EXIT

Engine timing, valves 05

 EXIT

05 Engine timing, valves

Job No.
Camshaft and valves
...
Checking and replacement of hydraulic valve clearance compensating elements .......... 05-211
Checking camshaft timing ...................................... .......... 215
Removal and installation of camshaft .............................. .......... 220
Removal and installation of valve springs ............................ .......... 250
Checking valve springs ........................................ .......... 260
Replacing valve stem seals ...................................... .......... 270
Checking and machining valves. ................................. .......... 280
Replacing valve seat rings ...................................... .......... 290
Machining valve seats ......................................... .......... 291

Timing chain, chain tensioner, tensioning and slide rails

Removal and installation of chain tensioner ........................ . . ....... 310
Replacing timing chain ...................................... ....... 320
Removal and installation of tensioning rail ........................ ....... 330
Removal and installation of slide rails ............................ . . ....... 341
A. Removal and installation of slide rail (220) in cylinder head ......... .......

B. Removal and installation of guide rail (218) .................... .......

Drive for hydraulic oil pump

Removal and installation of drive for hydraulic oil pump. ...........,.,..,... ....... 437

05/l
 EXIT

05-211 Checking and replacement of hydraulic valve clearance compensating elements

Tightening torques Nm

Bolts for cylinder head cover 10

Bolt for camshaft timing gear 45

Bolts for camshaft bearing caps 25

Special tools

Torque wrench, double arm,

001 589 51 21 00
3/8 square, 8-32 Nm

Torque wrench with plug-in ratchet

001589662100
l/2 square, 25-l 30 Nm

Measuring bridge for residual stroke 601 589 08 21 00

Vacuum lifter for valve tappet 601589053300

Note

Store valve tappet in upright position only (open

end up).
185
Install removed valve tappets again at the same spot.

The basic position of valve tappets cannot be cor- 203

rected .

In the event of complaints about noise, perform the

following test jobs:

185 Camshaft
203 Valve tappet u 1053-11606

05.10-21 l/l
 EXIT

Checking

1 Run engine for approx. 5 minutes at 3000/min.

2 Remove cylinder head cover.

3 Set cam of respective valve tappet on base circle

(cam tip should point upwards).

4 Use a mandrel to push against valve tappet or try

to move valve tappet manually.

If, compared with others, the valve tappet drops

quickly, or in the event of play in relation to base
circle of cam, perform jobs item 6 and starting
item 8.

If a valve tappet has play, or if the sinking time is too

short, check basic position (item 5-7).

5 Measure and write down dimension X (cylinder

head parting surface to valve tappet). For this
purpose, place measuring bridge over valve tappet
about to be checked on cylinder head parting sur-
face.

Note: If required, measure dimension X on all

valve tappets.

6 Remove fan and fan cover.

7 Remove camshaft (05-220).

8 Measure dimension Y (cylinder head parting

surface to valve tappet).

The difference between dimension X and Y is

the initial stroke & installation position.

Nominal value: Value when new 0.25-l .6 mm,

value with used engine 0.25-2.5 mm.

05.10-21112
 EXIT

9 If valve tappet sinks quickly or if the nominal

dimension is not attained or exceeded, lift out valve
tappet by means of vacuum lifter.

10 Measure dimension L on valve tappet and

write down.

11 Measure dimension L 2 on valve tappet.

Dimension L I (difference between L and L 2)

should be 18-19 mm.

12 If dimension L 1 is higher or lower, remove

guide sleeve. For this purpose, pull guide sleeve (g)
out of valve tappet (203) by means of rotary move-
ments with pliers. Do not damage guide sleeve.

203 Valve tappet

a Thrust pin with ball
and cage
b Circlip
C Compression spring
9 Guide sleeve 105-26706

05.1 o-21 l/3

 EXIT

13 Pull thrust bolt (a) out of guide sleeve (g) and

remove compression spring (c).

14 Blow out all components with compressed air.

Blow through valve tappet at oil feed bore (arrow).

15 Remove circlip (b) from guide sleeve (g),

slightly rebend at edges (arrows) and mount again
on guide sleeve.

16 Assemble guide sleeve (g), compression spring

(c) and thrust pin (a) in correct sequence.

