Om602603 Engine Service Manual

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Mercedes-Benz
Mercedes-Benz of North America, Inc. . Montvale, NJ 07645

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Q Mercedes-Benz of North America, Inc., 1991
All rights reserved. Reproduction by any means, elec-

tronic or mechanical, including photocopying, record-
ing, 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 LZ S-2517-091

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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 repair
procedures and Mercedes-Benz vehicles. You should not attempt to use this manual if this is not
the case.
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
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G r o u p Index
General, Technical Data 00
Crankcase and Cylinder head 01
Crankshaft Assembly 03
ngine Timing, Valvetrain 05
Diesel Injection System 07.1
Air Intake System - Air Filter, Turbocharger 09
elt Drive 13
Intake and Exhaust Manifolds, mission Control System 14
Electrical System, Preglow 15
ngine Lubrication System 18
ngine Cooling System 20
Engine Suspension 22
Accelerator Control 30
Fuel Tank and Lines 47
Exhaust System 49
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General, technical data 00

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General, technical data 00
Job No.
Instructions for use of service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 - 005

Engine and vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 010
Vehicle identification number locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 015
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 020
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Instructions for use of servic 00-005
Complete Service Manual coverage for late Location of specific repair instructions
model year Mercedes-Benz vehicles requires
four individual manuals: First locate the Group No. in the Group Index.
Individual groups are separated by an easily
Service Manual, Engine visible dividing page, which is followed by the job
Service Manual, Chassis and Body index page. The exact job required is found in
Service Manual, Automatic Climate Control the job index. The initial page of a typical job
Electrical Troubleshooting Manual description appears as follows:
Throughout these manuals, the vehicles are 03-320 Installation of Crankshaft

identified by their chassis and engine numbers.
These numbers are made up of the first six digits Job Title appears on
of the respective serial number. For the actual same line as Group
location of chassis and engine numbers, see No.
page 00-015/l. 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 124.128 would apply
only to model 3000 2.5 Turbo.
03.9-320/l
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.
Special Instructions
AWarning Appears throughout service instructions indicating the possiblity of personal injury
if procedures are not followed.
Caution! Indicates possible equipment or vehicle damage if procedures are not followed.
Note Provides helpful information for the described procedure.
Installation note Provides detailed information during assembly.

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00 ngine and vehicle identification
Model I Sales designation I Engine

201.126 190 D 2.5 602.911
126.125 300 SDL Turbo (Federal) 603.961
126.125 300 SDL Turbo (California) 603.961
201.126 190 D 2.5 602.911
201.128 190 D 2.5 Turbo (Federal) 602.961
124.133 300 D Turbo 603.960
124.193 300TD Turbo 603.960
126.125 300 SDL Turbo 603.961
201.126 I 190 D 2.5 (Federal) I 602.911
201.126 I 190 D 2.5 (Federal) I 602.911
124.128 300 D 2.5 Turbo (Federal) 602.962
124.128 300 D 2.5 Turbo (Federal) 602.962
126.134 350 SD Turbo (Federal) 603.970
00 - 010/l
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hick identification number locations 00
Model 201
When ordering spare parts, please

specify chassrs and engine numbers.
1 Certrfication Tag (left door pillar)

2 Identification Tag (left windshield post)
3 Vehicle Identificatron No.
4 Engine No.
5 Body No. and Paintwork No.
6 InformatIon Tag
California version
Vacuum line routing for emission
control system
7 Emrsslon Control Tag
Model 124

specify chassis and engine numbers.
1 Certification Tag (left door pillar)

2 Identification Tag (left window post)
3 Vehicle Idenkficatron No.
4 Engine No.
6 lnformatron Tag
California version
Vacuum line routing for emission
control system
7 Emission Control Tag
8 Emrssron Control Tag
Catalyst Information
00 - 015/l
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Vehicle identification number locations
Model 124 f

specify chassrs and engine numbers.
1 Certrfication Tag (left door prllar)

2 ldentrftcatronTag (left wrndshreld post)
3 Vehicle ldentifrcatron No.
4 Engine No.
6 lnformatron Tag
Caltfornia version
Vacuum line routing for emrssron
control system
7 Emrssron Control Tag
Model 126
When ordenng spare parts, please

specrfy chassis and engine numbers.
Certification Tag (left door pillar)

ldentlficatron Tag (left wrndow post)
Vehicle ldentrfication No.
Engrne No.
Body No. and PaMwork No.
Emrssron Control Tag
lnformatron Tag
California version
Vacuum lrne routing
for emrssron control system
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Technical data
Diesel engines
axlmum spee 4600 t 50
120/4600
G(multi-component, 6 (multi-component,
pump, thermosta pump, thermosta pump, thermosta pump, thermosta

with bypass line, fan with bypass line, fan with bypass line, fan with bypass line, fan
with visco fan clutch, with visco fan clutch, with visco fan clutch,
00 - 020/l
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00 Technical data
Gasoline engines
Model i 126.125 1126.125 1 126.134 I.135
4-cycle diesel, MB 4-cycle diesel, MB 4-cycle diesel, MB
arranqemen
Bore/stroke mm I 87.0184.0 I 87.Oi84.0 I 89.0192.4
Total effective 2996 2996
piston
displacement cc
Compression
ratio
Engine output 11 O/4600 1071’4600

(SAE)kW/rpm 14814600 143) 4600
net bhp/rpm
Maximum torque 27312400 265/2400 3 1 o/2000
Nmirpm 20112400 195/2400 22812000
net lb-ft./rpm
Crankshaft 7 (multi-component, 7 (multi-component, 7 (multi-component,
bearings anti-friction bearings) anti-friction bearings) anti-friction bearings)
Valve Overhead Overhead Overhead
arrangement
Camshaft 1 overhead camshaft 1 overhead camshaft 1 overhead camshaft
arrangment
Cooling Coolant circulating Coolant circulating Coolant circulating

