Mercedes-Benz 207 D User manual

Mercedes-Benz Transporter
2070,3070,2100,4100,
2080,3080,3100,4080
601, 602 and 616 Engines
DETAILED DESCRIPTION 9F REMOVAL,
INSTALLATION, ADJUSTMENTS, REPAIRS,
OVERHAUL AND SERVICING
OF ALL THE MAJOR
VEHICLE PARTS (except
body) , INCL. ENGINE,
VALVES, DIESEL FUEL INJECTION SYSTEM,
CLUTCH, BRAKES, STEERING, TRANSMISSION
(e xc e pt overhaul), FRONT AND REAR AXLES AND
SUSPENSIONt ENGINE ELECTRICS -WITH
EXPLODED VIEWS AND COMPLETE TECHNICAL
DATA ANO WIRING DIAGRAMS.
www .' russek-manuals. co . uk
ANOTHER BOOK
PUBLISHED BY:
PETER RUSSEK
PUBLICATIONS LTD.
Telephone:
01494 4 40829
Mercedes-Benz
2070,3070,2100,4100
208D,308D,310D,408D
ADJUSTMENTS • TUNE-UP PETER
REPAIRS • OVERHAULS RUSS!\
SERVICING • FAULT FINDING
'------------l MANUALS
'

--
1
I
I
I
I
I
'
I.
0
j
I·
---- - ----- - ·-
POCKE I MECHANIC
Mercedes-Benz
207D, 307D,210D ,3 10D,
4100 , 2080 , 3080 , 4080
2.3, 2.4 and 2.9 Litre Diesel
COVERING:
GENERAL INFORMATION, DIMENSIONS, WEIGHTS,
CAPACITIES, GENERAL, SERVICING NOTES .........
.. ...... 4
ENGINES ..................................... ...... .. .. . .. ...... .. ...................... 9
LUBRICATION SYSTEM .. .................................... ......... ........ 65
COOLING SYSTEM ..... .. .... .. .. .. .... .. .... .. . .. . .. ....... .. ..... ............. 69
DIESEL FUEL INJECTION SYSTEM ........ .. .......................... 77
CLUTCH............................ ........................ .. . .. . .. . .. ................. 89
MANUAL TRANSMISSION ..................
.. .... .. ...... .. ................. 94
FRONT AXLE.................... ......... ..... .. . .. .. . .. .. .. . .. ... .. ............ .. 100
REAR AXLE AND PROPELLER SHAFT............................. 110
FRONT
AND REAR SUSPENSION .. .......... .. ...................... 118
STEERING ..... .. ................................................................... 120
BRAKE SYSTEM..... .. .. .... .. .................................................. 127
ELECTRICAL SYSTEM........ .. .................... .. ....................... 145
2.4 LITRE DIESEL ENGINE -TYPE 616 ............................ 153
SERVICING AND MAINTENANCE ............ .. ...... .. ...... .. .. .. ... 176
FAULT FINDING SECTION.......................
.. ........................ 179
WIRING DIAGRAMS ........ ...................... . .. .......................... 188
jay PETER RUSSEK)

ORDER NO.: 445
Published by
Peter Russek Publications Ltd.
3rd Floor, Block C
Commercial Square
High Wycombe, Buc
ks , HP11 2RH
Tel.: High Wycombe [phone]
[phone]
Fax: [phone]
E-mail: [e-mail]. uk
'NWW . russek-manuals. co. uk
ISBN. NO . 1-898780-45-5
WITH
FAULT FINDING SECTION
AT END OF MANUAL
The publisher would like to thank Daimler Chrysler U. K. Ltd. for their
invaluable support in producing this manual.
No part of this publication may be reproduced, stored in a retrieval system or
transmitted in any form, electronic, mechanical, photocopying, recording,
translati
ng or other means without prior permissi on by the author.
No liability can be accepted for any inaccuracies or Omissions in this
workshop manual, although every possible care has been taken to make
it as
complete and accurate as possible Every care has also been taken to
prevent personal injury or damage to equipment when working on the vehicle
We have tried to cover all models produc
ed to the day of publication, but are
un able to refer to all modifications and changes for certain markets or up-
dat
in g of models.
Re-published and re-printed January 2006
© Peter R. D.Russek - 2000 P rin ted in E ng land
PREFACE
Small though this Workshop Manual is in size, it Jacks no detail in covering
most
of the servicing and repair of the Mercedes Van and Camper Diesel
models listed on the outside cover with 2.3 and 2.9 litre engine (engine types
601 and 602) and th e earlier 2.4 litre engine (engine type 616).
Brief, easy-to-follow instructions are given, free from all necessary
complications and repetitions, yet containing all the required technical detail
and information, and many diagrams and illustrations.
Compiled a nd illustrated by experts, this manual provides a concise source of
helpful information, all of which has been cross-checked for accuracy to the
manufacturer's official service and repa
ir procedures, but many instructions
have derived from act
ua l practice to facilitate your work. Where special tools
are required, these are identified in the text if absolutely necessary and we do
not hesitate to advise you
if we feel that the operation cannot be properly
undertaken without the use
of such tools.
The readers own judgement must ultimately
de cide just what wor1< he will feel
able to undertake, but there Is no doubt, that with this manual to assist him,
there will be many more occasions where the delay, inconvenience and the
cost
of having the van off the road can be avoided or minimised.
