Inspecting component condition 0050 © Inspect all components - engine, transmission, shock absorbers, stesring, power steering pump, rear axle, checking condition and for leakage. Remove lower engine compartment cover (6190) or noise encapsulation panel (2490). Note: Install the lower engine compartment cover or noise encapsulation panel only after all the other ‘maintenance jobs have been completed. Mode! 107 up to 07.1985 123 126 up to 08.1985, 201 up to 12.1984 “> Maintenance Manual GD supplement 5: March 1999 o0s0/1Inspecting condition of lines and hoses 0051 Model 107 through 07.1985 123 126 through 08.1985 201 through 12.1984 ‘Inspect lines and hoses on engine, automatic transmission, and power steering pump checking condition and for leakage. => Matotonance Manusi GD supplement March 1983 0051/1Inspecting components, lines and hoses 0053 Model 107 starting 08.1985 124 126 starting 09.1985 129 201 starting 01.1985 140 Note: To perform this job number, the engine compartment lower panels or the lower noise encapsulation panels must be removed and then reinstalled after completion of all maintenance work (see jobs 6190 or 9490, respectively) «> Maintonance Manual GA) March 19: 0053/10053 Inspecting components, lines and hoses Inspect engine and fuel system, including lines and hoses, for leaks. Check for chafe marks and proper routing. Engine Crankcase Coolant pump and housing Oil pan Air-oil cooler with hoses Fuel system Fuel tank Injection pump Fuel pump Crankcase seal, front Timing housing cover Coolant and heating hoses Fuel filters Prefiter Fuel cooler starting 1986 Cylinder head cover Radiator il filter Fuel pump assembly Injection system Fuel preheatingInspecting components, lines and hoses 0053 Check condition of manual transmission. hydraulic clutch system, damper struts, shock absorbers, and rear axle. If traces of oil are found on lower engine compartment panels, determine source. Manual transmission, clutch hydraulic system, and rear axle Sealing rings Fill and drain plugs Housing cover Clutch line and hose Damper struts or shock absorbers Leaks Mounting > Maintenance Manusi GA) March 1993 0053/30053 Inspecting components, lines and hoses Check condition of automatic transmission, level control and power steering, including lines and hoses. Check for chafe marks and proper routing. ‘Automatic transmission, power steering Torque converter Sealing rings and gasket Housing plugs Line connections Hoses il pan Level controvADS Suspension struts, Line connections Hoses Leveling valves Hydraulic oil reservoir Hydraulic oil pump Suspension pressure reservoirs Distribution vaive Control valve Damping valve units 0053/4Inspecting components, lines and hoses 0053 Check condition of brake system including lines and hose . Check for chafe marks and proper routing, 42-5149-57 Brake system Lines Hoses Master cylinder Fluid reservoir Brake calipers ABS hydraulic unit => Matotenance Manual GD. March 1993, 0053/5Inspecting components, lines and hoses 0053 ‘Check condition of all ines and hoses. Check for chafe marks and proper routing. Vehicles with 4MATIC 0052/6Vehicles with ASD0053 Inspecting components, lines and hoses Check condition of all ines and hoses. Check for chafe marks and proper routing. Vehicles with ASRII Models 124, 201 Vehicles with ASRIII Models 124.034/036 '* Inspect lines and charging pump. Inspect pressure reservoir through opening in plastic cover under left front fender.Inspecting components, lines and hoses 0053 Check condition of all lines and hoses. Check for chafe marks and proper routing 42-5146-57 Vehicles with ASRIL Model 126 ‘© Inspect lines and charging pump. Inspect Pressure reservoir through opening in plastic cover under left front fender. A> Maintenance Manuel GD: march 1992 0059/90053 Inspecting components, lines and hoses Check condition of ail ines and hoses. Check for chafe marks and proper routing. Pa25t47-57 Vehicles with ASRIL Model 129 '® inspect the pressure reservoir connections from underneath the vehicle through opening in engine compartment left side wall. 0053/10Inspecting components, lines and hoses 0053 Check condition of all ines and hoses. Check for chafe marks and proper routing, 42-5148-57 Vehicles with ASRIIL Model 140 ‘© Inspect the pressure reservoir connections by removing left front fender lower side panel. 4m Mointonance Manuat GB). march 1983, 0053/11Suspension and body structure inspection 0090 Check the following for damage and corrosion: © Rear suspension control arms. (semi-trailing arm suspension). © Rear suspension links (multiclink suspension). © Aarms and bushings. {4Z> Maintenance Manust GA) supplement 5 March 19830090 Suspension and body structure inspection © Rocker panel. ‘© Bumper and mounting on body.Water leakage and corrosion inspection 0091 Model 107 through 07.1985 123 126 through 08.1985 201 through 12.1984 Check the following for water entry and corrosion: © Foot wells front and rear. © Lateral trunk recesses. > Maintenance Manust GD. supplements - March 1983 0091/1Engine oil and filter change 01 01 .05 Engine 102.961/983 Specified SAE F viscosity classes ow. during continuous ambient temperatures on Following the SAE grades exactly according tothe ambiont | +20 air temperatures would resuit in frequent engine oi changes. °. ‘The temperature ranges forthe SAE grades shouid thoreiore bo | 20 regarded as a guideline which may be exceeded for brief periods. pe erm ak Olt capacity In Iiters Engine 102.961 102.983 Total capacity during oil and fiter change 45 5.0 Oil pan 43 48 Oil dipstick color code light blue gray Torque specifications (Nm) Oil pan drain plug 30 25 Center bolt, oil fiter cover 25 25 Special tools 117 589020700} | 000 589 27 21 00 “=> Maistenance Manual GD + supplement 5 » March 1983, 0101.05/10101.05 Engine oil and filter change * © Before suctioning or draining engine oil, drain oil fiter, by unscrewing center bolt and removing together with cil fiter cover. © Suction engine oil via oil dipstick tube with ‘engine at operating temperature. tno suction unit is available: © Drain engine oil from oil pan (arrow). Replace fiter lement. 0101.05/2Engine oil and filter change 0101.05 © Replace rubber seal ring (1) on cover. ‘© Check seal ring (2) on center bolt and replace as appropriate. NOTE: Thero are two oil fter versions which differ in cover and rubber seal ring diameter and in thickness of rubber seal ring. Use care not to use the incorrect rubber seal ring (1). ‘© Torque center bolt to 25 Nm with torque wrench. © {foil has been drained from oil pan, replace seal ring on drain plug. © Tighten oil drain plug to 30 Nm, or for engine 102.983 to 25 Nm. © Add engine oil. © Run engine and chack for leaks. © Check oil level approx. 2 min. after stopping engine at operating temperature. ‘ee Maronance Maruat GD + supplements March 1603 0101.05/3Engine oil and filter change 0101.06 Specified SAE viscosity classes during continuous amblent temperatures Following the SAE grades exactly according tothe ambient | +20 air temperatures would resut in frequent engine ol changes. “The temperature ranges for the SAE grades should therefore be | 20 regarded as a guideline which may be exceeded for brief periods ll capacity In titers Engine 102.985 103 104 oF Engine [Model | Total capacity during oil and fiter | Oil dipstick identification [change il dipstick color [identification on code dipstick handle 102 [201 5.0 gray = 103 124, 126, [6.0 ted - 201 103/124 es ted - 4MATIC 104 [124,129 [75 - 10407 104 [140 75 = 60322 ‘Torque specifications (Nm) Engine Nm il pan drain plug all 25 Spin on oi fitter 402, 103 20 Threaded cover 104 20 <=> Maintenance Manust GD: supplement s - March 1963 0101.06/10101.06 Engine oil and filter change Special tools 117 589 02 07 09] 103 589 02 09 00 NOTE: Change engine oil only with engine at operating temperature. Removing old oll filter Engine 102 and 103 © Before suctioning or draining engine cil, unscrew spin-on filter with socket wrench insert 74 mm (arrow). Apply a light seating blow against socket wrench insert, so that itis tightly seated on filter. While unscrewing, some oil may run out until the check valves in oil filter cartridge close. For this reason, hold or place a suitable rag under mounting surface at bottom of cil fier. Note: If the spin on oil filter cannot be loosened with the socket wrench element, remove the air cleaner and drive in a screwdriver or other suitable tool to provide leverage to remove the oil filter. 001 589 72 21 09] Engine 103 101.062Engine oil and filter change 0101.06 Engine 104 ‘* Prior to suctioning or draining of engine oil, unscrew screw cover (2) with socket wrench element 74 mrn, ‘® Remove threaded cover (2) with oil fter element (4). On Model 140, remove air filter and replace after installing oil filter cartridge. Removing old olf Engine 102, 103, 104 © Suction engine oil via dipstick tube with engine at operating temperature. If no suction unit is available: © Drain engine oil from oil pan (arrow). First remove engine compartment lower panel and reinstall upon completion of maintenance jobs. Engine 102 => Maintenance Manus! GA. supplement - March 1992 0101.06/30101.06 Engine oil and filter change ¢ On 4MATIC vehicles open drain plug (5) on large oil pan (4) only. © If the oil has been drained out of oil pan, replace seal ring on oil drain plug. © Tighten oil drain plug to 25 Nm. Installing new oll filter Engine 102 and 103 © Clean mating surface (arrow) on oil fiter mounting flange. 0101.06/4Engine oil and filter change 0101.06 © Slightly lubricate gasket (arrows) on new spin-on filter. '* Screw on filter and tighten by hand. Then turn filter with 74 mm socket wrench ‘element (arrow) an additional 1/4 turn (90°) (20Nm). Engine 104 ‘* Replace seal ring (3). ‘© Insert oil filter element (4) into threaded cover (2). © Insort threaded cover with oil filter element and tighten to 20 Nm. => Mastenance Manual GA supplement 4» March 1992 0101.06/50101.06 Engine oil and filter change Filling engine oll © Add engine oil (arrow). ‘© Run engine and check for leaks. © Chock oil level (arrow) approx. 2 minutes after shutting off engine at operating temperature. Engine 103 and 104 0101.06/6Engine oil and filter change 0101.10 Engine 110 Specified SAE °F viscosity classes on. during continuous ambient temperatures ee Following the SAE grades ‘exactly according tothe ambiont | vao. a temperatures would rest in ‘requent engine oil changes. ° “The tomperature ranges forthe SAE grades shouid therofor be | -20. regarded as a guideine which may be exceeded for brit poriods. ll capacity in liters Oli dipstick color code pink yellow/green burgundy Total capacity during oil and filter change 65 6.0 Oil pan 6.0 55 ‘Torque specifications (Nm) il pan drain plug 0 Center bolt, oil fiter cover 35. Special tools A> maintenance manual G). supplement’s- March 1999 0101.10/10101.10 Engine oil and filter change © Suction engine oil via oil dipstick tube with engine at operating temperature. tno suction unit is available: © Drain engine oil from oil pan (arrow). © Unscrew and empty oil fiter lower half (3). © Wash and blow out oil filter lower half. ‘© Chock sealing ring (2) and replace as necessary. For this purpose, pull compression spring together with spring retainer (5) off fastening screw (1). Make sure that the compression spring and retainer is correctly installed during assembly. © Replace rubber sealing ring (4). © Install oil filter lower half with a new filter ‘element (6) and torque fastening screw (1) to. 35 Nm. pra-aoti“ —O aS NY = 0101.10Engine oil and filter change 01 01 1 0 © If oil has been drained from oil pan, replace sealing ring on drain plug, © Torque oil drain plug to 40 Nm. # Add engine oil. © Run engine and check for leaks. © Check oil level approx. 2 min. after stopping engine at operating temperature. Engine 110 => Maintenance Manust GD. supplement §- March 1983 0101.10/3Engine oil and filter change 01 01 .20 Engine 116 117 119 120 Specified SAE °F °c viscosity classes wo [E" during continuous 8 ambient temperatures “ Flowing the SAE grados r° ‘exacty according tothe ambiont | ae. a tomperatures would rsutin frequont engine of changes. ° “The temperature ranges for the SAE grades shouid teretorobo | -2o 4] regarded 3s a guideline which ‘may bo exceeded for bit ae eee Oll capacity In titers Engine | Model Total capacity | Dipstick identification during oil and fiter change [cotor code color code | identification number (red round handle | bottle opener | °°!0") shaped handle 116,117 _ [107 8 blue 7 = 116,117 _ [126 8 light blue gray | gray z 19 124, 129, 140 8 - gray - 120 140 10 . : 72010 Torque specifications (Nm) Model 107 126 124, 129, 140 Oil pan drain plug 50 40 40 Center bolt, ol fiter cover : 25 20 Center bolt, ol fiter lower housing 25 7 7 Threaded cover (Engine 120) 7 7 20 > Wanntenance Manuat GD supplements - March 1993 0101.20/10101.20 Engine oil and filter change Special tools Removing old oll filter Engine 116, 117 In model 126 Engine 119 In model 124, 129, 140 © Remove flexible air duct (arrow). 0101.20/2Engine oil and filter change Engine 120 © Remove left air filter housing and mass air flow sensor as an assembly (job no. 09-0015). Engine 120 Removing old oll NOTE: Change engine oi only with engine at operating temperature. Engine 116, 117 in model 126 Engine 119 In model 124, 128, 140 © Drain oit fiter prior to suctioning or draining engine oil. For this purpose, loosen center screw (1) and remove together with oil fiter cover. Engine 116, 117 in model 126 Engine 119 A> Hatrtenance Manus! @D- supplement 4 - March 1882 0101.20/30101.20 Engine oil and filter change Engine 120 in model 140 ‘© Before suctioning or draining engine oil, remove threaded cover (2) using 74 mm insert. ‘© Remove threaded cover (2) and oil filter cartridge (4). Engino 120 All Engines ‘© Suction engine oil via oil dipstick tube with engine at operating temperature. Engine 119 in model 129 if no suction unit is available: © Drain engine oil from oil pan (arrow). Model 107 0101.20/4Engine oil and filter change 01 01 .20 Model 126, 129 Mode! 140 © On model 129 and 140, remove engine compartment lower panel first and reinstall after completing maintenance jobs (refer to job item 6190), © Ifthe oil has been drained from oil pan, replace seal ring on oil drain plug. ‘© Tighten oil drain plug. Refer to table for correct torque. 