rece
>
4.0. Technical Data
+ L207b, L307 298%,
‘Number of Cylinders
Compression Ratio
~ 601, 602 engines a
* 618 engine at
Max. BHP. (DIN):
= bib enone 23 ka 200 rpm
Meo engine 157 kgm (119 Rib) at 2000 ~ 2800
om
10
602 engine
= 618 engine
Crankshaft bearings
Coaling system
Lbrication
Airdlesner
Valve Timing - New Timing Chain ~ 604 and 602 engines:
Int valve opens
01 and 602 engines:
Timing = New Timing Chain - 616.
valve opens
Valve Timing — Used Timing Chain - 616 engine:
All vaives 2 moe
Valve Clearances ~ 616 Engine — Engine warm
+ inlet valves 0.10 mm (0.004in )
818 Engine — Engine cod
0.48 mm (0.006)
(0.36 mm (0.018in)
1A, Engine - Removal and Installation
The engine and transmission is removed from the vehicle as a complete unit
after the parts shown in Fig. 1.1 are removed from the front end of the
Vehicle. The transmission can then be removed from the engine. Engine and sion re a heavy unit and a suitable host or ean i required tit
are ascombly, remembering that the weight» more than 200 Ibs. The
Govcrpton ja general gue ine, as we cannot rfer 9 every
Variation andlor equipment tat may be tes to your venice
Fig. 1.1 ~ Tho engine is removed from the vehicle after the Mustrated parts have
been removed from the front and of the vehicle.
+ Place the bonnet into the vertical position until the lock engages.
Remove the drivers seat.
* Disconnect the two battery cables. The battery can also be removed to
have more space for other operations.
‘+ Remove the engine cover and the radiator gre,
‘+ Open the expansion tank cap. It is assumed thatthe engine is fairy cold
Drain the cooling system as described in Section "Cooling System
Remove the radiator as described in the same section.
ke hose.
nt bumper and the radiator crossm:
front exhaust pipe from the exh:
racket on the transmission
‘+ Disconnect the propelier shaft from the
the speedometer cable from the transmission.
1),
nifold and free the
ismission. Also disconnect,
the cylinder
* Unscrew the earth cable.
rect the electrical
ads from the starter motor and
f. Free the cable
* Disconnect the electrical lead from the glow plug relay
‘+ Disconnect all vacuum hoses from the engine.
* Ifa power-assisted steering is fited, remove the drive belt and unscrew
the belt pulley from the pump shaft. Unscrew the complete steering
‘pump and remove it together withthe connected hoses
‘+ Disconnect the fuel pipe from the pre-fter. Close the open connections:
in suitable manner to prevent entry of dir
* Remove the vacuum hose fro the vacuum pump atthe locaton shown
inFig. 1.3,
Fig. 1.3 ~ Disconnect the vacuum
hose for the brake servo unit from
the vacuum pump (exhaustor pump).
+ Unscrew the gear change
lever knob, remove the rubber
‘gaiter and withdraw the lever
‘+ Remove the starter motor,
Disconnect the oi pipes from the oi flter housing.
Remove th tamp from the oil sump.
Remove the neck, Fig. 1.4 shows the location.
Remove the transmission mounting from the crossmember
SStacken the engine mounting supports from the er
‘+ Use a hand crane or suitable hoist and with ropes or chains attach the
Power unit, utiising the liting eyes. Also place a mobile jack underneath
B enginetvansmision unt to Suppo fom below. Bafre removing
the Giire engine and tranamesion mourn ensure tha the welght of
the sacoisy ts wal supported,
Fig.
‘erossmember underneath
Fig. 1.4 - The olf flor neck must
bbe removed in order to tako out the
ongine.
+ Disconnect the throttle
Contr
+ Unscrew the crossmember
lundemeath the transmission and
also undemeath the engine. Figs.
4.5 and 1.6 show where the items
are attached, Check once more
thatthe unit is supported.
4.8 - The attachment of the
the
The installation is a reversal of the
5] removal procedure, but the following
points should be noted:
* Check the engine mountings and
the oil and fuel pipes (hoses) for
damage and replace parts as
necessary,
+ If a manual transmission is fitted, take the opportunity to check the
clutch release bearing and replace if necessary
+ Do not connect or refit any of the disconnected parts unt the engine
and transmission are refiied to their mountings and the engine is free
‘rom the ropes or chains.
+ Remove the engine mounts if
‘available, check the spring length when the loads given in Section 1.3.0. are
applied.
