AR88.10-S-1300A Removing and installing inner fender in front fender 28.2.

97
MODEL 638

1 Plastic nut
2 Mounting screw
3 Inner fender

S88.10-2501-11

ed Removal, installation
1 Unscrew mounting nuts (1)
at top of wheelhouse
2 Unscrew mounting screw on inside i Plastic screw with spreading plug
3 Unscrew mounting screw (2) from beneath
4 Remove inner fender (3)
5 Reinstall in opposite order

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR05.10-S-4650A Removing and installing intermediate gear of high pressure pump 17.9.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 KW)
with CODE (MQ5) Engine OM611 DE22 LA (90 KW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 KW)

S05.10-2507-09
1 Exhaust camshaft 9 Chain tensioner 17 Vacuum pump
2 Inlet camshaft 10 Seal 18 Bolt
3 Retaining pin 11 Cylinder head cover 19 Dowel pin
4 Front cover at cylinder head 12 Slide rail in cylinder head Y20 Injector 1
5 Inlet camshaft sprocket 13 Bolt Y21 Injector 2
6 Exhaust camshaft sprocket 14 Intermediate gear of high Y22 Injector 3
7 Guide pin pressure pump Y23 Injector 4
8 High pressure pump 15 Liner
16 Fuel pump

ed Removing, installing
1 Disconnect ground lead from battery AR54.10-S-0005A
2 Remove injectors (Y20, Y21, Y22, Y23) AR07.16-S-1000A
3 Remove cylinder head cover (11) AR01.20-S-5014D
4 Position piston of cylinder 1 to ignition TDC p Rotate engine at crankshaft. Do not AR01.00-S-0120D
crank engine at the bolt of the camshaft
sprocket. Do not crank engine back.
i Markings of camshaft/camshaft bearing
cap must be aligned.
5 Install retaining lock for crankshaft/starter ring AR03.30-S-5000C
gear
6 Lock inlet camshaft (2) i Insert the retaining pin (3) through the 1st
camshaft bearing cap into the hole (A) in the
inlet camshaft sprocket (5).
l *111589031500
N Remove chain tensioner (9) p Installation: Replace seal (10). AR05.10-S-7800D
8 Remove front cover at cylinder head (4) AR01.30-S-5700A
9 Remove slide rail in cylinder head (12) AR05.10-S-8432A
10 Remove high pressure pump (8) AR07.02-S-1020A
11 Mark camshaft sprocket (6) relative to timing
chain
12 Unbolt camshaft sprocket (6) from exhaust p Installation: Replace bolts of camshaft
camshaft (1) sprocket (13).
n *BA05.10-P-1003-01A
l *001589760900
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
13 Take off exhaust camshaft sprocket (6) i Pay attention to guide pin (7).
Take off exhaust camshart sprocket (6) with
timing chain fitted on. Protect timing chain
from dropping down after removing the
exhaust camshaft sprocket (6).

14 Unscrew bolts at intermediate gear of high n *BA05.10-P-1005-01A

pressure pump (14)
l *001589760900
15 Take out intermediate gear of high pressure
pump (14) together with liner (15)
16 Install in the reverse order
g Inspecting
17 Inspect basic position of the camshafts, set if AR05.20-S-6010C
necessary
18 Set the basic position of camshafts AR05.20-S-6020B
a Danger! Risk of accident from vehicle starting off by Secure vehicle to prevent it moving off by AS00.00-Z-0005-01A
itself when engine running. Risk of injury itself.
from bruises and burns if you hold your hand Wear closed and close-fitting work clothes.
into engine when it is started or when it is
Do not grasp hot or rotating parts.
running.
19 Run engine and inspect for oil leaks
a Danger! Risk of explosion from fuel igniting. Risk of Keep sources of ignition away from the AS07.16-Z-0001-01A
injury to skin and eyes from fuel jet flowing hazardous area.
out Do not carry out any work on the system
when it is pressurized.
20 Run engine and inspect fuel system for leaks