pump, thermostat pump, thermostat pump, thermostat
with bypass line, fan with bypass line, fan with bypass line, fan
with visco fan clutch, with visco fan clutch, with visco fan clutch,
finned tube radiator finned tube radiator finned tube radiator
Lubrication Pressure lubrication Pressure lubrication Pressure lubrication
via gear type pump via gear type pump via gear type pump
Oil filter Combination full flow Combination full flow Combination full flow
1 and bypass filter 1 and bypass filter and bypass filter
Air cleaner Dry paper cartridge Dry paper cartridge Dry paper cartridge
00 - 02012
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Technical data cm
Filling capacities
Model 201.126 201.128 124.128 124.133, 126.125
I (Federal) (Federal) I 124.193 I (Federal)
Sales designation 190 D 2.5 190 D 2.5 300 D 2.5 300 D Turbo 300 SDL Turbo
Turbo Turbo 300 TD Turbo
Engine 602.911 602.961
-r-m ~ 602.962 I 603.960 I 603.961
~~~
Fuel tank/reserve
aoorox. I
7019.0
I 7019.0
72/l 0.0 I 90112.5
Engine oil initial filling 8.2 9.2 9.2

approx. I I I
During oil and filter 7.0 8.0 8.0
change approx. I I I
Marks on dipstick 5.513.5 6.0/4.0 6.Oi4.0 6.5i4.5 6.514.5
max./min. approx. I I I
Oil-to-air cooler with 0.7 1.1 0.65
hoses I I
Cooling system with 8.0 8.0 9.0 10.0 12.5
heater
approx. I
Filling capacities (continued)
~350 SDL Turbo

Engine 603.961 603.970
Fuel tan k/reserve 90/l 2.5 90/l 2.5
approx. I
Engine oil initial filling
approx. I
During oil and filter 8.0 7.5
change approx. I
Marks on dipstick 6.514.5 6.514.5
max./min. approx. I
Oil-to-air cooler with 0.65 0.65
hoses
Cooling system with
heater
aoorox. I
00 - 02013
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00 Technical data
Electrical system
Model 201.126 201.128 124.128 124.133, 126.125
(Federal) (Federal) 124.193 (Federal)
Sales designation 190 0 2.5 300 D 2.5 300 0 Turbo 300 SDL Turbo
Turbo Turbo 300 TD Turbo
Engine 602.911 602.961 602.962 603.960 603.961
Battery
Voltage 12v 12 v 12v 12v 12v
Capacity 62 Ah 92 Ah 92 Ah 92 Ah
(M.Y. 1986)
92 Ah (from
M. Y. 1987)
Starter Bosch 12 v 12V 12v
2.2 kW 2.2 kW 1.5 kW
Alternator 14V70A 14V70A 14V70A 14V70A 14v 80A
Electrical system
Model 126.125 126.134.1.135
I (California) (Federal)
Sales designation 300SDL Turbo 350 SD Turbo
350 SDL Turbo
603.970
Battery
Voltage 12v 12v
Capacity 62 Ah 62 Ah
Starter Bosch 12 v 12v
2.2 kW 1.7 kW
Alternator I 14V70A I 14v 80A
0 0 - 020/4
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Crankcase and Cylinder Head 01

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01 Crankcase and cylinder head
Job No.
Engine and model survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 - 001

Removal and installation of noise capsule at bottom of engine compartment . . . . . . . . . . . . 01 - 006
Opening hood, setting vertical warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 - 008
Testing compression pressure ............................................. - 010
Checking cylinders for leaks ............................................... - 015
Evaluating cylinder bores ................................................. - 020
Removal and installation of engine (oil capacity) ................................. - 030
Crankcase ventilation - Function ............................................ - 040
Measuring, boring and honing cylinder bores ................................... - 110
Boring, honing and replacement of cylinder sleeves .............................. - 115
Planing crankcase parting surface ........................................... - 120
Removal and Installation of steel balls in main oil duct ............................ - 130
Replacement of freeze plugs in crankcase ..................................... - 140
Removal and installation of timing cover ...................................... -210
Removal and installation of end cover ........................................ - 222
Removal and installation of oil pan .......................................... - 310
Repair notes for cylinder heads and cylinder head gaskets ......................... - 400
Refinishing prechamber sealing surface ....................................... - 410
Removal and installation of cylinder head ..................................... - 415
Removal and installation of prechambers ...................................... - 417
Facing cylinder head mating surface ......................................... - 418
Boring out camshaft bearing bores (repair stage) ................................ - 419
Pressure-testing cylinder head ............................................. - 420
01/l
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01-001 Engine and r?lodel suwey
output Torque (SAE)

Engine Vehrcle Sales No. Displacement Bore I
& (SAE) Nm/rpm
version model desrgnation Cyl. (cm? Stroke
Kw(hp)/rpm (net lb.-fthpm)
190 D 2.5 84.0 187.0 6914600 165 12800

602.911 201.126
I 22.0
2497
(93 14600) (12212800)
602.961 201.128 5 84.0 187.0 92 14600 22812400

Federal (12314600) (16812400)
602.962 124.128 5 84.0 187.0 90 14600 223 / 2400

Federal (120/4600) (164 / 2400)
603.960 124.133 6 2996 84.0 187.0 107/4600 265 12400

124.193 300 TD Turbo (14314600) (195 / 2400)
603.961 126.125 6 2996 87.0 / 84.0 110/4600 273 /2400

Federal (148 /4600) (201 / 2400)
603.961 126.125 6 2996 87.0 184.0 107 /4600 265 12400

California (143/4600) (195 12400)
603.970 126.134 350 SD Turbo 22.0 6 89.0 192.4 100/4000 310 12000
Federal 126.135 350 SDLTurbo (133/4000) (228 12000)
1.10 - 001/l
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Model 201
Noise capsule at bottom of engine compartment, front (1) Noise capsule at bottom of engine compartment, rear (2)
Noise capsule, front and rear (1, 2) . . . . . . . . . . Remove sheet metal screws (arrows), reinstall
and remove capsule, install.
Note
Install engine compartment capsule so that
edges of side part of capsule engage in bottom
part of capsule.
01.10 - 006/2
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01-008 Opening hood, setting vertical, warnings
AWarning
There is risk of injury whenever the engine is
running and the hood is open.
Opening hood
1 To unlock the hood, pull the lever (533) on

the left below the instrument panel in the
direction of the arrow. The hood opens to the
safety hook stop.
Model126
Model 124
01.10 - 008/l
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2 Close hood by pushing down forcibly.
Model201
Model 124, 126, 201

3 Pull the handle (535) extending from the
grille as far as the stop and open hood (it may
be necessary to lift the hood slightly to release
the handle).
Note
Do not attempt to lift the hood with handle (535).
The windshield wiper arm must not be pivoted
forward when the hood is lifted.
Moving hood into vertical position
Model 124 (production up to August 1988)

4 Push lock lever (537) on the left hood
support (536) in direction of arrow. Lift hood
slightly upward to keep the lock lever (537) from
reengaging again.
Repeat the preceding at the right hood support
and set the hood in a vertical position.
5 To close the hood, push in lock lever at the

right hood support, and close the hood by
pushing down forcibly.
1.10 - 00812
EXIT
Model 126
6 Push hood down slightly. Push lock lever
(538) on the left hood support (539) down in the
direction of the arrow. Push hood up slightly to
keep the lock lever (538) from reengaging.
Repeat the preceding at the right hood support
and set the hood in a vertical position.
7 To close the hood, push the lock lever (538)

at the left hood support in the direction of the
arrow, and close the hood by pushing down
forcibly.
Model 201
8 Pull lock (541) on hood damper (540) in
direction of arrow and set the hood in a vertical
position.
9 When the hood is set vertical, a lock

engages on the left hood support.
10 Close hood. Push in the lock lever (arrow)

and close the hood by pushing down forcibly.
01 10 - 008/3
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01-010 Testing compression pressure
Engine ,.............................. warm up to operating temperature

(approx. 80 “C) (item 1).
Note
Check compression only with engine at
operating temperature.
Nozzle holder (1) ....................... remove, install (07-230).
Plug connector (X27) . . . . . . . . . . . . . . . . . . . . for starter harness, disconnect, reconnect
(items 3 - 4).
Note
The plug connector (X27) illustrated in the figure
is installed on model 124. The installation point
and version of the plug connector differs
depending on the model.
01.10 - 010/l
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Contact handle .... ...... .......... .. ... for compression pressure recorder
001 589 78 21 00, connect, adapter line
124 589 36 63 00 (items 3 - 5).
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turn over a number of times to clean out; the
transmission must be in neutral and the shutoff
lever on the injection pump pressed to “stop”
(item 6).
Compression pressure recorder (01) . . . . . . . . . bolt appropriate adapter (03) and flexible
connector (02) into precombustion chamber of
cylinder to be checked (item 7).
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . check; shift transmission to neutral and turn
engine over at least 9 revolutions with the
shutoff lever on the injection pump pushed to
“stop” (items 8 - 9).
Note
Check compression in remaining cylinders in
same manner.
Measured compression values .............. compare with specified test values (item 10).
Note
If one or more cylinders do not have the
minimum compression, determine cause.
Test values with engine at operating temperature (approx. 80 “C) bar

Compression pressure, normal 26 - 32
Minimum compression pressure approx. 18
Permissible difference between individual cylinders max. 3
Tightening torques Nm
Union nuts on injection lines (reference value) 10-20
Nozzle holders in prechambers 70+10
Nozzle holders for angular injection 30
01.10 - 01012
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Special tools
602 589 00 6300

ol !
Testing
1 Warm engine up to operating temperature

(approx. 80 “C).
Note
Check compression only with engine at
2 Remove all nozzle holders (07-230).
Models 124 and 126

3 Connect contact handle for compression
pressure recorder 001 589 78 21 00; disconnect
plug connector (X27) on left side of engine
compartment and connect connection line (04)
of contact handle to plug (Kl50) with adapter line
(124 589 36 63 00 (05).
Model124
Model126
01.10 - 010/3
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Model 201
4 Connect contact handle of compression
pressure recorder 001 589 78 21 00; disconnect
plug connector (X27) on left side of firewall and
connect connection line (04) of contact handle to
plug (Kl50) with adapter line 124 589 36 63 00.
5 Connect second connection line from

contact handle to positive pole (K130) on battery
(arrow).
6 Crank engine a number of times with starter

with transmission in neutral and shutoff lever on
injection pump (arrow) pressed to “stop” to
remove combustion residues in the
precombustion chamber of the cylinder.
Note
Always hold shutoff lever on injection pump
depressed when cranking engine. This prevents
fuel from being pumped and therefore running
out of the disconnected injection lines.
01.10 - 01014
EXIT
7 Bolt compression pressure recorder into pre-

chamber of cylinder to be tested with appropriate
adapter (03) and flexible connector (02).
Note
On engines with angular injection use adapter
602 589 00 63 00.
8 Crank engine at least 8 revolutions to test

compression.
9 Perform test on remaining cylinders in same

manner.
10 After completing the compression test

compare pressures measured with specified
values.
Note
If one or more cylinders do not have the
minimum compression pressure, check cylinder
for leakage (01-015) and determine cause.
11 Install in reverse order.
01.10 - OlO&
EXIT
01-015 Checking cylinders for leaks
PO1 4224-57
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . warm up to operating temperature

(approx. 80 “C) (item 1).
Nozzle holders (4) . . . . . . . . . . . . . . . . . . . . . . remove, install (07-230).
Coolant expansion tank (1) . . . . . . . . . . . . . . . . AWarning
Open cap (2) on coolant expansion tank only at
coolant temperatures below 90 “C.
Remove cap (2) install. Add coolant,

if necessary (items 3 - 4).
Air cleaner on naturally aspirated engines (6)
and on Turbo-engines (3) . . . . . . . . . . . . . . . . . remove air cleaner cover, install (item 5).
Oil filler cap (5) . ... .... .. . ... . . ......... remove, install (item 6).
01.10 - 015/l
EXIT
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . move piston of cylinder to be checked to TDC,

ignition stroke, connect and calibrate cylinder
leakage tester (items 7 - 9).
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . determine pressure loss (items 10 - 12).
Note
Check other cylinders in firing order.
Permissible pressure loss

Total, engine max. 25 %
Valves and cylinder head gasket max. 10 %

Piston rings max. 20 %
Union nuts on injection lines (reference value) 10-20
Nozzle holders in prechambers 70+10
Nozzle holders for angular injection 30
Special tool
1 000589650900
Commercially available tools

Cylinder leakage tester e.g. Bosch, EFAW 210 A
Sun, CLT 228
Adapters and connectors e.g. Bosch
Order no. 1 687 010 016
01.10 - 01512
EXIT
Testing
1 Warm engine up to operating temperature

(approx. 80 “C).
2 Remove all nozzle holders (07-230).
A Warning
Open cap on coolant expansion tank only at
coolant temperatures below 90 “C.
3 Remove cap on coolant expansion tank.
4 Check coolant level in coolant expansion

tank and add, if necessary.
5 Open retaining strap on air cleaner cover on

naturally aspirated engines or unscrew hex. head
bolts on air cleaner cap on Turbo-engines,
remove air cleaner cap and take out filter
cartridge.
6 Remove 011 filler cap.
7 Move piston in cylinder to be checked to

TDC, ignition stroke.
8 Bolt appropriate adapter (01) with straight or

angular connector (02) into precombustion
chamber of cylinder to be checked.
9 Calibrate cylinder leakage tester and bolt

connection hose (03) of tester onto connector
(02).
01.10 - 01X.3
EXIT
10 Fill cylinder with compressed air and read off

any pressure loss on tester.
11 If pressure is lost, determine cause; check

by listening whether pressure is exhausted
through cylinder head gasket, intake manifold,
exhaust, oil filler cap or prechambers of adjacent
cylinder(s) and check for formation of air bubbles
in coolant in coolant expansion tank.
Note
If pressure loss and air loss through the oil filler
cap are present , the possible causes can be
limited by spraying engine oil on the piston
crown of the cylinder being tested. The oil seals
the gap between the piston and cylinder. If
pressure loss is no longer present for a short
time, the cause is in all probability the piston,
piston rings or cylinder running surface.
The position of the piston ring gaps can result in

incorrect determination of the cause. If it is
suspected that the pressure loss results from the
piston ring gaps being positioned directly above
one another, completely reassemble engine and
repeat test after operating engine for a short
time.
01.10 - 01514
EXIT
12 Perform test on other cylinders in engine

ignition sequence.
lgnltlon sequence, engme 602
r-0 153624
lgnttlon sequence, engme 603 PO1-0117-13
13 Assemble in opposite order.
01.10 - 01515
EXIT
EXIT
valuating cylinder bores

Prellminaty operations:
Prechambers removed
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in cylinder to be tested, move to bottom dead

center.
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . illuminate cylinder with illumination unit and
check visually for damage; for this purpose
insert the probe (01) of the illumination unit
through the precombustion chamber bore into
the cylinder.
Note
When inspecting differentiate between ” Optical
stripes” and “Scoring”. “Optical stripes” can
result from the ring gap. if honing marks are still
visible, the engine is okay. “Scoring marks”
honing marks no longer visible, repair engine.
01.10 - 02011
EXIT
Commerciallv available tool

Cylinder illumination unit e. g. Karl Storz Gmbt-i,
D-7200 Tuttlingen
Motoskop TW (cold light)
with lens probes
103 26 CW (570 mm) and
103 26 CT (210 mm)
01.10 - 020/2
EXIT
01-030 emoval and installation of engine (oil capacity)
Preliminary operations:
Noise capsule part at bottom of engine compartment
removed (01-006).
Exhaust system removed (49-l 00).
emoval, installation, models 124, 126 and 201
POl-0225.57
Battery (120) . . . . . . . . . . . . . . . . . . . . , . , . disconnect positive and negative terminals,

reconnect (items 1 - 4).
Naturally aspirated engines:
Air intake hose (5) . . . . . . . . . . . . . . . . . , . . . . remove, attach (item 5).
Air cleaner cover (4) . . . . . . . . . . remove together with filter cartridge, attach
(item 5.1).
Turbo-engines:
Intake hose (2) . . . . . ., . . . . . . .
I to exhaust gas turbocharger, remove, attach
(item 6).
Radiator (16) ..... . . . . . . . . . . . . . . . . . . . remove, install (20-420).
Transmission oil lines . . . . . . . . . . . . . . . . . . . on vehicles with automatic transmission,
unbolt, install and plug with clamps
000 589 40 37 00 (item 7).
01.10 - 030/l
EXIT
Air conditioner:
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caution!
Attach protective plate immediately after
removing radiator.
Coolant hoses ......................... disconnect between engine and chassis, pull
off, install (item 9).
Fan (14, 15) . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, install, 25 Nm and 45 Nm
(items 10 - 11).
Note
On vehicles with viscodrive fan clutch
Use screwdriver socket 103 589 01 09 99,
torque wrench 001 589 72 21 00 and holding
tool 603 589 00 40 00.
Air conditioner:
Poly-V-belts (13) ........, remove, install (13-342).
Refrigerant compressor (12) remove, install, 25 Nm (item 12).
Note
Do not unbolt the refrigerant lines on the
compressor. Fasten compressor to chassis at
side.
Vacuum hoses and fuel lines remove between engine and chassis,
disconnect, reinstall (item 13).
Models 124 and 126:
Control cable (230) . . . . . . . . . . * ....... for engine control, unhook, hook in (item 14).
Model 201:
Engine control linkage (7) . . . . ....... unhook, hook in (item 15).
Note
Adjust control linkage (30-300).
Electrical connection lines . . . . . . . ....... between engine and chassis, disconnect plug
connectors and connections, reconnect
(item 16).
Oil pressure switch and oil level sensor ....... disconnect plug connectors, reconnect
(item 17).
Starter ............................... unbolt connection lines, connect (item 18).
Alternator ............................. disconnect plug connectors, reconnect
(item 19).
Engine electrical harness (5) ............... remove, reattach (item 20).
Power steering pump (10) ................. evacuate oil out of power steering supply
reservoir, use hand pump 112 589 00 72 00
and remove oil lines, reinstall, 30 Nm
(items 21 - 22).
01.10 - 03012
._
EXIT
Vehicles with level control and/or ASD:

Oil pump (1) or tandem pump (11) . . . . . . . . . . . unbolt oil lines and hoses between engine and
chassis, reinstall (item 23).
Turbo-engines or naturally aspirated engines
with exhaust gas recirculation:
Air/oil cooler (9) . . . . . . . . . . . . . . . . . . . . . . . . unbolt oil lines between cooler and engine,
reinstall (item 24).
PO l-0226-57
Turbo-engine with automatic transmission and

trailer hitch in combination with air conditioner:
Transmission oil/air cooler (17) ............. oil lines and hoses between cooler and engine,
remove, replace (item 25).
Model 201 (up to 03/85):
Mount for engine stop (25) . . . . . . . . . . . . . . . . remove, install, 25 Nm (item 26).
Note
Check engine stop, adjust, 130 Nm (22-220),
adjustment gauge 201 589 04 23 00.
01.10 - 030/3
EXIT
Model 201 (up to 03185):

Engine shock absorber (24), left . . . . . . . . . . . . . remove, install, 10 Nm (item 27).
Model 126:
Engine shock absorbers (24), left and right . . . . . remove, install, 10 Nm (item 28).
Manual transmissions:
Shift linkage (20) . . . . . . . . . . . . . . . . . . . . . . . unhook, hook in (item 29).
Clutch master cylinder (18) . . . . . . . . . . . . . . . . remove hydraulic line, replace and bleed master
cylinder (item 29.1).
Automatic transmissions:
Shift linkage (20) . . . . . . . . . . . . . . . . . . . . . . . unhook, hook in (30).
Starter lockout, back-up light switch (S16/1) . . . . disconnect wires, reconnect (item 30).
Kickdown solenoid valve (Y3/1 yl ) . . . . . . . . . . . disconnect wire, reconnect (item 30.1).
Speedometer shaft (19) or inductive
speedometer sensor (L2) . . . . . . . . . . . . . . . . . remove, reinstall (item 31).
Engine speed sensor (L3) and starter
ground strap . . . . . . . . . . . . . . . . . . . . . . . . . . remove, reinstall (item 32).
Lateral exhaust support (23) . . . . . . . . . . . . . . . remove, reinstall (item 33).
Heat baffle plates (22) .................... on center tunnel, remove, install (item 34).
Drive shaft (492) ...... .. ... . ... ... ...... remove, reinstall, 40 Nm and 60 Nm
(item 35).
Note
Replace self-locking hex. nuts.
Drive shaft intermediate bearing (495) . . . . . . . . loosen, tighten, 25 Nm (item 36).
Clamping nut (500) ...................... on intermediate bearing, loosen, tighten,
30 - 40 Nm, open-end wrench
126 589 00 01 00 or 201 589 00 01 00 and
torque wrench 001 589 66 21 00 (item 37).
01.10 - 030/4
EXIT
Following installation:
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . check engine oil, add, if required or fill engine
with new oil.
Cooling system ...................... fill up and perform pressure test (20-017),
pressure tester 124 589 15 21 00.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . start and check engine oil and cooling system
for leakage.
Engine oil capacities with oil dipstick code

(see “Service Product Specifications” for approved engine oils)
Number
code on
handle
602141)
60316
1) 1st version, color code “red”
2nd version, color code “black”
3rd version, color code “brown”
2) Only for engines with exhaust gas recirculation and side part on oil pan
3) 1 st version, color code “black”
Specified viscosity classes for engine oil

according to SAE for continuous ambient
temperatures OF T;
+66 -
Exact adherence to the SAE class specified for +66 -
the various ambient temperatures would result in +50 -
frequent oil changes. The temperature limits for

+32 -
the SAE classes should therefore be regarded
as guidelines which may be exceeded for short +,.I -
+5 -
periods. -4 -
See ” Service Product Specifications” for further I

information regarding specified viscosity classes
and approved engine oils.
01.10 - 030/6
EXIT
M 12~1.5~13 30
Oil drain plug in oil pan
M 14X15x22 25
Hex. head bolt, magnetic fan clutch 25

Allen bolt, viscodrive fan clutch 45
Hex. head bolts, refrigerant compressor 25
Oil lines, power steering pump 30
Allen bolts, mount, engine stop, front 10
Adjustment bolt, engine stop, front 130
Hex. nuts, engine shock absorber 10
Hex. head bolts, engine shock absorber mount 10
Hex. nuts, drive shaft on transmission flange 40

Hex. nuts, drive shaft on transmission flange, engine 603.96 60
Hex. head bolts, drive shaft intermediate bearing 25
Clamping nut, drive shaft intermediate bearing 30 - 40
Hex. head bolts, cross member center piece 45
Hex. head bolts, engine support, rear 45
Hex. head bolts, engine mount, rear 25
Hex. nut, engine mount, rear 70
Adjustment bolt, engine mount (rubber) rear 30
Allen bolt, engine mount, front 40
Allen bolt, engine mount, front, model 126 70
Special tools
112 589 00 72 00 103 589 01 09 00 603589004000 001 589 72 21 00

27 20 20 00
126 589 00 01 00 001 589 66 21 00 1 000 589 40 3700

41 00
01.10 - 030/7
EXIT

7 mm socket on flexible shaft for hose e. g. Hazet,
clamps with worm drive D-5630 Remscheid
Order no. 426-7
Engine hoist no. 3188 8. g. Backer,
(self-braking) D-5630 Remscheid,
HerderstraOe
Self-made tools
Guard plate for air conditioner condenser Dimensions: approx. 480 x 600 x 1
Guard plate for unit compartment firewall Dimensions: approx. 320 X 380 X 1
Removal, installation
1 Disconnect positive and negative cables on

battery.
Models 124 and 126:

2 Remove cable cover on unit compartment
firewall, for this purpose remove plastic screws
(arrows) and remove cover.
Model 201:
3 Remove cable cover on unit compartment
firewall, for this purpose remove rubber sealing
strip (29) over cable cover (30), disconnect clips
(31) and fold cover upward.
4 Lay battery positive cable across engine.
01.10 - 030/8
EXIT

5 Remove air intake hose (arrow).
5.1 Open retaining clips on air cleaner cover and

remove cleaner cover and filter cartridge.
PlS-2os!-13
Turbo-engines:
6 Remove intake hose to exhaust gas
turbocharger.
7 On vehicles with automatic transmission plug

oil cooler lines with clamps 000 589 40 37 00
(arrow).
P27-2048-13
8 Remove radiator (20-420).
Caution!
On vehicles with air conditioner attach guard
plate to condenser immediately after removing
radiator.
9 Loosen and remove all coolant hoses

between engine and chassis.
01.10 - 03019
EXIT
10 Remove fan with viscodrive fan clutch; hold

V-belt pulley with counterholder (01)
603 589 00 40 00 and remove Allen bolt with
socket (03) 103 589 01 09 00 and torque wrench
(02) 001 589 72 21 00. Remove fan.
Installation note
Tightening torque 45 Nm.
Fans with magnetic fan clutch:

11 Remove fan; remove Allen bolt (arrow).
Remove fan.
Installation note
Vehicles with air conditioning:

12 Remove poly V-belts (13-342), remove hex.
head bolts (arrows) for refrigerant compressor
and attach refrigerant compressor
at side on chassis.
Note
Do not unbolt refrigerant lines on refrigerant
compressor.
Installation note
Tightening torque for hex. head bolts on
refrigerant compressor 25 Nm.
13 Loosen and disconnect all vacuum hoses

and fuel lines between engine and chassis.
01.10 - 030/10
EXIT
Models 124 and 201:

14 Unhook engine control; press out guide
piece (240) on control lever (208) and remove
control cable (230).
Model 126:
15 Unhook engine control linkage; unhook
connecting rod (arrow) on control shaft.
Installation note
Adjust control cable (30-300).
16 Disconnect all electrical lines between

engine and chassis; for this purpose disconnect
plug connectors and connections.
17 Disconnect plugs on oil pressure switch (43)

and oil level sensor (44).
18 Remove connection cables on starter (45)

and remove harness from holder (46) above
starter.
PO1 2454 13
01.10 - 030/11
EXIT
19 Oisconnect plug connector (arrow) on

alternator.
20 Completely remove engine wiring harness,

for this purpose disconnect all clips and cable
connectors.
21 Evacuate oil from supply reservoir for power

steering pump or tandem pump using hand
pump 112 589 00 72 00.
22 Unscrew oil lines for power steering on

power steering pump (arrows) or on tandem
pump-
Installation note
Replace oil which has leaked out.
Power steeringpump
Vehicles with level control and/orASB:

23 Remove oil lines and hoses (arrows) for
hydraulic pump or tandem pump between engine
and chassis.
Hydraulic pump
Tandem pump
01.10 - 030112
EXIT
Turbo-engines or naturally aspirated engines

with exhaust gas recirculation:
24 Unbolt oil lines and hoses (arrows) for air oil
cooler in left wheelhouse between radiator and
engine.
Turbo-engines with automatic transmission

and trailer hitch in combination with air
conditioning:
25 Unbolt oil lines and hoses (arrows) for
transmission air oil cooler in right wheelhouse
between radiator and engine.
Model 201 (up to 03/85):

26 Remove Allen bolts (arrows) on mount for
engine stop and remove mount.
Installation note
Tightening torque 25 Nm. Check engine stop
with adjustment gauge 201 589 04 23 00 and
adjust (22-220). Tightening torque for adjustment
bolt 130 Nm.
P22-2035.13A
Model 201 (up to 03/85):

27 Remove engine shock absorber, left, for this
purpose remove hex. head bolts (arrows) on
mount and remove engine shock absorber from
frame cross member.
Installation note
01.10 - 030113
EXIT
Model 126:
28 Unbolt engine shock absorbers (24) on left
and right; for this purpose unscrew hex. nut (50)
and press shock absorber upward out of mount
on frame cross member (49).
Installation note
Vehicles with manual transmission:

29 Unhook shift linkage (21) on transmission.
29.1 Unbolt hydraulic lines on clutch master

cylinder (arrow).
Installation note
Bleed clutch master cylinder.
01.10 - 030114
EXIT
Vehicles with automatic transmission:

30 Unhook shift linkage on transmission and
disconnect connector for starter lockout, back-up
light switch (S1611).
30.1 Disconnect connector for kickdown

solenoid valve on right side of transmission.
31 Unbolt speedometer shaft or speedometer

inductive sensor (arrow) and remove the two
bottom hex. head bolts for the starter. Position
speedometer shaft or connection wire to side.
32 Unbolt engine speed sensor (L3) and starter

ground strap (arrow) on chassis.
33 Remove hex. head bolts (arrows) for lateral

exhaust support on transmission and remove
support.
34 Unbolt heat baffle plates on center tunnel.
01.10 - 030/15
EXIT
35 Remove hex. head bolts (arrows) for drive

shaft on transmission flange and press drive
shaft off of transmission flange.
Installation note
Replace self-locking hex. nuts.
Tightening torque
Engine 602, 603.91 40 Nm
Engine 603.96 60 Nm.
36 Loosen hex. head bolts (494) on drive shaft

intermediate flange.
Installation note
37 Loosen clamping nut (500) with open-end

wrench
126 589 00 01 00 (SW46) or
201 589 00 01 00 (SW41) and
torque wrench 001 589 66 21 00.
Push drive shaft back as far as possible (in P41-2041-13
direction of arrow).
Installation note
Tightening torque 30 - 40 Nm.
Model 126:
38 Unbolt hex. head bolts (51) on cross
member center piece (50) and remove cross
member center piece.
Installation note
Replace self-locking hex. head bolts.
01.10 - 03006
EXIT
Caution!
Attach guard plate on unit compartment firewall.
39 Fasten engine hoist cables to front and rear

suspension eyes on engine. Align engine hoist
so that engine is positioned horizontally.
Suspension eye, front
Suspension eye, fear
01.10 - 030/17
EXIT
40 Remove hex. head nuts (47) on mount for

rear engine support. Remove hex. head bolts
(48) and remove engine support with mount.
Installation note
Tightening torque
Hex. nuts 70 Nm
Hex. head bolts 45 Nm.
Check adjustment bolt on rubber mounts,
tightening torque 30 Nm.
41 Remove Allen bolts for front engine mounts

from frame cross member from bottom.
Installation note
Tightening torque
Model 124 and 201 40 Nm
Model 126 70 Nm.
Allen bolt, engine mount, left
P22-2012-n
Allen bolt, engine mount, right
01.10 - 030118
EXIT
42 Lift engine with transmission at angle out of

engine compartment, continuously correct angle
with engine hoist, maximum angle approx. 45”.
AWarning
When lifting engine pay attention to rear
suspension eye on engine and engine oil filter.
43 Install in opposite order.
After installation:
44 Check engine oil, add, if required or refill
engine oil and fill up cooling system.
44.1 Perform pressure test on cooling system

(20-017), pressure tester 124 589 15 21 00.
44.2 Start engine and check engine oil and

cooling systems for leakage.
01.10 - 030119
EXIT
01-040 Crankcase ventilation - Function
A. Standard version
Crankcase ventilation, naturally aspirated engine, standard version

Engine 602
126 011 separator
127 Return pipe
140 Dlstrlbution pipe
A Blow-by gasses
B Fresh am
The crankcase ventilation on standard version

naturally aspirated engines is a closed,
maintenance-free system.
01.10 - 04011
EXIT
The blow-by gasses from the crankcase flow

through the oil separator (126) into the cylinder
head cover and a hose to the distribution pipe
(140) on the intake manifold depending on the
intake manifold vacuum.
These gasses are distributed uniformly to all

cylinders by the intake manifold and drawn into
the combustion chambers together with the
intake air.
The oil deposited in the oil separator runs back

to the cylinder head through the return pipe
(127).
POl-o155-57
Crankcase ventilation, standard version turbo-engines

Engines 602.96, 603.96, 603.97
126 011 separator
b To arr cleaner housmg
A Blow-by gasses
B Fresh air
0 1 . 1 0 - 04012
EXIT
The crankcase ventilation for the standard

version turbo-engines corresponds to that of the
naturally aspirated engine.
l-lowever on the turbo-engines, after removal of

the engine oil, the blow-by gasses flow from the
cylinder head cover to the intake hose.
. Naturally aspirated and turbo-engines with exhaust gas recirculation
POl-0156-57
Crankcase ventilation on engines with exhaust gas recirculation

Engine 602.91
126 011 separator
127 Return pipe
140 Dlstnbutlon pipe
141 Pressure control valve
a Vent hole, dia. 3 mm
A Blow-by gasses
f3 Fresh air
01.10 - 040/3
EXIT
Crankcase ventilation on engines with exhaust gas recirculation

Engines 602.96, 603.96( 97
126
126 011 separator

b To air cleaner housmg
A Blow-by gasses
B Fresh am
The crankcase ventilation on naturally aspirated

engines with exhaust gas recirculation differs
from that of the standard version by addition of a
built-in pressure control valve (141).
The pressure control valve is required because

on engines with exhaust gas recirculation an
additional throttle valve installed in the intake
system results in significantly higher vacuums.
If the vacuum were too high, the engine oil

would be sucked out of the crankcase.
The pressure control valve prevents this by

keeping the vacuum constant above a certain
value.
01.10 - 04014
EXIT
POl-0154-53
Pressure control valve

Engines 602.91, 603.91
125 Cylinder head cover 141a Diaphragm
126 Oil separator 142 Spring
127 Return pipe 143 Holder
141 Pressure control valve a Vent hole
The pressure control valve is designed as a

diaphragm-type valve and built into the oil
separator in the cylinder head cover.
A hole is present in the cylinder head cover to

vent the diaphragm chamber in the pressure
control valve (arrow). This hole must not be
plugged by dirt or preservation agents.
01.10 - 040/5
EXIT
142 l4la
125 140a 140b I al
I
126
Pressure control valve, engines 602.96, 603.96

125 Cylinder head cover 140b Intermediate section
126 Oil separator 141a Pressure control valve
127 Return pipe 142 Spring
140a Angle fitting a Vent hole
Turbo-engines with exhaust gas recirculation are

also equipped with a pressure control valve
(141 a). For space reasons this valve is installed
in the rear section of the cylinder head cover.
Note
Because of increased pressure difference
between the intake manifold and the crankcase,
a stronger compression spring (142) with a
higher spring rate was used. The following table
indicates the vehicle and engine models in which
the modified springs were first installed.in
addition to engines 602.962 and 603.970
beginning model year 1990.
Production breakpoint: 01/88

Model Engine Engine end no. Vehicle ident. end no.
manual automatic
transmission transmission
124.133 0 17932
124.193
124.128 602.962 1 From Model Year 1990
126.134 603.970 From Model Year 1990
126.135
201.126 ~602.911 1073017 014820
l
not avarlable
01.10 - 04016
EXIT
01-110 Measuring, boring and honing cylinder bores

Pistons removed(03-316).
A. Measuring
ngines with and without cylinder sleeves
c e
/M----N
d
_-----_
_c----_
d
__-----__
e
POl-0158-57
Cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . clean thoroughly.

Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . Measure cylinder bore diameter with internal
measuring instrument at 3 measuring points (c,
d, e) in longitudinal direction (A) and transverse
direction (B).
Note
Compare measured cylinder bore diameters with
standard or repair stage specifications for engine
(except for engines with cylinder sleeves).
01.10 - 110/l
EXIT
Observe group ident. letters A, X or E3 stamped

on the crankcase or piston crown. On used
engines the difference between the diameter
measured at point (c) and the original diameter is
equal to the wear (max. permissible wear
0.2 mm).
The original diameter can be measured at the
piston top land after it has been cleaned
thoroughly (the top land is the area between the
piston crown and the top surface of the block in
the TDC position on ignition stroke).
oring and honing

Engines without cylinder sleeves
PO1-0231-37
Cylinder bore diameter (0) . . . . . . . . . . . . . . . . measure.
01.10 - 110/2
EXIT
Bore diameter (D,) . . . . . . . . , . . . . . . . . . . . . . determine and adjust boring tool.

Note
The bore diameter “Dl” is the cylinder bore
diameter “D” minus the material which will be
removed by honing. The material removed by
honing should not exceed max. 0.05 mm. Select
repair stage diameter ‘ID” according to engine
model and group code letter A, X, 6” (stamped
in block).
Boring operation . . . . . . . * . . . . . . . . . . . . . . . perform according to operating instructions for
boring tool used.
Cylinder bore . . ....................... bevel at upper and lower edges of cylinder (see
drawing for dimensions).
I-ioning operation ....................... perform according to specified data.
Maximum permissible wear for cylinder bores

Measuring range “a” (upper reversal point of 1st piston ring) in longitudinal
and/or transverse direction 0.2 mm
Standard and repair stage diameter “D” for cyl nder bores
602, 603 603.970
Version ( Cylinder 1 G;p code Cylinder dia. D in mm Cylinder dia. D in mm
Standard 1 - 4, 5, 6 87.000 - 87.006 89.000 - 89.006

over 87.006 - 87.012 over 89.006 - 89.012
over 87.012 - 87.018 over 89.012 - 89.018
Repair stage ‘) 87.700 - 87.706 89.700 - 89.706
( + 0,7 mm) 87.706 - 87.712 89.706 - 89.712
87.712 - 87.718 89.712 - 89.718
1) Does not app I y f0 r engines with cylinder sleeves. Cylinder sleeves must be replaced when the wear llmlt IS reached.
Machining tolerances
Permissible out-of-round and conicity of cylinder bore 0.07 mm
Permissible roughness of cylinder bore (R3Z) 0.003 - 0.006 mm

Permissible waviness of cylinder bore 50 O/O of roughness
l-ioning angle 45”
Roughness of block parting surface 0.006 - 0.016 mm
Chamfer of cylinder bores refer to figure
EXIT
Introduction of engines without cylinder

sleeves
Note
Beginning in 1987 the cylinder sleeves were
eliminated partially on engines 602/603 . The
following tables show exactly when and on which
model or engine the new version was
introduced. Engine 603.970 was introduced into
production without cylinder sleeves.
Installation of cylinder sleeves is not permissible.
Production breakpoint:
Commercially available tool

Internal measuring instrument for 50 - 150 mm dia., e.g. Hommel Handel
with 0.01 mm increments and measuring point D-5000 Koln 71
pressure relief Sunnen Grm-2125
01.10 - 110/4
EXIT
oring, honing and replacement of cylinder sleeves

Prehminary operations:
Pistons removed (03-316).
,69
PO1 -023247
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . measure (01-l 10).

Cylinder sleeves (68) . . . . . . . . . . . . . . . . . . . . press out, punch 603 589 00 15 00 (item 1).
Block (69) . . . . . . . . . . . . . . . . . . . . . . . . . . . . clean basic bores for sleeves and check
diameter (see table) with internal measuring
instrument (items 2 and 3).
Note
If the permissible values are exceeded, replace
block.
Cylinder sleeves ...... ..... ............. press in and maintain pressure for approx. 7
seconds to seat sleeve, punch
603 589 00 15 00 (item 4).
01.10 - 115/l
EXIT
Cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . bore out to standard diameter “D” and hone,

see Note in (01-l 10). Observe group code
letters (A, X, B) (items 5 - 9).
Diameter “D” for cylinder sleeves

602, 603
Cylinder dia. D in mm
Standard 1) 87.000 - 87.006

over 87.006 - 87.012
over 87.012 - 87.018
‘1 There are no repatr stages for engmes with cylmder sleeves.
Dimensions for basic bore in block

Bore dia. “B” 92.650 - 92.750 mm
Bore dia. ‘ID” 90.550 - 90.650 mm
Bore dia. “E” 90.000 - 90.935 mm
Depth “A” sleeve seat 3.8 - 4.0 mm
Depth “C” sleeve seat 4.77 - 5.23 mm
Permissible out-of-round of basic bore in block 0.01 mm
Permissible out-of-round and conicity of cylinder bore 0.07 mm
Permissible roughness of cylinder bore (R3Z) 0.003 - 0.006 mm

Permissible waviness of cylinder bore 50 % of roughness
l-loning angle 45”
Roughness of block parting surface 0.006 - 0.016 mm
Chamfer of cylinder bores 30”
POl-0159-13
01 10 - 115/2
EXIT
Special tool
603 589 00 15 00
01

Internal measuring instrument for 50 - 100 mm dia., e.g. Hommel Wandel
with 0.01 mm increments and measuring point D-5000 Koln 71
pressure relief Sunnen Grm -2125
Replacement
1 Press out cylinder sleeves.
2 Thoroughly clean basic bore.
3 Measure basic bore (D) in block.
If the limits are exceeded (see table) the block

cannot be reused.
POl-2253-13
4 Position new cylinder sleeves and press in
with press.
After pressing in cylinder sleeves maintain

pressure for approx. 7 seconds with press
(setting pressure).
01.10 - 115/3
EXIT
Boring and honing
5 Mill or grind off projecting collar on sleeve.

Remove as little material as possible from the
block parting surface. Guide milling cutter or
grinding wheel carefully over cylinder bores.
6 Bore out cylinder sleeves in two steps.

Leave at least 0.03 mm additional material in the
bores for honing.
7 Chamfer cylinder sleeves.
8 Hone cylinder bores.
9 Measure cylinder bores and select matching

pistons (01410).
01.10 - 11514
..................................................... ............
EXIT
01420 Planing crankcase parting surface

Prellmlnafy operations:
Piston extension checked and pistons removed (03-316).
PO1 -0233-57
Parting surface (1) . . . . . . . . . . . . . . . . . . . . . . plane according to operating instructions for

planing tool used.
Note
Observe specified dimensions and machining
data!
Cylinder bores (2) .,-.................... ch‘amfer at top of cylinder.
After reassembly . . . . . . . . . . . . . . . . . . . . . . . . check engine timing (05-215).
01.10 - 120/l
EXIT
Data
Height of block in new state from center of main 234.97 - 235.03
bearing bore
Minimum height after required material removal from center 234.60
of main bearing bore
in longitudial direction 0.06

Permissible unevenness of parting surface
in transverse direction 0.06
Permissible roughness of upper parting surface 0.006 - 0.016

Permissible deviation in parallel between upper parting surface and 0.05
lower parting surface in longitudinal direction
Chamfer of cylinder bores see figure
Distance between piston crown and block parting surface Projection max. 0.965
Projection min. 0.735
I PO3-0093-13
Cylinder bore chamfer
01.10 - 120/2
EXIT
01-130 Removal and installation of steel balls in main oil duct

Prelrmlnary operations:
Coolant pump removed with housing (20-230).
Flywheel removed (03-410).
POl-0161-15
PO1-0160-15
Steel ball, rear, 15 mm dia. (9) Steel ball, front, 17 mm dia. (10)
Steel balls (9, 10) ..................... . . knock out, insert.

Punch 601 589 08 15 00 (items 1 - 6).
Note
If not damaged the steel balls can be reinstalled
a number of times. In the event of leakage
reseat steel balls approx. 1 mm deeper
(dimension marked on punch).
Leaky steel balls ........................ replace with plug, remedy measures
(items 7 - 9).
After reassembling engine ................. warm up engine and check for leakage in area
of steel balls.
Tightening torque Nm
01.10 - 130/l
EXIT
Replacement parts for steel balls Part no.

Plug M 18 x 1.5 (front) 000 908 018 002
Plug M 16 x 1.5 (rear) 000 906 016 002
Gasket A 18 007 603 018 103
Sealant for replacement of rear steel ball

Loctite 241 002 989 94 71
Special tool
Knocking out
1 Knock out both steel balls from rear toward

front with suitable steel rod.
Note
The steel balls can be reused a number of
times. Replace damaged balls under all
circumstances.
POl-2267-13
Inserting
2 Thoroughly clean seat for steel ball in engine

block.
3 Insert steel ball with slight quantity of grease

on punch 601 589 08 15 00.
01.10 - 13012
EXIT
4 Position steel balls on hole and drive in to

specified stop on punch.
5 After reassembling engine, warm up engine

and check for leakage in area of steel balls.
Note
If one of the steel balls does not seal sufficiently
after inserting or if leakage is present following
leakage test, replace steel ball with plug.
Replacing steel ball with plug
6 Knock steel ball out again.
7 Cut thread in hole for leaky ball.
Note
Front bore M 18 X 1.5 10 m m deep
Rear bore M 16 X 1.5 14 mm deep
8 Thoroughly clean oil duct, screw in front plug

with gasket and rear plug with sealant
002 989 94 71, tightening torque 50 Nm.
01.10 - 13013
EXIT
eplacement of freeze plugs in crankcase

Coolant drained (20-010).
Attachment parts In area of freeze plug removed.
PlB 2036 131
Freeze plug, left, 34 mm dia. (8) Freeze plug, right, 34 mm dia. (8b)
Freeze plug, front, 17 mm dia. (8a) Freeze plug, rear, 34 mm dia. (11)
Freezeplugs(8,8a,8b, 11) . . . . . . . . . . . . . . . remove, knock in. Installation punch

102 589 12 15 00, 17 mm dia. or punch
102 589 00 15 00, 34 mm dia. (items 1 - 6).
Note
Seal freeze plugs with sealant
002 989 94 71. Allow sealant to harden
for approx. 45 minutes.
01.10 - 14011
EXIT
After reassembling engine ................. allow engine to warm up and check for leakage
at newly installed freeze plug .
Note
The number of freeze plugs differs on the
individual engine models. The figure shows
engine model 603 as an example.
Sealant
Loctite 241 002 989 94 71
Special tools
102 589 12 15 00 102589001500

01
Removal
1 Position chisel with small blade or screw-

driver in deep-drawn edge of freeze plug.
01.10 - 14012
EXIT
2 Carefully knock in freeze plug at one side

until it rotates around its own longitudinal axis
and can be gripped with a pair of pliers.
3 Pull out freeze plug.
4 Clean sealing surface; surface must be free

of grease.
Installation
5 Coat sealing surface with sealant

002 989 94 71.
6 Knock in new freeze plug with install-ation

punch 102 589 12 15 00 (17 mm dia.) or 102
589 00 15 00 (34 mm dia.).
.
Caution!
Allow sealant to harden for approx. 45 minutes
before filling coolant.
7 After reassembling engine, allow engine to

warm up and check for leakage at new freeze
plug installed.
01.10 - 140/3
EXIT
01-210 Removal and installation of thina cover

Prelimtnary operations:
Engrne compartment capsule, bottom section removed (01-006).
Radiator removed (20-420).
Magnetic or vlscodnve fan clutch removed (20-335, 20-312).
Crankshaft pulley and hub removed (03-341).
Poly-V-belt tensioning device removed (13-345).
Piston vacuum pump removed (43-618).
Power steenng pump or tandem pump removed (46-710).
Hydraulrc pump on cylinder head removed (05437).
Alternator removed (15-510).
Engtne 011 drained.
POl-0250-57
Air conditioning:
Condenser . . . . . . . . . . . . . . . . . , . . . . . . . . . .
Caution!
Attach guard plate.
Cylinder head cover (125) .................

remove if not yet removed, install, 10 Nm
(item 1).
Note
On turbo-engines the charge air pipe must be
removed before removing the cylinder head
cover.
01.10 - 210/l
EXIT
Front hex. head bolt (116) ................. for fuel filter, remove, reinstall, 25 Nm
(item 2).
Holder (62) . . . . . . . . . . . . . . . . . . . . . . . . . . . for oil dipstick tube, remove, reinstall, 25 Nm
(item 3).
Hex. head bolts (417) . . . . . . . , . . . . . . . . . . . . on mount (416) for alternator, remove, reinstall
and remove mount, install, 45 or 25 Nm
(item 4).
Holder for TDC sensor (42 or 44) I . . . . . . . . . mark position and unbolt, reinstall (item 5).
Note
Check TDC sensor adjustment, readjust if
required (03-345).
Model 201 (up to 03185):
Mount (6) for engine stop . . . . . .......... remove, reinstall, 25 Nm (item 6).
Model 201 (up to 03185):

Engine shock absorber (24) left . . . . . . . . . . . remove, install, 10 Nm (item 7).
Note
Check engine stop, adjust, 130 Nm (22-220)
Model 126:
Engine shock absorbers (24) left and right . . . . . remove, install, 10 Nm (item 8).
Front suspension eye on engine ............. hook in engine hoist (item 9).
Engine mounts (28), front, left and right . . . . . . . remove Allen bolts at bottom, reinstall,
40 and 70 Nm (item 10).
01.10 - 21012
EXIT
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lower back on engine mounts with engine hoist

(item 14).
Hex. head bolts (66, 67) . . . . . . . . . . * . . . . . . for mounting injection pump, remove, reinstall,
25 Nm (item 15).
Allen bolts (1 15) . . . . . ................. in timing chain housing, remove, reinstall,
25 Nm (item 16).
Hex. head bolts (35, 36) ................. in timing case cover, remove, reinstall,
25 Nm (item 17).
Timing case cover (28) ................. remove, install (item 17).
Caution!
When removing timing case cover pay attention
to cylinder head gasket and oil pan gasket.
Avoid damaging. Replace damaged cylinder
head gasket.
Note
Clean parting surface on timing case cover, seal
cover with sealant 001 989 95 20.
Check crankshaft radial seal in timing case

cover, remove if required, install, sleeve
601 589 03 14 00 (item 17).
After installation . . . . . . . . . . . . . . . . . . . . . . . . warm up engine and check for leakage
(item 19).
Sealant
Hvlomar 001 989 25 20
01.10 - 21013
EXIT
Adjustment screw, engine stop, front 130

Hex. head bolts, cylinder head cover 10
Cylinder head bolts in timing chain case 25

Hex. head bolts, mount, alternator 45
Hex. head bolts, oil pan M6 10
M8 25
Hex. head bolts for mounting injection pump 25
-_-
Hex. head bolts for mounting timing case cover 25
Hex. head bolts for engine shock absorber mount 10
Decial tools
601 589 03 14 00 001 589 66 21 00

03 00
01.10 - 21014
EXIT

Connection 314” square ratchet e.g. Hazet,
to l/2" square head D-5630 Remscheid
Order no. 1058 R. 1
Engine hoist no. 3188 e.g. Backer,
(self-braking) D-5630 Remscheid,
HerderstraOe
_ -.____
7 mm socket on flexible shaft for hose e.g. Hazet,
Order no. 426-7
Self-made tool .._-._.-_.

Guard plate for air conditioner condenser Dimensions: approx. 480 x 600 x 1
Caution!
On vehicles with air conditioning attach guard
plate to condenser before starting work.
1 Remove cylinder head cover, if not already

removed.
Installation note
Note
On turbo-engines the charge air pipe (arrow)
must be removed before removing the cylinder
head cover.
01.10 - 21ok.j
EXIT
2 Remove hex. head bolts (116) at front

of fuel filter.
3 Unbolt holder (62) for oil dipstick tube,

25 Nm.
4 Remove hex. head bolts (arrows) on mount

for alternator and remove mount.
Installation note
Tightening torques
Mounting bolts for mount 45 Nm
Mounting bolt on timing
case cover 25 Nm.
5 Mark position of mount for TDC sensor

(42 or 44) and unbolt mount.
Installation note
Check TDC sensor and adjust if required
(03-345).
01.10 - 210/6
EXIT
Model 201 (up to 03185):

engine stop at front and remove mount.
Installation note
Check engine stop with adjustment gauge
201 589 04 23 00 and adjust (22-220).
Tightening torque for adjustment bolt 130 Nm.
P22 2035 13A
Model 201 (up to 03185):

7 Remove engine shock absorber on left;
remove hex. head bolts (arrows) on mount and
remove engine shock absorber from frame cross
member.
Installation note
Model 126:
8 Remove engine shock absorbers (24) on left
and right; unscrew hex. nuts (50) and press
shock absorber upward out of mount on frame
cross member (49).
Installation note
POl-o249-15
01.10 - 21017
EXIT
9 Attach engine hoist cable to front suspension

eye (arrow).
10 Remove Allen bolts for front engine mount