The manual
Is called "Pocket Mechanic" and is produced In a handy glove
pocket size with the aim that it should be kept in the vehicle whil
st you are
travelling. Many garage mechanics themselves use these publications in
their
wor1< and if you have the manual with you in the vehicle you will have an
invaluable source
of reference which will quickly repay its modest Initial cost
A general faultfinding (troubleshooting) section is included at the end of the
manual and all items listed are taken from actual experience, together with
the necessary remedies to correct faults and malfunctioning
of certain parts.
Important Note: The main text of the engine Section and some
other sections associated with the engine , covers the 601 and
602 engine, although techn ical data are also given for the 616
engine. Differences
for the 616 engine are described at the end
of the manual in a separate section .
2 3

ORDER NO.: 445
Published by
Peter Russek Publications Ltd.
3rd Floor, Block C
Commercial Square
High Wycombe, Buc
ks , HP11 2RH
Tel.: High Wycombe [phone]
[phone]
Fax: [phone]
E-mail: [e-mail]. uk
'NWW . russek-manuals. co. uk
ISBN. NO . 1-898780-45-5
WITH
FAULT FINDING SECTION
AT END OF MANUAL
The publisher would like to thank Daimler Chrysler U. K. Ltd. for their
invaluable support in producing this manual.
No part of this publication may be reproduced, stored in a retrieval system or
transmitted in any form, electronic, mechanical, photocopying, recording,
translati
ng or other means without prior permissi on by the author.
No liability can be accepted for any inaccuracies or Omissions in this
workshop manual, although every possible care has been taken to make
it as
complete and accurate as possible Every care has also been taken to
prevent personal injury or damage to equipment when working on the vehicle
We have tried to cover all models produc
ed to the day of publication, but are
un able to refer to all modifications and changes for certain markets or up-
dat
in g of models.
Re-published and re-printed January 2006
© Peter R. D.Russek - 2000 P rin ted in E ng land
PREFACE
Small though this Workshop Manual is in size, it Jacks no detail in covering
most
of the servicing and repair of the Mercedes Van and Camper Diesel
models listed on the outside cover with 2.3 and 2.9 litre engine (engine types
601 and 602) and th e earlier 2.4 litre engine (engine type 616).
Brief, easy-to-follow instructions are given, free from all necessary
complications and repetitions, yet containing all the required technical detail
and information, and many diagrams and illustrations.
Compiled a nd illustrated by experts, this manual provides a concise source of
helpful information, all of which has been cross-checked for accuracy to the
manufacturer's official service and repa
ir procedures, but many instructions
have derived from act
ua l practice to facilitate your work. Where special tools
are required, these are identified in the text if absolutely necessary and we do
not hesitate to advise you
if we feel that the operation cannot be properly
undertaken without the use
of such tools.
The readers own judgement must ultimately
de cide just what wor1< he will feel
able to undertake, but there Is no doubt, that with this manual to assist him,
there will be many more occasions where the delay, inconvenience and the
cost
of having the van off the road can be avoided or minimised.
The manual
Is called "Pocket Mechanic" and is produced In a handy glove
pocket size with the aim that it should be kept in the vehicle whil
st you are
travelling. Many garage mechanics themselves use these publications in
their
wor1< and if you have the manual with you in the vehicle you will have an
invaluable source
of reference which will quickly repay its modest Initial cost
A general faultfinding (troubleshooting) section is included at the end of the
manual and all items listed are taken from actual experience, together with
the necessary remedies to correct faults and malfunctioning
of certain parts.
Important Note: The main text of the engine Section and some
other sections associated with the engine , covers the 601 and
602 engine, although techn ical data are also given for the 616
engine. Differences
for the 616 engine are described at the end
of the manual in a separate section .
2 3

0. INTRODUCTION
Our "Pocket Mechanics" are based on easy-to-follow step-by-step Instructions and
advice, which enables you to carry out many, jobs yourself. Moreover, now you have
the means to avoid these frustrating delays and Inconveniences which so often result
from not knowing the right approach to carry out repairs which are often of a
comparatively simple nature.
Whilst special tools are required to carry out certain operations, we show you In this
manual the essential design and construction of such equipment, whenever possible,
to enable you in many cases to Improvise or use alternative tools. Experience shows
that It Is advantageous to use only genuine parts since these give you the assurance
of
a first class job. You will find that many parts are Identical In the range covered In this
manual, but our advice Is to find out before purchasing new parts -Always buy
you r
spare
parts from an officially appointed dealer.
0. 0. General ln fo nn ation
The manual covers the listed Mercedes-Benz commercial vehicles with 2.3 and 2 .9 litre
engine, but also refers to models with the earlier four-cylinder engine with 2.4 litre
capacity. Models 2080, 3080 and 4080 are fitted with a 2.3 litre four-cylinder diesel
engine with a performance of
58 IN'/ (78 HP) at 3800 rpm (engine type 601). The
remaining models are fitted with the 2 .9 litre five-cylinder engine with a performance
of
70 11M/ (95 HP)at 3800 rpm (engine type 602). The engine Is similar to the four-cylinder
engine, with the additional cylinder added on. Models
2070 and 3070 are fitted with
the 2.4 litre engine, engine type
616 .
Details of the 616 engine are covered under separate headings, whenever
differences are
such that a new Section Is necessary.