n Timing chain, chain tensioner

Number Designation Engine

611.980

BA05.10-P-1003-01A Bolt of camshaft sprocket to exhaust camshaft Nm 18

BA05.10-P-1005-01A Bolt of intermediate gear of high pressure pump to Nm 40

cylinder head

111 589 03 15 00 602 589 00 33 00 611 589 00 33 00 611 589 00 68 00

Retaining pins Impact extractor Extraction claw Round brush

000 589 26 68 00 001 589 76 09 00

Brake caliper brush External Torx set

Repair materials

Number Designation Order number

BR00.45-Z-1036-06A Special grease A 001 989 42 51 10

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2
AR88.00-S-2302A Removing and installing lock cross member 5.5.95
MODEL 638.0 /1 /2

S88.00-2500-09
1 Engine hood lock 3 Front grille mount 4 Lock cross member
2 Holder for supply reservoir

ed Removal, installation
1 Unscrew holder for supply reservoir (2) for
power steering pump
2 Unscrew screws for mounting front grille (3)
3 Unscrew lock cross member (4) n *BA88.00-N-1001-01A
4 Remove lock cross member (4) i Installation: Insert rod for fastening
radiator into lock cross member
5 Unhook control cable on engine hood lock
(1)
6.1 Remove engine hood lock (1) i Only when replacing lock cross member AR88.40-S-3200A
7 Install in opposite order

n Lock cross member

Number Designation Model

638

BA88.00-N-1001-01A Lock cross member screws on body Nm 25

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR09.20-S-1330A Removing and installing mixing housing with exhaust gas recirculation 15.10.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

S09.20-2510-09
1 Vacuum hose 7 Vacuum hose 13 Nut
2 Mixing housing 8 EGR valve 14 Bolt
3 Vacuum pump 9 Throttle flap valve 15 Intake manifold
4 Bolt 10 Fuel filter 16 Oil filler pipe
5 Vacuum hose 11 Bolt 17 Seal
6 Vacuum hose 12 Bolt 18 Screw clip

ed Removing, installing
1 Disconnect ground cable at battery AR54.10-S-0005A
2 Remove air cleaner crosspipe AR09.10-S-8031A
3 Take off screw clip (18) at charge air hose i Expose charge air hose (1)
(1) to mixing housing (2) and detach charge
air hose (1)
k *WH58.30-Z-1001-06A
4 Remove vacuum hose at vacuum pump (3)
5 Unscrew bolt (4) at bracket of fuel filter (10) l *001589760900
to mixing housing (2)
6 Unscrew bolt (11) at rear bracket to mixing n *BA09.20-P-1008-01A
housing (2)
l *001589760900
7 Detach vacuum hoses (5, 6, 7) i Pay attention to installation position of
vacuum hoses
8 Unscrew nut (13) at EGR valve (8) to i Installation: replace self-locking nuts
exhaust gas heat exchanger (6) (13). Replace gasket.
n *BA14.20-N-1004-01C
9 Unscrew bolts (14) at mixing housing (2) to n *BA09.20-P-1007-01A
intake manifold (15)
l *001589760900
10 Remove intake manifold (15) together with p Ensure scrupulous cleanliness
EGR valve (8)
i Installation: replace seals (17)
11 Install in the reverse order

n Intake manifold

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
 Number Designation Engine
611.980

BA09.20-P-1007-01A Bolt of mixing housing to intake Nm 8

manifold

BA09.20-P-1008-01A Bolt of mixing housing to rear bracket Nm 8

n Exhaust gas recirculation

Number Designation Engine

611.980

BA14.20-N-1004-01C Nut of intermediate pipe to EGR valve Nm 8

001 589 76 09 00
External torx set

Commercially available tools

Number Designation
WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose clamps with worm drive

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2
AR13.22-S-1202B Removing and installing poly V-belt 16.10.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

