Mercedes-Benz 201.028 Service Manual

Mercedes-Benz

Mercedes-Benz of North America, Inc.

-

Montvale, NJ 07645

0 Mercedes-Benz of North America, Inc., 1993

All rights reserved. Reproduction by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from the publisher.

Published by Mercedes-Benz of North America, Inc.

Printed in U.S.A.

Part number S-2347-93A

I n t r o d u c t i o n

This service manual is the product of existing technical publications. Special care has been taken to provide accurate information on removal, disassembly, inspection, installation, and adjustment procedures, together with the necessary technical data for the particular 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 by

trained Mercedes-Benz personnel

at authorized

Mercedes-Benz dealerships.

The information contained in this special publication is ordinarily issued by Mercedes-Benz of

North America, Inc., in conjunction with supplementary service literature and special tools supplied

only to

its authorized dealers.

The repair and maintenance procedures outlined herein are intended for use by

trained Mercedes-Benz service and dealership personnel. This

manual can also be useful for Mercedes-Benz owners in diagnosing vehicle systems and performing repairs. 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.

Special tools required in performing certain service jobs are identified in the manual and are 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.

If your Mercedes-Benz model differs from the specifications contained in the manual you select, consult your authorized Mercedes-Benz dealer.

All procedures, illustrations and specifications contained in this manual were based on the latest information available at the time of publication.

All rights are 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.

Caution!

The proper performance of service and repair procedures is essential for both the safety of the mechanic and the safe and efficient operation of the vehicle.

The use of incorrect service procedures and tools may greatly increase the risk of personal injury and render the vehicle unsafe. The procedures in this manual are described in such a manner that the service may be performed safely and accurately.

However, it is a general assumption that the reader is familiar with basic automotive procedures and Mercedes-Benz vehicles. You should not attempt to use this manual if this the case.

repair is not

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.

Service and Parts Literature

General, Technical Data

Crankcase and cylinder head

Crankshaft assembly

Engine timing, valvetrain

Continuous Fuel Injection System (CFI)

Air filter

Belt drive

Intake and exhaust manifolds, emission control system

Electrical system, engine

Engine lubrication system

Engine cooling system

Engine suspension

Accelerator control, cruise control, electronic accelerator

Fuel system

Exhaust system

Group Index

07.3

09

03

05

00

01

14

15

20

22

30

General, technical

data

00

00 General,

technical

Job No.

Instructions for use of service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00 - 005

Engine and vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- 010

Vehicle identification number locations .......................................

- 015

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- 020

00/l

I n s t r u c t i o n s f o r u s e o f servic 00-005

Complete Service Manual coverage for late model year Mercedes-Benz vehicles requires four individual manuals:

Service Manual, Engine

Service Manual, Chassis and Body

Service Manual, Automatic Climate Control

Electrical Troubleshooting Manual

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 00-015’1. In cases where the repair instructions apply to all versions, only the first three digits of the respective number are referenced.

For example, chassis 124 applies to all

124 models. However, chassis

124.051 would apply only to model 300CE with engine 104.

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. The exact job required is found in the job index. The initial page of a typical job description appears as follows:

03-324 Replacement of front crankshaft radial seal

Job Title appears on same line as Group

No.

Job No.

Page No.

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 differentiation between individual components, and are not intended for ordering purposes.

AWarning

Caution!

Note

Special Instructions

Appears throughout service instructions indicating the possiblity of personal injury if procedures are not followed.

Indicates possible equipment or vehicle damage if procedures are not followed.

Provides helpful information for the described procedure.

Installation note

Provides detailed information during assembly.

.oo -

005 11

ine and vehicle identification

This manual applies to the following passenger cars, starting model year 1984.

Gasoline engines

Model Year

1984

1985

1 Model

I 201.024

I 201.024

1 Sales Designation

I

190

E 2.3

I

190

E 2.3

I

IE

9

102.961

I

102.985

1991

1992

1993

I 201.028

I 201.028

I 201.028

I 190 E 2.3

I 190 E 2.3

I 190

E 2.3

I

I

102.985

102.985

I

102.985

00 - 010/l

I d e n t i f i c a t i o n n u m b e r l o c a t i o n s

Model

201

When ordering spare parts, please specify chassis and engine numbers.

00-615

7 a

Certrfication Tag (left door plllar) ldentlficatlon Tag (left wlndow post)

Vehicle ldentlficatlon No.

Engine No.

Body No. and Paintwork No.

lnformatron Tag

California version

Vacuum line routing for emission control system

Emlsslon Control Tag

Emlsslon Control Tag

Catalyst Information

(from model year 1964 up to 1966)

00 - 015 I1

T e c h n i c a l data

00

Gasoline engines

Model

Sales designation

Engine

Operation

20 1.024

190 E 2.3

(Model year 1984)

102.961

4-stroke spark ignition, mechanicallyielectronically controlled continuous fuel injection system with airflow sensor (CIS-E)

Aspiration

Number of cylinders

Cylinder arrangement

Bore, stroke mm

Normal

4

In-line 15” inclination

95580.25

Total effective piston displacement cc

Compression ratio

Firing order

Maximum speed rpm

Engine output

(SAE)kWrpm net bhp, rpm

2299

8.0 : 1 l-3-4-2

5700 t 50

8415000

11315000

Maximum torque

Nm, rpm net lb-fti’rpm

Crankshaft bearings

Valve arrangement

Camshaft arrangement

Oil cooling

Cooling

Lubrication

Oil filter

Air filter

18113500

13313500

S(multi-component, antifriction bearings)

Overhead, 2 per cylinder

1 overhead camshaft

Coolant circulation pump, thermostat with bypass line, fan with electromagnetic clutch, finned tube radiator

Pressure lubrication via gear type pump

Full flow filter

Dry air filter with paper cartridge

201.024

190 E 2.3

(Model years 1985 86)

102.985

4-stroke spark ignition, mechanically/electronically controlled continuous fuel injection system with airflow sensor (CIS-E)

Normal

In-line 15” inclination

95.5180.25

l-3-4-2

6200 A 50

184/3500

1361’3500

S(multi-component, antifriction bearings)

Overhead, 2 per cylinder

1 overhead camshaft

I

1 201.028

190 E 2.3

I (Model years 1987-8, 1991-3)

102.985

4-stroke spark ignition, mechanically~‘electronically controlled continuous fuel injection system with airflow sensor (CIS-E)

I Normal

In-line 15” inclination

I

I

95.5/80.25

l-3-4-2

6200 2 50

198/3500

14613500

5 (multi-component, antifriction bearings)

Overhead, 2 per cylinder

1 overhead camshaft

Coolant circulation pump, thermostat with bypass line, fan with electromagnetic clutch, finned tube radiator

Pressure lubrication via gear type pump

Full flow filter

Dry air filter with paper cartridqe

Coolant circulation pump, thermostat with bypass line, fan with electromagnetic clutch, finned tube radiator

I

Pressure lubrication via gear type pump

Full flow filter

I

Dry air filter with paper cartridae

00 - 020/l

.i._

QQ

Filling capacities

Model

Sales designation

Engine

Fuel tank/reserve approx. I

1 201.024

190 E 2.3

(Model Year 1984)

I

1 102.961

. . . . . . . .

T e c h n i c a l data

1 201.024

190 E 2.3

(Model Years 1985 6)

I

I 102.985

1 201.028

190 E 2.3

(Model Years 1987-8,

1991-3)

I

1 102.985

Electrical system

Starter Bosch

00 - 02012

Crankcase and cylinder head 01

01 Crankcase and cylinder head

Job No.

Engine and model survey ................................................ 01 - 001

Overview - Engines .................................................... 01 - 005

Removal and installation of bottom engine compartment cover .....................

01 - 006

Testing compression pressure .............................................. - 010

Testing cylinder leaktightness ............................................... - 015

Illuminating cylinders ..................................................... - 020

Removal and installation of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- 030

Crankcase ventilation - function ............................................. - 040

Measuring, boring and honing cylinders ........................................ - 110

Facing crankcase parting surface ............................................ - 120

Removal and installation of steel balls in main oil gallery ............................

- 130

Replacing core plug in crankcase ...........................................

- 140

Removal and installation of timing case cover ................................... - 210

Removal and installation of end cover ......................................... - 222

Removal and installation of oil pan ........................................... - 310

Repair instructions for crankcase, ............................................. - 403

Removal and installation of cylinder head cover .................................. - 406

Reconditioning spark plug thread in cylinder head ................................ - 407

Removal and installation of cylinder head ...................................... - 415

Matching measuring sensors to cylinder head ................................... - 416

Facing cylinder head mating face ............................................ - 418

Enlarging camshaft bearing bores (repair size) ................................... - 419

Pressure-testing cylinder head .............................................. - 420

01.11

01-001 Engine and Model Survey

Engine

102.961

102.985

102.985

1

Model 1 y;m;l 1 Sales designation

)

Power in kW at rprn

/

z;pression

201.024

*

1984 190 E 2.3

84:5000

I

201.024

11985-86 1190E2.3

1201.028

I

90/5000

1;;;;;;; ll9OE2.3

8.O:l

I

9.0:1

197:5100 19.0:1

01.1101 l-001/1

01-005 Overview - Engines, Models, Output and Compression Ratio

102.961 @ as of 1984 201.024

Sales designation

190 E 2.3

190 E 2.3

190 E 2.3

Output in KW at rpm net bhpirpm

84/5000

113i5000

90/5000

12015000

97:5100

130/5100

Compression ratio E : 1

8.0

8.0

9.0

01.0904 005il

01-006 Removal and installation of bottom engine compartment cover

Model 201

Self-tapping screws (arrows) . . . . . . . . . . . . . , , .

remove, screw in and remove, install engine compartment cover.

Note

On Model 201.028 @ install engine compartment cover so that the edge of the side parts grips above the bottom part.

01.0904 . 006/l

,_L,x,~~.~...z.Y

. . ________ii__________...........

..,

01-010

Testing compression pressure

Precedmg work:

Rernovtng spark plug (15-016).

01 Compression pressure recorder, special tool 001 589 76 ‘21 00

02 Adapter piece

04 Sealing cone with check valve

Test data with engine at normal operating temperature (80 “C) in bar

Subject I When new

Compression ratio E = 9.0 - 9.4

I 10 - 12

E=

10.0

E = 7.5 - 8.3

113.5 - 15.5

I

9 - 1 0

E = 7.2 (102.92) 1 8 - 9

Permissible difference between individual cylinders max. 3

1 Limit value

1 approx. 8.5

I aDDrox. 12

I approx. 7.5

1 approx. 6.5

01.0904 010/l

Special tools

001 589 76 21 001 1 1 2 4 5 8 9 3 6 6 3 0 0

Notes

Test compression pressure at normal operating temperature.

If the minimum compression pressure is not reached, test cylinder leaktightness (01-015).

Unscrew all the spark plugs for testing.

Turn crankshaft with starter and compression pressure recorder.

Warning!

The engines are equipped with an ignition system with variable ignition characteristics

(EZL).

Because of high ignition voltage, it is very dangerous to touch components of the ignition system (ignition coil, ignition cables, spark plug connector, plug-on unit)

when

l

the engine is running,

l l

the engine is started, the key in the steering lock is in position

2 and the engine is cranked by hand.

’ Geftihrliche Hochspannung!

Vorsicht bei Arbeiten an der

Danger! High voltage

Observe caution when working on the ignition system

PIS-0241-13

01.0904 . 01012

Testing

1 Switch off ignition. Detach connector from ignition distributor pickup (green cable on control module) (arrow).

Caution!

On injection engines, detach the fuel pump relay module (N1614) before turning the crankshaft to ensure that no fuel is injected.

Model 201

2 Connect compression pressure recorder.

This is done by clamping one of the two alligator clamps (arrow) of the compression pressure recorder, Part No. 001 589 76 21 00, to the positive terminal post of the battery.

3 Detach connector (X27) from plug connection (terminal 50).

4 Plug in connector of adapter cable (01),

Part No. 124 589 36 63 00.

Model 201

01.0904 - 01 o/3

5 Crank engine several times with starter motor, in idle position, selector

“P”, and parking brake applied lever in position so that residues and soot are ejected.

6 To test each cylinder, press the compression pressure recorder into the spark plug hole of the particular cylinder and, with the throttle valve fully opened, crank engine approx. 8 revolutions.

Test all the cylinders in this way.

7 Blow out spark plug recesses with compressed air. Remove any residues on the tapered sealing seat.

01.0904 - 01014

01-015

Testing cylinder leaktightness

Data

Total pressure loss

At valves and cylinder head gasket

At pistons and piston rings

Tightening torque

Spark plugs

Special tools

max. 25% max. 10% max. 20%

Nm

Commercial tool

Cylinder leaktightness tester

Testlng

1 Run engine until at normal operating temperature.

2 Blow out spark plug recesses with compressed air.

3 Remove spark plugs.

01.0904 - 01511 e. g. Bosch, EFAW 210 A

Sun, CLT 228

4 Top off coolant and leave filler opening at coolant expansion tank open.

5 Remove oil filler cap.

6 Remove air filter (09-400 or 09-410).

7 Connect cylinder leaktightness tester to a compressed air system and calibrate tester.

8 Position piston of No. 1 cylinder to ignition

TDC. This is done by turning the crankshaft with a tool combination consisting of wrench socket

(27 mm, l/2” square) and reversible ratchet handle, at the central bolt (front of crankshaft).

Note

The respective pistons are in the TDC position when the markings shown in the drawing opposite on the vibration damper or on the belt pulley are below the TDC pointer.

9 Open throttle fully.

10 Screw connection hose into the 1 st spark plug bore and attach to the connecting hose of the tester.

The crankshaft must not turn when performing this step.

11 Read off pressure loss at tester.

12 Determine by listening whether the pressure escapes through intake manifold, exhaust, oil filler opening, spark plug bore of adjacent cylinder or coolant filler opening.

13 Test all the cylinders in the firing order.

-_-.-I

‘r

1342

VE tA

P05.0110-13

01.0904 - 015/2

Notes

It is possible that the piston ring gaps of individual pistons are directly above each other which falsifies the test result.

In cases of doubt, allow vehicle to run and test cylinder leaktightness once again after some time.

After spraying oil onto the piston crown, it is possible to determine whether the leak exists at the piston rings or at the valves or the cylinder head gasket.

01.0904 - 015/3

01-020 Illuminating cylinders

Preceding work:

Removing spark plugs (15-018).

C iylinder (01) . . . . . . . . . . . . . . . . . , . . . . . . . .

illuminate with cylinder inspection lamp (Ol), distinguish between “optical rub marks and seizing rub marks”.

“Optical rub marks” may result from the ring gap. Traces of honing are still visible, engine in order.

“Seizing rub marks”; honing marks no longer visible, recondition engine.

Commercial tool

Cylinder inspection lamp 8. g. Karl Storz GmbH,

D-7200 Tuttlingen

Motoskop TW (cold light) with lens probes 103 26 CW

(570 mm) and 103 26 CT (210)

01 0904 02011

01-030 Removal and installation of englne

Preceding work:

Removal and installation of bottom engine compartment fairing (01-006).

Removal and installation of air filter (09-400 or 09-410).

R emoval and installation of radiator (20-420).

Battery positive cable ....................

Fan (75) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator cable connector .................

Lines for pressure oil pump ................

Cover for evaporator .....................

Cover for engine wiring harness .............

Starter wiring harness ....................

Terminal block terminal 50 .................

Terminal 30 ...........................

Engine wiring harness ....................

disconnect, connect.

remove, install, 25 Nm.

detach (step 3).

detach, attach (step 4).

insert (step 5).

remove at component partition wall

(steps 6 and 7).

remove, install (step 8).

disconnect, connect (step 9).

disconnect, connect at terminal block (step 10).

disconnect, connect at the individual connections (steps

11 to 18).

01.0904 .

030/l

Fuel evaporation system ..................

Ground cable ..........................

Accelerator control ......................

Fuel lines .............................

Coolant hose, heater supply line

Vacuum line, brake booster ................

Air conditioning compressor (425)

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

...........

Engine hoist ...........................

Guard plate ...........................

Exhaust system (48) . . . . . . . . . . . . .

Lambda sensor ........................

Engine supporting bracket

(12)

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

Drive shaft to transmission (2)

Clamping nut (2a)

. . . . . . . . . .

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

Speedometer shaft .....................

Ground cable at transmission ...............

Shift rods at transmission .................

Cable connector for starter lockout, backup light switch ............................

Cable for kickdown solenoid valve ...........

Front engine mounting (22) ................

detach, attach (step 19).

unbolt, bolt on at intake manifold (step 20).

disconnect, connect Bowden cable, adjust

(step 21).

detach, attach (step 22).

detach, attach (step 23).

detach, attach (step 24).

Note

On vehicles with air conditioning, the AC compressor can be unbolted with the lines connected and without draining the system

(steps 25 to 34).

attach to suspension lugs, detach (step 35).

insert between component compartment and engine, remove (step 37).

unbolt at exhaust manifold and transmission mount (51) bolt on (steps 38 and 39)

25 Nm.

remove, install (step 40).

unbolt, bolt on (step 42).

Tightening torques:

Bolt (1) 25 Nm,

Nut (2) 70 Nm.

detach, attach, replace self-locking nuts (7a)

(step 44).

loosen, tighten (step 45), 45 Nm.

disconnect, connect to transmission (step 46).

disconnect, connect (step 47).

detach, attach (step 48).

unplug, plug in (step 49).

disconnect, connect (step 50).

unbolt, bolt on at bottom (step 51), 40 Nm.

01 0904 -03012

Engine with transmission . . . . . . . . . . . . . . . .

Lines, hoses and engine mounts . . . . . . . . .

lift out, insert (step 52).

examine for signs of wear, replace if necessary.

Examine antifreeze protection, adjust to correct level if necessary. Test leaktightness.

Viscosity grades for engine oils according to SAE

Adhering to the SAE grades In accordance with ambient temperatures would result in frequent oil changes. Consequently, the temperature ranges are merely guidelines, which can be exceeded in the upper or lower limits for brief periods.

In moderate climatic zones SAE 30 may be used from the spring on for all engine models. SAE low-40 or SAE low-50 may be used as an all-seasons oil for all gasoline engines.

Refer to the most current “Factory Approved Service Products” for further information regarding specified viscosity grades and approved engine oils.

Oil capacity in liters

(refer to Factory Approved Service Products for approved engine oils)

Engine (total capacity when refilling)

Engine capacity when changing oil and filter

5.5

5.0

01.0904 030 3

Tightening torques

Fan to engine coolant pump

Exhaust pipe to exhaust manifold

Exhaust bracket to transmission

Hexagon bolt of belt pulley to power steering pump

Bracket for A/C compressor to oil sump

Bracket for AC compressor to AC compressor

V bracket servo pump - engine supporting bracket - AC compressor

Servo pump to supporting bracket

AC compressor to supporting bracket

Propeller shaft to transmission

Clamping nut to spline end of propeller shaft

Ground cable to transmission

Engine mount to axle carrier

Special tools

25

45

45

40

25

30

45

Nm

25

25

25

25

10

25

Commercial tool

Engine hoist No. 3188 self-locking

Shoe-made tools

Guard plate for radiator/evaporator

Metal panel for component compartment wall e. g. Messrs. Backer

HerderstraOe

D-5630 Remscheid

Dimensions approx. 480 X 600 X 1

Dimensions approx. 320 X 380 X 1

01.0904 - 03014

Note

Remove and install engine together with transmission.

1 Disconnect battery negative terminal, connect.

2 Remove fan. install.

3 Unplug cable connector (327) at alternator, plug in.

4 Detach lines for pressure oil pump at cylinder head, connect (arrows).

5 If equipped with air conditioning: install guard plate (arrow) to evaporator of air conditioning system.

01 0904 030!5

7 On Model 201, pull off rubber strip (1) above fire wall.

Take out clips (arrows), fold fixture upwards.

Model201

9 On Model 201, unplug cable connector (50) at the plug connection, plug in.

Model201

10 Unbolt battery positive terminal. Disconnect terminal (30) at cable connector and pull cable through component compartment wall and place over engine.

Model201termlnal30

01.0904 - 03016

11 Disconnect engine wiring harness at the individual connections and place over the component compartment wall.

-..

X 2 4

X24

X56

Yl

Y6 ya

Engine wrnng harness, shown on Model 201

82 Volume air flow sensor posrtion Indicator

Bl l/2 Engtne coolant temperature sensor (CFI),

2-ptn

B17/2 Intake air temperature sensor, CFI qectron system

Nll2 lgnttion control module

R17 Reference resistor, CFI Infectron system

S27/2 Deceleration shutoff mrcroswrtch

W1l x11

Engine ground (electric lead bolted on)

Oragnostic connector/termrnal block terminal TD

Connector, headlamp wrnng harness

Throttle body switch connector

Electrohydraukc actuator

Idle air control valve

Start valve

12 Detach twin connector (B1112) for engine coolant temperature sensor (CFI), plug in.

Unbolt engine ground (Wl l), bolt on.

Unplug throttle body switch connector (X56), plug in.

Unplug volume air flow sensor position indicator

(B2), plug in.

01 0904 - 03017

13 Unplug start valve (Ye), plug in.

Unplug electrohydraulic actuator (Yl), plug in.

Unplug idle air control valve (Y6), plug in.

14 Unplug deceleration shutoff microswitch

(S27:2), plug in.

15 Unplug connector for crankshaft position sensor on ignition control module (N112), plug in.

Unplug vacuum line (2) and 4-pin connector (3), plug in.

16 Unbolt terminal TD at terminal block of diagnostic connector (Xl l), bolt on. Unscrew diagnostic connector (Xl 1) and unplug on the bottom the grey cable for TDC pulse generator, plug in.

01

0904 03018

17 On models equipped with

cruise control,

unplug connector (arrow), plug in.

18 Unplug ignition cable 4 (arrow) at ignition distributor, plug in.

19 Detach vacuum lines (arrows) for fuel evaporative emission control system, attach.

I \ / I

20 Unbolt ground cable at intake manifold, screw on (arrow).

01.0904 . 03oi9

21 Detach Bowden cable (30) for accelerator control, attach. Press plastic guide (arrow) out of its seat in the fulcrum lever (13) to perform this step, and take Bowden cable (30) out of the slot in the fulcrum lever.

Installation instruction

Adjust Bowden cable (30) (30-325).

22 Reduce fuel pressure in the fuel lines by briefly opening fuel tank cap.

Unbolt fuel lines (379 and 380) bolt on.

Note

To prevent fuel flowing out of the disconnected fuel lines, both fuel lines can be plugged with a fitting (01, shop-made).

23 Disconnect engine coolant hose (68) for heater supply line at the cylinder head, connect.

01.0904 - 030110

24 Disconnect vacuum line for brake booster at intake manifold (arrow), connect.

25 On models with AC compressor, disconnect electric lead at AC compressor, connect (arrow).

26 Disconnect piping group (170) at the cylinder head, connect (arrows).

27 Extract oil from the reservoir for power steering.

28 Disconnect oil lines at power steering pump, connect.

01.0904 - 030111

Installation instruction

Adjust oil level of power steering to correct level.

When engine is running, top off oil to the marking. Turn steering several times from full left to full right lock.

Oil level when oil at normal operating temperature (approx. 80 “C) 18 - 26 mm below the top edge of reservoir.

Oil level when oil cold (room temperature, approx. 20 “C) between Min. and Max.

markings.

29 On models with AC compressor, remove poly V-belt, install (13-342).

30 Remove and install tensioning device for

V-belt (13-345).

31 Unbolt belt pulley for high pressure pump of power steering, bolt on (arrows).

32 Unbolt strut (145) for high pressure oil pump and AC compressor (arrows), bolt on.

Tightening torque 25 Nm.

01.0904

030812

33 Unbolt high pressure oil pump, bolt on

(arrows) and place to the side with the lines connected, tightening torque 25 Nm.

34 Unbolt AC compressor (425) at the supporting bracket, bolt on, and place to the side with lines connected. Bolts (149b), tightening torque 25 Nm.

Unbolt bracket (b), bolt on.