from frame cross member from bottom.
Installation note
Tightening torque
Model 126 70 Nm
Allen bolt, engine mount, left Pi?-2012-13‘
01.10 - 21018
EXIT
12 Hoist engine with engine hoist until hex.

head bolts in oil pan are accessible in area of
timing case cover.
13 Remove hex. head bolts in oil pan in area of

timing case cover and loosen remaining bolts.
Installation note
Tightening torque M6 10 Nm,
M8 25 Nm.
14 Lower engine back onto front engine

mounts.
15 Remove hex. head bolts (arrows) for

mounting injection pump. Remove square nuts
on injection pump flange.
Installation note
L- _ \ I PO-2212-13
16 Remove Allen bolts (arrows) in timing chain

case.
Installation note
POl-2365-13 I
01.10 - 210/g
EXIT
17 Remove all remaining hex. head bolts

(arrows) in timing case cover and remove timing
case cover.
Caution!
When removing timing case cover be careful of
cylinder head gasket and oil pan gasket. Avoid
damaging. Replace damaged gaskets.
POl-2217-U
Installation note
Clean gasket residues off of parting surface
on timing case cover.
Check crankshaft radial seal in timing case cover
and replace, if required, installation sleeve
601 589 03 14 00.
Coat parting surface of timing case cover with
sealant 001 989 25 20. Tightening torque
25 Nm.

PO&zw- 13
19 After installation warm up engine and check

timing case cover for leakage.
01.10 - 210110
EXIT
01-222 Removal and installation of end cover
Prelrmlnafy operattons:
Flywheel removed(03-410).
d 22
PO1-0139-15
Hex. head bolts (55) ..................... in oil pan, remove, reinstall, 25 Nm

(item 1).
Hex. head bolts (21) ...................., Hex. head bolts (21) in end cover (20), remove,
reinstall, 10 Nm (item 2).
Note
Coat threads of hex. head bolts with sealant
002 989 20 10.
01.10 - 222/l
EXIT
End cover (20) . . . . . . . . . . . . . . . . . . . . . . . . . press out together with crankshaft radial

seal (22), press in, installation sleeve
601 589 03 43 00 (item 3).
Note
Avoid damaging oil pan gasket.
Note
Clean gasket residues off of parting surface on
end cover and coat parting surface of cap with
sealant 002 989 00 20 10. Check crankshaft
radial seal and remove if required, install,
installation sleeve 601 589 03 43 00.
Sealant
Omnifit 002 989 00 20 10
Hex. head bolts, end cover 10
Hex. head bolts, oil pan 25
Special tools
601 589 03 43 00 001 589 72 21 00

03 00
01.10 - 2221'2
EXIT
1 Remove the two hex. head bolts (55) in the

oil pan.
Installation note
2 Remove hex. head bolts (21) in end cover

(20).
Installation note
Coat threads on hex. head bolts with sealant
002 989 00 20 10.
3 Press end cover off of crankcase at tabs

(arrows) and remove crankshaft radial seal
from crankshaft journal.
Note
When pressing the end cover on and off avoid
damagingthe oil pan gasket. .
Installation note
end cover. Check crankshaft radial seal and re-
place if required. Coat parting surface on end
cover with sealant 002 989 00 20 10 and slide
end cover together with radial seal over attached
installation sleeve 601 589 03 43 00.
01.10 - 222/3
EXIT
EXIT
01-310 Removal and installation of oil pan
A. Model 124, 126 and 201

Bottom section of engine compartment noise
capsule removed (01-006).
Model 124 and 201:
Torsion bar on front axle removed .
Models 124, 201 ,126 and 201 .128:
Steer. rod, left and steer. shock absorber, right rem..
Fan cowl loosened.
Q5b
PO1 -0238-57
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . disconnect negative cable, reconnect (item 1).

Engineoil ............................ drain, fill (item 2).
Note
Tightening torque for oil drain plug (3) 25
or 30 Nm. Observe specified oil capacity.
01.10 - 310/l
EXIT
Model 201 (up to 03185):

Mount, engine stop (6) . . remove, install, 25 Nm (item 3).
Note
Check engine stop, adjust, 130 Nm (22-220),
Model 201 (up to 03185):
Engine shock absorber (24), left . . . . . . . . . . . . . remove, install, 10 Nm (item 4).
Model 126:
Engine shock absorbers (24) left and right . . . . . remove, install, 10 Nm (item 5).
Engine speed sensor (L3) and ground strap . . . . remove, reinstall (item 6).
Oil level sensor (18) . . . . . . . . . . . . . . . . . . . . . disconnect plug, reconnect (item 7).
Automatic transmission
Oil lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . between transmission and oil cooler or
transmission air/oil cooler, unbolt at oil pan,
install and remove at radiator, reinstall (item 8).
Note
Plug oil lines before removal, clamp
000 589 40 37 00.
Oil pan with attached side sections:
Oil pan side section (45b) . . . . . . . . . . . . . . . . . remove, install (item 9).
Note
Replace gasket (45~) for oil pan side section.
Tightening torque for hex. head bolts (41)
10 Nm.
Front suspension eye on engine ............. hook in engine hoist, unhook (item 10).
Front engine mounts (28), left and right ....... remove Allen bolts from bottom, reinstall, 40
and 70 Nm (item 11).
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hoist with engine hoist, lower back on engine
mounts (item 12).
f-tex. head bolts (19) ..................... remove from oil pan (45), reinstall (item 13).
M6 bolts 10 Nm,
M8 bolts 25 Nm.
Note
Observe different lengths of hex. head bolts.
01.10 - 310/2
EXIT
Oil pan (45) ,.......................... remove from crankcase together with oil pan
gasket (45a), install (item 14).
Note
Remove oil pan toward front of vehicle while
turning crankshaft slightly if required. Clean
gasket residues from parting surface of oil pan.
Replace oil pan gasket (45a).
After installation . . . . . . . . . . . . . . . . . . . . . . . . warm up engine and check for leakage
(item 16).
Oil capacities with oil dipstick code

(see “Service Product Specifications” for approved engine oils)
Round handle
1) 1 st version color code “red”

2nd version color code “black”
3rd version color code “brown”
2) Only for engtnes with exhaust gas recirculation and side section on 011 pan
3) 1 st version color code “black”
M 12X1,5x13 3 0
Oil drain plug on oil pan
M 14X1,5x22 2 5

Adjustment bolt, engine stop, front 130
t-tex. head bolts, engine shock absorber mount 10
Hex. head bolts, oil pan side section 10
Hex. head bolts, oil pan M6 10
M8 25
01.10 - 31013
EXIT
Special tools
001 589 72 21 00 201 589 04 23 00 001 589 67 21 00

00 ) (_ 00 00 22 00
I

Engine hoist no. 3188 e.g. Backer
(self-braking) D-5630 Remscheid
HerderstraRe
1 Disconnect negative cable from battery.
2 Drain engine oil.
Installation note
Tightening torque for oil drain plug
M 12x1.5x13 30 Nm
M 14X15x22 25 Nm.
Observe specified oil capacity when filling
engine.
Model 201 (up to 03185):

front engine stop and remove mount.
Installation note
Tightening torque 25 Nm,.
Check engine stop with adjustment gauge
201 589 04 23 00 and adjust (22-220).
Tightening torque for adjustment bolt 130 Nm.
P22-2035.13A
01.10 - 31014
EXIT
Model 201 (up to 03185):

4 Remove engine shock absorber, left; remove
hex. head bolts (arrow) on mount and re-
move engine shock absorber from frame cross
member.
Installation note
Model 126:
Remove engine shock absorbers (24), left and
right; unscrew hex. nut (50) and press shock
absorber upward out of mount on frame cross
member (49).
Installation note
PO1-024915
6 Unbolt engine speed sensor (L3) and ground

strap for starter (arrow) on chassis.
01.10 - 31015
EXIT
7 Disconnect plug from oil level sensor

(arrow).

8 Clamp oil lines between transmission and
oil cooler or transmission air/oil cooler, clamp
000 589 40 37 00, screw oil lines off of oil pan
and radiator.
Installation note
Check transmission oil level, add if required.
POl-2373-13
POl-0143-53
Oil pan with attached side section:

9 Remove hex. head bolts (41) and remove oil
pan side section (45b) together with gasket
(45c).
Installation note
Replace gasket (45~).
01.10 - 31016
EXIT
10 Attach engine hoist cable to front suspension

eye on engine (arrow).
11 Remove Allen bolts for front engine mount

from frame cross member from below.
Installation note
Tightening torque
Model 126 70 Nm.
Allen bolt, engine mount, left
12 Lift engine at front with engine hoist as far as

possible.
01.10 - 31017
EXIT
13 Remove hex. head bolts (19) of oil pan (45).
Installation note
Observe different lengths of hex. head bolts.
Tightening torque M6 10 Nm,
M 8 25 Nm.
14 Remove oil pan (45) from crankcase toge- 45a-

ther with oil pan gasket (45a); remove oil pan
toward front of vehicle, turn crankshaft slightly if
required.
PO 1.023913
Installation note
oil pan. Replace oil pan gasket.
16 After assembly warm up engine and check

oil pan for leakage.
01.10 - 31018
EXIT
01400 Repair notes for cylinder heads and cylinder head gaskets
ngine 602, 603
Differentiation of cylinder heads for naturally

aspirated and turbo-engines
The cylinder heads for turbo-engines 602.96,

603.96 and 603.97 are reinforced at the water
jacket due to the higher combustion pressures.
On turbo-engines the diameter (d) of the pre-

combustion chamber bore is 15 mm, on naturally
aspirated engines 14 mm.
PO1-0123-15
The cylinder heads on turbo-engines are pro-

vided with an identification strip. This identi-
fication strip (arrow) is located on the parting
surface for the cylinder head cover at the front
right.
Caution!
Do not mix up cylinder heads for turbo-engines
and naturally aspirated engines.
POl-0151-13
01.10 - 400/l
EXIT
The cylinder head gasket for the turbo-engines

has stainless steel inserts around the combus-
tion chambers (arrow).
The combustion chamber inserts on the standard

gaskets installed on naturally aspirated engines
consist of normal sheet steel.
Only the cylinder head gaskets with stainless

steel inserts are available as replacement parts
for both the naturally aspirated and turbo-
engines.
Cylinder head gasket with Viton sealing ring
A Viton sealing ring is inserted at the rear oil

return passage to prevent oil leakage.
A 1st version with sheet metal jacket

W1-0124-13
B 2nd version with V~ton sealing ring

Engine end no. Vehicle ident. end no.
. not av&able
01.10 - 400/2
EXIT
Modifications in area of timing chain case
For production reasons the height of the bridge

in the cylinder head in the area of the timing
chain case was increased to 32 mm (previously
12 mm).
This modification made it necessary to change

the dimensions of the two cylinder head bolts
(arrow). The new bolt length is M 8 x 50 (pre-
viously M 8 x 30).

201.126 1602.911 1052292 011264 * *

I
* not avadable
Production change for protection against

cracks in water jacket
The bolt flutes on the exhaust side have been

reinforced and the recesses (hollows) between
the coolant ducts on the outlet side filled to
prevent cracks in the cylinder head water jacket.
The baseplate on the intake side was reinforced

from previously 11 mm to 14 mm.
01.10 - 400/3
EXIT
Cylinder head gasket for improved sealing
The cylinder head gasket has been equipped

with circumferential silicone sealing strips (arrow)
on both sides and a Viton sealing ring at the oil
return passage at the rear right to better prevent
water and oil leakage.
Production breakpoint: 1 O/88

manual automatic
. not available
Production breakpoint: 05189
* not avallable

manual automatic
* *
iO1.1261602.911 1083460 016487 I
* not available
01.10 - 40014
EXIT
Cylinder head gasket, engines 602, 603

(except for engine 603.970)
The combustion chamber insert (dotted line) has

been modified at the 1st cylinder on the cylinder
block side.
POl-0070.13A
* not avadable
. not avadable
01 10 - 40015
EXIT
Cylinder head gasket, engine 603.970

_
Combustion chamber insert modified.

Silicone sealing strip position changed on
both sides.
A. 1st version
(Gotze)
B. 2nd version
(Elrmg)
* not available
Improvement to passage supports in water

jacket
The passage supports in the cylinder head water

jacket were improved on the turbo-engines.
not available
01.10 - 400/6
EXIT
Reinforcements at valve tappet guides and

exhaust passages
The reinforcements at the valve tappet guides

and exhaust passages have been reinforced.
Modified cylinder heads can be recognized by
the cast no. on the intake side, see table.
Engine previous cast no. new cast no.

602 602 016 03 01 602 016 07 01
602 Turbo 602 016 06 01 602 016 08 01
603 Turbo 603 016 15 01 603 016 17 01
* not avadable
. not avadable
01 .lO - 400/7
EXIT
Combustion chamber recess
The size of the combustion chamber recess (d)

was increased to reduce the thermal load in the
cylinder head.

manual automatic
transmission transmission A F
126.1 1603.970 If rom start of production * *
I
201.126 1602.911 (065342 013489 * *
I
* not avadable
01.10 - 40018
EXIT
01410 efinishing precharnber sealing surface

Nozzle holder removed (0l-4 17).
Prechamber removed (01-417).
POl-0181-57
Prechamber mounting bores . . . . . . . . . . . . . . . plug or seal off toward combustion chamber

(item 2).
Countersinking tool
601 589006600(01,02,03) . . . . . . . . . . . . . . bolt into precombustion chamber mounting bore
to be refinished down to stop (items 3 - 4).
Interval “X” . . . . . . . . . . . . . . . . . . . . . . . . . . . measure between top of shaft (01) and top of
sleeve (02) (item 5).
Note
When the cylinder head is installed, measuring
interval “X” replaces measuring the projection
dimension ” C” .
01.10 - 410/l
EXIT
Prechamber sealing surface ................ refinish,

use countersinking tool 601 589 00 66 00 with
tap wrench, turn clockwise approx. 5 revolutions
while exerting slight pressure (item 6).
Caution!
Do not lift countersinking tool while refinishing.
Interval “X” . . . . . . . . . . . . . . . . . . . . . . . . . . . measure again (item 7).
Note
The difference between the 1st and 2nd
measurements corresponds to the material
removed and therefore the thickness of the
required spacer ring.
Countersinking tool ...................... unscrew and clean chips out of mounting bore
(item 8).
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turn over with starter to throw out any chips
which may have got into the combustion
chamber (item 9).
Spacer ring . . . . . . . . . . . . . . . . . . . . . . . . . . . select according to difference in measurements
and install (item 10).
Note
See table for thicknesses of available spacer
rings.
Refinished precombustion chamber . . . . . . . . . . mark with punch in area of mounting bore
(item 1 1).
Data
Precombustion chamber projection dimension “C” 7.6 - 8.1 mm
Parts
Designation Part no.
Spacer ring 0.3 mm 601 017 04 60
0.6 mm 601 017 02 60
1.0 mm 601 017 03 60
01.10 - 410/2
EXIT
Special tool
601 589 00 66 00
01
Refinishing
Note
Refinish prechamber sealing surface when
damaged or leaking. The first refinishing
operation on the prechamber sealing surface can
be performed with the cylinder head removed or
installed. If the sealing surfaces have already
been refinished once before, this can be
recognized by the markings (punch marks) in the
area of the prechamber mounting bores or on
the spacers installed. In this case
it is necessary to remove the cylinder head
to refinish again. The prechamber projection
dimension “C” (7.6 - 8.1 mm) can only be
measured precisely with the cylinder head
removed. Maintenance of this projection
dimension ensures that the necessary distance
between the prechamber and piston crown is
present when the piston is in the TDC position.
01.10 - 41013
EXIT
Cylinder head removed:

1 When the cylinder head is removed the
scope of work for refinishing is the same except
for items 5 and 7. Instead of items 5 and 7
measure the projection dimension (c).
Cylinder head installed:

2 Plug or seal off prechamber mounting bores
toward combustion chamber (e.g. with rag), so
that chips cannot get into the combustion
chamber.
3 Remove protective sleeve from

countersinking tool 601 589 00 66 00.
4 Install countersinking tool 601 589 00 66 00

into the prechamber mounting bore to be
refinished down to the stop.
5 Measure interval “X” between top of shaft

(01) and top of sleeve (02) and note value.
Note
When the cylinder head is installed, measuring
the interval ‘IX” replaces measuring the
projection dimension “C”.
01.10 - 41014
EXIT
6 Attach tap wrench to countersinking tool

601 589 00 66 00 and turn countersinking tool
clockwise approx. 5 rotations while exerting light
pressure.
Caution!
Do not lift countersinking tool while refinishing.
7 Measure dimension “X” again. The diffe-

rence between the first and second measure-
ments corresponds to the material removed.
Determine thickness of spacer ring:
Example:
Calculate material removed
Dimension before refinishing = 25.7 mm
Dimension after refinishing = 25.5 mm
Material removed = 0.2 mm
Note
In this example the thickness of the spacer ring
to be installed is 0.3 mm. Select the spacer ring
so that it is at least 0.1 mm thicker and max.
0.3 mm thicker than the amount of material
removed.
8 Remove countersinking tool

601 589 00 66 00 and remove chips.
Note
If sealing surface is not completely flat, install
countersinking tool again and refinish sealing
surface again. Then repeat measurement, items
5 and 7.
01.10 - 41015
EXIT
9 Remove rag from precombustion chamber

bore and turn over engine with starter to throw
out any chips which may have got into the
combustion chamber.
10 Insert proper spacer ring.
11 Mark cylinder head with punch mark above

each prechamber seat refinished (arrows).
01.10 - 41016
EXIT
01415 emoval and installation of cylinder head

Camshaft removed (05220).
Nozzle holders removed(01-417).
Poly-V-belt tensioning device removed (13-345).
POl-0243-57
AWarning
Remove cylinder head only after engine has
cooled off.
Battery (120) . . . . . . . . . . . . . . . . . . . . . . . . . . disconnect negative cable, if not already
disconnected (item 1).

Air intake hose (11) and air
cleaner cover (10) . . . . . . . . . . . . . _ . . . . . . . . if not already removed, remove together with
filter cartridge, install (item 2).
Turbo-engines:
Intake hose (1) . . . . . . . . . . . . . . . . . . . . . . . . . to exhaust gas turbocharger, remove, install
(item 3).
Fuel filter (12) ..... ..................... remove, install (items 4, 5, 35, 36).
01.10 - 415/l
EXIT
Holder (62) . . . . . . . . . . . . . . . . . . . . . . . . . . . for oil dipstick tube, remove, reinstall

(items 6, 34).
Engines with exhaust gas recirculation:
Pipe (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . between exhaust gas recirculation valve (13)
and intake manifold or charging air manifold,
remove, install (item 7).
Exhaust gas recirculation valve (13) .......... remove line to air guide housing, install
(items 7, 33).
Side exhaust support (5) .................. on transmission, unbolt, bolt on, 25 Nm (items
8, 32).
Exhaust pipe (4) ........................ unbolt from exhaust manifold (3), bolt on,
25 Nm (items 9, 31).
Pipe elbow (7) . . . . . . . . . . . . . . . . . . . . . . . . . for heater feed, remove, install (items 10, 11,
29).
Note
Replace O-ring.
Glow plugs . . . , . . . . . . . . . . . . . . . . . . . . . . . . unbolt connection lines (9) bolt on
(items 12, 37).
Intake manifold (8) on naturally aspirated engines
or charging air manifold on turbo-engines . . . . . . remove, install, 25 Nm (14-180).
01.10 - 415/2
EXIT
PO1 4244-57
Slide rail bolts (221, 222) .................. on cylinder head, knock out, knock in,
impact puller 116 589 20 33 00,
threaded rod 116 589 02 34 00 and
threaded insert 123 589 00 34 00
(items 14, 30).
Note
When installing coat collar on slide rail bolts with
sealant.
Slide rail (15) . . . . . . . . . . . . . . . . . . . . . . . . . . for timing chain, remove from timing chain case,
install (items 15, 28).
Allen bolts (16) ......................... in area of timing chain case, unbolt, bolt on, 25
Nm (items 16, 27).
01.10 - 415/3
EXIT
Cylinder head bolts (17, 18, 19) . . . . . . . . . . . . . unbolt in opposite order of torquing diagram,
check length of cylinder head bolts and replace
if necessary. Bolt on according to torquing
diagram, socket 601 589 00 10 00
(items 17, 20, 23 - 28).
Note
Observe different lengths of bolts and tightening
specifications.
Cylinder head (20) . . . . . . . . . . . . . . . . . . . . . . remove together with cylinder head gasket (21),
install (items 18, 19, 21, 22).
Note
Clean parting surfaces on cylinder head and
check for cracks. Install cylinder head with new
gasket.
After assembling engine . . . . . . . . . . . . . . . . . . check cooling and engine oil systems for
leakage (item 38).
Tightening torques and rotation angles (tightening in stages) Nm

Cylinder head bolts with 12-point Initial tightening torque Stage 1 15
Allen head (engine cold) Stage 2 35
Rotation angle Stage 3 90”
Interval for setting 10 min
Rotation angle Stage 4 90”
M 8 Allen bolts in area of timing chain case (reference value) 25

Exhaust pipe on exhaust manifold 25
Side exhaust support 25
01.10 - 4194
EXIT
Cylinder head bolt dimensions and maximum

permissible lengths (L)
New state Max. permissible

length (L) in mm
M 10x80 83,6
M 10x102 1056
M 10x115 118,6
Tightening sequence, engine 602
Tightening sequence, engine 603
01.10 - 41%
EXIT
Special tools
116589203300 116589023400 001 589 72 21 00

05 / 05 00

7 mm hex. socket on flexible shaft for hose e.g. Hazet,
Order no. 426-7
Removal
AWarning
Remove cylinder head only when engine is cool.
1 Disconnect negative cable on battery.
01.10 - 41516
EXIT

2 Remove air intake hose (arrow) and air
cleaner cover together with filter cartridge, if not
already removed.
Turbo-engines:
3 Remove intake hose to exhaust gas
turbocharger.
4 Disconnect fuel lines (arrows) from fuel filter

and remove lines from fuel filter.
5 Unbolt hex. head bolts (116) from fuel filter

and remove fuel filter from cylinder head.
01.10 - 415/7
EXIT
6 Unbolt holder (62) for oil dipstick tube from

cylinder head.
Engines with exhaust gas recirculation

(naturally aspirated engines):
7 Remove line (arrow) from exhaust gas
recirculation valve to air guide housing.
8 Unbolt hex. head bolts (1) for side exhaust

support (5) from transmission. Loosen hex. nuts
(2) on exhaust pipe.
9 Unbolt exhaust pipe at exhaust manifold.
01.10 - 415/8
EXIT
10 Pull off retainer (91) for heater feed line with

hook (01).
11 Unbolt pipe elbow (93) from oil filter and pull

pipe elbow off of connection fitting (89).
12 Unbolt connection lines from glow plugs.
13 Remove intake manifold (naturally aspirated

engines) or charge air manifold (turbo-engines)
(14-180).
Note
Leave exhaust manifold mounted on cylinder
head.
14 Knock slide rail bolts (221, 222) out of

cylinder head with impact puller
116 589 20 30 00, threaded rod
116 589 02 34 00 and threaded insert
123 589 00 34 00.
Note
If the slide rail bolts are too tight, puller
115 589 20 33 00 can also be used.
15 Remove slide rail for timing chain from

timing chain case.
16 Remove M 8 x 30 Allen bolts (arrows) from

the area of timing chain case.
Note
Longer bolts (M 8 x 50) are used in the area of
the timing chain case on engine model
602.91 starting 09187 or 10 87 respectively.
POl-2365-13
01.10 - 41519
EXIT
17 Unbolt cylinder head bolts in opposite order

of torquing sequence using socket
601 589 00 10 00.
18 Remove cylinder head from cylinder block

together with cylinder head gasket.
19 Clean parting surface on cylinder head and

check for cracks.
20 Check length (L) of cylinder head bolts.
Note
If the length (L) exceeds the maximum
dimension, use new cylinder head bolts for
installation.
PO10133-13
Installation
21 Position new cylinder head gasket on

cylinder block.
22 Position cylinder head.
Note
When positioning the cylinder head use fitted
sleeves for locating cylinder head.
23 Oil threads and head contact surface of

cylinder head bolts.
24 Install cylinder head bolts by hand making

note of different bolt lengths and sizes, see
tables below.
Note
Oil bolt head contact area.
01.10 - 415110
EXIT
Engine 602
Bolt diagram
Hole Bolt size
$5, 11, 13, 19 M 10x80
2,4,6,8,10, 12, 14, 16, 18, M 10x102

20,22
1, 7, 9, 15, 17, 21 M 10x115
a (Timing case area) M 8x30 or

M 8x50
b (Fuel filter) M 8X80
Engine 603
Bolt diagram
Hole Bolt size
3,5, 11, 13, 19, 21 M 10x80
2,4,6,8,10, 12, 14, 16, 18, M 10x102

20, 22, 24, 26
1, 7, 9, 15, 17, 23, 25 M 10x115
a (Timing case area) M 8x30 or

PO1-0128-13
M 8x50
b (Fuel filter) M 8x80
01.10 - 41511
EXIT
25 Tighten cylinder head bolts in stages in

specified in the torquing sequence, use socket
601 589 00 10 00.
26 Torque cylinder head bolts in specified

tightening sequence.
Tightening torques and rotation angles for cylinder head bolts

Stage 1 15 Nm
Stage 2 35 Nm
Stage 3 90”
Setting time 10 min
Stage 4 90”
27 Tighten Allen bolts (arrows) in area of timing

chain case, tighten in specified sequence, tight-
ening torque 25 Nm.
28 Install slide rail for timing chain in timing

chain case and knock in slide rail bolts
(221) 222).
Note
Coat collar on slide rail bolts with sealant.
01.10 - 415/12
EXIT
29 Install pipe elbow (93) for heater feed line

using new O-ring and slide onto connection
fitting (89). Attach retainer (91) with hook (01).
Note
Dip O-ring in coolant to facilitate installation.
00 not use grease or oil.
30 Install intake manifold (naturally aspirated

engines) or charge air manifold (turbo-engines)
(14-180).
31 Bolt exhaust pipe onto exhaust manifold,

32 Bolt side exhaust support (5) onto

transmission. Tighten hex. head bolts (1) and
hex. nuts (2), tightening torque 25 Nm.
Engines with exhaust gas recirculation

(naturally aspirated engines):
33 Attach line (arrow) from exhaust gas
recirculation valve to air guide housing.
01.10 - 415/13
EXIT
34 Bolt oil dipstick tube with holder (62) into

cylinder head.
35 Install fuel filter, tighten hex. head bolts

(116).
36 Connect fuel lines.
37 Bolt connection lines onto glow plugs.
38 After assembling engine check cooling and

oil system for leakage after warming up engine.
Note
It is not necessary to retorque the cylinder head
bolts.
01.10 - 41504
....................................................................
...................................................
EXIT
Prellmlnary operations:
Mount for engine control removed (30-300)
Nozzle holders removed (07.1-230).
Vertlcal qectlon Angular Injection

(example engine 601) (example engine 601)
Glow plugs (R9) . . . . . . . . . . . . . . . . . . . . . . . . remove, reinstall, 20 + 2 Nm (item 1).

Vertical injection:
Threaded ring (112) . . . . . . . . . . . . . . . . . . . . . remove, reinstall, 90 - 110 Nm, pin wrench 615
589 00 07 00 (item 2).
AWarning
When screwing in or out assure that the pin
wrench is seated in the grooves in the threaded
ring.
01.10 - 417/l
EXIT
Angular injection:
Threaded ring (112a) . . . . . . . . . . . . . . . . . . . . remove, reinstall, 70 Nm, splined wrench
603 589 00 09 00 (item 3).
Prechamber (110) .. ..... ...... . . ........ knock out, install, impact puller
602 589 00 33 00 and check (items 4, 6).
Note
Install prechamber so that the lug on the collar
of the prechamber is located in the recess in
the cylinder head.
Prechamber mounting bore . . . . . . . . . . . . . . . . in cylinder head, clean, check and cover
(item 5).
Note
Refinish prechamber sealing surface if required
(01-410).
Prechamber survey
603. 9622)
603.9702)
starting
09188
601/09 601125 601/26 601/30
or 23
‘) With exhaust gas recmulatlon startmg 02/89
01.10 - 417/2
EXIT
Differentiation, vertical and angular injection
F'O10112-17
A Prechamber, vertical injection B Prechamber angular injection, inclined 5”

Code 601107, 601117, 601/09, 601123 Code 601/l 4, 601 05
x Cone
y Recess
01.10 - 417/3
EXIT
C Prechamber, angular injection

Inclined 5”) turned 180”
Code 601125, 601 26, 601130
x Cone
y Recess
Differentiation, combustion neck diameter

The individual combustion neck diameters (d)
differ on naturally aspirated engines and turbo-
engines.
d = 14 mm naturally aspirated engines

PO50130-15
d = 15 mm turbo-engines
01.10 - 4174
EXIT
Differentiation, combustion bores

6 combustion bores with different diameters are
located in different planes and at different angles
in the bottom section of the prechamber
(combustion neck).
The injection angle is always 180”.
POl-O136-15
Combustion bore diameters (dia. in mm)

__.
Prechamber code 601107 or 601,109 or 601/14/25 601115126 601130
17 23
l-l Firing duct 790 770 7,O 790 790
J Combustion neck 14,0 150 14,o 15,o 15,o
K Combustion bore 195 195 178 198 178
L Combustion bore 372 392 390 370 390
M Combustion bore 390 390 370 390 390
N Combustion bore 290 290 2,5 2,5 2,5
0 Bore for glow plug 10,o 10,o 10,o 10,o 10,o
Glow plugs 20+2
Threaded ring, vertical injection go- 110
Threaded ring, angular injection 70
Special tools
615 589 00 07 00 603 589 00 09 00 602589003300

0-l 01
/
01.10 - 417/5
EXIT
001 5890066 21 00 I
1 Remove glow plugs (R9).
Installation note
Tightening torque 20 + 2 Nm.
Vertical injection:
2 Bolt threaded end (03) of pin wrench
615 589 00 07 00 into threaded ring of
prechamber.
PO5-2132-13
01.10 - 417/6
EXIT
2.1 Slide sleeve (02) of pin wrench over thread-

ed end and insert into grooves in threaded ring.
Caution!
The sleeve must be seated tightly in the grooves
of the threaded ring.
2.2 Counter sleeve (02) with hex. head bolt

(01).
2.3 Remove threaded ring with open-end

wrench on hex. end of sleeve (02).
Installation note
Oil threaded ring.
Tightening torque 90 - 110 Nm.
Angular injection:
3 Remove threaded ring with splined wrench
603 589 00 09 00.
Installation note
Oil threaded ring.
4 Bolt impact puller 602 589 00 33 00 into

prechamber and knock out prechamber.
01.10 - 417/7
EXIT
Installation note
Insert prechamber into mounting bore so that lug
on collar of prechamber fits in recess in cylinder
head (arrows).
5 Clean mounting bore for prechamber in

cylinder head, check and cover.
Note
Refinish prechamber sealing surface if required
(01-410).
6 Check prechambers.
Note
The spherical pin must not be burned or scaly.
If the combustion tips are burned or cracked in
the bottom section of the prechamber, check the
following:
1. Oil level at oil temperature of approx. 80 “C.
If the quantity of oil in the oil pan is too high,
correct oil level.
2. Check piston vacuum pump for damage or
replace vacuum box on injection pump.
To determine with component is unfit for use,

check vacuum lines (blackened with oil).
01.10 - 417,8
.... .................................... ..... ...................................................
EXIT
01418 Facing cylinder head mating surface

Valves removed.
Valve guides checked (05285).
Prechambers removed (01-417).
Cylrnder head pressure-tested (01-420).
/
1
PO1 Xl246-57
Mating surface (1) . . . . . . . . . . . . . . . . . . . . . . plane according to operating instructions of tool

manufacturer.
Note
Observe permissible minimum height (H) and
machining data.
Valve seats (2) . ....................... refinish until minimum interval (a) is reached
(05291).
After assembly . ....................... check engine timing (05215).
01.10 - 418/l
EXIT
Data
Total height of cylinder head in mm ‘) 142.9 - 143.1
Minimum height (H) after machining in mm 142.4
Material removal per facing operation in mm 0.5
In longltudlnal dlrectlon 0.08

Permissible unevenness of mating surface in mm
In transverse direction 0.0
Permissible deviation in parallel of upper mating surface in relation to lower 0.1

surface in longitudinal direction in mm
Roughness in mm 0.004
Test pressure with air under water in bars gauge pressure in mm 2
Minimum distance (a) (recess) with new valves and new Intake - 0.1 to - 1.0
valve seats in mm
Exhaust
Max. distance (a) (recess) with new valves and machined Intake - 1.0
valve seats in mm
Exhaust
1) It IS not permwble to machine the upper mating surface of the cylinder head.
Commerciallv available tools

Cylinder head clamping fixture e.g. Hunger,
D-8000 Munchen 70
Order No. 211.60.000
Valve seat machining tool, model VDSNL l/45/30 e.g. Hunger,
D-8000 Munchen 70
Order No.
Testing set for valve seats e.g. Hunger,
D-8000 Munchen 70
Order No. 216.93.300
65” correction blade No. 13 for bottom correction angle e.g. Hunger,
D-8000 Munchen 70
Order No. 216.64.622
01.10 - 418/2
EXIT
oring out camshaft bearing bores (repair stage)

Cylinder head removed (01-415).
Camshaft removed (05220).
Valves removed.
PO1-0062-57
Camshaft bearing caps (1) ................. remove, install, 25 Nm.

Camshaft bearing basic bores (D) ........... measure.
Note
It is only possible to rebore the camshaft
bearing bores once to max. 0.5 mm oversize.
Observe repair stage dimensions.
Camshaft bearing basic bores (D) . . . . . . . . . . . bore out according to operating instructions for
tool used.
Caution!
When boring ensure that the mating surface at
the rear of the cylinder head cover and the
mount for the sealing plate at the front are not
damaged.
01.10 - 419/l
EXIT
After boring . . . . . . . . . . . . . . . . . . . . . . . . . . . remove burrs on mating surfaces of camshaft

bearing caps (1) and mating surfaces on
cylinder head.
Note
Edges with burrs can lead to poor lubrication
during engine operation resulting in bearing
damage.
Install new camshaft (2) . . . . . . . . . . . . . . . . . . with oversize bearing journals (Dl ), code for
oversize camshaft (05215 or 05220).
Data, camshaft bearings

Standard dimension Camshaft bearing diameter D 30.95 - 31.04
Journal diameter Dl 29.934 - 30.95
Repair stage Camshaft bearing diameter D 31.45 - 31.54 -
Journal diameter Dl 31.434 - 31.45
Camshaft bearing bores Roughness 0.003 - 0.006
Permissible out-of-round 0,012
New value Wear
. limit
Bearing play radial 0.050, - 0.091 0.15
axial 0.030 - 0.100 0.15
Note
If bearings have seized or are scored deeply, the
camshaft bearings in the cylinder head can only
be rebored once to a maximum of 0.5 mm
oversize. After reboring replace damaged
camshaft with new camshaft with oversize
bearing journals.
Special tool
01.10 - 41912
EXIT
ressure-testing cylinder head

Cylinder head removed (0l-4 15).
Camshaft removed (05-220).
Valves removed.
Valve shaft seals removed (05-270).
Cooltng water return flttlng removed.
Cylinder head (1) . . . . . . . . . . . . . . . . . . . . . . . clean.

Pressure plate (2) ....................... bolt onto cylinder head with rubber sealing plate
601 589 00 25 00, unbolt.
Connection for cooling water return fitting and
heater feed line . . . . . . . . . . . . . . . . . . . . . . . . on cylinder head, plug tightly.
Compressed air . . . . . . . . . . . . . . . . . . . . . . . . connect to fitting (3) on pressure plate and allow
compressed air to flow into cylinder head at
pressure of 2 bars.
Cylinder head (1) with pressure plate (2) . . . . . . . fasten to suspension device 115 589 34 63 00
and immerse in water preheated to approx.
80 “C.
01.10 - 420/l
EXIT
Cylinder head (1) ....................... check for air bubbles exiting.
Note
Air bubbles indicate a leak, locate exit point for
air bubbles more precisely if possible.
Data
Test pressure with air under water 2 bar
Special tools
(601 5890100 25 00) 115 589 34 63 00

0-l

Electrically heated water basin e.g. Otto Dtirr,
D-7123 Sachsenheim-
Ochsenbach
01.10 - 420/2
EXIT
EXIT
03 Crankshaft assembly
Job No.
Checking, replacing and tightening connecting rod bolts .......................... 03 - 310

Reconditioning and squaring connecting rods .................................. 03 - 313
Removal and installation of pistons .......................................... - 316
Modifications to pistons .................................................. -317
Checking and reconditioning crankshaft ....................................... - 318
Installation of crankshaft and connecting rod bearings ............................. - 320
Modifications to crankshaft ................................................ - 321
Replacing front crankshaft radial sealing ring ................................... - 324
Removal and installation of pilot bearing in crankshaft ............................. - 330
Removal and installation of crankshaft pulley and hub ............................. - 341
Checking and correcting adjustment of TDC sensor .............................. - 345
Removal and installation of crankshaft sprocket ................................. - 350
Removal and installation of flywheel and driven plate ............................. - 410
Refinishing flywheel ..................................................... - 420
Replacing ring gear ..................................................... - 430
0311
EXIT
03-310 Checking, replacing and tightening connecting rod bolts
P03-0100-13
Stretch bolt dia. (dimension c) . . . . . . . . . . . . . . measure, minimum dia, = 7.1 mm.

If shaft dia. is less than 7.1 mm replace
connecting rod bolts.
Threads on connecting rod bolts , . . . . . . . . . , . oil.
Connecting rod bolts ..................... initially tighten to 30 Nm and then tighten to
rotation angle of 90 - 100”.
AWarning
Do not use torque wrench with flexible shaft for
rotation angle tightening.
Note
Estimate angle of rotation. For this purpose
insert adjustable torque wrench in break position
(locked) into ratchet.
Position adjustable torque wrench with plug-in
ratchet lengthwise in relation to engine and
continue to turn until it is transverse in relation
to engine.
03.10 - 310/l
EXIT
Dimensions
Part No. 102 038 00 71
Thread M 9x1
Necked down shaft dia. (c) in new condition 7.4 - 0.1
Minimum necked down shaft dia. (c)
Length (L) in new condition 52 - 0.3
Tightening torques and rotation angles

Initial tightening torque
Rotation angle
Special tool
001 589 72 21 00
00
03.10 - 31012
EXIT
03-313 Reconditioning and squaririg connecting rods

Prellmlnary jobs:
Pistons removed (03-316).
168 1-B--]
PO3-0097.15
Connecting rod bolts (168) and sleeves (167) . . . oil.

Connecting rod bearing cap ................ attach without connecting rod bearing shells
(165, 165a), remove, 30 Nm (item 1).
Basic bore (D) . . . . . . . . . . . . . . . . . . . . . . . . . measure, max. 51.619 mm, if dimension is
exceeded, machine bearing cap down max.
0.02 mm (item 2).
Connecting rod bushing (169) . . . . . . . . . . . . . . press in, approx. 2450 N and machine or ream
out (items 3, 4).
Connecting rod (166) . . . . . . . . . . . . . . . . . . . . touch up lateral thrust surfaces (item 5).
Connecting rod (166) . . . . . . . . . . . . . . . . . . . . square with connecting rod tester (items 6 - 8).
Caution!
The connecting rod bearing bore and
connecting rod bushing bore must be parallel to
one another.
03.10 - 313/l
EXIT
Data
Engine 602 603.96 148.97
Center of connecting rod bearing bore to center 149.03
of connecting rod bushing bore (L) E n g i n e 6 0 3 144.97
. 9 7 0
145.03
1 st version 23.974
Width of connecting rod (B) at connecting 24.026
rod bearing bore and connecting rod bushing bore 22.000
2nd version
21.948
51.600
Basic bore for connecting rod bearing shells
51.619
1 st version 29.500
29.521
2nd version
Basic bore for connecting rod bushing (D 1) 28.500
E n g i n e 6 0 2 . 9 1 -+-----
28.521
Engine 603.96 30.500

602.96 -
30.525
1 st version 29.560
29.600
Connecting rod bushing 0 2nd version 28.575
28.600
Engine 603.96 - 30.575
30.600
1 st version 27.018
Engine 27.024
602.91 26.000
Connecting rod bushing 2nd version
0 (D 2) 26.000
Engines 602.96, 603.96/97 28.000
28.000
Roughness of connecting rod bushing, inside 0.005

Permissible offset of connecting rod bearing bore in relation
to connecting rod bushing bore with reference to 100 mm
length 0.1
Permissible deviation of parallel axis alignment:

Connecting rod bearing bore in relation to connecting rod
bushing bore with reference to 100 mm length 0.045
Permissible difference in weight

within engine 49
03.10 - 31312
EXIT
Note on connecting rod versions

The axial play of the connecting rods is limited
by the piston pin eye (piston-guided connecting
rods). For this purpose appropriate thrust
surfaces (arrow) are cast on the piston pin eye.
Connecting rods for engines 602.96, 603.96/97

are not bored hollow.
PO3-0099- 15
Overheated connecting rods

Connecting rods which have been overheated
due to a damaged bearing (blue discoloration)
cannot be reused.
Matching connecting rods and connecting rod

bearing caps are marked (arrow). The connect-
ing rod shafts should not have any transverse
score marks or notches.
Replacement connecting rods are supplied with PO%2088-13
machined connecting rod bushings.
Connecting rod width

Connecting rod width (B) on engines 602 and
603 from start of production is 22 mm.
03.10 - 313/3
EXIT
Engines 602.91, 603.91 starting 1 l/85

The connecting rods are heat treated before
machining to reduce the tendency to warp.
Production beakpoint: 1 l/85
not registered
Engine 603.960 starting 01188

On these engines there are 3 bores (arrows)
with a dia. of 4.5 mm in the connecting rod
eye for lubrication of the piston pin.
P03-0101-13
03.10 - 313/4
EXIT
.
Engines 602.961, 602.962, 603.970 and
602.96, 603.96 starting 09188
On these engines the connecting rod eye is now

equipped with 2 bores (arrows) with a dia. of
4.5 mm.
Engines 602.91, 603.91

Shaft cross section of piston rods reduced (stan-
dardized with M 102) and material changed
49 Mn VS 3 (was CK 45 V 7 50).
Production breakpoint: 09 - 12/86
. not reglstered
Engine 602.91
Shaft cross section was changed back, material
49 Mn VS 3.
03.10 - 31315
EXIT
Production breakpoint:
. W86
. not registered
Tightening torque
Initial tightening torque 30 Nm
Connecting rod bolts
Rotation angle go- 100"
Special tool
001 589 66 21 00
\ 00 /

Connecting rod straightener e.g . Hahn & Kolb,
D-7000 Stuttgart
Model BC 503
Runout gauge e.g . Carl Mahr,

D-7300 Esslingen
Model 844 N
Reconditioning
1 Install connecting rod bearing cap without

connecting rod bearing. For this purpose lubri-
cate threads and bolt head contact surface and
tighten to 30 Nm.
03.10 - 31316
EXIT
2 Measure connecting rod bearing basic bore.

If the basic bore diameter exceeds the value of
51.619 mm or if it is conical, touch up bearing
cap at contact surface on surface plate up to
max. 0.02 mm.
3 Press in new connecting rod bushing (169)

such that oil bores are aligned (arrow). Pressing
force 2450 N.
4 Machine or ream connecting rod bushing

(169).
5 Touch up lateral thrust surfaces of connect-

ing rod (166) on surface plate.
Dl Connectmg rod bushing basic bore

02 Connectmg rod bushmg 0
165 Upper connecting rod bearmg shell
165 a Lower connecting rod bearmg shell
166 Connecting rod
167 Sleeve
168 Connecting rod bolts
169 Connecting rod bushing
B Connecting rod width
D Basic bore
L Center of connecting rod bearing bore to PO3.0097-15
center of connecting rod bushing bore b
Squaring
6 Square connecting rod with connecting rod

tester.
7 Align connecting rod bearing bore with

connecting rod bushing bore (parallel alignment).
03.10 - 313/7
EXIT
8 Check offset of connecting rod bearing bore

in relation to connecting rod bushing bore and
correct, if required.
03.10 - 31318
EXIT
03-316 Removal and installation of pistons

Preliminary jobs:
Engine removed (01-030).
Cylinder head removed(0 l-4 15).
011 pan removed (01-310).
166a
168
PO3-0105-15
Cylinder .......................... . . . . clean.

Connecting rod bolts (168) ............ . * remove, check (03-310), reinstall
(items 2, 12).
Caution !
Do not mix up upper and lower connecting rod
bearing shells (165, 165a).
Connecting rod bearing cap (166 a) . . . . . . remove, oil connecting rod bearing, position
connecting rod bearing cap (166 a) so that code
numbers match on connecting rod (166)
(item 11).
Piston (177) . . . . . . . . . . . . . . . . . . . . . . . remove together with connecting rod (166)
toward top (item 2), check piston rings (178,
179, 180) for easy motion, check gap tolerance
and axial play. Oil piston and cylinder.
Caution !
Do not heat piston.
Attach clamping strap 000 589 04 14 00 and

insert piston into cylinder bore (item 10). The
arrow on the piston crown should point toward
the front of the vehicle.
03.10 - 316/l
EXIT
Piston pin retainer (176) . . . . . . . . . . . . . . . . . . remove, install (items 3, 7).

Piston pin (175) . . . . . . . . . . . . . . . . . . . . . . . press out, oil, press in by hand (items 3, 6).
Piston (177) . . ...................... . remove from connecting rod (166) (item 3),
position on connecting rod (166), the arrow
should point toward the front of the vehicle and
the retaining groove in the connecting rod
toward the left side of the engine (item 5).
After installation:
Crankshaft . . . . . . . . . . . . . . . . . . a....... turn and check clearance between connecting
rod and crankshaft (item 13).
Piston (177) . . ....................... move to TDC and measure distance between
piston crown and crankcase mating surface
(item 14).
Projecting length max.: 0.965 mm
Projecting length min.: 0.735 mm
Cross reference, pistons - cylinders

Piston code Group code Piston dia.
Engine Cylinder dia.
number letter
A 86.970-86.976 87.000-87.006
602.96, 603.96 09’), 01’ ), ooq upon 86.982-86.988 upon 87.012-87.018

134)
l) Engines 602 and 603.96 from begInnIng of productlon.
*) Engine 602.91 starting 02/88.
3) Engine 602.91 starting 09/88.
6) Engine 602.91 03/88 up to 06188.
7, Engine 602.91 06/88 up to 11188.
03.10 - 31612
EXIT
Cross reference, pistons - cylinders
Piston projecting length

Distance between piston crown and crankcase Projection max.0,965
parting surface Projection min.0,735
Test values When new Wear limit
Difference in weight between pistons in one engine 20 g
Piston pin diameter Engines 1 st version 26.995-27.000

602.91 2nd version 25.995-26.000
Engines 27.995-28.000
602.961, 603.96
1 st version 22.05-22.35
Distance, piston pin eye
2nd version 24.1-24.3
Piston pin
clearance
in piston
1 st version 0.126-0.274
Connecting rod in piston (end play)
2nd version 0.050-0.402
Groove 1 0.25-0.45 1.0
Piston ring gap clearance Groove 2 0.20-0.40 1.0
Groove 3 0.20-0.40 1.0
Groove 1 0.090-O. 122 0.20
Piston ring side clearance Groove 2 0.050-0.085 0.15
Groove 3 0.030-0.065 0.1
Tightening torque and rotation angle

Connecting rod bolts Initial tightening torque 30 Nm
Rotation angle 90 - 100”
03.10 - 316/3
EXIT
Special tools
Standard tool
Dial gauge Al DIN 878 e.g. Mahr,
D-7300 Esslingen
Order No. 810
Removal
175
1 Remove combustion residues in cylinder. c
2 Remove connecting rod bolts (168), re-

move connecting rod bearing cap (166a) and
remove connecting rod (166) together with
piston (177) in upward direction.
Caution !
Do not mix up upper and lower connecting rod
bearing shells (165, 165a).
165 -
33
175 Piston pm 165a ____%
176 Piston pm retainer
178 Piston ring
179 Piston ring 168
180 Piston ring
PO3-0105-1s
3 Remove piston pin retainer (arrow) and

press out piston pin, remove piston from
connecting rod.
4 Recondition and square connecting rod

(03-313).
PO3-2107-13
03.10 - 31614
EXIT
Installation
Note
The group code letters (arrows) are stamped on
the crankcase mating surface. Only pistons with
the group code letter “X” are available for repair.
These pistons should also be installed in cylinder
bores with group code letters “A” or ” 6”.
When repairing hone cylinder bores according to

dimensions of present pistons “X” plus piston
clearance.
5 Position piston on connecting rod so that

arrow (1) points toward front of vehicle and
retaining grooves (2) in connecting rod point
toward left side of engine.
Caution !
Do not heat pistons.
PO3-2106-
6 Coat piston pins with oil and press in by

hand.
03.10 - 31615
EXIT
7 Insert piston pin retainer into groove (arrow).
Check piston rings for easy motion.
When installing used pistons check gap and side

clearance of piston rings.
8 Oil cleaned cylinder bores, connecting rod

bearing journals, connecting rod bearing shells
and pistons.
PO3-2109-n
9 Turn piston rings so that gaps are distributed

uniformly around circumference of piston.
10 Attach clamping strap 000 589 04 14 00 and

install piston.
The arrow on the piston crown must point toward

the front of the vehicle.
11 Position connecting rod bearing caps on

connecting rods with codes (arrow) on same
side.
12 Check connecting rod bolts, replace and

tighten (03-310).
13 Turn crankshaft and check clearance

between connecting rod and crankshaft.
14 Measure distance between piston crown and

PO3-2088-13
crankcase parting surface with pistons in TDC
position (see table).
03.10 - 31616
.
EXIT
03-317 Modifications to pistons
Piston pin bearings, engine 602

Piston pin bore provided with angular oil pockets
(previously flat oil pockets) for improved
lubrication.
"not reglstered
Engine 602.91
The piston skirt has been provided with a larger
recess (arrow) for better clearance on engines
with oil injection nozzles or exhaust gas
recirculation..
P03010313
03.10 - 317/l
EXIT
Each piston is equipped with two compression

rings and one oil scraper ring. The first piston
ring groove is provided with a Niresit ring carrier.
178 Bevelled nng with expander, 3 mm thick,

runnrng surface chrome-plated
179 Taper face ring with InsIde bevel, 2 mm
thick, running surface chrome-plated
180 Rectangular ring, 2 mm thrck, runnrng PO3-0104-13
surface chrome-plated
Engine 602.91 starting 09189

The height of the ring groove for the rectangular
ring (180) has been increased from 2.0 to
2.5 mm. 17a0.
-179-
Piston code 16 (Mahle co.) /
Piston code 17 (Alcan co.) :
2iiffE
:Q c ’
@
178 Bevelled rrng with expander, 3 mm thick,

running surface chrome-plated
179 Taper face ring with lnstde bevel, 2 mm thrck,
running surface chrome-plated
180 Rectangular nng, 2.5 mm thick, running PO3-0104-13
These pistons can also be installed in engines

with cylinder sleeves.
Engine 602.91
Temporary installation of pistons from Alcan co., piston code 12, KS co., piston code 14
Production breakpoint 03188
(Piston code 12, Alcan co.)
Model Engine Engine end No. Vehicle ident end No.
manual automatic
201.126 061160 to 012853 to * l
061260 012867
* not reglstered
03.10 - 31712
EXIT
* not registered
Production breakpoint: 04 - OW88
. not regrstered

(Piston code 14, KS co.)
* not reglstered

l
not reglstered
Production breakpoint: 1 l/88

Model Engtne Engine end No. Vehicle ident end No.
manual automatic
201.126 067047 to 013749 to * t
070443 014296
. not registered
03.10 - 317i3
EXIT

* not registered

l
not reglstered
Engines 602.961, 603.96/97 starting 12/87

(turbo)
Piston pins
The size of the piston pin has been increased to
reduce the surface pressure.
Engine 602.961, 603.96:

Dl = 28 mm
02 = 13,5 mm
L = 70 mm
PO3-0165-13
Engine 602.91:
01 = 26 mm
02 = 14 mm
L = 55 mm
03.10 - 317t4
.......................................................................... ..........................
EXIT
Pistons with angular channel

Due to the higher thermal load the pistons are
cooled with oil via an annular channel in the
piston crown. Moreover the piston pins are
supplied with oil injected through the two bores
(2.0 mm dia., arrows), ending in the annular
channel.
The required oil is supplied via injection nozzles

located in the crankcase on the right side.
The annular channel is deleted on engine

603.970. Only the piston crown is supplied
with oil.
A recess is located on the piston skirt (arrow) for

the oil injection nozzle.
The prechamber recess in the piston crown has

a diameter of 18 mm (normally aspirated engine
= 17mm).
PO3 2210-13
Piston crown
On engines 602.96 and 603.97 from the start of
production and on engine 603.96 starting 08188
‘moose horn’recess pistons are installed
(previously ‘star’ recessed pistons).
The piston crown is coated with aluminum oxide
on both piston versions.
A. ‘Moose horn' pston
03.10 - 317/5
EXIT
B. ‘Star’ recessed piston PO3-0107 w
These pistons each have two compression rings

and one oil scraper ring. The piston skirt is