1 Poly V-belt
2 Tensioning device
3 Tensioning pulley
4 Pin

S13.22-2503-06

e Removing
1 Slacken poly V-belt (1) AR13.22-P-3902-01HB
2 Take off poly V-belt (1) p Slacken tensioning device (2) when
working on engine or on timing case cover.
Inspect belt pulley for dirt and damage,
replace if necessary.
Inspect poly V-belt (1) i Inspect poly V-belt, replace if necessary
according to condition
d Installing
3 Fit on poly V-belt (1) i Do not use belt wax or similar products
Running diagram of poly V-belt AR13.22-P-3902-02HB
4 Tension poly V-belt (1) AR13.22-P-3902-04HB

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR22.10-S-1160B Removing and installing rear engine mount 19.10.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

1 Bolt
2 Rear engine mount
3 Bolt
4 Axle-engine subframe
5 Bearing cap of middle drive shaft

S22.10-2509-06

ed Removing, installing
1 Unscrew bolt (4) together with nut of rear n *BA22.10-N-1006-01I
engine mounts (2) at axle-engine subframe
2 Unscrew bolt (1) together with nut of rear n *BA22.10-N-1007-01I
engine mount (2) at bearing cap of center
input shaft (5)
3 Remove rear engine mount (2)
4 Install in the reverse order

n Engine mounts, engine supports

Number Designation Model 638 with

Engine 611.980

BA22.10-N-1006-01I Bolt with nut of torque support to axle-engine Nm 106

subframe

BA22.10-N-1007-01I Bolt with nut of torque support to rubber mount of Nm 106

generator support

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR15.30-S-7100C Removing and installing starter 18.10.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 KW)
with CODE (MQ5) Engine OM611 DE22 LA (90 KW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 KW)

1 Nut
2 Nut
3 Bolt
4 Cable

M1 Starter

S15.30-2507-06

ed Removing, installing
1 Disconnect ground cable from battery AR54.10-S-0005A
2 Unscrew nut (1) at cable (4) of starter (M1) n *BA15.30-N-1002-01G
3 Unscrew nut (2) at cable (4) of starter n *BA15.30-N-1003-01G
4 Run cables (4) out of screw stud of starter i Expose cables (4).
(M1)
5 Unscrew bolt (3) of transmission at starter i Hold starter tight.
(M1)
n *BA15.30-N-1001-01G
6 Lift starter (M1) up and out
7 Install in the reverse order

n Starter

Number Designation Engine

611.980

BA15.30-N-1001-01G Bolt of starter to crankcase Nm 53

BA15.30-N-1002-01G Nut of connection circuit 30 Nm 20

BA15.30-N-1003-01G Nut of connection of circuit 50 Nm 7

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR43.05-S-1320B Removing and installing vacuum pump 15.6.98
MODEL 638.094 /194 /294 with ENGINE 611.980
with CODE (MQ4) engine OM611 DE22 LA (75 KW)
with CODE (MQ5) engine OM611 DE22 LA (90 KW)
MODEL 638.094 /194 with ENGINE 611.980 with CODE (MQ3) engine OM611 DE22 A (60 KW)

1 Vacuum line
2 Vacuum pump
3 Detent
4 Bolt
5 Sealing ring
6 Engine support

S43.05-2500-12

ed Removing, installing
1 Remove engine support (6) i AR22.10-S-1200B
2 Detach vacuum line (1) from vacuum pump p Press together detent (3) and pull off
(2) vacuum line (1).
i Operate the brake pedal a few times to
reduce the vacuum.
3 Unscrew bolt (4) from vacuum pump (2) n *BA43.05-N-1003-01A
l *001589760900
4 Remove vacuum pump (2) p Installation: Clean sealing surfaces,
replace sealing ring (5).
Pay attention to position of driver on the back
of the pump.
5 Install in reverse order

n Vacuum pump

Number Designation Engine

611.980

BA43.05-N-1003-01A Bolt, vacuum pump to cylinder head Nm 14

001 589 76 09 00

External Torx set

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR05.10-S-7800D Removing, installing chain tensioner 25.5.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 KW)
with CODE (MQ5) Engine OM611 DE22 LA (90 KW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 KW)