35 Attach engine hoist into the suspension lug of the engine.

Adjust engine hoist so that the engine can be raised horizontally.

36 Disconnect all remaining lines, e. g. vacuum, oil, fuel lines and electric cables, running to the engine; connect.

37 Insert guard plate (arrow) between component compartment and engine, remove.

01.0904 _ 030113

38 Unbolt exhaust at the exhaust manifold, bolt on (arrows), tightening torque 25 Nm.

39 Unbolt exhaust holder (50 and 51) at the exhaust and transmission, bolt on, tightening torque 25 Nm.

40 Remove lambda sensor at exhaust pipe, install. Remove cover (arrow) to perform this step.

41 Remove and install exhaust system (49-100).

42 Unbolt engine supporting bracket (12), bolt on.

Tightening torques:

Bolt (1)

Nut (2)

25 Nm,

70 Nm.

01.0904 - 030/14

43 Unbolt shield, bolt on (arrows).

44 Unbolt drive shaft, bolt on. Loosen the bolts

(7) and nut (7a) to perform this step. Tightening torque 45 Nm.

Note

Flexible coupling remains on drive shaft.

45 Loosen clamping nut (2a), tighten (wrench waf 41i46).

Push drive shaft back as far as possible. Tightening torque 45 Nm.

46 Detach speedometer shaft at transmission, attach. Remove bolt (404) to perform this step.

01.0964 - 030/15

47 Unbolt ground cable (149) at transmission, bolt on. Tightening torque 45 Nm.

48 Detach shift rods at transmission, attach

(arrows). Take the clip locks off the transmission shift levers to perform this step.

49 If equipped with automatic transmission, turn white plastic lock on starter lockout, backup light switch (53) approx. 45’ to the right and unplug cable connector, plug in.

50 Unplug cable (arrow) at the kickdown solenoid valve, plug in.

ol.0904 - 030116

51 Remove both bolts (22) for engine mounting.

Tightening torque 40 Nm.

52 Lift out engine together with transmission at an angle of approx. 45”.

53 Install in the reverse order.

54 Check front and rear engine mounts.

55 Check fluid levels, adjust to correct levels necessary.

if

56 Check leaktightness with engine running.

01.0904 - 030117

01-040 Crankcase Ventilation - Function

Englne 102.985 (CFI system)

109 011 separator

202 Idle air distributor

(bypass passage dia.

1.5 mm)

A Fresh air

0 Elowby gases

Function

The engine blowby gases flow through the oil separator (109) at the cylinder head cover and through a pipeline to the idle air distributor (202) or to the air filter (clean air side).

The oil separated out in the oil separator (109) flows back through a passage (dia. 3 mm) to the cylinder head.

At a high intake manifold vacuum, the blowby gases are drawn through the bypass passage

(dia. 1.5 mm) in the idle air distributor (202) and the idle air passage in the intake manifold and flow to the combustion chambers. At the same time, a small quantity of clean air from the air filter is drawn in as well through the bypass passage.

At a low or no Intake manifold vacuum. the blowby gases flow to the clean a!r side In the air filter and pass together with the ntake air to the combustion chambers.

01.0904 - 04011

01-l 10 Measuring, boring and honing cylinders

Data

Standard

2

1st repair size 0

( + 0.5)

1

2

2nd repair

(+t -0)

1

0

E;_ 1 st version

102.985

95.498 -

95.508

95.509 95.518

95.519 - 95.528

95.998 -

96.008

96.009 -

96.018

95.519 - 96.028

96.498 -

96.508

96.509 - 96.518

96.519 - 96.528

I Gr.

code letter

X

B

195.500 - 95.506

95.507 - 95.512

95.513 - 95.518

96.000 - 96.006

96.007 -

96.012

96.013 - 96.018

96.500 - 96.506

96.507 -

96.512

96.513 - 96.518

Averaged peak-to-valley height (Rz) after ceramic finish honing

Permissible height of unevenness (Wt)

I 0.002 - 0.004

I

50 % of PTV height

Commercial tool

Snap gauge for internal measurements, 0 80 - 100 mm e. g. Hahn und Kolb

BorsigstraRe 50

D-7000 Stuttgart 30

Order No. G422K

01.0904 - 110/l

Note

Since 04/88 the tolerance stages of piston and cylinder bore dia. have been identified with letters (hitherto figures, refer to data). As previously in the figures, the letters are also stamped in the mating face of the crankcase and in the piston crowns.

Identification of tolerance stages previous current

Standard in’mlementation: 041’88

Model

When performing repairs, ensure that the tolerance stage identification of piston and cylinder bore agrees. It is possible to install pistons with a code letter identification in cylinder bores with a digit identification if this tolerance stage identification agrees according to the table.

If, when performing repairs, no identical pairing is possible, reference can be made to the piston installation play of 0.016 - 0.040 mm to determine a suitable piston.

01.0904 - 11012

Measuring

Measure the cleaned cylinder bores with an internal measuring device at measuring points 1,

2 and 3 in longitudinal direction A (piston pin axis) and in transverse direction B.

With pistons installed, measuring point 3 is just above the piston, which must be at bottom dead center.

I

Chamfer the cylinder bores after boring.

The material allowance for honing should be not more than 0.05 mm.

Measuring points 1 - 3

A Longltudmal direction

B Transverse direction a Top reversal point of 1st piston nng b Bottom dead center of piston c Bottom reversal point of 011 scraper rmg

I

01 0904 1 lOi

01-120 Facing crankcase parting surface

POl-0041-33

Data

Permissible variation of parallelism of top to bottom crankcase mating face in longitudinal direction I

0.1

Test pressure with air under water in bar gauge pressure

01.0904 - 120/l

Note

Chamfer the cylinder bores after completing machine work.

If the crankcase mating face has been remachined, the timing must be reset (05215).

The timing case cover must be bolted tight to the crankcase machining the and also be machined when top or bottom crankcase mating faces.

PO3-0060.13

01.0904 - 120/2

01-130 Removal and installation of steel balls in main oil gallery

Preceding work:

Removal of engine coolant pump (20-210).

Removal of flywheel (03-410).

Both steel balls . . . . . . . . . . . . . . . . . . . . . . . . .

Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cup on fitting mandrel . . . , . . . . . . . . . . . . . . , .

Steel ball , I , , . , , , . , . . . , . . , . . . . , . . . . . . , knock out together from back to front with a round steel bar (dia. 11 mm, approx. 500 mm long). If the rear ball moves into the cross passage to the oil filter, remove the oil filter to enable the ball to be removed.

thoroughly clean in the area in which the steel balls are pressed in.

coat with grease and install cup.

steel ball into the position with the installation mandrel and knock in each at front and rear as the mandrel.

far as the stop on

Special

tool

01.0904 .

130/l

Notes

The main oil gallery is closed with steel balls, dia. 15 mm at the front, dia. 12 mm at the rear.

When reconditioning the engine, the steel bails must be knocked out from the rear in order to clean the main oil galleries.

Undamaged steel balls may be reused several times without machining the ball seat.

Replace damaged steel balls.

If a leak exists, reset steel balls approx. 1 mm

(size is fixed on installation mandrel). Special tool 102 589 07 15 00.

Should the leaks not be repaired after this, knock out both steel balls and seal the main oil passage end in question with a screw plug.

9 Front steel ball (0 15 mm)

10 Rear steel ball (0 12 mm)

01.0904 - 130/2

This is done by tapping an Ml 6 X 1.5 thread approx. 10 mm deep at the front of the main oil gallery. Thoroughly remove chips from the oil gallery.

Coat Ml6 x 1.5 screw plug Part No.

000 906 016 002 with sealing adhesive

002 989 94 71 and screw in (arrow).

Tap an Ml 4 X 1.5 thread approx. 12 mm deep into the rear of the main oil gallery. Thoroughly remove chips from the main oil gallery.

Coat Ml 4 X 1.5 screw plug, Part No.

000 906 014 000, with sealing adhesive

002 989 94 71 and screw in (arrow).

01.0904 - 13013

01-140 Replacing core plug in crankcase

PO1 -2073-13

PO,-2072-n

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components which restrict access

Core plug (4)

...........

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

Sealing surface in crankcase . . . . . . . . . . . . . . .

New core plug .........................

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

drain completely, pour in (20-010).

remove, install.

remove.

Position a chisel with narrow blade or a screwdriver in the deep-drawn edge of the plug

(step 3).

Carefully knock in plug on one side far enough for it to turn through its own longitudinal axis

(approx. go”), and pull out with the pliers

(step 4).

Thoroughly clean of residues. The sealing surface must be free of grease.

install.

Coat sealing surface with the sealant Loctite

241, 002 989 94 71. Note curing time of approx.

45 minutes (step 6).

Knock in core plug with the matching mandrel

(step 7).

run until warm and check leaktightness.

01.0904 - 14011

Special tools

tO2589031509 ~ 0 2 5 8 9 0 0 1 5 0 ~

Replacement

1 Completely drain engine coolant (20-010).

2 Remove components which restrict access.

3 Position a chisel with narrow blade or a screwdriver into the deep-drawn edge of the plug.

4 Carefully knock in plug on one side far enough for it to turn through its own longitudinal axis (approx. 90’) and withdraw with pliers.

5 Thoroughly clean sealing surface of residues. The sealing surface must be free of grease.

6 Coat sealing surface with sealant Loctite

241, 002 989 94 71.

Note

The sealant must cure for approx. 45 minutes before adding the engine coolant.

0 1 . 0 9 0 4 - 140/2

7 Knock in new core plug with the matching mandrel.

mm 0 Special tool

102 589 00 15 00

102 589 03 15 00

8 Install removed components.

9 Add engine coolant (20-010).

10 Run engine until warm and check leaktightness.

01.0904 - 14oi3

01-210 Removal and installation of tlmlng case cover

Preceding work:

Removal of radtator (20-420).

Removal of power steering pump (46-710).

Removal of torsion bar (32-300).

Removal of 011 sump (01-310).

Removal of V-belt tensioning device (13345).

Removal of vibration damper or hub and belt pulley (03-342)

Removal of engine coolant pump (20-210).

Removal of air filter (09-400. or 09-410).

Removal of ignrtton distributor (15-l 10).

Removal of pressure oil pump for level control (32640).

Cylinder head cover (81)

Hexagon socket bolts (77) .................

Strut (145)

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

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

A/C compressor (425) ....................

remove, install, together with ignition cable and distributor cover (01-406).

3 off, remove and install, 25 Nm (reference value, step 2).

unbolt, bolt on, 25 Nm (step 3).

unscrew, screw on and place to the side with connected lines, 25 Nm. Unbolt, bolt on bracket

(b), 10 Nm (step 4).

01.0904 210/l

Connector (327) ............

Alternator (G2) .............

Bracket (156) ..............

. .

TDC pulse generator cable (1) .

Bracket (8) ................

Timing case cover

Mating surfaces

Timing case cover

..........

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

..........

. . * . . . .

. . . . . . . .

, . . . . . . .

. . , . . . .

. . . . . . . .

. . . . . . .

. . . . . . . .

. . . . . . . .

unplug at alternator, plug in (step 5).

unscrew, screw on, 30 Nm (step 6).

for alternator, unbolt, bolt on, 25 Nm

(step 7).

unbolt, bolt on (step 8). If timing case cover has been replaced, the TDC pulse generator bracket must be adjusted (03345).

for oil pump strainer basket, unbolt, bolt on, 25

Nm, (step 9).

remove remaining bolts, take off timing case cover (steps 10 and 11). Do not damage cylinder head gasket: replace cylinder head gasket if damaged.

clean (step 12).

coat with sealant 001 989 25 20 and install timing case cover (steps 13 and 14). Use fitting tool 102 589 00 14 00 and spacer ring

102 589 01 14 00 for replacement of radial seal.

Special tools

01 0904 - 21012

Notes

The timing case cover closes off the crankcase at the front. It is fixed in position with 2 straight pins 10 x 14 and attached to the crankcase with

15 hexagon bolts.

The timing case cover is sealed to the crankcase with the sealant Loctite 573, Part No.

001 989 25 20.

The timing case cover also acts as a support or housing for the following components or component parts:

Engine coolant pump

Ignition distributor

Oil pump

Oil overpressure valve

Radial seal for sealing crankshaft at front

Setting pointer

TDC pulse generator

Front side of timing case cover

45

46

Crankshaft radial seal

Setting pointer for TDC e Coolant pump chamber with inlet

I Bracket for TDC pulse generator

01 0904 -2103

To avoid any engine coolant mixing with the engine oil should a leak occur between crankcase and timing case cover, a groove

(arrows) has been provided around the coolant inlet (h) to allow the coolant to flow to the outside.

39

3 8

2 3

The timing case cover is always supplied as a replacement part with the oil pump installed, but without radial seal for the front of the crankshaft and without oil suction pipe with oil strainer.

Note

A gasket for sealing the timing case must not be installed on these engines (with single belt drive).

1

Rear stde of timing case cover

O-ring

23 Oil overpressure valve plug

38 Thrust piece f

39 Bearing bush for Intermediate gear shaft

Oil pump g Mount for lgnltlon dlstnbutor h Coolant Inlet

The timing case cover was modified effective

11107.

The contours on the rear side have been lowered. This is detectible from the cast Part No.

102 015 11 01 on the front side of the cover.

This timing case cover can also be installed on engines manufactured prior to this date.

A Previous version

B Present version

01.0904 - 210/4

POl-2621-13

Standard imcblementation:

11/87

Model Engine End No.

201.028

Removal

1 Remove cylinder head cover (01-406).

2 Remove hexagon socket bolts (3 off MB, arrows) in the chain box with a stud wrench

116 589 03 07 00. Tightening torque 25 Nm

(reference value).

020073

3 Remove strut (145) for power steering pump and AC compressor (arrows). Tightening torque

45 Nm.

01.0904 - 210/5

4

On models equipped with AC compressor, unbolt compressor. Unbolt bracket (b) to perform this step.

Place A/C compressor to the side with the pipe group connected.

5 Unplug connector (327) at the alternator, plug in.

6 Remove bolts (49 and

51),

bolt on; remove alternator, insert. Tightening torque 30 Nm.

7 Unbolt bracket (156), bolt on. Tightening torque 25 Nm.

6 Unbolt TDC pulse generator cable (1) at the holder (2), screw on.

01.0904. 21016

9 Unbolt bracket (8) for oil pump strainer basket, bolt on (arrows).

10 Remove remaining bolts (arrows) for timing case cover.

11 Remove timing case cover.

Caution!

Do not damage cylinder head gasket. Replace cylinder head gasket if damaged.

Installation

12 Clean mating faces.

13

Coat mating face of timing case cover with the sealant, Part No. 001 989 25 20.

14 Carefully install timing case cover, paying attention to the cylinder head gasket, and bolt tight.

Note bolt lengths.

01.0904 - 210,'7

15 If the radial seal has been removed, insert new radial seal with the sleeve

102 589 00 14 00.

102 589 01 14 00 for the timing case cover with double roller chain.

Note

If the timing case cover has been replaced, the

TDC pulse generator holder must be adjusted

(03-345).

16 The remaining parts are installed in the reverse order.

17 Run engine and check for leaks.

01.0904 _ 21018

01-222 Removal and installation of end cover

Preceding work:

Removal of transmission (26-020 or 27-600).

Removal of flywheel (03-410).

*

PO3-0002-35

- 3 4

End cover

(19) . . . . . . . . . . . . . . . . . . . . . . . . .

Radial seal (20) . . . . . . . . . . . . . . . . . . . . . . . .

remove, install (pay attention to instructions).

Clean mating face, insert roll pins (17). Coat mating face and bolts (21 and 34) with sealant

001 989 45 20 10, 10 Nm.

replace, use special tool 601 589 03 43 00.

Special tools

01.0904 222/‘1

Notes

The center installation position relative to crankshaft center is fixed with two roll pins (17).

Press end cover off at both side plates (arrows).

17 Roll pin

21 Bolt-washer assy (M6 x 22)

34 Bolt-washer assy (M6 x 65)

Push end cover with radial seal installed in place over the bolted-on assembly sleeve.

01.0904 22212

01-310 Removal and installation of oil pan

Preceding work:

Removal of air filter (09-400 or 09-410).

Removal of bottom engine compartment cover (01-006).

Removal of torsion bar (32-300).

Engineoil . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable (351a) . . . . . . . . . . . . . . . . . . . . . . . . . .

Clips (la) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust pipes (48) . . . . . . . . . . . . . . . . . . . . . .

drain, add. Unscrew oil drain plug (28) to perform this step, screw in, 25 Nm. Replace sealing ring (29).

unplug, plug in.

pull off, detach, attach fan shroud (l), place over fan.

unbolt at exhaust manifold, bolt on, 25 Nm (step

4).

01.0904 310/l

Pipe clip (53) . . . . .

. .

Bolts (35) . . . . . . . .

Bolts (22) . . . . . . . .

Oil pan (26) . . . . . .

. .

........

. . . .

. .

........

. . . .

. .

........

. . . .

. . . .

unbolt, bolt on, 25 Nm (step 5). Replace nuts

(50).

2 off MlO, unbolt, bolt on, 45 Nm

(step 6).

unbolt, bolt on, 45 Nm, attach engine hoist to suspension lugs and raise

(steps 7 and 8).

remove, install. Remove bolts (32, 34) for this step, bolt on. Clean sealing surface. Replace gasket (31) (step 9).

Tightening torque:

M6

M8

10

Nm,

25 Nm.

Oil capacity in litres

Total capacity for oil and filter change

Oil pan max. / min.

Special tools

1 e

C 1165690307Ot 1 1 7 5 8 9 0 2 0 7

Commercial tool

Engine hoist No. 3180 e. g. Messrs. Backer

HerderstraOe

D-5630 Remscheid

Showmade tools

Metal panel for component compartment wall

Guard plate for radiator/evaporator

5.5

4.8 12.8

Dimensions: approx.320 X 380 X 1

Dimensions: approx. 480 X 600 X 1

01.0904 - 31012

Note

The O-ring for sealing the oil level pickup to the oil pan has been improved. In addition, the diameter has been increased from 3 mm to

3.15 mm. Color: green (previously black).

Standard implementation: 09186

Model Engine

201.024 @

I

102.985

In June 1987 the O-ring of the oil level pickup was once again modified.

Modification

dl d2

I

40.20

I

37.20

3.15

3.2

I

ransmlsslon

Po1.0117-13

01.0904 . 31013

Removal and installation

1 Drain engine oil.

2 Unplug cable (351a) at the oil level pickup, plug in.

3 Detach clips (la) for fan shroud, detach, attach fan shroud (1) place over fan.

4 Unbolt exhaust pipes at exhaust manifold, bolt on (arrows).

5 Unscrew pipe clip (53) at the front exhaust bracket to the transmission. Replace nuts (50).

Tightening torque 25 Nm.

01.0904 . 31014

6 Remove two bolts at the transmission engine joint (MlO, arrows), bolt on. Tightening torque 45 Nm.

7 Remove both bottom mounting fixture, bolt on.

bolts (22) for engine

Tightening torque

45 Nm.

Len side shown

8 Raise engine with the engine hoist.

9 Remove remaining bolts (32, 34) for attaching oil pan, bolt on and remove oil pan.

Tightening torque:

M6 10 Nm,

M8 25 Nm.

10 Carefully clean mating face at oil pan and on crankcase.

01.0904 - 310/5

11 install oil pan with new gasket. Pay attention to bolt lengths and tightening torques.

12 Lower engine and attach engine mounts.

13 Add engine oil and adjust to correct level.

14 Check for leaks with engine running.

01.0904 . 31 Oi6

01-403 Repair instructions for crankcase, cylinder heads and cylinder head gaskets

Crankcase

The tapped hole for attaching the power steering pump carrier (compared to engines with multibelt drive) have been converted from M8 to MlO.

The M 38 X 1.5 tapped hole for mounting the coolant preheater on the left side is shorter. It is sealed with a screw plug (5) and an O-ring from engines 116/l 17 and 601.

The crankshaft bearings in the crankcase have been modified (size “5”).

Multi-belt drive =24 mm

Single-belt drive =20 mm

01.0904 4031

At the same time, the crankshaft bearing covers are 8 mm lower (H = 40 mm).

Engines with multi-belt drive

(102.985)

H=46 mm

Engines with single-belt drive

(102.961)

H=40 mm

Fastening bolts of the crankshaft bearing covers converted to Ml 1 X 62 twelve-side stretch bolts with collar. Previously, Ml 2 X 70 hexagon bolts.

A M 12 x 70 hexagon bolts

B Mt 1 x 62 twelve-side stretch bolt

Bolt projections (A, 6, C) on crankcase for fastening bolts of timing case cover lengthened.

01 0904 - 40312

POl-0053.13

Because of the lengthened bolt extensions, the power steering pump carrier has been provided with a semi-circular cutout at the second reinforcing rib (arrow).

Standard Implementation: 06186

Engine End No.

transmission

1 Vehicle ident End No.

Cylinder head

The same cylinder head is installed on engines

102.9221924 as on engines 102.962/982/985.

Only one cylinder head version is supplied as a replacement part.

This cylinder head must not be installed on the previous engine 102.961.

01.0904 - 4033

A core plug, Part No. 000 443 025 003 should be inserted with MB sealant 002 989 94 71 and the installation mandrel 102 589 02 15 00 for engine 102.985.

Caution!

If the core hole is not closed (arrow), coolant may get into the cylinders on engine 102.985.

An oil pipe (A) is inserted in the oil feed passage at the rear of the cylinder head to prevent the oil passages running empty when the engine is off.

I

Since 071’87 the oil pipe (A) has a stop collar

(arrow). This prevents the oil pipe “migrating upward” in the cylinder head. At the same time, the recess in the cylinder head has been modified.

X

Y

I

9.0 mm I 9.5

mm

I

7.0 mm I 7.0 mm

01 0904 . 40314

PO1.2077.13

POl-0097-(5

PO1-0191-13

No oil passage is provided at the 4th bearing point for camshaft lubrication (arrow).

Cylinder head gasket

Cylinder head gaskets of asbestos-free material were installed for a certain period on engines

102.985.

Standard implementation:

Februarv - March 1988 (manufacturer Elrina)

Vehicle ldent End No.

I not covered

The

cylinder head gasket in the chain box area was modified with implementation of the double roller chain (6, arrow).

In addition, sealing surfaces with modified coating and widened combustion chamber chamfered faces (c) as well as silicone strips (d) running all round the outer edge.

01.0904 - 4035

Standard imDlementation:

01188

Model

To achieve greater clearance for the double roller chain, the front wall at the cylinder head was lengthened. In addition, the bolt extensions were flattened off at the radius (f).

A Single roller charn

B Double roller cham

Standard implementation:

01188

01 .OW4

4036

01406 Removal and installation of cylinder head cover

Preceding work:

Removing air filter (09-400 or 09-410).

B a

PO1 - OOll- 37

Ignition cable (16)

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

Ignition distributor cover (15)

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

Spark plug connector (d)

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

Vent line (e)

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

Holder (b)

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

Cap nut (96) or hexagon nut (c)

Cylinder head cover (81)

Gasket (93)

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

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

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

unplug at distributor cover, plug in.

unbolt at distributor, bolt on.

detach from spark plugs, fit on.

detach, attach.

unbolt, bolt on if equipped with automatic transmission.

unbolt, bolt on, 15 Nm.

remove with ignition cables, refit.

Pay attention to instructions.

check, replace if necessary.

1

01.0904 406/l

Special tool

Notes

The cylinder head cover is manufactured from a magnesium alloy and is coated on the outside with a black colored plastic.

A two-part, glass fibre reinforced polyamide rectangular tube (107) in which the ignition cables run is inserted in a longitudinal groove of the cylinder head cover.

In addition, the ignition cables and the vent line at the face end of the cylinder head cover run through a plastic holder (arrow).

On the inside, the oil separator (109) and the related outlet pipe are fixed in place with the hose piece (arrow) of the crankcase ventilation

(function description 01-140).

r

0 1 . 0 9 0 4 4 0 6 ’2

The spacer sleeves (arrows) prevent the gasket being squeezed when tightened.