graphitized.
Piston codes: 00 Engine 602.96 /

13 Engine 603.96
PO3-0104-13
178 / Bevelled nng with expander, 3 mm thick, runntng

179 1Taper face ring wtth inside bevel, 2 mm thick,
180 1Rectangular nng with InsIde bevel, 2.5 mm thick,
running surface molybdenum-coated
03.10 - 317 6
EXIT
03-318 Checking and reconditioning crankshaft

Prellmlnary lobs:
Crankshaft removed.
Crankshaft ................... . . . . . * . . . clean

Crack test ................... . . . . . . . . . perform; apply fluorescent powder (magnaflux)
or use penetration method.
Hardness test (scleroscope hardness) . . * . . . . . perform with impact hardness tester
000 589 20 21 00.
Distance (A = 5 - 6 mm) ........ . . . . . . . . . when hardening journals without hardened
fillets, maintain distance A between hardened
runout and fillet radius.
Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . can be hardened inductively or with flame.
Caution !
Harden journals with hardened fillets (arrows)
inductively only.
03.10 - 318/l
EXIT
Data
Crankshaft Crankshaft Fitted bearing Connecting Connecting rod
normal dimen- bearing journal Associated rod bearing bearing journal
sions and repair dia. thickness of journal dia. width
stages thrust
washers Width of journal
2 6 . 5 2 ” 24.532’
2.15 - -
26.50 24.50 27.96
Standard
dimension 57.965 2 6 . 6 2 ” 24.632’ 47.965 28.04
2.20 - -
26.60 24.60
2 6 . 7 2 ” 24.732’
1st repair stage - -
26.70 24.70
2.25
or
2nd repair stage
or 26.92” 24. 932’ 47.650
57.465
- - - 28.30
57.200 2.35 26.90 24.90 47.200
3rd repair stage
57.215 or or 47.215
56.950 2 7 . 0 2 ” 25.032’ 46.950
4th repair stage 2.40 I_ -
56.965 27.00 25.00 46.965
') Up to 06184
2) Stafttng 07184
Test values
Permissible deviation of crankshaft main and rod journals in mm I 0.005
Permissible conicity of crankshaft main and rod journals in mm I 0.01
Permissible roughness of crankshaft main and rod journals (Ra) in mm I 0.005 - 0.015
Permissible deviation of flywheel flange from true in mm I 0.02
Permissible axial runout of fitted bearing in mm
Fillet radii in mm
Permissible deviation of crankshaft main Journal II. IV 0.16

journals when mounted in outer crankshaft __
bearing journals in mm
Journal III 0.25
Scleroscope hardness of crankshaft main and rod journals

Permissible unbalance of crankshaft I 10 cmg
03.10 - 31812
............................................. ............. EXIT
Special tool
Note
When testing and reconditioning crankshafts,
proceed in sequence shown in diagram below.
03.10 - 31813
EXIT
Diagramm
A. Testing, grinding
Visual check
Heavy damage
Crack test ‘)
Cracks present
I Yes I No
Hardness test ‘)
All bearing journals
Scleroscope hardness min. 55 on 213 of journal
circumference
03.10 - 31814
EXIT
Measure journals
Check whether regrinding is still possible

within last specified repair stage 4.
Yes I No
I Scrap
I Grind crankshaft
Crack test
Cracks present
Lapping
Dimension check
Dimensions okay
Yes I No
03.10 - 31815
EXIT
. Hardening
Check whether regrinding is still possible within specified repair stage 4.
Induction hardening
Facilities available
I Check hardness by etching ‘)
03.10 - 31816
EXIT
‘) Explanations on diagram
Crack test
Clean crankshaft. Bearing journals should be
free of oil and grease.
Magnetize crankshaft and apply fluorescent
powder (magnaflux).
A fluorescent penetration method may also be
used (immersion in bath or using spray can).
Agent:
Paint or fluorescent powder,
cleaning agent,
developer
Hardness test
Test hardness with impact hardness tester
000 589 20 21 00 (scleroscope hardness).
The minimum hardness of 55 should be present

on 213 of journal circumference.
Hardening
Journals without hardened fillets can be
hardened inductively or flame-hardened.
Journals with hardened fillets (arrows) must
always be hardened inductively.
If this is not possible, scrap crankshaft.
PO&OOYl-13
03.10 - 31817
EXIT
Checking hardening results

To achieve perfect hardening check adjustment
of hardening equipment using microsections.
These can be obtained from scrapped

crankshafts hardened for testing purposes.
Check hardening by etching the journal surface

with a 2% solution of alcoholic nitric acid
vJO3).
Dark spots should not appear on the journal

surface.
Unhardened fillets will become dark.
In the case of hardened fillets they should

appear as bright as the surface of the journals.
We recommend comparing the etching test with

a journal tested via metallographic microsection.
Then carefully wash off nitric acid with alcohol.
Corrosion protection
Crankshafts which are not installed again
immediately should be lubricated with engine
break-in oil (SAE 30).
03.10 - 31818
EXIT
03-320 Installation of crankshaft and connecting rod bearings

Prelmnary jobs:
Mam 011 passage m crankcase open (01-l 30).
Oil passages In crankcase and crankshaft cleaned.
Crankshaft tested (03-318).
Connectmg rods recondltloned (03-313).
4 .
4a
~~ PO3-0109-31
Crankshaft bearing caps (2, 3) . . . . . . . . . . . . . . install without bearing shells, observe

markings, tighten.
Tightening torque or rotation angle:
Crankshaft bearing bolt M 12 (4) 90 Nm
Crankshaft bolt M 11 (4 a) 55 Nm, 90 - 100".
03.10 - 320/l
EXIT
Basic bores ........................... measure conicity in directions A, B and C,

min. 62.500 mm, max. 62.519 mm (item 3).
Crankshaft bearing caps (2, 3) .............. remove (item 4).
Crankshaft bearing shells (146, 147) .......... insert (item 4).
Caution!
Do not mix up upper and lower crankshaft
bearing shells.
Crankshaft bearing caps (2, 3) .............. position in proper order, position washers (4 b)
and tighten crankshaft bearing bolts (4 and 4a)
(item 4).
Tightening torque and tightening rotation angle
crankshaft bearing bolts M 12 (4) 90 Nm
crankshaft bearing bolts M 11 (4a) 55 Nm,
90 - 100” (item 4).
Crankshaft .............. ............ measure bearing journals, determine bearing
clearance (item 5).
Fitted bearing journal . . . . . . . . ........... measure width and match appropriate thrust
washers (item 7).
Crankshaft bearing caps (2, 3) ............ remove crankshaft bearing bolts (4 and 4a),
remove caps, remove lower bearing shells (147)
and insert crankshaft (145) with thrust washers
(148, 148a), position lower bearing shells (147)
(items 8, 9). The oil grooves must point toward
the crankshaft. Oil crankshaft, bearing shells
and thrust washers.
Crankshaft bearing caps (2, 3) ............ position in correct order and tighten crankshaft
bearing bolts (4 and 4 a) (items 10, 11).
Tightening torque and tightening rotation angle
crankshaft bearing bolts M 12 (4) 90 Nm,
crankshaft bearing bolts M 11 (4a) 55 Nm,
90 - 100”.
Crankshaft (145) .........I ., . . . . . . . . . . measure end play, new value 0.100 - 0.254 mm;
wear limit 0.30 mm.
03.10 - 32012
EXIT
3
166
165 -
33 166a
8/
165a-cb
Connecting rod bearing caps (166 a) . . . . . . . . . install without bearing shells and tighten,
30 Nm. Observe marking.
Basic bore for rod bearing ................. measure (03-313).
Rod bearing shells (165, 165 a) . . . . . . . . . . . . . insert, install rod bearing cap and tighten,
rod bearing bolts (168) 30 Nm.
Caution!
Do not mix up upper and lower rod bearing
shells.
Connecting rod bearing diameter . . . . . . . . . . . . measure and note value (item 15).
Connecting rod bearing journals ............. measure, new value 47.950 mm, determine
bearing clearance, wear limit 47.965 mm
(item 16).
Connecting rod radial clearance ............. measure, new value 0.030 to 0.055 mm;
wear limit 0.08 mm (item 16).
Pistons (177) . . . . . . . . . . . . . . . . . . . . . . . . . . attach to connecting rod (166) together with
piston pins (175) and piston pin retainers (176)
and install (observe installation position)
(03-316).
03.10 - 32013
EXIT
Pistons (177) and connecting rods (166) . . . . . . . install (arrow on piston crown toward front of
vehicle) (03-316).
Connecting rod bearing end play . . . . . . . . . . . . measure, new value 0.12 to 0.26 mm; wear
limit 0.50 mm (item 20).
Oil pump and oil filter . . . . . . . . . . . . . . . . . . . . disassemble and clean, renew oil pressure valve
and install initial operation oil filter cartridge.
Data
Crankshaft Crankshaft Fitted bearing Connecting Connecting
standard dimen- bearing journal Associated rod bearing rod bearing
sions and repair dia. thickness of journal dia. journal width
stages thrust Width
washers of journal
26.52” 24.532’
2.15 - -
26.50 24.50 27.96
Standard
dimension 57.965 2 6 . 6 2 ” 24.632’ 47.965 28.04
2.20 - -
26.60 24.60
2 6 . 7 2 ” 24.732’
1 st repair stage P -
26.70 24.70
2.25
or
2nd repair stage
or 2 6 . 9 2 ” 24.932’
57.465 47.650
- - - 28.30
57.200 2.35 26.90 24.90 47.200
3rd repair stage
I
57.215 or or ~47.215
I
56.950 2 7 . 0 2 ” 25.032’
- -
’46.950
4th repair stage I2.40
56.965 27.00 25.00 46.965
’ ) Up to 06184
2) Starting 07/84
03.10 - 32014
.
EXIT
Basic bore and bearing play in mm Crankshaft bearing Connecting rod beartng
Basic bore width on

fitted bearing Engines 602 and 603
Engines 602 and 603
Connecting rod width
Permissible out-of-round of basic bore 0.01
Permissible conicity of basic bore 0.01

New value 0.030 - 0.055’)
Bearing play, radial
Wear limit 0.08
New value 0.100 - 0.254 0.12 - 0.26
Bearing play, axial
Wear limit 0.30 0.50
‘1 For radial play, set to medium value.
Bearing shells
Width of bearing Thickness of fitted Wall thickness
shells in mm bearing thrust Connecting rod
washers in mm bearing in mm
17.30 - 17.50 I 2.15 or 2.20 1.80
1st repair stage 2.37 2.25 1.92

2nd repair stage 2.50 or 2.05
3rd repair stage 2.62 2.35 2.17
4th repair stage 2.75 or 2.30
2.40
03.10 - 3206
EXIT
Engine 602.91
The tolerance range for the wall thicknesses of
the connecting rod bearings was replaced
starting 08185 with three stages. The stages are
indicated by a color code.
Only connecting rod bearing shells with the color
code yellow are available as replacement parts.
Color code Dimension

Red 1.804 to 1.808 mm
Yellow 1.808 tol.812
Blue 1.812 to1.816
Engines 602.96, 603.96 and 603.96/97

Upper connecting rod bearing shells from Glyco
with improved coating (cathode dust coating
method).
03.10 - 32016
EXIT
Engines 602.96, 603.96/97

The groove for fixing the connecting rod bearing
was modified to assure correct installation
position.
Dimension A: 3.2 mm for all engines

Dimension B: 2.5 mm 602.96, 603.96197
3.5 mm 602.91
PO3-0095 13
‘) Engines 602.96 and 603.97 from star-t of productlon
Note
The axial forces of the crankshaft are taken up
by the thrust washers.
PO3-0115-13
03.10 - 32Oi7
EXIT
The thrust washers (148 and 148a) installed in

the crankcase and in the bearing caps have a
different shape.
The thrust washers in the crankshaft bearing

caps each have two retaining lugs to prevent
rotation and installation errors, whereby the lower
retaining lugs are off-center.
When reconditioning crankshafts, regrind width-

of fitted bearing journals to one of the
dimensions shown in the table (section “Data”).
Match thrust washers to respective journal width

(table).
cb
146
-2 Bearing cap
9
148
4 Crankshaft bearing
boltM 12x60
4a Crankshaft bearmg
bolt M 11 x 62
4b Washer
145 Crankshaft
146 Beartng shell
148 Upper thrustwasher PO3 0092 17
! 48a Lower thrust washer
Thrust washers of the same thickness must

always be installed on both sides.
Do not regrind thrus? washers.
Thrust washers are available for replacement in

sets only. One set consists of one upper and
one lower thrust washer (148 and 148a).
03.10 - 32018
EXIT
Association of crankshaft bearing shells and crankcases
I 1 punch mark 2 punch marks 3 punch marks ‘)

1 Bearing shell association with color code
Blue I Blue Yellow Yellow
Yellow I Blue Yellow Red

Red I Yellow Yellow Red
I) Color dots on crankshaft cheeks or counterwelghts next to crankshaft Journals.
*) Punch marks on parting surface of crankcase on 011 pan side next to basic bore.
The standard dimension crankshaft bearing

shells with color codes blue, yellow and red are
available as parts.
They must be matched according to the table.
This eliminates the necessity of measuring the
bearing clearance.
PO3-2066-13
Punch marks for matching crankshaft bearing shells
When ordering crankshaft bearing shells the

code 52 for blue
54 for yellow
und 56 for red
must be indicated in addition to the part No.
Only the yellow version bearing shells are

available for the connecting rod bearing shells.
03.10 - 32019
EXIT
Thrust washer sets

Thickness in mm Set
Part No.
2.15 601 030 00 62

2.20 601 030 01 62
2.25 601 030 02 62
2.35 601 030 03 62
2.40 601 030 04 62
Tightening torques and rotation angle

M 12 90 Nm
Crankshaft bearing bolts
M 11 Initial tightening torque 55 Nm
Initial tightening torque 30 Nm
Connecting rod bolts
M 18 x 1.5 x 50 bolts on crankshaft 320 Nm
Special tools
000 589 51 37 00 000 589 04 14 00 001 589 72 21 00

03 03 13 00

Connecting rod straightener e.g . Hahn & Kolb,
D-7000 Stuttgart
Model BC 503
Internal gauge e.g. Carl Mahr,
D-7300 Esslingen
Model 844 N
Micrometer screw e.g. Carl Mahr,
D-7300 Esslingen
Dial gauge Al DIN 878 e.g. Carl Mahr,
D-7300 Esslingen
Model 810
03.10 - 320/10
EXIT
Installation of crankshaft and connecting rod

bearings
1 Attach crankshaft bearing cap.
Note
All bearing caps are fitted laterally into crankcase
(arrows) and are fastened with two M 12 x 60
or M 11 x 60 bolts each.
The pilot fit (arrows) is offset 0.5 mm from the

center so that the bearing caps can be mounted
in one position only.
The bearing caps are also identified from front to

rear with the code numbers 1, 2, 3, 4 etc. and
must not be mixed up.
2 Lubricate crankshaft bearing bolts for

crankshaft bearing caps and tighten.
Tightening torque and rotation angle:

Crankshaft bearing bolts M 12 90 Nm,
crankshaft bearing bolts M 11 55 Nm,
90 - 100”.
3 Measure basic bore in directions A, B and C

at two levels (conicity).
POl-o179-13
If specified value for one basic bore is exceeded

or conical, touch up bearing cap at parting
surface on surface plate up to max. 0.02 mm.
03.10 - 320111
EXIT
4 Remove crankshaft bearing bolts, insert

crankshaft bearing shells, install crankshaft
bearing caps and tighten.

Crankshaft bearing bolts M 12 90 Nm
go- 100".
Caution!
Observe order of crankshaft bearing caps. Do
not interchange upper and lower crankshaft
bearing shells.
Engine 602
Fitted bearing: bearing 4
03.10 - 320112
EXIT
Engine 603
FItted bearing: bearmg 5
A Upper bearing shells, crankcase 6 Lower bearing shells (cap shells)
5 Measure crankshaft bearings and note

values.
I\‘
\ ( PO3-2020-13
03.10 - 320/13
EXIT
6 Measure crankshaft bearing journals, deter-

mine crankshaft bearing radial clearance.
Note
The bearing clearance can be corrected by
exchanging bearing shells. Attempt to achieve
the mean value of the specified bearing
clearance.
Caution!
Observe different wall thicknesses.
PO3-2116-13
7 Measure width of fitted bearing journal and

find proper thrust washers (see table, section
Data).
8 Removecrankshaft bearing bolts, remove

lower crankshaft bearing shell, oil crankshaft,
position in crankcase and oil lower crankshaft
bearing shell and reposition.
Caution!
The two oil grooves (arrows) in the thrust
washers should point toward the crankshaft
cheeks.
9 Oil thrust washers and slide into grooves

at fitted bearing (crankcase).
PO3-2118-13
03.10 - 320/14
EXIT
10 Position crankshaft bearing caps in proper

order.
Note
The crankshaft bearing caps are marked with
code numbers at the marking points (arrows).
PO3-2113-1:
11 Tighten crankshaft bearing caps.

Crankshaft bearing bolts M 12 90 Nm
90 - 100”.
12 Measure crankshaft end play.
13 Turn crankshaft by hand and assure that it

runs free.
Installation of connecting rod bearings and

connecting rods
14 Insert connecting rod bearing shells, install

connecting rod bearing caps with bearing shells
and tighten connecting rod bolts to 30 Nm.
Connecting rod bearing shells are available only

in the yellow version.
03.10 - 320/15
EXIT
Note
The upper connecting rod bearing shells for
engines 603.96 are made using a different
material starting 05186 due to the higher load.
Caution!
Do not mix the upper and lower bearing shells.
They can be recognized by the stamped-in part
number.
Upper bearing shells 603 08 10

PO3-0115-13
or 603 15 10
Lower bearing shells 601 04 11
or 601 08 11
A 3.2 mm all engines
8 2.5 m m engines 603.96, 603.97
The bore for lubrication of the piston pin has 3.2 m m engine 602
been eliminated.
Due to higher loads in engine 603.970, the

upper connecting rod bearing shells are made of
a different material than the lower shells.
To prevent misassembly, the upper locating
groove is 0.7 mm narrower.
15 Measure connecting rod bearing diameters

and note.
16 Measure connecting rod bearing journals.

Determine connecting rod bearing radial
clearance.
The bearing clearance can be corrected by

changing the bearing shells, whereby it should
be attempted to achieve the mean value of the
specified bearing clearance. Observe different
wall thicknesses.
17 Install pistons on connecting rods (03-316).
18 Coat bearing shells, crankshaft, pistons and

cylinder walls with engine oil, install connecting
rods with pistons (03-316).
03.10 - 320/16
EXIT
19 Tighten connecting rod bolts to initial torque

of 30 Nm and then turn 90 - 100”.
20 Measure connecting rod bearing end play

while moving connecting rod directly at piston
pin. Assure that connecting rod moves freely in
relation to crankshaft. Use dial gauge holder
363 589 02 21 00.
Caution!
Disassemble oil pump and clean, replace if re-
quired. Replace oil pressure valve. Disassemble
oil filter and clean.
Install initial operation oil filter cartridge. Change

oil filter cartridge and oil after 1000-l 500 km.
03.10 - 320/17
EXIT
03-321 Modifications to crankshaft
Increased displace-
ment engine 603.970
The stroke was in-

creased to 94.2 mm and
the web width (b)
reduced to 21.75 mm to
increase the
displacement (3.5 I) on
the 603.970 engines.
Engine 602.96 crankshaft webs

On engine 602.96 starting 12187 the web width
(D) was increased by 8 mm for a total of 90 mm.
D 90 mm (engine 602.961)
03.10 - 321/l
EXIT
Engine 602.91 flywheel locating pin

Cylindrical pin in crankshaft for locating the
flywheel and driven plate.
Production breakooint: 01186

Vehicle ident end No.
not registered
l
03.10 - 32112
EXIT
This page int ntiowally left blank.
03.10 - 32113
EXIT
03-324 Replacing front crankshaft radial sealing ring

Preliminary jobs:
Poly-V-belt removed (13-342).
163
161a
162
I
Q
162
162b
PO34123-35
Engines 602, 603:

Crankshaft pulley (161 a) with vibration damper
(163) and Allen screws (162) and
washers (162 b) . . . . . . . . . . . . . . . . . . . . . . . .
remove, install (03-341) (item 2).
Note
The vibration damper for engine 602 is not
interchangable with that from motor 603.
Do not interchange during repairs.
Hub (157) with hex. head bolts (160) and
Belleville washers (159) . . . . . . . . . . . . . . . . . . . remove, install (item 3).
Note
The cylindrical pin (158) centers the crankshaft
pulley and vibration damper.
03.10 - 324/l
EXIT
Crankshaft radial seal (31) ................. replace. Deburr and clean mounting bore. Coat
sealing lip with oil and press in with special tool
601 589 03 14 00 (item 4).
Note
The sealing ring for the repair crankshaft radial
seal is offset 3 mm toward the inside so that it
will not run in a groove left on the hub by the
standard crankshaft radial seal.
Part No. for repair crankshaft radial seal:

010 997 34 47 or 010 997 68 47.
Allen bolts for crankshaft pulley 25
Mounting bolt for hub 320
Special tools
001 589 66 21 00 (601

10358;;33OO/j """0; 400: 601 589 03 14 00 001 589 74 21 00
00 03 00
Commercially
____ _ available too tool
Adapter 314” square socket e.g. l-iazet,
to 1,‘2” square head D-5630 Remscheid
Order No. 1058 R-l
03.10 - 32412
EXIT
Replacement
Engine 601.921
1 Remove crankshaft pulley (03-341).
Engines 602, 603

2 Remove crankshaft pulley with vibration
damper (03-341).
Caution!
Do not interchange vibration dampers.
3 Remove crankshaft hub (03-341).
Note
The cylindrical pin centers the crankshaft pulley
and vibration damper.
4 Press out crankshaft radial seal with screw-

driver. Do not damage crankshaft journal or
mounting bore.
Installation note
Deburr and clean mounting bore for crankshaft
radial seal.
Coat sealing lip of new crankshaft radial seal

with oil and press in with special tool
601 589 03 14 00.
Assure that the crankshaft radial seal is seated

properly.
5 Reinstall in opposite order.
03.10 _ 32413
EXIT
eplacing rear crankshaft radial sealing ring
150a
600
PO3-0118-55
Flywheel (149)
and driven plate (150a) . . . . . . . . . . . . . . . . . . . remove, install, (03-410) (items 1, 9).
Crankshaft radial seal (600) ................ remove, replace. Check running surface on
crankshaft flange, clean mounting bore, coat
sealing lip of crankshaft radial seal with oil and
press in with special tool 601 589 03 43 00
(items 2 - 8).
Caution!
Ensure that radial seal is seated properly.
Crankshaft radial seal (600) ................ check for leakage with engine running (item 10).
03.10 - 327/l
EXIT
Note
The sealing ring for the repair crankshaft radial
seal is offset 3 mm toward the inside so that it
will not run in a groove left on the hub by the
standard crankshaft radial seal.
A Standard crankshaft radial seal

B Repair crankshaft radial seal
Special tools
Renewal
1 Remove flywheel or flywheel and driven

plate (03-410).
2 Press crankshaft radial seal out of end cover

with screwdriver.
Do not damage crankshaft flange or end cover.

Cover crankshaft flange with rag.
03.10 - 32712
EXIT
3 Check running surface for crankshaft radial

seal on crankshaft flange for damage.
4 Clean mounting hole for crankshaft radial

seal, deburr, if required.
5 Bolt inner part of installation tool

601 589 03 43 00 onto crankshaft flange.
6 Coat sealing lip of crankshaft radial seal and

opposite running surface lightly with oil, do not
use grease.
7 Slide crankshaft radial seal (arrow) over

inner part of installation tool 601 589 03 43 00.
8 Press crankshaft radial seal against stop in

end cover with outer part of installation tool
601 589 03 43 00.
Note
Assure that crankshaft radial seal is properly
seated.
9 Install flywheel or flywheel and driven plate

(03-410).
PO%2129-13
10 Check for leakage with engine running.
03.10 - 32713
EXIT
Note
For reasons of standardization the same radial
ball bearing (134) as in engine 102 is installed.
The ball bearing is sealed on both sides with
Viton cover discs and cemented into the
crankshaft.
PO3409&13
130 a Spacer ring
Replacement parts
Designation Part No.
Spacer ring 102 031 02 51
Locking ring 102 031 01 33
Ball bearing 115 980 01 15
Engines 602, 603 from start of production.
For repair these parts can also be installed in

engines produced earlier.
Cement
Loctite 241 002 989 94 71
Special tools
03.10 - 33012
EXIT
1 Pull radial ball bearing out of crankshaft

together with locking ring, use internal puller
000 589 25 33 00 and countersupport
000 589 33 33 00.
Installation note
Knock in spacer ring flush.
Coat new ball bearing with cement

002 989 94 71 and knock into crankshaft with
suitable punch on outer race.
03.10 - 33013
EXIT
03-341 Removal and installation of crankshaft pulley and hub
163
161a
162
162b
PO3-0123-35
Engines 602, 603:

Crankshaft pulley (161 a) and vibration
damper (163) ..........................
remove, install, use washers (162 b) and Allen
screws (162), 25 Nm. Use lock
601 589 02 40 00 (items 1, 3).
Note
The crankshaft pulley and vibration damper are
centered by the cylindrical pin (158).
Do not mix up vibration dampers.
03.10 - 341/l
EXIT
H u b ( 1 5 7 ) ..,.....................,, . . . remove, install, hex. head bolt (160) 320 Nm.

Install Belleville washer (159) with arched side
toward crankshaft pulley. Use puller
103 589 00 33 00 (items 2 - 4).
Crankshaft radial seal (31) ............. . . . . replace (03-324) (item 5).
Engines 602 and 603

The scale and TDC pin are located in the
vibration damper.
3,i 2oa 155 l55a
145
28 Timing case cover ! ‘
7 I I
31 Crankshaft radial seal
145 Crankshaft
155 Woodruff key
155a Woodruff key
156 Crankshaft sprocket
157 Hub
158 Cylindrical pm 8 x 8 mm
159 Bellevrlle washer
160 BoltM 18x1.5x50
161a Crankshaft pulley
Dra. 152 mm engines 601, 602
Dia. 173 mm engine 603
162 Allen bolt M 8 x 28
162b Washer B 8
PO3-0120-15
Engine 602
The vibration damper on engine 602 has a 35
mm wide machined recess (arrow) on the front
and are therefore lighter.
A Vrbratron damper, engine 602

B Vrbratton damper, engine 603
PO%01 64-15
03.10 - 341/2
EXIT
Engine 602.96
The vibration damper for engine 602.96 is a two-
mass vibration damper. The diameter (D) was
increased by 9 mm for a total of 228 mm
(naturally aspirated engines, single-mass
vibration damper 219 mm).
Caution!
These vibration dampers cannot be installed on
engine 602.91.
Engine 603.96
The vibration damper of engine 603.96 is a
single-mass vibration damper and identical with
that of the naturally aspirated engine except for
the resonant frequency. Do not interchange.
Engine 603.96 Color: grey PO3-0166-15
Allen bolts on pulley 25
Crankshaft flange bolt 320
Special tools
001 589 74 21 00 103589003300 601 589 03 14 00

00 03 03
.
Commercially available tool - ~-__---

Adapter 314” square socket e.g. l-lazet ,
to l/2” square head D-5630 Remscheid
Order No. 1058 R-1
03.10 - 34113
EXIT
Engines 602 and 603

3 Unbolt crankshaft pulley (161a) and vibration
damper (163) and remove.
31 28 155 l55a
Screw out hex. head bolt (160).
Installation note
Install Belleville washers (159) with arch toward
crankshaft pulley (161 a). The crankshaft pulley
(161 a) and vibration damper (163) are centered
with the cylindrical pin (158).
160
Do interchange vibration damper (163).
159
162
Tightening torques 162
Hex. head bolt (160) 320 Nm,

Allen bolts (162) 25 Nm.
PO3-0120-1s
28 Timing case cover

31 Crankshaft radial seal
145 Crankshaft
155 Woodruff key
155a Woodruff key
156 Crankshaft sprocket
157 Hub
158 Cyllndncal pin 8 x 8 mm
159 Bellevllle washers
160 BoltM 18x1.5x50
161a Crankshaft pulley
Dia. 152 mm engines 601, 602
Dia. 173 mm engtne 603
162 Allen screw M 8 x 28
162b Washer 6 8
4 Pull hub off of crankshaft journal with puller

103 589 00 33 00.
5 Replace crankshaft radial seal (03-324).
03.10 - 34114
EXIT
03-345 Checking and correcting adjustment of TDC sensor
-01
PO3-0124-15
Holder for TDC sensor, engines 602 and 603 from start of
productlon
Cylinder 1 ............................ turn to approx. 10” BTDC, ignition stroke

(item 1).
03.10 - 34511
EXIT
Gauge (01) . . . . . . . . . . . . . . . . . . . . . . . . . . . boltinto preignition chamber bore and set

dial gauge (07) on gauge to 5 mm pretension
(item 2).
Note
If cylinder head is removed, position gauge pin
of dial gauge directly on piston crown (177).
Use dial gauge holder 363 589 02 21 00.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turn in running direction until dial gauge pointer
stops moving (TDC position), set dial gauge
scale to zero (item 3).
Engine . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . turn until dial gauge moves back 3.22 mm
on engines 602 and 603 or until dial gauge
moves back 3.65 mm on engines 601.921,
603.97 (item 4).
Note
Corresponds to crankshaft position of 20”
ATDC.
Holder for TDC sensor (42) or (44) . . . . . . . . . . . install locating device 603 589 01 21 00
(item 5).
Note
The pin on the crankshaft pulley or on the
vibration damper must catch in the groove on
the locating device, if not, correct position of
holder.
Holder for TDC sensor (42) or (44) . . . . . . . . . . . correct by loosening bolt (41), move holder for
TDC sensor until pin on crankshaft pulley or
vibration damper catches in locating device
603 589 01 21 00 and tighten bolt (41)
(items 6 - 8).
03.10 - 34512
EXIT
Special tools
603 589 01 21 00
03

Dial gauge A 1 DIN 878 e.g. Mahr,
D-7300 Esslingen
Order No. 870
Testing
Note
The holder for the TDC sensor is fastened to the
timing case cover.
44 Holder TDC sensor, engines 602 and

603 from start of productlon
PO3-2138-l
Check adjustment of holder and correct, if

required:
a) When holder is replaced.
b) When crankshaft and hub, vibration damper

and crankshaft pulley are replaced.
c) When timing case cover is removed,

installed or replaced.
0310 - 3450
EXIT
1 Position piston in cylinder 1 to approx. 10"

BTDC, ignition stroke.
Holder for TDC sensor, engines 602 and 603 from

start of productlon
2 Bolt gauge 601 589 07 21 00 up to

precombustion chamber bore and attach dial
gauge to gauge with 5 mm pretension (small
pointer on dial gauge).
If the cylinder head is removed, the measuring

pin on the dial gauge can be positioned directly
on the piston crown. Set dial gauge holder
363 589 02 21 00 on crankcase mating surface.
03 10 - 345i4
EXIT
3 Turn crankshaft slowly in normal direction of

rotation until large pointer on dial gauge (07)
stops (TDC position). Turn dial gauge scale until
large pointer points to zero.
01 Gauge PO3-0124-15
177 Plston crown
4 Turn crankshaft in normal direction of

rotation slowly until the gauge moves back
3.22 mm on engines 602 and 603 or 3.65 mm
on engine 603.97.
Note
After the dial gauge has moved back (crankshaft
position 20” ATDC) the pin in the crankshaft
pulley or in the vibration damper should be
located exactly below the TDC sensor (arrow).
5 Position locating device 603 589 01 21 00 in

holder for TDC sensor.
The pin on the crankshaft pulley or on the

vibration damper must catch in the groove in the
locating device.
If the pin on the crankshaft pulley or on the

vibration damper does not catch, correct position
of holder for TDC sensor.
03.10 - 34515
EXIT
Correcting
6 Loosen holder (42 or 44) with screw (41)

and move until pin on crankshaft pulley or on
vibration damper catches in the groove in the
locating device 603 589 01 21 00.
42 Holder for TDC sensor, engine 601.921
7 Screw holder for TDC sensor down tight.
8 Remove dial gauge and gauge

601 589 07 21 00 and locating device
603 589 01 21 00.
44 Holder for TDC sensor engines 602, 603 from

start of productlon
03.10 - 34516
EXIT
03-350 Removal and installation of crankshaft sprocket

Prelrmlnary jobs:
Timing case cover removed (01-210).
Vehicles with level control: Dnve
for 011 pump removed (05-437).
PO3-0125-35
Tensioning bracket (262) .................. remove together with torsion spring (261),
install (items 1, 17).
Oil pump sprocket (257) . . . .............. unbolt hex. head bolt (259) and remove together
with washer (258) (item 2).
Chain for oil pump drive (263) .............. remove (item 3).
Chain tensioner (224) . . . . . .............. remove, install. Replace sealing ring (237)
(05-310) (items 4, 13).
Camshaft sprocket (188) . . . .............. mark in relation to timing chain (210), remove
retaining bolt (190) together with washer (189)
and remove camshaft sprocket (items 6 - 8).
Note
Observe differences in bolts.
Crankshaft sprocket (156) . . . . . . . . . . . . . . . . mark in relation to timing chain (210)
(item 5).
03.10 - 350/l
EXIT
Crankshaft sprocket (156) . . . . . . . . . . . . . . . . . pull off with puller 601 589 07 33 00 and check
retaining wedge (155a), replace, if required
(items 9 - 10).
Crankshaft sprocket (156) ...........*... replace, transfer color code and knock onto
crankshaft with installation punch
116 589 07 15 00 while paying attention to
retaining wedge (155a) (items 11 - 12).
Camshaft sprocket (188) . . . . . . . . *....... position on mark, install timing chain and
tighten. Remove hex. head bolts (190) and
washers (189). Hex. head bolt 65 Nm, 12-point
bolt 25 Nm/90” rotation angle (item 13).
Crankshaft ........... . .............. continue to turn and check adjustment markings
at TDC position (item 15).
Oil pump sprocket (257) . ............... install with chain for oil pump drive (263) and
tighten hex. head bolt (259) 25 Nm (item 16).
Note
Install chain sprocket so that arch points toward
oil pump.
Engine . . . . . . . . . . . . . . * . * . . . . . . . . . . . . allow to run and check for leakage (item 18).
Bolt for camshaft sprocket

Starting 1 l/88 the bolt for mounting the camshaft
sprocket was changed from an M 10 bolt to an
M 11 stretch bolt on engines 602.91/96;
603.91196 and 603.970
(see 05-220).
0 3 . 1 0 - 35012
.......................................................... ....................
EXIT
Tightening torques and rotation angles Nm

Hex. head bolt for camshaft sprocket 65
12-point bolt for camshaft sprocket 25 90”
Hex. head bolt for oil pump sprocket 25
Special tools
116 589 07 15 00 001 589 66 21 00

i 35 00
Removal
1 Remove clamping bracket (262) and torsion

spring (261).
2 Remove hex. head bolt (259) with washer

(258) and remove oil pump sprocket (257).
3 Remove chain for oil pump drive (263).
4 Remove chain tensioner (05-310).
5 Mark position of timing chain and crankshaft

sprocket in relation to one another.
03.10 - 350/3
EXIT
6 Mark position of timing chain and camshaft

sprocket in relation to one another.
7 unbolt hex head bolt and remove with

washer.
8 Remove camshaft sprocket and allow timing

chain to sag.
c
9 Pull off crankshaft sprocket with puller
601 589 07 33 00.
10 Check condition of retaining wedge in

crankshaft, replace, if required.
Installation
11 Transfer color code from old crankshaft

sprocket to new crankshaft sprocket.
12 Knock crankshaft sprocket onto crankshaft

with installation punch 116 589 07 15 00. Pay
attention to retaining wedge.
PO&20-J-13
03.10 - 35014
EXIT
13 Install camshaft sprocket and timing chain

making note of marking and tighten.

Wex. head bolt 65 Nm,
12-point bolt 25 Nm, 90”.
14 Install chain tensioner and replace sealing

ring (05-3 10).
15 Continue to turn crankshaft and check

adjustment marking at TDC (arrows).
16 Install chain for oil pump drive together with

oil pump chain sprocket and tighten.
Note
Install oil pump sprocket so that arch points
toward oil pump (arrows).
PlS-2031.13
I
17 Attach clamping bracket (262) and torsion

spring (261).
03.10 - 35015
., ._ . . . . . EXIT
ernoval and installation of flywheel and driven plate
149
152a
15oc
149a
149b
PO-57
Flywheel (149, 149a, 149b) . . . . . . . . . . . . . . . . unbolt, reinstall. Position lock

601 589 02 40 00 in flywheel ring gear and
remove flywheel together with driven plate
(150a, 150~) and spacer disc (150b)
(items 1, 2).
Driven plate (153) engine 603.970 . . . . . . . . . . . unbolt, reinstall.
Position lock 601 589 02 40 00 in teeth on
driven plate and remove driven plate and spacer
disc (150b) (items 1, 2).
03.10 - 410/l
EXIT
Stretch bolts (152, 152a) .................. check, max. length, 1 st version (152a) 26.5 mm,
2nd version (152) 22.5 mm, necked down shank
diameter min. 8 mm, replace stretch bolts if
required (item 2).
Initial torque 35 Nm,
rotation angle 90 - 100”.
Stretch bolts (152~) on two-mass flywheel (149b)
engine 602.91, ........... ..............
check, max. length 57.2 mm, necked down
shank diameter min. 8.1 mm, replace stretch
bolts if required (item 2).
Stretch bolts 152 152a 152~

manual and automatic
automatic transmission transmission, two-
transmission
Driven plate Driven plate
2nd version 1 st version
Part number 102 032 00 71

Thread D lM 10x1
Necked down New state 1 8,5 - 0,2 8,5 - 0,2 I 8,5 - 0,2
shank dia. d
Length L New state I 22 + 0,2

Max. length I 22,5
03.10 - 41012
EXIT
Flywheels for manual transmissions
Engine 602
D 252.94-252,98 mm
Dl 223.00-223.07 mm
H 57 mm
03.10 - 41013
EXIT
Engine 602.96
Engine 602.96 has a lighter flywheel than engine
602.91 with automatic transmission.
A Flywheel, engine 602.91

B Flywheel, engme 602.96
145 Crankshaft
149 Flywheel
150a Driven plate
151 Rmg gear
152a Stretch bolt
152b Cylindmalpm PO3-0126-15
Engine 603.96
-----152b
-145
----l52a
145 Crankshaft
149 Flywheel
150a Driven plate
151 Rmg gear
152a Stretch bolt
152b Cylmdrlcal pm PO3-0127-15
03.10 - 41014
EXIT
Two-mass flywheels with manual

transmissions, engine 602.91 starting 09188.
Stop damper
2 Primary flywheel weight
3 Fitted pin
4 Radial ball bearing
5 Stretch bolt M 10 x 1 x 57
6 Self-allgnlng beanng
7 Spacer bolt
8 Torsion damper
9 Friction device
10 Secondary flywheel weight
11 Spacer bolt
12 Ring gear
Flywheels with automatic transmissions
A Flywheel, engine 602

B Flywheel, engine 603
03.10 - 41015
EXIT
Tightening torques and rotation angles Nm

Stretch bolts for flywheel 35 90 - 100”
Stretch bolts for two-mass flywheel 40 90 - 100”
Special tools
1 601 589024000 1 1 001 5896621 00
1 Remove hex. head bolts (55) and insert lock

601 589 02 40 00 into ring gear on flywheel and
tighten with hex. head bolts (55).
Installation note
Flywheels do not require balancing.
Flywheels are not interchangeable.
PO3-209@-13
03.10 - 41017
EXIT
Engines 602, 603

Screw out stretch bolts and remove flywheel and
driven plate.
Installation note
The cylindrical pin (arrow) centers the flywheel,
driven plate and spacer disc.
Check stretch bolts, max. length 22.5 mm,
necked down shank dia. min. 8 mm, renew
stretch bolts if required.

Driven plate (engine 603.97)

Screw out stretch bolts (152), remove spacer
disc (150b) and driven plate (153).
Installation note
necked down shank dia. min. 8 mm, replace

rotation angle 90 - 100”. L PO3-0 174.13
03.10 - 410/8
EXIT
Two-mass flywheel with manual

transmission, engine 602.91
Remove stretch bolts and remove two-mass
flywheel.
Installation note
necked down shank dia. min. 8.1 mm, replace

rotation angle 9 0 - 1 0 0 ”.
03.10 - 410/g
EXIT
03420 efinisking flywheel
Prellmlnary lobs:
Flywheel and driven plate removed (03-410).
PO3-0133-15
Engine 602 Engine 603 (except for 603.97)
Dimension (b) ....................... . . measure, max. 17 mm, min. 15.6 mm.

If material removal causes dimension (a) to
exceed max. causing dimension (b) to be less
than 15.6 mm, replace flywheel.
Dimension (a) ........................ . . measure, engine 602: 22.5 mm, engine 603:
19.4 mm. Maximum material removal 1 mm,
if material removal is greater than 1 mm,
replace flywheel.
Caution!
If the clutch surface (A) is refinished, the
mounting surface (B) must be refinished by the
same amount so that distance (a) is
maintained.
03.10 - 420/l
EXIT
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refinish
Caution!
The two-mass flywheel cannot be refinished.
Clamp flywheel in lathe so that permissible
deviation from flat = 0.05 mm is not exceeded.
Data
Engine 602 603
Distance a 22.5 2 0.1 19.420.1
in new state 16.6 + 0.4
Distance b
for repair up to 15.6 + 0.4
Permissible deviation from flat on clutch
surface or clutch attachment surface 0.05 mm
Note
Flywheels for manual transmissions with burned
spots, scoring or cracks on the clutch surface
should be refinished by precision turning.
If the scoremarks or cracks are greater than the

maximum permissible material removal
dimension, replace flywheel.
After machining the clutch surface should not

have any porous spots or chatter marks.
03.10 - 420/2
EXIT
@placing ring gear
Preliminary jobs:
Flywheel and driven plate removed (03-410).
Flywheel (149) ......................... check, centering flange dia. (a) for ring gear
275.00 + 0.05 mm. Clean mounting surface for
ring gear on flywheel before installing ring gear.
Ring gear (151) ........................ drill hole into old ring gear and break up with a
chisel or heat quickly and then remove
immediately. Heat new ring gear and install on
flywheel. Temperature for shrink fit 220 “C.
Lateral runout on ring gear max. 0.4 mm.
Standard accessories
Temperature measuring chalk e.g. AW Faber-Castell,
Color No. 2815/220 (white) thermochrome D-8504 Stein bei Nurnberg
03 10 - 430/l
EXIT
Caution!
The ring gear is hardened. For this reason do
not exceed 220 “C at any point while heating
with hot plate or heating furnace.
Use temperature measuring chalk in accordance

with directions.
Use open flame only In exceptional cases. Apply

flame to inside of ring gear only.
After replacing ring gear, it is not necessary to

balance the flywheel.
03 10 - 43012
EXIT
ine Timing, Valvstr

EXIT
ngine thing, valves 05
Job No.
Checking and renewal of hydraulic valve clearance compensating elements . . . . . . . . . . . . 05 - 211

Checking camshaft timing ................................................ - 215
. Removal and installation of camshaft ......................................... - 220
Removal and installation of valve springs ...................................... - 250
Checking valve springs .................................................. - 260
Renewal of valve stem seals .............................................. - 270
Checking and machining valves ............................................ - 280
Checking and renewal of valve guides ........................................ - 285
Replacing1 of valve seat inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 290
Machining valve seats ................................................... - 291
Removing and installing chain tensioner ...................................... -310
Renewal of timing chain .................................................. - 320
Removal and installation of tensioner rail ...................................... - 330
Removal and installation of guide rail ......................................... - 341
Removal and installation of pressure oil pump drive .............................. - 437
EXIT
05-211 Checking and renewal of hydraulic valve clearance compensating

elements
185
-0188-17
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bring to operating temperature (80°C).

Engine oil level ....................... check.
Caution!
Do not overfill.
Turbo engine:
Charge air pipe ......................... remove, install.
Cylinder head cover ..................... remove, install, 10 Nm.
Valve tappet (203) ...................... check with a mandrel, to do this first check on
the cylinder which is exactly on Ignition TDC
(cam tips for inlet and exhaust valve pornt
upwards).
Caution!
Unnecessary rotation of the engrne causes the
valve clearance compensating elements to sink.
05 10 211 1
EXIT
A valve clearance compensating element must

only be removed when an air gap >0.4 mm is
established between cam and element. The
engine must not be turned by the camshaft
timing gear bolt.
If the valve tappet sinks quicker than the others,

measure pre-stroke.
Pre-stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . measure, reference value: 0.25 - 2.0 mm
(Numbers 6 - 10).
With excessive pre-stroke:
Valve tappet (203) . . . . . . . . . . . . . . . . . . . remove, install in the same posrtion again,
magnetic lifter 102 589 02 61 00.
Dimension Ll . . . . . . . . . . . . . . . . . . . . . . . determine. The dimension Ll is the difference
between the dimensions L and L2. Reference
value 18 - 19 mm (Number 12 - 14).
Parts of the valve tappet ............... clean. The valve tappet must be replaced if oil
loss cannot be eliminated.
Data 1st Design 2nd Design 3rd Design

from 08 84 from 01 90
Plunger “b” dimension W 2 (mm) 8.0 8.6 9.1
Guide sleeve “g” dimens. f-4 1 (mm) 12.5 13.2 13.2
Note
Hydraulic valve clearance compensating
a
elements have been fitted with a larger oil
b
reservoir chamber since the start of production
9
on engines 602 and 603.
a Storage chamber
Break date: 08184
05.10 _ 211 2
EXIT
From 09/87 valve tappets have been installed

with a ventilation bore (d = 0.2 mm), in order to
prevent tappet rattle during short distance
operation.
a Reservoirchamber
b Plunger
C Working chamber
1
not recorded
05 10 - 211 3
EXIT
From 01,90 revised valve clearance

compensating elements have been installed.
These compensating elements have a reduced
residual stroke, i.e. the stroke of the plunger (b)
and the working chamber (c) have been reduced
and the reservoir chamber (a) enlarged.
Less oil is needed in the working chamber due
to the reduced stroke. Therefore the working
chamber fills up more quickly after initial engine
starting.
not recorded
l
Hexagon bolts for cylinder head cover 10
05 10 - 211 4
EXIT
Special tools
001 589 72 21 00 001 589 66 21 00 601 589 08 21 00 102 589 03 40 00

00 / 05 05
L /
Conventional tool
Dial gauge e. g. Mahr
D-7300 Esslingen
Part No. 810
Checking
1 Run engine to operating temperature (80°C).
2 Check engine oil level, making absolutely

sure it is not overfilled.
Turbo engine:
3 Remove charge air pipe.
4 Remove cylinder head cover.
Caution!
Turning the engine unnecessarily causes valve
play compensating elements to sink.
The engine must not be turned by the camshaft
timing gear bolt.
5 First check the cylinder which is exactly on

TDC. (Cam tips for inlet and outlet valves point
upwards).
0510 - 211 5
EXIT
6 In order to check with a mandrel press lightly

on the valve clearance compensating element
and thus check the clearance. Continue turning
the engine until the next cylinder in the firing
order can be checked.
A valve clearance compensating element must
only be replaced when a clearance of >0.4 mm
is established between cam and element. If the
valve tappet sinks quicker than the others, or
has play at the cam base circle, the pre-stroke of
the valve tappet must be measured.
Measuring pre-stroke
7 The basic setting of the dial gauge has to be
undertaken before measurement. To do this
insert the dial gauge in the measuring bridge
601 589 08 21 00 and push in until there is a
preload of approx. 1 mm. The probe in the
measuring bridge must be in the basic position
(lower stop).
The basic setting must not be changed during

measurement.
8 In order to measure and note dimension “X”

(cylinder head mating surface to valve tappet),
put measuring bridge on the cylinder head
mating surface over the valve tappet.
Note
If required, measure dimension “X” on all valve
tappets.
0510 - 211 6
EXIT
9 Remove camshaft (05220).
10 Measure dimension “Y” (cylinder head

mating surface to valve tappet).
The difference between the dimension “X” and

“Y” is the pre-stroke of the valve tappet.
Reference value: 0.25 - 2.0 mm.
Example:
No. 1 Cylinder A (exhaust) E (Inlet)
Dimension “Y” mm 2.82 2.98

Dimension “X” mm 1.95 1.92
Pre-stroke mm 0.87 1.06
11 If the valve tappet sinks too quickly or if the

dimension differs from the reference value, lift
out valve tappet with the magnetic lifter
102 589 03 40 00.
Note location of valve tappet.
’ \\J
^^_ ^^__+
.^
0510 - 211 7
EXIT
12 Measure dimension “L” on valve tappet.

13 Measure dimension “L2” on valve tappet.
The dimension Ll is the difference between

L and L2.
Reference value: 18 - 19 mm
14 If the dimension "Ll" is outside the

reference value remove guide sleeve.
To do this pull out guide sleeve out of the valve
tappet with rotary movements using pliers.
Do not damage guide sleeve.
15 Pull plunger out of the guide sleeve and

remove compression spring.
16 Blow through all individual parts with

compressed air.
Blow air through valve tappet at the oil supply

bore and ventilation bore (arrows).
PO5 2264 13
17 Remove snap ring from the guide sleeves

and pinch slightly at the edges (arrows) and
reassemble on the guide sleeve.
18 Install guide sleeve, compression spring

and plunger in sequence.
PO50189-13
05 10 - 211 8
EXIT
19 Fill plunger with engine oil. Press off ball

valve with a suitable pin and then ventilate the
working chamber by pumping the plunger, close
ball valve and possibly replenish oil. Then no oil
should escape from the ball valve when it is
gently compressed.
Note
If oil escapes, renew valve tappet.
20 Fill valve tappet with engine oil and insert

vented plunger with guide sleeve into the valve POS- 2011-13
tappet.
Fit guide sleeve Into valve tappet until the snap

ring engages, press in, if necessary.
21 Recheck dimension "Ll “.
22 Check oil supply to cylinder head. To do

this unscrew sealing plug of the oil channel
in cylinder head.
Blow compressed air into the oil channel, while

checking exit bores (arrows) at the seat for the
valve tappet for air.
23 Lubricate valve tappet and install in the same

position, noting sequence.
24 Install camshafts (05-220).
25 Install cylinder head cover, 10 Nm.
furbo engine:
26 Install charge air pipe.
05.10 - 211 9
EXIT
05-215 Checking camshaft timing
Preceding work:
Cylinder head cover removed.
InjectIon nozzles removed (07.1-230).
Charge air pipe removed (turbo engines).
Dial gauge holder 363 589 02 21 00 . . . . . . . . . . attach, remove at the No. 1 cylinder inlet valve.
Dial gauge with 3 mm preload on valve tappet.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turn in direction of rotation.
Caution!
Engine must not be turned by the camshaft.
W ith 2 mm valve stroke ................... engine must be at 12” after TDC.
Timing
*) Not used.
3) With Ml 1 thread from 111'88.
“) On used camshafts.
5, Repalr camshafts with 0.5 mm larger bearing diameter and Ml0 thread.
6) Repair camshafts with 0.5 mm larger beanng diameter and Ml 1 !hread.
05 10 - 215 1
EXIT
Bolts for cylinder head cover 10
Special tool
363 589 02 21 00
00
Conventional tool
Dial gauge A 1 DIN 878 e. g. Mahr
D-7300 Esslingen
Part No. 810
Note
It is not possible to correct timing. The trming
chain should be checked for elongation if the
test values differ.
The timing chain is to be replaced with more
than 4” at the crankshaft.
Checking
Caution!
timing gear bolt. Do not turn engine backwards
during measurement, otherwise measuring errors
result.
1 Turn crankshaft in direction of rotation of

the engine until cam tip of the 2nd cam points
upwards.
05.10 - 2152
EXIT
2 Fasten dial gauge holder 363 589 02 21 00

on the cylinder head (above the No. 1 cylinder
inlet valve).
3 Insert dial gauge and extension and fasten

so that probe pin sits on the valve tappet with a
preload of 3 mm (small dial gauge pointer).
4 Turn dial gauge scale until the large pointer

is on “0”.
Caution!
The probe pin of the dial gauge must be exactly
vertical to the valve tappet.
5 Turn crankshaft further in direction of

rotation of engine, unttl the small pointer of the
dial gauge has moved back by 2 mm to 1 mm.
In this position the marking at the crankshaft

pulley or vibration damper must be at 11 - 12"
after TDC. If this value is more than 12" the
camshaft is to be replaced or the timing chain
checked for elongation.
05.10 215~3
EXIT
05-220 Removal and installation of camshaft
203
ws-m92-37
Turbo engine:
Charge air pipe . . ... .. ... ... . . ... ... . . . . remove, install.
Cylinder head cover (125) ................. remove, install, 10 Nm.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . position on ignition TDC of No. 1 cylinder.
Caution!
timing gear bolt.
Chain tensioner (224) . . . . . . . . . . . . . . . . . . . . remove. install, replace sealing ring (237)
(05310).
With self-levelling suspension:
Drive of the pressure 011 pump (400) . . . . . . . . . remove, install (05437).
0510 - 220 1
EXIT
Camshaft timing gear (188) . . . . . . . . . . . . . . . . mark at timing chain (210). Remove, install
camshaft timing gear. Different bolts (190) and
washers (189). Hexagon bolt, 65 Nm, bihexa-
gonal head bolt, 25 Nm 90” angle of rotation.
Caution!
When assembling the camshaft timing gear
ensure that the straight pin (187) is not pushed
out towards the rear.
Camshaft bearing cap (80, 81, 82) . . . . . . . . . . . remove, install, note sequence, hexagon bolts
(84) and washers (84a), 25 Nm.
Caution!
Note torquing diagram!
Camshaft (185) ........................ remove, install. Check for ease of movement.
Lock washer (186) . . . . . . . . . . . . . . . . . . . . . . check.
Valve tappet (203) . . . . . . . . . . . . . . . . . . . . . . remove, install, check.
Magnet lifter 102 589 03 40 00.