Many different body versions and model numbers are used in the range of vehicles
marketed. The following table shows some
of the models together with their type
designation and fitted engine to the later model range. These numbers
are sometlme5
referred to, mainly in the technical data sections and you should familiarise yourself
with the model number of your vehicle. We should like to stress that not all vehicles are
sold in any particular country.
All vehicles covered in the manual are fitted with a four-speed or five-speed
transmission.
Model
MB 2080
MB 3080
MB 4080
MB 2100
MB 3100
MB 4100
0.1.
601 .3
602.3
611 .3
601 .4
602.4
611.4
Model Number
I dentificatio n
601.940
601.940
601 . 940
602 . 940
602 . 940
602 . 940
Fitted engine
When your purchases the vehicle you will have received various data cards which have
all important vehicle details, as for example chassis number and component numbers
as well as identification
of optional equipment, etc. You Owner's Manual will give you
further Instructions
on the use of these cards. Owner's Manuals were obtainable under
No . 601 584 36 96 , but you will have to check if this number is still valid, as it Is
possible that they are no longer available.
4
Fig . 0.1 - The posHion of the vehicle
Identification
number (1) and the type
ldentlfiCitlon plate (2).
The type Identification plate with the vehicle
Identification number can be found on the
door entry
at the position shown In Fig. 01 .
Immediately next to it you will find an
additional plate, giving again the vehicle
number, the max. permissible
vehicle weight and the basic setting of the
headlamps. Details of the body/number and
the paint work are given
In a plate, fitted to
the
LH. door pillar, as shown In Fig. 0.2.
Fig . 0.2 - WHh the door open you will see a
type plate (1) with details of the body and pain
Identification
codes.
The engine number can be found near
the injection pipes at the position
shown in Fig.0.3, on the l.H. side of
the cylinder block . Transmission, rear
axle and steering also have a serial
number,
stamped into the housing .
Always quote the complete chassis
number and/or engine number and the
model year, when ordering parts.
Important is also the actual model
number, which will indicate the construction of the vehicle, for example two or
four wheels on the etc.
Fig . 0.3- The engine number can be found at (1 ).
5

0. INTRODUCTION
Our "Pocket Mechanics" are based on easy-to-follow step-by-step Instructions and
advice, which enables you to carry out many, jobs yourself. Moreover, now you have
the means to avoid these frustrating delays and Inconveniences which so often result
from not knowing the right approach to carry out repairs which are often of a
comparatively simple nature.
Whilst special tools are required to carry out certain operations, we show you In this
manual the essential design and construction of such equipment, whenever possible,
to enable you in many cases to Improvise or use alternative tools. Experience shows
that It Is advantageous to use only genuine parts since these give you the assurance
of
a first class job. You will find that many parts are Identical In the range covered In this
manual, but our advice Is to find out before purchasing new parts -Always buy
you r
spare
parts from an officially appointed dealer.
0. 0. General ln fo nn ation
The manual covers the listed Mercedes-Benz commercial vehicles with 2.3 and 2 .9 litre
engine, but also refers to models with the earlier four-cylinder engine with 2.4 litre
capacity. Models 2080, 3080 and 4080 are fitted with a 2.3 litre four-cylinder diesel
engine with a performance of
58 IN'/ (78 HP) at 3800 rpm (engine type 601). The
remaining models are fitted with the 2 .9 litre five-cylinder engine with a performance
of
70 11M/ (95 HP)at 3800 rpm (engine type 602). The engine Is similar to the four-cylinder
engine, with the additional cylinder added on. Models
2070 and 3070 are fitted with
the 2.4 litre engine, engine type
616 .
Details of the 616 engine are covered under separate headings, whenever
differences are
such that a new Section Is necessary.
Many different body versions and model numbers are used in the range of vehicles
marketed. The following table shows some
of the models together with their type
designation and fitted engine to the later model range. These numbers
are sometlme5
referred to, mainly in the technical data sections and you should familiarise yourself
with the model number of your vehicle. We should like to stress that not all vehicles are
sold in any particular country.
All vehicles covered in the manual are fitted with a four-speed or five-speed
transmission.
Model
MB 2080
MB 3080
MB 4080
MB 2100
MB 3100
MB 4100
0.1.
601 .3
602.3
611 .3
601 .4
602.4
611.4
Model Number
I dentificatio n
601.940
601.940
601 . 940
602 . 940
602 . 940
602 . 940
Fitted engine
When your purchases the vehicle you will have received various data cards which have
all important vehicle details, as for example chassis number and component numbers
as well as identification
of optional equipment, etc. You Owner's Manual will give you
further Instructions
on the use of these cards. Owner's Manuals were obtainable under
No . 601 584 36 96 , but you will have to check if this number is still valid, as it Is
possible that they are no longer available.
4
Fig . 0.1 - The posHion of the vehicle
Identification
number (1) and the type
ldentlfiCitlon plate (2).
The type Identification plate with the vehicle
Identification number can be found on the
door entry
at the position shown In Fig. 01 .
Immediately next to it you will find an
additional plate, giving again the vehicle
number, the max. permissible
vehicle weight and the basic setting of the
headlamps. Details of the body/number and
the paint work are given
In a plate, fitted to
the
LH. door pillar, as shown In Fig. 0.2.
Fig . 0.2 - WHh the door open you will see a
type plate (1) with details of the body and pain
Identification
codes.
The engine number can be found near
the injection pipes at the position
shown in Fig.0.3, on the l.H. side of
the cylinder block . Transmission, rear
axle and steering also have a serial
number,
stamped into the housing .