In January 1986 a cylinder head cover made of plastic was fitted (on engines without pressure oil pump for level control).

Distinguishing features: l Collar bolt

(151) l Hose connection for crankcase ventilation with larger OD.

I

The cylinder head gasket has wider plates

(arrows) for sealing the bolt guides.

Caution1

If the cylinder head cover has to be replaced,

8. g. because of cracking, install the previous magnesium cylinder head cover.

A Cylinder head cover (magnesium)

B Plasttc cylmder head cover

152

POl-2128.13

01.0904 - 406/3

Model affected

Model

As of February/March 1985 the oil separator is installed in the cylinder head cover with a vent pipe.

Standard implementation: 02/85

On models with level control

A 1 st verson

B 2nd verson ransmisslon

0 1 . 0 9 0 4 406i4

Standard implementation:

03/@ 15

Model Engine Engine End No.

Manual transmission

201.024 @ 102.985

Since 12:88

a

cylinder head cover has been installed which has a recessed wall (arrows) in the area of the spark plug recesses.

This prevents the valve spring or the valve spring plate rubbing the cylinder head cover and causing noises.

The modified cylinder head cover can also be installed on previous engines in the event of complaints.

1 Chassis End No.

Cylinder head cover 1 st version

Cylinder head cover 2nd verson

0 1 . 0 9 0 4 406/‘5

01-407 Reconditioning spark plug thread In cylinder head

Special tool

Note

The spark plug threads in the cylinder head can be reconditioned on all gasoline engines with the

HELI-COIL repair set.

The cylinder head should only be removed for reconditioning the spark plug thread if the spark plug bore in question is not accessible for the tool.

Recondltionina

1 Set piston at the cylinder in question to

20” - 30” before TDC.

01.0904 _ 407/l

2 Pack grooves of the combination tap (9) of the tapping unit (1, ill. note) with grease and screw combination tap into the damaged thread.

At the same time, press the guide bush (11) into the spark plug recess. Screw in combination tap far enough for the guide tube (12) to move up and be touching the stop ring (10).

Caution!

If the cylinder head is installed, unbolt combination tap after approx. each five turns, clean grooves of swarf and grease and again pack with grease.

3 Check length of the HELI-COIL thread insert

(8).

Use only the HELI-COIL inset-t with 9.1 mm block length.

4 Install HELI-COIL thread insert. To perform this step, insert HELI-COIL insert (8) into the tool

(2, ill. note) so that the bar (arrow) of the insert is facing the preload cartridge (16).

Turn HELI-COIL insert with the turning spindle

(13) far enough through the preload cartridge until the bar (arrow) is flush with the face of the preload cartridge.

01.0904 . 407/2

Install installation tool onto the tapped hole, hold jacket sleeve (15) tight and turn spindle for long enough until the stop ring (14) is touching the jacket sleeve.

Note

When installing the HELI-COIL thread insert, turn back jacket sleeve slightly (15) if it is jamming.

5 Break off bar (arrow) of the HELI-COIL thread insert.

This is done by installing the sleeve (18) of the bar breaking unit (3, ill. note) over the bar, introducing the opened pliers (17) as far as the mark (arrow) into the sleeve and closing pliers.

The serrated tooth lock (s) must engage.

Turn sleeve to the left as far as the stop and hold tight. Move pliers slightly up and down and break off bar.

Caution!

It is essential to remove a bar which may have dropped on the piston crown with a magnet.

6 Caulk HELI-COIL thread insert. This is done by greasing the conical thread of the caulking tool (6) screwing caulking tool into the fitted

HELI-COIL insert, tightening to 25 Nm and removing the caulking tool.

01 0904 - 40713

I

7 Mill mounting seat for the copper seal (7).

This is done by screwing in the guide mandrel

(4) far enough for the stop collar (arrow) to be touching the tapped hole.

Push milling cutter (5) over guide mandrel and mill the seat for the sealing ring. Always blow out the chips from time to time.

Once the milling cutter is seated on the stop collar of the guide mandrel, the required milling depth is reached (no further cutting resistance).

Once again thoroughly blow out spark plug recess before then removing the guide mandrel.

Turn crankshaft several times with starter motor and contact handle in order to remove any chips which may have dropped onto the piston crown.

8 Place copper seal (7) into the milled mounting seat, screw in spark plug and tighten to 30 Nm.

Note

When performing this step, the tapered seat of the spark plug is pressed into the copper seal.

9 Loosen spark plug fully and tighten to

15 Nm.

01.0904 . 407/4

01-415 Removal and installation of cylinder head

Preceding work:

Removal of air filter (09-400).

Draining engine coolant (20-010).

Removal of guide rail in cylinder head (05340).

Removing poly V-belt (13-342).

Fan shroud (1) and fan (75) . . . . . . . . . . . . . . . .

Cylinder head cover (81) . . . . . . . . . . . . . . . . . .

Exhaust pipes (48) . . . . . . . . . . . . . . . . . . . . . .

Dipstick guide tube (40a) . . . . . . . . . . . . . . . . . .

Bowden cable (30) . . . . . . . . . . . . . . . . . . . . . .

Intake manifold strut (160) and return spring (180) . . . . . . ‘. . . . . . . . . . . . . . . . .

remove, install, 25 Nm (steps 1 and 2).

remove, install, with ignition cable and distributor cover (01-406).

unbolt at exhaust manifold, bolt on, 25 Nm (step

4).

unbolt, bolt on (step 5).

detach, attach, adjust (30-325, step 6).

at intake manifold, unbolt, bolt on, return spring, detach, attach (steps 7 and 8).

01 0904 - 4151

Engine coolant hose (68) supply line for heater . .

Engine wiring harness ....................

Brake booster vacuum line ................

Fuel lines .............................

Air conditioning pipe group holder ...........

Piston of No. 1 cylinder ...................

Alternator .............................

Closing nut (40)

Camshaft gear (4) .......................

Pressure oil pump (69) ...................

Camshaft gear (4) .......................

Hexagon socket bolts (77)

Cylinder head bolts (75)

Cylinder head (51)

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

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

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

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

disconnect, connect (step 9).

disconnect, connect (steps 10 to 14).

disconnect, connect (step 15).

disconnect, connect, dump overpressure

(step 16).

disconnect, connect (step 17).

set to ignition TDC (step 18).

swing away to the outside

(steps 19 and 20).

for chain tensioner, remove and install, replace sealing ring (41) (05310, step 21).

mark relative to timing chain (step 22).

unbolt, bolt on, place to the side with lines connected (step 23).

unbolt, bolt on, 80 Nm, check TDC marking

(steps 24 and 25).

unbolt, bolt on with pin wrench

116 589 03 07 00, 25 Nm (reference value),

(step 26).

unbolt, bolt in, check, tighten (steps 27, 31 to

33).

Refer to table for tightening torques.

remove, refit, clean mating surfaces, replace cylinder head gasket (74) (steps 28 to 30).

Tightening torques in

Nm and angle of rotation torque

Diagram for step-by-step tightening: refer to step 31 for order:

Step-by-step tightening

angle of rotatlon torque

when engine cold

I 1st stage

2nd stage

Hexagon socket bolts 25 Nm (reference value)

-

I 3rd stage

01.0904 - 415~2

Special tools

1165890307Ot

1

001 589 51 21 Ot

I

001 589 6621 00 001 589 7221 00

4

Note

Remove cylinder head together with camshaft, intake manifold and exhaust manifold once engine has cooled down.

Removal and installation

1 Detach fan shroud (1) and place over fan.

When installing, ensure clearance to fan.

2 Unbolt fan (79, remove together with fan shroud, bolt on.

3 Remove cylinder head cover together with spark plug connector and distributor cover

(01-406).

4 Unbolt exhaust pipes at exhaust manifold, bolt on.

01.0904 - 41513

5 Unscrew dipstick guide tube at exhaust manifold, screw in (arrow).

6 Detach Bowden cable (30) for accelerator control, attach, press plastic guide (arrow) out of its seat in the fulcrum lever (13) to perform this step, and take Bowden cable (30) out of the slot in the fulcrum lever.

Compress plastic clip (28) and push clip together with Bowden cable to the rear through the holder

(16).

Adjust Bowden cable (30) (30-325).

7 Unbolt strut at intake manifold. To perform this step, unbolt 2 hexagon socket bolts (arrows) on injection engine, bolt on.

Detach return spring for throttle body assembly

(below intake manifold), attach.

01.0904 - 415/4

8 Detach coolant hose (68) of supply line for heater, attach.

9 Detach connector pickup of control cable

(arrow) and 4-pin connector pickup (3) at ignition control module, plug in.

10 Detach cable from reference resistor (R16)

(Model 201 only).

11 Unbolt terminal TD at the diagnostic connector (Xl 1) bolt on.

12 Unbolt diagnostic connector (Xl l), unplug grey cable from the TDC pulse generator at the rear of the diagnostic connector, plug in.

13 Unplug all connectors and vacuum lines at therm0 valves and temperature switches, plug in.

01.0904 - 41515

14 Disconnect vacuum line for brake booster, connect (arrow).

15 Lower fuel pressure in the fuel lines by briefly opening fuel filler cap.

Unbolt fuel lines (379, 380), bolt on. When detaching the fuel line (380), hold connection to prevent it from turning.

16 On models equipped with air conditioning, unbolt bracket for pipe group (170) of AC compressor at cylinder head, bolt on.

17 Set engine to ignition TDC of No. 1 cylinder.

01.0904 . 41516

18 Loosen bottom bolt (49) for alternator fixture, tighten.

19 Remove top bolt (51) swivel alternator out of the way to the outside (arrow).

. . . . . . . . .

20 Unscrew locking nut (40) of the chain tensioner, bolt on. Replace seal (41). Tightening torque 70 Nm.

21 Mark camshaft gear and timing chain relative to each other.

22 Unbolt pressure oil pump, place to the side with lines connected, bolt on (arrows).

01.0904 - 41517

23 Unbolt camshaft gear, remove and bolt on.

Place timing chain in chain box. Tightening torque 80 Nm.

Hold camshaft gear tight with an open-end wrench (waf 24 mm) for loosening or tightening the camshaft bolt.

24 Check setting marking on camshaft (arrow).

25 Unscrew hexagon socket bolts (arrows) with the pin wrench 116 589 03 07 00, screw on.

Tightening torque 25 Nm (reference value).

01.0904 - 4138

26 Remove cylinder head bolts in stages in the reverse order of the tightening diagram with the torque wrench insert 617 589 00 10 00 with engine cold.

27 Remove cylinder head (51).

28 Clean mating faces on cylinder head and crankcase.

29 Replace cylinder head gasket.

30 Check the shaft length of the cylinder head bolts.

If the maximum length (L) of 122 mm is exceeded, the bolts should be replaced with new ones.

31 Oil thread and head contact face of cylinder head bolts and insert.

01 0904 - 41519

Pal-0094-33

32 Tighten cylinder head bolts in stages in the order of the tightening diagram, beginning with

1.

1st tightening stage 55 Nm

2nd tightening stage 90” angle of rotation

3rd tightening stage 90” angle of rotation

Hexagon socket bolts (a), 25 Nm.

33 Check for leaks with engine running.

Pal-0094-33

01.0904 - 415/10

01-416 Matching measuring sensors to cylinder head

Note

Different temperature switches, thermo-time switches or thermovalves are installed in the measuring sensor box on the cylinder head depending on the engine version.

5

6

POl-0068-13

Items on cvlinder head

Item 1

Temperature switch for magnetic fan coupling and 2nd stage auxiliary fan red 100 “C.

Temperature switch for magnetic fan coupling red 100 “C.

PO+0010-m

01.0904 - 416/l

Item 2

Temperature sensor for AX compressor blue.

Item 2

and 5

Screw plug Ml4 x 1.5

Item 3

Thermovalve for:

Ignition switchover

Purge white red black

60 “C

50 “C

40 “C

Item

4

Temperature switch for intake manifold heater black 110 “C.

01.0904 .416,2

Temperature sensor for:

CFI control

Ignition control and CFI control module black green

Temperature sensor for CFI injection system black.

Double temperature sensor for ON board, CFI control and ignition control black.

Item 6

Temperature sensor for instrument cluster.

010904 _ 416:3

01-418 Facing cylinder head mating face

Data mating face

POI-oooe- 54

01.0904 - 418il

Valve clearance to cylinder head mating face

Engines

Minimum clearance “A” with new valve seats and valves

Inlet (172)

Exhaust (173)

Maximum clearance “A” with machined valve seats and reground valves

Inlet (172)

Exhaust (173)

102.961 @ as of 1984

1.2

0.5

2.1

1.4

Commercial tools

Surface grinding machine with milling device for light alloy surfaces.

Knife-edge straightedge approx. 500 mm long e. g. Sceledum, Type RTY

Messrs. Roaro u. Fi.

Schioiltaly e. g. Messrs. Roaro u. Fi.

Schioiltaly

Note

Only machine cylinder head mating face if there are porous or damaged areas.

Caution!

Clamp cylinder head absolutely flat for facing.

Failure to observe this instruction may result in the camshaft jamming when the cylinder head is reinstalled. In this case, the cylinder head must be replaced.

Facing

1 Face cylinder head mating face.

2 Remachine valve seats far enough for the minimum distance “A” to be achieved (05291

3 Check timing (05-215).

at a

1

PO5-0055-13

01.0904 - 41812

01-419 Enlarging camshaft bearing bores (repalr size)

Preceding work:

Removal and installation of cylinder head (01-415).

Removal and installation of camshaft (05-220).

Disassembling cylinder head.

Camshaft bearing data

Normal size

Repair size

Camshaft bearing dia. D

Journal dia. Dl

Camshaft bearing dia. D

01.0904 419/l

Note

If bearing seizure or severe scoring is present, the camshaft bearings in the cylinder head can be enlarged by 0.5 mm and camshafts with oversize bearing journals installed.

These camshafts have different code numbers

(05215 and 220).

If the rocker arm bearing brackets are equipped for enlarging without the rocker arm shafts, the fastening bolts of the bearing brackets must be tightened to max. 15 Nm otherwise the bores for the rocker arm shafts will be distorted. When machining the basic bores, ensure that the halfbores for mounting the cylinder head cover gasket or the sealing disc at front and rear on the cylinder head are not widened. After widening the basic bores, the edges at the mating face of the cylinder head bracket (A) or at the mating face of the cylinder head (B) on the camshaft bearings 1 to 4 must be machined in accordance with the specified dimensions. If the edges are not machined, the lubrication film will tear at these points, causing damage

(seizure) to the camshaft bearings.

01.0904 - 41912

The bearing brackets differ. Each bearing bracket has a number stamped to identify it. This number must agree with the number stamped on the cylinder head (arrows). If correctly installed, the contact faces for the oil pump are facing to the rear and the code numbers are on the righthand side (direction of travel) (arrows).

POS-0101-55

01.0904 .419/3

01-420 Pressure-testing cylinder head

Pressure-testing plate ....................

Bores and connections ...................

Compressed air hose ....................

Cylinder head ..........................

bolt onto cleaned cylinder head.

plug.

connect and adjust compressed air to 2 bar gauge pressure.

Attach to suspension device and immerse into the heated water (approx. 80 “C).

If air bubbles rise up, determine leak point and mark.

Special tools

Commercial tool

Electrically heated water bath

010904 -420/l e. g. Messrs. Otto Dtirr

D-71 23 Sachsenheim-Ochsenbach

Crankshaft assembly 03

Crankshaft assembly 03

Job No.

Checking, replacing and torquing conrod bolts .................................

Reconditioning and checking angles on bearing bores ...........................

Removal and installation of pistons .........................................

Checking and reconditioning crankshaft ......................................

Installation of crankshaft bearings ........... _ ..............................

Replacing front crankshaft radial seal .......................................

Replacing rear crankshaft radial seal ........................................

Removal and installation of grooved bail bearing in crankshaft ......................

Removal and installation of vibration damper ..................................

Checking and correcting setting of TDC pulse generator ..........................

Removal and installation of crankshaft gear ...................................

Removal and installation of flywheel or flex plate ...............................

Remachining flywheel ..................................................

Replacing ring gear on flywheel ...........................................

03 - 310

0 3 - 3 1 3

. -316

. -318

. - 320

. - 324

. - 327

. - 330

. - 342

. - 345

. - 350

* -410

. - 420

. - 430

03il

03-310 Checking, replacing and torquing conrod bolts

PO3-0146-13

Conrod bolts . . . . . . . . . . . . . . . . . .

Thread and bolt head contact surface .

Conrod bolt initial and angle of rotation torque . . . . . . . . . . . . . . . . . . . . . .

. , . . . . * before reuse, measure the smallest bolt shaft dia. If the dia. reaches or is less than the minimum shaft dia. of 7.1 mm, replace the conrod bolt.

. . . . . . .

oil before installing.

. . . . . . . initial torque 30 Nm.

Angle of rotation torque 90 -

1 OO", use special tool 001 589 66 21 00.

Pay

attention

to note.

Dimensions of conrod bolts

Part No.

I Thread dia.

I Stretch shaft dia. when new I Minimum stretch shaft dia. “c”

Torque of conrod bolt

Initial tightening torque

Angle of rotation torque

30 Nm

90” -

100"

03.0905 3 1 O/l

Special tool

Note

In September 1988 conrod bolts with a longer thread were installed.

These conrod bolts are not supplied as replacement parts.

L---e-----

A 1st version

6 2nd version

03.0905 -

31012

Standard imolementation: 09/86

Model Engine

201.028

102.985

If no torque wrench is available, the conrod bolt can be tightened according to the specified torquing angle with a socket wrench in a single operation. To prevent any angular errors, do not use a bending rod torque wrench for tightening according to angle degrees.

Engine End No.

Manual transmission

027063 - 028449

Automatic transmission

I 076715 - 077418

030905 - 31013

03-313 Reconditlonlng and checking angles of bearing bores

$I

31

GJ

31a

QB

26

\

28

Conrod bolt (28) . . . . . . . . . . . . . . . . . . , . . . . .

Conrod bearing cover (26) .........

. . . . . . .

Basic bore ....................

Conrod bushing (27) .............

. . . . . . .

. . . . . . .

check (03-310).

install without bearing shells (31 and 31a), oil thread and bolt head contact surface,

30 Nm.

measure; if the value of 51.619 mm is exceeded, or if it is conical, dress bearing cover up to max. 0.02 mm (step 3).

press in, pay attention to oil holes. Insertion pressure approx. 2500 N.

Hollow out conrod bushing by turning or reaming. Dress side contact surfaces on dressing plate (steps 4 to 6).

03.0905 - 313/l

Conrod (25) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axial twist . . . . . . . . . . . . . . . . . . . . . . . . . .

check angles of bearing bores with conrod tester. Align conrod bearing bore to small end bushing bore (steps 7 and 8).

to small end bushing bore, check (step 9).

Special tool

Commercial tool

Conrod aligning tool 8. g.

Hahn & Kolb

D-7000 Stuttgart

Model BC 503

03.0905 - 313!2

Data

Centre of conrod bearing bore to center of small end bushing bore

(L, Fig. para 4)

Width of conrod at conrod bearing bore and at small end bushing bore

(8, Fig. para 4)

Basic bore for conrod bearing shells

Basic bore for small end bushing (Dl, Fig. para 4)

Small end bushing OD

Small end bushing ID (D2, Fig. para 4)

144 95

145.05

22 000

21.948

51 600

51.619

24 521

24.500

24 590

24.550

22.007

22.013

0.005

0.1

Peak-to-valley height of small end bushing on inside

Permissible axial twist of conrod bearing bore to small end bushing bore related to 100 mm length

Permissible variation of axial parallelism: conrod bearing bore to small end bushing bore related to 100 mm length

Permissible variation of conrod bearing bore from roughness

Permissible difference in weight of complete conrod within an engine

I 0.02

5 grams

030905 - 3130

Note

The end play of the conrod is limited not at the crankshaft journals but at the piston pin bosses

(piston-guided conrod, arrows).

Conrods which have been overheated as a result of a bearing damage (blue discolouration), must not be reused.

Conrod and conrod bearing cover are marked together. The conrod shaft must not show any cross scoring and notches.

Conrods are supplied as replacement parts with a machined small end bushing.

To reduce the distortion tendency, conrods with a modified material were installed from June through September 1985 and are installed effective February 1987.

0 3 0 9 0 5 - 313,4 w

-AA

PO3-2015-13

Standard im

Model lementation: June throuah Seotember 1985

Engine Engine End No.

transmission

201.024

201.024 @

* not covered

102.961

102.985

Effective 09/89 all conrods are subject to additonal heat treatment to prevent conrod distortion resulting in noises when the engine is operating at normal temperature.

Vehicle ldent End No.

Reconditioning

1 Check conrod bolts, replace if necessary

(03-310).

2 Install conrod bearing cover. To perform the step, oil thread and bolt head contact surface and tighten to 30 + 5 Nm.

3 Measure conrod bearing basic bore. If the basic bore exceeds the value of 51.619 mm or is conical, dress contact face of bearing cover on a surface plate to max. 0.02 mm.

0 3 0 9 0 5 - 3 1 3 5

4 Press in new small end bushing so that the olil bores are aligned (arrow).

Press-fitting pressure 2500 N.

5 Hollow out small end bushing by turning or reaming.

6 Dress side contact faces of conrod on the surface plate.

Checking angles

7 Check angles of bearing bores with a conrod tester.

8 Align conrod bearing bore to small end bushing bore (parallelism).

9 Check axial relative to small twist of conrod bearing bore end bushing bore and correct, if necessary.

2 7

03.0905 - 3136

03-316 Removal and installation of pistons

Preceding work:

Removal of engine (01-030).

Removal of cylinder head (01-415).

Removal of oil pan (01-310).

32

33

34

35

373

- 26

Q%

28

II

Conrod bearing cover (26) . . . . . . . . . . . . . . . . .

Conrod bolt (28) . . . . . . . . . . . . . . . . . . . . . . . .

Piston (32) and conrod (25) . . . . . . . . . . . . . . . .

Locking ring (37) . . . . . . . . . . . . . . . . . . . . . . .

Piston pin (36) . . . . . . . . . . . . . . . . . . . . . . . . .

unbolt, bolt on, 30 Nm and 90” angle of rotation torque. Do not mix up top and bottom bearing shells. Pay attention to matching of conrod and bearing cap (step 12).

check (03-310).

push out of crankcase upwards.

remove (step 3) and insert (step 9).

press out and press in by hand (step 8).

Installation lnstructlon

Insert conrod into piston so that the chamfered splash bore in the small end bearing with the arrow in the piston crown are pointing in direction of travel;

do not

heat piston.

03.0905 - 316.‘1

Piston (32) . . . . . . . . . . . . . .

Piston rings (33, 34 and 35) . .

Piston (32) with conrod (25) . . .

Piston projection . . . . . . . . . . .

. . .

. .

. . *

. . . .

. . . .

. . . .

. . . .

check condition, pay attention to installation position.

check condition, pay attention to installation position, “Top” must face upwards. Position ring gaps evenly around circumference of piston.

install with tensioning strap 000 589 04 14 00, oil piston beforehand and clean cylinder bores

(steps 10 and 11).

check in TDC position (step 14).

Special tools

IO0 589 51 3700 I ~ 0 0 0 5 8 9 0 4 1 4 0 0 1 I001 589 72 21 001

Matching pistons and cylinders

102.922!924

102.962963

Standard

(normal size)

I*

Repair size 1

( + 0.5)

0

L -

89.482

89 478

89.492

89.502

89 498

89.508

89 509

89.518

89 519

89.528

A 89.473

89.479

89 500

89.506

89

507

89.512

89 513

ZzG

03.0905 - 31612

Engine

Repair size 2

(+ 1.0)

Group No.