4 Maintenance Manual GD supplement 4 - March 1992 0101.20/50101.20 Engine oil and filter change Installing new oil filter Engine 116, 117 in model 107 ‘© Unscrew oil filter housing (3) and drain. ‘© Wash out oil fter housing and blow out. © Check seal ring (2) and replace as necessary. For this purpose, pull compression spring with spring washer (6) from fastening screw (1). Be sure to properly install compression spring with spring washer during assembly. ‘* Replace rubber seal ring (4) ‘© Install oil fiter lower part with a new fitter ‘element (6) and tighten fastening screw (1) to 25 Nm. Engine 116, 117 in model 126 Engine 119 in model 124, 129, 140 © Replace filter element while making sure that the large rubber seal (24 mm ID) points in downward direction. Engine 116, 117 in model 126 © Replace rubber seal ring (1) on cover. © Check seal ring (2) on center screw and replace as necessary. © Tighten center screw to 25 Nm. 2——_s Engine 116, 117 in model 107, Engine 116, 117 in model 126 0101.206Engine oil and filter change 0101.20 Engine 119 In model 124, 129, 140 Replace rubber seal rings (4 and 4a) on cover. Tighten center screw to 20 Nm. Engine 119 Engine 120 in model 140 © Replace seal (3). ‘© Insert oil filter cartridge (4) in threaded cover @). © Insert cartridge with cover and tighten. © Install loft air filter housing and mass air flow sensor assembly. Engine 120 Se Maintenance Mansi GD. supplement ¢ » March 1982 0101.20/70101.20 Engine oil and filter change Filling engine olt All engines © Add engine oil (arrow). Run engine and chock for leaks. Check oil lovel with engine at operating temperature approx. 2 minutes after stopping ‘engine (arrow). Engine 116, 117 in modol 107, 126 Engine 119 in model 129 Engine 120 in model 140 © Install air duct (engine 116, 117 in model 126, ongine 119 in models 124, 129, 140). 0101.20/8Engine oil and filter change 0101.40 Specified SAE viscosity classes during continuous ambient temperatures Following the SAE grades exactly according to the ambient air temperatures would resut in frequent engine ol changes. The temperature rangos for the SAE grades should therefore be regarded as a guideline which may be exceeded for bret periods. Q caution: ‘SAE 10W single grade olls must not be used In engine 617.95. Olll capacity in titers Engine 616 617 ‘aw-ensews0} 1) For continuous ambient temperatures above +30 °C (86 °F), SAE 40 can be used. 2) Excopt Turbodiesel engine 617.95 Engine 616,617.91 | 617.95 617.95 (04/84) Ol dipstick color code red white ‘cher brown Total capacity during oil and fiter change _| 6.6 78 8.0 il pan 43 48 48 Torque specifications (Nm) il pan drain plug Mounting nuts, oil filter cover 40 25 ‘eS maintenance Manual G2) supplement 5 March 1983 0101.40/10101.40 Engine oil and filter change Special tools 117 589 02 07 00) 001 589 51 21 00) Due to the different sizes, the fiter element and the rubber seal ring on the cap should not be ‘exchanged with those on engines 601, 602 and 603. Prior to suctioning or draining engine oil, empty oil filter. For this purpose, loosen nuts (arrows) and remove cover. Engine 601,602,603 Engine 616,617 Dimension L1 119 mm Dimension L1 131 mm 12 49mm Lz 55mm 0101.40/2Engine oil and filter change 01 01 -40 Suction engine oil via oil dipstick tube with engine at operating temperature. If no suction unit is available: Drain engine oil from oil pan (arrow). ee Maintenance Manust G9). Nov. 1989, 0101.40/30101.40 Engine oil and filter change Replace filter element. Replace rubber seal ring (1) on cover. Check the oil port on the oil tube for foreign matter (arrow). If itis blocked, remove the foreign matter by hand. Then blow through the oil port with compressed air; air must noticeably come out of the bottom of the oil tube. ifthe oil ort is not open or if no air comes out, replace oil filter cap and oil tube. 0101.40/4Engine oil and filter change 0101.40 Tighten nuts to 25 Nm with torque wrench. IF oil has been drained from oil pan, replace seal ring on drain plug. Tighten oil drain plug to 40 Nm. ‘Add engine oil. Run engine and check for leaks. Check oil approx. 2 min. after stopping engine at operating temperature. <> Maintenance Manual G- Nov. 1389 0101.40/5Engine oil and filter change 01 01 .45 Engine 601 602 603 Specified SAE F viscosity classes . during continuous ambient temperatures. ties [Aes Following the SAE grades rs sc a 13 exact according tothe ambient | ze air temperatures would result in {requent engine of changes. ° ‘The temperature ranges for the ‘SAE grades should therefore bo regarded as a guideline which may be exceeded for biet periods sie 308 Oil capacity In liters Oil dipstick identification Total capacity Engine Mode! during oil and fitter bottle opener change round handle | shaped Identification no. handle 601 201 6 black : - 602.91 201 65 a red 60214 (1986-88) black brown 602.91 201 (1989) |7 - green : 602.96 124, 201 7 - black : green 603.96 124,126 [75 - black - 603.97 126 76 a * 60316 Torque specifications (Nm) Mounting nuts, oil filter cap 25 Oil pan drain plug 12 x 1.5 x 13 30 Oil pan drain plug 14 x 1.5 x 13 25, Return pipe in ol fiter cover 25 (model 124 only) => Maintenance Manat GD - supplements - March 1999 0101.45/101 01 .45 Engine oil and filter change Special tools 117889020700} | 001 s89 51 21 00] Due to the different sizes, the filter element and the rubber seal ring on the cap should not be ‘exchanged with those on engines 615, 616 and 617, On vehicles with air oil cooler (turbocharged engines) the oil need not be drained from the air cil cooler. NOTE: Change engine oil only with engine at operating temperature. Engine 601,602,608 Engine 616,617 Dimension L1 113mm Dimension L1 131 mm 249mm 255mm 0101.45/2Engine oil and filter change 0101.45 Empty oil filter prior to drawing off or draining engine oil. For this purpose, unscrew nuts (arrows) and remove cover. For this purpose, for reasons of available space, ‘on engine 603 in model 124 (up to January 1986) loosen rubber gasket or sealing strip on Unit partition as follows and pull slightly in upward direction. With split rubber gasket Pull off holding clamp (1). With one-piece rubber gasket Unscrew screw (arrow). => Maintenance Manust G- Nov. 1968 0101.45/30101.45 Engine oil and filter change With two-piece oll filter cover (starting February 1986, engine 603 in model 124) Unscrew return pipe (276) and remove. Unscrew oil filter cover retaining nuts and remove cover. Suction engine oil via oil dipstick tube with ‘engine at operating temperature. tno suction unit is available: Remove lower noise encapsulation panel and install after finishing all maintenance work. Drain engine oil from oil pan (arrow). Note: The oil in air-oil cooler need not bo drained. 0101.45/4Engine oil and filter change 0101.45 Replace filter element. Replace rubber seal ring (1) on cover. Check the oil port on the oil tube for foreign matter (arrow). If it is blocked, remove the foreign matter by hand. Then blow through the oil port with compressed air; air must noticeably come out of the bottom of oil tube. If the oil port is not open or if no air comes out, replace oil filter cap and oil tube. Prazasra A> Maintenance Manual @- Nov. 1989 0101.45/50101.45 Engine oil and filter change Tighten nuts to 25 Nm with a torque wrench. If the oil has been drained from oil pan, replace seal ring on oil drain plug. Tighten oil drain plug to 30 or 25 Nm. Add engine oil Run engine and check for leaks. Check oil level approx. w minutes after stop- ping engine at operating temperature. 0101.45/6Adjusting valve clearance 0560. 1 0 Engine 110 Adjusting specifications in mm Cold engine (approx. 20°C) __ Warm engine (60°C + 15°C) Intake 0.101) 0.15 1) Exhaust 0.25 0.30 3) 0.05 mm more during extended ambient temperatures below -20°C. Torque specifications (Nm) Cylinder head cover cap nuts and bolts 5 Valve adjusting screws 20-40 Special tools P| || 110 689 01 01 09] 110 589.0001 00} [617 588.004000) | 617 589.0028 00 617 589.01 23 09) 117 589 00 23 00 117 58901 2300] [617 589022300] [001 589650900} —_{ 001 se0 46 21 08] 7 Maintenance Manual GD supplements - March 1983 0560.10/10560.10 Adjusting valve clearance NOTE: Check or adjust valve clearance with engine cold or warm. Note layout of intake and exhaust valves. Checking ‘* Remove rubber gaskets. © Measure valve clearance between slide surface of rocker arm and cam base circle of camshatt (arrow). Rotating engine: (a) With socket wrench on crankshaft balancer hex bolt. AXcautiont Do not use camshaft sprocket mounting bolt to turn engine. Do not rotate crankshaft In reverse. BeExhaust TP Imake Yrssers 0560.10/2Adjusting valve clearance 0560.1 0 (b) With starter: ‘Switch off ignition and connect terminals as indicated. Model 123 ‘On cable connector to engine hamess, disconnect cable terminal 16 (cable color red/purple), so that the ignition coil and the fuel pump are not activated. Connect terminal 30 and terminal 50 on cable connector, Instead of terminal 30, connection can also be made to battery +. <=> Maintenance Marat GD. Nov. 1988 0560.10/30560.10 Adjusting Adjust valve clearance by turning valve adjusting screw (2) with valve adjusting wrench. The valve clearance is correctly adjusted it slip gauge requires tight pul. NOTE: If adjustment is inadequate, replace plunger (4). Plungers are available in various sizes (refer to spare part documentation). ‘At end of adjusting jobs, check tension springs (1) for perfect seat. NOTE: A torque check is required on loose valve adjusting screws. For this purpose, remove tensioning springs by means of a screwdriver land measure torque with valve adjusting wrench, part no. 110 689 00 01 00 and a torque wrench (e.g. part no. 000 589 27 21 00). Hf the torque of the valve adjusting screw is below 20 Nm, replace valve adjusting screw (2) or valve adjusting screw (2) together with threaded bushing (3). Adjusting valve clearance 1 Valve adjusting wrench 110 $89 00 07 00 0560.10/4Adjusting valve clearance 0560.20 Engine 616 617 Adjusting specifications In mm Engine Cold engine (approx. 20°C) __ Warm engine (60°C + 15°C) 616, 617 Intake 0.10 1) 0.16 3) 616, 617.91 Exhaust 0.30 0.35 617.95 Exhaust 0.35 0.40 1) 0.05 mm more during extended ambient temperatures below -20°C. Torque specifications (Nm) Gylinder head cover cap nuts 15 Special tools S| P| | || 615589000100] [615589000300] [617589004000] [617 589.00 2300] —_| 617 58901 23 00} 117 589002300] [617 589022300] {617529032900} [617 589.04 23.00) | 001 58965 09 00) 001 589 76 21 09] cose ay > Maintenance Manust GB). supplement 5+ March 1983 (0560.20/10560.20 Adjusting valve clearance NOTE: Check or adjust valve clearance with engine cold or warm, Note layout of intake and exhaust valves. Adjusting ‘¢ Measuring valve clearance between sliding surface of rocker arm and cam base circle of camshaft (arrow), by positioning camshaft 50 that tip of cam is vertical relative to rocker arm. Valve clearance is correctly adjusted If feeler gauge can be pulled through with some resistance. ‘* Position start and stop cable to “Stop or tum starter key to “O". 0560.20/2Adjusting valve clearance 0560.20 ‘The engine can be cranked as follows: a) With socket wrench on crankshaft balancer hex bolt. ZXcauTion: do not use camshaft sprocket ‘mounting bolt to turn engine. Do not rotate crankshaft in reverse. b) With starter Model 123 with engine 616 and 617.912 Connect remote starter switch to terminal 30 and 50 at starter. Remote starter switch may also be connected to battery + instead of terminal 30. Model 123 with engine 617.952 (turbodiesel) Connect contact handle to terminal 30 and 60 at cable connector. The cable connector is fitted in the right hand wheel housing. ee Maintenance Manual GD: Nov. 1989 0560.20/30560.20 Adjusting valve clearance Model 126 with engine 617.951 (turbodiesel) Connect contact handle to terminal 30 and 50 at cable connector. The cable connector is fitted to the right hand side member. © Place retaining wrench (17) to hexagon of valve spring plate. Loosen hex nut (7), by holding locknut (8) at valve with valve adjusting wrench (14). ‘© Sot valve clearance by turning cap nut. © After adjusting, secure cap nut with locknut. ‘Also check that cap and locknuts of valves which were not adjusted are tight. © Re-check valve clearance, 0560.20/4Checking valve clearance 0561 Engine 102.983 ‘Adjust valve clearance on separate order only Adjusting specifications in mm Cold engine (up to 50°C Warm engine (60-80°C) Coolant temperature) Intake 0.10-0.20 0.16-0.25 Exhaust 0.25-0.95 0.30-0.40 1) 0.05 mm more during extended ambient temperatures below -20°C. Torque specifications (Nm) Cylinder head cover cap nuts 9 ‘Screws, ignition cable cover 20-40 Special tools ‘ \ 617 589002000] {617589002300} [617 saa 01 23.00] 117 589 00 28 00 117 589 01 29 00) \ \ o>» 617 589 02 29.00 617589032300] [617 589.08 23.00] | 360 589.00 23 001 001 589 65 09 00) \ \ (001 589 76 21 00 124 589 36 63 09] <> Maintenance Manual GD). Supplements « March 1993 0561/10561 Checking valve clearance A waanine: Because of the high ignition voltage, it is dangerous to touch ignition components (ignition Coil, ignition cables, spark plug connector, ‘module push connectors) when © the engine is running, © the engine is being started, © the key in in position 2 while the engine is being turned manually. NOTE: Check valve clearance with engine cold or warm. Note layout of intake and exhaust valves. Measure valve clearance between bucket tappet and cam base circle (arrows). ‘Turn the camshaft in such a way that the cam points up (base circle on bucket tappet). Valve clearance Is set correctly if the feeler gauge blades, minimum or maximum thickness, can be pulled through with some resistance (e.g., intake with cold engine, feeler gauge blade 0.10 or 0.20 mm). Gefahrliche Hochspannung! Yorsicht bei Arbeiten an der Zindanlage Danger! High voltage ‘Observe caution when working on the ignition system Danger! Haute tension Attention lors de travaux au sysléme d'allumage 0561/2Checking valve clearance 0561 ‘Turning the engine crankshaft: a) By hand Use socket wrench adaptor (27 mm, 1/2 drive) and ratchet, on the vibration damper bolt. Q caution: The engine must not be turned via the camshaft. Do not turn crankshaft backwards. After turing off ignition, disconnect crankshaft Position sensor (L5, green cable) from ignition control module, b) With starter: Disconnect crankshaft position sensor (LS, green cable) from ignition control module. A caution: Before turning engine, pull out fuel pump relay module (N16/4), to prevent fuel from being injected, Se Maintenance Manus! GA): Supplement § - March 1993 0561/30561 Checking valve clearance Connect once clamp of remote starter switch to the battery positive terminal. Disconnect connector (X27) from plug connector 50. Connect plug from adapter cable (01) 124 589 36 63 00. Checking © Remove cylinder head cover. Remove securing screws (709), remove ignition ‘cable valley cover (708), pull off the spark plug connectors and lay the ignition cable to the side. Loosen hose clamp (712) and pull off the hoses (711 and 713) on the cylinder head cover (85). 