17 Fill thrust pin with engine oil. Press on ball

valve with a suitable pin and vent work chamber by
pumping movements of thrust pin, close ball valve
and add oil, if required. Then, no more oil should
flow out at ball valve under slight pressure.

If oil flows out, renew complete valve tappet.

18 Fill valve tappet (203) with engine oil and

install vented thrust pin with guide sleeve into
valve tappet.

Push guide sleeve into valve tappet until circlip

engages.

19 Check dimension L l, refer to item 9 and 10.

05.10-211/4
 EXIT

20 Check oil supply in cylinder head. For this pur-

pose, unscrew closing plug of oil duct on cylinder
head rear.

Blow with compressed air into oil duct, while check-

ing outlet bore on seat for valve tappet for passage.

21 Lubricate valve tappet and install, pay attention

to sequence.

22 Install camshaft (05-220).

23 Install cylinder head cover.

24 Install fan and fan cover.

25 Run engine at 3000/min.

05.10-211/5
 EXIT

05-215 Checking camshaft timing

Timing at 2 mm valve lift

Engine

601 11 17O 28 15O

1
with used timing chain (after approx. 20 000 km)

) The camshaft code number is stamped into collar adjacent to TDC notch.

Tightening torque Nm

Bolts for cylinder head cover 10

Special tools

Dial gauge holder 363 589 02 21 00

Box-end wrench element, open 14 mm, l/4 drive ( .

000589 77 0300
for coupling nut on injection line W1,004.1051011

Conventional tool

e. g_ Mahr, D-7300 Esslingen

Dial gauge A 1 DIN 878
Order No. 810

05.1 o-21 5/l

 EXIT

Note

During assembly jobs alignment of marks (arrows) in

ignition TDC position of 1st cylinder is adequate.

In special cases, e. g. in the event of complaints about

output, perform the following checkup with regard
to begin of opening at intake valve of 1st cylinder.

Timing is measured at 2 mm tappet travel.

Corrections are not possible at the moment.

Checking

1 Remove cylinder head cover.

2 Remove injection nozzles (07.1-230).

3 Turn crankshaft until cam tip of 2nd cam is

pointing upwards.

Attention!
Do not rotate engine on screw of camshaft timing
gear. Do not rotate engine in reverse while measuring,
since this would result in considerable measuring
faults.

4 Tighten dial gauge holder on cylinder head (above

1st cylinder intake valve).

5 Position dial gauge with extension and fasten in

such a manner that the sensor pin is seated on valve
tappet (arrow) under a preload of 3 mm (small needle
of dial gauge).

Turn dial of dial gauge until large needle points to

0.

Attention!
Sensor pin of dial gauge should be seated accurately
vertical on valve tappet.

05.10-215/2
 EXIT

6 Continue turning crankshaft in direction of

rotation of engine until small needle of dial gauge
has moved back by 2 mm (valve lift) to 1 mm.

In this position, the value on balancing disk should

be the same as the specified value intake valve
opens.

7 Install injection nozzles (07 l-230).

8 Install cylinder head cover.

05.10-215/3
 EXIT

05-220 Removal and installation of camshaft

Timing at 2 mm valve lift

Exhaust valve

rox. 20 000 km)

) The camshaft code number is stamped into collar adjacent to TDC notch.

Data

Camshaft code number 05

Permissible runout of center
bearing journal and of camshaft
Camshaft timing gear seat 0.020
timing gear seat when
2nd bearing point 0.030
mounting camshaft in outer
3rd bearing point 0.025
bearing points

when new 64-75

Scleroscope hardness of cams
limit value

Diameter of camshaft bearing journals 30,944-30,950

Tightening torques Nm

Bolts for cylinder head cover 10

Bolt for camshaft timing gear on camshaft 45

Bolts for camshaft bearing caps 25

Special tools

Torque wrench with plug-in ratchet,

001 589 66 21 00
l/2 square, 25-l 30 Nm

Torque wrench, double arm,

001 589 51 21 00
3/8 square, 8-32 Nm

Vacuum lifter for valve tappet 601 589 05 33 00

05.1 O-220/1
 EXIT

Note

The camshaft is a chill casting and mounted in five

bearings.

The diameter (D) of all five bearing points is 31 .O mm.

Groove (A) serves to locate the camshaft axially by

means of a circlip inserted in cylinder head.

A cyl. pin on collar (6) serves to locate the

camshaft timing gear.