89 968

89.982

89 978

89.992

89 988

9o.002

89 998

9o.008

90 009

90.018

90

019

90.028

102.982i985

Standard

(normal size)

Repair size 1

(+ 0.5)

Repair size 2

( + 1 .O)

95 969

95.981

A

95 979

95.991

95 989

96.001

96 469

96.481

96 479

96.491

95 998

96.008

96 96.018

009

96 019

96.028

96 498

96.508

96

509

96.518

03.0905 - 31613

Test data

Piston play with Group No. 0, 1 or 2 with Group code letter

A, X or B

When new

I 0.016 - 0.040

Wear limit

-

End gap of piston rings

Note

The pistons and cylinder bores are arranged into three diameter groups within the tolerance and were previously identified with the figures 0, 1 and 2.

As of April 1988 the tolerance stages are identified with the Group code letters A, X and B.

The identification is given as before in the mating face of the crankcase and in the piston crown.

previously I now

03.0905 - 31614

Only pistons with the Group code letter “X” are supplied for repair purposes. These pistons should also be installed in the cylinder bores with the Group code letters “A” or “B”.

Only pistons with Group code letters are also supplied for the previous engines with Group numbers 0, 1 and 2, namely piston “x” for

Group No. 0 and 1. Piston “B” for Group No. 2.

When performing repairs, the cylinder bores should be honed according to the dimensions of the existing pistons plus piston play.

The piston crown is designed differently in the individual engines. The piston crown of normal compression engines is either smooth or provided with a recess. In addition, there are two valve niches each in the piston crown.

030905 - 316/5

Caution!

A recess with a diameter of 50 mm appears on the piston crown of pistons in repair size version.

Piston crown smooth, two valve niches

Engine 102.985

Recess in piston crown, two valve niches

D 70 mm dia.

T vanes according to piston

(normal size, repair srzes)

All low compression engines have a step on the piston crown (except 102.985 @, 1985 additionally one valve niche).

33 Rectangular ring wrth Internal chamfer, runnrng surface chrome-plated

34 Taper face 011 scraper ring, running surface precksion-turned

35 Chamferred 011 control nng wrth garter spring, runnrng surfaces chrome-plated

T Herght of size 2.0 mm

03 0905 31616

PO3-0012-13

PO3.0013.13

PO3-0010-13

3

:

I j7

T

L

PO3-0011-13

Engme 102.985 @

As the design of the piston crown (flat, recess or step) has an influence on the compression, the pistons are not interchangeable.

Two repair sizes (each step + 0.5 mm dia.) are approved for the pistons of all engines.

The shape of the piston and the roughness of the grinding pattern of the pistons has been modified from 0.8 mm to 1.2 mm on Engine

102.982 as a noise-reducing measure.

03.0905 -316/7

PO3-0014-U

On engine 102.985 @ the rectangular ring manufactured by Gotze is installed in groove I of the piston manufactured by Mahle and KS.

The running surface of this piston ring is chrome-plated, asymmetrically crowned and sharp-edged at the bottom to reduce oil consumption.

Standard lmplementatlon: 0318 8

T

(Mahle)

Engine End No.

Manual transmission ransmrssron

201.028 @ 1102.985

023341

Vehicle ldent End No.

Standard Implementation: 03188

(KS)

201.028 @ 102.985

023788

The Group code numbers on the pistons and on the mating face of the crankcase have been replaced by Group code letters.

As a result, the cylinder diameters and matching of pistons and cylinders have also been modified

(refer to data).

070989 492527

Crankcase with Group numbers

03.0905 - 31616

Crankcase with Group code letters

Removal and installation

1 Unbolt conrod bearing cover and remove conrod together with piston upwards.

2 Check conrod bolts (03310).

3 Remove piston pin locking element with screwdriver and press out piston pin.

4 Recondition conrod and check angles of bearing bores, if necessary (03-313).

5 If the pistons are worn, check the gap clearance and end play of the piston rings (refer to table). Check that the piston rings move easily. Pay attention to installation position:

“Top” must be facing upwards. Distribute the ring gaps evenly around the circumference of the piston.

6 Oil piston pin and small end bushes.

7 Install piston so that the chamfered splash bore in the small end bearing (arrow) and the arrow in the piston crown are facing in direction of travel.

Caution!

Do not heat piston.

03.0905 _ 31619

PO3-2014.13A

8 Press in piston pin by hand.

9 Insert piston pin locking element into the groove.

10 Oil cleaned cylinder bores, conrod bearing journals, conrod bearing shells and pistons.

I I Install tensioning strap for piston rings and install piston into cylinder bore with arrow facing in direction of travel.

12 Mount conrod bearing cover onto the conrod with the code marks (arrows) aligned with each other and torque conrod bolts to an initial torque of 30 Nm and angle of rotation torque of 90”.

13 Turn crankshaft and check clearance between piston pin boss and conrod.

03.0905 - 316ilO

14 Measure the distance between piston crown and crankcase mating face with the pistons in the TDC postion (refer to table).

03.0905 . 316111

03-318 Checking and reconditioning crankshaft

Data

Normal size II

4th repair size

03.0905 - 31811

Crankpin width

28 000

28.084

up to 28.30

Permissible out-of-roundness of crankshaft journals and crankpins

Permissible conicity crankpins crankshaft journals

Permissible axial runout of fit bearing

Fillet radii at the crankshaft bearing journals crankpins

Bearing journals ground and fine-lapped, max peak-to-valley height R, (pm)

Crankshaft journal1 dia. front

Permissible variation of front crankshaft journal from concentricity ‘) ‘)

Running surface dia. for rear radial seal

Permissible variation of rear crankshaft flange

Permissible variation of crankshaft journals from concentricity ‘) from concentricity ‘) from axial runout ‘) journal II, IV journal Ill

Scleroscopic hardness of crankshaft journals and crankpins

0.0025

0.010

0.010

0.02

2.0 - 2.2

2.8 - 3.0

0.15

I

29.987 - 30.000

0.030

92.874 - 92.928

0.02

0.012

1) When crankshaft mounted on outer crankshaft journals I and V and one full rotation.

2) If measurement performed when crankshaft installed, eliminate radial beanng play by pressmg against crankshaft journal.

3) The llmlt value must exist at least at 2/3 of the circumference of the journal.

Note

Maximum wear limit of crankshaft journals and crankpins 0.02 mmm. The repair sizes listed in the table must be strictly adhered to. In addition, it is essential to adhere to the fillet radii at the crankshaft journals and crankpins when regrinding.

03.0905 - 31812

Special tool

jooo5892**1 OOJ

Note

Adhere to the sequence of operations of the diagram below when checking and reconditioning crankshafts.

Dianram

‘) Refer to Section “Explanatory notes regarding diagram”.

03.0905 .

31 a/3

A. Checking, grinding

Visual inspection

Severe damage f

Scrap

Crack test ‘)

Cracks present

I Yes

Hardness test ‘)

All journals/crankpins

Scleroscopic hardness at least 60 at 213 of circumference of journallcrankpin

Measuring journals/crankpins

Do dimensions agree

Check whether regrinding still possible within the last specified repair size 4.

I

No

03.0905 - 31814

Grind crankshaft

Dimensional inspection

Refer to Checking/Regrinding

Fit parts to crankshaft

End of inspection

I

03 0905 - 31815

B. Hardening

Check whether regrinding is still possible within the last specified repair size

4.

Yes No

1

I

Hardening ‘)

Journal1 with radius hardening

I

Scrap

Journal without radius hardening

Induction hardening

System available

Yes No

Induction or flame hardening

I

1 1 I y ction hardening

Check hardening by etching ‘) lmenslons agree

Journal1 with radius hardening

I

Journal without radius hardening

03.0905 318/6

Explanatory notes regarding diagram

Crack test

Clean crankshaft. The bearing journals must be free of oil and grease.

Magnetize crankshaft and apply fluorescent powder (flux).

A dye penetration method (immersing in bath or with spray can) may also be used.

Helpful tools: die, UV oil or fluorescent powder, cleaning agent, developer

Hardness test

Test hardness with the drop hardness tester

(scleroscopic hardness).

The minimum hardness of 60 must exist at

2’3 of the circumference of the journal.

Hardening

The journals without hardened radii may be hardened inductively or with a flame. By contrast, the journals with hardened radii

(arrows) must always be hardened inductively.

If this is not possible, scrap crankshaft.

When hardening the journals without hardened radii, it is important to adhere to the distance A between hardening runout and radius

(4 - 5 mm).

030905 - 31w

PO3-0072-13

Inspection of hardening

To achieve proper hardening, check the setting of the hardening system by metallographic ground surfaces.

These can be removed from test hardening operations on scrapped crankshafts.

Check hardening by etching the surface of the journal with a 2 % alcoholic nitric acid (HNOs).

No dark spots should appear on the surface of the journal.

Non-hardened radii change to a dark colour.

By contrast, the hardened radii must be just as bright as the surface of the journal.

As a comparison, it is recommended to perform etching on a metallographically tested journal.

Following this, carefully wash off the nitric acid with alcohol.

Corrosion protection

Crankshafts which are not immediately reinstalled, must be oiled with initial operation engine oil (SAE 30).

03.0905 31&8

03-320 Installation of crankshafts bearings

Preceding work:

Engine removed and disassembled.

Main oil passage in crankcase open (01-l 30).

Clean 011 passages In crankcase and in crankshaft.

Check crankshaft for cracks, dimenslonal tolerance, hardness and concentricity (03-318).

_.

27

25

‘\

4

$I

31

QJ

31a

QTI

26

28

3 a

PQ3-0160-57

Crankshaft bearing covers (2 and 2 a) . . . . . . . .

Basic bore . . . . . . . . . . . . , . . . . . . . . . . . . . . .

install without bearing shells, pay attention to markings, tighten. Hex. bolt 90 Nm, stretch bolt, initial torque 55 Nm, angle of rotation torque 90”

(steps 1 and 2).

measure conicity in direction A, B and C

(step 3).

03 0905 . 32011

Crankshaft bearing shells

(24 and

24 a) . , . . . . .

Bearing diameters .......................

Crankshaft (1) .........................

Thrust bearing journals . . . . . . . . . . . . . . . .

Bearing shells (24) . . . . . . . . . . . . . . . . . . . , . .

Thrust washers (23) . . . . . . . . . . . . . . . . . . . .

Thrust bearing cover (2a) . . . . . . . . . . . . . . . . .

Crankshaft bearing cover (2) . . . . . . . . . . . . . .

Crankshaft bearing end play . . . . . . . . . . . . . .

Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conrod bearing shells (31 and 31 a) ..........

Bearing diameter .......................

Wrist pins ............................

Piston ...............................

Conrod bearing cover (26) . . . . . . . . . . . . . .

insert, adhere to tightening torques

(step 4).

measure and note values (step 5).

measure crankshaft bearing journals, determine bearing play (step 6).

measure width and match appropriate thrust washers (step 7).

oil with engine oil and insert crankshaft

(step 8).

oil and fit into grooves of thrust bearings, pay attention to oil grooves (step 9).

oil together with thrust washers (23 a) and install (step

10).

install, hexagon bolt, 90 Nm, stretch bolt (3 a), initial torque 55 Nm, angle of rotation torque 90”

(steps 11 and 12).

measure. Check ease of movement of crankshaft (steps

13 and 14).

recondition and check angles (03-313).

insert, initial torque 30 Nm, angle of rotation torque 90” (step 16).

measure and note value (step 17).

measure, determine bearing play (step 18).

install on conrod (pay attention to installation position and install (03-316).

install, initial torque 30 Nm, angle of rotation torque 90” (step 20).

Caution!

Note step 20.

03.0905 - 32012

Special tools

Commercial tools

Quick caliper for internal measurements, dia. 40 - 60 mm

Quick caliper for internal measurements, dia. 60 - 80 mm

Bow-type measuring bolt 25 - 50 mm

Bow-type measuring bolt 50 - 75 mm e. g. Hahn und Kolb

BorsigstraOe 50

D-7000 Stuttgart 30

Order No. G 222 K

Order No. G 322 K

Order No. 31346 025

Order No. 31346 050

03.0905 - 320/3

Data

Crankshaft normal size and repair sizes

Normal size

Crankshaft bearing journal dia.

57.96Q ‘)

57.965

Thrust bearings

Matched thickness of thrust washers

4.15

or

4.20

57.960

Crankshaft ournal width at thrust oearing

28 500

28.521

3r

28.621

vVrist pin dia.

47 955

47.965

Wrist pin width

28 000

28.084

Normal size I

57.945

1st repair size

2nd repair size

4.25

1735 or

4.40

L

28.721

3r

28 900 zzi=

3r

47 705

47.715

47.455

47.465

3rd repair size 57 205

57.215

47 205

47.215

4th repair size

L

56.965

29.021

46 955

46.965

1) Colored dots on the crank webs or counterwelghts next to the crankshaft journals: blue, yellow, red.

up to 28.30

Basic bore and bearina dav

Basic bore width at thrust bearing

Axial bearing play wear limit

I

0.070

03.0905 - 32014

Notes

Engine removed and disassembled.

Main oil passage in crankcase open (01-130).

Oil passages in crankcase and in crankshaft carefully cleaned.

Crankshaft checked for cracks, hardness, dimensional tolerance and concentricity (03-318).

Normal bearing shells and

thrust washers

are installed on the 3rd crankshaft bearing (thrust bearing).

The thrust washers absorb the axial forces of the crankshaft.

The thrust washers (23 and 23a) inserted in the crankcase and in the bearing cover on both sides are each identical.

The thrust washers each have two retaining lugs in the bearing cover as an anti-twist lock and to avoid assembly errors, the bottom lugs being fitted off-center. In addition, all the thrust washers are chamfered at one end.

When repairing crankshafts, the thrust bearing journals must be reground in the width to one of the dimensions stated in the table (Section

“Data”).

Q

23

1 cb

24a

b

23a

1 Crankshaft

2 Bearing cover

3 M 12 x 60 bolts (1 St versm)

3a Ml 1 x 62 collar bolts (2nd version)

4b Washer

23 Thrust washer in crankcase

23a Thrust washer in bearing cover

24 Bearing shell in crankcase

03.0905 - 32Oi5

Thrust washers of the same thickness must always be installed on both sides.

It is not permitted to regrind thrust washers.

The thrust washers are available only as sets as replacement parts. A set consists of one top and one bottom thrust washer (23 and 23a).

Matching crankshaft bearing shells to crankcase

Crankshaft journal bearing ‘) Basic bores in crankcase

1 chisel marks 2 chisel marks 3 chisel marks2)

Matching bearing shells with color coding blue yellow blue

1 blue red yellow

1) Colored dots on the crank webs or counterwelghts next to the crankshaft journals.

2, Chisel marks In mating face of crankcase at 011 sump end next to baste bore.

I yellow

I yellow yellow

I yellow red red

The normal size crankshaft bearing shells with the color coding blue, yellow and red are supplied as replacement parts.

They should be matched according to the table.

The bearing plays do not therefore need to be measured.

Chisel marks for matching crankshaft bearing shells

In June 1986 the crankshaft bearings were modified from 24 mm to 20 mm (size “B”).

PO3-2066.13

03.0905 - 320~6

At the same time, the crankshaft bearing covers were reduced in height by 8 mm (H = 40 mm).

-I

I

H

I

A 1 st version

B 2nd version

H 48 mm

B 2 4 m m

H 4 0 m m

B 20 mm

Likewise, the bolts of the crankshaft bearing covers were converted to M 11 X 62 twelve-sided stretch bolts with collar.

Previously, Ml 2 x 70 hexagon bolts.

A Ml 2 x 70 hexagon bolts

B Ml 1 x62 twelve-sided stretch bolt

In view of the narrower crankshaft bearings,

4.15 mm thick thrust washers are installed on crankshaft bearing 3 (thrust bearing).

03.0905 - 32017

A 2.15 mm thick thrust washers

B 4.15 mm thick thrust washers

PO1.0053-13

Standard implementation: 06186

During the period November through

December 1987 and December 1987 through

January 1988, single-section thrust washers from two different suppliers were installed.

A Two-section thrust washers

B Single-sectlon thrust washers

03.0905 . 32018

PO3-0045-15

PO3-0046-13

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

Matching crankshaft bearings, installing crankshaft

Note

These operations should be performed if the dimensions of the crankshaft journals or of the basic bearing bores in the crankcase and at the conrod are not known, e.g. if the crankshafts have been remachined.

All the bearing covers fit into the side of the crankcase (arrows) and are attached each with

2 bolts.

The fit (arrows) is offset from the center so that the bearing covers can only be installed in one position.

In addition, they are marked from front to rear with the code numbers 1, 2, 4 and 5 (arrows), with the exception of the thrust bearing covers,, and must not be interchanged or replaced.

1 Install crankshaft bearing covers without bearing shells.

2 Oil fastening bolts for crankshaft bearing covers and tighten to 90 Nm (hexagon bolts) or

55 Nm initial torque and 90” angle of rotation torque (stretch bolts), respectively.

I

I pe--d4

------Jo

3

0

0 0 0 n n

0

I

I

3 Measure basic bore in two planes in the direction A, B and C (conicity).

If a basic bore exceeds the specified value or is conical, dress the mating face of the bearing cover on a surface plate to max. 0.02 mm.

03.0905 - 32019

4 Insert crankshaft bearing shells, install bearing covers, screw in fastening bolts and tighten to 90 Nm (hexagon bolts) or 55 Nm initial torque and 90” angle of rotation torque

(stretch bolts), respectively.

\

)\

PO32019.13

A Bearing shells in crankcase

B Bearing shells in bearmg covers

C Thrust bearings with thrust washers

03.0905 . 320110

5 Measure and note bearing diameters.

6 Measure crankshaft bearing journals, determine radial play of crankshaft bearings.

Note

Bearing play can be corrected by replacing the bearing shells (refer to table for matching crankshaft bearing shells to crankcase).

7 Measure width of thrust bearing journal and match appropriate thrust washers (refer to table,

Section 11 Data”).

8 Oil bearing shells and crankshaft with engine oil and insert crankshaft.

9 Oil thrust washers with engine oil and fit the grooves on the thrust bearing (crankcase).

I \ ‘I

PO32020-13

03.0905 _ z-320/11

Caution!

The two oil grooves (arrows) in the thrust washers must be facing the crankshaft webs.

10 Install thrust bearing cover.

Caution!

Oil thrust washers with engine oil and place into the grooves on the thrust bearing cover. The two oil grooves in the thrust washers must be facing the crankshaft webs.

When installing the thrust bearing cover, hold both thrust washers tight.

11 Install crankshaft bearing cover.

12 Tighten fastening bolts of bearing covers to

90 Nm (hexagon bolts) or 55 Nm initial torque and 90” angle of rotation torque (stretch bolts), respectively.

13 Measure end play of crankshaft bearings.

14 Rotate crankshaft by hand and check whether it runs freely.

03.0905 . 320/12

Matching conrod bearings and installing conrod

15 Recondition conrod and check angles of bearing bores relative to each other

(03313).

16 Insert conrod bearing shells. Install conrod bearing cover with bearing shell and tighten conrod bolts to an initial torque of 30 Nm and angle of rotation torque of 90”.

Note

Conrod bearing shells are supplied only in the yellow version.

17 Measure bearing diameter and note.

18 Measure wrist pins, determine radial play of conrod bearings.

Note

If the conrod bearing play exceeds the specified value, dress mating face of conrod bearing cover on a surface plate to max. 0.02 mm.

19 Fit pistons to conrod and install (03-316).

Note

The conrod must be installed on the pistons so that the

chamfered

splash bore in the small end bearing (arrow) and the arrow in the piston crown are facing the direction of travel.

03.0905 - 320113

20 Tighten conrod bolts to an initial torque of

30 Nm and angle of rotation torque of 90”.

Caution!

Remove oil pump, clean, replace, if necessary, oil pump gears and drive sleeve (18-210).

Remove oil pressure relief valve and check ease of movement of pistons (18-215). Remove oil filter (18-l lo), disassemble and clean.

Install initial operation oil filter element. After

1000 - 1500 km, change engine oil and oil filter element.

03.0905 - 320114

03-324 Replacing front crankshaft radial seal

Preceding work:

Drain coolant (20-010).

Remove radiator (20-420).

Remove poly V-Belt (13-342).

Remove belt pulley and vlbratlon damper (03342).

45

Radial seal (45) ........................

remove, replace and install

(steps 1, 3 and 4)

Spacer ring (7) .........................

check, replace if necessary (step 2).

Mounting hole .........................

clean, check.

03.0905 - 324/l

Special tools

1 0 2 5 8 9 0 0 1 4 0 0 102 58901 14 00 102 58900 33

00

Notes

Since August 1986 (implementation of use of double roller chain) a 4 mm narrower radial seal has been installed.

Size “C” 8 mm (previously 12 mm).

For the same reason, the mounting in the timing case cover (D) was made 3.4 mm flatter.

Size I’D” 9.8 mm (previously 13.2 mm).

Standard implementation: 08/86

radial seal

POl-0194-13

03.0905 - 32412

As a result of the modified installation position of the dust lip on the narrower radial seal, the chamfer on the vibration damper is shorter.

Size “E” 0.8 mm (previously 2 mm).

PO3-0141-13

Standard implementation: 08/86 vibration damper transmwon

039381 201.024 @ 102.985

004202

A radial seal of a further manufacturer was installed for a certain period.

Identification: outer ring black inner ring red

267452

03.0905 - 32413

Removal and installation

Note

Before replacing the front crankshaft radial seal, it is necessary to determine whether the leak is occurring at the timing case cover itself (shrink holes, cracks).

This is done by cleaning the bottom area of the timing case cover free of oil, drying and spraying it with “MB contrast spray white”,

Part No. 009 989 03 59. Run engine and pinpoint oil leak after 2 - 5 minutes.

1 Pry radial seal (45) out of the timing case cover with a screwdriver.

When performing the step, ensure that the crankshaft journal and the mounting hole in the timing case are not damaged. Cover over crankshaft journal with a rag.

Deburr mounting hole, if necessary.

03.0905 . 32414

2 Check whether the sealing lip of the radial seal has worn at the spacer ring (7) (groove). If necessary, remove spacer ring with the puller

102 589 00 33 00.

If necessary, install new spacer ring.

3 Oil the sealing lip of radial seal (45).

Caution!

Do not use any grease. Grease prevents the inclined webs on the sealing lip from positioning.

4 Pull in radial seal with an installation tool.

Installation instruction

Use special tool 102 589 00 14 00 on engines with single roller chain, use additionally the

‘spacer ring 102 589 01 14 00 (01) on engines with double roller chain.

03.0905 - 324el

03-327 Replacing rear crankshaft radial seal

Preceding work:

Removing VansmIssIon (26-020 or 27-600).

Removing flywheel or driven member (03-410).

-

Radial seal (20) ........................

remove, replace and install.

Mounting hole .........................

clean, check.

Sealing lip ............................

oil.

Leaks when engine running ................

check.

03.0905 - 327/l

Special tool

Notes

The sealing lip of the replacement radial seal is offset to the inside by 3 mm so that it does not run in a groove which may have been produced on the running surface on the crankshaft by the standard radial seal.

A Standard radial seal

6 Repalr radial seal

The radial seal1 is installed into the end cover flush without any sealant.

Oil leaks can be determined after spraying the cleaned and dried surrounding area with

Mercedes-Benz contrast spray white, Part No.

000 989 03 59.

PO3-0078-15

_I

1

03.0905 - 32712

Removal and installation

1 Press radial seal out of the end cover with a screwdriver.

When performing this step, ensure that the crankshaft flange and the mounting hole in the end cover are not damaged. Cover over crankshaft flange with a rag.

2 Check running surface for radial seal on the crankshaft for signs of damage.

3 Clean mounting hole in the end cover for the radial seal, deburr if necessary.

4 Screw inner part of installation tool onto crankshaft flange.

5 Oil sealing lip of radial seal.

Caution!

Do not use any grease. Grease prevents the inclined webs on the sealing lip from repositioning.

6 Install radial seal (arrow) over the inner part of the Installation tool.

03.0905 - 32713

7

Press the radial seal (arrow) into the end cover as far as the stop with the outer part of the installation tool.

Caution!

The radial seal must be positioned exactly at right angles to the crankshaft flange or inner part of the installation tool to ensure that it provides a proper seal.

8

Check for leaks with engine running.