Always quote the complete chassis
number and/or engine number and the
model year, when ordering parts.
Important is also the actual model
number, which will indicate the construction of the vehicle, for example two or
four wheels on the etc.
Fig . 0.3- The engine number can be found at (1 ).
5

0.2 Fi lli ng Capacities
Fuel tank .. . . . . . . ...... . . .... . . . ... . . . . .... . .. 70 (121itres reserve)
-Optional .......... . .... . ... . . ....... .... . . 2 x 651itres (131itres reserve)
Engi
ne :
601 , four-cylinder, complete re-fill . ... ... . ..................... 7. 3lltres
601 , oil change with fitter . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . ..... 6.5 litres
602, five-cylinder, complete re-fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 litres
602, oil change with fitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 litres
616, four-cylinder, complete re-fill . . . . . . . . . . . . . . . .. . . . . . . . . . . . 7.
511tres
616, oil change with fitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 litres
Min Oil Fill Capacity:
601 engine ....................................... . ....... 5.0 litres
602 engine ....... . .... ........ .... . ...................... 5.5 litres
616 engine
............. . . . .. . ... .. ...... . ..•............. 3.5 litres
Cooling System:
601 engine .......... . . .... . . .... .. ....................... 7.0 litres
602 engine. ............... . .. . . . . . .. . . . . ... ... . .......... 7.51itres
616 engine
............. . ..... . .. .... ..... . . . ........... 11 . 7111res
Transmission ..... . .. ......... . ......... ................ . . . ... 2.3 lltres
Automatic transmission (fluid change) ......... ............. . .... . .. 5.9 litres
Power assisted steering . .
.... . . .. . ....... . .... .. ...... . .. ..... . . 1.6 lltres
Rear axle:
• Axletype741.400and741.401 .. ........ ............ ........... 1.61itres
-Axle type 741 .404 and 741 .405 . . . . . . ... ..................... . .. 1.81itres
Axle type
741 .5 (twin wheels) .. . .. ........ .. . .. . ...... .• ...... , , 1.8
litres
0.3. General Servicing Notes
The servicing and overhaul instructions in this Workshop Manual are laid out In an
easy-to-follow step-by-step fashion and no diffiCulty should be encountered, If the text
and diagrams are followed carefully and methodically. The "Technical Data• sections
form an important part
of the repair procedures and should always be referred to during
work on the vehicle.
In order that we can Include as much data as possible, you will find that we do nol
generally repeat
In the text the values already given under the technical data headings
Again, to make the best use of the space available, we do not repeat at each operation
the more obvious steps necessary -we feel it to be far more helpful
to concentrate on
the difficult or awkward procedures In greater detail. However, we summarise below a
few of the more Important procedures and draw your attention to various points of
general interest that apply to all operations.
Always use the torque settings given
In the various main sections of the manual.
These are grouped together in separate sub-sections for convenient reference.
Bolts and nuts should be assembled
in a clean and very lightly oiled condition and
fa ces and threads should always be inspected to make sure that they are free from
damage burrs or scoring. DO
NOT degrease bolts or nuts.
All joint washers, gaskets, tabs and lock washers, split pins and "0" rings must be
replaced on assembly. Seals will,
In the majority of cases, also need to be replaced, If
the shaft and seal have been separatecj. Always lubricate the lip of the seal before
assembly and take care that the seal lip
Is facing the correct direction.
6
References to the left-hand and right-hand sides are always to be taken es if the
observer is at the rear of the vehicle, facing forwards, unless otherwise stated.
Always make sure that the vehicle Is adequately supported, and on firm ground, before
commencing any work on the underside of the car. A small jack or a make shift prop
can
be highly dangerous and proper axle stands are an essential requirement for your
own safely.
Dirt, grease and mineral oil will rapidly destroy the seals of the hydraulic system and
even the smallest amounts must
be prevented from entering the system or coming Into
contact with the components. Use clean brake fluid or one of the proprietary cleaners
to wash the hydraulic system parts. An acceptable alternative cleaner Is methylated
spirit, but It this Is used, It should not be allowed to remain In contact with the rubber
parts for longer than necessary. It Is also Important that all traces of the fluid should be
removed from the system before final assembly.
Always use genuine manufacturer's spares and replacements
for the best results.
Since the manufacturer uses metric units when building the cars
It Is recommended
that, these are used for all precise units. Inch conversions are given in most cases but
these are not necessarily precise conversions, being rounded off for the unimportant
values.
Removal and installation Instructions,
In this Workshop Manual, cover the steps to take
away or put back the unit or part
In question. Other Instructions, usually headed
·servicing", will cover the dismantling and repair of the unit once it has been stripped
from the vehicle
It Is pointed out that the major instructions cover a complete overhaul
of all parts but, obviously, this will not always be either necessary and should not be
carried out needlessly.
There are a number of variations In unit parts on the range of vehicles covered in this
Workshop Manual.
We strongly recommend that you take care to Identify the precise
model, and the year of manufacture, before obtaining any spares or replacement parts.
Std .: To Indicate sizes and limits of components as supplied by the
manufacturer. Also
to Indicate the production tolerances of new unused parts.
OIS Paris supplied as Oversize or Undersize or recommended limits for such parts,
to enable them to be used with worn or re-machlned mating parts.
U/S 0/S Indicates a part that Is larger than Std. size U/S may Indicate a bore of a
bushing or female part that
Is smaller than Std.