A Groove for axial locating

z=
B Stop for camshaft z
P
timing gear and
mounting of cyl. pin
0 Bearing points
I :
BA

The code number is stamped into flange adjacent to

TDC notch (arrow).

TDC mark (arrow) and code number

Removal

1 Remove cylinder head cover.

2 Set crankshaft to ignition TDC of 1st cylinder.

Attention!
Do not rotate engine on fastening screw of camshaft
timing gear.

Do not rotate engine in reverse.

TDC mark on pulley

05.1 o-220/2
 EXIT

3 Remove chain tensioner (244) (05-340).

4 Mark camshaft timing gear and timing chain in

relation to each other.

5 Remove camshaft timing gear.

To loosen screws, apply counterhold on camshaft

with a mandrel.

6 On vehicles with level control, the camshaft timing

gear and the driver sleeve are fastened with a hex.
socket screw. Remove driver sleeve. For this purpose,
unscrew pressure oil pump and put aside with lines
connected.

7 Uniformly loosen all camshaft bearing screws and

remove camshaft bearing caps. l-

Note: To prevent tilting of camshaft under influence

of spring-loaded valve tappets, loosen camshaft
bearing screws and unscrew uniformly.

05.10-220/3 46 43
 EXIT

8 Remove camshaft in upward direction.

84
188 /

187

190

Cylinder head
ii:
185
Camshaft bearing bracket
Camshaft
189q

186 ;ir;lg,,r axial locating

187
188 Camshaft timing gear
189 Washer
190 ScrewMlOx50

9 Remove circlip for axial locating (186) camshaft

longitudinal alignment and check for condition.

10 Pull out valve tappet by means of vacuum lifter

601 589 05 33 00.

11 Check valve tappet for condition (visual checkup)

and renew, if required.

Note: Install valve tappets at the same spot where

they were installed before.

Installation

Note: If a new camshaft has been installed or if the

cylinder head has been machined, check camshaft
for easy operation.

12 Insert circlip for axial locating (arrow) in

cylinder head.

13 Lubricate camshaft and place into cylinder head

(without valve tappets).

14 Position camshaft bearing cap and tighten uni-

formly to 25 Nm. Pay attention to identification of
bearing caps.

05.1 O-220/4
 EXIT

15 When checking for easy operation, the camshaft

can be rotated by means of a hex. socket screw
M 10 x 30, which is screwed in through camshaft
timing gear instead of fastening screw.

If the camshaft can be rotated with an effort only,

proceed as follows:

01 Hex. socket screw M 10 x 30

Loosen camshaft bearing caps individually. Then turn

camshaft as required.

Repeat until tight bearing point has been found.

Remove camshaft and measure respective bearing

point. Nominal 0.050-0.81 mm.

Check camshaft for runout.

16 Lubricate valve tappets and insert. Pay attention

to sequence.

17 Lubricate camshaft and place into cylinder head,

pay attention to circlip (186).

1054 -13481

18 Install camshaft bearing caps.

Note: Be sure to tighten camshaft bearing caps uni-

formly, so that the camshaft is not loaded on one
side only under influence of valve tappet counter-
pressure.

05.1 o-22015
 EXIT

19 Mount camshaft timing gear. Pay attention to

color marks.

Tighten fastening screw for camshaft timing gear to

45 Nm. For this purpose, apply counterhold to cam-
shaft timing gear by means of a screwdriver or steel
pin.

20 Install chain tensioner.

21 On vehicles with level control, mount pressure

oil pump and driver.

22 Set engine to ignition TDC of 1 st cylinder and

check marks (arrows).