1 Chain tensioner
2 Seal
3 Guide pulley
4 Bolt
5 Bracket
6 Bolt
7 Cover

Y75 Electric shutoff valve

S05.10-2506-06

ed Removing, installing
1 Remove guide pulley (3) AR13.22-S-0001B
2 Position piston of cylinder 1 to ignition TDCp Rotate engine at crankshaft. Do not AR01.00-S-0120D
rotate engine at the bolt of the camshaft
sprocket. Do not crank engine back.
a Danger! Risk of explosion from fuel vapors igniting. No fire, naked flames or smoking. Avoid AS47.00-Z-0001-01A
Risk of poisoning from enhaling fuel vapors sparks.
and open working with fuel. Risk of injury Pour fuels only into canisters provided for
from fuel splashing into eyes. this purpose, and store in such canisters.
Wear protective gloves and, if necessary,
eye protection when handling fuel.
3 Detach electric shutoff valve (Y75) AR07.16-S-1040A
4 Unscrew bolt (6) of bracket (5) of fuel supply n *BA07.16-P-1012-01A
shutoff valve (Y75) at timing case cover
l *001589760900
5 Remove chain tensioner (1) i Installation: Replace seal (2).
i Before installing, fill chain tensioner with
engine oil. Position chain tensioner with
thrust pin facing down in engine oil until it is
over the collar at the hexagon. Use a press
or column drill to slowly depress thrust pin
fully 7 - 10 times.
After filling, it must be possible to compress
the chain tensioner slowly and evenly only by
using considerable force.
l *000589109900
n *BA05.10-P-1004-01A
6 Install in the reverse order
g Inspecting

a Danger! Risk of accident from vehicle starting off by Secure vehicle to prevent it moving off by AS00.00-Z-0005-01A
itself when engine running. Risk of injury itself.
from bruises and burns if you hold your hand Wear appropriate workclothes when carrying
into engine when it is started or when it is out work on the vehicle.
running.
N Run engine and inspect for leaks
Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
n Timing chain, chain tensioner

Number Designation Engine

611.980

BA05.10-P-1004-01A Chain tensioner to timing case cover Nm 80

n Common rail diesel injection (CDI)

Number Designation Engine

611.980

BA07.16-P-1012-01A Bolt of bracket of fuel supply shutoff valve to Nm 12

timing case cover

000 589 10 99 00 001 589 76 09 00

Tool kit External Torx set

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2
AR01.20-S-5014D Removing, installing cylinder head cover 25.8.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

1 Injection line
2 Bolt
3 Tensioning claw
4 Bolt
5 Cylinder head cover
6 Cylinder head
7 Bracket
8 Camshaft Hall sensor
9 Gasket
10 Gasket
11 Leak oil line
12 Locking element
13 Bolt
14 Seal

Y20 Injector 1
Y21 Injector 2
Y23 Injector 3
Y24 Injector 4

S01.20-2502-06

ed Removing, installing
a Danger! Risk of explosion from ignition. Risk of
poisoning from inhaling and swallowing fuel.
Risk of injury as a result of fuel coming into
contact with skin and eyes.
1 Remove injectors (Y20, Y21, Y22, Y23)
Notes on injectors
2 Take off bracket (7) of EGR valve at the
cylinder head cover (5)
3 Unplug connector at camshaft Hall sensor (8)
4 Unplug lines running over cylinder head
cover (5)
No fire, naked flame or smoking. AS47.00-Z-0001-01A
Pour fuels only into suitable and
appropriately marked containers.
Wear protective clothing when handling fuel.
p Installation: to avoid any stresses AR07.16-S-1000A
occurring when installing the injection lines,
these should be fitted on properly before
installing the injectors
l *602589003300
l *611589013300
l *611589006800
l *000589266800
l *001589760900
p Clean injector recesses and nozzles with aAH07.16-P-1000-01A
wire brush. Grease injector recesses with
special grease, clean injector recesses with a
round brush and cylinder brush, blow out and
cover over. Seal nozzle recesses with a pin
before cleaning.
i Set brush length to about 3 mm for
cleaning the sealing seat.
p Replace injector seal (14) and bolts (2) of
the tensioning claws (3).
Special grease *BR00.45-Z-1036-06A
n *BA01.20-P-1004-01A
l *001589760900
i Place lines to the side