The springs must not be distorted. A spring placed with its flat coll on a
surface must not deviate atthe top by more than 2 mm (0,08 in).
‘Valve Guides: Valve guides for iniet and exhaust valves are made of cast
Clean the rade of he guides by puting & petoksoaked cot tough the
‘Quides. Valve stems can be
Measure the inside diameter
Necessary for this operation,
28 -
‘should be no need to grind-in the valves. Use correction cutters to bring the
Fig. 1.21 ~ The maximum dimension “A between the valve face and cylinder
hhead face ist shown on the LH. side. Measure this dimension as shown on the
Ri side.
‘wear limit is 1.0 mm,
‘Valves can be ground into their seats in the conventional manner.
Valves: The stems of inlet vaives and exhaust valves have been specially
treated, Le. the ends of the valve stems must not be ground of.
Valves can be cleaned best with a rotating wire
‘mm in the case of the exhaust valves.
30
it is only required to replace the exhaust valves, if these for
burnt out at their valve head edges.
ener: Place the camshaft with both end journals into "V" blocks
‘lamp the shaft between the centres ofa lathe and apply a dal gauge to
Centre journal, as shown in Fig. 123. Slowly rotate the shat to check fot Fig. 1.28 Checking a camshaft
for run-out,
p] run-out if the dial gauge
reading exceeds 0.01 mm, fita
+ Make sure to fit the correct
shaft if the shaft is to be
replaced. Check the identi-
cation number when ordering a new shaft
Replacing Valve Stem Oil Seats (Cylinder Head fitted): Valve stem oil
seals are available in repair kits. Included in the
sleeves which must be pushed over the valves 4
‘seals. Valve stem seals are different in ciameter a
by their shape (Fig. 124)
Fig. 1.24 ~ Sectional view ofthe valve stom oll seals. On
the leit for the exhaust valves; on the right for the Inlet
valves.
Normally a special too! is used to fit the seals, but a well fiting piece of tube
Of suitable diameter can be used. Take care not to damage the sealing lip
and the spring. 7
The valve cotter halves and the valve
Centre. The operation is more difficult on a five-cylinder the
Crankshaft must be rotated by a certain angle to move the next piston to
TD.C. Only attempt this operation if you are competent. Start by setting the
piston of the No. 1 cylinder to the top dead centre position. Valve stems
‘Seals of cylinders Nos. 1 and 4 can be replaced inthis positon,
‘+ Remove the camshaft (see description later on).
32
Telease the valve spring lifter. Make sure that the cotter halves: position by tapping the end of the valve stem with a plastic mallet. Place
‘2 rag over the valve end - just in case,
‘+ Fitthe camshaft as described later on and carry out all other operations
in reverse order to the dismanting procedure.
1.3.0.6. _ Hydraulic Valve Clearance Compensation
“The function of the hyat
eliminate valve cleara
ve clearance compensating elements is to
1e dimensional changes in the valve train
42 Valve spring retainer _h Oil bores
(valve lash) due to heat expansion and wear are compensated by the
elements. The rocker arm is in constant contact with the cam. The
Compensating elements cannot be repaired, but can be checked for correct
functioning as described below. Figs. 1.25 and 1.26 show sectonal views of
34
_avalve with clearance compensation. We:
‘operation, All references refer to Fig. 1.25,
‘The hydraulic valve compensating elemer
‘and operate the valves directly via a ball
ofthe following
the element can completely retract. The
‘rom the work chamber (b) flows through an annular gap, ie.
168 between the guide sleeve and the thrust pin to the oll supply
‘When the cam lobe has moved past the valve tappet, the thrust pin (6) wil
The thrust spring (8) forces the thrust pin upwards until the
ts against the cam.
sulting from the upward movement of the thrust pin in the
“work chamber (0) opens the ball valve and the oll can fow from the supply
“chamber (h) into the work chamber (b). The ball valve closes when the valve
appet presses against the cam and puts the thrust pin under load. The olin
the work chamber acts as a “hydrauitc rigid connection” and opens the valve
ing and depending on the engine speed and the
is only pushed down slightly.
‘chamber (a) is sufficient to fil the
‘conditions of the engine. Oil of leak
ir are able to escape via the
1nd the rocker lever. ‘The oil ejected from: ‘chamber flows via the annular gap between the guide sleeve and the thrust 434. PISTON AND CONT
pn and the two return bores (c) nto the oil supply chamber. Baio. ma
"Aldimensions ae given in metic urs
| Pistons - 601 and 602 Engines
+ After removal ofa tappet (see below), mark the cylinder number and the Piston iat Std
‘compensating element in suitable manner. Always fit original parts in
their same locations.
ition, ie. the open side
‘+f the tappet cannot be
depressed or excessive
clearance can be felt between
the tappet and the back of the
tappet to its original position, but this operation is beyond the scope of
‘the home mechanic.