23 Mount cylinder head cover.

24 Run engine, check for leaks.

05.10-220/6
 EXIT

05-250 Removal and installation of valve springs

Tightening torques Nm

Bolts for cylinder head cover 10

Screw for camshaft timing gear 45

Screws for camshaft bearing caps 25

Special tools

Torque wrench, double arm,

001 589 51 21 00
3/8 square, 8-32 Nm

Torque wrench with plug-in ratchet,

l/2 square, 2 5 - l 3 0 N m 001 5 8 9 6 6 21 0 0

Vacuum lifter for valve tappets 601589053300

Supporting bridge for valve spring depressor 601 589 02 59 00

Valve spring depressor for valve springs 601 5890261 00

Assembly board for clamping

601 589 01 59 00
cylinder head

Magnetic lifter for valve cone halves 116589066300

05.1 O-250/1
 EXIT

185
203
202
Valve arrangement intake side

70 Cylinder head
73 Valve seat ring intake
75 Valve guide intake
77a Oil duct
78 Core hole cap
Camshaft bearing bracket
:: Hex. screw M 8 x 45
84a Washer
185 Camshaft
195 intake valve
197 Thrust ring
197a Locking ring
198 Valve spring
200 Valve stem seal intake
201 Valve spring retainer
202 Valve key
1053-11524
203 Valve tappet

Valve arrangement exhaust side

70 Cylinder head
Valve seat ring exhaust
;: Valve guide exhaust
77a Oil duct
Camshaft bearing bracket
ZI Hex. screw M 8 x 45
84a Washer
185 Camshaft
196 Exhaust valve
197 Thrust ring
197a Locking ring
198 Valve spring
199 Valve stem seal exhaust
201 Valve spring retainer
202 Valve key
203 Valve tappet
1053-1152311

Note

Each valve has a single progressively acting valve

spring (198).

For this reason, install spring only with color marks

below.

Color marks:
yellow/green or purple/green

05.1 o-250/2
 EXIT

A thrust ring (197) inserted under valve springs is

supported at cylinder head via torsion lock naps.

Similar to all engines, the counterbearing of the valve

springs in upward direction are in the shape of valve
spring retainers (201), which are fastened to the
valves by means of valve cone halves (202).

With cylinder head removed, the valves can be

removed as follows:

Clamp cylinder head with 4 cylinder head screws on

assembly board 601 589 01 59 00.

Fasten supporting bridge 601 589 02 59 00 to

cylinder head and remove valve springs by means of
valve spring compressor and magnetic lifter.

Note: Install valve tappets again at the same spot

from which they were removed before.

Removal

1 Remove camshaft (05-220).

2 Remove chain tensioner (05-310).

3 Remove fan and fan cover.

4 Lift out valve tappets with vacuum lifter.

5 Set piston of respective cylinder to ignition TDC.

Note: For rotating engine, lift timing chain so that

chain cannot be pulled in downward direction.

The pistons are in TDC position when the following

marks are under TDC indicator (arrow).

Mark Piston at TDC

TDC 1 and 4
180 (notch) 2 and 3

05.1 O-25013
 EXIT

6 Fasten supporting bridge for valve spring depres-

sor on cylinder head.

7 Push valve spring retainer down by means of valve

spring depressor.

8 Remove valve cone halves with magnetic lifter.

9 Remove vale springs and valve spring retainers.

10 Check valve spring (05-260).

Installation

11 Install valve spring with color dots in downward

position.

12 Lubricate valve tappets and install, pay attention

to sequence.

13 Install camshaft (05-220).

14 Install chain tensioner (05-310).

15 Mount cylinder head cover.

16 Install fan and fan cover.

05.1 O-25014
 .............................................
............................................ .......................................... ...................
EXIT

05--260 Checking valve springs

Valve spring data

Part No. Color code OD Wire Length Spring force with preloaded
dia. unloaded length when new limit value
mm mm mm N N

yellow/green
601 0 5 3 01 2 0 or 33.2 4.25 50.8 27 720-770 648
purple/green

Checking

1 Check valve springs with a valve spring tester or

a spring test scale.

2 Check spring force at specified length.

3 If less than limit value, renew valve springs.

05.1 o-260/1
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05-270 Replacing valve stem seals

Tightening torques NM

Bolts for cylinder head cover 10

Screw for camshaft timing gear 45

Screws for camshaft bearing caps 25

Special tools

Torque wrench, double arm,

001 589 51 21 00
318 square, 8-32 Nm

Torque wrench with plug-in ratchet

001 589 66 21 00
l/2 square, 25-l 30 Nm

Vacuum lifter for valve tappets 601 589 05 33 00

Support bridge for valve spring depressor 601 589 02 59 00

Valve spring depressor for valve springs 601 589 02 61 00

Magnetic lifter for valve cone halves 116589066300

Assembly mandrel for valve stem seal

601 589024390
intake and exhaust

Valve sealing pliers 000 589 53 37 00

05.1 O-270/1
 EXIT

Note

The valve stem seals are supplied as a repair kit.