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
5 Unscrew bolts (4) of cylinder head cover (5) p Installation: do not fully tighten bolts (4)
as injectors (Y20 - Y23) are aligned by
means of the cylinder head cover (5).
Otherwise, this may result in gas leakages
and the injectors (Y20 - Y23) baking tight in
the cylinder head (6), and may also result in
impermissible stresses in the injection lines
(1).
n *BA01.20-P-1001-01A
l *001589760900
6 Remove cylinder head cover (5) i Installation: clean sealing surfaces.
Replace gaskets (9, 10) of cylinder head
cover (5). Ensure scrupulous cleanliness.
7.1 Remove camshaft Hall sensor (8) i Only if cylinder head cover is replaced AR15.10-S-2000B
8 Install in the reverse order

n Crankcase ventilation, cylinder head cover

Number Designation Engine

611.980

BA01.20-P-1001-01A Bolt of cylinder head cover to cylinder head Nm 9

BA01.20-P-1004-01A Bolt of bracket to cylinder head cover Nm 16

000 589 26 68 00 001 589 76 09 00 602 589 00 33 00 611 589 00 68 00

Brake caliper brush External torx set Impact extractor Round brush

611 589 01 33 00
Extraction claw

Repair materials
Number Designation Order number
BR00.45-Z-1036-06A Special grease A 001 989 42 51 10

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 2
AR01.20-S-5015A Removing, installing trim panel of cylinder head cover 16.9.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

1 Mixing housing with exhaust gas

recirculation
2 Bolt
3 Bracket
4 Cylinder head cover
5 Bolt
6 Trim panel of cylinder head cover
7 Crankcase ventilation hose

S01.20-2503-06

ed Removing, installing
1 Remove mixing housing with exhaust gas AR09.20-S-1330A
recirculation (1)
2 Remove bolts (2) of bracket (3) at cylinder n *BA01.20-P-1004-01A
head cover (4)
l *001589760900
3 Remove bolts (5) of trim panel of cylinder n *BA01.20-P-1002-01A
head cover (6)
l *001589760900
4 Remove trim panel of cylinder head cover (6) i Installation: ensure that the crankcase
ventilation hose (7) is correctly inserted
5 Install in the reverse order

n Crankcase ventilation, cylinder head cover

Number Designation Engine

611.980

BA01.20-P-1002-01A Bolt of trim panel of cylinder head cover to Nm 10

cylinder head cover

BA01.20-P-1004-01A Bolt of bracket to cylinder head cover Nm 16

001 589 76 09 00
External torx set

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR01.00-S-0120D Rotate the engine from the front part of the crankshaft 17.8.98
ENGINE 611.980 in MODEL 638.094 /194 /294
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
ENGINE 611.980 in MODEL 638.094 /194 with CODE (MQ3) Engine OM611 DE22 A (60 kW)

1 Belt pulley/vibration damper

S01.00-2503-12

ed Removing, installing
1 Separate ground cable from battery
2 Rotate crankshaft with the bolt of the belt p Always rotate in direction of running of
pulley/vibration damper (1) engine
3 Install in the reverse order

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR13.22-P-3902-02HB Running diagram of poly V-belt

Illustrated on engine 611, belt drive without coolant compressor

1 Tensioning pulley
2 Crankshaft
3 Coolant pump
4 Alternator
5 Guide pulley
7 Power steering pump

P13.22-0267-01
Illustrated on engine 611, 612.961/962/963/967/990, belt drive with coolant compressor

1 Tensioning pulley
2 Crankshaft
3 Coolant pump
4 Alternator
5 Guide pulley
6 Refrigerant compressor
7 Power steering pump

P13.22-0268-01
Shown on ENGINE 612.965/966, belt drive, with coolant
compressor

1 Tensioning pulley
2 Crankshaft
3 Coolant pump
4 Alternator
5 Guide pulley
6 Refrigerant compressor
7 Power steering pump
8 Guide pulley