After installation . . . . . . . . . . . . . . . . . . . . . . . . allow engine to run, check for leaks.
05.10 _ 220 2
EXIT
Data
Bearing 602 603
position engine
Camshaft timing 0.025 0.025

gear seat
Permitted eccentricity
of center bearing pin 2nd and 5th bearing
and camshaft gear seat
when accepting the
camshaft in the outer
bearing positions
2nd and 6th bearing - 0.030
position
3rd and 5th beanng - 0.045

position
4th bearing position - 0.060
Diameter of camshaft bearing pins 31.445

(repair stage + 0.5 mm)
31.434
Camshaft code numbers

The code number is stamped on the flange
next to the TDC notch (arrow).
TDC marking (arrow) and code number
135 10 - 220 3
EXIT
Engine Thread for Camshaft

sprocket code number
wheel
602, 603 Ml0 07, OS’)
Ml1 11, 13’)

‘1 Repair camshaft with 0.5 mm larger bearing0
Washer for camshaft timing gear bolt

A revised washer with a larger outer diameter (c)
has been fitted in order to prevent the camshaft
timing gear bolt loosening.
A
B
1 st Design
2nd Design
c9 @ PO50205-l 3

Model Engine Engine end No. Vehicle Identification end No.
Manual Automatic
007763
* 1
008022
* l
033213 I
. not recorded
05 10 220 4
EXIT
Camshaft timing gear bolt

From 11,‘88 the camshaft timing gear fixing has
been revised from a Ml 0 hexagon bolt to a Ml 1
bihexagon necked down bolt on all engines.
Tightening torques
Hexagon bolt (A) 65 Nm
&hexagon necked down bolt (6)
Pre-torque 25 Nm
Torsion angle 90”
ql+y
_swl3_
Caution!
0
Note revised plain washer!
52 4
Use the plain washer (A) for the hexagon bolt,

and plain washer (B) for the bihexagon necked
down bolt.
Use carrier (A) for previous hexagon bolt, carrier 1

(B) for bihexagon necked down bolt.
pf33oo213
05.10 - 2205
EXIT
transmission
000187 * 1
019336
201 014216 * *
004561
”
not recorded
Tightening torques and angles of rotation Nm

Hexagon bolts on cylinder head cover 10
Hexagon bolts on camshaft timing gear 65
Bihexagonal head bolt on camshaft timing gear 25 90”
Hexagon bolts on camshaft bearing cap 25
Special tools
001 589 66 21 00 102 589 03 40 00 001 589 72 21 00

00 05 00
Removal
Turbo engine:
1 Remove, install charge air pipe.
05 10 - 2206
EXIT
3 Position engine on ignition TDC of No. 1

cylinder (arrow).
Caution!
Do not turn engine by the camshaft timing gear
bolt. Do not turn engine backwards.
4 Remove chain tensioner (05310).
With self-levelling suspension

5 Remove pressure oil pump (05437).
6 Align camshaft timing gear and timing chain.
7 Unscrew hexagon bolt or bihexagonal head I i

bolt on camshaft timing gear, whilst holding the
camshaft with a mandrel.
8 Remove camshaft trming gear and allow

timing chain to sag.
Note
The timing chain is prevented from twisting when
the timing case cover is assembled.
Caution!
Note different bolt and washer.
0510 2207
EXIT
Caution!
9 It is absolutely essential to observe the
following sequence during removal and
installation in order to avoid damage to the
camshaft:
Engine 602
Unscrew both hexagon bolts on camshaft
1 2 3 4 5 6
bearing caps 1, 2 and 6 (dark arrows).
Loosen both hexagon bolts on camshaft bearing

caps 3, 4 and 5 in increments of one turn
respectively, until counterpressure is reduced
(light arrows).
PO5-0203-13
Engine 603
Unscrew both hexagon bolts on camshaft
bearing caps 1, 5 and 6 (dark arrows).
Loosen both hexagon bolts on camshaft bearing

caps 2, 3, 4 and 7 in increments of one turn
respectively, until counterpressure is reduced
(light arrows).
10 Remove camshaft upwards.
PO5-0204-13
05 10 - 220 8
EXIT
11 Remove lock washer for axial fixing (arrow)

and check condition.
12 Pull out valve tappet with magnetic lifter

102 589 03 40 00.
13 Check valve tappet for condition (visual

inspection), replace if necessary.
Caution!
Install valve tappet in the same position again.
Installation
14 Insert lock washer for axial fixing (arrow) in

cylinder head.
15 Lubricate camshaft and place on the cylinder

head so that the TDC marking (arrow) pornts
vertrcally upwards.
16 Install camshaft bearing caps. Note marking

on beanng caps.
0510 - 2209
EXIT
Assemble camshaft bearing cap bolts (light

arrows) and torque alternately in increments of
one turn respectively in accordance with torquing
diagram, see work stage 9.
Engine 602; camshaft bearing caps 3, 4 and 5

Engine 603; camshaft bearing caps 2, 3, 4 and 7
The remaining camshaft bearing caps (dark

arrows) can then be assembled at random.
17 Install camshaft timing gear according to

marking and trghten. Check strarght pin for
correct seating.
Tightening torques and angle of rotation

Hexagon bolt 65 Nm,
Bihexagonal head bolt 25 Nm, 90”
18 Install chain tensioner (05-310).

19 Install pressure oil pump (05-437).
20 Position engine on TDC of the No. 1 cylinder

and check markings (arrows).
21 Install cylinder head cover. Tightening torque

10 Nm.
Turbo engine:
Install charge air pipe.
After installation:
22 Allow engine to run, check for leaks.
EXIT
05-250 Removal and installation of valve springs

Preceding work:
Camshaft removed (05-220)
203
202
201
A. Cylinder head removed

Cylinder head (70) . . . . . . . . . . . . . . . . . . . . clamp.
Assembly table 601 589 01 59 00, support
bridge 601 589 02 59 00.
Valve tappet (203) . . . . . I remove, rnstall.
Magnetic lifter 102 589 03 40 00.
Valve springs (198) ...... remove, install, check (05-260).
Lever press 601 589 02 61 00, magnetic lifter
102 589 03 40 00. Color marking downwards.
Valve stem seals (199, 200) replace (05-270).
05.10 - 250.1
EXIT
B. Cylinder head installed

Valve tappet (203) . . . . . . . . . . . . . . . . . . . . . . remove, install.
Piston of cylinder concerned . . . . . . . . . . . . . . . position on TDC.
Retaining gear 601 589 01 40 00.
Valve springs (198) ... . . . . . . . . . . . . . . . . . . . remove, install, check (05260).
Support bridge 601 589 02 59 00, lever press
601 589 02 61 00.
Color marking downwards.
Valve stem seals (199, 200) . . . . . . . . . . . . . . . replace (05-270).
Since 03’86 the lower valve spring retainers

have been revised. They are now the same as
those on the engines 102 and 103
(standardization).
Production breakpoint: ‘03186
000016
* x
124.133 603.960 -
124.193 I I
001093 * *
126.125
015830 003949
* 215978
201.126 602.911
I I
. not recorded
05 10 - 250 2
EXIT
Since 08/88 the valve spring retainers are in bath

nitrided material (previously case hardened).
Standardization with engines 102 and 103.
transmission
* *
124.133 603.960 - 018302
124.193 I I
013824
* t
201.126 067330
201.128 602.961 - 003806 * I

I I
. not recorded
Note
Color markings of valve springs yellow green or
violet!green or yellow blue or violet blue.
05 10 - 253 3
EXIT
Special tools
! 102 589 05 03 40 00 601 589 02 59 00 116 589 06 63 00 104 589 00 37 t

05 05
601 589 02 43 00
05
A. Cylinder head removed
Removal and installation ’Fh

7
1 Clamp cylinder head on assembly table

601 589 01 59 00 wtth 4 cylinder head bolts.
2 Remove valve tappets. Magnetic lifter

102 589 03 40 00.
Installation note
Lubricate valve tappets. Note sequence.
3 Attach support bridge 601 589 02 59 00 to

cylinder head.
4 Press valve spring retainers downwards with

lever press 601 589 02 61 00.
05.10. 2504
EXIT
5 Remove valve totters with magnetic lifter

116 589 06 63 00.
6 Take out valve springs and valve spring

retainers.
Installation note
Install valve springs with the color marking
downwards.
7 Check valve springs (05260).
8 Replace valve stem seals (05270).
9 Installation takes place in the reverse

sequence.
. Cylinder head installed
Removal and installation
1 Remove valve tappets with magnetic lifter

102 589 03 40 00.
Installation note
Lubncate valve tappets, note sequence.
2 Place piston of the cylinder concerned on

TDC.
Use retaining gear 603 589 01 40 00 instead of
camshaft timing gear or camshaft in order to turn
the engine.
05 10 250 5
EXIT
3 Attach support bridge 601 589 02 59 00 for

lever press on cylinder head.
4 Press valve spring retainers downwards with

lever press 601 589 02 61 00.
5 Remove valve totters with magnetic lifter

116 589 06 63 00.
6 Remove valve springs and valve spring

retainers.
Installation note
Install valve springs with the color markings
downwards.
7 Check valve springs (05-260).
8 Replace valve stem seals (05-270).
9 Installation takes place in the reverse

sequence.
05 10 - 2506
EXIT
054260 Checking valve springs
Preceding work:
Valve springs removed (05-250).
Spring force . . . . , . . . . . . . . . . . . . . . . . . . . . . check at specified length. If limit is not

achieved, replace valve spring.
Valve spring data

Part No. Color Spring force New value Limit
marking at preloaded
length
N
601 053 01 20 yellow/green 27 710 - 790 648

(1 st design) or
violet/green
601 053 03 20 yellow, blue 27 680 - 740 612

(2nd design) or
violet blue
Conventional tool
Spring test scales e. g. Berco
Model CM130
05 10 - 26081
EXIT
05270 Replacing of valve stem seals
Preceding work:
PO5-0195-m
Valve stem seals (199, 200) . . . . . . . . . . . . . . . remove, install. Pliers 104 589 00 37 00,
mandrel 601 589 02 43 00. Note color marking.
Valve stem . . . . . . . . . , . . . . . . . . . . . . . . . . de-burr at groove.
Valve stem seal designs

Distinguishing features:
Intake valve stem seal (199) Exhaust valve stem seal (200)
Chamfer (arrow) shouldered Chamfer (arrow) straight
d = 7.3 mm d = 8.2 mm
W ire ring: phosphated (black) W ire rtng: bright galvanized (yellow)
Color: brown Color: brown
-d-I -_d-1
PO5-0040-13A
05 10 2-o 1
EXIT
Valve stem seals with standardized exterior

dimensions are installed due to automatic
cylinder head assembly.
. not recorded
Inlet valve stem seals without gas lip have been

fitted since 09 89 and exh,aust valve stem seals
without gas lip since 04 90.
05 10 - 270 2
EXIT
Viton material
A Intake valve stem seal

8 Exhaust valve stem seal PO5-0087-33
Production breakpoint: 09/89 (Inlet)

Model Engine Engine end No. Vehicle identification end No.
Manual Automatic
124.128 003020
124.133
124.193
126.135
201.126 016477
201.128 602.961 1 000177 007086

‘1
*
from st, of productlon
not reel led
05 10 - 270!3
EXIT
Prod&ion breakpoint: 04190 (Exhaust)

Model Engine Vehicle identification end No.
124.128 602.962
124.133 603.960
124.193
126.135 603.970
201.126 602.911 017538
r
* *
201.128 602.961 002151 007954
.'1
from stal of production
not recoi led
601 589 02 43 00
0 5 1 0 270 4
EXIT
OS-280 Checking and machining valves
Preceding work:
Cylinder head removed(01-415).
Valves removed.
PO50191.15
Valves
(Intake valve 195, exhaust valve 196) ......... clean, check visually.
Valve stem ............................ check for eccentricity (max. 0.03 mm).
Valve seat ............................ check for eccentricity (max. 0.03 mm), grind.
Dimensions and angles ................... check (table).
05 10 - 280 1
EXIT
Data
Engine 602.91 602.96 602.91 602.96

603.96 603.96
Valve head Q (D) 37.90 37.90 34.90 34.90

38.10 38.10 35.10 35.10
Height (h) of New value 1.75-2.05

valve head Limit 1.6
Setting angle (a) for 45” + 15’

machining the valve
i7 970 8.960 8.960

Valve stem 0 (D 1)
7.955 8.945 8.945
Valve seat reinforcement with with I with I with

Sodium filled without with
I without with
106.6 106.6 106.6 106.6

Valve length (L)
106.2 106.2 106.2 106.2
I 1
W idth of valve seat 2.0 12.0 12.0
Max. permitted eccentricity on

0.03 0.03 0.03 0.03
valve stem and valve seat
Marking on end of stem E 601 02 E 601 04 1 A 601 05 I A 601 05
From 04,87 only exhaust valves with valve heads

from revised material have been fitted.
0 5 1 0 - 280,2
EXIT
Note
On turbo engines the surface of the inlet valve
head is ground (non-machined on naturally
aspirated engines).
The stem of the exhaust valve (196) is chrome-

plated and filled with sodium on turbo engines.
AWarning
Unserviceable sodium-filled valves must be
neutralised before scrapping. They must
therefore be collected by the respective
departmental supervisor and dispatched to:
Mercedes-Benz AG
Werk Marienfelde
DaimlerstraOe 145
Anlieferstelle KST 3153
PO!%0196-15
Arbeitsvorbereitung TAI
196 Exhaust valve
The locatron of the hydraulic valve clearance

compensating elements must be checked after
machining or replacing the valves, and corrected
if required (05211).
Conventional tools
Valve grinder e. g. Krupp,
or D-5309 Meckenhelm
Valve poppet turning equipment Model VS
e. g. Hunger,
D-8000 Munchen 70
Model VKDR 1
Part No. 203.00.200
Dral gauge e. g. Mahr

D-7300 Esslingen
Part No. 810
05 10 - 280 3
EXIT
Checking and machining h
1 Clean valves and carry out visual inspection.
Valves with a burnt valve head, with insufficient

valve head height (h) and with worn or scored
valve stem should be replaced.
POS-0035-13
2 Measure eccentricity on valve stem.

Replace valve if eccentricity exceeds 0.03 mm.
3 Machine valve seat.
Note operating instructions for the machining

equipment and adjustment angle (a) 45” + 15’.
4 Measure eccentricity on valve seat and

height (h) of valve head.
If eccentricity is more than 0.03 mm or the

height (h) less than 1.6 mm, valve should be
replaced.
05 10 - 280 4
EXIT
05285 Checking and replacing valve guides
Preceding work:
Cylinder head removed (01-415).
Valves removed.
204
206
Checking
Seat for valve stem seal (205) .............. check. Replace valve guide (204) if valve stem
seal is loose.
Valve guide .. . . . .. . . .. . . . . .. . . .. . .
(204) clean. Cylindrical brush 000 589 10 68 00.
Valve guide (204) inside 0 . . . . . . . . . . . . . . . . . . . . check. Plug gauge: 102 589 00 23 00 intake,
117 589 03 23 00 exhaust.
Replace valve guide, if reject pin of plug gauge
fits completely in the valve guide.
Replacement
Valve guide (204) . . . . . . . . . . . . . . . . . . . . . . . drive out, drive home.
Drift:
103 589 03 15 00 intake,
103 589 02 15 00 exhaust.
Punch:
601 589 06 15 00 intake,
601 589 02 15 00 exhaust.
Ream,
Reamers:
000 589 21 53 00 intake
000 589 10 53 00 exhaust
05.10 - 2851’1
EXIT
Basic bore of valve guide

in cylinder head (70) . . . . . . . .. . . . . . . . .. . . . check. If required bore out to next
repair stage.
Broach (14.20 mm) 115 589 00 53 00.
Guide sleeves:
102 589 00 63 00 intake,
102 589 08 63 00 exhaust.
Broach (14.40 mm) 115 589 01 53 00
Guide sleeve 601 589 15 63 00.
Valve seat insert (206) . . . . . . . . . . . . . . . . . . . check for eccentricity (05-291).
Valve guides (grey cast iron)

Length
(L)
14 240-14 251 14,200-14,211
601 050 08 24
i-=+-D-l
POs-o187-15
05.10.285 2
EXIT
Special tools
.
?
I
I
I
II -
I
103 589 03 15 00
05
103 589 02 15 00
05
102589002300
05
117 589 03 23 00
05
_
J
000 589 21 53 00
05
-1
000 589 10 53 00 115 589 00 53 00
05
102 589 08 63 00
Conventional tool
e. g. Hunger,
Cylinder head clamping fixture D-8000 Mijnchen 70
Part No. 221.60.000
05 lO.c?853
EXIT
Broach base bore in cylinder head

(Repair stage)
Decarbonize and clean cylinder head carefully,
particularly the inside of the valve seat inserts.
Select correct guide sleeve (2) and remove
swarf from the tip of the broach (1) with a stiff
plastic brush or srmilar tool.
Note
The broach cutter must be cleaned before each
broaching operating.
Provide guide sleeve, basic bore and complete
broach with ample supplies of paraffin.
Insert broach into the guide sleeve so that when

the guide sleeve rests on the valve seat insert
(3) the first cutter of the broach is located in the
base bore. In so doing note that the correct side
of the guide sleeve is put on the valve seat.
Centre guide sleeve by rotary movements in the
valve seat insert.
Note
Dnve the broach quickly through with an
aluminium mandrel, approx. 130 mm long, and a
plastic hammer of approx. 250 g.
1 Broach
2 Guide s l e e v e
3 Valve seat tnser-t PO50163-17
05.10 - 285 4
EXIT
r
Note
The high spot (arrow) on the intake valve seat
inserts is to be removed before inserting the
guide sleeve.
PO5-0164-11
Inserting valve guide

Drive home valve guides with punch and
hammer, when the valve guides are not super-
cooled and the cylinder head is not heated up.
Coat valve guides with wax or 011 before driving
home.
Assignment of guide sleeve - valve seats

Valve seat Guide sleeve Basic bore 0 in cylinder head
Part No.
Intake
102 589 00 63 00 14.2 mm
Exhaust
Intake
601 589 15 63 00 14.4 mm
Exhaust
05 10 - 2855
EXIT
05290 Replacing valve seat inserts
Precedmg work:
Valve guides checked (05-285).
PO50183-15
Valve seat insert . . . . . . . . . . . . . . . . . . . . . . . . turn out valve seat insert with the lathe tool.
Note operating instructions for the valve seat
turning equipment.
Basic bore (D2) . . . . . . . . . . . . . . . . . . . . . . . . check (table). Bore out to the repair stage, if
required.
Caution!
Machine basic bore for the valve seat insert if
minimum overlap is not achieved (Number 3).
Valve seat insert . . . . . . . . . . . . . . . . . . . . . . . . supercool with liquid nitrogen and insert
into basic bore.
AWarning
Do not touch supercooled valve seat inserts
with bare hands.
Valve seat insert must be square to the cylinder
head.
Valve seats , . . . , . . . . . . . . . . . . . . . . . . . . . . machine (05291).
05 10 - 290 1
EXIT
Data
I Intake I Exhaust
Overlap of valve seat inserts
in cylinder head
02
Dl 33.400 30.400
33.600 30.600
l-l
t (New value)
A (Thrs dimension is valid up to the upper 133.4 133.4

edge of cylinder head on reworked
cylinder head parting surface)
a 37” 30’ 37” 30’
Note
Exhaust valve seat inserts are made from
centrifugally cast material on the naturally-
aspirated engines, and srntered metal on turbo
engines.
The intake valve seat inserts are made from

sintered metal on all engines.
0510-2902
EXIT
The hardened valve seat inserts (sintered metal) r I 1

had a high spot (arrow) on inside of the insert for
a short time.
PO5 -0164-11
This high spot must be turned off in order to

machine the valve seat insert. There is a repair
valve seat insert with larger outside diameter as
a replacement part for all valve seat insert
designs. After replacing the valve seat inserts
the location of the hydraulic valve clearance
compensating elements must be checked and
corrected, if necessary (05211).
Conventional tools
Cylinder head clamping fixture e. g. Hunger,
D-8000 Munchen 70
Part No. 221.60.000
Seat insert lathe tool, size 2 e. g. Hunger,

D-8000 Munchen 70
Part No. 220.03-l 10
Valve seat turning equipment, model VDSNL 1 45 30 e. g. Hunger,

D-8000 Munchen 70
Part No. 236.03.308
Test set for valves e. g. Hunger,

D-8000 Munchen 70
Part No. 216.93.300
65” correction steel No. 13 for e. g. Hunger,

lower correction angle D-8000 Mtinchen 70
Part No. 216.64.622
Internal-thread-measuring equipment (range 25 - 60 mm) e. g. Mahr,

D-7300 Esslingen
Part No. 844
External micrometer (range 25 - 50 mm) e. g. Mahr,

D-7300 Esslingen
Part No. 40 S
05 10 - 290 3
EXIT
Replacement
1 Turn out old valve seat insert with lathe tool.
Note operating instructions for the tool.
2 Check valve guides, replace if required

(05285).
3 Measure basic bore 02.
A new valve seat insert standard dimension can

be used, when the specified overlap exists.
If the minimum overlap is not achieved, machine

basic bore for valve seat insert.
4 Turn basic bore D2 with the seat insert lathe

tool so that the bore is properly cleaned up.
5 Measure machine base bore.
6 Turn valve seat insert repair stage so that

the specified overlap is produced. Compensate
height of reworked front face, If applicable.
7 Heat up cylinder head to approx. 80°C in

water bath.
8 Supercool valve seat insert with liquid

nitrogen.
Drive home valve seat insert with suitable pilot

bar.
10 Machining valve seats (05291).
05 10 290 4
EXIT
05291 Machining valve seats
Preceding work:
Valve guides checked (05-285).
Valve seats (53) . . . . . . . . . . . . . . . . . . . . . . . . machine in accordance with tool manufacturer’s

operating instructions. Refer to data for
adjustments.
Note
Only loosen the pilot when eccentricity of the
valve seat has been checked.
Eccentricity of valve seat .................. check (Number 2).
Valve seat width (b) . . . . . . . . . . . . . . . . . . . . . measure, correct if required (Number 3).
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . insert and measure distance (A).
05.10 - 291il
EXIT
Data
Valve seat I Intake I Exhaust
Valve seat width (b) Il.2 - 1.7 Il.5 - 2.0
Valve seat angle (a) I 45” 45”
Upper correction angle

(P) /15’ 1150
Lower correction angle
(Y) 15’ 15’
Permitted concentricity
deviation of valve seat I 0*03 I 0.03 PO50142-13
Minimum gap (a) on 0.1 - 0.5 0.1 - 0.5

new valves and new
valve seats
Gap (a) on reworked - 1.0 - 1.0

valve seats and
reground valves
The gap (a) reduces by the same amount as

cylinder head parting surface has been
reworked.
PO5-0133-13
I
Conventional tools
Cylinder head clamping fixture e. g. Hunger,
D-8000 Munchen 70
Part No. 211.60.000
Valve seat turning equipment, model VDSNL l/45 30 e. g. Hunger,

D-8000 Munchen 70
Part No. 236.03.308
Test set for valve seats e. g. Hunger,

D-8000 Munchen 70
Part No. 216.93.300
65” correction steel No. 13 for lower correction angle e. g. Hunger,

D-8000 Munchen 70
Part No. 216.64.622
05 10 2912
EXIT
Note
Clamp cylinder head in the clamp fixture for
dismantling and machining. Machine valve seats
with valve seat turning equipment, with valve
seat grinder or valve seat miller. The location of
the hydraulic valve clearance compensating
elements must be checked after machining the
valve seat Inserts and, if required corrected
(05211).
Machining valve seats
1 Machine valve seat (45”) (see tool

manufacturer’s operating Instructions).
Caution!
Only loosen pilot (5) when eccentricity of the
valve seat has been checked.
6 Clamping fixture
8 Forward feed operation
2 Check eccentricity of valve seat

(max. 0.03 mm).
Slide fitting sleeve ( 19) and dial gauge holder

(20) and dial gauge (18) onto the pilot (5).
3 Measure valve seat width (b) and, if required

make a 15” adjustment at the top (p) and 65”
adjustment at the bottom (y).
Valve seat width (b)

Intake: 1.2 - 1.7 mm
Exhaust: 1.5 - 2.0 mm.
PO5-0142-13
!
05 ‘0 231 3
EXIT
4 Insert valves and measure distance (a).
Distance (a) 0.1 - 0.5 mm.
If (a) IS outside tolerance, replace valve seat

insert (05290).
05.10 - 291 4
EXIT
OS-31 0 Removing and installing chain tensioner
244
215
PO5 0182 37
Chain tensioner (224) . . . . . . . . . . . . . . . . . . . . remove, install, 65 Nm.

Replace sealing ring and install chain tensioner
filled with SAE 10 engine oil.
0510 - 3101
EXIT
Filling chain tensioner with engine oil:

Place chain tensioner with the plunger bolt
downwards in SAE engine oil until over the collar
on the hexagon. Press plunger up to the stop
7 - 10 times slowly with the aid of a press or
power drill.
It should be possible to compress the chain

tensioner quite slowly, evenly and with little effort
after filling with oil.
Note
A revised valve disk (231) has been fitted in the
chain tensioner in order to avoid peak pressures
of the chain tensioner on the tensioner rail.
225 Sealing plug

226 Alumlnlum gasket
A 25x30
227 5 mm 0 ball
228 Ball guide
229 Compression spring
231 Valve disk
232 0-rrng
233 Plunger
233a Filler piece
234 Compression sprtng
235 Housng
236 B 16 snap nng
a Supply bore from
cyltnder head
b To 011 pan
A Former design
B Current design
05 10 - 310 2
EXIT
The outside diameter of the sealing surface on

the chain tensioner housrng has been enlarged
by 2 mm. This necessitates a sealing ring (237)
having dimensions of 27 x 32 mm (previously
25 x 30).
This revision prevents the formation of burrs on

the sealing ring (picture, circular cut-out) when
tightening the chain tenstoner.
This chain tensioner can also be installed In - 237

PO5-0206-13
vehicles of earlier manufacture.
dl 32 mm
d2 27 mm
A Previous design
B Rewsed design
. not recorded
05.10 - 3103
EXIT
Special tool
05 10 310 5
EXIT
05-320 Renewal of timing chain
Preceding work: Operation No. of Operatron Texts and Work Units,

Cylinder head cover removed. Standard Texts and Flat Rates . 05-7601
InjectIon nozzles removed (07.1-230).
Fan and fan shroud removed (20-312 or 20-335).
244
215
PO50 1 8 2 3 7
Chain tensioner (244) .................... Remove and install (05-310).

Camshaft timing gear (188) ..,.......,...., check for scores and pitting (Number 2).
Timing chain . . . . . . . . . . , . . . . . . . . , . . , . separate, mount new timing chain with
connecting link to the old timing chain, turn
engine and raise old timing chain and detach
(Numbers 3 - 5).
Caution!
The trmlng chain must remain In engagement on
the camshaft and crankshaft gear as the engine
is turned.
0510-3201
EXIT
Timing chain . . . . . . . insert connecting link from behind and rivet the
link pins individually with assembly tool
000 589 58 43 00 (Numbers 6 - 10).
Tightening torque of spindle 30 - 35 Nm.
Link pin rivet . . . . . . . check (Number 11).
After installation . . . . . turn crankshaft, check adjustment marking at
TDC position (Number 13).
Note
Since 10 86 timtng chains from an additional
manufacturer have been fitted (Daido).
Identification: DID and 06BD on outer clip of the

timing chain.
Production breakpoint: 1 O/86

Model Engine Engine end No. Vehicle identification end
Manual Automatic No.
005200-005645 351660- 024286-

358256 024446
126.125 006408-006754 290826- *

293731
335707- 287778-
338278 291247
201.128 602.961 - 000107-000107 335707- *

I I 338278
. not recorded
05 10 - 3202
EXIT
Since 02 89 timing chains have increased

clearance sleeves (Iwis Company).
. not recorded
Since 09 89 timing chains (Daido Company)

have been installed again.
124.133 023241 066158 122989

124.193 I 603.g60 I -
f t
126.135 ( 603.970 I- 488196
201.126 1602.911 1082936 016428 533524 666204
not recorded
”
G5 10 320 3
EXIT
Repair timing chain I 1

Only a riveted design of connecting link (A) is
avatlable for the timing chain. Design (6) is not
to be used.
The outer clips of connecting link (A) are colored

blue and its link pins have no grooves. W
r\‘%
The outer clip of revised connecting link (A)

must be pressed on and riveted with assembly
tool 000 589 58 43 00.
The former assembly tool 000 589 57 43 00 for

connecting link with stop spring (B) can be
modified with the conversion kit
000 589 58 43 80.
Part No. of the assembly tool is to be changed

to 000 589 58 43 00.
Special tools
000 589 5 8 4 3 0 0 001 589 72 21 00
.-_A
0510 3204
EXIT
Renewal
1 Remove chain tensioner (05310)
2 Check camshaft timing gear for scores and

pitting. Cover chain case with a cloth and grand
off both link pins at a timing chain link.
3 Mount new timing chain with connecting link

on the old timing chain.
4 Slowly turn crankshaft in the direction of

rotation of the engine, while simultaneously
raising the old timing chain until the connecting
link is located at the uppermost position of the
camshaft timing gear.
Pull out the released end of the old timing chain
evenly, to match pulling on the new timing chain.
Caution!
The timing charn must remain engaged with the
camshaft and crankshaft gear while engine is
turned.
5 Detach old timing chain and connect the

ends of the new timing chain with a connecting
link. Secure ends of chain on camshaft timing
gear with wire.
6 Insert connecting link In the timing chain

from behind (arrow).
05 10 320 5
EXIT
7 Place loose enclosed outer clip of the

connecting link (with the IWIS marking stamped
on) in assembly tool 000 589 58 43 00 (arrow).
The outer clip is retained magnetically.
PO5-2053 - 13
8 Put assembly tool 000 589 58 43 00 on

connecting link and press on clip up to the stop.
Caution!
Put clip on so that both rivet pins engage.
9 Turn punch (02) of assembly tool

000 589 58 43 00 so that the notch (arrow)
points forwards.
PO5-2056-13
10 Place assembly tool exactly over the center

of the pins. Rivet the connecting link pins
individually, whilst tightening spindle to
approx. 30 - 35 Nm (Reference value).
05 10 3206
EXIT
11 Check link pin rivet, If necessary re-rivet

(arrows).
12 Install chain tensioner (05-310).
13 Turn crankshaft and check adjustment

marking at TDC posltton of engine.
Note
If adjustment markings do not align, the
camshaft timing (05215) and start of delivery of
the injection pump (07.1-l 11) must be checked.
II
L_LL,-,_
3 /p
I I
---., /-
PO6-2206-13 -
05 10 320 7
EXIT
05-330 Removal and installation of tensloner rail
Preceding work:
Cylinder head removed (01-4 15)
Tlmlng case cover removed (01-210)
Chain tensioner removed (05-310).
244
215
PO5 0182 37
Tensioner rail (215) . . . . . .. .. . . . . . .. .. . . .. pull off, reinstall.
Note
Plastic support of the tensioner rail cannot be
replaced.
05 10 330 1
EXIT
Note
Since 08 86 unhardened straight pins have been
fltted for the tensioner rail bearing.

Model Engine Engine end No. Vehicle ldentlficatlon end No.
Manual Automattc
I I transmission transmission A F
124.133 003526 313431 019062

124.193 I 603.g60 I -
1 2 6 . 1 2 5 1 6 0 3 . 9 6 1 (- 004997 1278305 *
201.126 602.911 025293 006190 332559 266086
I not recorded
05 10 330 2
EXIT
Data
Since 09 86 the lead-in tangent (abutment
surface) on the tensioner rail has been extended,
thus reducing linrng wear.
Dotted line shows former desrgn.
PO5 0215 15

Model Engrne Engine end No. Vehicle identrficatron
Manual Automatic end No.
transmission transmissron A F
124.133 I 603.960 I- 004863 342586 023347

124.193
126.125 603.961 - 006205 389319 *

I I
201.126 028504 006859 333489 286635
0510 3303
EXIT
05341 Removal and installation of guide rail

Preceding work:
Poly-V belt removed (13-345).
Chatn tensloner removed (05-310)
A. Removal and installation of guide rail in cylinder head
188
PO!!-01 99-35
Cylinder head cover (125) ................. remove, install, bolt (132) 10 Nm.
Pressure oil pump drive . . . . . . . . . . . . . . . . . . . remove, rnstall (05437).
Camshaft timing gear (188) . . . . . . . . . . . . . . . . mark at timing chain. Remove, install camshaft
timing gear. Drfferent bolts (190) and washers
(189) with different tightening torques. Hexagon
bolt 65 Nm. Bihexagonal head bolt 25 Nm 90”
(05220) (Numbers 3 - 5).
05 10 - 341 1
EXIT
Bearing pins (221, 222) . . . . . . . . . . . . . . . . . . . remove, install.

Special tools 116 589 20 33 00 and
116 589 01 34 00.
Check guide blade (220), replace If necessary.
(Number 6).
Caution!
The extractor 115 589 20 33 00 can be used
together with stud 115 589 01 34 00 If the
bearing pins have seized.
Tightening torques and angle of rotation Nm

Hexagon bolts on cylinder head cover 10
Hexagon bolt on camshaft timing gear 65
Brhexagonal head bolt on camshaft timing gear 25 90”
Special tools
L--
116589203300 115589203300 115589013400 001 589 66 21 00

I
'L -P5
05 05 00
001 589 72 21 00
05 10 - 341 2
EXIT
Removal

2 Remove pressure 011 pump drive
(05437).
3 Align timing chain and camshaft timing gear.
4 Remove hexagon bolt or blhexagonal head

bolt on camshaft timing gear, while holding
camshaft with a mandrel.
5 Remove camshaft timing gear and allow

timing chain to sag.
Caution!
Note different bolt and washer (05220).
6 Drive out both bearing bolts with the Impact

puller 116 589 20 33 00, and 116 589 01 34 00
and remove guide rail. Check guide rail and
replace if necessary.
Caution!
Seized bearing bolts can also be pulled out with
puller 115 589 20 33 00 and stud
115 589 01 34 00.
PO5 2258 13
05 10 341 3
EXIT
Installation
6 Coat bearing pin collar with sealing

compound.
7 Insert guide rail and drive home bearing pin

with impact puller 116 589 20 33 00 and
116 589 01 34 00.
PO5 2258 13
8 Install camshaft timing gear according to the

marking and tighten, noting the color markings.
Tightening torque and angle of rotation

Hexagon bolt 65 Nm,
Brhexagonal head bolt 25 Nm, 90”.
9 Position engine on ignrtron TDC of No. 1

cylinder and check marking (arrows).
AWarning
Do not turn engrne by camshaft timing gear bolt.

10 Install pressure oil pump drive (05-437).
11 Install cylinder head cover, 10 Nm.
0510 - 3414
EXIT
Preceding work,
Tlmlng case cover removed (01-210).
Chain tensioner removed (05-310).
B. Removal and installation of guide rail in timing case
POMrn 15
Guiding rail (218) ................,...... pull off from guiding blade bolt (222), put on.
Check guiding rail, renew If necessary.
Note
Since 09 86 unhardened straight pins have been
fitted for the guiding rail bearing.
05 10.341 5
EXIT

Model Engine Engine end No. Vehicle identlficatlon
Manual Automatic end No.
124.133 003526 313431 019062

124.193 I 603*g60 I-
126.125 603.961 - 004997 278305 -
I I
201.126 602.911 025293 006190 332559 266086
135 10 341 6
EXIT
05437 Removal and installation of pressure oil pump drive

Preceding work:
406
PO5-019355
Cylinder head cover (125) . . . . . . . . . . . . . . . . . remove, Install, fixing bolt (132), 10 Nm.
Pressure oil pump (400) . . . . . . . . . . . . . . . . . . unbolt, reinstall, fixing bolt (408) wrth washers
(408a), 11 Nm, put pressure 011 pump to one
side with lines connected.
Note
Do not unbolt the upper and lower bolt with
continuous thread (vrsrble between housrng and
cover).
O-ring (404) ....................... . * . replace.
Carrier (403) ...................... . . . remove, install, check.
Bolt(407) ........................ . . . unbolt, reinstall. Note different bolt (05-220).
Tightening torque and angle of rotation
Hexagon bolt 25 Nm,
Bihexagonal necked down bolt 25 Nm, 90”.
Carrier sleeve (406) . . . . . . . . . . . . . . . . . . . . remove, install. Use grease when Installing.
Note different design (05220).
05 10 4371
EXIT
Note
Since 11 88 the camshaft timing gear has been
fitted with a blhexagonal necked down bolt Ml 1
(previously hexagon bolt MlO). The carrter has
been revised as a result of this change.
ul
t
_!I!!.& i_ _I !*10,4
A Prewcus Design
B Rewsed Design
Model Engine Engine end No. Vehicle identlficatlon end No.

Manual Automatic
124 000187 * 1
019336
201 602.911 070124 014216 * .

602.961 - 004561
. not recorded
Special tool
001 589 72 21 00
00
- ~_ I
EXIT
ystern - Air r, Turbocharger - 09

EXIT
Air Intake System - Air Filter, Turbocharger 09
Job No.
Function of turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 - 050

Testing turbocharger boost pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 - 100
Removal and installation of turbocharger .................................... 09 - 150
Function of engine overload protection - Turbodiesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 - 200
Testing engine overload protection - Turbodiesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 - 250
Removal and installation of air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 - 400
Removal and installation of air cleaner - Turbodiesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 - 400
0911
EXIT
09-050 Function of turbocharger
Turbocharger survey
602.96 Garrett TB 025 1990 or 0.85-0.95 bar (13.75 - 14.25 psi)

T 025
KKK K14 *)
603.96 Garrett TB 03 ‘) 3, or T 03 ‘) 3, 0.85-0.95 bar (13.75 - 14.25 psi)
KKK K24 ‘) 3,
l) Optronal
2) Productron breakpornt at a later point In time
KKK = Kuhnle, Kopp und Kausch.
3) For Callfornla with air recirculation valve.
Engine 602.961, Garrett TB 025
Boost pressure control

Turbine housing valve
Fresh air Inlet
Compressed air
Bypass passage
Exhaust Inlet
Exhaust outlet
011 feed
011 discharge
Engine 603.96, Garrett TB 03
a Boost pressure control valve

C Compressor housing
h Turbine housing
09.10 III - 050/l

EXIT
Garrett TB 03 with air recirculation valve
a Boost pressure control

b Air recirculation valve
C Compressor houslng Po%?o4313
KKK-K24 with air recirculation valve

b Air reclrculatlon valve
C Compressor houslng
h Turbtne housing
General
The exhaust gas turbocharger (EGT) is a flow

machine. The energy of the engine exhaust gas
is used for driving a turbine, which in turn drives
a compressor through a shaft. The EGT is
installed between the exhaust manifold and the
exhaust pipe. It is connected to the engine oil
circuit for lubrication and cooling.
A boost pressure control valve, fitted to the

turbine housing or separately, ensures that a
boost pressure of 0.95 bar is not exceeded. if a
problem develops in the boost pressure control
valve, engine failure is prevented by means of an
engine overload protection system.
09.10 III - 050,2

EXIT
The exhaust gases of the engine are passed through the shaft (n) to the turbine wheel (i) to
through the exhaust manifold into the turbine be driven at the same speed. The maximum
housing (h) and flow onto the turbine wheel (i). rotation speed is approx. 135,000 rpm. The
The flow energy of the exhaust gases starts the fresh air drawn in by the compressor wheel (d)
turbine wheel (i) rotating. This causes the is compressed and sent to the engine.
compressor wheel (d) which is connected
C nfm I k j
I
d
e-----
h i
P07-0473-57A
Functional diagram turbocharger KKK K24 (Engine 603.96)

a Boost pressure control valve m Charge housing
C Compressor housing Shaft
d Compressor wheel Fresh arr Inlet
e Control line Compressed air (to engine)
f Axial bearing Bypass passage/boost pressure control valve
g Beanng bushing Exhaust Inlet
h Turbtne houslng Exhaust outlet
I Turbine wheel Oil feed
I Spnng 011 discharge
k Diaphragm Control pressure
I Valve
09.10 III - 05013

EXIT
d 137 i
PO9-0026-59
Function diagram
1 Injectton pump Boost pressure control valve
103 ALDA unit Compressor wheel
110 Exhaust manifold Control line
137 Turbocharger Air admIssIon
138 Charge air pipe Turbine wheel
S66 Pressure switch, engine overload protection Compressor Inlet (fresh air)
Y30 Switch-over valve, engme overload protectlon Compressor outlet (compressed arr)
Exhaust gases to turbine wheel
Exhaust outlet
09.10 III - 050/4

EXIT
Air Recirculation Valve

(refer also to EDS Operation No. 07.1-010) characteristic map.
In order to create more favorable combustion After the closing operation, a residual vacuum of
conditions for the trap oxidizer, the air approx. 30 mbar is retained at the air circulation
recirculation valve is continuously opened or valve.
closed in accordance with the performance
b C m I e k i
F-
Ar
f
I D
h
I Ii
9
PQ7-0472-57
Function diagram turbocharger KKK with air recirculation valve California

Model year 1986187
Control valve, exhaust gas control flap Compressor Inlet (fresh air)
AIM recwculatlon valve Compressor outlet (compressor air)
Compressor houslng Bypass passage, boost pressure control valve
Compressor wheel Exhaust gas to turbine wheel
Connector hose Exhaust gas outlet
Axial bearing Vacuum connectlon to vacuum transducer
9 Bearing bush Recirculated air
h Turbine houslng Lubrication 011 Inlet
Turbine wheel Lubrlcatron011 outlet
Compressron sprtng K Boost pressure (control valve exhaust gas control
k Diaphragm flap)
Boost pressure control valve
m lntermedrate housrng
09.10 III - 05015

EXIT
Boost pressure Control Valve (KKK)

To prevent the boost pressure from rising above
a certain level, a boost pressure control valve (a)
h I i
is attached to the turbine housing (h). The boost
pressure is taken from the compressor housing
and passed through the connecting hose (14) to
the boost pressure control valve. When
maximum boost pressure is reached, the boost
pressure control valve begins to open and allows
the exhaust gas to flow along the bypass
passage (c). Part of the exhaust gas flows
directly into the exhaust system, resulting in a
constant boost pressure level.
14 Connecting h o s e
e Control line
h Turbine housing
1 Spnng
k Diaphragm
I Valve
C Bypass passage
E Exhaust gas outlet
1000 _
900
800
7 0 0
6 0 0
5 0 0
4 0 0
1 2 0 0 1600 2 0 0 0 2 4 0 0 2 8 0 0 3 2 0 0 3 6 0 0 4000 4 4 0 0 4800
Boost pressure diagram - full load
09.10 III - 050/6

EXIT
Idle and Lower Part Load

No boost pressure occurs during idling and in
the lower part load range; therefore, the engine
operates as a naturally aspirated engine.
Upper Part Load and Full Load

As the engine load and speed increase, e.g. with
an increase in the exhaust gas flow, the turbine
wheel (i) is accelerated producing a boost
pressure up to a certain value via the
compressor wheel (d). The compressed charge
air is passed through the charge air pipe to the
individual cylinders. The boost pressure allows
an increased quantity of fuel to flow through the
ALDA unit at the injection pump.
Although boost pressure exists in the decelera-

tion mode, fuel injection is stopped as a result of
the control rod position (deceleration fuel cutoff).
09.10 III - 05017

EXIT
09-l 00 Testing turbocharger boost pressure
PO9-0030-59
Tester (001) . . . . . . . . . . . . . . . . . . . . . . . . . . . connect, disconnect.

Pulse generator (021) .................... connect, disconnect.
Tester (020) with Y distributor . . . . . . . . . . . . . . connect to measuring point “A” and test boost
pressure.
Tester (020) with Y distributor . . . . . . . . . . . . . . connect to measuring point “B” and test boost
pressure.
09.10 III - 100/l

EXIT
Tester (020) with Y distributor . . . . . . . . . . . . . . connect to measuring point “C” and test boost
pressure.
Specification: 0.85-0.95 bar gauge pressure at
4000 rpm full load in drive position “3”.
Note
This test can be conducted on the .
dynamometer or on the road.
If the specified boost pressure is not reached,

perform the following checks:
Connecting line from boost pressure control

valve to compressor housing.
Switchover valve of engine overload protection
(09-250).
White vacuum line and rubber connections.
If all components are in working order, replace
turbocharger.
Test data
Boost pressure at full load in drive position “3” at 0.85-0.95 bar gauge pressure
n = 4000 rpm
Special tool
603 589 03 21 00
Commercial tester
Digital tester (or tachometer installed in car) e.g. Bosch, MOT 002.01
Sun, DIT 9000
Sun, FMT-101 S/Master 3,
Sun, MCM-2110,
All-Test 361 O-MB
09 10 III- 10012
EXIT
emoval and Installation of turbocharger
P14-0080-57
Vehicle .............................. drive onto the platform or inspection pit.

Bottom section of noise encapsulation . . . . . . . . detach, attach.
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, install (09-400).
Hose clip (144) ......................... loosen and detach, attach intake hose (167).
Partition wall (A) between trap oxidizer and air
cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, install (9 bolts) of which 6 are
accessible from above, 3 accessible from below
(Figure 4).
Vacuum lines red/violet/brown on EGR valve (60)
and red/violet/blue on air recirculation valve . . . . detach, attach.
Clip (119) on corrugated pipe (61) . . . . . . . . . . . loosen, tighten. Tightening torque 45 Nm.
09.10 III - 15011

EXIT
Corrugated pipe (61) ..................... remove, install.

Exhaust gas recirculation valve (60) .......... remove, install.
Trap oxidizer (139) on exhaust manifold . . . . . . . unbolt, bolt on.
Supporting bracket . . ....... .. . ..... ..... unbolt, bolt on and remove at the same time
with trap oxidizer.
Charge air connecting line (138 a) ........... remove, install. Replace gasket (138 d).
Engine breather ........................ detach, attach.
Mixing pipe (135) with exhaust gas recirculation
valve (60) ............................ remove, install.
Oil feed line (141) of turbocharger (137) ....... unbolt, bolt on. Replace seal.
Mounting bracket (134) ................... unscrew, screw on.
Nuts (134 a) (from top and bottom) .......... loosen, unscrew.
Mounting bracket (177) ................... remove, install.
Turbocharger (137) ...................... remove, install.
Note
The specified tightening torques are reference
values.
Note
For the conversion, the car must be driven onto
an inspection pit or platform.
1 Completely remove noise encapsulation

from below.
2 Remove air cleaner entirely.
3 Loosen hose clip (144) from air flow sensor

and detach intake hose (167).
09.10 III - 150/2

EXIT
4 Remove partition wall “A” (9 bolts), of which

6 (WAFlO) are accessible from above, 2 (WAF8)
and 1 (WAFIO) accessible from below.
5 Detach vacuum lines red/violet/brown on

EGR valve and red/violet/blue on air recirculation
valve.
6 Loosen clips “B” on corrugated pipe, and

remove corrugated pipe.
7 Unbolt trap oxidizer from exhaust manifold,

remove trap oxidizer and supporting bracket at
the same time.
8 Remove charge air connecting line (138 a).
09.10 III - 150 3

EXIT
9 Detach engine breather hose.
10 Detach mixing pipe (135) with exhaust gas

recirculation valve from cylinder head.
11 Unbolt oil feed line (141) from turbocharger

(replace seal).
12 Loosen both mounting brackets (134) on the

exhaust manifold and turbocharger.
13 Loosen bolts of exhaust pipe - accessible

from above (arrows).
14 Loosen bottom bolt of exhaust flange.
15 Unbolt mounting (177) from alternator flange

to turbine housing on both components.
16 Remove turbocharger.
17 Install corrugated pipe with flange onto new

turbocharger.
18 Clean sealing surfaces mechanically.
09.10 III - 150/4

.................. ...............
EXIT
20 Install new trap oxidizer, insert supporting

bracket at the same time and install. Tightening
torque 45 Nm.
21 Install EGR valve together with corrugated

pipe.
22 Install partition panel.
23 Connect vacuum line red/violetbrown to

EGR valve and vacuum line red/violetblue to air
recirculation valve.
24 Connect intake hose to air flow sensor and

tighten hose clip.
25 Install air cleaner complete.
26 Completely reinstall bottom section of noise

encapsulation .
09.10 III - 15015

EXIT
09-200 Function of engine overload protectiom - Turbodiesel
A pressure switch is installed in the charge air

pipe as an overload protection for the 54
52
mechanical parts of the engine. In the event that 50
48
the boost pressure rises above 1 .l k 0.15 bar 46
4 4
gauge pressure, air is admitted to the ALDA unit
42
through the switchover valve and the fuel 4 0
38
quantity is limited to that of a naturally aspirated 36 I
engine. 34 i
32
30
28
1 1 1
1200 1600 2000 2400 2600 3200 3600 4000 4 4 0 0 4800 [/mm;
PO9-0025-13
A Naturally aspirated engine quantity (P = 1050 mbar)

B Full load quantrty with turbocharglng
Location of Components
1 Injection pump
2 Governor
3 Fuel pump
6 Stop unit
65 Vacuum COntfOl Valve
103 ALDA unit
Y22 Actuator PO7-2430-138
Y30 Switch-over valve,

engine overload protection
09.10 III - 200/l

EXIT
S66 Switch, engme overload protectlon
Pressure, vacuum diagrams (refer to 07.1-500).
Wiring diagrams (refer to 07.1-400).
09.10 III - 2001’2

EXIT
09450 Testing engine overload protection - Turbodiesel
d 137 i
PO9-0027-59
1 Injection pump Boost pressure control valve

103 ALDA unit Compressor wheel
110 Exhaust mantfold Control line
137 Turbocharger Air admIssIon
138 Charge air pipe Turbine wheel
S66 Pressure switch, engine overload protection Compressor Inlet (fresh air)
Y30 Switch-over valve, engine overload protectlon Compressor outlet (precompressed air)
Exhaust gases to turbine wheel
Exhaust outlet
09.10 III - 250/l

EXIT
2-pin connector on swrtchover valve (Y30) . . . . . detach and briefly energize with voltage. The
switchover valve must audibly actuate; replace if
necessary.
l-pin connector on pressure switch (S66) . . . . . . detach and test for continuity with ohmmeter.
The pressure switch (S66) is open in the off
position.
Engine overload protection switch (S66) . . . . . . . remove.
Connect pressure switch to cable of nozzle
tester KDJE-P 400.
Connect ohmmeter to pin of pressure switch
and to housing. Build up pressure of 1 .l 2
0.15 bar at nozzle tester; the pressure switch
must not have any continuity. Replace pressure
switch if necessary.
Special tools
I201 589 00 99 00
Commercial tester
Digital multimeter e.g.Sun, DMM 5
Valve tester e.g. Bosch, KDJE-P 400

(Bosch Order Designation)
Optionally O-6 bar pressure gauge e.g. Bosch No. 1687 231 000
Optionally nozzle tester EFEP 60l-i e.g.Bosch No. 0684 200 700
09 10111-2502
................ .......................... EXIT
emoval and installation of air cleaner
A. Standard version and Federal as of 1984
102a
A
Suction line (98) . . . . . installation position.

Closing catch, 6 off (92) open, close.
Air cleaner cover (90) . ................... remove, reinstall.
Air cleaner filter element (91) ............... remove, reinstall.
Nut (95a) .......... remove, reinstall.
Washer (95b) ....... remove, reinstall.
Bolt (9%) . . . . . . . . . . remove, reinstall.
Bracket, 2 off (95) . . . remove, reinstall.
Air guide housing (94) . remove, reinstall.
Sealing boot (93) . . . . remove, reinstall,
ensure proper seating.
Rubber, 4 off (96) . . . . replace according to condition.
Intake scoop (102) . . . remove, reinstall.
Pin (102a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace according to condition.
09.10 II - 40011
EXIT
Engine 602.91
Air cleaner cover (90) and filter element (91) of
revised material.
Production breakpoint: December 1989

Model Engine Engine end no. Engine end no.
Manual transmission Automatic transmission
201.126 602.911 086698 016956
09.10 II - 40012
EXIT
. Model 201
PO9-0028-57
Air cleaner element (91) . . . . . . . . . . . . . . . . . . remove, install. Ensure correct position during
installation.
Air cleaner cover (90) .................... remove, install.
Air guide housing (94) .................... remove, install.
Air guide housing (94 a) .................. remove, install.
Cup seal (142) ......................... remove, install.
Hose strap (144) ....................... slacken, tighten, remove, install.
Intake pipe air line (145) .................. remove, install.
Stopper (146) .......................... renew according to condition.
Nut(95a) ............................ bolt on, unbolt.
Air flow sensor (B2’1) .................... remove, install.
Wire clip (92) .......................... unclip, clip in place.
Air cleaner cover (90 a) ................... remove, install.
Washer (95 b) ......................... remove, install.
Bolt (95 c) ............................ remove, install.
09.10 III - 40013

EXIT
Repair Instruction
When the engine is running, the fender cover
(right) must be removed, otherwise the fresh air
intake (arrow) is blocked.
09.10 Ill - 40014

EXIT
elt Drive 13
EXIT
elt Drive 13
Job No.
Removal and tnstallatlon of poly V-belt ...................................... 13 - 342

Checking condltlon of poly V-belt and tensioner ................................ 13 - 343
Removal, lnstallatlon and dlsmantllng of poly V-belt tensioner ...................... 13 - 345
13/l
EXIT
13-342 Removal and installation of poly V-belt
Fan shroud (1) . . . . . . . . . . . . . . . . . . . . . . . . . On engine 602 In model 201 remove, install wltl
one-piece radiator fan shroud (20-420,
Number 2).
On engine 602 tn model 201 wtth divided fan
shroud, remove, install fan shroud (Number 3).
Detach fan shroud on engines 602 and 603 In
model 124, place above fan.
Viscofan coupling (298) ................... unbolt, relnstall, remove together with fan
shroud, bolt (297), 45 Nm.
Specral tools 103 589 01 09 00 and
603 589 00 40 00.
Tension lever (374) and tension spring (380) . . . . release, by removing nut (378), take out bolt
(375) and remove poly V-belt, Install and tenslor
(Numbers 6 - 11).
13,10-342/l
EXIT
Caution!
Check poly V-belt section and tenstoner for
damage and contamlnatlon, replace If required.
Do not use belt wax or slmllar lubricant.
Check seating of poly V-belt.
Poly V-belt dimensions
Engine Poly V-belt layout

Length of poly V-belt in mm
602 I- I 2030 I 2100

603 - 2080 2145 (2120)')
') Up to 09185
*I Engine 603970
Note
Engine 602
Poly V-belt of different material and revised
design.
1310 -342/2
EXIT
Engines 602.91 and 602.961

Poly V-belt (B drive) provided by additional
manufacturer (Gates).
. not recorded
Special tools