Different valve stem seals are installed during series

production, refer to drawings.

All versions are made of the same elastomere

material.

I Ds are different according to valve stems.

199 Valve stem seal exhaust

200 Valve stem seal intake

Another version is externally the same for intake or

exhaust valves. They differ at ID and on wire rings,
which are phosphated (black) on the versions
named above and high-polish galvanized (yellow)
at exhaust valve.

Valve stem seal

Renewing

1 Remove valve springs (05-250).

2 Pull off valve stem seals with pliers

000 589 53 37 00.

Attention!
Do not damage valve stem and valve guide.

05.1 O-270/2
 EXIT

3 Deburr valve stem on groove (arrow).

4 Renew dented valve cone halves, spring retainers

and thrust rings.

5 Lubricate valve stem seal and press on with

assembly mandrel 601 589 02 43 00.

For this purpose, be sure to place an assembly sleeve

(included in repair kit) on valve stem.

6 Install valve springs (05-250).

05.1 O-270/3
 EXIT

OS-280 Checking and machining valves

Data

Engine Height h of Adjusting

valve disk angle ,,a for 1 iTiedia. 1 z:, 1 %f~~~ 1 E$:h
when new limit value machining valve

Intake valve

601 37.90 - 0.5-0.7 45 + 15 7.970 with without 106 --L- 5

38.10 7.955 106.3

Exhaust valve

Conventional tools

e. g. Krupp, D-5309 Meckenheim

Valve cone grinding machine Model VS
or
valve cone machining tool e. g. Hunger, D-6000 Miinchen 70
Type VKDR 1, order No. 203.00.200

Identification on stem end

Engine Intake valve Exhaust valve

601 E 601 02 A 601 02

195 Intake valve

196 Exhaust valve

05.1 O-280/1
 EXIT

Checking and machining

1 Clean valves and check visually. h

Renew valves with burnt valve disk, with insufficient

height h of valve disk and with worn or scored
valve stem.

2 Measure runout on valve stem. If runout exceeds

0.03 mm, renew valve.

3 Machine valve seat.

Pay attention to operating instructions of machining

unit and adjusting angle 45+ 15.

4 Measure runout on valve seat and height h of

valve disk.

Renew valve, if limit values are not attained.

05.1 O-280/2
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05-290 Replacing valve seat rings

Data

Intake Exhaust

Overlap of valve seat rings in cylinder head 0.068-O. 100

40 .ooo 37 .ooo
Normal dimension -
40.016 37.016
D 2
Repair stage
max. up to

40.100 37.100
Normal d i m e n s i o n ____
40.084 37.084
D ~-
Roughing dimension
Repair stage

33.400 30.400
Dl
33.600 30.600

Normal dimension 6.97 6- . 9 7-

H
and repair stages 7.00 7.00

9.35
t
9.25

2.37 2.44
t l
2.25 2.25

Special tools

Check plug 8 m m dia. for intake valve guide 102 5 8 9 0 0 2 3 0 0

now-WV
Check plug 9 mm dia. for exhaust valve guide 117589032300

05.10-290/l
 EXIT

Conventional tools

e. g. Hunger, D-8000 Miinchen 70

Cylinder head clamping device
Order No. 221.60.000

e. g. Hunger, D-8000 Miinchen 70

Ring seat turning tool, size 2
Order No. 220.03.110

e. g. Hunger, D-8000 Miinchen 70

Valve seat machining tool, type VDSNL l/45/30
Order No. 236.03.308

e. g. Hunger, D-8000 Miinchen 70

Test set for valves
Order No. 2 16.93.300

Internal measuring instrument e. g. Mahr, D-7300 Esslingen

(measuring range 25-60 mm) Order No. 844

External micrometer e. g. Mahr, D-7300 Esslingen

(measuring range 25-50 mm) Order No. 40 S

Note

For all valve seat ring versions each spare part is a

repair valve seat ring with a larger OD.

Renewing

1 Unscrew old valve seat ring with ring seat turning

tool.

Pay attention to operating instructions of turning

tool.

2 Check valve guides and renew, if required

(05-285).

05.10-290/2
 EXIT

3 Measure basic bore D 1.

A new normal dimension valve seat ring can be used

if the specified overlap is available.