0561/4Checking valve clearance 0561 ‘© Remove cap nuts (101) and remove cylinder head cover. '* According to engine temperature and valve {intake or exhaust), try to pull the corresponding feeler gauge blade (minimum and maximum thickness) between the bucket tappet and the cam base circle, If the feeler gauge with the minimum thickness cannot be pulled through, or if the feeler gauge blade with the maximum thickness can be pulled through lightly, adjust the valve clearance (on separate order). * Check cylinder head cover gasket (97) and sealing rings (98) for damage and replace if necessary. ‘eS Maintenance Manust GA). supplement § - March 1999 0561/5,0561 Checking vaive clearance * Replace cylinder head cover in reverse order of its removal. Gradually tighten cap nuts in steps to 9 Nm. '® Route ignition cable according to the symbols and guide ribs in the ignition cable valley. Note: Check the valleys for foreign matter 2.3)- 1S before the spark plug connectors are reattached. © Check for leaks with engine running. por ta Note the following when adjusting vaive clearance Torque specifications (Nm) Nuts, camshaft bearing brackets 21 Bolts, timing gear to camshaft 12 Special tools pe Adjusting ‘© Remove appropriate camshatt. Turn the engine to the TDC position of the first cylinder; the holes (2 mm, arrows) in the timing gears must be opposite each other. Mark the camshaft and timing gear for alignment. Remove retaining screws (329, four for each timing gear). Using a plastic mallet, carefully tap the camshaft toward the rear to separate it from the timing gear center collar. 0561/6Checking valve clearance 0561 NOTE: If both camshafts are taken out at the ‘same time, mark each for later identification because they are identical © Unscrew fastening nuts (73) and take off Example (intake, engine cold) bearing brackets (66). Measured value 0.25 red average valu 0.15 * Pull out the corresponding bucket tappet Deeted eveede ane (219) with the magnetic lifter. Difference 1) 0.10 Thickness of removed disk 28 oc Tek Out ck (20): Thickness of disk to be 29 Installed * Position new disk. Tl valve Goaranco & oxcesswvo, add We aifrance the thickness of tho removed disk; it valve clearance is too small, subtract the diference. With an intake valve clearance of less than 0.10 mm always putin @0.10 mm thianer disk. A> Malotenance Manual GD. supplements - March 1982 0561/70561 Checking valve clearance ‘© Sot disks in the valve spring retainer. © Oil and install bucket tappets. © Oil and install camshaft. Before tightening the camshaft on the timing g0ar, carefully tap the camshaft toward the front on the center collar of the timing gear with a plastic hammer. Observe previously inscribed alignment marks. NOTE: The camshaft can be secured to the timing gear in only one position. ‘The camshaft bearing brackets are numbered for identification: Intake camshaft identification numbers 7-10. Exhaust camshaft identification numbers 2-5. The stamped identification numbers must be adjacent to the inside stud bolts. Tighten ail nuts equally, in steps. ‘© Chock the valve clearance again (check measurement). 0561/8Checking and adjusting idle speed 0750.1 1 Test values Idle speed rpm ‘Special tool 601 589 04 21 00) Equipment Digital tester Engine 601 1984 750 +50 Bosch MOT 001.03, © Connect digital tester (001) and impulse transmitter (021). > Maintenance Manual GD. supplements: March 1953 0750.11/10750.1 1 Checking and adjusting idle speed * Disongage connecting rod (204) on guide lever (214). © Run engine to approx. 80°C coolant temperature. © Check idle speed 750 +50 rpm, adjust by turing vacuum control unit (4), if required, loosen counter nut (4a) for this purpose. © Engage connecting rod (204) free of tension. ‘© Switch on all additional units and check ‘engine for smooth running, 0750.11/2Checking and adjusting idle speed 0750.16 Engine 616 617.912 1981 Test values Engine Idle speed rpm. 616.912 1981 750 +50 617.912 1981 760 +50 Special tool 616 589 00 21 09) Equipment Digital tester Bosch MOT 001.03 © Connect impulse transmitter (021) and digital tester (001). ‘© Run engine to approx. 80°C coolant temperature. © Turn button for idle adjuster on instrument panel fully to the right. “> Maintenance Manual G+ supplement 5 - March 1983 0750.16/10750.16 Checking and adjustin idle speed © Disconnect push rod (41) at angle lever. © Check idle speed. If necessary, loosen lock ‘nut (3) and adjust idle speed to specified speed of 75050 rpm with idle speed adjusting screw (4). PAY oe 0750.16/2Checking and adjusting idle speed 0750.16 Checking adjustment of regulating linkage. a) Vehicles with manual transmission Adjust push rod (41) by pressing shutoff lever (arrow) against stop. Adjust push rod so that play between lower edge of ball head and upper edge of ball socket is 5-6 mm (distance “a”). Connect push rod. 'b) Vehicles with automatic transmission ‘Adjust push rod (41) so that reversing lever (68) just rests on perceptible selector cam leading edge. The regulating lever must also rest against the idle speed stop of the injection pump. Engine 617.912 => maintenance Manual GD: Nov. 1909 0750.16/30750.16 Checking and adjusting idle speed © Check Bowden cable for cruise control and adjust as necessary. Press throttle valve lever against the stop; the Bowden cable must rest free of tension against regulating lever. Adjust Bowden cable with adjusting screw if required, Release throttle valve lever {idle setting). In this position the Bowden cable must have play. ‘© Move selector lever to drive, switch on climate control, tun power steering to full lock. Engine should stil run smoothly Readjust speed if necessary. QS caution: If speed is set higher, the engine will leave the idle speed control range and may accelerate up to maximum engine speed (at no load). 0750.16/4Checking and adjusting idle speed 0750.17 Engine 617.95 Test values Idle speed /rpm 700 -800 Equipment Digital tester e.g. Bosch, MOT 011.03, © Connect digital tester to diagnosis socket '* Run engine to approx. 80°C coolant temperature. * Detach push rod (70) at angle lever. © Check idle speed. If necessary, loosen lock nut (3) and adjust idle speed with adjusting screw (4) to a speed of 700-800 rpm. Note: The idle speed can also be adjusted using the tachometer in the vehicle. => Maintenance Manual D+ supplement s- March 1993 0750.17/10750.17 ‘© Adjust push rod (60) so that roller (15) in reversing lever (68) rests at final stop free of tension. ¢ Adjust cruise control. For this purpose, detach pull rod (21) and push lever of actuating element clockwise against idle speed stop. When connecting pull rod (21), make sure that the lever of the actuating element is pushed away from idle speed stop by approx. 1 mm. Readjust pull rod, if required. * Move selector lever to drive, switch on automatic climate control. When power steering is turned to full lock, engine must still run smoothly. Readjust speed, if required, 4S caution: f speed is sot higher, engine wil leave idle speed contol range and may increase to maximum engine speed (at no load). Checking and adjusting idle speed 0750.17/2Checking and adjusting idle speed 0750.1 8 Engine 616.912 1982/1983 Adjust engines according to data of respective exhaust gas information plate, Identification: Information plate on cross member in front of radiator. Test values Idle speed rpm 750 + 50 Special tool 616 589 00 63 00) Commercial tools Tachometer Connect tachometer and adapter. Run engine until coolant temperature is approx. 80°C. Turn knob for idle speed adjuster on instrument panel completely to the right. ==> Maintenance Manust GS) - supplement § - March 1959 0750.18/10750.18 Checking and adjusting idle speed Detach pushrod (41) at angle lever. Move guide lever (68) into idle speed position. Sot edge of lever arm of guide lever (68) to mark (arrow) of cap (70) (seen from above). lf necessary, check idle speed. Loosen locknut (8) and set idle speed adjusting screw (4) to specified speed 750 +50 rpm. Check adjustment of regulating linkage. Adjust pushrod (41) and attach free of tension. Regulating lever of injection pump should rest against idle speed stop. 0750.18/2Checking and adjusting idle speed 0750.18 Adjusting cruise contro/Tempomat: a) With manual transmission Check connecting rod (22) for specified length of 178 mm. Detach connecting rod (21) on actuator, check whether regulation is in idle ‘speed position. Push lever of actuator clockwise to idle speed position. Check whether connecting rod (21) is 1 mm longer than lever of actuator and adjust, it required. Attach connecting rod (21). b) With automatic transmission Check pull rod (23) for specified length of 178 mm. Detach connecting rod (21) on actuator. Check whether regulation is in idle speed Position. Push lever of actuator clockwise into idle speed position. Check whether connecting rod (21) is 1. mm. onger than lever of actuator and adjust, if required. Attach connecting rod (21). Manual transmission ‘Automatic transmission <=> Maintenance Manual @D + nov. 1989 0750.18/3Checking and adjusting idle speed 0758 Engine 110 1981 Test values Idle speed rpm 750+50 Special tools 116 589 27 21 00) Commercial tool Tachometer Connect tachometer and oil telethermometer. Switch off climate control, move selector lever to “pe, Check whether throttle valve lever rests against idle speed stop. ‘Adjust cruise control (tempomat). Check whether actuating element rests against idle speed stop of cruise control (tempomat). To check, disconnect pull rod (21) and push lever of actuating element clockwise against idle speed stop. When engaging pull rod (21), make sure that the lever of the actuating element is pushed away from idle speed stop by approx. 1 mm. Readjust pull rod, if required. Run engine to 75-85°C oil temperature. => tairtanance Manus @- novos9 o7s8/10758 Checking and adjusting idle speed Check idle speed and set to specified speed, if required, by means of idle speed air screw (10). o7sar2Checking injection timing 0760 1 Engine 616 617 Test values Engine 616,617 Start of delivery BTOC’) 2ae ete ‘Jota Pall rogulatng lover of jocton pump Yo Full load Slop during moasuromnent and Gaconnedt vacuum hose al Vasuum Unt Torque specifications (Nm) Pipe connection 40 Special tools 000 589.27 21.00} [000s8968.03.00] [636 s89 02 23 00 Disconnect vacuum hose at vacuum unit > Maintenance Manust @- Nov.1988 0760.1/10760.1 Checking injection ti Unscrew pipe connection (1) of first injection pump element, remove compression spring and delivery valve. Install pipe connection (1) without compression spring and delivery valve. ‘Attention! Do not slacken barrel-and-valve assembly (2). Screw on overflow pipe. Pull regulating lever of injection pump to full load stop during measurement. ‘Tum crankshaft in direction of rotation until fuel just stops dripping. This position represents start of delivery. {f injection timing has to be adjusted, refer to adjustment instructions Remove overflow pipe and unscrew pipe connection. Fit delivery valve, compression spring and pipe connection. ‘Torque pipe connection in one movement to 40- 50 Nm. Run engine and check for leaks. Ifa pipe connection leaks, it must be replaced. When fitting a new pipe connection, use new copper sealing ring under delivery valve holder. 