Tappet Removal and installation:
‘= Remove the camshaft as described later on.
‘= Use a suction tool to remove the tappets. Mark them, ifthey are to be
refitted,
‘+ Fitthe tappets into their original bores, if re-used. Refit the camshaft as,
described and carry out all other operations in reverse order to the
removal procedure. Max. twit of connecting rods 0.10 mm per 100 mm
Max. Bond of connecting red (0.045 mm per 100 mm
Max. weight ference in same engine: ‘5 gram (por set)
Piston Diameter St, — Piston No. 03,28
‘Cass 0 80,98
Cass 90.9¢mm
Case 2 91,00mm
Piston Diameter ~ Sto, ~ Piston No. 95, 44
‘Case 0
Class 1
Class 2
= Wee im
Max. weight ference uithin engine
2 Neth
25.995 ~ 26,000 mm
0.012002 mm
(0.000 0.010 mm
Connecting Rode cor 1ds are pushed out towards the top of the
Ditonto ene sma en beret ynnecting rods are pust ne
‘entre big end bore Pansies 8, using a hammer handle alter connecting rod bearing caps:
38 wr
have been removed. Before removal of the assemblies note the following,
points:
‘+ Pistons and cylinder bores are graded in three diameter classes with
specified tolerance groups and marked withthe letters A, X and B or 0,
Fig. 1.28 ~ Identification (marking) of piston crown and
cylinder block face withthe group code lattes.
is best done with a centre liner is
= punch (ojinder No. 1 one punch mark, etc,
the bearing caps and the
the assembles out of the cylinder bore. Any carbon
per edge of the bores can be carefully removed with &
tons, using a piston rng piers possible FA.
we rovused, ark them accordance wh fe
Measuring the Cylinder Bores
de caliper is necessary to measure the diameter of the cylinder
following operations are not possible if none is available or 4.33 - Removal or installation of,
Fig
[Note that al cylinder bores must be re-bored, even if only one of the bores is
ouside the diameter limit. A tolerance of 0.20 mm is permissible. the wear
| outside the limits, it is possible to have new cylinder liners fitted to the
four dealer will advise you what can be done.
To measure the running clearance, determine the pistor
lamers as descibed above and calculate the diference between the
imensions.
a
difference is more than 0.12 mm, have the
ize pistons.
parts should be thoroughly inspected. Signs of seizure, grooves
‘part to be replaced. Check the pistons.
the connecting rod bots check their diameter at
In Fig, 137 tis Is smaller than given for he
tion, ref the bolt. A second check is carried out by ‘New connecting rods are supplied toget
-* bush and can be fitted as supplied.
Checking the Big End Bearing Clearance
in connection with the crankshaft (Section
These operations are described
fitted, check the piston crown markings to ensure the
fied. ifthe original pistons are fitted, arrange them in
with the eylinder number markings.
‘connecting rods have been replaced check the bottom of the big end
‘punch marks are stamped into the
Fig. 1.39 The arrow Inthe piston crown (1) must
{ate tv front end of tho engine when the locating
lugs for the Dearing shells (2) are on the LH. side
‘ofthe cylinder block.
“+ Insert the connecting rod into the piston
sure that the
failure (blueish colour) must not be refited
* ri
‘Gonnecing ond besring caps are matched to each cther and must be
+ Generously lubricate the piston pin
Sngine ol and insert into the ; ‘connecting rod, using thumb pressure only. Never heat the piston to ft
the piston pin. Fit the cirips to both sides ofthe piston, making sure of
‘their engagement around the groove. Move the piston up and down to
check for ftee movement,
‘+ Using a pair of piston ring pliers, fit the piston rings from the top of the
piston, starting with the bottom ring. The two compression rings could
bbe mixed up and Figs. 1.40 should be referred to avoid mistakes. Under
no citcumstances micup the upper and lower compression rings.
