternative Rated no load speed Water temperature Idle speed - for smoke test Governed speed range - for smoke test Maximum time at governed speed Test mode Probe type Smoke opacity - EU limit Smoke opacity - homologation value

Starting and charging

Battery Starter motor Starter motor Maximum cranking amps

Manufacturer: Mercedes-Benz Engine code: 602.912 Tuned for: +AT/AC (A)(CH)(S)

Model: 200-500/E/D/C/T (124) (84-93) 2,5D 250D Output: 66 (90) 4600 Year: 1989-93

Autodata Limited 2010 Valid forever. 29.10.2013 V8.500-

Alternator Alternator Alternator output Regulated voltage

Make Bosch Type 0 120 489 332 A/V/rpm 55/14/2500 V 13,0-14,5 V/A 11/12 secs 10 Max Beru 718 MJ Bosch 0 250 201 001/026 Champion CH156 Lucas/CAV HDS216 mm Hydraulic mm Hydraulic bar 26-32 bar/rpm 3,0/3000 bar 0,8-1,2 C 85 mm 6PKx2030 mm 6PKx2125

Glow plugs
Glow plug nominal rating Glow plug activation time Glow plug - part no. Glow plug - part no. Glow plug - part no. Glow plug - part no.

Service checks and adjustments

Valve clearance - INLET Valve clearance - EXHAUST Compression pressure Oil pressure Radiator cap Thermostat (primary/secondary) open Drive belt size - alternator Drive belt size - PAS/AC

Lubricants and capacities

Engine oil options Ambient temperature range Engine oil grade Engine oil classification Ambient temperature range Engine oil grade Engine oil classification Ambient temperature range Engine oil grade Engine oil classification Ambient temperature range Engine oil grade Engine oil classification 118 Engine with filter(s) Manual transmission oil grade Manual transmission Automatic transmission fluid Automatic transmission (drain & refill) Differential oil grade - rear 276 Differential rear Cooling system - total capacity Brake fluid Brake fluid Power steering fluid Power steering fluid Other lubricants and capacities SAE ATF-A litres 1,5 Type Dexron II litres 5,5 SAE 90W litres 0,7 litres 8,0 AC=9,0 Type DOT 4+ litres 0,6 Type 000 989 88 03 litres 1,0 Renew bolts/nuts No Stage 1 Renew bolts/nuts No Stage 1 25 Nm 25 Nm 35 Nm+90-100 All temperatures SAE 5W/30, 5W/40 OEM MB 288.5 -20C > SAE 5W/50 OEM MB 299.1 -15C > SAE 10W/30, 10W/40, 10W/50 OEM MB 299.1 -5C > SAE 20W/40, 20W/50 OEM MB 228.1 litres

Tightening torques
30 Cylinder head instructions Main bearings 11 37 70 Main bearings Big end bearings Big end bearings Oil pump to cylinder block Sump bolts Sump drain bolt Flywheel/driveplate Other engine tightening torques

Manufacturer: Mercedes-Benz Engine code: 602.912 Tuned for: +AT/AC (A)(CH)(S)

Model: 200-500/E/D/C/T (124) (84-93) 2,5D 250D Output: 66 (90) 4600 Year: 1989-93

Autodata Limited 2010 Valid forever. 29.10.2013 V8.500-

Clutch pressure plate 36 45 Crankshaft pulley/damper centre bolt Camshaft sprocket/gear Camshaft carrier/cap Camshaft/rocker cover Inlet manifold to cylinder head Exhaust manifold to cylinder head Injector/clamp Injector pipe unions Injector nozzle to holder Fuel/injection pump sprocket/gear Glow plugs Chassis tightening torques Rear hub 40 39 39 39 39 39 336 Steering track rod end Brake disc to hub Brake caliper to carrier Brake caliper carrier to hub Brake disc to hub Brake caliper carrier to hub ABS sensor ABS sensor Road wheels Minimum disc thickness - solid Minimum disc thickness - ventilated Minimum disc thickness Disc runout Disc runout Minimum pad thickness Minimum pad thickness Maximum drum diameter Parking brake travel