Max.: Where gtven against a clearance or dimension Indicates the maximum
anowable If
In excess of the value given It Is recommended that the appropriate
part
Is frtted.
TIR: Indicates the Total Indicator Reading as shown by a dial Indicator (dial
gauge).
TDC: Top Dead Centre (No. 1 piston on tiring stroke).
MP: Multi-Purpose grease.
0. 4. Jac king up of th e Ve hi cle
For small jobs, jack up the vehicle as described In the Owner's Manual, with the
hydraulic jack supplied with the vehicle. If a mobile jack Is used, make sure it can take
the weight of the vehicle. Additional weights should always be removed from the cargo
room
of the vehicle.
To Jack up the vehicle completely, first jack up the front end. Chock the rear wheels to
prevent the vehicle from rolling off the jack or apply the handbrake. Place a mobile
jack
underneath the front axle. If the hydraulic vehicle jack Is used, place it underneath the
spring as shown In Fig. 04, Immediately In front of the front axle.
7

0.2 Fi lli ng Capacities
Fuel tank .. . . . . . . ...... . . .... . . . ... . . . . .... . .. 70 (121itres reserve)
-Optional .......... . .... . ... . . ....... .... . . 2 x 651itres (131itres reserve)
Engi
ne :
601 , four-cylinder, complete re-fill . ... ... . ..................... 7. 3lltres
601 , oil change with fitter . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . ..... 6.5 litres
602, five-cylinder, complete re-fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 litres
602, oil change with fitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 litres
616, four-cylinder, complete re-fill . . . . . . . . . . . . . . . .. . . . . . . . . . . . 7.
511tres
616, oil change with fitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 litres
Min Oil Fill Capacity:
601 engine ....................................... . ....... 5.0 litres
602 engine ....... . .... ........ .... . ...................... 5.5 litres
616 engine
............. . . . .. . ... .. ...... . ..•............. 3.5 litres
Cooling System:
601 engine .......... . . .... . . .... .. ....................... 7.0 litres
602 engine. ............... . .. . . . . . .. . . . . ... ... . .......... 7.51itres
616 engine
............. . ..... . .. .... ..... . . . ........... 11 . 7111res
Transmission ..... . .. ......... . ......... ................ . . . ... 2.3 lltres
Automatic transmission (fluid change) ......... ............. . .... . .. 5.9 litres
Power assisted steering . .
.... . . .. . ....... . .... .. ...... . .. ..... . . 1.6 lltres
Rear axle:
• Axletype741.400and741.401 .. ........ ............ ........... 1.61itres
-Axle type 741 .404 and 741 .405 . . . . . . ... ..................... . .. 1.81itres
Axle type
741 .5 (twin wheels) .. . .. ........ .. . .. . ...... .• ...... , , 1.8
litres
0.3. General Servicing Notes
The servicing and overhaul instructions in this Workshop Manual are laid out In an
easy-to-follow step-by-step fashion and no diffiCulty should be encountered, If the text
and diagrams are followed carefully and methodically. The "Technical Data• sections
form an important part
of the repair procedures and should always be referred to during
work on the vehicle.
In order that we can Include as much data as possible, you will find that we do nol
generally repeat
In the text the values already given under the technical data headings
Again, to make the best use of the space available, we do not repeat at each operation
the more obvious steps necessary -we feel it to be far more helpful
to concentrate on
the difficult or awkward procedures In greater detail. However, we summarise below a
few of the more Important procedures and draw your attention to various points of
general interest that apply to all operations.
Always use the torque settings given
In the various main sections of the manual.
These are grouped together in separate sub-sections for convenient reference.
Bolts and nuts should be assembled
in a clean and very lightly oiled condition and
fa ces and threads should always be inspected to make sure that they are free from
damage burrs or scoring. DO
NOT degrease bolts or nuts.
All joint washers, gaskets, tabs and lock washers, split pins and "0" rings must be
replaced on assembly. Seals will,
In the majority of cases, also need to be replaced, If
the shaft and seal have been separatecj. Always lubricate the lip of the seal before
assembly and take care that the seal lip
Is facing the correct direction.
6
References to the left-hand and right-hand sides are always to be taken es if the
observer is at the rear of the vehicle, facing forwards, unless otherwise stated.
Always make sure that the vehicle Is adequately supported, and on firm ground, before
commencing any work on the underside of the car. A small jack or a make shift prop
can
be highly dangerous and proper axle stands are an essential requirement for your
own safely.
Dirt, grease and mineral oil will rapidly destroy the seals of the hydraulic system and
even the smallest amounts must
be prevented from entering the system or coming Into
contact with the components. Use clean brake fluid or one of the proprietary cleaners
to wash the hydraulic system parts. An acceptable alternative cleaner Is methylated
spirit, but It this Is used, It should not be allowed to remain In contact with the rubber
parts for longer than necessary. It Is also Important that all traces of the fluid should be
removed from the system before final assembly.
Always use genuine manufacturer's spares and replacements
for the best results.
Since the manufacturer uses metric units when building the cars
It Is recommended
that, these are used for all precise units. Inch conversions are given in most cases but
these are not necessarily precise conversions, being rounded off for the unimportant
values.
Removal and installation Instructions,
In this Workshop Manual, cover the steps to take
away or put back the unit or part
In question. Other Instructions, usually headed
·servicing", will cover the dismantling and repair of the unit once it has been stripped
from the vehicle
It Is pointed out that the major instructions cover a complete overhaul
of all parts but, obviously, this will not always be either necessary and should not be
carried out needlessly.