03.0905 - 32714

03-330 Removal and installation of grooved ball bearlng in crankshaft

Preceding work:

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

Removing clutch (25050).

Grooved ball bearing (19) and locking ring (21) . .

withdraw, special tool 000 589 33 33 00 and

000 589 25 33 00.

Before installation, coat outer race of grooved ball bearing with adhesive 002 989 94 71.

Knock in grooved ball bearing as far as the stop, outer race flush.

03.0905 - 330/l

Special tools

Removal and installation

1 Withdraw grooved ball bearing with locking ring from the crankshaft, special tool

000 589 33 33 00 and 000 589 25 33 00.

2 Coat the new grooved ball bearing with the adhesive 002 989 94

71 and knock the outer race with a suitable drift to insert it into the crankshaft as far as the stop.

3 Knock in locking ring (132) flush.

03.0905 - 330:2

03-342 Removal and installation of vibration damper or hub and belt pulley

Preceding work:

Dranng coolant (20-010).

Removing radiator (20-420).

Removing poly V-belt (13-340).

-.

PO3-0029 -55

Retaining lock on starter ring gear ...........

remove and install, special tool

601 589 02 40 00.

Belt pulley (13) .........................

unbolt, bolt on, 25 Nm.

Hexagon bolt (8) ........................

unscrew, bolt on, 300 Nm.

Shock absorber (28) .....................

Unbolt at bottom, bolt on (step 4) and press up,

25 Nm.

Vibration damper (11) ....................

pull off, special tool 601 589 08 33 00, fit on.

Special tools

03.0905 . 342/l

Commercial tool

314” square socket to 112” square driver coupler e. g. Hazet

D-5630 Remscheid

Order No. 1058 R-l

On vehicles with air conditioning/automatic climate control, the belt pulley (13) was installed with a hub with rubber part (38, damping part) with ball bearing (40) up to December 1984.

The uneven running of the crankshaft, particularly at low engine speeds and during cutin surges of the AC compressor, are damped by the coupling so that the V-belt runs practically slip-free on the belt pulley.

39

40

41

42

44

8a

9

10

1OP

11

13

15b

22

6

7

2

5

1 KW Crankshaft

1ZK Crankcase

Oil pump outer gear

Crankshaft gear

Strarght pm 3 x 5 mm

Spacer ring

M 18 x 1.5 x 75 stretch bolt

Woodruff key

Bellevrlle spnng washer

26

38

Oil pump Inner gear

Vibratron damper

Belt pulley

M6 x 13 bolts

011 pump dnve sleeve

Oil sump

Hub wrth rubber part and steel ring

Flange

Ball bearing

45

Lockrng nng

End cover

Timrng case cover

Radial seal

‘8 ‘P 7 ,4,5 4,4 2,2 1KW

03.0905 - 34212

In order to provide greater clearance for the top shock absorber of the poly V-belt tensioning device, the shape of the vibration damper has been modified.

Size “a” = 133.1

mm dia., previously

145 mm dia.

A 1st version

B 2nd version

Standard implementation:

1

O/87

201.028

I

102.985

The spacer ring on the crankshaft was made

3.65 mm narrower with implementation of the double roller chain.

Removal and installation

1 Attach retaining lock 601 589 02 40 00 with two bolts to the oil pan (arrows).

03.0905 - 3421’3

2

Remove bolts (15) and take off belt pulley

(13). Tightening torque 25 Nm.

3 Remove bolt (8) and take off Eelleville spring washers (10).

Installation Instruction

Oil bolt threads and Belleville spring washers.

Install Belleville spring washers with curved side facing bolt head.

4 Remove bolt (34) for bottom shock absorber mounting and swing shock abosrber (28) upwards. Tightening torque 25 Nm.

03.0905 _ 342J4

PO3-0064-13

5 Pull off vibration damper (11) with the puller

103 589 00 33 00.

Installation instruction

When installing the vibration damper, check whether the groove in the hub is aligned with the

Belleville spring washer in the crankshaft.

03.0905 - 34215

03-345 Checking and correcting setting of TDC pulse generator

Preceding work:

Removing poly V-belt (13-342).

Removing cylilnder head cover (01-406).

Removing spark plugs (15-016).

PO3-0025-36

Fan and fan coupling . . . . . . . . . . . . . . . . . . . . .

No.

1 cylinder piston .....................

remove and install (step 1).

set to ignition TDC (step 2).

No.

1 cylinder rocker arm bearing bracket ......

remove and install, 20 Nm (step 3).

Valve spring ...........................

remove from 1st intake valve, install (05-250).

Valve stem seal ........................

remove from 1st intake valve, install (step 5 and

05-270).

03.0905 . 34511

TDC setting

Hexagon nut ........... . .

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

Dial gauge ............. . .

Turn crankshaft

Fixing device

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

......... .

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

. . * . . . . . . . . . .

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

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

measure by attaching dial gauge holder

363 589 02 21 00 to cylinder head. Mount valve on piston crown. Turn back crankshaft to approx. 10” before TDC of No 1 cylinder. Inset-t dial gauge in holder. Fit tracer pin of dial gauge onto valve stem with preload of 2 mm. Slowly turn crankshaft in direction of rotation of engine until the large pointer stops (TDC setting, steps

6 through 11).

unbolt at TDC pulse generator, withdraw TDC pulse generator (step 12).

loosen and set preload of 5 mm, position scale of gauge to “0” (step 13).

until dial gauge has moved back by 2.85 mm or

3.07 mm, respectively (step 14).

Insert special tool 119 589 00 21 00 into setting slide. The pin in the vibration damper must engage in the groove of the fixing device; correct setting slide, if necessary (steps 14 through 19).

Data

Piston travel at crankshaft setting

20” after TDC

03.0905 - 34512

Speclal tools

363 589 02 21 00 001 589 51 21 001 I102 589 00 61 OC

1102589 01 61 001 1116589066300)

I

104 58900 3700

Commercial tool

Dial gauge A 1 DIN 878 8. g.

Mahr

D-7300 Esslingen

Order No. 311000

Notes

The TDS pulse generator with holder (1) is attached to the timing case cover.

The pin in the vibration damper or on the belt pulley must be positioned exactly below the TDC pulse generator at a crankshaft setting of 20” after TDC.

The adjustment of the TDC pulse generator must be checked or corrected: l When replacing the crankshaft or the vibration damper.

l l

When replacing the timing case cover.

When installing parts to reconditioned engines.

03.0905 - 34513

The crankshaft setting 20” after TDC is determined from the piston travel, starting from ignition TDC of No. 1 piston.

The piston travel is measured either with the intake valve of No. 1 cylinder mounted on the piston crown and dial gauge or, if the cylinder head is removed, directly by mounting the dial gauge pin on the piston crown.

Checking

1 Remove and install fan shroud (1) and fan

(75) tightening torque of bolt (SO), 25 Nm.

2 Set engine to ignition TDC of No. 1 cylinder.

3 Remove and install rocker arm bearing bracket (61) by unscrewing oil pipe. Tightening torque of bolts (63), 21 Nm.

03.0905 - 34514

PO3.2026.13

4 Remove and install valve spring at No. 1 intake valve (05-250).

5 Remove and install valve stem seal of No. 1 intake valve. Oil new valve stem seal and press on by hand. Mount assembly sleeve on the valve stem for performing this step (05-270).

6 Mount valve on piston crown.

7 Turn back crankshaft to approx. 10” before

TDC of No. 1 cylinder.

8 Bolt dial gauge holder 363 589 02 21 00 with threaded sleeve onto cylinder head set bolt at front left.

Note

With cylinder head removed, mount a magnetic dial gauge holder onto the mating face of the crankcase.

03 0905 - 34515

9 Insert dial gauge with extension.

10 Mount dial gauge with 2 mm preload onto the valve stem or piston crown.

11 Slowly turn crankshaft in direction of rotattion of engine until the larger pointer of the dial gauge stops (TDC setting).

12 Unscrew hexagon nut (la) and withdraw

TDC pulse generator (1).

13 Loosen dial gauge and mount extension with 5 mm preload onto the valve stem or piston crown. Turn scale of gauge until the large pointer is at zero.

14 Turn on crankshaft in direction of rotation until the dial gauge has moved back by the appropriate value (data in table).

15 Position fixing device 119 589 00 21 00 into the setting slide (2).

The pin on the vibration damper must engage in the groove of the fixing device (1).

If the pin does not engage, adjust position of setting slide.

03 0905 - 34516

Adjustment

16 Loosen nut (2a) and move setting slide (2) far enough for the pin on the vibration damper to engage in the groove of the fixing device.

17 Tighten nut (2aj and withdraw fixina device.

18 Insert TDC pulse generator and bolt on.

19 Remove dial gauge and dial gauge holder.

03.0905 - 3497

03-350 Removal and installation of crankshaft gear

Preceding work:

Removing liming case cover (01-210).

Removing chain tensioner (05-310).

w

PO3-0031-3s

Timing chain (21) camshaft gear (4) and crankshaft gear (5 or 5a) ..................

Camshaft gear (4) .......................

Tensioning rail (22) ......................

mark relative to each other (steps 1 and 2).

remove and place timing chain in chain box

(step 3). Install (step lo), 80 Nm.

pull off and insert.

Note

Drill bearing pin (26) of engines with double roller chain, tap M6 thread and knock out with impact extractor

115 589 12

33 00 and extension 100 589 00 43 00.

When installing tensioning rail, insert new bearing pin together with tensioning rail

(steps 4 and 9).

03.0905 - 35011

Crankshaft gear (5 or 5a) . . . . . . . . . . , . . . . . .

pull off with puller 102 589 05 33 00 together with oil pump drive sleeve.

Transfer colour marking to new crankshaft gear.

Knock in crankshaft gear, if necessary, with drift

116 589 07 15 00, pay attention to straight pin

(6) (steps 5 through 8).

Special tools

/’

I

I’

1165890034Ot 116 589 07 15 O(

Note

As of January 1988 a double roller timing chain has been installed.

03.0905 - 35012

Removal and installation

1 Mark timing chain and camshaft gear rerlative to each other.

2 Mark timing chain and crankshaft gear relative to each other.

3 Unbolt camshaft gear and place timing chain in chain box.

4 Pull tensioning rail (22) off bearing pin (26) .

I /\ ? \/

PO3.2056.13

PO3-2054.13A

Note

On

engines with double roller chain, knock out bearing pin of tensioning rail with the impact extractor 115 589 12 33 00 and the extension

100 589 00 43 00.

To perform the step, tap an M6 thread approx.

10 mm deep into the bearing pin.

03 0905 - 350/3

5 Pull off crankshaft gear and oil pump drive sleeve with the puller 102 589 05 33 00.

6 If the crankshaft gear is replaced, transfer color marking from the old to the new crankshaft gear.

7 Install crankshaft gear onto crankshaft. If this proves difficult, knock in with the impact drift

116 589 07 15 00.

Pay attention to the straight pin for locating, when performing this step.

8 Insert drive sleeve.

9 Insert tensioning rail.

On engines with double roller chain, insert tensioning rail and knock in new bearing pin as far as the stop.

10 Install camshaft gear (pay attention to color marking), tightening torque 80 Nm.

11 Check for leaks with engine running.

03.0905 35014

PO3.2035-13 I

03-410 Removal and Installation of flywheel or flex plate

Precedmg work:

Removing transmssion (26-020 or 27-600).

Removtng clutch (25-050).

PO3-0020-35

Retaining lock on starter ring gear . . . . . . . . . . .

remove and install, special tool

601 589 02 40 00 (step 2).

Stretch bolt (18) . . . . . . . . . . . , . . . , . . . . . . . .

unbolt, bolt in, check length/stretch shaft dia., initial torque 30 Nm, angle of rotation torque

90”, with two-mass flywheel 50 Nm, angle of rotation torque 90” (steps 6 and 7).

Flywheel (16) or flex plate (43) with spacer disc (44) . . . . . . . . . . . . . . . . . . . . . . . .

detach, attach (step 5).

Special tools

001 569 66 21001 [ 601 569 02 40 00 1

03.0905 - 41011

Stretch bolt

Part No.

Thread dia. D

Thread shaft dia. d

Length L

1) Stretch bolt with two-mass flywheel when new minimum dia.

when new maximum length

I 102

032 00

71

I

MlOxl

I 8.5 -0.2

I

8.0

I

22 20.2

22.5

I 103 032 00 71 ‘)

MlOxl

8.5 -0.2

8.1

57 kO.2

Notes

The engines

102.9221924i962/963

have the same flywheels (standard flywheel). Compared to this standard flywheel, the flywheel of engine

102.985 is lighter and the hole circle for the tapped holes for mounting the clutch are larger.

The flywheels must not be interchanged and can be replaced without the need for static or ’ dynamic balancing.

1

-

f

60

i--- H 4 I

A Engines 102.922/924/962/963

D 253 mm

Dl 223 mm

H 58.6 mm

8 Engine 102.985

D 265 mm

Dl 237 m m

H 57 mm

-

.

I--H

PO3-0026.15

03.0905 . 410/2

._...__ . . ..-. _

The flex plate of the engines with automatic transmission is identical on all engines. Flywheel and flex plate with ring gear can be replaced without the need for static or dynamic balancing.

Arrangement of flex plate on crankshaft of engines with automatic transmission.

17 Ring gear ia Ml0 x 1 x22 stretch bolt

43 Flex plate

44 Spacer disc

44a Spacer disc (bonded on)

Arrangement of flywheel on crankshaft of engines with manual transmission.

16 Flywheel

17 Ring gear la MlOxl x22 stretch bolt

- 1 6

- 1 8

030905 - 4100

With the distributor ignition (DI - formerly EZL), the flywheel or the flex plate was provided with two segments (A) offset by 180“.

As the segments rotate past the position sensor this produces an alternating voltage as a result of induction.

If the segments are damaged, replace the flywheel or the flex plate.

Flywheel of manual transmission

Flex plate of automatic transmission

Removal and installation

1 Remove end cover (30) from the rear of the oil pan. Remove bolts (arrows), bolt in, tightening torque 10 Nm.

Press off end cover with screwdriver, fit on.

2 Attach retaining lock 601 589 02 40 00 with both bolts (arrows). The pins on the retaining lock must mesh into the ring gear teeth.

3 Unscrew stretch bolts (18).

Take off flywheel or driven member with bonded spacer disc (44a) and spacer disc (44).

03.0905 - 41 o/4

4 Check stretch bolts (see table).

5 install flywheel or flex plate (43) with bonded disc and disc (44), pay attention to centering of installation pin.

6 Bolt in stretch bolts (18) and tighten to an initial torque of 30 Nm or 50 Nm, respectively, for the two-mass flywheel.

7 Torque stretch bolts (18) in

a

single operation by the specified angle of rotation torque of 90”.

03.0905 . 410/5

03-420 Remachining flywheel

Preceding work:

Removing flywheel (03410).

Permissible axial runout at clutch face up to for repairs

Notes

The two-mass flywheel cannot be machined and is only available as a complete replacement part.

Flywheels for manual transmissions which have scorch marks, scoring or cracks in the clutch face, should be machined by precision turning.

PO3-0074-15

03.0905 - 42011

If grooves or cracks are deeper than the maximum permissible material removal, the flywheel must be replaced.

If the clutch face A is machined, the mounting face B must be machined by the same amount in order to maintain the distance a.

The size b must be maintained as a minimum when performing repairs.

The flywheel must be properly clamped for machining to ensure that the permissible axial runout of 0.05 mm is not exceeded.

After machining, the clutch face must not show any shrink holes or chatter marks.

03.0905 - 42012

03-430 Replacing ring gear on flywheel

Preceding work:

Removing flywheel (03-410).

16

PO3-0030 -3.5

Ring gear (17) . . . . . . . . . , . . . . . .

* .

Flywheel (16)

Flex plate (43)

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

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

. .

. .

. .

. .

. .

. .

Drill old ring gear and snap open with a chisel or heat rapidly and then remove immediately. Heat new ring gear to 220 “C and fit onto the flywheel immediately. Pay attention to instruction. Lateral runout at ring gear max.

0.4 mm.

. .

Centering collar dia. (a) for ring gear 275,31 -

27539 mm.

Clean contact surface of ring gear at flywheel before installation on ring gear.

. .

This ring gear is welded on and cannot be replaced. Replace driven member complete.

Commercial accessories

Temperature measuring chalk

Colour No. 2815/220 (white) Thermochrom e. g. AW Faber-Caste11

D-8504 Stein bei Nurnberg

03.0905 - 430/l

Notes

The ring gear is hardened. For this reason, do not exceed

a

temperature of 220 “C (yellow annealing colour) at any point when heating. This is only reliably possible by using a heating plate or heating oven.

Use a temperature measuring chalk corresponding to the instructions if possible.

Only use a flame in exceptional cases.

Coat only the inside of the ring gear for this purpose.

After replacing a ring gear, the flywheel does not need to be balanced.

To avoid damage to the ring gear, a ring gear with axially chamferred teeth was installed for a brief period to vehicles with automatic transmission.

Standard implementation:

April - July 1986 standard

Model Engine Engine End No.

Manual transmission

201.028

102.985

Automatic transmission

033406 - 038268

03.0905 - 43Oi2

ngine timing, valvetrain 05

ngine timing, valvetrain

Job No.

Checking and replacement of hydraulic valve clearance compensating element

. . . . . . . . . .

05 - 211

Checking and correcting the installation position of hydraulic valve clearance . . , . . . . . . . .

05 -

214

Checking and adjusting camshaft timing ......................................

-215

Removal and installation of camshaft .........................................

-220

Removal and installation of rocker arm bearing supports with rocker arms ..............

Replacement of rocker arms and rocker arm bearing supports .......................

-235

-240

Removal and installation of valve springs ......................................

-250

Checking valve springs ..................................................

-260

Replacement of valve stem seals ...........................................

- 270

-280

Checking and machining valves ............................................

Checking and replacing valve guides .........................................

- 285

Replacing valve seat ring .................................................

-290

Machining valve seats ...................................................

-291

Removal and installation of chain tensioner ....................................

-310

Replacement of timing chain ..............................................

-320

Installation of oil spray nozzle retroactively .....................................

-328

Removal and installation of tensioning blade ...................................

-330

Removal and installation of guide rails ........................................

-340

Removal and installation of idler gear shaft ....................................

-412

Removal and installation of oil pressure pump drive ..............................

-437

05/'1

05-211

Checking and replacement compensatlsn @lenlent of hydraulic valve clearance

Preceding work:

AN cleaner removed (09-400 and 09-410).

Cylinder head cover removed (01-406).

Check

Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

position hydraulic element under test on the base circle. Load hydraulic element for approx.

5 to 10 seconds. If the element drops, remove it. To do this remove corresponding rocker arm bearing support (OS- 235). If a leaking hydraulic element is not found, check fitting position (OS-

214).

Note

When pressure testing the compensating elements, do not press valves against the piston crown (Numbers 1 and 2).

05.0906 - 211il

Valve clearance compensating element (58) . . . .

Fill up reservoir chamber of valve clearance compensating element on test with engine oil.

Press on ball valve with a suitable pin and vent working chamber by pumping set bolt up and down. Close ball valve, if necessary replenish oil. After this no oil shall escape at ball valve when compressed and set bolt may not drop. If this is not the case, replace compensating element (Number 3).

Note

If compensating element is satisfactory, check oil bores in cylinder head, rocker shaft and rocker arm for passage, and clean if required.

If several compensating elements are soft, replace oil pipe in cylinder head

(01-415),

for this purpose remove cylinder head (Ol- 415).

Replacement

Valve clearance compensating element (58) . . . .

Rocker arm bearing support

(61) . . . . . . . . . . . .

With oil reservoir chamber full and original washer (57) push into the rocker arm up to the stop on the snap ring (56)

(Number 4).

Install (05-235), at the same time fit original ball socket (55).

Note

Use ball socket 103 055 00 24, if a new ball socket is to be installed. Check and if required correct fitting position (05-214, Numbers

5 and 6).

05.0906 - 211/2

Special tool

102 589 04 21 00

Hydraulic valve clearance compensation

57

59

60

61

43

46

51

55

56 b

C

62

63

64

65 a

Valve

Valve spring retainer

Rocker arm

Ball socket

Snap ring

Washer

Guide sleeve

Compression spring

Telescopic type ball beanng traveler

Compression spnng

Ball (5 mm 0)

Set bolt

Sealing cap

Oil reservoir chamber

Working chamber

Return and venting bores

Valve adjustment Is no longer required when equipped with hydraulic valve clearance adjusters

The maintenance-free hydraulic valve clearance compensating elements located in the rocker arms eliminate valve clearance, i.e. dimensional changes in the valve train due to thermal expansion and wear are compensated by the elements. Valve train noise is low, because rocker arm is in continuous contact with the cam.

05.0906 - 211/3

PO5-0019-15

The hydraulic valve clearance compensating elements consist of the following components: l Set bolt (64) with oil reservoir chamber (a) as well as return and venting bores (c) and a ball valve, consisting of a 5 mm 0 ball (63), telescopic type ball bearing traveler

(61) and compression spring (62).

l Guide sleeve (59) with working chamber (b), compression spring (60) and sealing cap

(65).

5 8 -

5 5 -

/ po5-0033-15

The element can drop completely when the engine is not running and the cam tip presses against the rocker arm and thus also against the element. Oil expelled from the working chamber

(b) flows via the annular gap (built-in clearance between guide sleeve and set bolt) to the reservoir chamber (a).

When the cam tip moves away from the rocker arm, the set bolt (64) is relieved of load and the compression spring (60) presses the set bolt upwards until the rocker arm contacts the cam.

The vacuum, arising from the upward movement of the set bolt, opens the ball valve, and oil flows out of the reservoir chamber (a) into the working chamber (b).

As soon as the cam presses against the rocker arm and thus loads the set bolt, the ball valve closes. The oil in the working chamber acts as an “hydraulically rigid connection” and the respective valve is opened.

When the engine is running, depending on engine speed and cam position, the set bolt is only pressed slightly downwards.

05.0906 - 211/4

The oil needed for operating the hydraulic valve clearance compensating elements, flows from the longitudinal channel and the transverse bores in the cylinder head to the rocker arm bearing points. From here it reaches the ring channel (f) through the bore (h) in the rocker arm and the reservoir chamber (a) via grooves in the washer

(57).

Any air in the reservoir chamber can separate from the oil (solid oil), with the result that, if necessary, defoamed oil is led to the working chamber.

The oil quantity in the reservoir chamber is sufficient to fill the working chamber under all engine operating conditions. Any air in the reservoir chamber can escape to the ring channel (f) via the grooves in the washer (57) and from there via the annular gap between washer and rocker arm and the joint gap of the snap ring (56).

In order that the hydraulic valve clearance compensating elements can be supplied with oil pressure corresponding to the respective engine speed, oil flows unrestricted via nozzle (A) into the longitudinal channel (a) in the cylinder head

(pressure-orientated oil feed). The nozzle simultaneously blocks off the oil return, preventing the channels up to the hydraulic elements emptying when the engine is not running.

The sealing cap (65) is shaped so that it secures the hydraulic valve clearance compensating element captive in the rocker arm.

Only store the compensating elements upright, and do not dismantle them. It is essential that rocker arm, compensating element, washer (57) and ball socket (55) are installed in their original position.

05.0906 - 211/S

P Ol-0087- 1s

Checking

1 Position camshaft on the hydraulic element under test so that the rocker arms contact the cam base circle.

2 Press on the rocker arm with a hammer butt or similar above the hydraulic valve clearance compensating element for 5 - 10 seconds.

If one compensating element drops noticeably compared to others, compensating element should be removed. To do this, remove rocker arm bearing support (05235) and press the compensating element (58) together with the washer carefully out of the rocker arm with an aluminium or brass mandrel.

If a leaking compensating element cannot be detected, try to move the rocker arm by hand.

If play is detected when doing this, check and correct fitting position of the hydraulic valve clearance compensating elements (05-214).

Caution!

When testing compensating elements, do not press valves against the piston crown.

3 Fill reservoir chamber of the hydraulic valve clearance compensating element with engine oil, carefully press on ball valve in the setbolt with a wire (approx. 1.5 mm (21) and press setbolt downwards as far as the stop and release.