001 589 72 21 00 103 589 01 09 00

00 20
/ /
Removal
1 Remove radiator with one-piece fan shroud

on engine 602.911 in model 201 (20-420).
2 On engine 602 in model 201 wtth divided

fan shroud, open and remove, by taking out
lockrng pin (1) and turning ring (2) to the left.
Place ring on the fan, pull out housing (3) and
remove ring.
13.10 - 34213
EXIT
3 On engines 602 and 603 in model 124

Detach fan shroud and lay on the fan. Unscrew
Viscofan couplrng wtth fan and remove wtth fan
shroud.
Use screw driver bit 103 589 01 09 00 and

steady 603 589 00 40 00 In order to detach and
tighten up the hexagon socket bolt for the
Viscofan coupling.
4 On the engine 603.96 (TURBO) the Visco-

fan coupling cannot be removed wrthout mP13-2074-Q
L
removing the radiator.
5 Detach tensloner, by unscrewing nut (378).

Put a lever ( 12 - 13 mm dia., approx. 300 mm
long) or nm wrench from vehicle tool kit In the
hole In the spring tension lever (374). Press
lever slightly to the left, until bolt (375) can be
slid back In the direction of the manifold.
Release tension spnng (380) by swinging lever

to the right..
Remove poly V-belt, by pressing back the Idler

pulley.
Check poly V-belt section and tensioner for
damage and contamrnatron, replace If required
(e.g. worn bearing pornts on tensioner, dents In
pulley etc.).
13.10 - 34214
EXIT
Putting on poly V-belt
Caution!
Do not use any belt wax or similar products.
6 Raise Idler pulley slightly. Turn poly V-belt on

the back, form a small loop and slide between
coolant pump pulley and crankshaft pulley.
7 Press poly V-belt with the left hand firmly

onto coolant pump pulley and turn this to the left
(arrow) unttl poly V-belt rides up onto idler pulley.
8 Put poly V-belt on Idler pulley and crankshaft

pulley. Then rotate the free part of poly V-belt
and place onto the refrigeration compressor,
power steering pump, coolant pump and
alternator pulley.
9 Tension poly V-belt and install tensioner.
1 3 . 1 0 - 34215
EXIT
11 Check seating of poly V-belt on the pulleys.
12 On engine 602 in model 124 install fan or

Viscofan coupling with fan and fan shroud.
Tightening torque of Viscofan coupling fixing bolt

45 Nm.
Use steady 603 589 00 40 00 for trghtentng up.
13 On engine 602.911 in model 201 Install

radiator (20-420) without divided fan shroud.
B Pulley layout on vehicles with power steering
Length of belt
Engine 602: 2030 mm
Engine 603: 2080 mm
1 Idler pulley
2 Crankshaft
5 Alternator
7 Power steering pump
8 Coolant pump
PlJ-0012-n
C Pulley layout on vehicles with power steering

and refrigeration compressor
Length of belt
Engine 602: 2100 mm
Engine 603: 2145 mm
Engine 603.970: 2120 mm
1 Idler pulley
2 Crankshaft
3 Refrrgeratlon compressor
5 Alternator
7 Power steerlng pump
8 Coolant pump
13.10 - 342/6
EXIT
13-343 Checking condition of poly V-belt and tensioner
P134m4-3s
CompressIon pressure plotter . . . . . . . . . . . . . . connect 001 589 76 21 00 with adapter

124 589 366 300 to positive terminal of battery
and terminal 50 (Numbers 1 - 3).
Poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . , . . . mark at a clearly vlslble point with chalk (arrow).

Turn engine In Increments.
Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . check condition.
Caution!
Note different design.
13.10 -343/l
EXIT
A. Poly V-belts
The poly V-belt IS to be replaced tf one of the

followlng damaged patterns is determtned during
testing.
1
Damage pattern
D D I
C Lumps of rubber In base of ribs.
0 Deposits of dirt or stones.
P13-2021-13
Flank wear
F Ribs are polnted.
E New poly V-belt - ribs are trapezoidal.
G Strand vlslble In base of ribs (lighter points).
K Strand torn out sideways.

L Outer strands frayed.
13.10 - 343l2
EXIT
Rib detached from base of belt (arrow).
t--l Transverse cracks in ribs and or

J Rib fractures J H J I
‘H
I J H
I
P13-2022-U I
t-i Transverse cracks in several ribs.
M Transverse cracks on the back.
PO-0042-u
13.10 - 343/3
EXIT
Special tools
Model 124 and 126

1 Connect compression pressure plotter
001 589 78 21 00, by separating plug connection
(X 27) at the left unit compartment wall and
connect connector lead (04) of the compression
pressure plotter to the plug (terminal 50) with
adapter lead 124 589 36 63 00 (05).
Model 124
Model 126
Model 201
2 Connect compression pressure plotter
001 589 78 21 00, by separating plug connector
(X 27) at left front wall and connect the connec-
tor lead (04) of compression pressure plotter to
the plug (terminal 50) with adapter lead
124 589 36 63 00.
13 lo- 34314
Model 201
EXIT
3 Connect up second connector lead of the

compresslon plotter to positive terminal
(termtnal 30) of the battery.
4 Mark poly V-belt with chalk at a clearly

visible point (arrow).
5 Turn engine In increments and check poly V-

belt for damage.
Complete process when marking is visible again

(one complete belt revolution).
P13-0025.13
13.10 - 34315
EXIT
The following parts are to be checked on the

370 ____
tension lever bearing (1 st design up to 10 85):
6 Check bearing pin (30) of tension lever (360) 361
for firm seating. 360
355
Note
The collar of bearing pm (30) must contact the 357 \‘
\
\
timing case cover (28). The Idler pulley must not I
356 I
have any altgnment problems.
7 Check tensioner with bearing bush.
Note 368
/
The Idler pulley must not exhibit any alignment 365
faults. The bearing bushes are worn when there 366a---#
IS a detectable play between the beanng pin (30)
and tension lever (360).
PI3 0059 15
13.10 - 34316
EXIT
13-345 Removal, installation and dismantling of poly V-belt tensioner

Precedrng work:
Fan and fan shroud removed (20-312 or 20-335).
Radiator removed (only Model 201, 126, 20-420).
Poly V-belt removed (13-340).
II 376
346
Pi 3-0060-35
Sealing cap (368) . . .... . .... . .. . .. .. . .. . press off, press on.

Idler pulley (366) . . . . ........ . .. . ... . .. .. remove, install, 25 Nm.
Pulley (346) . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, Install.
Hexagon socket bolt, 10 Nm
Internal Torx bolt, 14 Nm.
Damper (370) .......................... unbolt, install, 25 Nm. Check for function.
Tension spring (376) ..................... remove, assemble.
13.10 -345/l
EXIT
Tensioner - 1st design:

Sealtng cap (355) . . . ........... . . . . remove, install.
Tensloner (360) . . . . . ........... . * . . . remove, install. 10 Nm. Check for condition and
wear.
Beanng pin (30) . . . . . . ........... . . . * . remove, Install, 100 Nm. Clean thread and coat
with Omnrfrt 100 M orange 002 989 23 71.
Tensioner - 2nd design:
Beartng pm (30) . . . . . . . . . . . . . * . . . . . deleted. Use dowel screw fitting bolt (356),
100 Nm. Clean thread and coat with Omnrfit
100 M orange 002 989 23 71.
Note
Only the 2nd design IS now available as a
replacement part. Complete with bearing and
close-tolerance bolt.
Adhesives
Omnrflt 100 M orange 002 989 23 71
Tightening torques (NW

Hexagon socket bolt on Idler pulley 25
Hexagon socket bolt on coolant pump pulley 10
Internal Torx bolt on coolant pump pulley 14
Hexagon bolts on damper 25
Internal hexagon bolt on tensronrng lever 10

Bearing pin for tension lever bearing 100
Dowel screw for tension lever bearing 100
Poly V-belt dimensions
‘) UotoO985
?I E:qlrle GO3 970
13.10 - 345/2
EXIT
Special tools
f /9‘ f /
;-?
, ‘*
25
.I(
i/i....
t
001 589 66 21 00 001 589 72 21 00
\ 00 00 /
1
Note
Idler pulleys on vehicles without power steering
have grooves for the ribs of the poly V-belt In the
running surface.
Idler pulleys have flat running surfaces.
Color marking of tension spring:

Vehicles wtth power steenng pump, blue.
P13-0056-13
13.10 - 34513
EXIT
370
361
360
368
365
PlJ 0059 15
Tension lever (2nd design)

28 Tlrmlng case cover
30a Dowel screw
360 Tensm lever
362 Angular ccrltact ball
oemng
363 Washer
368 Sealmg cap
124.133 603.962 - 000016 from start of productlon

124.193 I I
. riot recorded
Engine 602
Single-acting damper for belt tensioner,
previously double-acting.
13.10 - 34514
EXIT

Vehicle identlficatton end No.
306516 237404
Between 07 89 and 09 89 and from 06 90 the

dampers for the tensioner have vulcantzed lower
rubber bearings..
A Pressed-on rubber bearing

Pl3-0023.15
6 Vhzanved rubber bearmg
13 10 - 345/5
EXIT
I not recorced
Since 03 90 fixing bolts for the power steertng

pump have been hot galvanized, previously
phosphated, for Improved surface protection.
1310-34516
EXIT
ine- low System - 1

EXIT
Electrical System - Engine - Preglow System 15
Job No.
Function of preglow system .............................................. 15 - 705

Function of preglow system - Turbodiesel .................................... 15 - 705
Checking preglow system without afterglow function ............................ 15 - 710
Testing preglow system without afterglow function - Turbodiesel .................... 15 - 710
Checking preglow system with afterglow function ............................... 15 - 711
Testing preglow system with afterglow function - Turbodiesel ...................... 15 - 711
Removal and installation of glow plugs ...................................... 15 - 715
Removal and installation of glow plugs - Turbodiesel ............................ 15 - 715
1511
EXIT
15-705 FlJnction of preglow systen-i
A. General
Combustion in the diesel engine occurs through

the injection of self-igniting diesel fuel into highly
compressed and therefore, hot combustion air.
If the engine is cold, the self-ignition temperature

is not reached by compression alone. A preglow
system is therefore required to increase the
temperature of the compressed air and to allow
the engine to start by directly igniting fuel
particles on the glow plugs.
The duration of preglow depends on the ambient

temperature.
Construction of the quick-start pencil-type

glow plugs
The main components of the pencil-type glow
plugs are a housing with screw-in thread M 12 x
1.25 and a heater pin pressed into the housing.
15.10 II - 705/l
EXIT
The single-pole connection pin is secured to the

housing by means of a permenant connection
consisting of a brass round nut.
The pencil-type glow plugs are designed for a

voltage of 11.5 V and are connected in parallel.
The heating element consists of a series-

connected heater and control coil.
1 Control coil
2 Heater cod
PO7-0445-13
When the glow system is turned on, a current of

approx. 30 A is supplied to each glow plug. The
heater coil heats up the glow plug very rapidly.
The control coil resistance increases with rising
temperature, limiting the current to approx.
8-16 A. The glow plug is thus protected against
overload.
Current curve of the quick-start pencd 0 10 20 30 40

type glow plug t El
PIS-0394-13
After a glow period of 9 seconds, a heating

element temperature of 900°C is reached, the
maximum temperature of 1180 “C being reached
after 30 seconds. Tpa 1000
800
0 10 20 30 40 50 60
Temperature curve of quick-start t cs3

pencd-type glow plug
PlS0355-15
15 loll - 705 2
EXIT
. Quick-start preglow system
N14
1153-11609/Z
Fl
2,5sw/gn C J---l v
I
I?9
Wiring diagram model 201 .126

Ale16 Preglow lndlcator In Instrument cluster Fl Central electncs
N14 Preglow time-delay relay I79 Glow plugs
a Power relay W9 Ground, front left (near headlamp unit)
b Electronic unit e X35 Terminal block terminal 30/terminal 61
c Temperature sensor (NTC reslstor) @atW)
d Reed relay
15 10 II - 705 3
EXIT
Preglow time relay

The preglow time-delay relay is installed in the
engine compartment on the left wheel arch.
After removing the protective cap the electrical

connections and the 80-A fuse are accessible.
Model 201
An NTC resistor in the preglow time-delay relay

registers the relay ambient temperature.
Functions of the preglow time-delay relay

The preglow time-delay relay has the following
functions:
l Activating the glow current

l Indicating readiness to start
l Safety cutout
l Identifying faults
Note
With unfavorable tolerances of the pencil-type
glow plugs or the Reed relay (d) it is permissible
that the fault indication responds only if two
pencil-type glow plugs R9 are defective.
The fault indication (monitoring of pencil-type

glow plugs) is effected by comparing the current
of the 1st pencil-type glow plug with the current
of the 2nd to 5th pencil-type glow plugs
connected in parallel.
15.10 II - 705,'4
EXIT
48OA+ J
Engmes 602
1
r -. J
1154-1302Ol1
The currents of the two lines to the pencil-type

glow plugs 1 and 2-5 are directed via two
counterwound Reed relay windings with different
numbers of windings.
With identical current flow in both windings the

magnetic fields cancel each other and the Reed
contact does not respond.
If the equilibrium of the magnetic fields is

disturbed by the failure of one or several pencil-
type glow plugs, the Reed contact closes and
the electronics unit (b) is activated.
The preglow indicator lamp switches off

immediately and, consequently, no longer lights
up at the start of the preglow process.
15.10 II - 705/5
EXIT
Glow current control

When actuating the key in position “2” (preglow,
driving) the preglow time-delay relay (voltage) on
terminal 15 is switched on. The power relay (a)
closes the power circuit from terminal 30 (plus)
via the fuse to the pencil-type glow plugs.
If the key is turned to position “3” (start), the

power relay (a) remains retracted, activated by
terminal 50. The glowing process is continued
until the key is returned to position “2”.
Ready-for-starting indication
A temperature sensor installed in the preglow
time-delay relay determines the glow period.
The preglow indicator lamp in the instrument

cluster lights up when the glow system is turned
on.
If the required glow time, dependent on the

ambient temperature of the preglow time-delay
relay, has been reached, the preglow indicator
lamp goes out, indicating readiness to start.
-30 -20 -10 ‘0 -10 +20 +30 +40 +50 l 6 0 +70 +80
TEi
Preglow time
15.10 II - 705~6
EXIT
Safety cut-out
If the engine does not start within 20-25 seconds
after the readiness for starting has been 60
indicated, the glow current is interrupted by the 55
safety cut-out. If the engine is started thereafter, 50
the glow system is again switched on for the 45
duration of the starting process. 40
The safety cut-out is no longer fixed. It is 35
determined from the time up to readiness for 30
starting (the preglow indicator lamp goes out) 25
20
plus 20-35 seconds.
15
‘8
4
- 3 0 - 2 0 - 1 0 ?O +lO +20 +30 l 4 0 +50 +60 +70 +60
TCcl
a Preglow time
P15-0387-15
b Safety cut-out
Fault display
A fault in the preglow system is indicated by
failure of the preglow indicator lamp to light up
when actuating the key in position “2”.
The following faults are registered:
Interruption of the line to the connection

terminal 30.
80-A fuse defective.
Power relay in the preglow time-delay relay
defective.
Interruption of one or several lines to the
pencil-type glow plugs.
Interruption of one or several pencil-type
glow plugs.
15.10 II - 705 7
EXIT
C. Preglow system with afterglow
The preglow system has been changed from the

previous system in the following areas:
l Preglow time-delay relay

l Coolant temperature sensor
l Pencil-type glow plugs
Reglow time-delay relay

Reglow time
The duration of preglow until the preglow
indicator lamp goes out is dependent on coolant
temperature (see diagram).
10
7,5
5
2,5
Preglow time t In seconds -30 -20 -10 0 10 20 30 40 50 60 70 80
Coolant temperature T In “C
Afterglowing time
In order to improve the warm-up characteristics
of the engine, the glow process is continued with
the engine running as a function of the coolant
temperature.
AfterglowIng time t In seconds

- 3 0 - 2 0 -10 0 10 20 30 40 50 60 70
TM
P15-0398.13
70
b) Version MJ 89, code 830
60
Afterglowing time up to a maximum of 60 s (see
diagram)
50
40
ml
30
20
Afterglowing time t In seconds 10

0
-30 -20 -10 0 10 20 30 40
JEI
P15-0*!05-15
15.10 II - 705,8
EXIT
Production breakpoint: January 1989 (preglow system with afterglowing)

Model Engine Engine end no. Engine end no.
Manual transmission Automatic transmission
124.133 603.960 __ 017932
124.193
201.126 602.911 073017 014820
Monitoring of glow plugs

The glow plugs are monitored individually by a
microprocessor in the preglow time relay.
In addition, the glow plugs are constantly

monitored during vehicle operation by a low test
current. Failure of one or several glow plugs is
indicated if the preglow indicator lamp lights up
for approx. 1 minute with the engine running.
15.10 II - 705/g
EXIT
Fault indication by preglow indicator lamp

l Lamp fails to light up even during preglow,
lights up for approx.1 minute while dnving.
Fault: One or more glow plugs defective.
l Lamp fails to light up during preglowing and

also while driving.
Fault: Indicator lamp defective, line
interruption to the indicator lamp, preglow
time relay defective.
l Lamp lights up permanently.

Fault: Preglow time relay defective (relay
sticking).
l Lamp fails to light up, engine is hard to start

or fails to start altogether.
Fault: Short circuit on one or more glow
plugs, line interruption, preglow time relay
defective.
Protection of preglow current circuit

Instead of the 80-A fuse an electronic cut-out
has been installed. If a short circuit occurs, the
power circuit is interrupted. After the short circuit
has been eliminated, the fuse of the relay is
restored to the operational state by turning the
key in the steering lock back to “0”.
15.10 II - 705/10
1.
EXIT
Coolant temperature sensor

A coolant temperature sensor (B20) or (Sl11'8) is
installed to control the preglow and afterglow
times.
Arrangement engine 602
Pencil-type glow plugs

For afterglowing, pencil-type glow plugs with
three different heater tube lengths are installed
(see Checking preglow 15-711).
15.10 II - 70501
EXIT
Wiring diagram engine 602.911 model year 1989 code 830
------7N14
Al e16
I I I 215 rt
1 2,5 SW L----a
2,s SW gn
SW !Je -
1153-16517 -2,5sw/bl ---d

R9_
Ale16 Instrument cluster preglow lndlcator I79 Glow plugs

820 Temperature sensor (preglow) W9 Ground, front left (near headlamp unit)
Fl Central electncs x25 Connector preglow cable harness
N14 Preglow time-delay relay a X35 Terminal block terminal 30, terminal 61
(battery)
15.10 II - 705112
EXIT
15-705 Function of preglow system - Turbodiesel
General
Combustion in the diesel engine occurs through

the injection of self-igniting diesel fuel into highly
compressed and therefore, hot combustion air.
When the engine is cold, the self-ignition

temperature is not reached by compression
alone. A preglow system is therefore required to
increase the temperature of the compressed air
and to allow the engine to start by directly
igniting fuel particles on the glow plugs.
The duration of preglow depends on the ambient

temperature.
Design of the quick-start pencil-type glow

plugs
The pencil-type glow plugs consist essentially of
a housing
- with an Ml 2 x 1.25 internal thread and
a heating element press-fitted into the housing.
The single-pole connecting pin is screwed into

the housing by a non-detachable brass round
nut.
The pencil-type glow plugs are designed for a
voltage of 11.5 Volts and are connected in
parallel.
15.10 III - 705/l

EXIT
The heating element consists of a series-

connected heating and control coil.
1 Control wIndIng
2 Heating wIndIng PO7-0445-13
When the glow system is turned on, a current of

approx. 30 A is supplied to each glow plug. The
heater coil heats the glow plug very rapidly. The
control coil resistance increases with rising
temperature, limiting the current to approximately
8-15 A. The glow plug is thus protected against
overload.
0 10 20 30 40
t cs3
Current curve of quick-start pencil-type glow plug
After a glow period of 9 seconds, a heating

element temperature of 900°C is reached, the
maximum temperature of 1180°C being reached
after 30 seconds.
800
0 lb 2b 3b 4b 56 8b
t cs3
Temperature curve of quick-start

Pl s-0395-
penci-type glow plug
15 10 III - 705 2
EXIT
N14
Al e16
n
I 25sw l,_.____,
25 SW gn
SW SF ~-Q--=-I
‘;q
1 2.5swhi --+Jl+-=--j
- 2,5sw/bl 1
R9
PIS-0399-5s
Wiring Diagram Engine 602.961, Model 201.128

Ale16 Instrument cluster, preglow Indicator R9 Glow plugs
820 Temperature sensor (preglow) W9 Ground, front left (next to lamp unit)
Fl Electrical centre a X35 terminal block, termtnal 30
N14 Preglow time relay
15.10 III - 705/3

EXIT
e16 S1611 Fl Blll7 N14
P15-OS-55A
Wiring Diagram Engine 602.962, Model 124.128

Ale16 Instrument cluster, preglow Indicator x4 Terminal block, terminal 30 (fuse and relay box)
61117 Temperature sensor (preglow) x25 Plug connector, preglow wrnng harness
Fl Fuse and relay box X26 Plug connector, intenor/engine 12-pin
N14 Preglow time relay x49/2 Plug connector, starter lockout and backup light
R9 Glow plugs switch
S16/1 Starter lockout and backup lrght swatch (with S2/2 glow start switch terminal 50
automatrc transmrssion only) Kl Relay, over-voltage protection contact 3 (with
Wl Main ground (behrnd Instrument cluster) air-condrtronlng system only)
w9 Ground, front left (next to lamp unrt) X27 plug connector, starter wiring harness
contact 2
15.10 III - 70514

EXIT
Pfeglow time relay

The preglow time relay is housed in the engine
compartment on the left wheel arch.
The electrical connections are accessible after
removing the protective cap.
lnstallatlon of preglow time relay shown on Model 201
Functions of preglow time relay

The preglow time relay has the following
functions:
l Activating the glow current
l Indicating readiness to start
l Safety cutout
l Identifying faults
Preglow without afterglow Model 124 engine

603.96
T Ambient temperature of preglow time relay in
“C
t Preglow time in seconds
t cs3
15 10 III - 7055
EXIT
Preglow with afterglow
Preglow Time
T Coolant temperature in “C
t Preglow time in seconds
10
7,5
5
2,5
-30 -20 -10 0 10 20 30 40 50 80 70 80
Afterglow Time
To improve warm-up properties, the glow plugs
continue to glow when the engine is running
dependent on the coolant temperature.
a) Version:
Model 201 Engine 602.961 Model Year 1988
t Afterglow time in seconds
Afterglow time up to max. 175 s (refer to -30 -20 -10 0 10 20 30 40 50 60 70
diagram)
b) Version:
Models 124, 201 Engine 602.9611962,
Model 124 Engine 603.96 from Model Year 1989
60
t Afterglow time in seconds
Afterglow time up to max. 60 s (refer to diagram)
10
0
-30 -20 -10 0 10 20 30 40
ml
15.10 III - 7051'6

EXIT
Safety cutout
If the engine is not started within 20-25 seconds
after the readiness to start indication being
60L, , , , , , , , , , ,
given, the glow current is interrupted by the
safety cutout. If the engine is then started, the
glow system is switched on again for the
duration of the starting operation.
The duration of safety cutout is not fixed. It is the
combination of time up to readiness to start
(preglow indicator lamp going out) plus
20-25 seconds.
b Safety cutout
Switching the glow current

When the key is moved into position “2”
(preglow, drive), the preglow time relay is
switched on (voltage to terminal 15). The
preglow time relay closes the circuit from
terminal 30 (positive) to the glow plugs (R9).
If the key is turned into position “3” (start), the

preglow time relay remains activated and
remains retracted through terminal 50. The glow
process is continued until the key is turned back
to position “2”.
Readiness to start indication
a) Model 124 Engine 603.96

When the glow system is switched on, the
preglow indicator lamp in the instrument cluster
lights up. The glow duration is determined by a
temperature sensor installed in the preglow time
relay. Once the required glow time has been
reached, depending on the ambient temperature
of the preglow time relay, the preglow indicator
lamp goes out, thus indicating that the engine is
ready to start.
15.10 III - 70517

EXIT
Model 201 Engine 602.961, Fault Indication

Model 124 Engine 602.962, Engine 603.96
effective 1989 Models 124, 201 Engine 602.961, 602.962,
When the glow system is switched on, the 603.96 Effective 1989
preglow indicator lamp in the instrument cluster A fault in the preglow system is indicated by the
lights up. The glow duration is determined by preglow indicator lamp failing to light up when
the temperature sensor in the coolant. Once the the key is turned into position “‘2”. In addition,
required glow time has been reached, the the preglow indicator lights up for approx. 1
preglow time relay switches off the preglow minute when the engine is running.
indicator lamp, indicating that the engine is
ready to start. The following faults are detected:
l Interrupt in the cable to connection terminal
Fault Indication 30.
l Preglow time relay faulty.
Model 124 Engine 603.96 l Open circuit in one or more cables to the
A fault in the preglow system is indicated by the glow plugs.
preglow indicator lamp failing to light up when l Open circuit in one or more glow plugs.
the key is moved into position “2”. l Short-circuit at one or more glow plugs or in
the cables.
The following faults are detected:
l Interrupt in the cable to connection terminal
30.
l 80 ampere fuse faulty.
l Fault in power relay of preglow time relay.
l Interrupt in one or more cables to the glow
plugs.
0 Open circuit in one or more glow plugs.
15.10 III - 70518

EXIT
15-710 Checking preglow system without afterglow function

Engines 602/603
Multimeter e.g. Sun, DMM 5
Checking
Electrical wiring diagrams (see 15705).
1 Checking glow bulb and wiring

If preglow indicator lamp fails to light up when
switching on the preglow system despite
opportunity to start.
Pull 4 or 5pin coupling off preglow time relay,

turn key to position “2”) bridge jacks 1 and 3 of
the coupling.
If the preglow indicator lamp fails to light up,

check or replace glow bulb.
If the glow bulb is OK, check the black cable

from the coupling jack 3 of the preglow time
relay up to the preglow indicator lamp for open
circuit. Eliminate open circuit.
If the preglow indicator lamp lights up, the

preglow time relay is defective. Replace preglow
time relay.
15 10 II - 710/l
EXIT
2 Checking the main power circuit of the

preglow system for open circuit
Problem:
Preglow Indicator lamp fails to ltght up, engine
cannot be started.
With the multimeter in the volt measuring range,

check voltage on terminal 30 of the preglow time
relay against ground.
P152202-13
If no voltage is present. check red 4 mm wire

from the termrnal block X35 termrnal 30 to the
preglow ttme relay terminal 30 for open circuit
and elrminate open circuit if necessary.
If voltage IS present (approx. 12 V), check 80-A

fuse for tight seat or an open crrcuit, replace if
required.
If no fault was found so far, check voltage on

jack 1 of the 4-pin coupling of the preglow time
relay against ground.
15 loll- 71082
............... .............................................. EXIT
If no voltage is present with preglow system

switched on (model 201) check red/black wire
from the central electrical coupling S jack 4 to
the coupling jack 1 of the preglow time relay for
an open circuit and eliminate open circuit.
On model 124, check pink/red wire from fuse 7

(unprotected side) via connector engine/interior
12-pole X 26 to coupling jack 1 of the preglow
time relay for open circuit and eliminate open
circuit.
. I
i-l /
i I !
0,75 rt/.sw --J
1154 - 10 ?03/2
Model 201.1
If voltage is present (approx. 12 V), connect

multimeter in volt measuring range to jack 1
(terminal 15) and jack 4 (terminal 31) and
measure voltage (set value approx. 12 V).
If no voltage is indicated, check brown wire from

jack 4 to ground for open circuit and eliminate
open circuit.
If no fault was established to this point, the

preglow time relay is defective, replace preglow
P15-0392-13
time relay.
15.10 II - 710/3
EXIT
3 Checking pencil-type glow plugs and

their lines
Problem:
Preglow indicator lamp fails to light up, engine is
hard to start; an open circuit in one or more
pencil-type glow plugs or in the lines leading to
the pencil-type glow plugs is possible.
Problem:
Preglow indicator lamp lights up, engine is hard
to start after reaching start readiness; an open
circuit of a pencil-type glow plug or a line to the
pencil-type glow plugs of cylinders no. 2 to 5 is
possible or incorrect power may be consumed
by the pencil-type glow plugs in cylinders 1
through 6.
Measuring power consumption of the pencil-type

glow plugs with the DC current probe.
For this purpose place the current probe over

the individual lines on the preglow time relay.
Cylinder 1 = 2.5 black/blue

Cylinder 2 = 2.5 black/purple
Cylinder 3 = 2.5 black/red
Cylinder 4 = 2.5 black/yellow
Cylinder 5 = 2.5 black/green
Cylinder 6 = 2.5 black/white
Turn key in steering lock to position “2”) the

power consumption of each glow plug should be
8-15 A after lo-20 seconds.
If the value is above 15 A, replace glow plug.
At a value below 8 A, check electric lines or

glow plug with multimeter ohm measuring range
for open circuit.
15.10 II - 71014
EXIT
In order to test for an open circuit pull 6-pin

coupling off preglow time relay.
Using the multimeter ohm measuring range

measure the resistance to ground (engine block)
‘---$-‘T----l
of one after the other as follows: =T--
i j i i
Jack 1 of couplmg = Pencll-type glow plug cylmder 1

Jack 2 of coupltng = Pen&type glow plug cylinder 2
Jack 3 of couplmg = PencMype glow plug cylmder 3
Jack 4 of couplmg = PencMype glow plug cylmder 4
Jack 5 of coupling = Pencil-type glow plug cylinder 5 i
Jack 6 of couplmg = Pencil-type glow plug cylmder 6
P15-0388-13
If infinite resistance is measured, an open circuit

in the respective pencil-type glow plug or the
feed line or the connection is the problem.
Eliminate open circuit in the feed line or replace

glow plug.
Note
It may be possible that the indicator lamp (due to
unfavorable tolerances) indicates a fault only
upon failure of 2 pencil-type glow plugs in the
cylinders 2-5.
In order to ensure that the fault indication in the

preglow time relay is accurate, 2 pencil-type
glow plugs of the cylinders 2 to 5 have to be
disconnected in this case and the preglow
process repeated.
15.10 II - 71oc5
EXIT
15-711 Checking preglow system with afterglow function

Engines 602/603
Multimeter e.g. Sun, DMM 5
Checking
Electrical wiring diagrams (see 15705).
Checking glow bulb and its wiring

Problem:
Preglow indicator lamp fails to light up when
turning on the preglow system despite start
readiness.
Pull 6-pin coupling off preglow time relay, turn

key to position “2”, bridge jacks 1 and 3 of the
coupling.
If the preglow indicator lamp fails to light up,

check or replace glow bulb.
P15-0401-13
If the glow bulb is OK, check black wire from

coupling jack 3 of the preglow time relay to the
preglow indicator lamp for an open circuit.
Eliminate open circuit.

time relay.
Lamp lights up permanently.

Fault: Preglow time relay defective (relay
P15-0390-13
sticking).
15.10 II - 711 1
EXIT
Checking main power circuit of preglow

system for open circuit
Problem:
Preglow indicator lamp fails to light up, engine
cannot be started.
Using the multimeter volt measuring range,

check the voltage on terminal 30 of the preglow
time relay against ground (arrow).
0115-35652
If no voltage is present, check 4 mm red wire

from the terminal block X35 terminal 30 to the
preglow time relay terminal 30 for open circuit
and eliminate open circuit.
If no fault was established to this point, measure

voltage on jack 1 of the 6-pin coupling of the
preglow time relay against ground.
Model 201
If no voltage is present with the preglow system
switched on, check red black wire from the
central electrical coupling S jack 4 to the
coupling jack 1 of the preglow time relay for
open circuit and eliminate open circuit.
151011 711 2
EXIT
If voltage is present, connect multimeter volt

measuring range to jack 1 (terminal 15) and jack
4 (terminal 31) and measure voltage.
If no voltage is indicated, check brown wire from

jack 4 to ground for open circuit and eliminate
open circuit.
If no fault was established to this point, the

time relay.
Checking pencil-type glow plugs and their

lines
Problem:
P15-0402-15
Preglow indicator lamp fails to light up when
switching on.
Lights up for approx. 1 minute while driving.
Engine is hard to start.
An open circuit of one or more pencil-type glow
plugs or their lines to the pencil-type glow plugs
is possible.
Measure power consumption of the pencil-type

glow plugs using the multimeter ampere
measuring range and DC current probe.
For this purpose place current probe over the
individual wires on the preglow time relay.

Cylinder 2 = 2.5 black/purple
Cylinder 3 = 2.5 black/red
Cylinder 5 = 2.5 black/green
Turn key in steering lock to position “2”, the

power consumption for each glow plug should be
14-l 6 A after approx. 8 seconds.
If the value is higher than 16 A, replace glow

Plug*
With a value below 14 A, check wire and glow

olua for ooen circuit.
15.10 II - 711/3
EXIT
In order to check for an open circuit, pull 6-pin

coupling off preglow time relay.
With the multimeter ohm measuring range

measure the resistance against ground (engine
block) one after the other as follows:
Jack 1 of couplmg = Pencll-type glow plug cylinder 1

Jack 2 of couplmg = Penctl-type glow plug cylinder 2
Jack 3 of couplmg = Pencll-type glow plug cylmder 3
Jack 4 of couplmg = Pencil-type glow plug cylinder 4
P15-0388-13
If infinite resistance is measured, an open circuit

of the respective pencil-type glow plug or the
feed line or the connection is the problem.
Eliminate open circuit in the feed line or replace

glow plug.
Preglow power circuit protection

An electronic cut-out is installed in the preglow
time relay. If a short circuit occurs in the glow
plugs or in the electrical lines the power circuit is
interrupted.
Note
After a short circuit is repaired, the relay is
operational again when the key in the steering
lock is turned back to position “0”.
15.10 II - 711/4
EXIT
Checking temperature sensor with line

Preglow time until preglow indicator lamp goes
out is excessive or too short. (see table).
Pull plug off preglow time relay and measure
resistance against ground using multimeter ohm
measuring range.
Setvalueat+25”C2442Qk170Q
+80 “C29l Q,+16 !-I
P15-0403-13
If set value is not attained:

Replace temperature sensor.
If infinite resistance is indicated:

Eliminate open circuit in electrical wire.
If resistance < 1 32 is indicated:

Eliminate short circuit in electrical line.
15.10 II - 711/'5
EXIT
15-711 Testing preglow system with afterglow function - Turbodiesel
Models 124, 201 with Engines 602.961, effective Model Year 1989, 602.962, 603.96, effective
Model Year 1989
Commercial Tool
Multimeter e.g. Sun, DMM-5
Testing Bulb and Its Wiring

If the following problem occurs:
Preglow indicator lamp does not light up when
the preglow system is switched on, despite
being able to start engine.
Detach 6-pin connector from preglow time relay,

turn key into position “2”, bridge contacts 1 and
3 of the connector. If the preglow indicator lamp
does not light up, test bulb or replace if
necessary.
If the bulb is in order, test black cable from

connector contact 3 of the preglow time relay to
the preglow indicator lamp for open circuit.
Rectify open circuit.
preglow time relay is defective. Replace preglow
time relay.
Lamp shows a steady light.
Fault: preglow time relay defective (relay
sticking).
15.10 III - 711/l

EXIT
Testing Main Circuit of Breglow System for

Interruption
If the following problem occurs:
Preglow indicator lamp does not light up, engine
cannot be started.
With the multimeter set to the Volts range, test
the voltage at terminal 30 of the preglow time
relay to ground (arrow).
P16-2206-13
If no voltage is indicated, test 4 mm2 red cable

from terminal block (X35) terminal 30 to the
preglow time relay terminal 30 for open circuit.
Rectify open circuit.
If no fault has been detected to this point, test

voltage at contact 1 of the 6-pin connector of the
preglow time relay to ground.
Model 201
If no voltage is indicated when the preglow
system is switched on, test red/black cable from
the electrical centre connector S contact 4 to the
connector contact 1 of the preglow time relay for
open circuit or rectify open circuit.
15.10 III - 711/2

EXIT
Model 124
Test pink/red cable from fuse 7 (unprotected
side) through plug connection of engine wiring
harness to the connector contact 1 of the
preglow time relay for open circuit. Rectify open
circuit.
If voltage is indicated, connect multimeter Volts

range to contact 1 (terminal 15) and contact 4
(terminal 31) and test voltage. If no voltage is
indicated, test brown cable from contact 4 to
ground for open circuit. Rectify open circuit. If no
fault has been detected to this point, the preglow
time relay is defective. Replace preglow time
relay.
P15-0402-15
Testing Glow Plugs and Their Wiring

If the following problems occur:
l Preglow indicator lamp does not light up
when switching on
l Lights up for approx. 1 min. when driving
l Engine is difficult to start
there may be an open circuit in one or more

glow plugs or in the cables to the glow plugs.
15.10 III - 711:3

EXIT
Test current consumption of the glow plugs with

multimeter set to Amperes range and with D.C.
clamp. The clamp is placed over the individual
cables at the preglow time relay for the step.

Cylinder 2 = 2.5 black/‘violet
Cylinder 3 = 2.5 black//red
Cylinder 5 = 2.5 blacki’green
Turn key in the steering lock to position “2”, the

current consumption of each glow plug must be
14-l 6 A after 1 O-12 seconds.
If the reading is higher than 16 A, replace glow
plug. If the reading is less than 14 A, test glow
plug cable for open circuit.
Detach 6-pin connector from preglow time relay

for testing for open circuit. With the multimeter
set to Ohms range, measure in turn the
resistance to ground (engine block) at
-_( 1 Connector = glow plug cylinder 1

--C 2 Connector = glow plug cylinder 2
--_( 3 Connector = glow plug cylinder 3
----C 4 Connector = glow plug cylinder 4
---C
----c
5
6
Connector
Connector
=
=
glow plug cylinder 5
glow plug cylinder 6 L.-_i___.Lj
P15-0388-13
15.10 III - 71114

.................................................. ... ............ EXIT
If infinite resistance is measured, there is an

open circuit in the respective glow plug or in the
lead or the connection. Rectify open circuit in
the lead or replace glow plug.
Safeguarding Preglow Circuit

An electronic short-circuit safeguard is installed
in the preglow time relay. The circuit is inter-
rupted if a short-circuit develops in the glow
plugs or in the cables.
The relay is again operational

0 once the short-circuit has been rectified and
l the key turned back to position “0”.
Testing temperature sensor with wiring

Preglow time until preglow indicator lamp goes
out is too short or too long (refer to table).
Detach plug on preglow time relay and test F
resistance to ground F with multimeter set to
Ohms range.
Specification a t + 2 5 “C2442 Q ?170 Q

a t + 1 8 0 “C291 fi k16 Sz
If specified value is achieved:
Replace temperature sensor. If resistance 00 Q is
indicated: rectify open circuit in cable. If resis- P15-0403-13
tance < 1 R is indicated: rectify short-circuit in

cable.
15.10 III - 711/5

EXIT
15-715 Removal and installation of glow plugs
Complete air cleaner ..................... remove, reinstall (09-400).

Electrical line on glow plugs ................ connect, disconnect,
Glow plugs (R9) 4, 5 or 6 off . . . . . . . . . . . . . . . remove, reinstall,
tightening torque 20 + 2 Nm
Observe distinguishing features pencil-type glow
plugs.
15.10 II - 715/l
EXIT
Tightening torques NITI

Quick-start pencil-type glow plugs 20+2
-_ .--- .- -_--._
Electrical line on glow plugs 4
Engine 602 602 602.961 602.911

I I
Injection/preglow Vertical injection Inclined injection Inclined injection Inclined injection
system without afterglow precham ber prechamber 5” 16 5” without
function 5”/180” 60 s s afterglow afterglow function
afterglow function function
Beru no. 0100221107 I 0100221162 I 0100221153 0100221138
Bosch no. 0250201001 I 0250201026 I-

Length of glow 25 23 27 27
tube
Glowing current 8-15 14 - 16 14- 16 14- 16

after approx. 8 s
in ampere
Identification yellow transparent with black transparent

circular groove
around the
hexagon
15 10 II - 71512
......................................................................................... ........ .................
EXIT
Removal
1 Remove, reinstall complete air cleaner

housing (09-400).
2 Unscrew nuts from glow plugs.
The nuts (1) cannot be lost as they have been

inserted in the terminals (2) of the wiring
harness.
116-26300
3 Unscrew glow plugs.
Installation
4 Installation occurs in reverse order.
15.10 II - 7153
. . . .
EXIT
emoval and Installation of glow plugs - TurbodIesel
Cable to glow plugs ..................... disconnect, connect.

Pencil-type glow plugs (R9) ................ remove, install.
Quick-start pencil-type glow plugs
Cable to glow plugs
Commercial tool
318” ratchet with universal joint
15.10 III - 715/l

EXIT
Distinguishing Features of Pencil-tme Glow Pluas

Engine
Injection preglow system

without afterglow prechamber 5°11800
Beru No.
Bosch No.
Length of glow tube 25
Glow current after approx.

8 s in amperes
Identification
nular groove around
15.10 III - 715/2

EXIT
EXIT
ngine Lubrication System 18
Job No.
Engine oil and filter change .............................................. 18 - 002

Oil circuit, oil pressure, overpressure and bypass valve, oil filter .................... 18 - 005
Removal and installation of oil spray nozzles .................................. 18 - 040
Removal and installation of oil filter ......................................... 18 - 110
Modifications to oil filter ................................................. 18 - 115
Removal and installation of oil pump ........................................ 18 - 210
Replacement of oil pump chain ............................................ 18 - 212
Removal and installation of oil pressure relief valve ............................. 18 - 215
Testing oil level indicator ................................................ 18 - 220
Function of oil level indicator ............................................. 18 - 225
Removal and installation of oil level sensor ................................... 18 - 226
EXIT
18-002 Engine oil and filter change
Specified viscosity class for engine oil in

accordance with SAE at prolonged outside
temperatures OF I
l w l 30
Precise use of the SAE class according to l w l 20
outside air temperatures would necessitate l w l 10
frequently changing the engine oil. The

l 32 0
temperature limits for the SAE classes should
to
therefore be regarded as guidelines which can l 1. -
l 5 - 15
be exceeded for short periods. -1 - 20
See “Service Product Specifications”for

further information on specified viscosity classes
and approved engine oils.
l) SAE 40 may be used at prolonged outstde
temperatures above + 30 “C.
18.10 - 002/l
EXIT
Oil car>acitv in liters

Model Capacity for oil and Dipstick marking
filter change
marking
I Colored
1 marking I I
Numerical marking
on handle
(color red)
6.5 (6.8 U.S. Qt.) I- I 60214’) I
I green’)
I green3)
7.5 (8.0 U.S. Qt.) I black I- I
303.96/‘97 1 126
1st version - rea colorea marung
7.5 (8.0 U.S. Qt.) I- I 60316 I
2nd verston - black colored marking

3rd version - brown colored marking
2, On engines with exhaust gas recirculation and side part on 011 sump
3) 1st version black
Oil filter cover fastening nuts 25
Oil drain plug on oil sump M 12x1,5x13 30
M 14x1,5x22 25
Return pipe in oil filter cover’) 25
l) Only engtne 603 In Model 124
Special tools
117 589 02 07 00 001 589 72 21 00

18 26 35 00
Commercial tool
Engine oil extractor e.g. Deutsche Tecalimit
Am Metallwerk 11
D-4800 Bielefeld
1810 - 002/2
EXIT
Note
On models with air-to-oil cooler (turbo engines)

the oil does not need to be drained from the air-
to-oil cooler.
Caution!
The filter element and the rubber seal on the oil
filter cover must not be confused with that of
engines 615, 616 and 617 as these are different
in size.
Engine 602, 603

Size Ll 113 mm
L2 49 mm
Engine 615, 616, 6 17

Size Ll 131 mm
P1mci83-13
L2 55 mm
Caution!
Change engine oil only when engine at normal
1 Empty oil filter before extracting or draining

the engine oil. This is done by unscrewing the
nuts (arrows) and taking off the cover.
For reasons of space, when performing this step

on engine 603 in Model 124 (up to 01186)
detach rubber gasket or sealing strip on the
component partition wall in the manner described
below, and pull up slightly.
Divided rubber gasket

Pull off retaining clip (1).
18.10 . 0020
EXIT
One-piece rubber gasket

Remove screw (arrow).
2-part oil filter cover

(effective 02/86, engine 603 in model 124)
Unscrew return pipe (276) and take off. Unscrew

oil filter cover fastening nuts and take off cover.
2 Extract engine oil through the dipstick guide

tube when the engine is at normal operating
temperature.
If no extractor is available:
3 Remove engine compartment cover below

(01-006).
4 Drain engine oil out of sump (arrow).
Note
The oil in the air-to-oil cooler does not need to
be drained.
18.10 - 002/4
EXIT
5 Replace filter element.
6 Replace rubber seal (1) on the cover.
P18-2057- 13
7 Examine restriction opening on oil pipe for

foreign bodies (arrow). If it is blocked, remove
foreign bodies by hand. Following this, blow
compressed air into restriction opening. Air must
be felt to escape at the bottom of the oil pipe. If
the restriction opening is not clear or if no air
flows out, replace oil filter cover together with oil
pipe.
P18-Olll- 13
8 Tighten nuts and return pipe to 25 Nm.
18.10 - 002/5
EXIT
9 If the oil has been drained from the sump,

replace sealing ring of oil drain plug.
10 Tighten oil drain plug to 30 or 25 Nm,

respectively.
11 Add engine oil.
12 Run engine and examine for signs of leaks
13 Check oil level approx. 2 minutes after

turning off engine at normal operating
temperature.
14 Install engine compartment covering (Ol-

006).
18.10 - 00216
EXIT
1 e-005 Oil circuit, oil pressure, overpressure and bypass valve, oil filter
A 14 185 203 275 52
I; I
18 240 P160116-55
Oil circuit diagram engine 602.91

14 011 spray nozzle 203 Valve tappet
18 Timing dewe 240 Oil pump
52 Oil pressure gauge 275 011 filter
185 Camshaft A Injection pump
18.10 - 00511
EXIT
185 203 275
P18-0108-55
18 240 238
Oil circuit diagram engine 602.91 with exhaust gas recirculation

1 InjectIon pump 275 Oil filter
18 Tlmtng device 296 Oil pressure switch
185 Camshaft 351 Oil level sensor
203 Valve tappet A Unfiltered 011 to air-to-oil cooler
238 Oil spray nozzle B Unfiltered 011 from air-to-oil cooler
240 011 pump
Note
Engine 602.91 with exhaust gas recirculation and manual transmission in combination with air
conditioning.
1810 - 00512
I..
EXIT
1 m5 203 275
1’8 240 238 P18-0041- 55
Oil circuit diagram engines 602.96, 603.96197 (Turbo)

1 InjectIon pump 296 011 pressure switch
18 Timing device 351 Oil level sensor
185 Camshaft A Unfiltered 011 to air-to-oil cooler
203 Valve tappet B Unfiltered 011 from air-to-oil cooler
238 011 spray nozzle a To exhaust gas turbocharger
240 011 pump b From exhaust gas turbocharger
275 Oil filter
18.10 - 005/3
EXIT
Dipstick
Effective 051’84 the Min and Max markings on a a

engine 601 are made of plastic.
42a Max marking

42b Min marking
42c Round handle
A - B Filling range
On engine 602 a dipstick with black handle

was fitted to achieve standardization with
engine 603.
42a Max marking

42b Min marking
42c Handle shaped
like a bottle
opener
A - I3 Filling range
18.10 - 005/4
EXIT
Effective 01187 a dipstick with green handle

(previously black) is fitted to engine 602.96
(Turbo).

Model Engine Engine End No. Vehicle ldent End No.
manual automatic
* *
201.128 1602.961 I- 000405 I
* not regtstered
Engine 602.91 is fitted with a dipstick with a

brown handle.
” not registered
Effective 03/90 the oil level sensor position on

engine 602.91 is lowered, which results in a
change to the dipstick.
Dipstick marking
Color: red
Marking on handle 60214
Size: A - 6 previously 28 mm, now 24 mm

a previously 516 mm, now
516 mm
POl-0182-15
18.10 - 00515
EXIT
Production breakpoint:03/90
I I
manual automatic
I I transmission transmission
201.122 1602.911 1089320 0 17352 558126 723643
On engine 603.970 the dipstick is

marked on handle with the number 60316.
POl-0064-14
a 512 mm
A - B Ftlltng range
Dipstick marking
Round handle
l) 1 st version color marking “red”

2nd version color marking “black”
3rd version color marking “brown”
*) Only on engines with exhaust gas reclrculatlon and side part on 011 sump
3) 1 st version color marking “black”
Note
The dipsticks must not be interchanged.
18.10 - 00516
. . . . . . . . EXIT
Oil pressure and oil pressure indicator
Specified oil pressure at normal operating

temperature
idle speed 3000 rpm
Oil pressure 2 0.3 bar L 3 bar
Voltage exists at the gauge in the instrument

cluster when ignition is switched on. In the
pressure sensor on the oil filter housing (arrow)
ground is switched to the gauge. Any change in
oil pressure results in different electrical
resistances in the pressure sensor and hus in a
different reading in the gauge.
Resistances of pressure sensor as a

function of oil pressure
bar gauge pressure 0 1 2 3
Resistance approx. Q 10 69 129 184
Oil overpressure valve
The oil is drawn through the suction strainer to

the suction chamber (B) from the lowest point in
the sump. From here, the oil flows through the
gears to the pressure chamber (A) and on into
the main oil gallery to the filter.
From an oil pressure of 5.8 bar gauge pressure, a-

the piston (252) is pushed against the compres-
sion spring (251) and opens the relief bore
(arrows) to the suction chamber (8).
At the same time, the oil flows over two flat

faces fitted to the collar (a) into the damping
chamber (C). This oil counteracts the piston
movements produced by the pulsating oil
pressure and results in a damping of the piston.
249 Screw plug

250 Guide pm
18.10 - 005/7
EXIT
ypass valve
As the filter element becomes increasingly

fouled, the lubrication points of the engine are
supplied with less and less oil and the pressure
in the oil filter rises. Once the filter element is so
severely fouled that the oil pressure is 2 bar
above the pressure of the oil delivered by the
pump, the bypass valve (285) opens. As a result,
unfiltered oil flows directly from the sump to the
lubrication point, bypassing the filter element.
275 Oil filter housing

283 Spnng plate
285 Bypass valve
286 Return check valve seat
287 Return check valve cone
290 8 mm 0 ball
b To the beanng points
C Finely flltered 011 to sump
Oil filter element

The full-flow and bypass-flow filter elements are
combined in a cartridge.
During the inspection (800 - 1000 miles) the

break-in oil filter element (A) should be replaced
by the combination oil filter element (B).
The combination oil filter element (B) must be

replaced every 7500 miles.
P1K?os6-13
Caution!
The filter element and the rubber seal on the oil
filter cover must not be interchanged with those
of engines 615, 616 and 617 as they are
different in size.
Engine 602, 603

Size Ll 113 mm
L2 49 mm
Engine 615, 616, 617

Size Ll 131 mm
L2 55 mm Plaam3-13
18.10 - 00518
................................................................................................. .. .................................... .......
EXIT
Oil filter (without air-to-oil cooler

connections)
The oil flows from the inlet passage (a) through

the return check valve (286, 287) into the oil
filter housing and flows direct to the oil filter