If the minimum overlap is not attained, machine

basic bore for valve seat ring.

4 Machine basic bore D 1 with ring seat turning

tool until the bore is just clean.

5 Measure machined basic bore.

6 Machine repair stage valve seat ring in such a

manner that the specified overlap is obtained.

7 Heat cylinder head in water bath to approx.

80 C.

8 Undercool valve seat ring with liquid nitrogen.

9 Knock in valve seat ring with a suitable guide

mandrel.

10 Machine valve seats (05-291).

05.1 O-290/3
 EXIT

05-291 Machining valve seats

Data

Intake Exhaust

Valve seat width b

Valve seat angle Q 45O

Correction angle at top P 15O

Correction angle bottom y 60

\, 11
Permissible
out-of-true 0.05
of valve seat

Valve distance to cylinder head parting surface

Minimum distance a with new valves

Intake/Exhaust -0.1 to -0.5
and new valve seats

Max. distance a with Intake

refinished valve seats and
reground valves Exhaust

The max. distance is reduced by the same dimension by which the cylinder head parting surface has been
refinished.

Intake
38.10
Valve disk dia.
Exhaust 34.90
35.10

Special tools

Check plug 8 mm dia. for intake valve guide 102589002300

Check plug 9 mm dia. for exhaust valve guide 117589032300

05.10-291/l
 EXIT

Conventional tools

e.g. Hunger, D-8000 Miinchen 70

Cylinder head clamping device Order No. 221.60.000

Valve seat machining tool, e. g. Hunger, D-8000 Miinchen 70

type VDSNL l/45/30 Order No. 236.03.308

e. g. Hunger, D-8000 Miinchen 70

Test set for valve seats Order No. 216.93.300

60 correction bit No. 13 e. g, Hunger, D-8000 Miinchen 70

for correction angle, bottom Order No. 216.64.622

Note

Clamp cylinder head into clamping

device for disassembly and
machining.

Machine valve seats with valve seat

machining tool, with valve seat
grinding machine or with valve
seat milling cutter.

Machining valve seats

1 Check valve guides and renew, if required.

05.10-291/2
 EXIT

2 Machine valve seat (4515) (refer to operating

instructions of tool manufacturer).

Attention!
Loosen pilot only after runout of valve seat has been
checked (item 3).

3 Check runout of valve seat.

For this purpose, slip fitted sleeve (19) with dial

gauge holder (20) and dial gauge on pilot (5).

5 Pilot
18 Dial gauge
19 Fitted sleeve
20 Dial gauge holder -

4 Measure valve seat width (b) and, if required,

correct at top (0) with 15 and below (y) with 60.

5 Insert valves and measure distance a.

If required, renew valve seat ring (05-290).

1054-11629

05.10-291/3
 EXIT

OS-31 0 Removal and installation of chain tensioner

Tightening torques Nm

Chain tensioner in cylinder head 80

Closing plug for chain tensioner 60

Note

Install chain tensioner in filled condition on prin-

ciple.

Suitably, completely renew chain tensioner com-

plained about.

The hydraulic chain tensioner is supplied with

pressure oil through an oil duct in cylinder head.

Check valve (227 and 228) and pressure limiting

valve (227 and 231). together with compression
spring (2301, will keep the contact pressure of thrust
pin (233) on tensioning rail approximately constant,
independent of engine oil pressure.

The filling pin (233a) contributes to faster venting

when filling in oil.

279 2yO 2p 2 3 3 2?2 277 2?6 234

225 Closing plug 233 Thrust pin

226 Aluminum seal 233a Filling member
A 25 x 30 234 Compression spring
227 Ball dia. 5 mm 235 Housing
228 Ball guide 236 Circlip B 16
229 Compression spring a Feed bore from
230 Compression spring cylinder head
231 Valve disk b To oil pan
232 O-ring

05.1 o-31 O/l

 EXIT

Removal

1 Unscrew chain tensioner (224).

Installation

2 Fill chain tensioner. For this purpose, set chain

tensioner with thrust pin in downward direction into
engine oil SAE 10, with the oil extending over
flange on hexagon. Press thrust bolt 7-10 times
slowly down against stop with the assistance of a
press or a column-type drill press.

Upon filling, compression of chain tensioner should

be possible very slowly and uniformly only, and
under considerable force.