1 Pipe conection 2 Barrel-and:-valve assembly 0760.1/2Checking injection ti 0760.2 Englne 601 602 603, Test values Indirect injection timing (after TDC) Model year Ri (reference impulse) Ri (reference impulse) checking value adjusting value 1984-89 15 41° 15° starting 1990 14° +0.5° 14° +0.5° Tightening torques (reference values) Nm Closing plug to regulator (measuring point) 30-35 Injection pump flange 20-25 Special tools a [crrane 02} [ermernn| [essa é [errens ona oo} larareas Equipment For use with adapter Digital testers: e. on Equipment For use without adapter Digital testers (Diesel tester) eg. e.g. e.g. Bosch, ETD 019.00 Hartmann & Braun, EOMT S Bosch, ETD 019.00 ‘Sun, DIT 9000 AVL, Diesel Tester 875 > Maintenance Manus! GA). supplement § - oct 1983 0760.2/10760.2 Checking injection Connection diagram for available testers for use with adapter, e.g. Bosch MOT 001.03, Hartmann & Braun, EOMT 3 001 Digital tester 2 Governor 010 Adapter 2 Al-transmitr in 011 Trigger camp 59 TOC-vansmiter 015 Tost cable wit connector 016 ——_Diagnostc socket 017 ——R-transmiter 021 ——_TDC-impulse transmiter 0760.22Checking inje in timing 0760.2 Connection diagram for testers for use without adapter, .g. Bosch ETD 019.00, SUN DIT 9000, AVL Diesel-Toster 875 001 Digital testor 2 Goveror 015 Test cable with connector 2 lransmiter pin 016 Diagnostic socket 59 ‘TDC-tranemiter 017 ——_—R-trenamiter 021 TOC-mpuise vansmiter => Maintenance Manual GB: supplement 6 - Oct 1983, 0760.2/30760.2 Checking Remove air cleaner cover (arrows). Remove plug (11) on governor. Note: Catch escaping oil. Connect digital tester according to connection diagram. 0760.24 Checking injection timing (017 Ri-vansmitar on governor (artow) (ijecton pum)0760.2 Checking injection ti (021 TOC-impulse transmitter on holdor Engine 601 Read R-value (indirect injection timing) at idle speed on digital tester. Ri-nominal value: 15° ATDC on 1984-89 models; 14° +0.5° ATDC on 1990 and later models. Perform leak test with engine running. Check engine oil level and correct, if required. (021 TOC-impulse transmit on holder (arow) Engines 602, 603 <=> Mointenance Manust GD). supplement s - oct 1983 0760.2/5Adjusting injection timing 0761 Test values Engine 601 602 603, Indirect injection timing (after TOC) Model year Al (reference impulse) Al (reference impulse) checking value adjusting value 1984-89 141° 15° starting 1990 14° +0.5° 14° +0.5° Adjusting Injection timing (position sensor RIV method) - after checking (0760.2) ‘Tur crankshaft in direction of rotation to Injection pump mounting bolts (13 and 13A) at flange and bracket see : Indicator (008) and clamp (009) ............ Pivot injection pump by turning injection timing adjustment screw (8) Adjustment screw direction Right Retard injection timing Left = Advance injection timing value in chart loosen, 20-25 Nm. connect to B+ both lamps, A and B, must light up in indicator (008) Ri (reference impulse) adjusting value: refer to chart eS Maintenance Manus! GD. supplements + Oct 1993 0761/10761 Position sensor (007) Plug (arrow)... Regulating linkage. Leak check with running engine... . Engine oil level. Note: Check injection timing before adjusting (0760.2) Adjusting 1. Turn crankshaft in direction of rotation to 15° ATDC on 1984-89 models; 14° ATDC on 1990 and later modols. 2, Loosen mounting bolts (arrows) at injection pump flange and bracket (arrow). Bracket mounting bot Adjusting injection timing remove serew in check, adjust if necessary (repair instruction 30-300) + perform check, correct if necessary 7612Adjusting injection timing 0761 3. Connect indicator (008) and clamp (008)to battery positive terminal. 4, Pivot injection pump by tuming adjusting ‘screw until both lamps A and B light. Adjustment screw direction Right Retard injection timing Left = Advance injection timing RI nominal value: 15° ATDC on 1984-89 models; 14° +0.5° ATDC on 1990 and later models. Note: Ifthe adjustment range is inadequate, the pump must be repositioned. Refer to SMS, Job No. 07.1-200, Injection pump removal and installation. 5. Torque mounting bolts on injection pump flange and bracket to 20-25 Nm. 6. Remove position transmitter. 7. Install screw in plug, torque to 30-35 Nm. 8. Check regulating linkage, and adjust if necessary (SMS, Job No. 30-300). 9. Check for leaks with engine running. 10. Check engine oil level, and correct if necessary. @<> Matrtonance Manva! ©): supplements - ost 1985 0761/30761 Adjusting injection ti Adjusting Injection timing using digital tester (RIV method) - after checking (0760.2) +4 = eT Injection pump mounting bolts (18 and 13A) at flange and bracket ee Engine 0.2... ee eees Rl value (indirect injection timing) Adjustment screw (8) direction Right Retard injection timing Lett ‘Advance injection timing Engine .. a Injection pump mounting bolts (13 and 13A) at flange and bracket : Tester . oe Plug (arrow) on governor . . Regulating linkage Leak check with running engine . Engine oil level... . loosen run at idle speed adjust by turning injection timing adjustment. screw (8) Rl (reference impulse) adjusting value: refer to chart shut off torque to 20-25 Nm. disconnect screw in and torque to 30-35 Nm check, adjust it necessary (repair instruction SMS, Job No. 30-300) perform check, correct i necessary 0761/4Adjusting injection timing 0761 Note: Check injection timing before adjusting (0760.2) 1. Loosen mounting bolts (arrows) at injection pump flange and bracket (arrow) Bracket mounting bot 2, Run engine at idle speed. 3. Adjust il value (indirect injection timing) by turning adjusting screw. RI nominal value: 16° ATDC on 1984-89 models; 14° +0.5° ATDC on 1990 and later models. Adjustment screw direction Right = Retard injection timing Left = Advance injection timing => Matntenance Manus! GD: supplement 6 - oct 1983 0761/50761 Adjusting injection timing Note: If the adjustment range is inadequate, the pump must be repositioned. Refer to SMS, Job No. 07.1-200, injection pump removal and installation. 4. Tur engine off. 5. Disconnect tester. Install screw in plug on governor and torque to 30-35 Nm. 7. Torque mounting bolts on injection pump flange and bracket to 20-25 Nm. 8. Check regulating linkage, and adjust it necessary (SMS, Job No. 30-300), 9. Check for leaks with engine running. 10. Check engine oil level, and correct if necessary. o761/6Replacing fuel filter 0780. Loosen mounting screw (1) and remove housing with filter element in downward direction. Install new filter element with housing (3) and gasket (4). Bleeding fuel system Engines 616, 617 Fuel filter Loosen hollow bolt (8, upper illustration) and using hand pump, pump manually until fuel flows out free of bubbles. Retighten hollow bolt Bleeding Injection pump Pump manually until overflow valve on injaction pump opens with an audible buzzing sound. Engines 601, 602, 603 When starting, injection system will bleed automatically. Run engine and check for leaks. Diesel engines 3S Cys’ — A Engine 616, 617 g.. c on e777 Engine 601, 602, 603 “> Maintenance Manual G2). Nov 1989 0780.11Replacing fuel filter 0780.3 Engine 102 110 116 117 with CIs Remove protective cover. Disconnect fuel lines. Loosen mounting screws (arrows) and remove filter. Unscrew fitting from old filter and attach to new filter with new seal ring, Install new fuel filter inflow direction. with plastic sleeve. Sleeve should project on both sides of the holder since contact corrosion may ocour if there is direct contact with the holder. Replace plastic sleeve, if necessary. Connect steel line to fiter. Retighten mounting screws. Check for leaks. “> Maintenance Manual GA). Nov. 1989 0780.3/1Replacing fuel filter 0780.4 Engine 102 103 104 116 117 119 with CIS-E Remove protective cover by removing mounting bolts (arrows). On model 201 (2nd version) pull ‘out expanding rivets. Model 201 2nd version Model 201 (rd vorsion as of 08.1985) ‘=> Maionanance Manual G+ Nov. 1989 0780.410780.4 Replacing fuel filter Disconnect fuel line and fuel hose. Loosen mounting screws (arrow) pivot holder down and remove filter. Install new fuel filter and plastic sleeve in flow direction. Sleeve should project on both sides of the holder since contact corrosion may occur if there is direct contact with the holder. Replace plastic sleeve, if necessary. (On model 124, an additional plastic sleeve is required. Install protective cover. Model 126 0780.420780.4 Replacing fuel filter Model 124.026/0301050 as of 11. 1986, and 124.230 Model 128 Model 201 1st vorsion ‘Model 201 2nd vorsion 0780.4/3 ‘a> Warnanance Maruat GD: Nov. 18680780.4 Replacing fuel filter Mode! 201.029/034 staring 10.1988 0790.4/4Replacing fuel filter © Remove protective cover by removing screws (arrows). '® Disconnect fuel lines and fuel hose from fuel filter (55). '® Loosen clamping screw (arrow) and remove fuel fiter towards rear. © Install new fuel fier with plastic sleeve so that sleeve extends on both sides of holder since contact corrosion may occur if there is direct. contact with the holder. © Run engine briefly to check connections for leakage. © Reinstall protective cover. “A> Maintonence Manual GA)- supplement 4 » March 1992 0780.5 Engine 104 119 120 with LH Model 124 Modal 128 0780.5/10780.5 Replacing fuel filter Model 140Replacing fuel filter 0780.6 Engine 104 with HFM-SFI ZS warninet ‘Apply parking brake before performing work with engine running. Place automatic transmission selector lever in Park positon. ‘Shown on fvet pump assombly with two fuel pumps. > Maintenance Manual @ - supplement s - March 1983 0780.6/10780.6 Replacing fuel filter Special tools 000 589 40 37 00) QS warninet Observe fuel-related safety precautions. ‘* Release fuel tank pressure by opening filler cap. * Disconnect battery negative cable and cover battery negative terminal. ‘Remove protective cover by removing screws (arrows). Disconnect fua! lines and fuel hose from fuel fiter (55). Model 124 © Loosen clamping screw (arrow) and remove fuel filter towards rear. © Install now fuel filter with plastic sleeve so that sleeve extends on both sides of holder since contact corrosion may occur if there is direct contact with the holder. * Run engine briefly to check connections for leakage. © Reinstall protective cover. Mode! 124 0780.82Replacing fuel prefilter 0781 Diesel engines Replace fuel prefilter. Run engine and check for leaks. Engine 601.91, 602.91 “= Maintenance Manual G)- supplement 3 - Feb. 1991 o781tReplacing fuel prefilter 0781 Engine 602.96, 603.98, 603.97 07612Cleaning metal-reinforced air filter element 0932 Diesel engines Note: Under severe operating conditions, such {as poor road conditions resulting in substantial dust deposits in the air cleaner, the air fitter element is to be cleaned at every maintenance service. This applies only to filter elements reinforced with perforated metal. Filters without the perforated metal reinforcement should be replaced, not cleaned. Cleaning Using no more than § bar pressure, blow compressed air through the element from the reinforced side, holding the nozzle about 20 cm away from the perforated metal. Caution! Never blow directly into the folds of the filter since this can tear the element resulting in unfiltered air entering the engine. Do not wash, eat out, or oil the filter element. Clean the air filter housing and cover. Check whether filter element sealing compound is damaged and replace element, if necessary. Check whether air filter cover seal is damaged and replace, it required. Carefully install air filter element and note that the rubber seals are installed correctly. => Matctenance Manual @- supplement 2 - Mar. 1990 0932/1Replacing air filter element 0980 All engines. except engines 116 117 with secondary alr injection pump All engines except engine 120 © Remove air filter element. © Clean out air cleaner housing and cover. © Inspect air cleaner cover seal and replace if damaged. © Carefully insert new air filter element and note correct location of rubber seals. Engine 120 © Pull out slide (1). Remove air cleaner (2).and remove air filter element (3) © Clean air cleaner housing (2). © Press filter element into air cleaner (2). ‘* Push air cleaner in until it contacts stop. © Push slide (1) in. A> Wairtenance Manuat GD - supplement 5 - March 1983 0980/1Replacing air filter elements Remove air filter element (1) and (2).. Clean out air fiter housing and air filter cover. Inspect filter cover seal and replace if damaged. Carefully insert new air filter element and note correct location of rubber seals. <=> Maintenance Manus! GD. Nov. 1988 0981 Engine 116 117 with alr pump OA Sit x 1. Engin fer element 2 Air pump fier element 0981/1Checking condition and tension of V-belts 1350.05 Engine 102 with multiple belt drive V-belt Location Tension (KG) Tension (KG) New V-belt Used V-belt Air conditioning compressor 50 40-45 B Power steering pump 50 40-45 Generator--coolant pump 30 20-25 1 Crankshaft 2 Coolant pump 3 Generator 4 AIC compressor 5 Tensioning pulley 6 Power steering pune Bet A AVC compressor Bet Powor steering pump Bet C Coolant pump - generator Special tools SSS} 001 589 69 21 00) A> Maictenance Manus! GD - supplament §- March 1992 1350.05/11 350.05 Checking condition and tension of V-belts Note Refer to operating instructions for use of measuring instrument. The specified tensioning values refer to the KG scales on the instrument (arrow). Checking condition of V-belt Replace cracked or worn V-belts. Tensioning ‘© Before tensioning, remove lower engine compartment panel. V-belt A Alr conditioning compressor © Loosen bolt (3). © Tension V-belt with adjusting screw (4). © Tighten bolt (3). 