element (280). It flows through the filter element
and then through the riser pipe (281) and the
passage (b) to the main oil gallery and on to the
main bearings. The finely filtered oil flows
through the return pipe (276) and the passage
(c) to the oil pan.
A rubber seal is fitted in the oil filter element
(280) to separate the full flow and bypass flow.
271 M 8 nut
272 M 8 stud
273 Cover 280a
274 0-nng 281
275 011 filter houslng
276 Return pipe
277 Check valve
278 0-nng
279 0-rrng
280 011 filter element
280a Full-flow filter
281 Rtser pipe 282- \
282 Locking ring
283 Spring plate
284 Spring
285 Bypass valve cone
286 Return check valve
seat I-- _I__ 289
cone
r----- 288
P18-0085-37
288 Compression spnng
289 Spring plate
18.10 - 00519
EXIT
Note
When changing the oil filter element, unscrew
the cover (273) and raise it slightly. As a result,
the return pipe (276) attached to the cover
clears an opening which connects the passages
(b) and (c) to each other. The oil in the filter
flows back along passage (c) into the oil pan.
The return pipe on engines 601, 602 and in

engine 603 - 1st version is press-fitted. On
engine 603 in model 124 - 2nd version, this
return pipe can be unscrewed when changing oil
to more easily remove the oil filter cover.
Oil filter (with air-to-oil cooler connections)
A thermostat (295) for controlling the oil circuit

through the air-to-oil cooler is fitted in the oil
filter.
Start of opening approx. 110 “C oil temperature.

Fully open at approx. 125 “C oil temperature.
When the thermostat is fully open, only a slight

quantity of oil flows directly to the oil filter
element.
18.10 - 005/10
EXIT
274a-
271 M 8 nut
272 M 8 stud 271
273 Cover
274 0-nrlg
274a Seal (only engine 603 273
In model 124) 274
275 011 filter housing
275 -
276 Return pipe
277 Check valve 276 -
278 O-ring
280
279 0-nng
280 011 filter element
280a Full-flow filter part
281 Rrser pope
282 Lockrng nng 280a--
283 Spring plate
281~
284 Spring
285 Bypass valve cone
seat
287 Return check valve 277
cone
278
288 Compressron spnng
289 Spring plate
295 Thermostat
296 Spring
295
A Unfiltered 011 to air-to-or1 285
cooler - 296
B Unfiltered oil from air- 279
to-oil cooler
a To 011 filter 289
b To bearing points 288
287
C To 011 pan Pl a-0099-37
The air-to-oil cooler lines at the oil filter

housing are sealed by O-rings (265).
264 Air-to-oil cooler lanes

265 O-ring
266 2screwsM6x16
275 011 filter housing P18-01~15
18.10 - 005/11
EXIT
Air-to-oil cooler (engines 602, 603 with

exhaust gas circulation and engines with
turbocharger)
The air-to-oil cooler is attached to the left
wheelhouse behind the bumper.
Oil capacity:
Engine 602.91 0.4 liters
Engines 602.96 1 0.9 liters
Engine 603.96197 0.65 liters
The air-to-oil cooler is shielded by a cover plate.
When changing the oil, it is not necessary to

drain the oil in the air-to-oil cooler.
Cover for air-to-oil cooler, shown on model 124
Lubrication of exhaust gas turbocharger
The oil supply of the turbocharger comes from

an oil passage in the crankcase and from an oil
feed line (A) connected at that point.
The oil return line (6) is likewise located on the
right side of the crankcase and is connected
directly above the oil pan.
Oil return
Part of the oil from the cylinder head returns to
the oil pan through the timing chain case.
Because of the installation position tilted 15” to
the right, the cylinder heads and crankcase are
fitted with two and three return passages
(arrows), respectively, for improving the oil
return.
Engine601
011 return In cylinder head
18.10 - OOW12
EXIT
Engines 602 and 603

P182104-13
011 return In cylmder head
Engines 602 and 603

Pie-2105-13
Oil return in crankcase
18.10 - 00913
EXIT
emoval and installation of oil spray nozzles

Preceding work:
P18-0101-15
Hex. bolt (238a) ........................ unbolt, bolt in, 10 Nm.

Oil spray nozzle (238) .................... take off, fit on.
Note
To remove, position crankshaft so that the oil
spray nozzle is accessible; do not tilt oil spray
nozzle and do not grasp at the nozzle neck.
Cover over oil feed bores. Replace oil spray
nozzles which have a sharply out-of-round
nozzle bore or formation of flash at the nozzle
outlet. Blow through oil spray nozzle with
compressed air in flow direction of oil. Do not
use any hard objects for cleaning. Position oil
spray nozzle vertical to the mating surface on
the crankcase and press into place.
18 10 - 04011
EXIT
Caution!
The oil spray nozzles of the naturally aspirated
engines (with exhaust gas recirculation and
engine 603.970) must not be confused with
those of the turbo engines, which have a
different spray direction.
Hex. bolt of oil spray nozzle 10
Special tool
001 589 72 21 00
\ 00
Note
Since 1 l/88 die-cast oil spray nozzles have been
fitted to the naturally aspirated and turbo engines
(previously white heart malleable cast iron).
. not registered
18.10 - 04012
EXIT
18-110 Removal and installation of oil filter
Preceding work:
Naturally asplrated engtne:air filter removed (09-400).
PlB-o114-57
Hex. nuts (271) ........................ on oil filter cover (273) unbolt, bolt on,
25 Nm.
Oil filter cover (273) ..................... remove, refit.
Gasket (274) and seals (9) ................ remove, insert. Replace gasket and seals.
Engine 603
Return pipe (276) ....................... on oil filter cover, unscrew, screw in, 25 Nm.
Replace seals (9).
Oil filter element (280) .................... withdraw, insert.
Bracket or clips ........................ for starter cable, heater return and vacuum line
to oil filter housing, detach, attach.
18.10 - 110/l
EXIT
Engine with exhaust gas recirculation

Pipe(l) . . . . . . . . . . . . . . . . . . . . . . s ...... between EGR valve and intake manifold or
charge air distribution pipe, detach from oil filter
housing, attach.
Oil delivery line (2) ................ ...... unbolt, reinstall.
Electrical connection .............. ...... detach from oil pressure sensor (296) attach.
With air-to-oil cooler
Connection line . . . . . . . . . . , . . . ...... detach from oil filter housing, attach.
Replace seal.
Hex. socket screws (291) . . . . . . . . ...... on flange of oil filter housing (275) unscrew,
screw in, 25 Nm.
Oil filter housing (275) . . . . take off from crankcase together with gasket
(270), attach. Replace gasket.
Caution!
Seal bores when cleaning sealing surfaces on
crankcase.
Oil filter cover hex. nut 25
Return pipe 25
Special tool
001 589 72 21 00
\ 00 /
1 Unscrew hex. nuts (arrows) on oil filter

cover.
Installation instruction
2 Take off oil filter cover together with seal.
Replace seal of oil filter cover.
Check clear passage of return pipe.
18.10 - 11012
EXIT
Engine 603
3 Unbolt return pipe (276) and remove,
25 Nm.
Replace seals.
Check that the passage of return pipe is clear.
4 Withdraw oil filter element.
Replace oil filter element.
5 Remove brackets (a, b) for starter cable and

heater return pipe along with clip (c) for the
vacuum line from the oil filter housing.
Engine with exhaust gas recirculation

Remove pipe (1) between EGR valve and intake
manifold or charge air distribution pipe from the
oil filter housing.
18.10 - 110/3
EXIT
6 Detach electrical connection at oil pressure

sensor (arrow).
With air-to-oil cooler

7 Unscrew hex. socket screws (266) and 275
I
remove connection line (264) from the oil filter
housing (275).
Replace seal (265).
8 Unscrew hex. socket screws at the flange of

the oil filter housing.
9 Remove oil filter housing together with

gasket from the crankcase and seal connection
bore in the crankcase.
Clean mating surfaces and replace gasket.
P18-0100-15
18.10 - 11014
EXIT
18-115 Modifications to oil filter
271
272
273
Engine 603.960 in model 124.1331.93, Mode
274
Year 1987
275
The oil filter housing has a thermostat (295)
276
between the engine and the oil cooler for
280
controlling the oil cooling.
Start of opening: approx. 11 OC oil temperature.

Fully opened: approx. 125C oil temperature. 280
281
With the thermostat fully opened, a small
quantity of oil will continue to flow to the oil filter
element. - 277
278
The oil cooler lines on the oil filter are sealed by 282
O-rings (previously screw connections with 283
284
conical seal). - 295
285
- 296
279
286 ~ 289
287 - 288
271 Nut, M 8 286 Valve seat return

272 Stud, M 8 flow check valve
273 Cover 287 Valve cone return
274 O-ring flow check valve
275 Housfng 288 CompressIon sprtng
276 Return tube 289 Spnng seat
277 Check valve 295 Thermostat
278 0-nng 296 Spring
279 0-ring a Supply from 011 pump
280 011 filter element b To bearrngs
280a Full flow filter section c Return to 011 pan
281 Rser A Unfiltered 011
282 Retalnrng nng to 011 cooler
283 Spnng seat B Unfiltered 011
284 Spnng from oil cooler
285 Valve cone bypass va
Oil filter cover with removable oil return pipe

(only engine 603 in model 124)
The oil filter cover has been modified. The return
pipe (276) can be removed. This facrlitates the
011 change.
18.10 . 115 1
EXIT
Elimination of thread on hole for

initial filling
The tapped hole with M 10 x 1 screw plug at
the hole for initial filling (arrow) has been
modified into a fit hole with ball (8 mm dia.).
not reglstered
Modification of shape of gasket between oil

filter housing and crankcase
The new gasket is pierced only in the area of the
supply and return lines. This achieves improved
sealing.
A 1 st version
P18-0107-13
B 2nd veraon
* not reglstered
18.10 - 115/2
.................................. ............. ....................................................
EXIT
18-210 Removal and installation of oil pump

Preceding work:
011 sump removed (Ol -310A).
Front axle houslng removed (Ol -3108).
Pla411937
Engines 602 and 603

Support (265) . . . . . . . . . . . . . . . . . . . . . . . . . . unbolt from oil pump pickup, screw on, hex. bolt
(266, 267), 10 Nm.
Oil pump (240) ......................... detach, attach, hex. socket screws (260),
25 Nm.
18.10 - 210/l
EXIT
Notes
Modification to shape of oil deflector plate
The vibration properties have been improved by
modifying the shape of the oil deflector plate
(arrow).
A 1st version
B 2nd veraon P18-0115-15
Production breakpoint:04187
t not reglstered
Production modification of oil pump chain

An oil pump chain with open sleeves is fitted to
reduce wear.
Production breakooint: 06/88

Vehicle ldent End No.
* not registered
18.10 - 210/2
EXIT
Oil pump, engine 603.96

Since 01 90 oil pumps with relief groove for
preventing noise have been fitted to these
engines.

manual automatic
124.133 603.960 025426 025426 * *
124.193 I I
* not regIstered
Oil pump chain

Engines 602 and 603
Since 03,90 oil pump chains made by the
manufacturer Daido have been installed.

Engine End No. Vehicle ldent End No.
l
not registered
Hex. bolt of sprocket wheel 25

Hex. socket screws of oil pump 25
Hex. bolts of intake manifold bracket (engine 602, 603) 25
18.10 - 210/3
EXIT
Special tools
001 589 72 21 00
00
/
1 Unbolt hex. bolt (259) and remove sprocket

wheel from chain.
249 011 overpressure valve screw plug

260 Hex. socket screws P18-2094-13
Tightening torque 25 Nm. Install sprocket wheel
so that the curvature is facing the oil pump
(arrows).
18.10 - 21014
EXIT
Engines 602 and 603

2 Unbolt hex. bolt (266) at the support (265) of
the oil pump prckup.
3 Unscrew hex. socket screws (260) of the oil

pump (240a) and remove oil pump.
Tightening torque 25 Nm. P1&2101-13
Engine 602.96 and 603.970

4 Unscrew other hex. socket screws (260) and
remove oil deflector plate (239).
Engme 602.96
240a 011 pump
249 011 overpressure
valve screw plug
5 Installation is performed in the reverse order. I I I
Engine 603.97
18.10 - 210/5
EXIT
Preceding work:
011 sump removed (Ol -3lOA).
Front axle houslng removed (01-3108).
P1&012&57
Bolt (259) ............................ loosen, tighten, 25 Nm (step 1).

Rivet link pin .......................... grind open (step 2).
Oil pump drive gear (257) ................. replace (steps 3, 4).
New oil pump chain to old oil pump chain ...... link, fit on (steps 5, 6).
Rivet link (263a) ........................ insert from behind into oil pump chain (step 7).
Plate (263b) ........................... insert into rivet tool, press on (steps 10 - 12).
Oil pump chain rivet link pins ............... rivet individually, approx. 30 Nm (step 14).
18.10 - 212/l
EXIT
Special tools
000 589 58 43 00 001 589 72 21 00 103 589 01 63 00

05 \ 00 05
Note
The oil pump drive gear should be replaced
together with the oil pump chain.
1 Loosen bolt (259). Tightening torque 25 Nm.
2 Grind open both rivet link pins (arrows) at

a double link of the oil pump chain. Press out
ground open double link.
3 Remove bolt (259) together with washer

(258).
4 Insert new oil pump drive gear with the

curved face pointing toward oil pump.
Pl&2031-13
18.10 - 212/2
EXIT
5 Attach new oil pump chain with rivet link to

the old oil pump chain.
6 Fit on new oil pump chain linked to old oil

pump chain by slowly turning the crankshaft in
direction of rotation of engine.
7 Detach old oil pump chain. Insert rivet link

from behind into the new oil pump chain.
8 Insert thrust piece (03) into the riveting tool

as shown in the drawing and tighten with the
screw (arrow).
Note
The number 2 is stamped on the side of the
thrust piece (03).
POS-2285-13
9 Insert moving jaw (02) with the figure 2 into

the riveting tool as shown in drawing.
Po5-2286-13
10 Insert plate (arrow) into the moving jaw (02)

(magnetic adhesion).
POS-2123-13
18.10 - 21213
EXIT
11 Fit web (arrow) onto both rollers at rivet link.
Note
The rivet heads of the rivet link pins must be
guided into the groove (C).
12 Screw in spindle (04) until firm resistance is

felt.
Note
During installation, ensure that the pins of the
rivet link are guided into the holes of the plate.
13 Remove riveting tool and switch over the

moving jaw (02) to the riveting profile (D).
PO5-2125-13
14 Position riveting tool exactly in center of rivet

link pin.
Rivet pins of the rivet link individually by
tightening the spindle (04) to approx. 30 Nm.
15 Check riveting; re-rivet, if necessary.
I I Pm-2128-13
18.10 - 21214
EXIT
18-215 emoval and installation of oil pressure relief valve

Precedmg work:
Ott pan removed (01-310).
P18-0121-57
Screw plug (249) . . . . . . . . . . . . . . . . . . . . . . . Caution!

The screw plug is spring-tensioned. Unbolt,
install, 50 Nm.
Replace seal.
Guide pin (250), compression spring (251) and
piston (252) . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, install.
Special tool
001 589 66 21 00
\ 00
18.10 . 2150
EXIT
18-220 Testing oil level indicator
1 Instrument cluster
5 lgnltlon lock
351 011 level sensor Pl8-0036-36
a Electrows
b Fuse 8 A
Problems
A. Indicator lamp shows a steady light

when engine running and oil level
correct.
8. Indicator lamp does not light up when

key is in position “2”.
C. Indicator lamp does not light up when

engine running, oil temperature
* + 60 “C and oil level below “min”.
Test data
Resistance at max. oil level <lC?
Resistance at min. oil level

Battery voltage approx. 12 V
Commercial tool
Multimeter e.g. Sun, DMM-5
18.10 - 220/l
EXIT
Testing
A. Indicator lamp shows a steady light

when engine running and oil level correct
Test oil level sensor by detaching connector.

Measure resistance between oil level sensor
and ground.
Readout: < 1 Q
Test cable by removing Spin connector from

instrument cluster. Measure resistance
between contact 5 of Spin connector and
contact of oil level sensor plug.
Readout: < 1 Q
Yes I No
Replace gauge.
End of test
18.10 - 220,'2
EXIT

key is in position “2” (check function)
Test operation of bulb.

Result: bulb functions properly.
Yes I No
Remove instrument cluster. Measure voltage

with multimeter at contacts 6 and 9 of the 15
pin connector.
Readout: approx. 12 V
Yes No
P20-0076-13
End of test
18.10 - 22013
EXIT

engine running, oil temperature
* + 60 OC and oil level below “min”
Test operation of bulb.

Result: bulb functioning.
st oil level sensor by detaching connector.

st resistance between oil level sensor and
P18-0075-13
Instrument cluster.
Measure voltage between contacts 6 and 9 of
the 1 Spin connector. r I I
Yes
Replace wiring harness.

B V
P20-0076-13
Replace gauge.
End of test
18.10 - 220/4
EXIT
Wiring Diagrams Models 124, 126 and 201
Model 124
II---e14 e l e3pl p2e4 p3 e5 e6 e7 612 ell 613 62 h2 e6 hl p6 Al
0,?5 br/ gn J
L- 0,75 br/ bl
t I
X27
b d S42
P18-0136-57
Wiring diagram engine oil level indicator, coolant level indicator, windshield washer level indicator (see
Wiring Diagrams Volume 3 and Volume 4 for further information)
Al Instrument cluster B5 Oil pressure gauge sensor
et Left turn srgnal Indicator lamp s41 Coolant level rndrcator lamp switch
e2 Rrght turn signal rndrcator lamp S42 WIndshIeld washer rndrcator lamp switch
e3 Htgh beam rndrcator lamp s43 Oil level indicator lamp switch
e4 Fuel reserve warnrng lamp w2 Ground, front right (next to lamp unit)
e5 Battery charge rndrcator lamp X27 Connector, starter wtnng harness
e6 Brake pad wear rndrcator lamp a Main ground (behind instrument cluster) Wl
e7 Brake fluid and parking brake Indicator lamp b Fuse 7 terminal 15
e8 Instrument lrghtrng C Fuse 5 terminal 15
ell Coolant level rndrcator lamp d Lamp rndrcator unrt
e12 011 level Indicator lamp Preglow time relay terminal La
e13 WindshIeld washer level lndrcator lamp
el4 Exterror lamp failure rndrcator lamp
e16 Preglow rndrcator lamp
ht Warnrng buzzer
Pl Coolant temperature gauge
P2 Fuel gauge
Oil pressure gauge
Electronrc clock
18.10 - 220/5
EXIT
Model 201
el e3 pl p2 e4 e5 e6 e7 e12 ell e13 62 h2 p3 e0 hl
58d 58
1
. x5/2
Y
0
If Ib td s41 S42 s43 85

Plao138.57
Wiring diagram engine oil level indicator, coolant level indicator, windshield washer level indicator (see
Wiring Diagrams Volume 5 for further information)
Al Instrument cluster BS 011 pressure gauge sensor
el Left turn signal rndtcator lamp s41 Coolant level lndtcator lamp switch
e2 Right turn srgnal tndtcator lamp S42 Windscreen washer Indicator lamp switch
e3 High beam Indicator lamp s43 011 level Indicator lamp switch
e4 Fuel reserve warning lamp Wl Main ground (behind Instrument cluster)
e5 Battery charge lndrcator lamp x5/2 Connector, Interior/starter 4-pole
e6 Brake pad wear Indicator lamp a Main ground (behind Instrument cluster) Wl
e7 Brake fluid and parklng brake Indicator lamp b Electrical center connector contact 15 terminal 15
e8 Instrument ltghtrng unprotected
elf Coolant level lndrcator lamp C Electncal center connector D contact 2
e12 011 level Indicator lamp terminal 15 fuse 8
e13 Windshield washer level Indicator lamp d Electrical center connector D contact 8 alternator
e16 Preglow Indicator lamp terminal 61
hl Warning buzzer Preglow time relay
h2 Audible turn slgnal Indicator
Pl Coolant temperature gauge
P2 Fuel gauge
P3 Oil pressure gauge
~6 Electronic clock
18.10 - 22018
EXIT
18-225 Function of oil level indicator
1 Instrument cluster
5 lgnltlon lock
351 Oil level sensor Pm-0030-36
a Electrows
b Fuse 8A
General
The electrical oil level indicator monitors the

engine oil level in the sump when the engine
is running and engine oil temperature is above
+ 60 “C. When the ignition is switched on, the
indicator lamp lights up with a weak light (check
function) and goes out as soon as the engine is
started.
18.10 - 225/l
EXIT
Oil level sensor
The engine 011 level in the oil level sensor (351)

is equalized to the oil level in the sump (27)
through an outlet bore (b). The float (358) with
permanent magnet (359) senses the actual 27
engine oil level. The electronics in the instrument
cluster sends a permanent signal to the oil level
357
sensor. If the engine oil level is in the “Min”
358
range of the dipstick, the Reed contact (360) of
359
the float (358) is opened and the permanent
signal to the oil level sensor interrupted. The 360
indicator lamp lights up with a bright light (fault 361
signal). The Reed contact (360) is interrupted 352
shortly before the oil level has reached the
“Min” marking on the dipstick. If the cable from
the oil level sensor to the instrument cluster is
interrupted, the permanent signal to the oil level P18-0079-15
sensor is also interrupted and the indicator lamp

shows a bright light (fault signal).
352 Blmetal snap plate
3 6 5 O-ring
b Outlet bore 4 mm 0
Avoiding incorrect readings
As the engine oil is viscous below a temperature

of + 60 “C and only flows back to the sump
slowly, this could result in incorrect signals of the
indicator lamp. In this case, the bimetal snap 27
plate (352) closes the outlet bore (b) and the

float (358) only registers the oil level in the oil
357
level sensor (351). This eliminates the possibility
358
of an incorrect signal at low engine oil tempera-
359
tures. Once the oil temperature climbs above
+ 60 OC, the bimetal snap plate opens and 360
clears the outlet bore (b). Consequently, the float 361
(358) senses the actual engine oil level in the 352
sump (27). The bimetal snap plate closes at an

engine oil temperature of approx. + 30 “C.
P18-0079-15
359 Permanent magnet

365 O-ring
18.10 - 2252
EXIT
If the engine oil is drained during an oil change,

the oil also flows out of the oil level sensor.
Because the fresh engine oil added is colder
than + 60 “C, the bimetal snap plate closes the
outlet bore (b) i.e. there is no engine oil in the oil
level sensor and the indicator lamp would signal
insufficient engine oil although the engine oil
level is sufficient. In order to avoid this, the oil
level sensor is filled through the vent bore (a).
When driving through sharp corners, the engine
oil is pushed against the outer walls of the oil
pan. Particularly when negotiating left turns, the
engine oil level around the oil level sensor drops
and the sensor runs dry. The float (358) briefly
interrupts the Reed contact (360) and the
indicator lamp would show a bright light. The
electronics in the instrument cluster prevent the
indicator lamp from lighting up until after the
Weed contact (360) has been interrupted for
60 s. This avoids any incorrect signal when
negotiating sharp corners.
18 10 - 2251'3
............................... ................................................. EXIT
emoval and installation of oil level sensor

Preceding work:
Engine 011 dralned.
Engine compartment cladding bottom removed (01-006).
A. Engine 602,603
Pl&0112 57
Plug (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . for oil level sensor, disconnect, plug in.

Bolts (20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt in, 10 Nm. Remove and install oil
level sensor (351). Replace O-ring (365).
18.10 - 226 1
EXIT
Modifications
A larger diameter O-ring made of Viton is fitted

for sealing the oil level sensor at the sump.
Color: green (previously black).
Diameter 3.15 mm (previously 3 mm).
201.126 1602.911 / 027261 006588 * *
l
not registered
The seal of the oil level sensor at the sump has

been improved by modifications in size of the
O-ring.
New O-ring:
Previous Present
Size version version
mm mm
dl 40,20 37,20
d2 3,15 3,20
POl-0187-U
18.10 - 22612
EXIT

Model Engine End No. Vehicle ldent End No.
manual automatic
124.133 603.960 - 013429 * *
124.193 I I
126.125 013103 * *
I 603.g61 I-
*
* not reglstered
Oil level sensor bolts 10
Special tool
16.10 - 2260
EXIT
ine Csolin ystem - 20

EXIT
ngine Cooling System 20
Job No.
Coolant circuit and engine cooling .......................................... 20 - 005

Engine coolant replacement - Antifreeze table ................................. 20 - 010
Cleaning and flushing cooling and heating system .............................. 20 - 015
Removing oil from cooling and heating system ................................. 20 - 016
Checking cooling system for leaks ......................................... 20 - 017
Removal and installation of thermostat ...................................... 20 - 110
Removal and installation of coolant pump .................................... 20 - 210
Notes on coolant pump ................................................. 20 - 215
Removal and installation of coolant pump housing .............................. 20 - 230
Temperature-controlled viscous fan coupling .................................. 20 - 310
Removal and installation of viscous fan coupling ............................... 20 - 312
Magnetic fan coupling .................................................. 20 - 330
Removal and installation of magnetic fan coupling .............................. 20 - 335
Removal and installation of radiator ......................................... 20 - 420
Repairing radiator ..................................................... 20 - 425
Testing radiator or expansion tank cap ...................................... 20 - 430
Testing coolant level indicator ............................................. 20 - 440
Function of coolant level indicator .......................................... 20 - 445
Removal and installation of overflow tank ..................................... 20 - 450
--
20 1
EXIT
20-005 Coolant circuit and engine cooling
Coolant circuit engine 602.91
\ ._.~~ _-._
PM-0091.55
1 Expansion tank 9 From radiator to coolant pump via thermostat

2 Overflow line 12 Fllllng hose
3 From cylinder head to radiator 13 Vent line
4 Return from heating system (heat exchanger)
6 Feed to heattng system (heat exchanger) A. Radiator clrcult above 100 “C
B. Bypass clrcutt up to 85 “C
C. Cool water
D. Heatrng
20.10 - 005/l
EXIT
Coolant circuit engine 602.96, 603.96
P20-0106-S
1 Expansron tank 9 From radiator to coolant pump via thermostat

2 Overflow lrne 10 Overflow tank (engtne 603.96)
3 From cylrnder head to radiator 11 Radrator
4 Return from heatrng system (heat exchanger) 12 Fllltng hose
5 Fuel heat exchanger 13 Vent line
6 Feed to heating system (heat exchanger)
7 Heat exchanger A. Radrator crrcurt above 100 “C
8 Thermostat 6. Bypass clrcult up to 85 “C
C. Cooled water
D. Heating
Note
Engine 603.96 has an overflow tank (10) in
addition to the expansion tank. The overflow tank
is installed in the wheelhouse of the right front
fender.
20.10 . 005/2
EXIT
Function of overflow tank
The overflow tank protects the engine from loss

of coolant at high outside temperatures. Coolant
may flow out along the overflow line after
shutting off the engine at high outside
temperatures.
The coolant overflow is collected in the overflow

tank.
After the engine and the coolant has cooled

down, a vacuum is produced in the cooling
system which causes the coolant which has
flowed into the overflow tank to flow back into
the expansion tank.
To enable the vacuum to build up after cooling

down, the cap of the expansion tank must
provide a tight seal.
The cap (1.4 bar) is fitted with a rubber seal for
this purpose.
P20-217513
Function of coolant thermostat
Engine I Start of opening “C I Fully open “C

602 I 85 ,+ 2 I 100
602.96, 603.96 I 80 + 2 I 94
20.10 - 005/3
EXIT
Note
The function of the coolant thermostat is outlined
in the description below, using, as an example, a
naturally aspirated engine.
Warm-up period - coolant temperature up to

approx. 85 OC
Up to a coolant temperature of approx. 85 “C
the main valve is closed and the bypass plate is
fully open. The flow (B) from the radiator is thus
interrupted. The coolant flows through the
bypass passage (C) directly through the coolant
pump into the crankcase (D).
C From crankcase (bypass passage)

D To crankcase
D
P20-0094-13
Part-load operation - coolant temperature

approx. 85 OC up to maximum 100 OC
At coolant temperatures above approximately
85 - 100 O C the main valve and bypass plate are
mostly open, depending on engine load. The
coolant flows from the radiator (B) through the
bypass passage (C) through the coolant pump
into the crankcase (D).
I3 From radiator
C From crankcase (bypass passage)
D To crankcase D
P20-0093-13
Full-load operation - high outside

temperature (coolant at above 100 OC)
At coolant temperatures above approx. 100 “C
the main valve is fully open. The bypass
passage (C) is sealed off by the bypass plate.
The entire quantity of coolant flows through the
radiator.
The cooling system is automatically bled through

a ball valve in the coolant thermostat when it is
filled during engine operation.
P20-0092-13
20.10 - 0054
EXIT
ngine coolamt replacement - Antifreeze table

Preceding work:
Engine compartment covertng bottom removed (01-006).
fvo-oi la57
Heater switch .......................... set to maximum heating capacity.

Cap(8) .............................. remove, refit.
A Warning
Open cap only when coolant temperature is
below 90 OC.
Drain plug (1) .......................... open, close, 1.5 - 2 Nm, drain coolant (step 2).
Drain plug (12) and drain connection . . . . . . . . . open, close, 30 Nm, drain coolant (steps 3, 4).
Old coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . flush out.
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pour in up to marking on expansion tank (10)
(step 6).
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . run until coolant thermostat opens, approx. 90 -
100 “C (step 7).
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . check (step 8).
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . check for leaks (20-017).
20.10 - 010/l
EXIT
Total capacities of cooling system with heating system and mixing ratio of anti-
corrosion/antifreeze agent’) and water-n) in liters
Model Engine Total capacity of cooling system Mixing ratio anti-corrosion/antifreeze
with heating system agent/water for antifreeze prot. down to
-30 “C -45 “C
124 602.96 8 3.514.5 4.513.5

I
124, 126 (603.96/97 I10 4.515.5 5.514.5

201 3.514.5 4.5i3.5
l) See Service Product Speclflcations sheet 325.1 and 325.2

2) See Sewce Product Speclflcatlons sheet 310
Radiator drain plug 1.5 - 2
Crankcase drain plug 30

Drain connection (engine 602 and 603 only) 30
Special tools
001 589 72 21 00
00
/
Commercial tool
Antifreeze protection tester e.g. Ph. Gather,
Prestone-W-Check (Union Carbide) 4020 Mettmann
20.10 - 01012
EXIT
Notes, see VOI Environmental Protection

Catalog
Water
Use water which is clean and not too hard.
Usually drinking water satisfies these
requirements. The content of dissolved
substances in the water may result in corrosion.
Anti-corrosion/antifreeze protection
The anti-corrosion/antifreeze agent must perform
the following tasks:
- Adequate corrosion and cavitation protection
for all components
- Antifreeze protection
- Provides increased boiling point
50% by vol. anti-corrosion/antifreeze agent must

be added to the water. This concentration offers
antifreeze protection down to approx. -37 “C.
A higher concentration is only recommended for
very low ambient temperatures.
More than 55% by vol. anti-corrosion/‘antifreeze

agent reduces the antifreeze protection and
reduces the heating capacity.
55% by vol. anti-corrosion’antifreeze agent

offers antifreeze protection down to approx.
-45 O C. Anti- corrosion/antifreeze agent
increases the boiling point, in other words the
coolant does not evaporate so rapidly. This
avoids coolant being lost at high coolant
temperatures.
Use only approved anti-corrosion/antifreeze

agents (see Service Product Specifications
sheets 325.1 and 325.2).
20.10 - OlOf3
EXIT
Operational monitoring of coolant

Check the coolant for resistance to low tempera-
tures at the start of the cold season of the year.
Check anti- corrosion/antifreeze agent concen-
tration once a year in areas with high outside
temperatures.
When adding coolant (after loss of coolant), it

must be assured that there is an anti-corrosion/
antifreeze agent portion of 50% by vol. in the
coolant to provide antifreeze protection down to
-37 “C.
The anti-corrosion protection in the coolant is

reduced over the period of operation. The
coolant then has a sharply corrosive effect.
The maximum permissible period of use of the
specified coolant in car engines is 3 years.
Before adding fresh coolant, the used coolant
should be first flushed out of the system.
Draining
1 Set heating switch to maximum heating

capacity.
2 Open cap on expansion tank in stages, allow

system pressure to escape and remove cap.
A Warning
Open cap only when coolant temperature is
below 90 “C.
3 Open drain plug on the radiator.
Note
An extension hose can be fitted to the drain
connection for collecting coolant.
Tightening torque 1.5 - 2 Nm.
Drain plug on models wlthout air conditioning

P20-2043-13
20.10 - 01014
EXIT
Drain plug on models with air condltloning
On models with air conditioning, open flap for

towing lug at front right of lower bumper molding.
1 Drarn plug on models with air

condltlonrng
Note
On models with air conditioning, the plug below
the right side wheelhouse at the noise encapsu-
lation should be removed. An extension hose
can be fitted onto the drain connection of the
radiator through this opening.
Extension hose fltted on (with air condltionlng)
4 Unscrew drain plug (12) on crankcase.
20 10 - 010/5
EXIT
Note
Engines 602 and 603 have a drain connection
(12a) in place of the drain plug. A hose can be
fitted onto this drain connection for draining.
Filling in coolant
5 Flush out old coolant.
6 Slowly pour in coolant up to the marking

(arrow) on the expansion tank.
Marking on expamon tank
Note
The filler hose can be pressed down (arrow)
when adding coolant to ensure that it flows more
quickly from the expansion tank into the radiator
and engine.
7 Run engine until the coolant thermostat

opens (coolant temperature approx.
90 - 100 “C).
P20 - 2032 - 13
Note
Close filler connection at expansion tank from a
coolant temperature of approx. 60 - 70 “C.
8 Check coolant level; top off to specified

marking, if necessary.
9 Check cooling system for leaks (20-017).
20.10 - 010.6
EXIT
20-015 Cleaning and flushing cooling and heating system

Preceding work:
Engine compartment covering bottom removed (01-006).
e?o-o11i_x57
Coolant thermostat ...................... remove and install forcibly-opened thermostat

Part No. 000 589 74 63 00 (step 1).
Flushing connection pipe (01) .............. install and connect tap water hose (03)
(steps 2 and 3).
Cooling system ........................ flush (step 4 - 20, 22).
Cooling system expansion tank ............. remove and install, flush out (step 21).
Cooling system ........................ check for leaks (20-017).
Service products
Anti-corrosion/antifreeze agent 000 989 08 25
Citric acid powder (0.5 kg) 000 989 10 25
20.10 - 0151
EXIT
Special tools
117 589 20
00 90 00 I
Notes
High coolant temperatures and low heating
capacity may also be caused by deposits of
corrosion products in the radiator and in the heat
exchanger.
The deposits are recognizable as a jelly-like

mass or, when the radiator is empty and dry,
from a grey layer on the cooler connection
pipes.
In this case, the cooling and heating system can

be cleaned with a 10Y0 citric acid solution.
Radiators which have cooling pipes which are

fully or partially clogged, must be replaced.
Scope of flushing operation
1 Remove coolant thermostat and install

forcibly-opened thermostat 000 589 74 63 00
with sealing ring.
20.10 - 01512
EXIT
2 Connect flushing connection pipe Part No.

117 589 00 90 00 with connection hose between
radiator and coolant hose.
3 Connect a tap water hose to the flushing

connection pipe.
4 Open cap of expansion tank.
5 Set heater to “warm”.
Models with auxiliary heater

6 If automatic heating control is fitted, set the
temperature selectors to “Max” or, if automatic
climate control is fitted, press the “Defrost”
button so that the circulation pump is switched
on when the engine is running.
7 Open bleeder valve of the auxiliary heater.
8 Flush cooling and heating system with

flowing water for approx. 5 minutes with the
engine running (approx. 2500 rpm) so that the
remaining coolant is flushed out.
Caution!
During the flushing operation, the cooling system
must always be completely filled. Adjust feed
quantity accordingly.
9 Allow flushing water in the radiator and

crankcase to completely drain out. Screw in
drain plugs at radiator and crankcase.
10 Dissolve 15 kg citric acid powder (0.5 kg,

Part No. 000 989 16 25) in 5 liters of water in a
suitable vessel.
11 Pour cleaning solution into the coolant

expansion tank and top off with water as far as
the marking on the expansion tank.
12 Close bleeder screw of auxiliary heater.
13 Close cap of expansion tank.
20.10 - 01x3
EXIT
14 Run engine for 15 minutes at approx.

2500 rpm. The solution must flow through the
heat exchanger (step 5).
15 Following this, drain cleaning solution.
Caution!
Empty the cleaning solution (citric acid mixture)
into a standard workshop oil and water
separator.
16 Open the bleeder screw of the auxiliary

heater.
17 Flush cooling and heating system for approx.

10 minutes with flowing water with engine
running (2500 rpm). The water must flow through
the heat exchanger (see steps 5 and 8).
18 Remove flushing connection pipe and

connect coolant hose to the radiator.
19 Install normal coolant thermostat with new

seal.
20 Screw coolant drain plugs into radiator and

crankcase.
21 Remove coolant expansion tank, flush out

once again separately, and install.
Note
The cleaning solution is not completely removed
when drained because of pockets or recesses in
the coolant expansion tank.
22 If car fitted with auxiliary heater, connect

plastic hose to bleeder valve and open valve.
23 Add fresh coolant (20-010).
20.10 - 01!34
............................................................................................ ............................ ........ ... ............ EXIT
20-016 Removing oil from cooling and heatfng system

Preceding work:
Coolant thermostat removed (20-l 10).
f-fester control ......................... set to “warm” (step 1).

Cooling system ........................ fill with a 5 % flushing solution (step 2).
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . warm up to normal operating temperature and
run for approx. 5 minutes (step 3).
Flushing solution ........................ drain and fill cooling system twice with fresh
water, run engine each time for approx. 5
minutes, completely drain flushing solution
(steps 5 and 6).
Cooling system . . . . . . . . . . . . . . . , . . . . . . , . check for leaks (20-017).
20.10 - 016/l
EXIT
Special tool
124 589 15 21 00
\ 20 /
Note
Oil must be removed from the cooling system if
engine oil, automatic transmission fluid on
models fitted with automatic transmission, or
hydraulic oil entered the cooling system.
Removing oil
1 Set heater control to full capacity.
Caution!
On vehicles with light alloy radiators, strong
alkaline cleaners such as P3 Standard (supplier:
Henkel) must not be used.
2 Fill the cooling system with a 5 % solution of

water and neutral cleaner or with a mild alkaline
cleaner such as 3-Croni (supplier: Henkel) or
Grisiron 7220 (supplier: Farbwerke Hoechst).
3 Warm up engine to approx. 80 “C by

running at moderate rpm and maintain for
approx. 5 minutes at this temperature.
4 Switch off engine and allow cooling system

to cool down to approx. 50 “C.
5 Drain solution completely.
6 Immediately following this step, fill cooling

system twice with fresh water, warm up engine
(approx. 5 minutes) and drain.
20.10 - 016/'2
EXIT
20-017 Checking cooling system for leaks
Pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . open in stages, allow system pressure to

escape and remove.
AWarning
The pressure cap must only be opened if the
coolant temperature is below 90 “C.
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . must extend up to the mark on the expansion
tank (10).
Heater switch .......................... set to maximum heating capacity.
Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 589 15 21 00, attach to expansion tank (10)
and pressurize cooling system, approx. 1.4 bar
gauge pressure.
Check all cooling and heating hoses and their
connection points for loss of coolant. Check
condition of hose clips, tighten if necessary.
20.10 - 017/l
EXIT
Special tool
Commercial tool
e. g. Hazet,
7 mm wrench socket on flexible shaft for hose D-5630 Remscheid
clips with worm drive Order No. 426-7
Checking for leaks

1 Turn cap to 1st detent and allow system
pressure to escape, then turn to 2nd detent and
remove cap.
A, Warning
The pressure cap must only be opened if the
coolant temperature is below 90 “C.
2 The coolant level must extend up to the

marking on the expansion tank (arrow).
3 Pressurize cooling system with the tester

124 589 15 21 00 (approx. 1.4 bar).
4 Check all cooling and heating water hoses

and their connection points for loss of coolant.
Check that hose clips are in proper condition

and correctly seated, replace or tighten as
necessary.
20.10 - 017('2
EXIT
emoval and installation of thermostat

Precedmg work:
321
Housing cover (320) ..................... unscrew from coolant pump, screw on, bolts
(321) 10 Nm. Replace seal (319).
Thermostat (318) . . . . . . . . . . . . . . . . . . . . . . . check. Make note of installation position; the
recess on the thermostat must be aligned with
the rib in the thermostat housing cover.
Note
Thermostat and thermostat housing cover are
marked with a green dot on turbo engines.
Special tool
001 589 72 21 00
00
/
20.10 - 1101'1
EXIT
emoval and installation of coolant pump

Preceding work:
Coolant dralned (20-010).
Radiator removed (Model 201 .126 only) (20-420).
346
344
w
299a
Engine 602, 603:

Fan with viscous fan coupling (295) . . . . . . . . . . unbolt, bolt on, hexagon socket bolt (297), 45
Nm.
Use screwdriver 103 589 01 09 00,
torque wrench 001 589 66 21 00 and
counter holder 603 589 00 40 00 (step 2).
Belt pulley (299, 346) . . . . . . . . . . . . . . . . . . . . unbolt, bait on. Hexagon socket bolts (299a), 10
Nm, Torx screws (345), 15 Nm
(step 3).
20.10 - 21011
EXIT
Caution!
The magnet carrier must not be removed.
Engine 601: Remove cable, unbolt hexagon nut (349a) and

Magnet body (347) . . . . . . . . . . . . . . . . . . . . . remove magnet body (steps 4, 5).
Coolant pump (300) . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, replace hexagon bolts (308), 10
Nm. Replace gasket (307), clean sealing
surface.
Hexagon bolts of fan 25
Hexagon socket screws of viscous fan coupling 45
Hexagon bolts of coolant pump 10
Hexagon socket screw of belt pulley 10
Torx screw of belt pulley 15
Special tools
001 589 72 21 00 001 589 66 21 00 603 589 004000 103 589 01 09 00

00 00 20 20
20.10 - 21012
EXIT
Removal
Engine 602, 603

2 Detach fan cowl, place over the fan.
Unscrew viscous fan coupling, using screwdriver
insert 103 589 01 09 00 (03) torque wrench
001 589 72 21 00 (02) and counter holder
603 589 00 40 00 (01).
3 Unbolt hexagon socket bolts (345) and

remove belt pulley (346).
Note
The magnet carrier (348) is bonded to the
coolant pump housing and must not be removed.
6 Unbolt coolant pump.
7 Clean sealing surfaces.
20.10 - 210/3
EXIT
Installation
8 Insert coolant pump with new gasket and

tighten hexagon bolts.
9 Install magnet body and plug in cable.
10 Install belt pulley.
Tightening torque
Hexagon socket screw 10 Nm,
Hexagon socket torx screw 15 Nm.
The remaining parts are installed in reverse

order.
20.10 - 21014
... .......................................... ........ ..... EXIT
m-21 5 Notes on coolant pump
General
The coolant pump located at the bottom right of

the engine is attached to a light alloy housing
bolted to the crankcase. The coolant thermostat
(318) is also contained in this housing.
A flange (302) is pressed onto the coolant pump

shaft (303) for attaching the belt pulley. An
expansion space (E) is located between coolant
pump bearing (304) and cassette seal (305). The
fan is attached at the stub end (arrow).
301 Coolant pump housing

302 Flange
303 Coolant pump shaft
304 Coolant pump beanng
305 Cassette seal
306 Impeller
307 Gasket
308 Hexagon bolt
M 6x35
316 Fit pun
317 Light alloy housing
318 Coolant thermostat
319 Gasket
320 Inlet connectlon
B Inlet connectlon to radiator
C Pump chamber
D Inlet from crankcase
P20-0090-35
E Expanston space
20 10 - 21511
EXIT
296 -
Engine 602 and 603 297-

Arrangement of VISCOUS fan coupkng and coolant pump
5 Ball beanng 5-
295 Fan
296 3 bolts M 6 X 14
’ 297 Hexagon socket screw M 10 X 40
298 VISCOUS fan coupling 298-
345 4 hexagon bolts M 6 x 12
346 Belt pulley
The coolant pump of engine 602 and 603 is

306
strengthened at the coolant pump housing (301)
and at the coolant pump bearing (304) because
of the heavier viscous fan coupling.
The diameter of the impeller (306) on all the

engines is identical.
The coolant pump shaft has a tapped hole

M 10 X 22 at the front for attaching the viscous
fan coupling. I I
304 E 303 P20-0096-13
301 Coolant pump housrng

302 Flange
303 Coolant pump shaft
304 Coolant pump beanng
305 Cassette seal
306 Impeller
316 Fit sleeve
E Deformatton space
20.10 - 215;2
EXIT
20-230 Removal and installation of coolant pump housing

Preceding work:
Coolant pump removed (20-210).
Alternator removed (15510)
321
415
Pzo-o101-57
Ground cable to battery ................... disconnect, connect.

Supporting bracket for alternator (416) ........ unbolt, bolt on, hexagon bolts (417, 420) 25
Nm.
Return lines (326,326 a) . . . . . . . . . . . . . . . . . . unbolt at crankcase, bolt on, withdraw from
coolant pump housing (317) insert. Replace
O-ring (325).
Caution!
Do not coat O-ring with oil or grease; use only
antifreeze.
Engines 602.96, 603.96 with automatic
transmission:
Cable from temperature switch . . . . . . . . . . . . . detach, plug in.
Temperature switch . . . . . . . . . . . . . . . . . . . . . unscrew, refit.
20.10 - 230/l
EXIT
Coolant pump housing (317) . . . . . . . . . . . . . . . unbolt, bolt on, hexagon bolts (352),
10 Nm. Clean sealing surface and replace
gasket (315).
Cooling system . . . . . . , . . . . . . . . . . . . . . . . . check for leaks (20-017).
Hexagon bolts of coolant pump housing 10
Hexagon bolts of supporting bracket for alternator 25
Hexagon bolts of alternator 45
Special tools
001 589 72 21 00
00
I 001 589 00 66 21 00
Removal
1 Disconnect ground cable at the battery.
2 Unbolt supporting bracket for alternator

(arrows).
3 Unbolt return line (326) at the crankcase and

withdraw from the coolant pump housing.
20.10 - 23012
.......................... .................................
EXIT
Engines 602.96 and 603.96 with automatic

transmission:
4 Detach cable for temperature switch in
coolant pump housing and unscrew temperature
switch.
5 Unbolt coolant pump housing.
6 Clean sealing surfaces.
Installation
7 Replace O-ring on return line.
Note
Keep O-ring free of grease. The O-ring can be
dipped in coolant to ease installation.
8 Fit coolant pump housing onto the return line

and install onto crankcase with a new gasket.
9 Bolt return line onto the crankcase.
10 Install supporting bracket for alternator (419)

and tighten fastening bolts.
11 Connect ground cable to the battery.
20.10 - 2300
EXIT
20-310 Temperature-controlled viscous fan coupling
Function
The viscous fan coupling is a maintenance-free

hydraulic coupling which operates proportionately
to temperature.
When the engine is started (cold start), the fan

initially runs at a higher speed until the oil has
flowed back from the working chamber (B) into
6
the storage chamber (A). Following this, the fan 8
coupling shuts off. Fan speed in the off state 7
depends on engine speed. Fan speed, in any
case, does not exceed 1000 rpm.
This state is maintained until the engine has

reached the fan activating temperature.
Coupling body (secondary part)

2 Cover
3 Drlvlng plate (pnmary part)
4 Switch pin
5 Ball beartng
6 Beanng bush
7 Btmetal strip
8 Seal
9 Valve
A Storage chamber
B Working chamber
20.10 . 310/l
EXIT
If the coolant temperature rises due to higher

engine loads or high outside temperatures, the
n
arr which flows through the radiator and contacts
the bimetal strip (7) becomes warmer. The
bimetal strip (7) alters its shape as It heats up
and opens a valve (9) at approx. 71 “C by
means of a pin (4) and thus also the passage for
the oil from the storage chamber (A) into the
working chamber (B), which causes the fan to 6
activate. 8
7
The coolant temperature during this switching
operation remains between approx. 90 and 95
“C.
When the coupling IS engaged, fan speed

P2l%oo97-15
increases proportronally with increasing engine
speed In the lower rpm range, without exceeding
3300 rpm in the upper range.
Coupling body (secondary par-t)
Cover
Dnvlng plate (pnmary part)
Switch pin
Bail bearing
Beanng bush
Blmetal stnp
8 Seal
9 Valve
A Storage chamber
6 Working chamber
Checking activation temperature

Run engine at 4000 - 5000 rpm. Once a coolant
temperature of approx. 90 - 95 “C has been
reached, the speed of the viscous fan coupling
must increase, which can be clearly heard.
Repair
It is not possible to repair a defective coupling; it
must be replaced.
20 10 - 310 2
EXIT
Transportation and storage

Temperature-controlled viscous fan couplings
must be transported upright. For brief periods -
e. g. for installation purposes, the coupling may
be placed on the flange side, but never on the
front side.
Caution!
The bimetal strip must not be bent or damaged.
Distinguishing features
Engine 602.911 bimetal spring; color silver grey.
Imprinted Part No. 603 200 00 22 (arrow).
The viscous fan couplings of engine 602.96 and

603.96 have been strengthened to compensate
for an enlarged fan.
Bimetal spring; color metal-colored.
Red imprinted Part No. 603 200 04 22.
PM2174-13
20.10 - 31013
EXIT
20-312 Removal and installation of viscous fan coupling

Preceding work:
Radiator removed - only Model 201.126, 124.133, 124.193
(20-210).
P20-0104-55
Hose holder (15) ....................... unclip, clip in.

Retaining clip (1) ....................... pull off, fit on.
Fan cowl (11) .......................... place over the fan.
Caution!
Separate split fan cowls and remove.
Hexagon socket screw (297) . . . . . . . . . . . . . . . unscrew, screw in, 45 Nm, using screwdriver
insert 103 589 01 09 00, torque wrench
001 589 72 21 00 and counter-holder
603 589 00 40 00 (step 3).
Fan (295) with viscous fan coupling (289) . . . . . . remove at coolant pump (300) insert.
Fan (295) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . unscrew, screw on, hexagon socket screw
(296), 10 Nm.
Caution!
Notice direction of rotation of fan (295).
Inscription must be facing direction of travel.
20.10 - 312/l
EXIT
Hexagon socket bolts of fan 10
Hexagon socket screw of VISCOUS fan coupling 45
Note I
As a distinguishing feature on engines 602 and
603.91 a silver-colored sticker with Part No.
603 200 00 22 and 603 200 04 22, respectively,
is attached to the viscous fan coupling. A red
inscription appears on the same part for engine
603.96.
P20-2174.13
The hose holder for attaching the vent hose at

the fan cowl has been modified from a single-
section version to a two-section version.
A Previous version
B Present version
20.10 - 312 2
EXIT
Production breakpoint: 10187 - OY88
. not reglstered
Special tools
103 589 01 09 00 603 589 00 40 00
Removal
1 Remove clip together with vent line from fan

cowl (arrow).
2 Pull off retaining clips (1) for fan cowl. Place

fan cowl over the fan.
20.10 - 312/3
EXIT
3 Unbolt viscous fan coupling with torque

wrench 001 589 72 21 00 (02) and screwdriver
insert 103 589 01 09 00 (03). Hold the belt
pulley with the counter-holder
603 589 00 40 00 (01) when performing this
step.
4 Remove viscous fan coupling together with

fan and fastening bolt.
5 Unbolt fan from the viscous fan coupling.
Installation
Caution!
Notice direction of rotation of fan. Marking must
be pointing in direction of travel.