Repeat process two or three times.

05.0906 - 21116

PO5- 2011-13

After this, press compensating element setbolt heavily downwards for about 5 - 10 seconds with hammer butt or similar. If the setbolt drops noticeably when doing this, replace the compensating element.

Note

Compensating element must be vertical when filling the working chamber as well as during the test.

If compensating element does not drop noticeably, check the respective oil bore in the cylinder head (arrow) as well as the oil bores in the rocker shaft and in the rocker arm for free passage, and clean if required.

To do this remove rocker arm (05240).

If several compensating elements are loud or soft the oil nozzle in the cylinder head should be checked for firm seating and replaced if required.

Replacement

4 Slide new valve clearance compensating element (58) with the original washer (57) into the rocker arm (51) as far as the stop on the snap ring (56).

Note

Install new compensating element with the working chamber and reservoir chamber filled with oil. (See Figure 3 for filling the hydraulic valve clearance compensating element).

The grooves in the washer (57) must point to the compensating element (58) (Figure 5).

05.0906 - 21117

51

I 56

PO5-2012-13

5 Install rocker arm bearing support (05235).

In so doing install the original ball socket (55).

Note

Use ball socket Part No. 103 055 00 24 if a new ball socket is installed.

6 Check the installation position of the new valve clearance compensating element, correct if necessary (05-2 14).

7 Install in the reverse sequence.

PO5-2016-13

05.0906 - 211/8

05214 Checking and correcting the installation position of hydraulic valve clearance compensating elements

Preceding work:

Air cleaner removed (09-400 and 09-410).

Cylinder head cover removed (01-406).

PO5-0026-39

Camshaft

(1) . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring fixture . . . . . . . . . . . . . . . . . . . . . . .

position the cylinder under test so that rocker arm (51) contacts the cam base circle

(Number

1).

mount, set dial gauge with 5 mm pretension, set dial gauge pointer to

"0".

050906 - 214/l

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the residual stroke . . . . . . . . . . . . . . .

Rocker arm bearing support . . . . . . . . . . . . . .

Turn pressure pad (06) to the right until a detectable pressure point is reached.

Read setting range (residual stroke) on the dial gauge. Reference value 0.5 - 2.4 mm. Correct the fitting position if the residual stroke is larger or smaller (Number 2).

Remove and install rocker arm bearing support

(05235). Remove hydraulic valve clearance compensating element and slide into the rocker arm again up to the snap ring stop. If residual stroke is too small use a thinner washer (57), or a thicker washer if residual stroke is too large.

Measure residual stroke again. If the specified residual stroke has still not been achieved, a thinner or thicker ball socket (55) can be fitted

(Numbers 3 to 6) if necessary.

Note

Before installation of the hydraulic valve clearance compensating element fill reservoir chamber with engine oil.

Install, repeat test (Numbers 7 and 8). Prior to this, turn the engine with the starter and contact handle a few times.

1) Production:

2) Production: install in the case of repatr, when valve timing parts (rocker arm beanng supports, rocker arms, camshaft, etc.) are renewed. Camshaft with normal cam base circle without identification letter next to the camshaft identrfication number.

Install in the case of reparr, when valve timing parts (rocker arm beanng supports, rocker arms, camshaft, etc.) are renewed. Camshaft with small cam base circle and rdentlficatlon letter “E” next to the camshaft identification number.

3) Install In the case of repair, when valves and/or valve seat inserts have been resunk by machrnlng.

050906 - 214,'2

Washer

Ball socket

PO6-0087-1s

PO5-0025-13

Conventional tool

Oial gauge Al DIN 878 0.g .

Mahr, D-7300 Esslingen

Part No. 311000

05.0906 - 21413

Note

The fitting position of the hydraulic valve clearance compensating elements must be checked a) If there have been complaints of valve train noise and no malfunctions have been established when checking the compensating element in accordance with 05211.

b) If valve timing parts, which are installed or mounted on the cylinder head (apart from the camshaft timing gear, valve guides, valve stem seals) have been renewed, or when valves and/or valve seat inserts have been machined.

For testing, all timing parts located on the cylinder head must be installed correctly and working chamber of valve clearance compensating elements must be filled with engine oil.

The tests can also be carried out when the cylinder head is removed. To do this clamp cylinder head with four cylinder head bolts

(arrows) on assembly board 102 589 00 59 00

(1). In this case turn the camshaft on rear flats with a fork wrench (24 mm).

PO5- 2 0 3 4 - 1 3

05.0906 - 214/4

After the test, position camshaft so that indentation on the collar agrees with the edge on the cylinder head (arrow).

In order to determine the specified fitting position of the hydraulic valve clearance compensating element, the residual stroke “Z” of the compensating elements must be measured.

The permitted

residual stroke

is 0.5

to

2.4 mm.

If a residual stroke smaller than 0.5 mm or larger than 2.0 mm is measured despite installing a washer and a ball socket in accordance with the

“installation specification” table, compensation is to be carried out with the next thinnest or thickest washer or ball socket.

05.0906 - 21415

Checking

1 Position camshaft by turning the crankshaft so that the rocker arms contact the cam base circle on cylinder under test.

2 Place measuring fixture 102 589 04 21 00 so that the claws of the claw sleeve (03) contact the ring shaped area around the hemispherical mushroom pad of the guide sleeve (59).

05.0906 - 2146

PO5-0024-39

Turn the pressure pad (06) by hand to the right sufficiently until it contacts the washer (57, previous picture), and a clearly detectable pressure point is reached.

Note

The pressure pad must contact the washer and not the rocker arm.

3 Insert measuring pin adapter (04) in the central bore of the pressure pad (06), set dial gauge measuring pin on the measuring pin adapter with 5 mm pretension (small pointer) and attach the dial gauge to claw sleeve bracket

(arrow).

Position large dial gauge pointer on zero by turning the dial gauge scale.

4 Turn pressure pad (06) slowly to the right with a fork wrench (17 mm) on the hexagon until a clearly detectable pressure point is reached.

Read off setting range (residual stroke) on dial gauge. It must be 0.5 - 2.4 rnolp. In event of smaller or larger residual stroke, correct installation position of the hydraulic valve clearance compensating element.

05 0906 - 214/7

Corrections

5 Remove rocker arm bearing support

(05235).

6 Press hydraulic valve clearance compensating element (58), together with the washer

(57), carefully out of the rocker arm with an aluminum or brass mandrel, and finally slide into the rocker arm up to the snap ring stop (56) again. Use a thinner washer (residual stroke too small) or a thicker washer (residual stroke too large).

If specified residual stroke cannot be achieved with the washers available (57), depending on residual stroke measured, use a thinner or thicker ball socket (55) (see note, on the washer and ball socket tables).

Caution!

Before carrying out the installation fill reservoir chamber of the hydraulic valve clearance compensating element with engine oil (05- 211,

Number 3).

The grooves in the washer (57) must point in the direction of the compensating element setbolt.

7 Install rocker arm bearing support (05-235).

8 Repeat tests, Numbers 1 to 3.

Note

Before carrying out the test turn the crankshaft a few times by using the starter.

9 The installation is carried out in the reverse sequence of the removal.

10 Check for leaks when engine is running.

05.0906 - 214/8

POS-2012-13

POS-20

05215

Checking and ad)usting camsbft timing

Preceding work:

AIM cleaner removed (09-400 and 09-410).

Cyltnder head cover removed (01-406).

PO6-0030-37

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dial gauge bracket (02) . . . . . . . . . . . . . . . . . . .

Position the No.

1 cylinder camshaft so that the rocker arm @la) contacts the cam base circle.

Remove No. 1 cylinder rocker arm bearing support (05235). Remove rocker arm and hydraulic valve clearance compensating element and adjustable rocker arm 102 055 00 01 together with adjusting screw 102 050 0220

(164) and fit locknut (163). Eliminate valve clearance by turning the adjustment screw (164)

(Numbers 1 to 4).

Screw onto stud bolt at front left part of cylinder head (Number 5).

05.0906 - 215'1

Dial gauge (01)

Crankshaft

Adjustment

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

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

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

. . . . . . . . .

Insert and put tip vertically on valve spring retainer with 3 mm pretension (small pointer)

(Number 6).

Turn in the direction of rotation of the engine until the small pointer on the dial gauge has travelled back by 2 mm (valve stroke). The value now read off on the vibration damper must agree with the value in the table “Intake valve open” (Number 7).

Put engine on ignition TDC of No.1 cylinder

(Number 8).

Chain tensioner locknut (40)

Oil pressure pump . . .

. . . . .

. . . . . * . . .

. . . . . . . . .

. . . . . . . . .

Unbolt and bolt up, replace sealing ring

(41), 70 Nm (Numbers 9 and 19).

Unbolt, set to one side with lines connected

(Number 10).

Camshaft timing gear .

Woodruff key (6) . . . .

. . * . . . . . .

. . . . . . . . .

Align with timing chain.

Unbolt camshaft timing gear (Numbers

11 to 13 and 15).

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

Camshaft timing gear .

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

Select from table and insert (Numbers

14 and 15).

Assemble, note color marking, only install set bolt.

Repeat tests (Numbers 6 and

7).

Tighten set bolt (9).

80 Nm (Numbers 16 to 18).

Detach.

Dial gauge (01) and dial gauge (02) . . . . . . . . . .

Rocker arm bearing support and rocker arm with hydraulic valve clearance compensating element Install (Number 20).

Proceed with installation in reverse sequence

05.0906 21512

with 2 mm valve stroke

camshaft stamped at the rear of the camshaft

27128 ‘)

35 3)/36 ‘)/444)

11” (12O) 17”

Value for used c WI In brackets.

1) Repalr camshaft wtth 0.5 mm larger bearing diameter.

2) Camshaft with wider cam (19 mm) and tin-plated.

3) ChIlled cast iron camshaft.

4) ChIlled cast Iron camshaft (with crowned cams) from 09/89.

. Special tools

32”

Closes

before TDC

363 589 02 21 00 001 589 66 21 00 001 589 67 21 00

Conventional tool

Dial gauge A 1 DIN 878

Note

It is sufficient during assembly work, if the marking on the camshaft agrees with the cylinder head edge in the ignition TDC position of the No 1. cylinder (arrow). In special cases, for example when there are performance problems, the start of opening of No.

1 cylinder intake valve is to be checked as described in the following, and to be adjusted, if required. The valve timings are measured at

2 mm valve stroke. Valve clearance must be eliminated for this purpose.

e.g.

Mahr, D-7300 Esslingen

Bestell-Nr. 311000

05.0906 - 21513

Checking

1 Turn crankshaft until cam tips of No. 1 cylinder intake valve point downwards (valve closed).

Caution!

The engine must not be turned at the camshaft timing gear fixing bolt.

Under no circumstances turn engine backwards during the measurement, otherwise considerable measuring errors result, and chain tensioner lock setbolt can spring forwards.

2 Remove rocker arm bearing support of No. 1 cylinder (05235).

3 Install intake valve rocker arm against the rigid rocker arm @la) Part No. 102 055 00 01 together with the adjustment bolt (164) Part

No. 102 050 02 20 and the locknut (163) Part

No. 000936 008009 (05-240).

4 Install rocker arm bearing support, 21 Nm.

5 Install the dial gauge bracket with threaded sleeve onto the stud on the front left part of the cylinder head.

6 Insert dial gauge and attach so that tip is

exactly vertical

on valve spring retainer with a pretension of 3 mm (small pointer on the dial gauge). Turn dial gauge clockface until large pointer is on “0”.

050906 - 21514

7 Turn crankshaft in direction of rotation of the engine until dial gauge small pointer has returned by 2 mm (valve stroke). In this positic? t?~ value on the vibration damper must agree Nrth the value “intake valve opens after TDC” in the valve timing table.

Adjustment

If valve timing settings have to be corrected, an offset Woodruff key has to be installed, and a new timing chain when chain length is excessive.

Woodruff keys are available in the following stages:

Part No.

Offset mm

0.7

0.9

1.1

1.3

621 991 04 67

621 991 02 67

621 991 01 67

621 991 00 67 for a correction of approx.

6 ” C K A

8” CKA

9.5” CKA

11.5” CKA

CKA = CranK Angle

An offset of one tooth on the camshaft timing gear produces approx. 20 at the crankshaft.

Offsetting the Woodruff keys to the right (in direction of travel A) causes the valves to open earlier and an offset to the left (6) causes the valves to open later.

P05-0161-13

8 Position engine on ignition TDC of No. 1 cylinder.

05.0906 - 215 5

9 Unscrew hexagon cap nut (40) for chain tensioner and remove sealing ring (41) as well as compression spring (39) (see 05310).

Caution!

The chain tensioner hexagon cap nut is under pressure from the compression spring.

10 Unscrew oil pressure pump (arrows) and set to one side with the lines connected.

11 Align camshaft timing gear and timing chain.

12 Remove camshaft timing gear set bolt.

05.0906 - 2156

To do this hold in position with a fork wrench

(24 mm) on flats at the rear end of the camshaft.

Note

On vehicles with self-levelling suspension the camshaft timing gear and driving sleeve are attached by a bolt with hexagon recessed hole.

Take out the driving sleeve.

13 Remove camshaft timing gear.

14 Place cleaning rag over the timing case and remove Woodruff key (6).

15 Insert selected Woodruff key.

16 Put on camshaft timing gear. In the process note that the colour markings on the camshaft timing gear and the timing chain align.

Do not torque the set bolt (9) yet.

17 Repeat test Numbers 6 and 7.

18 Torque camshaft timing gear set bolt (9) to

80 Nm. For this hold in position with a fork wrench (24mm) on flats at the rear of the camshaft.

05.0906 - 21517

PO5-2025-13

19 Insert compression spring (39), replace sealing ring (41), bolt in screw plug (40) and tighten to 70 Nm.

20 Unbolt rocker arm bearing support from No.1

cylinder and withdraw rocker arm (51a) for hydraulic valve clearance compensation.

21 Install rocker arm bearing support, tightening torque 20 Nm (05- 235).

22 Remove dial gauge and dial gauge bracket.

23 The remaining installation takes place in the reverse sequence.

24 Check for leaks when engine is running.

PO5- 2021-13

05 0906 - 21518

05220 Removal and

installatisn

of camshaft

Preceding work:

Air cleaner removed (09-400 and 09-410).

Cylinder head cover removed (01-406).

63

Piston of No.

1 cylinder . . . . . . . . . . . . . . . . . .

Screw plug (40) . . . . . . . . . . . . . . . . . . . . . . . .

Oil pressure pump (68) . . . . . . . . . . . . . . . . . . .

Camshaft timing gear (4) and timing chain . . . . .

position on ignition TDC, note markings

(Numbers 1 and 2).

of the chain tensioner, unbolt, bolt in,

70

Nm.

Warning!

Screw plug is under pressure. Remove compression spring (39), replace sealing ring

(41)(Numbers 3 and

11).

unbolt, bolt in, set to one side with lines connected (Number 4).

align. When installing note markings. Screw

(9 and 9a), 80 Nm (Numbers 5 to 8).

05 0906 - 220/l

All rocker arm bearing supports (61) with rocker arms and oil pipe (67) . . . . . . . . . . . . . .

Camshaft

(1) . . . . . . . . . . . . . . . . . . . . . . . . . .

unbolt, bolt on, 20 Nm. Note oil pipe designs

(Number 9).

remove, replace, oil bearing points with engine oil. Check condition of camshaft, note identification number. Position engine on ignition

TDC and check markings on camshaft and vibration damper (Number

10).

Special tools

001 589 66 21 00 001 589 72 21 00

Test values

I

New value

I Wear limit

0.025

Permitted deviation from true running At the seat of when locating camshaft in bearing positions

1 and 5 camshaft timing gear

At the bearing points

2, 3 and 4

Camshaft bearing play radial axial

Camshaft journals 0 Normal dimension

Repair stage

Scleroscope hardness of the cams

I

I 0.030

I 0.050 - 0.091

I 0.070 -

0.150

1 32.000 - 32.025

I-

I

I-

I

0.11

I 0.18

1 32.500 - 32.525

I-

I 70 - 82 I 63

050906 - 22012

Camshaft id

Engine ntification numbers and val

Camshaft identification number stamped at rear of camshaft

Intake valve

102.96

102.985

27128 ‘)

35 3)/6 ‘)/444)

Value for used chains in brackets.

l) Repair camshaft with 0.5 mm larger beanng diameter.

2) Camshaft with wider cams (19 mm) and tin-plated.

3) ChIlled cast iron camshaft.

4) ChIlled cast iron camshaft (with crowned cams) from 09189.

Note

The camshaft supported on 5 bearings is drilled hollow. The bearing points are supplied with oil via the longitudinal bore (10.5 mm @), which is sealed at the front with the camshaft timing gear set bolt and at the rear with a pressed cover

(arrow). The oil feed takes place via a groove

(360”) and a transverse bore (3.5 mm 0) in the rear journals.

The diameter (D) of all 5 bearing points is

32 mm (repair stage 32.5 mm).

A fork wrench can be put on flats (A, 24 mm) at the rear end of the camshaft for turning the camshaft when camshaft timing gear is removed and for holding in position when loosening and tightening camshaft timing gear set bolt. The collar (B), which runs in a groove in the cylinder head, locates the camshaft axially.

Exhaust valve

32”

05.0906 - 220/3

The marking for the ignition TDC position of the

No.

1 piston is placed on this collar. It must match up with the edge on the cylinder head

(arrow).

The camshaft can be removed from above. The rocker arm bearing supports and the camshaft timing gear have to be removed for this.

If the camshaft is to be replaced, all the rocker arms have to be replaced as well.

In the event of scored bearings or pronounced striation, the camshaft bearings in the cylinder head and in the rocker arm bearing supports can be bored out by 0.5 mm and a camshaft with over dimensioned bearing spigots installed

(01-419).

05 0906 - 220/4

PO5-0145-53

The running in and wear characteristics have been improved by short- stroke honed camshafts

(formerly tin-plated).

Introduced in Droduction: Januarv 1986

Engine end number Vehicle identification end

Since October 1987 camshafts have been fitted with 19 mm wide tinplated cams (formerly

18 mm).

Identification number: 39

Note

As a temporary measure this camshaft has been given the identification number “3”.

Model Engine Engine end number Vehicle identification end

201.028

I 102.985

I 019320 I 062484 I 416851 I 435608

05.0906 - 220/5

Since 1988, in order to avoid camshaft wear, chilled cast iron camshafts and rocker arms with soldered on hard metal pads have been equipped.

If the chilled cast iron camshaft has been installed on previous engines, rocker arms with hard metal cam follower must also be installed.

As a temporary measure this camshaft has been given the identification number “5”.

Introduced in woduction: October 1988

Model Engine

201.028

I 102.985

From 09189 a chilled cast iron camshaft with crowned cams has been installed. This camshaft is also supplied as a replacement part.

Identification number: 44

Engine end number

Manual transmission

Engine end number

Automatic transmission

I 027671 I 077053

Engine end number Vehicle identification end

05.0906 - 220/6

In order to improve camshaft lubrication the oil feed bore in the cylinder head has been enlarged from 3 mm to 4 mm

0

(arrow).

The oil groove in the rocker arm bearing support has also been widened from 4 mm to 5.5 mm

(arrow).

The injection bores in the oil pipe for camshaft lubrication have a different diameter depending on position.

A Oil pipe first design

B Oil pipe second design

1

PO&2207-1s

01,8(4x)

A

01,3(4x)

2 3

B

4

03.5

0 4

3 4

POS-0162-13

05.0906 - 22017

Introduced in Droduction: Januarv 1988

Model Engine Engine end number

Manual transmission

201.028

I 102.985

022013

Removal and installation

1 Position piston of No. 1 cylinder on ignition

TDC.

Engine end number

Automatic transmission

2 Marking on camshaft collar must align with the edge on the cylinder head (arrow).

Before turning the crankshaft, switch off the ignition and remove the plug for the inductive sensor at the switching unit.

Caution!

Do not turn the engine by the camshaft timing gear set bolt.

Do not turn the crankshaft backwards.

05.0906 - 220/8

3 Unscrew the chain tensioner hexagon cap nut (40) and remove sealing ring (41) as well as compression spring, tightening torque 70 Nm

(05-310).

Caution!

The chain tensioner hexagon cap nut is pressurized by the compression spring.

4 Unbolt, bolt on oil pressure pump (68)

(arrows) and put to one side with the lines connected.

5 Align camshaft timing gear and timing chain.

05.0906 - 22019

6 Remove camshaft timing gear, remove timing chain and place in the timing case, tightening torque 80 Nm.

7 Remove and install Woodruff key (6) and spacer washer (7).

Installation note

Note color markings on camshaft timing gear and timing chain.

Assemble camshaft timing gear so that on the single roller chain the wide collar points to the camshaft and on the dual roller chain the curvature points to the camshaft.

8 In order to loosen or tighten up camshaft timing gear hold in position with flats at the rear of camshaft with a fork wrench (24 mm).

4

8

9

POS-0038-13

9 Remove and install rocker arm bearing supports (61) (05-235), tightening torque

20 Nm.

10 Remove camshaft. Before installing lubricate all bearing points with engine oil.

Check, whether the marking on set collar aligns with edge on the cylinder head.

Installation note

If camshaft is to be replaced, all rocker arms and rocker shafts have to be replaced as a set.

05.0906 - 220/10

11 Install hexagon cap nut (40) and compression spring (39) with new sealing ring (41), tightening torque 70 Nm.

12 The installation proceeds in reverse sequence.

13 Check for leaks when engine is running.

05.0906 - 220111

05-235 Removal and installation rocker arms of rocker arm bearing supports with

Preceding work:

AW cleaner removed (09-400 and 09-410).

Cylinder head cover removed (01-406).

61

0 5 - 0 0 4 6 - 3 5

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

turn, so that rocker arm of bearing support being removed is on base circle of cam

(cam tips pointing downwards).

Oil pipe (67) . . . . . . . . . . . . . . . . . . . . . . . . . . .

remove, install (Number 2).

Rocker arm bearing support

(61) . . . . . . . . . . . .

remove, install, 20 Nm (Number 3).

Installation note

Install ball socket (55) in original position.

Note identification number on cylinder head and camshaft bearing cap.

Special tool

05 0906 - 235/l

Note

The five bearing bores for camshaft support are each located half in the cylinder head and on top in the four rocker arm bearing supports. The front rocker arm bearing support has two half bearing bores.

Each of the four bearing supports is attached with four bolts (63) and with two installation sleeves (60). Each bearing support simultaneously acts as a rocker arm carrier.

PO5 -0039 -13

The rocker arm bearing supports can be distinguished by the following features.

Front bearing support

Code No.

1.

Two bearing positions (arrows).

Center bearing supports

Code No. 2 and 3. These two bearing supports are the same apart from the identification numbers.

Rear bearing support

Code No. 4. Connection bore for oil pipe

(arrow).

1 IV

POl-2076-13

05.0906 - 23512

The two oil grooves (arrows) act as oil supply to the hydraulic valve clearance compensating elements.

The oil pipe for camshaft lubrication is supplied with oil via the groove (arrow) on the rocker arm bearing support.

The rocker arm bearing supports should not be confused with each other. They are therefore identified on the right-hand side with the

Numbers 1, 2, 3 and 4 from the front to the back. The identification of the bearing support must agree with the number, which is cast in the cylinder head (arrows).

In the replacement parts area the bearing supports are made individually and without code numbers stamped on. The corresponding code number is to be applied after installation.

PO5-2036-13

POI-220?-19

05.0906 - 23513

The rocker arms for operating the valves are supported individually on a rocker shaft fitted in a bearing support on both sides (arrows).

Rocker arms with soldered on cemented carbide tips have been installed since October 1988

(arrow).

I I, // PO6-207%13//

PO5-2038-13

The oil required for lubricating the rocker arm bearings reaches the rocker arm bearing shaft

(50) and hydraulic valve clearance compensating element via a longitudinal channel in the cylinder head and a feed bore in the bearing support

(which is also the set bolt bore).