P13.00-2032-11
Illustrated on engine 613, 646, 647, 648, belt drive with coolant compressor

1 Tensioning pulley
2 Crankshaft
3 Coolant pump
4 Alternator
5 Guide pulley
6 Refrigerant compressor
7 Power steering pump
8 Guide pulley

P13.22-2013-01

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR13.22-P-3902-01HB Slacken poly V-belt
y Pin for locking poly V-belt tensioning device
Engine 611.960/961/962/980, WF58.50-P-1325-02A
612.961/962/963/965/966/967/990,
613.960/961, 646.951/961/962/963,
647.961, 648.960/961
1 Turn front part of tensioning device (1) in anti-clockwise direction (arrow) against the
force of the spring.

P13.22-0270-01
2 Insert pin (2) (shop-made tool) in the turned end position through the holes positioned
one above the other, into front part (1) and housing (3) in order to lock tensioning pulley
(4) in this position.

P13.22-0272-01

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR13.22-P-3902-04HB Tension poly V-belt
y Pin for locking poly V-belt tensioning device
Engine 611.960/961/962/980, WF58.50-P-1325-02A
612.961/962/963/965/966/967/990,
613.960/961, 646.951/961/962/963,
647.961, 648.960/961
1 Pull pin (2) (shop-made tool) out of the holes in the front part (1) and housing (3) of the
tensioning device in order to be able to turn tensioning pulley (4) into the initial position.
i Hold front part (1) of tensioning device tight when removing the pin (2) in order to
prevent the tensioning pulley (4) snapping back suddenly.

P13.22-0273-01
2 Slowly turn front part (1) of tensioning device in clockwise direction (arrow) until the poly
V-belt is automatically tensioned by the force of the spring.

P13.22-0271-01

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR01.30-P-5800-01HB Tightening diagram of cylinder head bolts

n Cylinder head tightening torques

Number Designation Engine Engine Engine

611.960/ 611.962 611.980
961

BA01.30-P-1005-01A Bolt of cylinder head to timing case cover M8 NM 20 20 20

BA01.30-P-1006-01A Bolt of front cover to cylinder head NM 14 14 14

BA01.30-P-1007-01A Bolt of cylinder head to crankcase 1st stage NM 60 60 60

2nd stage E° 90 90 90

Step 3 E° 90 90 90

n Cylinder head tightening torques

Number Designation Engine

611.981/
983/987

BA01.30-P-1005-01A Bolt of cylinder head to timing case cover M8 NM 20

BA01.30-P-1006-01A Bolt of front cover to cylinder head NM 14

BA01.30-P-1007-01A Bolt of cylinder head to crankcase 1st stage NM 60

2nd stage E° 90

Step 3 E° 90

p It is essential to pay attentio to the

following order when tightening the bolts:

1 Tighten bolts (15) to stage 1.

2 Tighten bolts (14).

3 Tighten bolts (15) to stage 2.

4 Inspect bolts (14), correct if necessary.

5 Tighten bolts (15) to stage 3.

i Slacken in the reverse order.

Tightening diagram/bolt assignment

Engine 611

14 Hexagon socket bolts M8 _90

P01.30-0337-05
(to timing case cover)
15 External torx bolt M12 _102

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1
AR05.20-P-6992-05A Unbolting camshaft bearing caps

n Camshaft

Number Designation Engine

611.960/961/962/980/
981/983/987
612.961/962/963/965/
966/981/990
613.960/961

BA05.20-P-1001-01F Bolt of camshaft bearing cap to cylinder head Nm 9

1 Remove camshaft bearing caps at bearing points 1,3,5 and also 6,8,10 (arrows).

p Pay attention to marking of bearing caps!

P05.20-0343-01
2 Slacken bolts of camshaft bearing caps 2,4 and 7,9 (arrows) in steps each of one turn
until the backpressure is eliminated.

p Camshafts must not be tilted when slackening the camshaft bearing caps.

3 Remove camshaft bearing caps (arrows).

P05.20-0349-01

Copyright Daimler AG 12/15/11 G/06/08. This WIS printout will not be recorded by the update service. Page 1