0p
crankpins are at bottom dead
rod assembles in the same
more for correct installation
It the engine operates with an EGR system, the pistons are cooled by oil
splash jets (if applicable, introduced for model year 1991 on 601/602
engines), engine) — Version 1
= Group 0 Cinder No.1
1
1.3.1.6. Pistons and Connecting Rods - Installation
‘Generously lubricate the cylinder bores with oil. Markings on connecting
rods-and bearing caps must be opposite each other. The arrows in the
piston crowns must face towards the front ofthe engine.
zt
46 -—
Group 1
“Group 2:
Nominal diameter - Group 0~ Gylnder No. to 4
208 mm ie a
Sep mm rc =
“Soup 60818. 0 28 mn
Note: Rept sos ae ot vail tis gine ed Cinder ines ne Sone
with nominal diameter. 7 iL /
ox wear, nail and across: wv 40 me (004i) 9 i 4
‘Max. out-ol-round or taper of bores: a) i= 6
New condfon 00131mm
wea at O05 mm DP 6
Meas pit bes ‘As for oer enpes 4 r
crankease \ -
Fermsetie uneveness ct * ig 4
Upper ernkase face 40m
Lower ark ae: paid asm Fig. 142 - View ofthe font ond ofthe eyndor Bock,
Diflerence between tera iowe Sein’ 10 men (0004 n) ‘tlt the lcaton ote various prt
1.3.2.1. Servicing
‘Special attention should be given to the eylinderbiock each time the
crankshaft has been removed, respective whether the bores are to be re-
machined or not.
Fig 1.41 ~ View of the rear end of
be obtained,
Tenace te steel ale a flows (8
esumed that he engin is ited:
Remove the of pump.
Remove the transmission and the
rod of 14
for wear. A five-efing epee
‘must point out that the special i Thoroughly clean the
‘stee! balls in position to ensure their correct seating, ae os fo seer Gi Ary ‘i
il galleries with compressed ait.
48 Fig. 1.44 — Fitting steel ball to the
cylinder block. The Insert shows the
+ Coat the ball-shaped recess of
the special drit with grease and
insert the ball
* Insert the steel bal
corresponding bore A
into position to its stop. Fig. 1.44 LZ
‘shows this operation
+ Refit the oil pump and the fywheel, reft the transmission and run the
engine. Check the area of the steel ball for leaks,
‘Measurement of the cylinder bores should be made in accordance with the E zi
data given in Sect and the instru oe
is started. Then start the engine and
ner as described
20. gives the distortion values.
oft it the sie ofthe
uth coda ae bot engin fey are be roused The
u irface of the cylinder block has also been modifi
On te se wer he ied ender
of 34mm ameter ros has and wees
ere ae to mor luge
rom Samet
2 A pag 36 mm
the block (shown with "i
also fitted to the rear end ("2", Fi
Welsh plugs can be replaced as follows:
/stem and remove all parts ob
i. transmission, intermediate flange,
ing the welsh plug
jection pump, ete.
8 swivelled by
Fig. 1.45 and
Fig. 1.46 ~The arrow shows the oll splash jt (engine with EGR
50 fan EGR system is fited, you wil find ol feed bores and oll cooling jets for
r the pistons. The jets are fitted at the position shown in Fig, 1.46. These
cylinder blocks cannot be fited to other models, Always seek advise fom
your Mercedes Dealer, if you are intending to fit a replacement cylinder
block,
1.3.3. CRANKSHAFT AND BEARINGS
1.3.3.0. Technical Data
eco anesaf placed with Nos, | and V journals (601) or an IV journals
(602) in"V" blocks
Main Bearing Journal Diameter - 601/602 engine:
‘Nominal :
Fermainbearngs nar
Fer big ond bentngs
Nominal <
‘strepair size
2nd repair size
5rd repair size:
‘th repair size
With of Joumal on ited Bearing
Nominal dimension: fe
{4.00 34.4 mm (with thrust washers)
‘3400: (wth flanged bearings)
Repair S28... “ven 34:59 me (wth rut washers)
1034.50 mm (wth anged bearings)
Crankshaft - Removal and Installation
Crankpin Diameter ~ 6011602 engines:
Nominal dimension. > 47.980 — 47.965 mm reried So take ois fe Ciel
etropair sae 47.000 47.715 mm ines,
2 ‘mark
faces with the bearing
Lift the crankshaft out of the eyinder block and remove the remaining
“rom the centre bearing location and the remaining
is together with the lower shell
‘an oil bore and a groove
'se when the crankshaft is installed.
wufactured before
9 cap bolts with double hexagon and shoulder the bolts to 5.5 kgm (396 fulb.) and then angle-tigten them a further 90 ~
100°. Bearing caps are offset and can only be fitted in one position.
Fig. 1.60 - Measuring the Inside
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