1 Camshaft

50 Rocker shaft

51 Rocker arm

55 Ball socket

58 Hydraulic valve clearance compensating element

68 Oil pipe

05 0906 _ 23514

The rocker shaft is secured in the axial and rotary direction by a bearing support set bolt.

For this a half bore is attached to the shaft, in which one half of the screw shaft is located

(arrow).

An M8 thread (D) has been incorporated in the front face for installation and removal of the rocker shaft.

Removal, installation

1 Turn engine so that the camshaft tips of the bearing support being removed point downwards and rocker arms are on the base circle.

2 Remove oil pipe (67), to do this unbolt, bolt up the two bolts (63) on the pipe clamps, tightening torque 20 Nm.

3 Remove, install relevant rocker arm bearing support, tightening torque 20 Nm.

Note

Loosen seized bearing supports using light blows with a plastic hammer.

The ball sockets (55) on the hydraulic elements can stick or fall down when removing the bearing support. Install ball sockets in their original positions.

install the rocker arm bearing support so that the support areas for the oil pipe point rear-wards, the code numbers of the bearing supports are on the right-hand side (direction of travel) and correspond to the number cast on the cylinder head (arrows).

05.0906 - 23515

eplacement of rocker arms and rocker arm bearing supports

Preceding work:

Air cleaner removed (09-400 and 09-410)

Cylinder head cover removed (01-406).

61

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pipe (67) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing support (61) . . . . . . . . . . . . . . . . . . . . .

Rocker shaft (50) . . . . . . . . . . . . . . . . . . . . . . .

New bearing support (61) . . . . . . . . . . . . . . . . .

position so that rocker arms of bearing support being removed is on base circle of the cam

(Number 1).

remove, install (Number 2) remove.

pull out with impact extractor 116 589 20 33 00 and extension 616 589 00 34 00. Lubricate new rocker arm and rocker shaft and install. Prior to this rebuild hydraulic valve clearance compensating element (05-211, Numbers

4 and 5).

install with rocker shaft without rocker arm,

20 Nm (Numbers 6 and 7).

05.0906 - 240/l

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing support (61) . . . .

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

turn and check for smooth running, possibly fit new bearing support (Number 8).

remove, complete with rocker arm (51) and install rocker shaft (50) and bearing support

(Numbers 9 and lo), 20 Nm.

Special tools

7 .

Threaded pm M8,

116589203300

001 589 66 21 00 116 589 20 33 00

Data

Rocker arm bore

Rocker shaft diameter

Radial clearance between rocker arm and rocker shaft

Rocker arm bearing support bore

Note

Only one bearing support can be replaced on an engine, otherwise camshaft binding will result.

18.016

__

17.089

=TKEB-

0.016

0.038

i 8.000

05.0906 - 2402

Only rocker arm bearing supports where camshaft bearing half bore is 0.05 mm larger than on production parts are supplied as spare parts. This prevents the camshaft binding when replacing a bearing support.

In the event of bearing seizure or pronounced striation the camshaft bearings can be bored out by 0.5 mm and a camshaft with oversized journals installed (01-419). These camshafts have different code numbers

(05215 and 05-220).

If the bearing supports are put together without rocker shafts, tighten the set bolts to max. 15

Nm, otherwise the shaft bores distort.

The radius on the rocker arm has been changed in order to increase the clearance between the rocker arm and the valve spring retainer (arrow).

05 0906 - 24013

In order to avoid camshaft wear, rocker arms with soldered on cemented carbide tips have been installed (arrow).

Only this rocker arm is still supplied as a replacement part.

These rocker arms may only be installed together with the chilled cast iron camshaft.

PO5-2038-13

0 5 . 0 9 0 6 - 24014

Replacement a) Rocker arms and rocker shafts

1 Turn the engine so that the cam tips of the bearing support being removed point downwards and the rocker arms are on the base circle.

2 Remove, install oil pipe (67).

3 Remove bearing support.

4 Pull out rocker shaft with the impact extractor 116 589 20 33 00 and extension

616 589 00 34 00 or with an M8 bolt.

5 Lubricate new rocker arm and rocker shaft and install.

b) Bearing suppoft

6 Lubricate new rocker shaft and install without rocker arm in the new bearing support.

Note

Insert the rocker shaft so that the half-bore

(arrow) is located in one half of the screw shaft.

7 Put on bearing support, tighten set bolts (63) to 20 Nm, install oil pipe (67).

05.0906 - 24015

8 Turn camshaft by the fiats with a fork wrench (24 mm) and check for ease of movement. If binding occurs, remove the bearing support again and replace with another.

9 Remove new rocker arm bearing support and pull out rocker shafts (Figure Number 4).

10 Lubricate rocker arms and rocker shafts and install in bearing support.

11 The installation proceeds in the reverse sequence.

05.0906 - 24016

emoval and installation of valve springs

Preceding work:

AIM cleaner removed (09-400 and 09-410).

Cylinder head cover removed (01-406).

Spark plugs removed (15-018).

63

5 - 0 0 4 8 - 3 7

A. Cylinder head removed

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . .

clamp on assembly board 102 589 00 59 00.

Remove, install rocker arm bearing supports.

Attach support bridge 102 589 01 59 00 to cylinder head. Remove, install valve springs with the lever compressor 601 589 02 61 00.

. Cylinder head Installed

Piston of the relevant cylinder . . . . . . . . . . . . . .

Oil pipe (67) . . . . . . . . . . . . . . . . . . . . . . . . . . .

position on ignition TDC (Number 1).

remove, install (Number 2).

0 5 0 9 0 6 - 250/l

Rocker arm bearing support

(61) . . . . . . . . . . . .

support . . . . . * * . . . . . . . . . . . . . * . . . . * . . .

Cylinder leakage tester . . . . . . . . . . . . . . . . . . .

Valve totters (45) . . . . . . . . . . . . . . . . . . . . . . .

remove, install, 20 Nm (Number 3).

Repair note

Lubricate camshaft journals.

Ball sockets (55) must be installed in the same position again.

Note installation position of the rocker arm bearing bolt.

install 102 589 01 61 00 (Number 4).

Disconnect, connect to the relevant cylinder

(Number 5). Pressurize cylinder.

remove and install with the lever compressor

601 589 02 61 00 and magnet 116 589 06 63

00. Remove, insert valve springs (Numbers 7 to

9).

Installation note

Install valve spring so that the color marking and the narrower coil point downwards.

Special tools

I

001 589 72 21 00

.

119 58901 61 00

/

116 58906 63 00 I

102 589

00

59

00

050906 - 25Ot2

Conventional tool

Cylinder leakage tester

Note

Valve springs and valve spring retainers with scoring on the mounting surfaces must be replaced.

e. g.

Bosch, E F A W 210 A

Sun, CLT 228

PO5-

- 4 0

- 5 4

The valve springs act progressively and must be installed so that the color marking (narrow coil) points towards the thrust collar (47).

Color marking : yellow/red or violet/red

A thrust collar (47) is inserted under the valve springs, which is supported on the cylinder head via anti-rotation lugs.

As on all other engines, the valve spring thrust bearing at the top forms valve spring retainers

(46) which are attached to the valves with valve cone halves (45).

05.0906 - 25013

A. Cylinder head removed

When the cylinder head is removed the valve springs can be removed as follows:

Clamp cylinder head with four cylinder head bolts (arrows) on assembly board

102 589 00 59 00 (1). Remove rocker arm bearing supports with rocker arms and camshaft.

Attach support bridge 102 589 01 59 00 to the cylinder head and remove the valve springs with the lever compressor.

05.0906 - 250/4

.

Cylinder headl installed

Removal, installation

1 Put piston of the relevant cylinder on ignition

TDC.

Note

The respective pistons are in the ignition TDC position, when the markings on vibration damper shown in the adjacent drawing are beneath the

TDC pointer.

Marking

Piston at TDC on cylinder

I TDC

1 and 4

I I

I 180”

2 and 3

2 Removal and installation of oil pipe (67).

3 Remove and install the required rocker arm bearing support (61) tightening torque 20 Nm.

Installation note

Before installing rocker arm bearing support lubricate camshaft journals.

Install the rocker arm bearing support so that the support area for the oil pipe points rearwards and the code number is on the right (in the direction of travel).

The ball sockets (55) must be installed in the same position again.

05.0906 - 2503

PO3-0058-13

4 Bolt up, unbolt support for lever compressor,

5 Connect cylinder leakage tester and pressur,ize cylinder.

6 Mount lever compressor on the support and install the valve spring retainer.

7 Compress valve spring and take out valve cone halves with the magnetic lever.

Caution!

Do

not remove the valve springs without compressed air in the cylinder, otherwise damage can occur due to contact between the valves and the piston.

8 Remove, install valve spring retainers and valve spring.

9 Check valve spring (05260) and valve spring retainers, replace as necessary.

10 Installation is the reverse of removal.

050906 - 250,6

05260 Checking valve springs

PO5-0032-13

I

Data

I

_

Valve spring

Part no.

I

Colour identification

(F)

053 02 20 yellow-red or violet-red

102 053 11 20 violet-yellow orange or yellow-yellow orange

Outside

0

mm

Wire

0

mm

Free length

Spring force at the pre-loaded length

Note

When carrying out repairs valve springs are to be checked for corrosion before reuse and to be replaced as necessary.

05.0906 - 260'1

Checking

1

Check valve springs with a valve spring tester or with a spring test scale.

2 Check spring force at the specified length.

3 If the limit value is not achieved, replace valve springs.

PO5-2129-1

05.0906 - 260/2

05270 Replacement of

Preceding work:

Air cleaner removed (09-400 and 09-410).

Cylinder head cover removed (01-406).

Spark plugs removed (1 S-01 8).

Valve springs removed (05-250).

valve stem seals

48

PO5-0047-34

Valve stem seal (48 and 49) . . . . . . . . . . . . . . .

extract with special tool 104 589 00 37 00.

Debut-r valve stem at the groove. Replace hammered valve cone halves, spring seats and thrust collars.

Lubricate valve stem seal and insert.

Special tool 601 589 02 43 00. Note color marking, use assembly sleeve.

Special tools

05.0906 - 270/l

Note

The valve stem seals including assembly sleeves are supplied in the repair set. Since September

1988 standardized valve stem seals in Viton

(formerly Polyacrylic) are installed for intake and exhaust valves. The valve stem seals must not be interchanged due to the different inside 0.

Distinguishing features:

Intake valve stem seal (48)

Chamfer (arrow) relieved d = 7.3 mm

Wire ring : phosphated (black)

Color: brown

Exhaust valve stem seal (49)

Chamfer (arrow) inclined d = 8.2 mm

Wire ring : bright galvanized (yellow)

Color: brown

Valve guides, which are opened out at the retaining groove for the valve stem seal, must be replaced.

When installing the valve stem seal on the intake valves it is absolutely essential that the plastic sleeve, which is enclosed in the repair set, is placed on the valve stem, because without the sleeve damage to the sealing lip of the valve stem seal is unavoidable.

05 0906 - 270/2

PO5 -0041-13

-d-’

PO5 -0040 -13

As a temporary measure valve stem seals with a smaller inlet 0 c = 16 mm (previously

17.5 mm) have been installed.

Identification:

revised outside contour

A Temporary

B Production design design

Intake valve stem seal

Introduced inproduction: January to Februarv 1986

Model Engine Engine end number

Manual transmission

201.024

I 102.985

I 003217 - 003513

Engine end number

Automatic transmission

I 029482 - 031994

PO5-0168-13

Exhaust valve stem seal

Introduction of Viton valve stem seal

Color identification:

brown

Introduced in production: June 1988

Model Engine

201.028 @

I 102.985

PO5-0169 -13

Engine end number

Manual transmission

Engine end number

Automatic transmission

I 025442~~ ~~~[074595 ~ - ----

05.0906 - 27013

05280 Checking and machining valves

PO5-0042-15

PO5 - 0 0 4 3 - 1 5

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking ............................

Machining valve seat .....................

clean valves.

Visual inspection:

Valves with burnt valve heads, insufficent val\ head height (h) worn or grooved valve stem must be replaced (Number

1).

Measure valve stem eccentricity. Replace va ,Ive when eccentricity is more than 0.03 mm

(Number 2).

Note operating instructions for machining equipment.

Note adjustment angle “a” 45 + 15’. Weplac 8 valve when maximum tolerances are reached

(Numbers 3 and 4).

05.0906 - 280/l

Conventional tools

Valve cone grinding machine or

Valve cone turning equipment

Data

Valve head @ D the valve head e.g.

Krupp,

D-5309 Meckenheim

VS Model e.g.

Hunger,

D-8000 Miinchen 70

Type VKDRl,

Part Number 203.00.200

Identification on end of stem

Engine

102.985

I Inlet valve

I

E 102 08

I Exhaust valve

I

A 102 03 27

05.0906 - 280/2

42

PO5 -0043 -15

42 Intake valve

Note

The exhaust valve stem is chrome-plated on these engines and filled with sodium due to high temperatures in the combustion chamber.

Warning!

Unserviceable sodium filled valves must be neutralised before scrapping. They must therefore be collected and sent to:

Mercedes Benz AG

Werk Marienfelde

DaimlerstraOe 145

Anlieferstelle KST 3153

Arbeitsvorbereitung TAI

43 Exhaust valve

After machining or replacing valves, the installed length of hydraulic valve clearance compensating elements must be checked and corrected if necessary (05214).

05 0906 28013

POS-0042 -15

Checking and machining

1 Clean valves and carry out visual inspection.

Valves with burnt valve heads with insufficient valve head height “h” and with worn or scored valve stem are to be replaced.

h

2 Measure valve stem eccentricity. Replace valve when an eccentricity of more than

0.03 mm is measured.

3 Machine valve seat. Note operating instructions of the machining equipment and adjustment angle

“a” 45 + 15’.

4 Measure valve seat eccentricity and valve head height “h”.

Replace valve if the limit values are reached.

PO50035-l 3

05.0906 - 28014

05285 Checking and replacing valve guides

PO50057-35

Valve stem seal seat (3) . . . . . . . . . . . . . . . . . .

check for wear. If the valve stem seal is no longer firmly seated, replace valve guide, special tools 103 589 02 15 00,

103 589 03 15

00.

Valve guide (54 and. 56) . . . . . . . . . . . . . . . . . .

clean, check, special tools

000 589 10 68 00, 102 589 00 23 00 and checking mandrel can be slid in longitudinally or laterally to the full extent (6.5 mm), replace valve guide. Special tools 103 589 02 15 00 and

103 589 03

15 00.

Insert: Super cool in liquid nitrogen approx. (3 minutes), special tools

102 589 04 15 00 and 102 589 05 15 00. See repair note. After insertion check inside 0 with testing mandrel, special tools

102 589 00 23 00 and 117 589 03 23 00; if required, ream, special tools

000 589 21 53 00 and 000 589 10 53 00.

05.0906 - 2831

Base bore for valve guide in the cylinder head (1) . . . . . . . . . . . . . . . . . . .

Valve seat ring (53 and 54) . . . . . . . . . . . . . . . .

check before inserting a valve guide.

Special tool 117 589 05 23 00. If normal dimension valve guide can be used;

Ream base bore with reamer 14.035 mm 0,

1105890300

When the checking pin can be inserted to the full extent, broach base bore to 14.2 mm 0.

Special tools 115 589 00 53 00,

102 589 00 63 00, 102 589 01 63 00 and

102 589 02 63 00.

See repair note.

after installing a new valve guide check for eccentricity, if necessary machine (05-291).

Special tools

000 589 10 68 00 117589052300 103589031500 103 589 02 15 00 102 589 00 23 O(

1 1 7 5 8 9 0 3 2 3 0 0 115589005300 110589035300 102 589 00 63 00 02 589 02 63 0

102 589 05 1500 000 589 10 53 00 102589016300

050906 - 285/2

Conventional tool

Cylinder head clamping fixture e.g.

f-lunger,

D-8000 Munchen 70

Part Number 221.60.000

Normal dimension

Repair stage

Exhaust valve

Normal dimension

Repair stage

Part Number

Outside rz! (D)

Color identification

1 1 0 2 0 5 0 1 7 2 4 1 1 0 2 0 5 0 1 0 2 4 1 1 0 2 0 5 0 1 8 2 4 1 1 0 2 0 5 0 1 3 2 4

114.044 - 14.051 114.214 - 14.222 114.044 - 14.051

14.214 - 14.222

grey-brown red grey-brown red

Base bore in cylinder head 114.030 - 14.035 114.198 - 14.203 114.030 - 14.035 114.198 - 14.203

Overlap

I

0.009 - 0.021

IO.01 1 - 0.024

1 0.009 - 0.021

0.011 - 0.024

Valve guide inside @ (A) 8.000 - 8.015

8.000 - 8.015

9.000 - 9.015

9.000 - 9.015

Length (L)

I

46.0

I

46.0

I

51.0

I 51.0

Note

Valve guides are made of different materials on the intake and exhaust side.

Intake valve guide (54): copper olours

Exhaust valve guide (56): brass colors

PO&0060-13

Valve guides produced by another manufacturer have been installed between June and

September 1986.

05.0906 - 2850

I Model

I

Engine Engine end number

1) not recorded

Broach base bore in cylinder head

(repair stage)

Remove rust and clean the cylinder head thoroughly, particularly the inside of valve

I

seat rings.

Select correct guide sleeve (2) and remove swat-f from the cutting edge of broach (1) with a stiff plastic brush or similar.

Note

The broaching tool cutting edges must be cleaned before every broaching process. Provide guide sleeve, base bore and complete broach with ample supply of kerosene.

Slide broaching tool in direction of broaching into the guide sleeve, so that when putting the guide sleeve on the valve seat ring (3) the first broach cutter is inserted in the base bore. When doing this, note that the correct side

(A or B) of the guide sleeve is placed on the valve seat. Center guide sleeve by rotary movements in valve seat ring.

Note

Drive home the broach briskly with an aluminium mandrel, approx. 130 mm long, and a plastic hammer of approx. 250 g.

Vehicle identification end

05.0906 - 28514

1 Broach

2 Guide sleeve

3 Valve seat ring

PO5-0163-17

Inserting valve guide

Drive in the valve guides with impact mandrel and hammer, when the valve guides are not super cooled and cylinder head is not heated up.

Coat valve guides with wax or oil before driving in.

Guide sleeve - valve seat allocation to enaine

Valve seat Engine Guide sleeve

Part No.

Intake 102 589 01 63 00

Exhaust

102.922/924

102.962.963

I

102.985

I 102.985

I

102 589 02 63 00

I 102 589 00 63 00 I

I

Base bore 0 in cylinder head

14.2mm

05.0906 - 285’5

05290 eplacing valve seat ring

1

PO5-0052-35

Valve seat ring (52 and 53) . . . . . . . . . . . . . . . .

Valve guides (54 and 56) . . . . . . . . . . . . . . . . .

Base bore (D2) . . . . . . . . . . . . . . . . . . . . . . . . .

Machined base bore

Cylinder head (1)

Valve seat ring

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

Valve seat ring repair stage . . . . . . . . . . . . . . . .

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

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

unscrew with seat ring turning tool

Note turning tool operating instructions.

check, replace if necessary (05-285).

measure.

Note

A new valve seat ring with normal dimensions can be used, when specified overlap is present.

If minimum overlap is not achieved, machine base bore for valve seat ring.

measure.

skim, so that the specified overlap is achieved.

heat up in water bath.

Super cool with liquid nitrogen and stamp with a suitable mandrel. Machine valve seat

(05-291).

05.0906 - 290/l

Special tools

‘I id

I

!i,

I

102 589 00 23 00

.

1 1 7 5 8 9 0 3 2 3 0 0

Conventional tools

Cylinder head clamping fixture

Ring seat turning tool

Valve seat turning device

Test set for valve seats

Internal measuring instrument

(measuring range 35 - 100 mm)

External micrometer

(measuring range 25 - 50 mm) e.g.

Hunger,

D-8000 Munchen 70

Part No. 221.60.000

e.g.

Hunger,

D-8000 Munchen 70

Size 2, Part No. 220.03.110

e.g.

Hunger,

D-8000 Munchen 70

Type VDSN l/45/30,

Part No. 236.03308

e.g.

l-iunger,

D-8000 Munchen 70

Part No. 216.93.300

e.g.

Mahr,

D-7300 Esslingen

Part No. 844 N e.g.

Mahr,

D-7300 Esslingen

Part No. 40 S l-f

05.0906 29012

Data

I

Intake

I Exhaust I

05.0906 29013

Exhaust

PO6-0064-N

Intake

Note

The valve seat rings are sintered metal on account of lead free fuel.

These hardened valve seat rings temporarily had a step (arrow) on the inside of the ring.

This step must be turned off in order to machine the valve seat ring. There is a repair valve seat ring with larger outside diameter as a replacement part for all valve seat ring designs. After renewing valve seat rings, the fitting condition of the hydraulic valve clearance compensating elements must be checked and corrected if necessary (05214).

PO5 -0164 -11

05.0906 - 29014

05291

Machining valve seats

PO5-006

Valve guides (56) . . . . . . . . . . . . . . .

Valve seats (53) . . . . . . . . . . . . . . . . . . . . . . . .

Valve seat eccentricity . . . . . . . . . . . . . . . . . . .

Valve seat width (b) . . . . . . . . . . . . . . . . . . . . .

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

check (05285).

machine in accordance with manufacturer’s operating instructions. See data for adjustment.

Note

Only loosen pilot, when eccentricity of valve seat ring has been checked.

check (Number 3).

measure, correct if required (Number 4).

insert and measure, stand off (A).

05.0906 -

29l;l

Conventional tools

Cylinder head clamping fixture

Valve seat turning equipment

Test set for valve seats

60” correction steel No. 13 for correction angle below(y)

Data Inlet Exhaust

e.g.

Hunger,

D-8000 Munchen 70

Part No. 221.60.000

e.g.

Hunger,

D-8000 Munchen 70

Type VDSN l/45/30,

Part No. 236.03.308

e.g.

Hunger,

D-8000 Munchen 70

Part No. 216.93.300

e.g.

Hunger,

D-8000 Munchen 70

Part No. 216.64.622

PO50060-13

05.0906 . 291!2

Valve distance to cylinder head parting surface

Engines 102.922/924

102.9621963

102.982/985

Minimum distance A with new valve seats and new valves

Largest distance A with reworked valve seats and reground valves

Largest distance A reduces by the same dimension, by which the cylinder head parting surface has been reworked.

Note

Clamp cylinder head in clamping fixture for stripping down and machining.

Machine valve seats with valve seat turning equipment, with valve seat grinding machine or with valve seat miller. After machining the valve seat rings the installation position of the hydraulic valve clearance compensating elements must be checked and corrected if necessary (05214).

05.0906 -

291’3

Machining valve seats

1 Check valve guide, replace if necessary

(05-285).

2 Machine valve seats (see manufacturer’s operating instructions).

Caution!

Only loosen pilot, when eccentricity of valve seat has been checked (Number 3).

3 Check valve seat eccentricity. For this push test sleeve (19) with dial gauge bracket (20) and dial gauge on the pilot (5).

5 Pilot

18 Dial gauge

19 Test sleeve

20 Dial gauge bracket

4 Measure valve seat width (b), and if required correct top(P) 15” angle and the bottom (y) 60” angle.

05.0906 29114

PO&0060-l

5 Insert valves and measure distance A.

05 0906 291i5

emoval and installation of chain tensioner

05-0066-57

V-ribbed belt ..........................

detach, assemble (13-342).

Bolt (49) .............................

loosen (Number 2).

Bolt (51)

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

unbolt (Number 3).

Alternator ............................

swing outwards.

Sealing plug (40) .......................

unbolt.

Note

The sealing plug is under pressure (Number 4).

Sealing ring (41) ........................

replace.

Compression spring (39) ..................

remove, install.

Chain tensioner casing (36) with setbolt (37) ........................

unbolt (Number 5).

0 5 0 9 0 6 - 3 1 0 1

Setbolt (37) with locking spring (38)

Chain tensioner casing (36) . . . . .

.........