1350.05/72Checking condition and tension of V-belts 1 350.05 V-belt B Power steering pump ‘© Loosen bolts (1, 2, and 3). © Tension V-belt with adjustment gear (4). © Tighten bots (1, 2, and 3). V-belt C Generator~Coolant pump © Loosen nuts (1 and 2) as well as bolt (3). Tension V-belt with adjusting screw (4). ‘© Tighten nuts (1 and 2), as well bolt (3) © Install lower engine compartment panel. +> Maintenance Manust GD - supplement §- March 1993, 1950.05/3Checking condition and tension of V-belts 1350.10 Engine 110 V-belt Location Tension (KG) Tension (KG) New V-belt Used V-belt A Generator--coolant pump 30 20-25 B Power steering pump 50 40-45 ° Air conditioning compressor 50 40-45 D ‘Secondary air injection pump 30 20-25 1 Crankshaft 2 Coolant pump 3 Generator 4.AIC compressor '5 Tensioning pulley 6 Power stoering pump 7 Secondary air injection pump Special tools Sse (001 589 69 21 00) > Maintonsnce Manual GB) » supplement s » March 1993, 1350.10/11350.10 ion and tension of V-belts Note Refer to operating instructions for use of measuring instrument. The specified tensioning values refer to the KG scales on the instrument (arrow). Checking condition of V-belt ¢ Replace cracked or worn V-belts. Tensioning V-belt A Generator-coolant pump © Loosen nuts (1, 2 and 3). ‘* Tension V-belt at hexagon or on engines with air conditioning compressor at 6 mm square of adjustment bolt (4). © Tighton nuts (1, 2 and 3). 1350.102Checking con ion and tension of V-belts 1350.10 V-belt A Generator 80 Acoolant pump Loosen nut (1), Note: Bolt (2) is installed from the rear of the generator on vehicles built starting July 1984. © On vehicle built up to July 1984, loosen bolt (2) from underneath the engine. ‘© On vehicle built starting July 1984, loosen bolt (2) from back of generator. © Loosen bolt (3). © Tension V-belt on hex of adjusting screw (4). © Tighten nut (1) and bolt (3). © Tighten bolt (2). V-belt B Power steering pump '® Loosen bolt (1) on face of power steering pump. ‘=> Maintenance Manus! G® + supplement 5 » March 1993 1350.10/31350.1 0 Checking condition and tension of V-belts © Loosen nut (2). © Adjust V-belt with adjustment bolt (3). © Tighten nut (2) and bolt (1). V-belt © Air conditioning compressor '® Loosen necked down bolt (21). Adjust V-belt with adjusting bolt (18). © Tighten necked down bolt (21) to 25 Nm. V-belt D Secondary alr injection pump '® Loosen mounting bolts (1 and 2). * Adjust V-belt by swiveling secondary air injection pump outward. © Tighten fastening bolts (1 and 2). 1350.10/4Checking condition and tension of V-belts 1350.20 Engine 116 117 V-belt Location Tension (KG) Tension (KG) Now V-belt Used V-belt A Coolant pump - power steering pump?) 30 20-25 B Gonerator 35 30-35 c Air conditioning compressor 50 40-45 ° ‘Secondary air injection pump 30 20-25 Double V-beR 1 Crankshat 2 Coolant pump 3 Generator ‘4 AIC compressor 5 Tonsioring pulley 6 Powor stooring pump 7 Secondary air injection pump Special tools “> Maintenance Manus! GD - supplement 5 - March 1989 1350.20/11 350.20 Checking condition and tension of V-belts Note Refer to operating instructions for handling of measuring instrument. ‘The specified tensioning values refer to KG scale of measuring instrument (arrow). Checking condition of V-belts Replace cracked, scorched or worn V-belts. Note: If one of the two V-belts of the double belt Leseaee drive has to be replaced due to wear, both V- belts must always be replaced. Only belts from one manufacturer may be installed together. V-belts are supplied only in sets as spare parts. Adjusting V-belt A Coolant pump - Power steering pump Loosen nuts (1,2 and 3 [fulcrum]). Adjust V-belt with adjustment screw (arrow). Power steering pump carrier (1st version) Power steering pump carr (2nd version} 1350.20/2Checking condition and tension of V-belts 1350.20 © Tighten nuts (1, 2 and 3). © Loosen fastening bolt (1) and nuts (2 and 3). © Adjust V-belt with adjustment bolt (4). ‘© Tighten fastening bolt (1) and nuts (2 and 3). 1350.20/31 350.20 Checking condition and tension of V-belts V-belt C Air conditioning compressor © Loosen fastening bolt (9). © Adjust the V-belt by turning the tensioning pulley (8). To do this place a right angle ‘open end wrench (22 mm) on the flat surface (10). ‘© Tighten fastening bolt (3). Note: As of November 1985 the mounting screw (9) is designed as a hex. socket screw. Use special tool 117 589 03 07 00. V-belt D Secondary alr injection pump © Loosen fastening bolts (1 and 2). © Adjust V-belt with adjustment whee! (3). © Tighten fastening bolts (1 and 2). 1350.20/4Checking condition and tension of V-belts 1350.40 Engine 616 617 Engine 616,617.91 617.95 616,617.91 617.95 V-belt Location Tension (KG) Tension (KG) Tension (KG) Tension (KG) Now V-belt New V-belt Used V-belt Used V-belt A Generator - 50 300) 40-45 20-28" coolant pump B Air conditioning 50 50 40-45 40-45, compressor © Power steering pump 0 50 40-45 40-45 TT Double Vibert 1 Crankshaft 2 Coolant pump 3 Generator 4. NIC comprossor 6 Power steering pump Special tools Rae) 001 589 69 21 09] > Maintenance Manus! @ + supplements - March 1999, 1350.40/11350.40 Checking condi in and tension of V-belts Note: Refer to operating instructions for handling of measuring instrument. The special tension data refer to KG scale of the ‘measuring instrument (arrow). Checking condition of V-belt Replace cracked, scorched or worn V-belts. Note: If one of the two V-belts of the double belt drive (engine 617.95) has to be replaced due to wear, both V-belts must be replaced. Only belts from one manufacturer may be installed together. V-belts are supplied only in sets as spare parts. Adjusting V-belt A Generator - Coolant pump © Loosen nut (1) and bolts (2 and 3). 1350.40/2Checking condition and tension of V-belts 1350.40 Adjust V-belt with nut (5). Tighten nut (1) and bolts (2 and 3). ‘Then keep turning nut (5) for approx. 1/4 to V2 tur (until tight). V-belt B Air conditioning compressor © Loosen bolts (6, 7 and 8). © Adjust V-belt with nut (9) of tensioning bolt (10). © Tighten bolts (6, 7 and 8). se<@ Mointenance Manus! GS) - supplement » March 1988 1350.40/31 350.40 Checking condition and tension of V-belts V-belt © Power steering pump © Loosen nuts (11, 12 and 13). ‘© Adjust V-belt with clamping bolt (14). © Tighten nuts (11, 12 and 13). 1350.40/4Inspecting poly-V-belt 1 351 Engines 102 103 104 119 120 601 602 603 Special tools 001 589 76 21 00) 126 589 96 63 00 Note: Turn crankshaft using starter and compression test recorder on all models except 140. Use ignition switch on model 140. a IMPORTANT NOTE! Model 124.034/036, 129, 140 Certain connectors must be disconnected when turing the crankshaft. This results in the setting of Diagnostic Trouble Codes which must then be erased from the following control modules: © LH-SFI control module. © Ignition control module. * Diagnostic module, if equipped. (Refer to Diagnostic Manual, Engines, Vol. 2, 3). AX wanninet Bocause of the high ignition voltage on gasoline Gefahrliche Hochspannung! engines, it is dangerous to touch ignition Vorsicht bei Arbeiten an der ‘components (ignition coil, ignition cables, spark Zundanlage plug connector, module push connectors) when Danger! High voltage © the engine is running, Observe caution when working the engine is being started, ‘on the ignition system ‘© the key is in position 2 while the engine is Danger! Haute tension being turned manually. ‘Attention lors de travaux au systeme dallumage SH Maintenance Manual GB). supplement 5 + March 1993, 1351/1Inspecting poly-V-belt 1351 engines. ‘© Switch off ignition on gasoline Disabling Ignition with EZL ignition contr module Models 124, 126, 129 and 201 off plug from crankshaft position sensor (green or black cable) on control module (arrow). Disconnect connector on model 140 1361/2Inspecting poly-V-belt Disabling fuel supply and connecting remote starter switch Model 124, 126, 201 except model 124 starting model year 1990 and mode! 201.029 starting model year 1990 © Before turning the engine, the fuel pump relay module (N16/4) should be pulled out, 50 that no fuel is injected into the engine. ‘Shown on madel 203, © Connect compression test recorder to battery positive (circuit 30) and to the plug (circuit 50) of the connector (X27). Insert adapter cable 124 589 36 63 00 (01) in the cable (02) of the compression test recorder. Mode! 124, left se component compartment wal Model 126 let side offre wall “> Maintenance Manual G- supplement S = March 1993 1351/31351 Inspecting poly-V-belt Mode! 201, let side component compartment wall Model 124 with Engine 103, 104 starting model year 1990, Model 201.029 starting model year 1990 © Remove component compartment cover. © To interrupt fuel supply, remove engine systems control module (MAS) (N16) by turning locking knob from position 1 to position 0. Pull unit up, Shown on model 126 Model 124 with engine 119 © In order to interrupt the fuel supply, disconnect engine plug connection (X26/17) of engine wiring hamess on right side of vehicle. 1351/4Inspecting poly-V-belt 1351 '* Remove component compartment cover. Connect remote starter switch to starter hamess connector (X27) (circuit 50) and to terminal block (X4/10) (circuit 30) position B located behind Module box. Model 129 ‘© Remove component compartment cover ¢ To interrupt fuel supply, remove engine systems control module (MAS) (N16) by turning locking knob from position 1 to position 0. Pull unit up. Mode! 129 © Disconnect plug (28) from starter harness connector (X27). Connect remote compression tester clamp (A) to plug (28) pin 1 (circuit 50) and clamp (B) to terminal block (X4/10) (Circuit 30). %<> tartonance Manuat GD supplements ~ March 1988 1351/51351 Inspecting poly-V-belt Model 140 © To interrupt the fuel supply disconnect ‘engine plug connector (X26/2) on right side of vehicle. Note for Diesel engines ‘© While cranking, pross shut off lever (arrow) to prevent the engine from starting, Checking poly-V-belt © Mark poly-V-belt clearly using chalk. © Crank engine in steps while checking the poly-V-belt for damage. ‘© End the process when the mark is again (one full turn of the belt). © The poly-V-belt must be replaced according to SMS Job No. 13-342 (on separate order) if the damage patterns on the following pages are evident: J P1a-0010-13 1351/6Inspecting poly-V-belt Damage pattems ¢ Rubber lumps in rib base (C). © Dirt or stone deposits (0). © Flank wear (F, ribs are pointed - trapezoidal when new, E). © Strand showing through rib base (G, brighter spots). © Transverse cracks (H) in several ribs. => Maintenance Manus! GD supplement 5 - March 1983 1351771351 Inspecting poly-V-belt © Transverse cracks in ribs (H) andior rib chunking (J). © Strand (K) pulled out laterally or outer strands frayed (L). ¢ Transverse cracks (M) on back. 1351/8Inspecting poly-V-belt 1351 © Rib separated from belt (arrow). © On diesel engines, with 1st version tensioning lever bearing, check the following parts: Check pivot shaft (30) of tensioning lever (360) for tight seat (visual inspection) © When the pivot shaft is loose, the shaft collar ‘no longer rests against the timing housing cover (28). This is also recognized by misalignment of tensioning pulley. Check tensioning lever bearing for wear (visual Inspection) ‘© Tensioning lever bearing bushings are worn ut, resulting in considerable play between pivot shaft (30) and tensioning lever (360). Recognized by ited postion of tensioning pally. Replacing poly-V-belt ‘Torque specifications (Nm) Engine Viscofan clutch on coolant pump or bearing 103, 104,602, 45 body 603 Tensioning device mounting bolt (M 12) 19mm ___102, 103 75 17mm 102 80. Fan to viscofan clutch 103, 104 10 Se Maintenance Manual G)- supplement § - March 1989 1351/91 351 Inspecting poly-V-belt Special tools ©] Fp femaiea) | ausmsee) | (asasusaes)t (eran | (atest > 104 589 00 01 09] Engine 102 © Loosen screw (25) by 1/4-1/2 tum. ~~ RZ * Loosen tensioning device with tensioning nut (24) (turn counterclockwise) until poly-V-belt (27) i ee can be removed. © Check the pulley profiles and the tensioning > device for damage and dirt and replace it required (e.g. worn out tensioning device bearing bushing, dents in the pulleys, etc.). 1351/10Inspecting poly-V-belt ‘® On vehicles produced up to the middle of October 1986, slide adjusting pointer (22) to the loft until the tip of the pointer is above the first dividing line of the adjusting scale (arrow). © On vehicles produced as of the middle of October 1986, slide adjusting pointer to the left Until the tip of the pointer is above the thin line (A) of the adjusting scale. Installing poly-V-belt: Start in numerical sequence of belt routing diagrams at tensioning pulley (1) (for illustrations, refer to following pages). Note: Do not use belt wax or similar products. ‘© Check the seating of the poly-V-belt on the belt pulleys. © On vehicles produced up to the middle of October 1986, turn the tensioning nut (24) to the right until the tip of the adjusting pointer (22) is Positioned between the 8th and Sth index mark. '® On vehicles produced as of the middle of October 1986, keep turning tensioning nut to the right until the tip of the adjusting pointor is centered above the thick line (E) of the adjusting scale. © Tighten bolt (25) as follows: ‘Width between flats 19 mm. 75Nm ‘Width between flats 17 mm. {shouldered bolt) 80 Nm ==> Moinrenance Manust GD). supplement 5 - March 1993 1351/111351 Inspecting poly-V-belt Engine 102 Belt routing diagram on vehicles with power steering and A/C compressor Bolt length: 1980 mm 1 Tensioning puley 2 Crankshaft 3. AIC compressor 5 Generator 7 Power steering pump 8 Coolant pump Engine 103 © Loosen fan cover and place on fan. © On Model 201: remove radiator. © Onalll models unscrew viscofan clutch with fan. Remove fan cover. © For loosening and tightening of hex. socket screw, use special tool 103 589 01 09 00 and torque wrench 001 589 72 21 00. © Lock pulley by simultaneously engaging counterhold 103 589 00 40 00 in bearing bracket ‘notch and in hub bore. © Loosen screw (16) by about 1/4 to 1/2 turn. Release tensioning device with tensioning rut (6) (turning counterclockwise) until belt can be removed. © Check pulley profiles and tensioning device for damage and contamination, replace if required (e.g. worn out bearing points of tensioning device, dents in pulleys ete.). 