There are a number of variations In unit parts on the range of vehicles covered in this
Workshop Manual.
We strongly recommend that you take care to Identify the precise
model, and the year of manufacture, before obtaining any spares or replacement parts.
Std .: To Indicate sizes and limits of components as supplied by the
manufacturer. Also
to Indicate the production tolerances of new unused parts.
OIS Paris supplied as Oversize or Undersize or recommended limits for such parts,
to enable them to be used with worn or re-machlned mating parts.
U/S 0/S Indicates a part that Is larger than Std. size U/S may Indicate a bore of a
bushing or female part that
Is smaller than Std.
Max.: Where gtven against a clearance or dimension Indicates the maximum
anowable If
In excess of the value given It Is recommended that the appropriate
part
Is frtted.
TIR: Indicates the Total Indicator Reading as shown by a dial Indicator (dial
gauge).
TDC: Top Dead Centre (No. 1 piston on tiring stroke).
MP: Multi-Purpose grease.
0. 4. Jac king up of th e Ve hi cle
For small jobs, jack up the vehicle as described In the Owner's Manual, with the
hydraulic jack supplied with the vehicle. If a mobile jack Is used, make sure it can take
the weight of the vehicle. Additional weights should always be removed from the cargo
room
of the vehicle.
To Jack up the vehicle completely, first jack up the front end. Chock the rear wheels to
prevent the vehicle from rolling off the jack or apply the handbrake. Place a mobile
jack
underneath the front axle. If the hydraulic vehicle jack Is used, place it underneath the
spring as shown In Fig. 04, Immediately In front of the front axle.
7

Fig. OA - Jacking up the front end of the
vehicle, using the hydraulic Jack supplied with
t he ve hicle.
Chassis stands should only be placed on
the L.H. and R.H. sides under the front axle.
Use chassis stands of the construction
shown In
Fig . 0.5, should be used, but again
make
sure that they are strong enough to
carry the weight of the vehicle. Make sure
the vehicle cannot slip off the stands.
Fig . 0.5- Three-legged chassis sta n ds are t he
safest method t o support the vehicle when
work has to be carried out o n the u ndersi d e o f
the vehicle.
The rear end of the vehicle Is jacked up
with a mobile jack or with the hydraulic jack
shown In Fig.0.6. Chassis stands are
placed underneath the axle beam, noting the points given above. Again make sure that
no additional weights are left in the cargo room.
Fig. 0.6 - Jacking up the r ear end of the
vehicle with the hydraulic jack
supplied.
Note: It is always difficult to raise a vehicle first on one side and then on the
other. Take care that the vehicle cannot tip-over when the first side is tiffed.
Ask a helper to support the vehicle from the other side. Never work
underneath the vehicle without adequate support.
8
[1 ENGINES
1.0. Technical Data
Fitted Engines:
-208 0 (Model 601 .3)
-308 0 (Model
602 .3)
-408 0 (Model 611 .3)
-
210 0 (Model 601.4)
- 310 0 (Model602.4)
- 410 0 (Model611.4)
- L2070
- L2070, L3070
Number of Cylinders:
-601 engine
- 602 engine
-616 engine
Injection Order:
-Four cylinder
-Five cylinder
Arrangement of cylinders
Camshaft
Arrangement
of valves
Cylinder bore, 601, 602 engines
-
616 engine
-Piston stroke, 601 , 602, 616 engines
Capacity:
-
601 engine
-602 engine
-616 engine
Compression Rallo:
-601, 602 engines
-616 engine
Max. B.H.P. (DIN):
-601 engine, with manual gearbox
-601 engine, with
AfT
-602 engine, with manual gearbox
-602 engine, with AfT
-616 engine
Max. Torque:
-
601 engine
-
602 engine
-616 engine
601.940
601.940
602.940
602 . 940
602.940
602 . 940
616 . 017
616 . 934
Four
Five
Four
1-3-4-2
1-2-4-5-3
In-line
Overhead camshaft, No . marked In end face
Overhead
89 . 00 mm (3.4565 ln .)
91.00 mm (3.6154 1n.)
92.40 mm (3.6711 ln.)
2299ccm
2874 ocm
2404ccm
22 : 1
21 : 1
58 WI at 3800 rpm
60 WI at 4000 rpm
70 WI at 3800 rpm
72 WI at 4000 rpm
48 WI at 4200 rpm
15.7 kgm (113
ft . lb .) at 2000 - 2800
rpm
19 .2 kgm (138 ft. lb .) at 2400 -2600
rpm
13.7 kgm (99 ft.lb.) at 2400 rpm
9

Fig. OA - Jacking up the front end of the
vehicle, using the hydraulic Jack supplied with
t he ve hicle.
Chassis stands should only be placed on
the L.H. and R.H. sides under the front axle.
Use chassis stands of the construction
shown In
Fig . 0.5, should be used, but again
make
sure that they are strong enough to
carry the weight of the vehicle. Make sure
the vehicle cannot slip off the stands.
Fig . 0.5- Three-legged chassis sta n ds are t he
safest method t o support the vehicle when
work has to be carried out o n the u ndersi d e o f
the vehicle.