.........

press out of chain tensioning casing in the direction of pressure. Check individual parts for wear (Number 6).

screw into cylinder crankcase, 15 Nm

(Number 7).

push in (Number 8).

Setbolt (37) with locking spring (38) .........

Sealing plug (40) with compression spring (39) and new sealing ring (41) . . . . . . . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .

\/belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When engine is running . . . . . . . . . . . . . . . . . . .

screw in, 70 Nm (Number 9).

mount (Number 10).

assemble (13-342).

check for leakage.

Special tools

Conventional tool

Stud driver insert

17 mm, l/2” square

Note

The housing (36) of valveless, hydraulic lock chain tensioner is bolted to the crank case (1).

The application force required to tension the chain is comprised of the force from compression spring (39) and oil pressure in the chain tensioner, depending on engine oil pressure.

41

1

4 0 a

3 9

38

37

36 e.g.

Hazet,

D-5630 Remscheid

Part No. 985/l

7

PO5-0070-

05.0906 - 31012

In the event of sudden load the oil feed bore with

1 .l

mm 0 (a) and an orifice bore (b) in the setbolt of 1.2 mm 0 prevents the oil escaping rapidly and thus has a damping effect. An embossing is provided in the chain tensioner casing (36) and a locking spring (38) on the setbolt.

38

The locking spring (38) has been modified in order to improve the function of the chain tensioner.

Changes:

l Ends free from burrs l Smaller twist

(dimension “a” = 0.1 mm, was 0.5 mm) l Improved material l Dimension “b” = 3.5 mm, was 4.0 mm.

36 Chain tensioner casing

37 Setbolt

38

39

Locking spring

Compression spring

40

41

Cap nut

Sealing ring

3 8 37 3 6

PO52052

-13

POS-0170-13

Introduced in production: December 1985

Model Engine

201.024 @

I 102.985

Engine end number

Manual transmission

I 003199

Engine end number

Automatic transmission

I 029429

050906 - 310/3

Removal and installation

1 Removal and installation of Poly V- belt

(13-342).

2

Loosen lower bolt (49) for alternator positioning.

3 Remove upper bolt

(51),

swing alternator outwards (arrow).

4 Unscrew sealing plug (40) and sealing ring

(41) and remove compression spring (39).

Caution!

Sealing plug is pressurized by the compression spring.

5 Unbolt chain tensioner case (36) from the cylinder crankcase with the stud driver insert.

6 The chain tensioner must be stripped down before assembly. To do this press the setbolt

(37) and locking spring (38) out of chain tensioner casing (36) in the direction of the arrow. Clean parts and check for wear.

05.0906 31014

POS-2080-13

7 Bolt chain tensioner casing (36) onto crankcase, tightening torque

15

Nm.

8 Push setbolt (37) and locking spring (38) into the assembled chain tensioner casing.

9 Mount compression spring (39) and sealing plug (40) with new sealing ring (41), tightening torque 70 Nm.

10 Mount alternator, tightening torque of the bolts (49 and 51), 25 Nm.

11 Install Poly V- belt (13-342).

12 Check for leaks when engine is running.

05.0906 - 31015

05-320 Weplacement of timing chain

Preceding work:

AIM cleaner removed (09-400 and 09-410).

Cylinder head cover removed (01-406).

40

41

39 0@@@

Gb

Spark plugs (15) . . . . . . . . . . . . . . . . . . . . . . . .

Chain tensioner (36 to 41) . . . . . . . . . . . . . . . .

Chain bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .

New timing chain with old timing chain (21) . . . . .

Exterior bracket . . . . . . . . . . . . . . . . . . . . . . . .

Riveting tool ..........................

Connector link bolt ......................

remove, install (15318).

remove and install (05310).

grind off (Number 3).

connect, pull in (Numbers 4 to 7).

press on with riveting tool 000 589 58 43 00, rivet set 103 589 01 63 00 for single roller chain, conversion set 000 589 53 43 for double roller chain (Numbers 8 to 10).

remove, convert (Number 11).

rivet individually (Numbers 12 and 13).

05 0906 - 320/l

Special tools

102 589 01 09OC 000 589 58 43 00 103 589 01 63 OC

Note

An open timing chain with connector link is supplied for repairs. The sprockets are to be checked for scores and pitting as well as the chain tensioner for perfect function before installing a new timing chain.

Improved timing chains have been installed since

November 1985.

Changes:

Sleeves (2) with recesses (notches, arrow and

A). f-lence improved oil supply to bolts (3) and sleeves (2).

A

3

2

I - -

A i

A

PO5-0165-13

050906 - 32012

Introduced in production: November 1985 - May 1986

Model Engine Engine end number

Manual transmission

2 0 1 . 0 2 4 @ ( 1 0 2 . 9 8 5 1003057-003893

201.024 @ 102.985

I I

003925

Engine end number

Automatic transmission

I 027366-036001

Engine end No.

Automatic transmission

036289

312513

Not recorded

Double roller timing chains have been installed since January 1988.

05.0906 - 32013

The former connector link with locking devices

(A) has been deleted. Only the connector link

(B) is still supplied for riveting.

A

B

Former connecting link with locking devices

Modified connecting link can be rlveted

Replacement

1 Remove, install spark plugs (15018).

2 Remove, install chain tensioner (05-310).

3 Cover the open part of the chain casing with a rag, grind off both chain bolts (arrows) at a double link in the timing chain.

4 Attach new timing chain and the connector link onto the old timing chain. To do this press out ground off double link.

5 Put the new timing chain connected with the old timing chain onto the camshaft timing gear.

Rotate crankshaft.

Caution!

The timing chain must remain engaged while rotating the camshaft timing gear.

05.0906 - 320/4

POS-2057-13

6 Pull out the released end of the old timing chain evenly, to correspond with drawing on the new timing chain.

Caution!

The timing chain must remain engaged while turning the camshaft timing gear and crankshaft gear.

7 Secure the ends of the chain to the camshaft timing gear with wire. Detach old timing chain and connect the ends of the new timing chain with the repair connector link.

Note

Connector link must be inserted from behind.

8 Fit riveting set 103 589 01 63 00 to the basic tool 000 589 43 00 corresponding to the timing chain design (single or double roller chain).

9 Put loosely attached exterior bracket of the connector link in the press tool (arrow).

The exterior bracket is held magnetically.

10 Put press tool on the connector link and press on bracket up to the stop.

Note

Put on clip so that both rivet pins engage.

05.0906 - 320/5

POS-2053-13

11 Remove assembly tool and turn punch (02) so that the notch (arrow) points forward.

12 Install assembly tool exactly over the center bolt. Rivet bolts of the connector links individually, tightening up spindle to approx. 30 -

35 Nm (reference value).

13

Check riveting (arrows), re-rivet if required.

14 Install chain tensioner (05310).

PO!%2056-13

05 0906 - 32016

15 Turn crankshaft and check adjustment markings at engine TDC position.

Note

If the adjustment markings do not align, the valve timing settings of the camshaft must be checked

(05215).

16 Assembly is completed in the reverse order.

0 5 . 0 9 0 6 - 32017

05328 Installation of oil spray nozzle retroactively

Preceding work:

Timing

case cover removed (01-210).

idler gear shaft removed (05-412).

POS-0076-35

Sealing plug (13) . . . . . . . . . . . . . . . . . . . . . . .

remove (Numbers 1 and 2).

Joggle plate ..........................

Part No. 102 589 14 15 00 bolt up, unbolt

(Number 3).

Oil spray nozzle (66b and 66~).

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

drive home up to stop (Number 4).

Idler gear shaft .........................

install (05-412).

Timing case cover ......................

install (01-210).

On engine ............................

change oil and filter.

When engine is running ..................

check for leaks.

Special tools

05.0906 - 3281'1

Note

In order to achieve better lubrication of the timing chain, an additional oil spray nozzle (66) has been fitted in the front face of the main oil channel. This oil spray nozzle, can be installed retroactively. The retroactive installation should only be carried out, when for example the timing case cover has already been removed for other work.

Production breakpoint of the various designs

Injection engines

66a 1st design March to April and May 1986

66b 2nd design November 1986 to July 1987

66c 3rd design July 1987

05.0906 - 328.2

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

Production breakpoint: March - April 1986

(Injection engines 1st design)

2 0 1 . 0 2 4 @ 1 1 0 2 . 9 8 5 1003626-003670

... ...

....

....... ...

I

033140-033543

Production breakpoint: May 1986

(Injection engines 1 st design)

201.024 @ 1 102.985 I00381 l-003828

I

03521 o-035424

Production breakpoint: November 1986

(Injection engines 2nd Design)

Model

201.028

I

I Engine

102.985

I Engine end No. Man. transm.

I 007099

I Engine end No. Autom. transm.

I 045782

Production breakpoint: July 1987

(Injection engines 3rd Design)

201.028

I 102.985

I 015733 I 057671

05.0906 - 3281’3

Installation

1 Remove sealing plug

(13),

to do this drill a core hole (5 mm 0, 10 mm deep).

Note

Carefully cover oil channel (a), bearing bore (A) and window (arrow).

2 Unscrew sealing plug with impact extractor

116 589 20 33 00 and stud 116 589 00 34 00

3 Attach joggle plate (AP) 102 589 14 15 00 with two hexagon bolts M8 x 15 (48).

P18-0009.13

1 Cylinder crankcase

48

Fixing bolts

50 Straight pin (guide for timing case cover)

66 011 spray nozzle

AP JOQQle plate

4 8

5 0

05.0906 - 32814

4 Select correct oil spray nozzle (carburettor or injection engine) and drive home the cylinder crankcase up to the stop. The correct fitting position of the oil spray nozzle is achieved when this is laid on the joggle plate, as shown in

Figure (Number 3).

I Carburettor engines (non-US)

2 Injection engines

5 Detach joggle plate.

6 Install idler gear shaft (05412).

7 Install timing case cover (01-210).

8 Change engine oil and filter.

9 Check for leaks when engine is running.

POS-0013.13

Parts required

Oil spray nozzle

Part No.

102 180 09 43 (Carburettor engine)

102 180 08 43 (Injection engine)

Standard Text and flat rates

Install oil spray nozzle for timing chain

(Idler gear shaft removed)

02-0367/01

The operation number

IS t’o be placed in front of the book/column number.

Related work, 5 flat rates or 0.4 hours

050906 - 328/5

emoval and installation of tensioner blade

Preceding work:

Timing case cover removed (01-210).

PO5-0071-35

Timing chain (21) and crankshaft gear . . . . . . . .

Timing chain and camshaft timing gear (4) . . . . .

mark (Number 1).

mark (Number 2).

Chain tensioner (36 to 41) . . . . . . . . . . . . . . . .

remove, install (05310).

Oil pressure pump (69) ...................

unbolt, bolt up, put to one side with lines connected (Number 4).

Camshaft timing gear (4) ..................

unbolt, bolt up, 80 Nm (Number 5).

Tensioner blade (22) .....................

remove from bearing bolt, put on.

Note

On double roller chain, spot drill bearing pin (26) and drive out with the impact extractor 115 589

12 33 00. Install new tensioner blade with bearing pin (Numbers 7 and 9).

Plastic support (23) .

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

Camshaft adjustment . . . . . . . . . . . . . . . . . . . .

check, possibly renew (Number 8).

check (Number

11).

05.0906 - 330/l

Special tools

001 589 72 21 00 116 589 03 34 00

Note

In order to achieve better guidance of the timing chain, the plastic support has lateral guide bars

(arrows). The plastic support is also fixed differently; in this way the support is prevented from slipping off the tensioner blade.

A Former design

B Current design

Production breakooint: Auaust 1986

Model Engine Engine end No.

Engine end No.

Man. transmission Auto. transmission

325157

05.0906 - 33012

.

Removal and installation

1 Align timing chain and crankshaft gear.

2 Align timing chain and camshaft timing gear.

-2 B

Pck5-2056-13

3 Remove chain tensioner (05-310).

4 Unbolt oil pressure pump with lines connected (arrows) and put to one side.

05.0906 - 330~3

5 Unbolt, bolt up camshaft timing gear, bolt

(9a), tightening torque 80 Nm. Note color markings on camshaft timing gear and crankshaft gear.

Note

On vehicles with oil pressure pump remove driving disc sleeve (70).

6 Swing tensioner blade (22) for single roller chain inwards and remove from bearing pin (26), install.

7 On engines with double roller chain, drive out bearing pin (26) of the tensioner blade with the impact extractor 116 589 20 33 00 and extension

116

589 03 34 00. To do this cut an

M6 thread approx. 10 mm deep on the bearing pin. Remove tensioner blade.

8 Check plastic support for wear, replace if necessary.

PO5-2032-13

05.0906 - 330/4

9 Insert new tensioner blade and drive home bearing pin up to stop.

10 Install chain tensioner (05310).

11 Turn crankshaft and check adjusting marking at TDC position of engine.

12 The installation proceeds in the reverse sequenceas removal.

13 Run engine, check for leaks.

05.0906 - 3306

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

05340 Removal and installation of guide rails

......

A. Guide rail (24) in cylinder heacd

Preceding work:

Air cleaner removed (09-400 and 09-410).

PO5-0078-57

Chain tensioner (39 to 41) ................

remove, install 70 Nm (Number 1).

Fan shroud (1) and fan (75) ...............

remove, install, bolt (80), 25 Nm (Number 2).

Piston of No. 1 cylinder ..................

position on ignition TDC (Number 3).

050906 - 340/l

Oil pressure pump (69) . . . . . . . . . . . . . . . . . . .

Timing chain and camshaft timing gear (4)

Guide rail bolt (26) . . . . . . . . . . . . . . . .

When engine is running . . . . . . . . . . . . .

unbolt, bolt up, put to one side with lines connected (Number 4).

align and unbolt, bolt (9 and 9a), 80 Nm

(Number 5).

extract, with impact extractor 116 589 20 33 00 and stud 100 589 00 34 00, drive home

Note

Insert guide rail bolt with sealant

001 989 25 20. Note that the fixing nose on the guide rail engages in the guide rail bolt

(Numbers 6 and

7).

check for leaks.

Special tools

1 1 6 5 8 9 2 0 3 3 0 0 100 58900 34 00

001 589 72 21 00

05.0906 - 34012

001 589 66 21 OC

Note

The guide rails have been changed with the introduction of the double roller chain.

A Guide rail for single roller chain

B Guide rail for double roller chain

Removal and installation

1 Removal and installation of chain tensioner

(05310). Tightening torque of hexagon cap nut

(40) 70 Nm.

2 Remove fan shroud (1) and fan (75).

Tightening torque of bolt (80) 25 Nm.

3 Position piston of No. 1 cylinder on ignition

-l-DC.

05.0906 - 34013

POS-0079-13

P20-0006-13

4 Unbolt oil pressure pump with lines connected (arrows) and set to one side.

5 Align timing chain and camshaft timing gear.

Unbolt camshaft timing gear and remove sprocket.

Note

When installing the sprocket note color markings. Tightening torque of set bolt

80 Nm.

6 Withdraw both guide rail bolts (26) with impact extractor 116 589 20 33 00 and stud

100 589 00 34 00.

Note

If the guide rail bolts are too tight, the extractor

115

589 20 33 00 with stud

115 589 00 34 00 can also be used.

050906 - 340!4

Impact extractor in place

7 Install guide rail (24) so that the locating lug

(arrow) engages in the groove of the upper guide rail bolt.

Note

Apply sealant 001 989 25 20 at collar of guide rail bolts.

8 Check for leaks when engine is running.

05.0906 - 340/5

.

Guide rail in cylinder crankcase

Preceding work:

PO5-0080-57

a. With single roller chain

Guide rail (25a, single roller chain) . . . . . . . . . . .

remove, put on (Number 1).

b. With double roller chain

Piston of No.

1 cylinder . . . . . . . . . . . . . . . . . .

Oil pressure pump (69) . . . . . . . . . . . . . . . . . . .

Chain tensioner . . . . . . . . . . . . . . . . . . . . . . . .

position on ignition TDC (Number 2).

unbolt, bolt up, put to one side with lines connected (Number 3).

remove, install (05310).

05 0906 - 340/6

Timing chain and camshaft timing gear (4) . . . . .

Timing chain and crankshaft gear . . . . . . . . . . . .

Bolt (20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing chain with crankshaft gear . . . . . . . . . . .

Idler gear shaft (18) . . . . . . . . . . . . . . . . . . . . .

Further installation . . . . . . . . . . . . . . . . . . . . . .

When engine is running . . . . . . . . . . . . . . . . . .

align and unbolt, (9 and 9a), 80 Nm (Number 5).

align (Number 6).

unscrew, remove clip

(19) and idler gear shaft

(18) (Numbers 7 and 8).

pull forward as far as possible, remove and fit guide rail (25b) (Number 9).

Note

When pushing back the crankshaft gear, and the timing chain, note the positioning pin in the camshaft flange and alignment of timing chain to tension lever.

install, bolt (20), 5 Nm (Number 10).

in reverse sequence.

check for leaks.

Special tool

1 001 589 66 21 00

05.0906 . 34017

Note

The guide rails have changed with the introduction of the double roller chain.

A Guide rail for single roller chain

B Guide rarl for double roller chain

Removal and installation a. With single roller chain

1

Pull off guide rail (23, install.

b. With double roller chain

2 Position piston of No.

1 cylinder on ignition

TDC.

3 Unbolt, bolt up oil pressure pump (arrows) and put to one side with lines connected.

05 0906 - 340/8

POS-0075-13

4 Remove chain tensioner (05310).

5 Align timing chain and camshaft timing gear and unbolt camshaft timing gear. Put timing chain in timing case.

6 Align timing chain and crankshaft gear.

7 Unscrew bolt (20) and remove retaining clip (19).

05.0906 - 340/9

Po5-2056-13

8 Pull out idler gear shaft (18) and remove timing chain.

9 Remove, install, pull timing chain and crankshaft gear forward as far as possible and remove guide rail (25b). Put on timing chain and push back crankshaft gear together with timing chain.

Note

When pushing back the crankshaft gear, note the positioning pin in the camshaft timing gear flange and the color marking.

10 Install idler gear shaft, tightening torque of the hexagonal socket screw (20) 5 Nm

(reference value).

POS-2085-13

PO5-2085-13

05.0906 - 340/10

11 Install timing chain and camshaft timing gear, note marking. Tightening torque of camshaft timing gear set bolt 80 Nm.

12 Install chain tensioner (05310). Tightening torque of sealing plug (40), 70 Nm.

13

Check adjustment marking of camshaft

(arrow) at ignition TDC position of engine, correct if necessary.

14 Install oil pressure pump, in so doing note driving disc.

15 The installation is the reverse of removal.

16 Check for leaks when engine is running.

05.0906 - 34Ot'll

emoval and installation of idler gear shaft

Preceding work:

Timing case cover removed (01-210).

Fuel pump removed (07.2-212, only carburettor engines).

PO5-0080-57

Chain tensioner (36 to 41) . . . . . . . . . . . . . . . .

Oil pressure pump (69) . . . . . . . . . . . . . . . . . . .

Camshaft timing gear (4) . . . . . . . . . . . . . . . . . .

Crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . .

Bolt (9 and 9a) . . . . . . . . . . . . . . . . . . . . . . . .

Guide rail (25a) . . . . . . . . . . . . . . . . . . . . . . . .

remove, install (05-310).

unbolt, bolt up, set to one side with lines connected (Number 2).

align with timing chain (Number 3).

align with timing chain (Number 4).

unbolt, bolt up and remove camshaft timing gear, 80 Nm. Note marking (Number 5).

remove, install (only on single roller chain,

Number 6).

05.0906 - 412/l

Hexagon socket bolt (20) . . . . . . . . . . . . . . . . . .

Idler gear shaft (18) . . . . . . . . . . . . . . . . . . . . .

When engine is running . . . . . . . . . . . . . . . . . .

unbolt, bolt up, 5 Nm. Remove, install retaining clip (19) (Number 7).

withdraw from rear bearing and remove from timing chain, insert (Numbers 8 and 9).

check for leaks.

Special tool

I 001 589 66 21 O(

Note

The idler gear (18b) is pressed on the idler gear shaft (18) supported on bearings in timing case cover and cylinder crankcase. It is fixed axially by a retaining clip (19) bolted on the cylinder crankcase, which engages in a groove on the idler gear shaft. The teeth for driving the ignition distributor (18~) are located behind the front bearing position.

Arrangement of idler gear shaft

Engines 102.985

05.0906 - 41212

I Cylinder crankcase

6 Beanng bush in timing case cover

17 Bearing bush In cylinder crankcase

18 Idler gear shaft

18b

18c

Idler gear

Teeth for ignition distnbutor drive

19 Retaining clip

20 Bolt M5x18

mm

44

Timing case cover

6

1

17

PO50090-13

Removal and installation

1 Remove chain tensioner (05-310).

2 Unbolt, bolt up oil pressure pump (arrows) and put to one side with lines connected.

3 Align camshaft timing gear and timing chain.

4 Align crankshaft gear and timing chain.

5 Unbolt camshaft timing gear and remove, put timing chain in timing case.

05.0906 - 41213

PO3-2056-13

6 Remove guide rail (25a) (only on single roller chain).

7

Unbolt hexagon socket bolt (20) and remove retaining clip (19).

8 Remove idler gear shaft (18), install, in so doing raise timing chain somewhat.

9 Install retaining clip (19) and secure with bolt

(20) tightening torque 5 Nm (reference value).

10 Install guide rail (25a).

11

Assemble camshaft timing gear, at the same time noting colored markings, tightening torque

80 Nm.

12 Check adjustment marking of the camshaft

(arrow) at ignition TDC position of engine, correct if necessary.

13 Install chain tensioner (05310).

14

The installation is the reverse of removal.

15 Check for leaks when engine is running.

05.0906 - 412'4

emoval and installation of oil pressure pump drive

Preceding work:

Cylinder head cover removed (01-406).

Set bolts (68) . . . . . . , . . . . . . . . . . , . . . . . . . .

Oil pressure pump (69) . . . . . . . . . . . . . . . . . . .

unbolt, bolt up, 15 Nm (Numbers 1 and 2).

remove together with driving disc (76). On

Model 201 set oil pressure pump with lines connected to one side.

Gasket (75) ...........................

renew.

Driving disc (76) ........................

remove, install.

Flange (71) ...........................

unbolt, bolt up, with attachment eye (22), 25 Nm

(Number 4).

O-Ring (73) ...........................

replace.

Hexagon socket bolt (9a) ..................

unbolt, bolt up, 80 Nm. Remove, install driving disc sleeve (70) (Number 5).

05.0906 - 43711

Special tools

001 589 66 21 00 001 589 72 21 OC

I Camshaft

4 Camshaft timing gear

6 Woodruff key

9a Hexagon socket bolt

21 Timing chain

69 Oil pressure pump

70 Driving disc sleeve

71 Flange

73 O-Ring

7 5

76

Gasket

Driving disc

81 Cylinder head cover

93 Cylinder head cover gasket

Note

The oil pressure pump (69) is driven directly by the camshaft (1) via the driving disc sleeve (70) and the driving disc (76) and is attached to the cylinder head by a flange (71). The fitting position of the flange on the cylinder head is fixed by two straight pins (arrows). The camshaft timing gear (4) is attached to the camshaft with the driving disc sleeve (70) and the hexagon socket screw (9a). The O-Ring (73) on the flange (71) seals the front semicircular bore in the cylinder head and in the cylinder head cover

(61).

69 75 93 21 81

05.0906 - 43712

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

Removal and installation

1 On Model 201 remove bolts (68), remove oil pressure pump and set to one side with lines connected.

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

Model 201

2 Remove, install driver (76).

Replace gasket (75).

3 Unbolt, bolt up flange (71) together with the attachment eye (22), renew O-Ring (73).

Tightening torque of bolts (72) 25 Nm. Note both dowels (70).

69

75

PO5-0081-13

POS-0083-13

05.0906 - 43713

4 Unscrew hexagon socket bolt (9a) and remove, insert driver sleeve (70), tightening torque 80 Nm.

9a

70

@a

05.0906 - 43714