135112Inspecting poly-V-belt 1 351 ‘© Turn adjusting pointer (219) to the right (seen from the front) and set adjacent to the 1st index mark (arrow), on vehicles as of 02,1988, set on the cast mark on the right (seen from the front). Installing poly-V-belt: ‘© Start in numbering sequence of belt routing diagrams, start with tensioning pulley (1) © Do not use belt wax or similar products. © Turn clamping nut (231) to the right until the adjusting pointer is positioned over the 7th index mark (arrow), on vehicles as of 2/88 over the left mark accordingly (seen from the front). © Tighten bolt (211) to 75 Nm (reference value). Note: Starting November 1986 the generator is installed with a lower collar screw 13 mm. When this collar screw is removed, the poly-V-belt can be loosened by swiveling the generator and can be tensioned to its original condition without loosening bolt (211). © Check if belt is correctly seated on pulleys. ‘© Insert and install viscofan clutch with fan cover. * When tightening hex. socket screw (tightening torque 45 Nm) apply counterhold to pulley. © To do this, insert counterhold at back of hub and engage simultaneously into holding groove of bearing bracket. ‘Then remove counterhold. “=> Maintenance Manual GA: supplement s - March 1993, 1351131 351 Inspecting poly-V-belt Engine 103 Belt routing diagram on vehicles with air conditioning compressor Bolt length: 2255 mm. 1 Tensioning pulley 2 Crankshaft 3 Compressor 4 Fon 5 Generator {6 Dotloctor pulley 7 Power steering pump 8 Coolant pump Engine 104 © Pull out locking pin (1) on fan cover. © Tum ring (2) to the left and remove. © Loosen screw (16) for approx. 1/4 to 1/2 tum, '® Loosen tensioning unit with tensioning nut (6) (turn counterclockwise) until the belt can be removed. © Check pulley profiles and tensioning device for damage and contamination and replace, if required (0.9. worn out bearing points of tensioning device, dents in pulley etc.) Install poly-V-belt: * Starting in numerical sequence of belt routing diagrams at tensioning pulley (1). Note: Do not use belt wax or similar products. 135114ig poly-V-belt © Set pointer (13) of tensioning unit to mark 2. ¢ Turn tensioning nut (5) downwards until adjusting pointer (13) is in alignment with mark 1 (arrow). '* Check seat of belt on pulleys. © Tighten screw (16) to 75 Nm. © Install ring of fan cover in reverse sequence. Engine 104 models 124, 129 up to 01/91 Belt routing diagram vehicles with air pump and with air conditioning compressor, Bolt length: 2445 mm; 6 ribs 1 Tonsioning pulley 2 Crankshaft 3 Air conditioning compressor 5 Fan 7 Air pump 8 Generator {9 Guide pulley, upper 10 Power steering pump 11 Coolant pump Engine 104 models 124, 129 starting 01/91, model 140 Bolt routing diagram vehicles with air pump and with air conditioning compressor, Bolt length: 2440 mm models 124, 129, 6 ribs; model 140 8 ribs 1 Tensioning puiley 2 Crankshatt 3 Air condoning compressor 5 Fan 7 Air pump 8 Generator ‘9 Guide pulley, upper 10 Power steering pump 11 Coolant pump > Maistenance Manual GD: supplements ~ March 1883 1351/151351 Inspecting poly-V-belt Engine 119 ‘* Pull locking pin from fan cover. ‘© Turn ring to the left and remove. © Loosen screw (16) approx. 1/4 to 1/2 turn. © Loosen tensioning device with tensioning nut (12) (turning counterclockwise) until the belt can be removed. ‘© Check pulley profiles and tensioning device for damage and contamination and replace, if required (0.9. worn out bearing points of tensioning device, dents in pulleys etc.). Installing poty-V-belt: '® In numerical sequence of belt routing diagrams, start with tensioning pulley (1). Note: Do not use belt wax or similar products. ‘© Sot pointer (19) of tensioning device to mark 1 ‘© Tum tensioning nut (12) clockwise until pointer (13) is in position 2. © Check that belt is seated correctly on pulleys. © Torque screw (16) to 100 Nm. ‘© Install fan cover in reverse order. 13 4 16 13: 2 16: 100Nm. 1351/16Inspecting poly-V-belt 1351 Engine 119 model 128 Bolt routing diagram Belt length: 2523 mm; 6 ribs 1. Tensioning puley 2. Crankshaft 3. AIC compressor 5.Fan 7. Air pump 8. Generator 10. Power steering pump 11. Coolant pump Engine 119.970 model 140.051 119.971 model 140.042 119.974 model 124.036 119.975 model 124.034 Belt routing diagram Bolt length: 2460 mm; 8 ribs 1. Tensioning puiley 2. Crankshaft 3. AC compressor 5. Fan 7. Air pump 8. Generator 10. Power steering pump 11. Coolant pump Engine 120 © Remove cooling fan (job no. 20-3128) © Using 15 mm wrench, swing tensioning roller (1) aside in direction of arrow up to stop and no further so that belt can be removed. Check pulley profiles and tensioning device for damage and contamination and replace, if required (0. worn out bearing points of tensioning device, dents in pulleys etc.) AS Maimtenance Manual GD). supplement § - March 1999 1351/171351 Inspecting poly-V-belt Installing poly-V-belt: In numerical sequence of belt routing diagrams, start with tensioning pulley (1). Note: Do not use belt wax or similar products. ‘© Pretension tensioning pulley (1) and install, bolt over pulley (1). Check that belt is seated correctly. Note: ‘When the belt length and tension are correct the positioning mark (P) will be within range (A). © Reverse procedure to install. Engine 120.980 Model 140.056/57 Belt routing diagram Belt length 2585 mm 8 ribs Tensioning pulley Crankshaft [AIC compressor Fan Ar pup Generator Guide pulley, upper Power steering pump ‘Coolant pump 136118Inspecting poly-V-belt 1 351 Engine 601, 602 and 603 (On engine 601, loosen fan cover and place on fan. Unscrew fan and remove with fan cover. ‘On engine 602.911 in model 201 with one piece fan cover, remove radiator. On engine 602 in model 201 with two piece fan shroud, pull locking pin (1) and turn ring (2) to the left. to open shroud and remove. Place ring on fan. Pull out shroud body (8) and remove ring. (On engine 602 In model 124, loosen fan cover and place on fan. Unscrew viscofan clutch with fan and remove with fan cover. To loosen and tighten hex. socket screw of viscofan clutch, use screwdriver insert 103 589 (01 09 00 and counterhold 603 589 00 40 00. == On engine 603.96 (TURBO), the viscofan — clutch cannot be removed without removing the radiator. '* Loosen tensioning device (vehicle tool or conventional tool): © Unscrew nut (378). © Insert a lever (12 - 13 mm dia., approx. 300 mm long) or wheel nut wrench from vehicle tool set into hole on spring tensioning lever (374). Push lever slightly to the left until screw (375) can be pushed back in direction of intake manifold. © Loosen draw spring (380) by swiveling lever to the right. © Push back tensioning pulley and remove poly-V-belt. © Check belt pulley profiles and tensioning device for damage (such as worn out pivot points of tensioning device, dents in pulleys, etc.) and contamination and replace, if necessary. > maintenance Manual GA). supplement § - March 1999 1351191351 Inspecting poly-V-belt Installing poly-V-belt: © Do not use belt wax or similar products. © Slightly pull up tensioning pulley. Make a (oop in the poly-V-belt with the V-grooves facing outwards, and slip between coolant pump pulley and crankshaft pulley. ‘® Push poly-V-belt firmly against coolant pump pulley and turn pulley counterclockwise (arrow) Until the poly-V-belt is adjacent to tensioning pulley. '® Position poly-V-belt on tensioning pulley and ‘on crankshaft pulley. Then turn free portion of poly-V-belt around and position on air conditioning compressor, power steering pump, coolant pump and generator pulleys. ‘© Tension poly-V-belt and screw on tensioning device. 1351/20Inspecting poly-V-belt 1351 '* Check seat of poly-V-belt on belt pulleys. © On engines 601, 602, 603.91 in model 124, install fan or viscofan clutch with fan and fan cover. © On engine 601, torque fan mounting screw to 28 Nm. © Torque viscofan clutch mounting screw to 45 Nm. When tightening use counter hold 603 589 (00 40 00. ‘© On engine 602.911 in model 201 without two piece fan shroud, install radiator. Bolt routing diagram for vehicles with power steering and automatic climate control Belt lengths: Engine 601: 2120 mm Engine 602: 2100 mm Engine 603.96: 2145 mm Engine 603.970: 2120 mm 1. Tensioning pulley 2. Crankshatt 3, AG compressor 5. Generator 7. Power steering pump 8. Coolant pump 44@> Maintenance Manust GD: supplement § - March 1993, 1361/21Checking intake/exhaust manifold seating 1 470 Check that all fasteners on intake manifold, boost air pipe, and exhaust manifold are tightened securely, and ratighten, if necessary. On vehicles with turbocharger, remove air fiter for access. Engine 616 617 A> Maintenance Manuel GD - supplement 1 - Dec. 1989, 147011Replacing oxygen sensor Model 123 Disconnect oxygen sensor connector (arrow). Loosen oxygen sensor wire retaining clips. Unscrew oxygen sensor (16). Apply lubricating paste Part no. 000 989 88 51 to threads of new oxygen sensor. Install oxygen sensor and torque to approx. 50-60 Nm. Remove oxygen sensor warning lamp bulb. Model 107, 126 Se Maintenance Manusi GD). Supplements - March 1998 (On model 107, push connector upward out of bracket (arrow) and disconnect. 1480 Engine 102 103 110 116 117 1191480 © On model 126, remove bracket (arrow) and push coupling upward, then disconnect. Remove oxygen sensor wire from retaining bracket. © Unscrew oxygen sensor. © Apply lubricating paste, part no. (000 989 88 51, to threads of new oxygen sensor. © Install oxygen sensor and torque to approx. 50-60 Nm. ‘Install bracket on model 126, and press wire into retaining strip. © On 1981-85 models only, romove oxygen sensor warning lamp bulb. Replacing oxygen sensor 1480/2Replacing oxygen sensor Model 124, 201 © Separate oxygen sensor connector (arrow) and sensor heater connector on right side of vehicle interior. © Push wire and grommet out through floor pan from inside. © Remove shield (arrow). © Unscrew oxygen sensor. © Apply lubricating paste, part no. 000 989 88 51, to threads of new oxygen sensor. © Install oxygen sensor and torque to approx. 50-60 Nm. On 1984-86 model 201 only (except 201.034), remove oxygen sensor warning lamp bulb. Model 129 ‘© The oxygen sensor connector (G3/2x1) is secured to the right side of the transmission tunnel. © Tum connector nut counterclockwise and separate connector. => Maintenance Mansi GD: supplement s~ March 1983 1480/31480 * Unscrew oxygen sensor. ‘© Apply lubricating paste, part no. 000 989 88 51, to threads of new oxygen sensor. ‘© Install oxygen sensor and torque to approx. 50-60 Nm. Model 201 with engine 102 California starting model year 1992 * Disconnect oxygen sensor heater coil connector (G3/2x1) and oxygen sensor signal connector (G3/2x2). © Unscrew oxygen sensor. ‘© Apply lubricating paste, part no. 000 989 88 51, to threads of new oxygen sensor. © Install oxygen sensor and torque to approx. 50-60 Nm. Replacing oxygen sensorReplacing oxygen sensor 1480 Maintenance note: The oxygen sensor must be replaced when the warning lamp illuminates for the first time at 60,000 +250 miles. After replacing the sensor, the warning lamp may be switched off via the button (arrow) on the oxygen sensor replacement indicator control module (N44/1).. The button must be pressed for longer than 2 seconds to turn off the lamp. In ignition/starter position “2”, the lamp remains lit even after resetting the control module. The lamp will only 40 out after the engine is started (circuit 61 recognition). The previously recorded mileage remains stored. The warning lamp will luminate for a second time at 120,000 miles. Note: ‘After the 120,000 mile indication, the on-off ratio, should be checked, and the oxygen sensor only replaced if necessary. {f the oxygen sensor is replaced outside of the interval limit, the oxygen sensor replacement indicator control module (N44/1) must be replaced. Starting model year 1993, the control module can be reset as often as needed. <$S> Maintenance Manuat GA). supplement §- March 1983 1480/5Check spark plugs, replace if necessary 1 550 All gasoline engines Special tools On engine 110 (illustration), blow out spark plug wells in cylinder head before removing spark plugs. Remove spark plugs and check for deposits on electrodes. If deposits are present, replace spark plugs. no deposits are present, regap spark plugs to specification. Install spark plugs and torque to 25-30 Nm. <> Maintenance Manuat GD. supplement t- Dec. 1989 1550/1Replacing sparkplugs 1 580 Gasoline engines Torque specifications Nm ‘Spark plugs with taper seat 10-20 Spark plugs with gasket 25.30 Special tools: | | AT mana) [wmnen) [maar] lwanna) [rman Engines 102.983, 104, 119 ‘© Remove spark plug valley cover. All engines © Twist spark plug connector slightly and pull off using special tool 103 689 00 37 00. © Blow out recesses with compressed air. A& Maintenance Menus! GD) - supplement s - March 1983 1580/1158! (0 Replacing sparkplugs wv A fat goat (A) tapered seat (8) © fat sat (©) CFI fuel Injection Motor Spark plug seal ‘Spark plug wrench 102, 103 Tapered seat (8) 102 589 01 09 00 104, 119 Flat seat © 120 589 02 09 00 1) 116, 117 Flat seat (a) 117 589 00 09 00 1) Insert Commercially available torque wrench LH-SFI fuel injection Motor Spark plug seal Cylinder Spark plug wrench 104 Flat seat © all 119 589 01 09 00 119 Flat seat © 4-8 and 6-7 120 589 02 09 00 1) 4and 8 119 689 01 09 00 120 Flat seat ©) 4-6 and 7-12 120 689 02 09 00 1) 6 119 689 01 09 00 4) Ingen commercially avaiable torque wrench 1580/21580 Replacing sparkplugs ‘Spark plug cover, removal and installation Engine 104 HFM-SFI Remove air cleaner crossover duct, ignition cable cover (6/1), and guide rail (5/2). Installation is in the reverse order of removal. Ignition colls, removal and installation Engine 104 HFM-SFI Remove ignition coils and cables with associated wiring. Installation is in the reverse order of removal. Partial removal of wiring condult Engine 120 Pull weatherstripping off partially. Remove covers for ignition control module (A) and for wiring harness (B). Remove screws for wiring conduit Disengage wiring conduit and push forwards. jing cover, pissin > Maintenance Manust @) + supplements - March 1993 1580/3Checking coolant level/antifreeze protection 2010 All models ZS warninet Open expansion tank/radiator cap only at coolant temperatures below 90°C. Specified coolant mixture: (Antifreeze protection to approx. -37°C) 50% water 60% antifreeze and anti-corrosion protection. Do not use additives. ‘Check concentration of antitreeze/anti-corrosion protection. Top up only on separate order. The corrosion protection/antifraeze protection should not drop below 40% by volume (corresponding to antifreeze protection to approx. -25°C), since with too low a proportion, corrosion protection becomes inadequate. Use only approved antifreeze. Refer to Factory Approved Service Products list. ‘* With coolant loss not caused by normal use determine the cause and repair on separate order. © Opening: Turn cap only to first detent to release excess pressure. ‘* Tum cap to second detent and remove cap from expansion tank radiator. => Moitenance Manust GD + supplement 5 - March 1993 2010/1201 0 Checking coolant level/antifreeze protection Coolant level should be as follows: '* With cold coolant, up to mark on tank (arrow). ‘© With warm coolant approx. 