3 Install chain tensioner with new sealing ring.

Thrust pin of chain tensioner should rest against

lug of tensioning rail.

224

215

156

215 Tensioning rail

224 Chain tensioner

05.1 o/31 o/2

 EXIT

05-320 Replacing timing chain

Tightening torques Nm

Bolts for cylinder head cover 10

Coupling nuts for injection lines (reference value) 1 O-20

Injection nozzles in prechambers 70+ 10

Special tools

Pressing-on tool 000 589 57 43 00

Torque wrench, double arm,

001 589 51 21 00
3/8 square, 8-32 Nm

Box-end wrench element, open, 14 mm, l/4 drive

000 589 77 03 00
for coupling nut on injection line

Note

A timing chain with connecting link is available for

repairs.

If only an endless timing chain is available, the

chain can be opened prior to installation (refer to
item 3).

During an engine overhaul, an endless timing chain

must be installed on principle.

Check sprockets for score marks and pitting.

Replacement part (repair timing chain with connect-

ing link)

Designation Part No.

Bushing chain with connecting link 001 997 16 94

Connecting link 000997 11 98

05.1 o-32011
 EXIT

Repair timing chain

The connecting link is held in place by a locking

spring.

The outer flanges are dyed blue.

,
The outer flange of connecting link is pressed on by
means of pressing-on tool 000 589 57 43 00.

Connecting link with locking spring 105-25310

Renewing

1 Remove injection nozzles (07.1-230).

2 Remove cylinder head cover.

3 Remove chain tensioner.

4 Remove fan and fan cover.

5 Cover chain box with a cleaning rag and cut

through both chain bolts on one link of timing chain
by means of a grinding wheel.

6 Connect new timing chain with connecting link to

old timing chain, while pushing out opened link
(Fig. item 6).

7 Slowly rotate crankshaft in rotating direction of

engine, while simultaneously pulling up the old
timing chain until the connecting link comes to rest
against uppermost point of camshaft timing gear.

Attention!
Timing chain should remain in mesh while rotating
camshaft and crankshaft timing gear.

8 Take off old timing chain and connect ends of

new timing chain with a connecting link.

For this purpose, secure chain ends with wire on

camshaft timing gear.

9 Insert connecting link from the rear into timing

chain (arrow).

Shown on engine 615

05.1 O-32012
 EXIT

10 Put separately enclosed outer flange of connect-

ing link (with punched in IWIS identification) into
pressing-on tool (arrow). The outer flange is held
magnetically.

11 Place pressing-on tool on connecting link and

press on flange up to stop, while holding pressing-on
tool on vertical lever.

12 Force locking spring in opposite direction of

engine rotation into grooves of chain pins (arrow).

13 Install chain tensioner.

14 Rotate crankshaft and check adjusting mark in

TDC position of engine.

Note: If the adjusting mark is not in order, check

timing of crankshaft (05-215) and timing of
injection pump (07.1-l 11).

15 Install cylinder head cover.

16 Install fan and fan cover.

05.1 O-320/3
 I..,. . . . . . . . . . . .

EXIT

05-330 Removal and installation of tensioning rail

Note

The plastic coating of tensioning rail is not exchange-

able.

224 -

215 -
-18

- 218

156- - 262

244
18 Injection timer 220 Slide rail
156 Sprocket 224 Chain tensioner
188 Camshaft timing gear 244 Oil pump sprocket
215 Tensioning rail 262 Tensioning clamp
218 Slide rail

Semoval

1 Remove cylinder head (01-415).

2 Remove timing housing cover (01-210).

3 Remove tensioning rail from bearing bolts.

Installation

Place tensioning rail on bearing bolt.

Install timing housing cover (01-210).

Install cylinder head (01-415).

Run engine and check for leaks.

05.1 o-330/1
 EXIT

05-341 Removal and installation of slide rails

Tightening torques Nm

Cylinder head cover 10

Screw for camshaft timing gear 45

Special tools

Impact puller for bearing bolt

116589203300
(basic unit)

Threaded bolt M 6,50 mm long

116589013400
for impact puller llOOL-b3b8

Torque wrench, double arm,

001 589 51 21 00
3/8 square, 8-32 Nm

Torque wrench with plug-in ratchet,

001 589 66 21 00
l/2 square, 25-130 Nm

Note

Remove timing housing cover for removal and instal-

lation of slide rail (218).