The rear end of the vehicle Is jacked up
with a mobile jack or with the hydraulic jack
shown In Fig.0.6. Chassis stands are
placed underneath the axle beam, noting the points given above. Again make sure that
no additional weights are left in the cargo room.
Fig. 0.6 - Jacking up the r ear end of the
vehicle with the hydraulic jack
supplied.
Note: It is always difficult to raise a vehicle first on one side and then on the
other. Take care that the vehicle cannot tip-over when the first side is tiffed.
Ask a helper to support the vehicle from the other side. Never work
underneath the vehicle without adequate support.
8
[1 ENGINES
1.0. Technical Data
Fitted Engines:
-208 0 (Model 601 .3)
-308 0 (Model
602 .3)
-408 0 (Model 611 .3)
-
210 0 (Model 601.4)
- 310 0 (Model602.4)
- 410 0 (Model611.4)
- L2070
- L2070, L3070
Number of Cylinders:
-601 engine
- 602 engine
-616 engine
Injection Order:
-Four cylinder
-Five cylinder
Arrangement of cylinders
Camshaft
Arrangement
of valves
Cylinder bore, 601, 602 engines
-
616 engine
-Piston stroke, 601 , 602, 616 engines
Capacity:
-
601 engine
-602 engine
-616 engine
Compression Rallo:
-601, 602 engines
-616 engine
Max. B.H.P. (DIN):
-601 engine, with manual gearbox
-601 engine, with
AfT
-602 engine, with manual gearbox
-602 engine, with AfT
-616 engine
Max. Torque:
-
601 engine
-
602 engine
-616 engine
601.940
601.940
602.940
602 . 940
602.940
602 . 940
616 . 017
616 . 934
Four
Five
Four
1-3-4-2
1-2-4-5-3
In-line
Overhead camshaft, No . marked In end face
Overhead
89 . 00 mm (3.4565 ln .)
91.00 mm (3.6154 1n.)
92.40 mm (3.6711 ln.)
2299ccm
2874 ocm
2404ccm
22 : 1
21 : 1
58 WI at 3800 rpm
60 WI at 4000 rpm
70 WI at 3800 rpm
72 WI at 4000 rpm
48 WI at 4200 rpm
15.7 kgm (113
ft . lb .) at 2000 - 2800
rpm
19 .2 kgm (138 ft. lb .) at 2400 -2600
rpm
13.7 kgm (99 ft.lb.) at 2400 rpm
9

Crankshaft bearings
Cooling system
Lubrication
Air cleaner
5 or 6 friction bearings
Thermo system with water pump,
thermostat, cooling fan with fluid
clutch, tube-type radiator
Pressure-feed lubrication with gear-type
oil pump, driven with chain from
crankshaft. With full-flow oil filter
Dry paper element air cleaner
Valve Timing - New Timing Chain- 601 and 602 engines :
-Inlet valve opens 11" A.T.D.C
-Inlet valve closes 17" A.B.D.C.
-Exhaust valve opens 28" B.B.D.C.
-Exhaust valve closes 15" B.T.D.C
Valve
Timing- Used Timing Chain (after 12 000 miles)- 601 and 802 engines:
-Inlet valve opens 12" A.T.D.C
-Inlet valve closes 18" A.B.D. C.
-Exhaust valve opens 27" B.B.D.C.
-Exhaust valve closes 14" B.T.D.C
Valve Timing- New Timing Chain- 818 engine:
-Inlet valve opens 11.5" A.T.D.C
-Inlet valve closes 13.
5" A.B.D.C.
-Exhaust valve opens 21" B.B.D.C.
-Exhaust valve closes 19" B.T.D.C
Valve
Timing- Used Timing Chain -616 engine:
All valves 2" more
Valve Clearances- 616 Engine -Engine warm:
-Inlet valves 0.10 mm (0.004 ln.)
-Exhaust valves 0. 30 mm (0 .012 in.)
Valve Clearances -616 Engine -Engine cold:
-Inlet valves
-Exhaust valves
0.15 mm (0 .0061n.)
0.35 mm
(0 .0181n.)
1.1.
Engine -Removal and Installation
The engine and transmission Is removed from the vehicle as a complete unit after the
parts shown in Fig. 1.1 are removed from the front end
of the vehicle. The transmission
can then
be removed from the engine. Engine and transmission are a heavy unit and a
suitable hoist or crane is required to
lift out the assembly, remembering that the weight
is more than 200 lbs. The following description Is a general guide line, as we cannot
refer to every possible variation and/or equipment that may be fitted
to your vehicle.
10
Place the bonnet Into the vertical.position until the lock engages. Remove the
d
ri vers seat.
-
Fig. 1.1 -The engine Is removed from the vehicle after the Illustrated parts have bei!n
removed
from the fr ont end Cil the vehicle.
• Disconnect the two battery cables. The battery can also be removed to have more
space for other operations.
• Remove the engine cover and the radiator grille.
• Open the expansion tank cap. It Is assumed that the engine Is fairly cold. Drain
the cooling system as described In Section "Cooling System". Remove the radiator
as described
In the same section.
Remove the air Intake hose.
• Remove the front bumper and the radiator crossmember (Fig. 1.1).
Separate the front exhaust pipe from the exhaust manifold and free the pipe from
the bracket on the transmission.
• Disconnect the propeller shaft from the transmission. Also disconnect the
speedometer cable from the transmission.