1 cm above mark. * On vehicles without separate expansion tank, up to marks as illustrated. Ss} SN costs Vehicles without coolant reservoir A Filing mark B Coolant warm © Coolant cold 20102Checking coolant level 2011 AS Warnings Open the expansion tankiradiator cap only at coolant temperatures below 90°C. © Opening: Turn cap only to first detent to release pressure. ‘© Turn cap to second detent and remove cap from expansion tank/radiator. Coolant level should be as follows: © Up to mark printed on tank (arrow). © With warm coolant approx. 1 cm above this mark. ‘I coolant loss is excessive, determine the ‘cause and repair on separate order. Model 107 starting 08.1985 124 126 starting 09.1985 129 140 201 starting 01.1985 > Maintenance Manual GD). supplement ¢- March 1982 20111Checking cooling and heating system 2050 Special tools Commercial tools 7 mm hex. socket wrench on flexible drive for worm drive hose clamps. Model107 up through 07.1985 123 126 up through 08.1985 201 up through 12.1984 obtain locally Warning! Perform leak test on cold engine only! Check hoses for porosity, hardening, swelling, cracks or chafing marks and correct routing. Replace defective hoses. © Apply pressure of 1.0 to 1.3 bar gauge to cooling system. © Check all hoses and connections for leakage. ‘© Retighten hose clamps, if required. Replace corroded hose clamps. ‘© Replace a corroded radiator/expansion tank cap. 2S Maintenance Menus! GD). supplement 2- Feb. 1991 2050/1Replacing coolant 2080 All models On separate order Total capacity of cooling system and ratio of antifreeze to water in liters Model Engine Total capacity of | Antifreeze Antifreeze cooling system | protection protection incl. heater to -37°C to -45°C (60 Vol. -%) (65 Vol. -%) age 116.96 125 6.25 7 117.96 13.8 6.75 78 ten) 110, 616 10 5 55 617.91 1" 55 6 617.95 125 6.25 7 ta 103, 104, 602.96 95 475 5.25 119 16.6 7.76 as 603.96 10 5 55 de 103 8 4 44 116.96 126 6.25 75 117.98 13.5 6.75 75 603.96/97| 10 5 85 617.95 12 6 65 ie 104 15 5.75 63 119 16 75 8.25 120 155 7.75 85 ‘&> ttrnenance Marunt @ + supplements ~ March 1988 208012080 Replacing coolant Model Engine Total capacity of | Antifreeze Antifreeze cooling system | protection protection incl. heater to -37°C to -45°C (60 Vol. -%) (65 Vol. -%) i) 104 145 7.25 8 119.970/971 16.5 8.25 9 120 18.5 7.78 10.25 603.98 10 5 55 at 102.961/985 85 4.25 475 601.921 103.942 95 476 5.25 102.983 8 4 45 602.911/961 Torque specifications (Nm) Radiator drain plug, model 107 (w/o light alloy radiator) 6-10 Radiator drain plug, model 107 (w/ light alloy radiator), 1.52 1) model 123, 124, 126, 129, 201 1) This torque can be achieved using a washer or coin.Replacing coolant 2080 Coolant Coolant composition 50% by volume of water 50% by volume of corrosion protection/antifreeze agent. Water Use clean water that is not too hard. Usually, though not always, tap water meets these requirements. The dissolved substances in the water can contribute to corrosion. If in doubt, have the water analyzed. Corrosion protectionvantifreeze Corrosion protection/antifreeze must provide the following: © Adequate corrosion and cavitation protection {or all components © Antifreeze protection © Higher boiling point. Approx. 50% by volume of antifreeze must bo added to the water. This concentration provides antifreeze protection down to approx. -37°C. A higher concentration is only practical with even lower ambient temperatures. Exceeding 55% by volume of corrosion protection/antifreeze agent reduces the antifreeze protection as well as the heat dissipating ability of the coolant. 55% by volume of corrosion protection/antifreeze agent proves antifreeze protection down to approx. -45°C. Corrosion protection/antifreeze increases the boiling point, i.e. the coolant does not vaporize as rapidly. At high coolant tomporatures, coolant boil over is avoided. Use only approved corrosion protection/antifreeze, Checking coolant In service Before the start of the cold season, check the coolant for antifreeze protection. In countries with high ambient temperatures, check corrosion protection/antifreeze concentration in coolant once a year. When refiling (after coolant loss), ensure that the coolant contains 50% by volume of corrosion protection/antifreeze (protection down to -87°C). The corrosion protection in the coolant diminishes during operation. The coolant then has a corrosive effect. ‘Thee coolant should be used for a maximum of 3 years. Before adding in new coolant, flush the old coolant from the cooling system. For draining and filling of coolant, see repair instruction 20-010. Disposal of coolant Old coolant must be disposed of according to local laws and waste water or environmental regulations. A> Watotenance Manust @ - supplements « March 19882080 Replacing coolant Engine block coolant drain locations, Engine 110 Right side of engine block to rear of engine mount bracket. Engine 116, 117, Right plug is forward of RH engine mount; left plug is forward of LH engine mount. 119 Engine 616, 617 _ Right side of engine block to rear of engine mount bracket, forward of starter. Engine block coolant drain, engine 102 Engine block coolant drain (170) with drain hose attached, engine 103, 104 Engine bock coolant drain, engine 120 208042080 lacing coolant Repl: Engine block coolant dain (12), engine 601Adjust engine stop, retorque engine mount bolts 2290.10 Engine 616 617 Torque specifications New Nuts (4) and bolts (6) of front engine stop 30 ‘Adjusting bolt (2) of front engine stop 130 Nut (1) at rear of engine stop (ref. value) 70 Bolts (14) on rear engine mount 20 ‘Adjusting bolt (11) on rear engine mount 30 Special tools 001 s89 66 21 00) 001 589 67 21 09] Locally fabricated tools Gauge for adjusting front engine stop <=> Maintenance Manust GD. supplement 1 - Dee. 1989 2290.10/12290.1 0 Adjust engine stop, retorque engine mount bolts Note: The vehicle weight must rest on the wheels. Torque or retorque all bolts and nuts to the specified torque with torque wrench except nut (1) on rear engine mount. On engine 617.91 loosening and retightening of bolts on front engine stop is not required. Front engine stop * Turn steering wheel to full lock either right or left \ Y} * Tighten bolts (6) and nuts) at front engine stop. When tightoning nuts (4) hold bolts (6) in position. ‘* Tighten nut (1) and bolts (14) on rear engine mount. * Lift lock (1) on front engine stop and move aside. Completely loosen adjusting bolt (2). Make sure that engine stop is not stuck to frame crossmember due to wax or paint. 2290.10/2Adjust en e stop, retorque engine mount bolts 2290.10 © Completely loosen adjusting bolt (11) on rear engine mount. © Place fabricated gauge (01) on front engine stop. ‘Shake engine from side to side by hand. Tighten adjusting bolt (11) on rear engine mount. ‘¢ Tighten adjusting bolt (2) on front engine ‘stop and secure with lock (1). ‘* Remove fabricated gauge. 1 2 Fear engine mount with engine stop Version: 4 & § cyinder models with automatic vansmission A> Maintenance Manual GD Supplement 1 - Dec. 1989 2290.10/3,Adjust engine stop 2291.10 Engine 616 617.91 Torque specifications Nm ‘Adjusting bolt (2) on front engine stop 130 ‘Adjusting bolt (11) on rear engine mount 30 Special tools Locally fabricated tools Gauge for adjusting front engine stop => Maintenance Mansi GD: supplement 1 - dec. 2291.10/12291 al (0) Adjust engine stop Front engine stop Note: The vehicle weight must rest on the suspension. ‘On engine 617.31 loosening and retightening of bolts on front engine stop is not required. © Tum steering wheel to full lock, either right or left. © Lift lock (1) on front engine stop and move aside. Completely loosen adjusting bolt (2). Make sure that engine stop is not stuck to frame cross member due to wax or paint. © Completely loosen adjusting bolt (11) on rear engine mount. © Place fabricated gauge (01) on front engine stop. © Shake engine from side to side by hand. \4 291.102Adjust engine stop 2291 | 0 ‘© Tighten adjusting bolt (11) on rear engine mount. ‘© Tighten adjusting bolt (2) on front engine stop and secure with lock (1). © Remove fabricated gauge. Rear engine mount with engine stop Version: 4 & 5 cylinder models with automatic transmission <=> Maintenance Manust GD. supplement 1 - De. 9 291.103Adjust engine stop, rear engine mount 2291 .20 Engine 103 in mode! 124 with 4MATIC Torque specifications (Nm) ‘Adjusting screw (140) on rear mount (reference value) 45 * Completely loosen adjusting bolt (140) on rear engine mount. © Start engine and depress gas pedal several times to rock engine to adjust engine stop. ‘¢ Tighten adjusting bolt (140) on rear engine ‘mount to 45 Nm. => Maintenance Manust GD + supplements - March 1983 2291.20/1Checking clutch disk for wear 2551 Models 123 124 129 201 Special tools 115 589 07 23 00) Insert slip gauge as far as possible between clutch housing and slave cylinder and note position of notches (arrow) in gauge. If notches are not visible: Clutch disk wear is acceptable. W notches are visible: Wear limit of disk has been reached. Replace clutch disk. ‘Stave oyiinder ‘Shim botwoon slave cyinder and clutch housing ‘Actuatng rod ‘Sip gauge => Maintenance Manus! GB: supplement 1- Dec. 1989 2551/1Manual transmission oil change 2601 Model 123 124 129 201 Oil grades approved oil Refer to MBNA Factory Approved Service Products list Capacities in liters Transmission type Capacity 4-speed transmission 716.0 1.6 716.21 1.3 5-spoed transmission 717.40 1.6 717.41 1.5 717.43 1.5 717.45 17 Special tools 117 889 02 07 09) Commercial tools 14 mm hex. driver insert, 1/2" square drive obtain locally se> Hairtenance Manual GD supplement 3- Feb. 2601/12601 Manual transmission oil change Note: When performing this job number, the engine compartment lower panel or the noise encapsulation panel must be removed, and replaced after completing all maintenance work (efer to job number 6190 or 9400). Warning! To help prevent risk of injury when opening filler plug on model 201, wear leather gloves; place an extension on wrench; or open filler plug by striking wrench. ‘* Drain oil only with transmission at operating temperature; remove both oil filler plug and drain plug. Clean drain plug with magnet. * Install oil drain plug and torque to max. 60 Nm. © Fill oil up to over flow (upper arrow). Install oil filler plug and torque to max. 60 Nm. * Check transmission for leaks at operating temperature. Transmission 716.21Manual transmission oil change 2601 Transmissic ion 797.40, ‘Transmission 71741, 717.43, 717.48 > Maintenance Manual GD. supplement 2- Feb. 1991 2601/3Manual transmission, checking, correcting oil level 261 0 Oll grades ATF approved oil Refer to MBNA Factory Approved Service Products list Special tools 117 589 02 07 09) Commercial tools 14 mm hex. driver insert, 1/2" square drive Note: When performing this job number, the engine compartment lower panel or the noise encapsulation panel must be removed, and replaced after completing all maintenance work {refer to job number 6190 or 9400). Warning! To help prevent risk of injury when opening filler plug on model 201, wear leather gloves; place an extension on wrench; or opan filler plug by striking wrench. obtain locally = Maintenance Manual G+ supplement 3- Fe 1991 2610/1261 0 Manual transmission, checking, correcting oil level © Remove oil filer plug (upper arrow in figure). If a minimal amount of oil runs out or if the oil level is at lower edge of opening, oil level is correct. not, add oil. Install oil filler plug and torque to max. 60 Nm. If oil loss is excessive, determine cause and repair on separate order. ‘Transmission 717.40 ‘Transmission 717.41, 717.43, 717.45 26102Automatic transmission fluid and filter change 2702 All models Oll grades ATF Refer to MBNA Factory Approved Service Products list Capacities in titers Models with Transmission Full capacity Oil change 4- and 5-cylinder 7224 et a engines 2 722.3 73 62 (exc. 102.98, |722.4 66 55 602.96) (102.98, 7A 60 602.96) 6-cylinder engines 722.1 66 53 722.3 73 6.2 722.4 7A 6.0 722.5 73 62 G-cylinder engines «3.8, 1981-82 | 722.3 73 62 9.8, 1983-85 86 77 4.2, 6.0, 5.6 |722.0 8.9 79 722.3 86 77 12-cylinder engines 722.3 86 aw Torque specifications Nm Drain plug, torque converter 14 Drain plug, oil pan (transmission 722.3, 722.4, 722.5) 14 Bolts, oil pan’ Transmission 722.0, 722.17 Bolts, oll pan’ Transmission 722.3, 722.4, 8 7225 Bolts, front axle crossmember (model 126) 45 Note: On vehicles operating under severe conditions (e.9. taxi operation, primarily city ‘operation, trailer operation, or operation in mountainous regions), perform additional cil change (without fiter change) in between normal interval. Se Maintenance Manuel GD supplement 4 March 1992 2702112702 Automatic transmission fluid and filter change Special tools 126 589 12 63 09] Note: When performing this job number, the ‘engine compartment lower panel or the noise encapsulation panel must be removed, and replaced after completing all maintenance work (refer to job number 6190 or 9400). Caution! Perform fluid change with engine stopped and selector lever in P position. (On model 126, remove front axle crossmember (4), to gain access to torque converter drain plug. Bolts (22) are self-locking (micro-encapsulated) and should be replaced. * Remove oil pan drain plug (1) on transmission 722.3, 722.4, and 722.5 and drain fluid. ‘Turn crankshaft until drain plug (2) of torque converter is accessible through opening in vent grille. Remove drain plug and allow fluid to drain.Automatic transmission fluid and filter change * Disconnect filler pipe (8) (transmission 722.0 and 722.1) and drain fluid, * Remove pan (3). * Replace fiter (5). * loan pan (3) and install, torque bolts (7) on transmission 722.0, 722.1, to 7 Nm and transmission 722.3, 722.4, 722.5 to 8 Nm. ‘© Install pan drain plug (1) and torque converter drain plug (2) and torque to 14 Nm, © Model 126: Install front axle crossmember, torque bolts to 45 Nm. > Maintenance Manual GA). supplement - Dec. 1990 270232702 Automatic transmission fl lid and filter change * Install oil filler pipe (8) (transmission 722.0, 722.1). © Actuate parking brake. ‘* Insert funnel (050) into dipstick opening and, with engine stopped, fil in approx. 