224

156

18 Injection timer 220 Slide rail

156 Sprocket 224 Chain tensioner
166 Camshaft timing gear 244 Oil pump sprocket
215 Tensioning rail 262 Tensioning clamp
218 Slide rail

05.1 o-341 /l
 EXIT

The longer bearing bolt (221), in cylinder head at

top, serves for supporting slide rail as well as for
spring tensioning lever of V-belt tensioning device.

A. Removal and installation of slide rail

(220) in cylinder head

Removal

1 Slacken V-belt and remove. For this purpose,

unscrew collar nut (378). Insert a mandrel into spring
tensioning lever (374) and relieve hex. screw (375)
against force of draw spring (380) until screw can be
pushed back in direction of intake manifold. Release
spring tensioning lever.

2 Unscrew screw (372) and remove holder (373) as

well as spring tensioning lever (374).

3 Remove cylinder head cover.

4 Mark timing chain and camshaft timing gear in

relation to each other.

5 Unscrew camshaft timing gear and remove. For

loosening hex. screw, apply counterhold to camshaft
with a screwdriver or mandrel.

05.10-341/2
 EXIT

6 Knock out both bearing bolts with impact puller

and remove guide rail.

Installation

7 Coat bearing bolt on collar with sealing compound.

8 Insert slide rail and knock in bearing bolt with

impact puller.

Apply counterhold to slide rail with screwdriver.

9 Mount camshaft timing gear. Pay attention to

color marks.

For assembly of camshaft timing gear, push back

thrust bolt of chain tensioner.

Tighten fastening screw for camshaft timing gear to

45 Nm. For this purpose, apply counterhold to
camshaft with a screwdriver or a mandrel.

10 Set engine to ignition TDC of 1st cylinder and

check mark (arrows).

11 Mount cylinder head cover.

05.10-34113
 EXIT

B. Removal and installation of guide

rail (218)

1 Remove timing housing cover (01-210).

2 Pull out slide rail (218).

3 For installation proceed vice versa.

14 OH nozzle 218 Slide rail

18 Injection timer 262 Tensioning clamp
?05-25877
215 Tensioning rail

05.1 o-341 I4
 EXIT

05-437 Removal and installation of drive for hydraulic oil pump

Tightening torques Nm

Cylinder head cover

Hex. socket screw for camshaft timing gear 45

Hydraulic oil pump (level control) on fastening flange 15

Special tools

Torque wrench, double arm,

3/8 8 - 3 2 Nm 001 589 51 21 00
square,

Torque wrench with plug-in ratchet,

001 589 66 21 00
l/2 square, 25-l 30 Nm

Note

Cylinder head
IF
84
Camshaft bearing cap
Combination screw M 8 x 45
401
402
403
Cyl. pin
Flange
Driven plate
125 Cylinder head cover 404 O-ring
129 Cylinder head cover gasket 405 Hex. socket screw
185 Camshaft 406 Drive sleeve
186 Lockwasher 407 Hex. socket screw
188 Camshaft timing gear
400 Hydraulic oil pump
4 0 3 4 0 2 4b5 4 0 4 4 0 6

The hydraulic oil pump (400) is directly driven by

camshaft (185) via drive sleeve (406) and is fastened
to cylinder head by means of a flange (4021.

The installation position of flange on cylinder head

is fixed by means of two cyl. pins (arrows).

05.10-437/l
 EXIT

The camshaft timing gear (188) is fastened to

camshaft together with drive sleeve (406) by means
of a hex. socket screw 1405).

The O-ring on flange (402) seals the half bore at front

on cylinder head and in cylinder head cover.

Removal

Remove cylinder head cover.

2 Unscrew hex. socket screws (arrows) and put

hydraulic oil pump aside with lines connected.

Remove driven plate.

3 Unscrew hex. socket screw (405) for camshaft

timing gear and drive sleeve and remove.

For loosening hex. socket screw, apply counterhold

to camshaft with holding wrench.

Installation

4 For installation proceed vice versa to removal.

Tighten hex. socket screw for camshaft timing gear

and drive sleeve to 45 Nm. For this purpose, apply
counterhold with a screwdriver or a mandrel.

05.10-437/2