6 Bolt fan onto the viscous fan coupling.
P20-2172-13
7 Fit fan with viscous fan coupling and

fastening screw onto the coolant pump.
8 Tighten the hexagon socket bolt with

screwdriver insert 103 589 01 09 00 (03) and
torque wrench 001 589 72 21 00 (02). Hold the
belt pulley securely with the counter-holder
603 589 00 40 00 (01) when performing this
step.
9 Install fan cowl.
10 Attach vent line at fan cowl.
2 0 . 1 0 - 312,/4
EXIT
20-330 Magnetic fan coupling
The magnetic fan coupling is activated by a 100

“C temperature switch (S2511) mounted at the
outlet connection.
The electromagnetic fan coupling is

maintenance-free.
Design of the electromagnetic fan coupling

The magnet body (347) is attached to the
magnet carrier (348) with 3 nuts (349).
The magnet carrier is bonded to the coolant

pump housing and does not need to be
removed.
344 344a
r-t44
302
303
Flange
Shaft
I UUII~ -+---346 317
304 Bearing
305 Cassette seal
306 Impeller 306
309 Tensioning plate
340 Collar bolt 341
341 Washer
343 Beanng 345
344 Fan 302
344a Armature
344b Leaf spnng
345 Hexagon socket screw M 6 x 12
346 Belt pulley U II
347 Magnet body
348 Magnet carrier
349 Hexagon nut
20.10 - 330/l
EXIT
The electric cable is connected to the magnet

body (347) via a coupling (arrow).
The belt pulley (346) is mounted to the coolant

pump shaft in front of the magnet body.
The belt pulley (346) is bolted to the flange of

the coolant pump with 4 hexagon socket bolts
(345) or torx bolts.
Function
The fan is activated only if the ignition is turned

on and the coolant is at a temperature above 98
- 102 “C.
344 344a
I
-mr- -7-l
111 I I iW-346
Voltage is applied constantly to the magnet body
(347) through fuse No. 10 terminal 15 (1 st 317
version).
344t
343. 306
Below a coolant temperature of 98 - 102 “C the 309.
fan is switched off and only rotates as a result of 340 +?=-Y 3 0 4 L-=-J
air flow over the fan when the vehicle is moving. 341
305
345.
A negative voltage is applied by the temperature 302.
switch in the outlet connection at no less than a
coolant temperature of 102 “C.
-l- - I m ,) 349 303-
P20-0089- 15
2010-3302
EXIT
The armature (344a) is attracted by the magnet

body (347) and presses against the face of the
belt pulley (346).
The fan becomes rigidly attached to the belt

pulley and rotates at coolant pump speed.
If the coolant temperature drops below 93 -

98 ‘C, the temperature switch opens and the
armature is lifted off the belt pulley (346) by leaf
springs (344b).
On vehicles with air conditioning, the fan and

electric auxiliary fan are activated through a
double contact relay which is activated by the 52
“C temperature switch at the fluid reservoir.
If the air conditioning is off, the 100 “C

temperature switch at the outlet connection
alone engages or disengages the fan.
The armature (344a) and the ball bearing (343)

are fitted to or to the inside of the fan.
The ball bearing is sealed on both sides with

cover plates.
Fan
The fan (A) has 6 blades and a diameter of

380 mm.
On vehicles with air conditioning, the fan (8) has

5 blades and a diameter of 430 mm.
20.10 - 33013
EXIT
Modification to electromagnetic coupling

Model 201
Effective 10 84 a modified electrical center has
been installed. As a result, the electromagnetic
coupling is operated by a positive voltage
through a 2-pin temperature switch (S25 1)
(previously negative voltage).
\-
1 D1
\
\ I
I
Pm-3165.13
\I
I
On vehicles with air conditioning positive is

connected through a relay also after the
pressure switch (14) closes.
2010. 330’4
............................................................... ................................................... ..... EXIT
20-335 Removal and installation of magnetic fan coupling

Precedtng work:
Retaining clips (1 a) ...................... remove, refit.

Fan cowl (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . detach, attach, place over fan.
Fan (344) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, 25 Nm.
Belt pulley (346) .,....._ ................ unbolt, bolt on, hexagon socket bolt
10 Nm or torx screw 14 Nm.
Magnet body (347) .......... ....... ..... pull off cable connection, fit on, unbolt nuts
(349a), bolt on.
Magnet carrier (348) ..................... do not remove from coolant pump, check for
tightness, secure with adhesive
001 989 45 20 10, if necessary.
Special tools
001 589 72 21 00
00
20.10 - 33511
EXIT
20420 Removal and installation of radiator
Preceding work:
Bottom engine compartment coverlng removed (01-006).
P20-0119-57

Oil lines at cooler ....................... unbolt, bolt on, clamp with special tool
000 589 40 37 00 (step 1).
Holder (15) ........................... for vent hose, unclip, clip in (step 4).
Flat spring (1) .......................... remove, insert.
Fan cowl (11) .......................... remove, insert. Place fan cowl (11) over the fan.
Coolant hoses (10, 14) ................... detach, attach, check condition.
Expanding rivets (5) ..................... remove, insert (step 5).

Radiator coverings (6, 7) .................. remove, install.
20.10 - 42011
EXIT
Retaining clip (4) . . .................... pull off, fit on.

Model 201.128
Radiator bridge . . . . .................... unbolt, on.
Model 201.128
Front bumper . . . I . .................... remove, attach (88-200).
Evaporator ............................ unbolt from radiator, screw on.
Flat spring (2) .......................... withdraw, insert.
Radiator (9) ........................... lift out, insert.
Installation dimensions for radiator, fan and fan cowl
l) Two-section fan cowl
20.10 - 420:2
EXIT
PO3- 0138 -15
Radlator’fan Fan/fan cowl
Special tool
Commercial tool
e. g. liazet,
7 mm wrench socket on flexible shaft
D-5630 Remscheid
for hose clips with worm drive Order No. 426-7
20.10 - 4200
EXIT
Removal

1 Clamp orl lines at automatic transmission
with special tool 000 589 40 37 00, moving the
spiral spring slightly to the side and unscrewing
at the radiator.
1 \ POl-2373-13
2 Seal off coolant hoses at the radiator.
3 Withdraw hose holder (15).
4 Pull out flat springs (1) for fan cowl, raise

cowl slightly and place over the fan.
5 Remove the expanding rivet (5) on the right

and left side for the side radiator covering.
6 Remove radiator coverings.

\
7 Remove the retaining clip (4) at the bottom

right and left.
P20-2166-13
20.10 - 42014
EXIT
Model 201.128
8 Unbolt radiator bridge (arrows).
Note
The front bumper must be removed on vehicles
with air conditioning in order to be able to unbolt
the evaporator from the radiator
(88-200).
Pm2112.13
9 Withdraw flat springs (2) for radiator and lift

out radiator.
Installation
Installation is performed in the reverse order.
Note
Ensure that the fixing mounts of the radiator are
correctly positioned into the rubber grommets of
the bottom holders and that the holders of the
fan cowl are correctly inserted into the retaining
clips on the radiator (arrows).
2 0 . 1 0 - 420/5
EXIT
epairing radiator
Preceding work:
Radiator removed (20-420)
P20 -0071-35
Radiator honeycomb (1) . . . . . . . . . . . . . . . . . . check for signs of damage.

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clean and seal hose connections and oil cooler
line (steps 1 - 4).
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pressure test with tester 124 589 15 21 00 and
605 589 00 25 00 in water bath, mark leak
point, reduce pressure and blow-dry radiator
with compressed air (steps 5 - 10).
Top and bottom water tanks (3, 4) . . . . . , . . . , . check for leaks.
Gasket (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for leaks.
Radiator , . . . , . , . . , . . . . . . . . . . . . . . . . . . . . seal leak point with repair kit radiator sealant
123 989 00 20 (steps 11 - 15).
A Warning
Note safety instructions!
20.10 - 425/l
EXIT
Radiator .............................. pressure-test at 1.4 bar gauge pressure in water

bath, check for leaks (steps 16 - 17).
Radiator .............................. install (20-420).
Sealant
Repair kit radiator sealing 123 989 00 20
Special tools
Commercial tool
7 mm wrench insert with flexible shaft e. g. Hazet,

for hose clips with worm drive D-5630 Remscherd
Order No. 426-7
Shop-made tool
Cap for top hose connection:
15 2 clips L 3646, Part No. 916026 036000

16 Piece of hose, Part No. 201 501 38 82
17 Reducer made from two tubes
A 35 mm dia.
B 39 mm dla
C 12mmdla
PZO-0082- 13
20.10 - 42512
................................................... ................................... EXIT
Shop-made tool
18 19 18 20
Cap for bottom hose connection:
18 2 clips L 3646, Par-t No. 916026 036000

19 Piece of hose, Part No. 201 501 38 82
20 Cap from a tube
A 35 mm dta.
B 39 mm dia.
P20-0072-13
Designation Use
Priming Preparation of
liquid base
Undiluted For properly sealing

sealant accessible points
Diluted For sealing difficult-to-reach

sealant points (e. g. sides of cooling
tubes)
Sealant and priming liquid have a storage life of

approx. 1 year provided they are always sealed
airtight after use.
Priming liquid which has become cloudy should

no longer be used.
The following parts or points in the coolant

circuit can be sealed with the sealant:
a) Plastic water tanks (3 and 4).

b) Heavy metal water tanks (holes up to
1.5 mm diameter).
c) Light and heavy metal cooling tubes (6).
d) Tube plate (2).
e) Beaded collar (connecting point between
radiator honeycomb and water tank).
f) Heat exchanger of heating system.
20 10 - 42513
EXIT
Fractured or cracked fastening straps or cracks

at the connection fittings cannot be repaired.
Brazing or soldering on heavy metal radiators

with plastic water tanks may only be performed
on the honeycomb (1) at a distance of at least
20 mm from the water tank otherwise the high
brazingsoldering temperature wtll damage the
gasket (5) and the water tank (3 and 4). Leaks
which are located closer to the water tank should
be repaired only with sealant.
The radiator does not have to be removed from

the vehicle for sealing. In this case, it is
sufficient to drain the coolant and to pressure-
test the cooling system with the tester (approx.
1.4 bar gauge pressure) after sealing.
Caution!
Light alloy radiators with plastic water tanks
cannot be repaired by brazingsoldering.
Sealant is available in diluted and undiluted form

in order to seal leaks of different accessibility at
the radiator (e. g. more difficult In the
honeycomb than at the water tank).
The various sealant versions and the priming

liquid are combined in a repair kit Part No.
123 989 00 20.
20.10 - 425,4
...................................................... .............. .....
EXIT
AWarning
The priming liquid is easily combustible (note
safety instructions, Hazard Class
A 1).
Acetic acid is released until the sealant has

completely cured. For this reason, avoid contact
with skin. Clean affected areas immediately with
water and soap. Rinse out eyes with water.
Consult a doctor if necessary.
Sealing
1 If the leakage point cannot be properly

located with the radiator installed, remove
radiator (20-420).
2 Clean radiator.
3 Seal hose connections with the shop-made

caps.
4 Seal connections of the transmission oil

cooler with plastic caps or plugs from old oil
cooler lines. Cut off the oil cooler lines just
behind the nipple and solder on.
5 Connect testers 124 589 15 21 00,

605 589 00 25 00 to the radiator.
6 Place radiator in a water bath.
7 Pressurize radiator with the tester and check

location of rising air bubbles.
8 Mark leakage points.
9 Remove radiator and reduce pressure.

P20-2153-13 I
20.10 - 425/5
EXIT
10 Blow-dry radiator with compressed air.
11 Clean leakage point and area around it with

a commercial cleaning agent (e. g. tri or white
spirit).
It is not necessary to remove any paint. The

radiator should then be blown-dry at the affected
point with compressed air.
There must not be any dust or grease residues

present on the surface.
12 Apply a very thin and even coat of priming

liquid with a brush.
Apply the priming liquid at and around the point

to be sealed. Pour the quantity of priming liquid
required for the repair in a separate vessel to
avoid polluting the entire can of priming liquid.
A Warning
Note safety instructions!
13 Allow priming liquid to dry for approximately

10 minutes at room temperature.
14 Apply diluted or undiluted sealant according

to accessibility. Use brush, spatula or the like for
spreading the sealant.
2 0 . 1 0 - 425/6
EXIT
Caution!
During application and spreading sealant, ensure
that no air is trapped.
Using the same method as for cleaning and

priming, apply the sealant not only at the point to
be sealed but also around it. If there are several
leak points at the beaded collar (arrows) it is
recommended to seal the beaded collar
completely around its circumference.
Seal leaks in the honeycomb from both sides.
After completing the sealing procedure, close

tube immediately. Acetic acid is released until
the sealant has completely cured. Avoid contact
with skin. Clean affected areas immediately with
water and soap. Rinse out eyes with water.
Contact a doctor if necessary.
15 Leave radiator upright or face-down for at

least 3 hours for the sealant to dry. Depending
on the quantity of sealant applied and the size of
the point treated, it may take up to 24 hours for
the sealant to cure to form a permanent elastic
joint at room temperature.
16 Pressure-test radiator for approx. 5 minutes

in a water bath at 1.4 bar gauge pressure.
If any leaks remain, repeat sealing operation

starting at step 8.
17 Remove testers and plugs.
18 Install radiator (20-420).
20.10 - 42W
...................................................................................................... ..................................... EXIT
20430 Testing radiator or expansion tank cap
P20-01~35
Double connection 000 589 77 63 00 ......... connect to leak tester 124 589 15 21 00.
Cooling system pressure cap ............... screw onto double connection 000 589 73 63
00.
Opening pressure ....................... test.
Pressure cap
Pressure cap code number I 120 140
Pressure relief valve new
opens
at bar gauge pressure used
Vacuum valve opens

0.1
at bar vacuum
20.10 - 43011
EXIT
Note
If corrosion is present on the expansion tank
cap, it must be replaced.
Engines 602.961, 603.960, 603.961

The opening pressure of the cap has been
increased from the previous 1.2 bar to 1.4 bar;
with standard antifreeze protection down to
-30 OC, the permissible coolant temperature is
increased as a result from 125 to 129 “C.
Production breakpoint: 02 - 09/86

Model Engine Engine End No. Vehicle End No.
manual automatic
124.133 603.960 * * * *
124.193 603.960 * * * 017987
126.125 603.961 * * * *
201.128 602.961 * * * 271512
f not registered
This cap is provided with a rubber seal (A) to

prevent any outside air from being drawn in
(when vacuum exists in cooling system).
P20-0107-13
20.10 - 430/2
EXIT
Effective 1 O/87 and 12/87, respectively, pressure

caps with and without guide ring (B) have been
fitted to engines 602, 603. Only the pressure cap
with guide ring is supplied as a replacement part,
however.
The modified pressure cap can also be fitted to

vehicles manufactured previous to production
dates with coolant expansion tank.
A Seal
8 Guide rr-tg P20-0074-13
Special tools
Testing pressure relieve valve
1 Attach double connection 000 589 73 63 00

to the leak tester 124 589 15 21 00.
2 Fit cooling system pressure cap onto the

double connection 000 589 73 63 00.
3 Test the opening pressure by pumping.
P50-2010-13
Testing vacuum valve
The vacuum valve (arrow) must be contacting

the rubber seal. It must be easily raised and
must spring back when released.
Note
Always replace expansion tank caps which are
corroded (surface rust).
P20-2171.13
20.10 - 430/3
EXIT
20440 n?sting CQQlant level indicator
Model 124
el e3pl p2e4 p3 e5 e 6 e7 812 ell 813 82 h2 e8 hl p6 Al
f a C b d s43 B5 s41 S42

P16-0136-57
Wiring diagram of engine oil level indicator, coolant level indicator, windshield washer level indicator
Al Instrument cluster B5 Oil pressure sensor

el Left turn signal rndrcator s41 Coolant level Indicator lamp switch
62 Right turn srgnal Indicator S42 Windshield washer level indicator lamp switch
e3 High beam rndrcator s43 Oil level Indicator lamp switch
e4 Fuel reserve warnrng lamp w2 Ground, front right next to lamp unrt
e5 Battery charge rndrcator X27 Plug connector, starter harness
e6 Brake pad wear lndrcator lamp a Main ground behlnd Instrument cluster Wl
87 Brake fluid and parkrng brake indicator lamp b Fuse 7 terminal 15
e6 Instrument lighting C Fuse 5 terminal 15
el 1 Coolant level lndrcator lamp d Lamp monitor unit
812 011 level lndrcator lamp Preglow time relay terminal La
e13 Wtndshleld washer level lndrcator lamp
814 Bulb failure Indicator lamp
e16 Preglow Indicator lamp
hl Wamrng buzzer
Pl Coolant temperature indicator
P2 Fuel gauge
~6 Electronic clock
20.10 - 440/l
EXIT
Model 126 1986
Al Instrument cluster B5 011 pressure sensor

el Left turn signal tndrcator s41 Coolant level rndrcator lamp switch
e2 Right turn srgnal rndrcator S42 Windshield washer level Indicator lamp switch
e3 High beam rndrcator s43 011 level lndrcator lamp swatch
e4 Fuel reserve warning lamp Wl Main ground behind Instrument cluster
e5 Battery charge lndrcator w2 Ground, front right next to lamp unit
e6 Brake pad wear rndtcator lamp X27 Plug connector, starter harness
e7 Brake fluid and parking brake tndrcator lamp f Preglow time relay terminal La
e8 Instrument lighting
el 1 Coolant level Indicator lamp
e12 011 level lndrcator lamp
e13 WIndshield washer level rndtcator lamp
e14 Bulb failure rndlcator lamp
e15 Alrbag indicator lamp (RSISRS)
e16 Preglow lndrcator lamp
hl Warning buzzer
h2 Audible turn signal rndlcator
Pl Coolant temperature Indicator
P2 Fuel gauge
P7 Electronic clocktachometer
20.10 - 44012
EXIT
Model 126 1990
813 elle6 07 e5 p2e4 p3 812 ~163 rl ~8 e8 h2 el e2 p7 e16 614 e15

_--
-1
-T-
I Al
ir
S42 s41 B5
P18-0137.57
Al Instrument cluster I35 011 pressure sensor

el Left turn signal lndrcator S10/2xl Connector, front right brake pad contact sensor
e2 Rrght turn slgnal rndrcator s41 Coolant level rndrcator lamp switch
e3 High beam Indicator S42 WIndshIeld washer level rndrcator lamp switch
e4 Fuel reserve warning lamp s43 011 level lndlcator lamp switch
e5 Battery charge Indicator WI Main ground behind Instrument cluster
e6 Brake pad wear lndlcator lamp X27 Plug connector, starter harness
e7 Brake flu/d and parkrng brake rndtcator lamp
e8 Instrument lighting
ell Coolant level tndrcator lamp
e12 011 level indicator lamp
e13 WindshIeld washer level lndlcator lamp
e14 Bulb failure Indicator lamp
e15 Arrbag indicator lamp (RSISRS)
e16 Preglow indicator lamp
h2 Audrble turn signal lndtcator
Pl Coolant temperature indicator
P2 Fuel gauge
P7 Electronic clock/tachometer
~6 Electronic speedometer
Vl Instrument lrghtlng rheostat
2010 - 44013
EXIT
Model 201
e16 p7
---tT-r-
If )b )a !c td s41 S42
Pl8-0138-57
(see Wiring Diagrams Volume 5 for further information)
Al Instrument cluster BS 011 pressure sensor
el Left turn srgnal indtcator s41 Coolant level lndtcator lamp switch
e2 Right turn slgnal Indicator S42 Windshield washer level lndrcator lamp switch
e3 High beam Indicator s43 011 level lndrcator lamp switch
e4 Fuel reserve warning lamp Wl Main ground (behind Instrument cluster)
e5 Battery charge indicator x5/2 Connector, interior/starter 4-pm
e6 Brake pad wear lndlcator lamp a Main ground behind Instrument cluster Wl
e7 Brake fluid and parking brake tndrcator lamp b Electrical centre, connector contact 15
e8 Instrument lighting termrnal 15 unprotected
ell Coolant level Indicator lamp C Electrical centre, connector D contact 2
e12 011 level Indicator lamp terminal 15 fuse 8
e13 WIndshield washer level Indicator lamp d Electncal center, connector D contact 8 alternator
e16 Preglow Indicator lamp terminal 61
hl Warning buzzer f Preglow time relay
h2 Audible turn signal Indicator
Pl Coolant temperature lndlcator
P2 Fuel gauge
~6 Electronic clock
20.10 - 44014
EXIT
Test data
Resistance at coolant level sensor with “max” coolant level @JQ
Resistance at coolant level sensor with “min” coolant level approx. 15 R
Battery voltage approx. 12 V
Commercial tool
Multimeter e. g. SUN,
DMM-5
Complaints
A. Indicator lamp remains on when engine

running and coolant level correct.
I%. Indicator lamp does not light up when

key in position “2”.

engine running and coolant level below
“min”.
Testing
A. Indicator lamp remains on when engine

running and coolant level correct.
Test coolant level sensor. Detach connector.

Connect both pins to multimeter and test
resistance.
Readout: 00 Q
20.10 - 440/s
EXIT
Check cable. Remove instrument cluster. Test

contact 12 of 15pin connector to ground with
multimeter.
Readout: 00 !A
P2Q-0066-13
I Replace gauge. I
I End of test _I
B. Indicator lamp does not light up when

key in position “2”.
Check operation of bulb.
Remove instrument cluster. Measure voltage

at contacts 6 and 9 of Spin connector with
multimeter.
Yes I No I
P20-0076-13
I Replace gauge. I
1
I End of test I
2 0 . 1 0 - 440/6
EXIT

engine running and coolant level below
“min”. Control function section ‘W in
order.
Check coolant level sensor. Detach connector.

Connect both pins to multimeter and test
resistance.
Readout: approx. 5 Q
Yes
Check cable. Connect multimeter to 2-pin

coolant level sensor connector (brown cable)
and battery positive.
Yes I No
P20-0077-13
Jumper coolant level sensor connector. With

key in position “2”, indicator lamp should light
UP.
Yes I No -.
====I
-.
Rectify open circuit according to
P 20-0078-13
20.10 - 440/7
EXIT
20-445 Function of coolant level indicator
550 Coolant level sensor

551 Float
552 0-rmg P20-0062-35
General
The coolant level indicator monitors the coolant

level in the expansion tank when the engine is
running.
The coolant level indicator lights up when the

ignition is switched on (control function) and
goes out as soon as the engine is running.
For the control function, the coolant level

indicator shows a weak light and a bright light if
there is a fault during engine operation.
Components
l Coolant level sensor (550) in expansion tank
l Indicator lamp in instrument cluster.
Symbol: radiator.
20.10 - 445/l
EXIT
To ensure that the coolant level sensor is

correctly installed, it has two lugs of different
width which fit into matching slots on the
expansion tank (arrows).
The sensor is press-fitted in the expansion tank

and sealed with an O-ring. Remove locking ring
in order to withdraw the coolant level sensor.
P20- 2128-13
Function
The coolant level in the expansion tank is

sensed by a float (551) with permanent magnet
attached to the coolant level sensor.
Below a certain coolant level the contact is

closed and the indicator lamp lights up.
Depending on driving style the indicator lamp

lights up briefly and later shows a steady light. If
the indicator lamp lights up, top off coolant.
2 0 . 1 0 - 44512
EXIT
emoval and installation of overflow tank
614
Front right wheel . . . . . . . . . . . . . . . . . . . . . . . remove, refit.

Partition panel (613) under front fender . . . . . . . . remove, install (step 2).
Vacuum reservoir (625) ................... remove, install (step 3).
Overflow tank (614) ..................... remove, install (step 4).
Special tool
001 589 66 21 00
00
20.10 - 4501'1
EXIT
1 Remove right front wheel.
2 Unscrew bolts (623) and nuts (622), remove

partition panel (6 13).
3 Detach vacuum hose (618). Remove bolts

(629) and remove vacuum tank (625).
4 Remove bolts (619) and nut (621). Detach

hose (615) and remove overflow tank (614).
5 Install in the reverse order.
20.10 - 450/2
EXIT
Suspension - 22
EXIT
Job No.
Function of hydraulic engine mounts ........................................ 22 - 210

Removal and installation of rear engine mount ................................. 22 - 212
Removal and installation of front engine stop ................................. 22 - 215
Adjusting engine stop .................................................. 22 - 220
Removal and installation of engine shock absorber .............................. 22 - 240
22/l
EXIT
22-210 Function of hydraulic engine mounts
7
4 Engine mount
5 Diaphragm
6 Plastic disc with
annular passage
7 Rubber stop plate 10
10 Rubber mount
a Diaphragm space
b Upper chamber
I
C Lower chamber I P22-0018-35
The hydraulic engine mounts are filled with a All parts of the engine mounting are
glycol mixture. The glycol mixture is located in maintenance-free.
two chambers (b and c). The two chambers are
connected to each other by an annular passage The hydraulic engine mounts have identical load
in the plastic disc (6). The glycol mixture flows bearing capacity on the left and right but differ
along the annular passage into the respective depending on the various engine and
chamber as the springs compress or rebound. transmission versions.
A diaphragm (5) limits the upper chamber (b).
Air is admitted to or released from the They are identified by a colored dot on the
diaphragm space (a) through two passages. housing in order to avoid interchanging them
The rubber stop plate (7) in the lower chamber accidentally.
(c) is firmly connected to the bearing foot and
limits the spring travel during compression. The
engine mount (4) is attached by a hexagon bolt
to the engine supporting bracket and by a
hexagon socket bolt to the frame cross
member.
22.10 - 210/l
...... ....................................................................... ........ ... ... EXIT
emoval and installation of rear engine mount

Preceding work:
Bottom engine compartment hng removed (01-006).
A. Vehicles with hydraulic engine mount
P22-004C57
Hexagon nut (1) . . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, 70 Nm.

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . remove support from below.
Hexagon bolts (17) . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt in, 35 Nm.
Engine supporting bracket (12) . . . . . . . . . . . . . remove together with engine mount (4), attach.
Hexagon bolts (14), 25 Nm.
22.10 - 212/l
EXIT
Note
Effective from the introduction of the hydraulic
engine mounts, the rear engine mount has been
provided with a catch bar (A). In addition, the
height (H) of the engine mounts has been
altered.
P224W25- 13
Dimensions
Model I Version I Height (H)
201
124 I all I 64 mm
Engine mount spring travel to the front

limited
As a result of a production modification the
spring travel of the engine mount to the front has
been restricted.
P22-0038-13
A Previous version
B Modlfled version
Hexagon nut engine mount - transmission 70
Hexagon bolt engine mount - engine supporting bracket 25
Hexagon bolts of engine supporting bracket 45

l) 603.913 and 603.963 effective 04188
22.10 - 21212
EXIT
Special tools
t
001 589 66 21 00 1 001 589 72 21 00
00 00 /
22.10 - 212/3
. .
EXIT
emoval and installation of front engine stop

Preceding work:
Adjusting bolt (1) . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt in, 130 Nm.

Note
Adjust engine stop (22-220).
Hexagon socket bolts (7) .................. unbolt, bolt in, 25 Nm.
Bracket (6) and engine stop (2) . . . . . . . . . . . . . remove, attach.
Hexagon socket bolts, engine stop bracket 25
Adjusting bolt 130
Special tools
001 589 67 21 00
22.10 - 2131
EXIT
22-220 Adjusting engine stop

Preceding work:
Bottom engtne compartment hxng removed (01-006).
P224042-53
Note
For this adjustment, the vehicle must be on its
wheels and ready to be driven.
The engine stop must not be treated with oil or
grease.
Adjusting bolt (1) . . . . . . . . . . . . . . . . . . . . . . . loosen at front engine stop, tighten,
130 Nm insert gauge 201 589 04 23 00 remove
(steps 1, 3 - 7).
Note
Loosen prepared engine stop from frame cross
member.
Adjusting bolt (11) ...................... loosen at rear engine mount, tighten,
30 Nm (steps 2, 5).
Adjusting bolt, front engine stop 130
Adjusting bolt, rear engine mount 30
Special tools
001 589 66 21 00 201 589 04 23 00 001 589 72 21 00

00 22 00
22.10 - 22011
EXIT
Loosening
Note
To adjust the engine stop, the vehicle must be
ready to be driven and on the ground. The
engine stop must not be treated with oil or
grease.
1 Loosen adjusting bolt (1) at engine stop (2)

fully.
Note
Loosen the engine stop which may be sticking to
the frame cross member due to wax or paint.
P22-0016-15
04 Gauge 201 589 04 23 00
2 Loosen adjusting bolt (11) at rear engine

supporting bracket fully.
12 Engme supportmg bracket

14 Engme mount hexagon bolts
Adjusting
3 Insert gauge 201 589 04 23 00 (02) at

engine stop.
4 Move engine by shaking slightly from left to

right by hand.
5 Tighten adjusting bolt at rear engine mount,

30 Nm.
6 Tighten adjusting bolt (1) at engine stop (2)

130 Nm.
7 Remove gauge (02).
22 10 . 22012
._ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I_
EXIT
22-240 Removal and installation of engine shock absorber

Preceding work:
Engine 603.96/97 in Model 126
32
33
P22-003?-17
Model 126
Model 126
Hexagon nut (31) . . . . . . . . . . . . . . . . . . . . . . . of left and right shock absorber (34), unscrew at
frame cross member and at engine supporting
bracket, screw on, 10 Nm.
Shock absorber (34) ..................... take off, install.
Note
Check condition of shock absorbers and all
attached parts; renew, if necessary.
22.10 - 240/l
EXIT
Hexagon nuts, shock absorber mounting 10
Hexagon bolts, shock absorber mount Model 201.128 10
Special tool
001 589 72 21 00
\ 00
22.10 - 24012
EXIT
EXIT
Fuel System 47
Job No.
Function of fuel tank with splash pot ........................................ 47 - 010

Function of fuel gauge sending unit ......................................... 47 - 020
Function of fuel gauge sending unit - Turbodiesel .............................. 47 - 020
Function of fuel tank breather and vent ...................................... 47 - 030
Function of fuel tank ventilation - Turbodiesel .................................. 47 - 030
Removal and installation of fuel tank ........................................ 47 - 100
Removal and installation of fuel gauge sending unit ............................. 47 - 120
4711
EXIT
47-010 Function of fuel tank with splash pot
P47-0071-55
Model 201 with naturally-asprrated engmes
67 Splash pot
68 Fuel falter
70 Return line
7011 Return nozzle
The sheet steel fuel tank is fitted with a splash

pot (67). The purpose of this is to ensure that
the engine is reliably supplied with fuel when the
fuel level in the tank is low and when negotiating
a lengthy series of curves.
When the fuel pump is running, the return fuel

jet flows at a high speed out of the return nozzle
(7011) into the splash pot. In this way it draws
fuel around the return nozzle into the splash pot
as well.
The level of fuel (h) in the splash pot is main-

tained even if the fuel level in the tank drops
below the height (h).
47 10 III- 010 1
EXIT
Model 201, 124, 126 with Turbocharged engines
67 Splash pot 70 Return line

68 Fuel filter 7011 Return nozzle
47 10 III - 010/'2
EXIT
47-020 Function of fuel gauge sending unit
1 Wiper contact
2 Float
3 Contact plate
4 Guide and contact rod
5 Reserve warnmg contact
As the fuel level drops, the resistance is

increased by the wiper contact (1). At the float
(2) the voltage drops and the gauge needle in
the instrument cluster moves back.
If the fuel level drops to the reserve quantity, the
reserve warning contact (5) closes and switches
ground to the reserve warning lamp. The reserve
warning lamp lights up when the ignition
is switched on (check function).
As soon as the engine starts, the lamp goes out
provided there is more fuel in the tank than the
reserve quantity.
47 10 III - 020/l
EXIT
Note
The reserve warning lamp shows a weaker light
for the check function, and a stronger light to
indicate reserve quantity.
Check fuel gauge (54-269).
Fuel gauge sending unit, Model 201

The installation angle has been modified from
approx. 15" (off perpendicular) to approx. 5”.
The instrument gauge has been adapted to the
new sending unit position (refer to Group 54).
Repair instructions
The modified sending unit (5”) may also be fitted
in place of the existing sending unit (15"), but
not vice versa.
Standard implementation: July 1987
Vehicle ident No.

A 394 178
F 390 243
Modifications effective 09188 (Model Care)

The fuel gauge sending unit has been modified
at the flange and in its length such that it is valid
for all fuel tanks of Model 201 effective 09188.
47.10 III - 02012

.................. ................................... ............................................. ... ..........................................
EXIT
47-020 Function of fuel gauge Sending unit - Turbodiesel
l---
*z
3-
4-
5 - - -
P47-0061-57
1 Wiper contact 4 Guide and contact rod

2 Float 5 Reserve fuel warnmg cmmt
3 Contact plate
If the fuel level drops, the resistance is increased

by the wiper contact (1) on the float (2), the
voltage drops and the needle on the gauge in
the instrument cluster moves back.
47.10 III -020/l

EXIT
If the fuel level drops to reserve quantity, the

reserve warning contact (5) closes and switches
ground to the reserve warning lamp. The reserve
warning lamp lights up if the ignition is switched
on (indicating function). As soon as the engine is
running, it goes out provided there is more fuel
in the tank than the reserve quantity.
Note
The reserve fuel warning lamp shows a weaker
light for the indicating function and a stronger
light for the reserve quantity.
Check fuel gauge (54-257).
47.10 III - 020/2

EXIT
47-030 Function of fuel tank breather and vent
Filler cap
P47- 0041-53
All models
1 Filer cap
2 Seahng ring
3 Locking bar
4 CompressIon spring
5 Filer neck
The fuel evaporation gases escape through the

filler cap at a pressure of 100-300 mbar gauge.
This only occurs, if, for example, the passage
in the vent line from the fuel tank is not clear. If
the system is operating properly, an
overpressure of up to 50 mbar may be present
in the fuel tank.
47 10 III - 030/l
EXIT
51
50 Fuel tank
51 Vent valve
51/l Protecttve rubber boot
54 Central pope
54/l Siphon breaker
64 Vent line
The vent system consists of a central pipe (54)

with an siphon breaker (5411) at each end.
The siphon breakers prevent fuel escaping
along the vent line. The vent line (64) runs from
the central pipe to the vent valve (51).
If an overpressure of 30-50 mbar is reached in

the fuel tank, the vent valve (4) opens and the
fuel vapors flow to the charcoal canister.
1 Compression sprtng
2 Valve housing
3 Spnng plate
4 Vent valve
5 Valve plate
6 Aw admIssion valve P47-0065-15
7 Connection fitting
47.10 III - 030/2

EXIT
If a vacuum of l-l 6 mbar is produced in the fuel

tank, the air admission valve (6) opens.
The protective rubber boot at the end of the vent

valve prevents dirt and splash water entering the
vent valve.
Standard implementation: -0066-15
Model Vehicle ident No.
April 1986 May 1986
201 A 296211 F 227064

P47-0067-11
Vent system modified

The vent system has been modified by the
addition of lines and siphon breakers (arrows) so
that no fuel can escape through the vent system
even under extreme conditions (rollover).
Standard implementation: phased-in (approx.

1 O/88)
PO7 -
47.10 III - 030/3

EXIT
47-030 Function of fuel tank ventilation - Turbodiesel
P47-0041-53
All Turbodiesel models

1 Cap Compression spring
2 Seahng ring Fdler neck
3 Closing bar
At a gauge pressure of 100-300 mbar, vaporized

fuel can escape through the fuel cap. This is
only the case if the vent line from the fuel tank is
not clear. If the system is operating properly, a
gauge pressure of up to 50 mbar may be
present in the fuel tank.
47 10 III -030/l
EXIT
54/l 54 64 54/l
P47-0064-55
The vent system KI the fuel tank (50) consists of

a central pipe (54) each with a siphon breaker
(54 1) at the ends. The siphon breakers prevent
fuel escaping through the vent line.
The vent line (64) runs from the central pipe to
the vent valve (51). The protective seal (5M) at
the end of the vent valve prevents dirt and
splash water from getting into the vent valve.
47.10 III - 03012

EXIT
If a gauge pressure of 30-50 mbar is present in

the fuel tank, the vent valve (4) opens and
allows the fuel vapors to escape.
1 Compression nng
2 Valve houslng
3 Spnng plate
4 Vent valve
5 Valve plate
6 AIM admlsslon valve
7 ConnectIon fGting P47-0065-15
If a vacuum of 1-16 mbar is produced in the fuel

tank, the air admission valve (6) opens.
Station wagons
These models are fitted with a modified vent
valve with a bright base section. The
performance is the same as for other vent
valves.
2 Valve housing
3 Spring plate
4 Vent valve
5 Valve plate
6 Air admIssIon valve
7 Connection fitttng
The dirt seal at the end of the vent valve

prevents dirt and splash water from getting into
the vent valve.
P47-0067-11
47.10 III - 03013

EXIT
Modified vent system

The vent system has been modified by additional
lines and siphon breakers (arrows) with the
result that no fuel can escape through the vent
system, even under extreme conditions
(rollover).
Production breakpoint: phased in (approx.

101’88).
6'47-2003-13
47.10 III - 030/4

EXIT
D. Model 201 naturally-aspirated versions
62
P47-0070-59
Safety regulations ....................... Observe, risk of accident!

Battery ground cable ..................... Disconnect, connect.
Filler cap (62) .......................... Remove, fit. Check seal (62/l), replace if
necessary.
Fuel tank (50) . . . . . . .................. Drain. Carefully pump out fuel to ensure no
fuel remains in the tank. Capacity approx.
55 liters (14.5 US gal.) .
Stick on 4 sound-absorbing strips (74), if
necessary, with MB Universal Adhesive
000 989 92 71 (steel fuel tank only).
Cup seal (60/l) . . . . .................. Remove, Install.
Lining of fuel tank . . . . . . . . . , * . . . . . . . . . . Detach, attach.
47.10 III - loon

EXIT
Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . * Detach, fit on connector at sending unit (64).

Check operation. Remove, install sending unit
(B4), if necessary, 39 Nm (47-120). Replace
seals.
Supply line (69) return line (70),
vent valve (51) . . . . . . . . . . . . . . . . . . . . . . . . . Disconnect, connect, 28 Nm. Check for re-use.
Collect remaining fuel. Seal connections. Ensure
cup seal (71) is correctly seated.
Nut (5012, 4 off) .................. . 21 Nm, use 4 washers (50/l).
Drain hose of tank recess ........... . . Before taking out the fuel tank, pull drain hose
slightly up the way and lay to behind edge of
fuel tank. Refit correctly after installation.
Fuel filter (68) .................... . . . . Remove, install if necessary, 39 Nm, clean.
Check for reuse. Replace seal (6811).
Run engine briefly ................ . , Check connections and joints for leaks.
Repair instruction
Fuel tanks effective from 09188 cannot be
installed in cars manufactured prior to this date.
effective 09188 I P47-2080-13
4 7 10 III - 1 0 0 1 8
EXIT
. Model 201 Turbodiesel versions
62
62/l
60/l
65
P47-0070-59
Safety regulations ....................... observe, risk of accident!

Battery ground cable ..................... disconnect, connect.
Cap(62) ............................. remove, install. Check seal (62/I), renew if
necessary.
Fuel tank (50) .......................... drain. Carefully pump out fuel to ensure that
there is no fuel remaining in the tank. Capacity
approx. 55 litres. Stick 4 sound-deadening strips
(74) with MB unrversal adhesive 000 989 92 71,
if necessary.
47.10 III - 10019

EXIT
Cup seal (SO/l) ........................ remove, install.

Panelling of fuel tank ..................... detach, attach.
Fuel gauge ............................ detach connector on sending unit (B4), fit on,
check operation. Remove, install sending unit
(B4) 39 Nm, if necessary (47-120). Renew seal
rings.
Supply hose (69) return hose (70), vent valve
(51) . . . . . . . . . . ..*........*........... disconnect, connect, 28 Nm. Check for re-use.
Collect remaining fuel, seal connections. Ensure
cup seal (71) is correctly fitted.
Nut (5012, 4 off) . . . . . . . . . . . . . . . . . . . . . . . . 21 Nm. Use 4 shims (5011).
Drain hose from tank recess . . . . . . . . . . . . . . . before removing the fuel tank, pull drain hose
slightly upwards and lay over edge of fuel tank.
Position correctly following installation.
Fuel filter (68) .......................... if necessary, remove, install, clean, 39 Nm.
Check for reuse. Replace seal (6811).
Run engine briefly ...................... Check joints for leaks.
47.10 III - lOO/lO

EXIT
emoval and installation of fuel gauge sending unit
A. Model 201
P47-0063-53
Battery ground cable ..................... Disconnect, connect.

Fuel tank lining ......................... Remove, install, Model 201 only partially.
Connector at sending unit (B4) . . . . . . . . . . . . . Remove, fit.
Sealing flange (65) . . . . . . . . . . . . . . . . . . . . . . Unbolt, bolt on, 39 Nm. If fuel tank full, pump
out approx. 8 litres (2 U.S. gal.) beforehand.
Replace sealing rings.
Sending unit (84) . . . . . . . . . . . . . . . . . . . . . . , Remove, install, run to drain, if necessay.
Remove locking pin below adhesive strip
(new part only).
Note
Refer to “Function of fuel gauge sending unit”
(47-020) for fuel gauge sending unit Model 201.
47.10 III - 12011

EXIT
. Models 124, 201 furbodiesel
P47-0063-53
Battery ground cable ..................... disconnect, connect.

Panelling of fuel tank ..................... remove, install. Model 201 only partially.
Connector on sending unit (B4) . . . . . . . . . . . . . detach, fit on.
Sealing flange (65) , . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, 39 Nm. Initially pump out
approx. 8 litres (2 U.S. gal.) if fuel tank full.
Replace seals.
Sending unit (84) . . . . . . . . . . . . . . . . . . . . . . . remove, install. Empty by running if necessary.
Remove locking pin below adhesive strip (new
part only).
4710111 - 1202
EXIT
EXIT
xhaust System
Job No.
Removal and installation of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 100

Removal and installation of exhaust system - Turbodiesel . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 100
EXIT
49400 Removal and installation of exhaust system
A. Model 201 with
Hexagon bolt (1) ........................ Replace, 20 Nm.

Front exhaust pipe (2) or front exhaust pipe with
oxidation catalytic converter (2a) . . . . . . . . . . . . Check flanges for signs of damage, tighten
evenly.
Self-locking hexagon nut (3) ............... Replace.
Self-locking hexagon nut (4) ............... Replace, 20 Nm.
Sintered sealing ring (5) .................. Examine for signs of damage, ensure correctly
seated.
Retaining clamp (6) ...................... Examine for re-use.
Center muffler (7) ....................... Examine for signs of damage.
Hexagon bolt (8) ........................ Replace.
Rear muffler (9) ........................ Examine for signs of damage.
49.10 III - 100/l

EXIT
Side supporting bracket (10) Loosen, fix.

Hexagon bolt (11) ..... . ..... .. ........ . . 20 Nm.
Washer (12)
Rubber pad (13) ... ._ . . . .. . ... ... .. .. . . . Examine for signs of wear.
Large rubber disc (14) , . . . . . . . . . . . . . . . . . . . Examine for signs of damage.
Spacer sleeve or small rubber disc (15)
Self-locking hexagon nut (16) ............... Replace, 7 Nm.
Cup spring (17) ........................ Replace, ensure correctly installed.
Rubber ring (18) . .... .... ....... ... . .... Examine for signs of damage and wear.
Hexagon bolt (19)
Washer (20)
Pipe clip (21)
Spring lock washer (22) . . . . . . . . . . . . . . . . . . Replace.
Hexagon nut (23) . . . . . . . . . . . . . . . . . . . . . . . 20 Nm.
Hexagon bolt (24) .. .. ... .. .... ... ...... . 20 Nm.
Hanger plate (25) . . . . . . . . . . . . . . . . . . . . . . . Examine for signs of damage and wear.
Tensioning plate (26)
49.10 III - 10012

EXIT
The description which follows does not cover

removal and installation of the exhaust system to
the full extent, but deals only with particularly
important points which should be noted during
removal, installation or partial replacement of
the exhaust system, e.g. the rear muffler with
push-in joint.
Removal
1 Detach rear section of noise capsule when

working on the front exhaust system.
2 Examine hanger parts for possible re-use,

3 Before installing the exhaust system, ensure

that the flange to the exhaust manifold is not
twisted; align flange if necessary. Clean com-
bustion residues from tapered connector pieces
of pipes and centered sealing rings (2, 5 and
22) if necessary, with emery cloth.
49.10 III - 10013

EXIT
Installation
Replacement of rear muffler.
4 Position new rear muffler with plug-in joint

precisely over removed system and mark length
of pipe of new rear muffler on removed system.
Cut through the pipe 80 mm away from the mark

(tolerance minus 10 mm) in the direction of rear
muffler to obtain an insertion depth of 70-80
mm.
5 Always replace self-locking hexagon nut.
6 Tighten the flanged joint to the manifold

evenly. Tightening torque of self-locking hexagon
nuts 20 Nm.
Model 201.1
Caution!
When installing the front exhaust system to the
manifold, do not allow the spiral hoses to be
tensioned by the weight of the system. Use the
side mounting brackets on the transmission as a
support (arrow).
49 10 III - 100'4
EXIT
7 Install rear exhaust system with center and

final mufflers, at the same time attaching the
exhaust system to the rubber hanger at the rear
axle support.
8 Install sintered sealing ring (5) at the flanged

joint and ensure it is correctly seated. Tightening
torque of self-locking hexagon nuts 20 Nm.
._...
2 Front exhaust pipe
1
5 Smtered sealmg rmg
6 Self-locking hexagon nut
7 Hexagon bolt 5
18 Flange
22 Rear exhaust pipe
9 Use a suitable hook to attach rubber rings to

the rear muffler.
49.10 III - loo,5

EXIT
10 Install rear muffler in such a way that the

retaining clamps of the rear muffler are
positioned approx. 10 mm ahead of the brackets
on the frame floor to ensure that the system is
correctly installed when the exhaust expands
(arrows).
Note
This applies only to replacement mufflers with
plug joints between the center and rear mufflers.
11 Install side mounting bracket of exhaust free

of tension. Tightening torque of self-locking
hexagon nuts at tensioning clamp is 7 Nm, of
hexagon bolts of side mounting bracket on
transmission 20 Nm.
Note
Install 4 cup springs on each side of the
retaining clamp in such a way that the convex
ends are apart (as shown in illustration).
12 Run engine and examine exhaust system for

leaks.
13 Install noise capsule.
49.10 III - 10016

EXIT
49-l 00 Removal and installation of exhaust system - Turbodiesel
A. Model 201 with Engine 602.96
P49-0018-57
Rear muffler (9) . . . . . . . . . . . . . . . . . . . . . . . . remove, install, check for damage, replace if

necessary.
Rubber buffer (13) . . . . . . . . . . . . . . . . . . . . . . check for wear, replace if necessary.
Pipe clamp (21) . . . . . . . . . . . . . . . . . . . . . . . . replace.
Center muffler (7) . . , . . . , . . . . . . . . , , . . , . . . remove, install, examine for signs of damage,
Hexagon bolts (8) and self-locking nuts (4) ..... replace. Tightening torque 20 Nm.
49 10 III - 100/l
EXIT
Sintered seal (5) . . ..... ........ ......... examine for signs of damage, Ensure correct
seating.
Retaining bar (6) with Belleville spring washers (17)
and self-locking nuts (16) . . . . . . . . . . . . . . . . . remove, refit. Tightening torque 7 Nm.
Installation note
Check parts and replace if necessary.
Caution!
Note pictorial information for assembling
Belleville spring washers.
Front exhaust pipe with flexible hose (2) . . . . . . . remove, install, check flange for damage,
tighten evenly and assemble flexible hose free
of tension. Replace self-locking nuts (16),
49.10 III - 100:2

EXIT
. Model 124 with ngines 602.96, 603.96
17 -
16 0
P49-0019-57
Rear muffler (9) . . . . . . . . . . . . . . . . . . . . . . . . remove, install, check for damage, replace if

necessary.
Tightening torque of nut (27) 20 Nm.
Rubber buffer (13) ...................... check for wear, replace if necessary.
Pipe clamp (21) . . . . . . . . . . . . . . . . . . . . . . . . replace.
Center muffler (7) ....................... remove, install, check for signs of damage,
Bolts (8) and self-locking nuts (4) . . . . . . . . . . . replace. Tightening torque 20 Nm.
Sintered seal (5) ........................ check for damage, ensure correct position.
49 10 III - 100/3
EXIT
Retaining bar (6) with Belleville spring washers (17)

and self-locking nuts (16) . . . . . . . . . . . . . . . . . detach, mount, tightening torque 7 Nm.
Installation note
Test parts and replace if necessary.
Caution!
Note pictorial information on assembly of
Belleville spring washers.
Front exhaust pipe with flexible hose (2) . . . . . . . remove, install, check flanges for signs of
damage, tighten evenly and install flexible hose
free of tension. Replace self-locking nuts (16).
49 10 III - loo/4

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EXIT

Mercedes-Benz of North America, Inc. . Montvale, NJ 07645

Q Mercedes-Benz of North America, Inc., 1991

All rights reserved. Reproduction by any means, elec-

Published by Mercedes-Benz of North America, Inc.

Part number LZ S-2517-091

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

MERCEDES-BENZ OF NORTH AMERICA, INC.

General, Technical Data 00

Crankcase and Cylinder head 01

ngine Timing, Valvetrain 05

Diesel Injection System 07.1

Air Intake System - Air Filter, Turbocharger 09

Intake and Exhaust Manifolds, mission Control System 14

Electrical System, Preglow 15

ngine Lubrication System 18

ngine Cooling System 20

Fuel Tank and Lines 47

General, technical data 00

General, technical data 00

Instructions for use of service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 - 005

Instructions for use of servic 00-005

Throughout these manuals, the vehicles are 03-320 Installation of Crankshaft

For example, chassis 124 applies to all 124

Technical data, tightening torques and tools are

All dimensions are in metric units unless

Note Provides helpful information for the described procedure.

Installation note Provides detailed information during assembly.

00 ngine and vehicle identification

Model I Sales designation I Engine

hick identification number locations 00

When ordering spare parts, please

1 Certrfication Tag (left door pillar)

When ordering spare parts, please

1 Certification Tag (left door pillar)

Vehicle identification number locations

When ordering spare parts, please

1 Certrfication Tag (left door prllar)

When ordenng spare parts, please

Certification Tag (left door pillar)

axlmum spee 4600 t 50

pump, thermosta pump, thermosta pump, thermosta pump, thermosta

4-cycle diesel, MB 4-cycle diesel, MB 4-cycle diesel, MB

Engine output 11 O/4600 1071’4600

Cooling Coolant circulating Coolant circulating Coolant circulating

Engine oil initial filling 8.2 9.2 9.2

Filling capacities (continued)

~350 SDL Turbo

Crankcase and Cylinder Head 01

01 Crankcase and cylinder head

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

01-001 Engine and r?lodel suwey

output Torque (SAE)

190 D 2.5 84.0 187.0 6914600 165 12800

602.961 201.128 5 84.0 187.0 92 14600 22812400

602.962 124.128 5 84.0 187.0 90 14600 223 / 2400

603.960 124.133 6 2996 84.0 187.0 107/4600 265 12400

603.961 126.125 6 2996 87.0 / 84.0 110/4600 273 /2400

603.961 126.125 6 2996 87.0 184.0 107 /4600 265 12400