4 liters of fluid. Start engine and run in selector lever position P at idle. Gradually add remaining fluid. Move selector lever through positions R-N-D-N-R, pausing in each position for several seconds, then return to position P. © Correct fluid level (refer to job no. 2710). 2702/4Automatic transmission, checking, correcting fluid level 2710 ‘All models Oil grades ATE Refer to MBNA Factory Approved Service Products list Special tools a 112 589 00 72 09] 125 589 12 63 00) Note: Too low o too high a fluid level wil affect the operation of the transmission. The fluid level should be checked regularly with the dipstick from the engine compartment. When checking fluid level, vehicle should be parked on level surface. The fluid level varies with fluid temperature. The min, and max, marks on the dipstick are based on a fluld temperature of 80°C (transmission at normal operating temperature). However, at a fluid temperature of 20-30°C the ‘max. cil level will read below the min. mark as follows: ‘Transmission 722.0 30 mm 722.1 30 mm 722.3 10 mm 722.4 12 mm 722.5 10 mm Check © Apply parking brake. © Place selector lever in position P. © Run engine for 1 to 2 minutes. “4S Maintenance Manual GA): supplement - Feb. 1991 arto271 0 Automatic transmission, checking, correcting fluid level © Open latch (position A), pull out dipstick (6), wipe with lint free rag (leather is best). © Insert dipstick fully with latch open, and read fuid level. © After measuring or correcting fluid level, close latch (position B). | SAL Dipstck latch, wansmission 722.3, 722.¢, 722.5 ‘® With the transmission at operating temperature, the oil level should be at the ‘max. mark. 202Automatic transmission, checking, correcting fluid level 271 0 © Ata transmission fluid temperature of 80°C 20°C -30°C approx. 20-30°C, the fluid level should be below min. mark, depending on type of transmission (as shown). If fuid loss is excessive, determine cause and 722.0 repair on separate order. 7221 min. e27-0170-13 go°c 20°C -30°C Correcting fluld level ‘Add necessary amount of fluid through funnel (050) into dipstick tube with engine running. Note: The distance between min. and max. mark on dipstick is approx. 0.3 liter of transmission fluid. ‘After filing fluid to specified level, apply parking brake. Move selector lever through positions R- N-D-N-R, pausing for a few seconds in each position, and retum to P position, to ensure that the operating pistons of the servo members are filed with fluid. Recheck fluid level and correct, it necessary. > Maintenance Manual GA). supplement 3 Feb. 1991 27103271 0 Automatic transmission, checking, correcting fluid level If fluid level Is too low, the pump will draw in air, (which can be heard), causing foaming and leading to an Incorrect fluid level reading. Stop engine and wait until fluid is no longer foaming (approx. 2 minutes). Add fluid and check level. Be sure to drain or draw off excessive fluid, to avoid excessive churning of the fluid by the gears. This results in excessive temperature increase causing the foaming fluid to be forced out through the breather. Extended operation in this condition will cause transmission damage. The oil cooler flushing syringe (010) with the attached hose can be use to remove excessive transmission fluid. a0Transfer case fluid change 2801 Oll grades Model 124 with 4MATIC ATE Refer to MBNA Factory Approved Service Products list Capacity during fluld change Liters, ‘All models: approx. 0.6 Torque specifications Nm Oil filer and drain plug 50 Special tools 7 589 02 07 00) Commercial tools 14 mm hex. driver insert, 1/2” square drive obtain locally Note: When checking fluid level and changing fluid, the vehicle should be level Bofore fluid change, check transfer case for oaks © Remove shielding plate under transfer case. © Drain fluid with transfer case at operating temperature. Fill specified fluid quantity. © Check fluid level. Fluid level should be up to filler hole. “> Maintenance Manusi GD). supplement a- Feb. 1991 2801/1Transfer case, checking, correcting fluid level 281 0 Model 124 with 4MATIC Oll grades ATF Refer to MBNA Factory Approved Service Products list Torque specifications Nm Oi filler and drain plug 50 Special tools 117 589 02 07 00] Commercial tools 14 mm hex. driver insert, 1/2" square drive obtain locally Note: When checking fluid level, the vehicle should be level. © Remove filer plug. Note: If more than approx. 50 cc of fluid flows out of filler hole, the mult-dise clutches AV or ZS are leaking. Check oil level in hydraulic oil reservoir in engine compartment. Repair or replace transfer case. © The fluid level is correct, if a small amount of fluid flows out or if fluid level extends up to lower edge of opening. Wnot, add fluid. © Install filer plug and torque to 50 Nm. > Maintenance Manual GA). supplement 2 Feb. 1991 2Bt0/1Clutch system, checking, correcting fluid level 2910 Hydraulle clutch fluld Use specified brake fluid only Model 123 201 up through 12.1984 DoT 4 Check fluid level in reservoir and add fluid up to max. mark, if necessary. Clean vent opening in reservoir cover (refer to job no. 4210), Handle brake fluid with care. Store brake fluid only in containers, which make accidental consumption of fluid impossible (Fatal dosage 100 cc). Make sure that brake fluid does not contact painted surfaces of vehicle, since the fluid acts as a paint solvent, Brake fluid is highly hygroscopic, meaning it will absorb moisture from the air, as a result of which the fluid's boiling point is lowered. Brak fluid should only be stored in well sealed containers. Even minute quantities of mineral oil wil rasult in failure of clutch and brake systems. Special care should be taken with brake fluid that is colorless or dyed yellow, since here the risk of confusion is the greatest. Whenever mineral oil is found in the clutch and brake system, or if the presence of mineral oil is suspected, the entire clutch and brake system should be thoroughly flushed. At the same time, replace the master cylinders and all rubber components, including hoses, in hydraulic system. => tarenance Maruat GD: supplement 1 - Dee. 1868 2910/12950 Clutch system, inspect 201 up through 12.1984 Model 123, © Check master and slave cylinder for leaks (visual inspection). and hoses for leaks, chafe © Check lines marks, and damago. K€ aInspecting, lubricating throttle linkage 3022 ‘© Remove air cleaner. © Lubricate pivots of control shafts, control levers, throttle linkage joints and control cables using only ATF. Refer to MBNA Factory Approved Service Products list. ‘© Check control shafts, control levers, guide levers, ball sockets, bowden cable, and throttle linkage for smooth operation and possible wear. © During assembly jobs use corrosion protection grease, part no. 000 989 87 51 10. Note: On model 126 with engine 603.961 as of 1986, note 2nd version control linkage. On vehicles with electronic accelerator, the linkage should only be moved when the ignition, is off to avoid setting a Diagnostic Trouble Code in the control module memory. All engines Engine 103 Engine 104 CFL Ae Maintenance Manual GD - supplements - March 1999 3022/13022 Inspecting, lubricating throttle linkage Engine 176, 177 with ASR M Engine 116,117 3022/2Inspecting, lubricating throttle linka, 3022 Engine 119 CF Engines with LH-SFl-njection Engine 119 LH-SFI without sited lever Engine 119 LH-SF! wih sloted lever S2<> Martanance Manual GD + supplements ~ March 1983 Engine 120 3022/33022 Inspecting, lubricating throttle linkage Engine 104 HFM-SFI 9022/4Inspecting, lubricating throttle linkage 3022 Engines 601, 602 with manual vansmission Do not lubricate friction damper (arrow). Maintenance Manual GD + supplement § - March 1988 Model 126 Engine 603.961 staring 1st version 3022/53022 Inspecting, lubricating throttle linkage Model 126 Engine 603.961 starting 1986 Do not lubricate bearings indicated by arrows 2nd version, Engine 603.970 Engine 617Inspecting, lubricating throttle linkage 3022 Engine 616.912 staring 1982 with manual ransmission Engine 616.912 starting 1982 with automatic transmission <> ttartanance Manus! G+ supplements = March 1989 3022/7Checking and adjusting idle speed adjuster 3052 ‘© Turn idle speed adjuster knob on instrument panel fully to the right and check distance between adjusting ringinipple and shaped spring, adjust, if necessary. Distance should be approx. 1.0 mm, © With engine off, depress accelerator and turn idle speed adjuster knob to the left. © With engine running, idle speed should now be approx. 1100 rpm. Adjust with screw (2) if necessary. Engine 616 617.912 => Maintenance Manat G- Nov. 1988 3052/1Level control, ADS, ASD, 4MATIC, fluid level 3211 All models Special tools 126 589 12.63 00 ou Hydraulic fluid MB part no. 000 989 91 03/10 Refer to Factory Approved Service Products list Note: Check fluid level with engine off. Correct it necessary. With system in operating condition, the oil level should be between the MAX. and MIN. marks. With vehicle loaded the resulting oil level will be near the MIN. mark (or below on vehicles with ‘small reservoirs.) 44> Maintenance Manual GA supplement 4 March 1982 32t1/t3211 Level control, ADS, ASD, 4MATIC, fluid level Remove cap with integral dipstick front fluid reservoir. Read fluid level after wiping and reinserting dipstick Use filter funnel (060) to add fluid. Model 123, 126 (1st version up through 08.1985) Plastic fluid raservoir hid reservoir Cap with integral ipstok. Max. mark Min, mark FRetum line, level conto - reservoir. orepn Model 126 (2nd version as of 09.1985) Plastic fd raservoir 2 Flid reservoir 2a Cap with intogal dipstick 2 Max mark b Min. mark © Return ina, level contol - reservo. 32112Level control, ADS, ASD, 4MATIC, fluid level 3211 Mode! 124, 201 Plastic fid reservoir 2 Fhid reservoir 2a Cap with intogral dipstick. ‘mark Min, mark © Return tine, level contol - reservoir Model 124 with MATIC oF ASD 2 Fhid reservar 2a Cap with ntogal dipstick a ‘mark Min. mark 1. Return line, hydraule unit (connection T)-fuid reservoir E2_ Without lovel contr Faotum ine level contro Aud reservar Mode! 129 with with ADS andlor ASD 2 Fluid reservoir 2a Cap wit integra dipstick. a Max. mark b Min. mark AS Maintenance Manual @)- supplement 4 March 1992 3211/33211 Level control, ADS, ASD, 4MATIC, fluid level 9211/4Inspecting self-leveling suspension Model Visual inspection Hydraulic fluid pump Fluid reservoir Level controller Pressure reservoir Spring struts Line connections Check hoses and lines for chafing, dents, cracks, corrosion, and leaks (with engine running). Note: To check for leaks that may only occur when the vehicle is loaded, check vehicle with the engine running and with vehicle rear loaded with approx. 180 kg (or 2 persons). 3251 123 126 up through 08.1985 <> Maintenance Manual GD: supplement - pec. 1989 3251/1Front axle, checking, correcting oil level 3310 Model 124 with 4MATIC Oil grades Hypoid gear oil SAE 90 Refer to Factory Approved Service Products list Special tools 117 589 02 07 00 Commercial tools 14 mm hex. driver insert, 1/2” square drive obtain locally Note: When checking oil level and changing oil, the vehicle should be in horizontal position. When performing this job number, remove ‘engine compartment lower panel or lower half of noise encapsulation, and reinstall ater completing all maintenance jobs (refer to job ‘number 6190 or 9490). Remove oil filer plug. Hf a minimal amount of oil runs out or if the oil level is at lower edge of opening, oil level is correct. If not, add oil. Install filer plug, and torque to 50 Nm. {foil loss is excessive, determine cause and repair on separate order. D> Maintenance Manual GAD. supplement 9 Feb. 1991 3310/1