25 Nm

25 Nm 10 Nm 25 Nm 25 Nm 70-80 Nm 10-20 Nm 70-80 Nm 65 Nm 20 Nm 200-240 Nm 50 Nm Front 10 Nm Front 35 Nm Front 115 Nm Rear 10 Nm Rear 50 Nm Front 22 Nm Rear 8 Nm 110 Nm Front 10 mm Front 19,4 mm Rear 7,3 mm Front 0,12 mm Rear 0,15 mm Front 2 mm Rear 2 mm Rear 164,2 mm No. of notches 1-2 Type R12 grams Type Suniso 5GS cm 120 Type 5/OHC cc 2497 Part No. 0 400 075 939 v = BTDC, n = ATDC v

Brake disc and drum dimensions

Air conditioning
50 51 52 53 Air conditioning refrigerant Air conditioning refrigerant quantity Air conditioning oil Air conditioning oil quantity No. of cylinders Capacity Fuel/injection pump assembly Dynamic timing

ff

Autodata Note 118 Without "ASSYST" service system = 6,5 litres With "ASSYST" service system = 7,0 litres Autodata Note 276 Rear axles with 168/185/187/198/210/215/240 mm diameter: Use new drain and refill plugs with threads coated with sealant once slackened. Autodata Note 30 Fig. 79379 12.88 Bolt length: S = 83,6 mm Max
Manufacturer: Mercedes-Benz Engine code: 602.912 Tuned for: +AT/AC (A)(CH)(S) Model: 200-500/E/D/C/T (124) (84-93) 2,5D 250D Output: 66 (90) 4600 Year: 1989-93 Autodata Limited 2010 Valid forever. 29.10.2013 V8.500-

M = 105,6 mm Max L = 118,6 mm Max 1) 25 Nm 2) 40 Nm 3) Wait 10 min 4) 90 5) 90 01.89 Bolt length: S = 82 mm Max M = 104 mm Max L = 117 mm Max 1) 15 Nm 2) 35 Nm 3) 90 4) Wait 10 min 5) 90 6) M8 = 25 Nm Autodata Note 11 M11 = 55 Nm + 90 M12 = 90 Nm Autodata Note 37 11.90 1) 30 Nm 2) 90-100 12.90 1) 40 Nm 2) 90-100 Autodata Note 70 M6 = 10 Nm M8 = 25 Nm M10 = 40 Nm Autodata Note 36 04.93 320 Nm 05.93 1) 200 Nm 2) 90 Autodata Note 45 A = 65 Nm B = 25 Nm + 90 Fig. 79262 Autodata Note 40 Use new nuts. Autodata Note 39 Use new bolts. Autodata Note 336 Do NOT lubricate bolts. Lightly coat mating surfaces between wheel centre hole and hub (use grease). Autodata Note 50
Manufacturer: Mercedes-Benz Engine code: 602.912 Tuned for: +AT/AC (A)(CH)(S) Model: 200-500/E/D/C/T (124) (84-93) 2,5D 250D Output: 66 (90) 4600 Year: 1989-93 Autodata Limited 2010 Valid forever. 29.10.2013 V8.500-

Later models use R134a, see label on compressor. Autodata Note 51 R12 = 1100 grams With rear AC = 1250 grams R134a = 950 grams With rear AC = 1150 grams Autodata Note 52 R134a = PAG Autodata Note 53 R134a = 160 cm 79379 79262

Cylinder layout

Manufacturer: Mercedes-Benz Engine code: 602.912 Tuned for: +AT/AC (A)(CH)(S)

Model: 200-500/E/D/C/T (124) (84-93) 2,5D 250D Output: 66 (90) 4600 Year: 1989-93

Autodata Limited 2010 Valid forever. 29.10.2013 V8.500-

Idle speed adjustment (A)

Idle speed adjustment (A)

Idle speed adjustment (A)

Manufacturer: Mercedes-Benz Engine code: 602.912 Tuned for: +AT/AC (A)(CH)(S)

Model: 200-500/E/D/C/T (124) (84-93) 2,5D 250D Output: 66 (90) 4600 Year: 1989-93

Autodata Limited 2010 Valid forever. 29.10.2013 V8.500-

Idle speed adjustment (A)

Tightening sequence

Manufacturer: Mercedes-Benz Engine code: 602.912 Tuned for: +AT/AC (A)(CH)(S)

Model: 200-500/E/D/C/T (124) (84-93) 2,5D 250D Output: 66 (90) 4600 Year: 1989-93

Autodata Limited 2010 Valid forever. 29.10.2013 V8.500-