Unscrew the clutch slave cylinder from the side
of the transmission without
disconnecting the hydraulic hose. Tie the cylinder
to the vehicle floor to prevent it
from hanging down on Its hose. Fig. 1.2 shows where the cylinder Is attached.
Unscrew the earth cable.
Fig. 1 .2- The clutch slave cylinder {1) Is
fltted to the side Cil the transmission.
• Disconnect the electrical leads
from the starter motor and the
alternator. Free the cable harness
from the engine (cut the cable
binders) and push the harness to one
side, where it cannot be in the way
during following operations.
• Disconnect the electrical lead
from the glow plug relay.
• Disconnect all vacuum hoses
from the engine.
11

Crankshaft bearings
Cooling system
Lubrication
Air cleaner
5 or 6 friction bearings
Thermo system with water pump,
thermostat, cooling fan with fluid
clutch, tube-type radiator
Pressure-feed lubrication with gear-type
oil pump, driven with chain from
crankshaft. With full-flow oil filter
Dry paper element air cleaner
Valve Timing - New Timing Chain- 601 and 602 engines :
-Inlet valve opens 11" A.T.D.C
-Inlet valve closes 17" A.B.D.C.
-Exhaust valve opens 28" B.B.D.C.
-Exhaust valve closes 15" B.T.D.C
Valve
Timing- Used Timing Chain (after 12 000 miles)- 601 and 802 engines:
-Inlet valve opens 12" A.T.D.C
-Inlet valve closes 18" A.B.D. C.
-Exhaust valve opens 27" B.B.D.C.
-Exhaust valve closes 14" B.T.D.C
Valve Timing- New Timing Chain- 818 engine:
-Inlet valve opens 11.5" A.T.D.C
-Inlet valve closes 13.
5" A.B.D.C.
-Exhaust valve opens 21" B.B.D.C.
-Exhaust valve closes 19" B.T.D.C
Valve
Timing- Used Timing Chain -616 engine:
All valves 2" more
Valve Clearances- 616 Engine -Engine warm:
-Inlet valves 0.10 mm (0.004 ln.)
-Exhaust valves 0. 30 mm (0 .012 in.)
Valve Clearances -616 Engine -Engine cold:
-Inlet valves
-Exhaust valves
0.15 mm (0 .0061n.)
0.35 mm
(0 .0181n.)
1.1.
Engine -Removal and Installation
The engine and transmission Is removed from the vehicle as a complete unit after the
parts shown in Fig. 1.1 are removed from the front end
of the vehicle. The transmission
can then
be removed from the engine. Engine and transmission are a heavy unit and a
suitable hoist or crane is required to
lift out the assembly, remembering that the weight
is more than 200 lbs. The following description Is a general guide line, as we cannot
refer to every possible variation and/or equipment that may be fitted
to your vehicle.
10
Place the bonnet Into the vertical.position until the lock engages. Remove the
d
ri vers seat.
-
Fig. 1.1 -The engine Is removed from the vehicle after the Illustrated parts have bei!n
removed
from the fr ont end Cil the vehicle.
• Disconnect the two battery cables. The battery can also be removed to have more
space for other operations.
• Remove the engine cover and the radiator grille.
• Open the expansion tank cap. It Is assumed that the engine Is fairly cold. Drain
the cooling system as described In Section "Cooling System". Remove the radiator
as described
In the same section.
Remove the air Intake hose.
• Remove the front bumper and the radiator crossmember (Fig. 1.1).
Separate the front exhaust pipe from the exhaust manifold and free the pipe from
the bracket on the transmission.
• Disconnect the propeller shaft from the transmission. Also disconnect the
speedometer cable from the transmission.
Unscrew the clutch slave cylinder from the side
of the transmission without
disconnecting the hydraulic hose. Tie the cylinder
to the vehicle floor to prevent it
from hanging down on Its hose. Fig. 1.2 shows where the cylinder Is attached.
Unscrew the earth cable.
Fig. 1 .2- The clutch slave cylinder {1) Is
fltted to the side Cil the transmission.
• Disconnect the electrical leads
from the starter motor and the
alternator. Free the cable harness
from the engine (cut the cable
binders) and push the harness to one
side, where it cannot be in the way
during following operations.
• Disconnect the electrical lead
from the glow plug relay.
• Disconnect all vacuum hoses
from the engine.
11

• If a power-assisted steering is fitted, remove the drive belt and unscrew the belt
pulley from the pump shaft. Unscrew the complete steering pump and remove it
together with the connected hoses.
Disconnect the fuel pipe from the pre-filter. Close the open connections In suitable
manner to prevent entry of dirt.
• Remove the vacuum hose from the vacuum pump at the location shown In Fig.
1.3.
Fig. 1 .3- DlsconnKt the vacuum hose for
the brake servo unit from the vacuum
pump (exhauster pump).
• Unscrew the gear change lever
knob, remove the rubber gaiter
and withdraw the lever after
removing the clamp bolt. During
later Installation tighten the clamp
bolt until the gap is 1.5 mm .
Slacken the heater hose behind
the thermostat housing and
withdraw.
• Remove the starter motor.
Fig . 1.5 - The attachment of
crossmember underneath the vehicle.
• Use a hand crane or suitable holst
and with ropes
or chains attach the
power unit, utilising the lifting eyes.
Also place a mobile jack underneath
the engine/transmission unit
to
support it from below. Before
removing any of the engine and
transmission mountings ensure that
the weight of the assembly is well
supported.
Disconnect the throttle control.
Fig. 1.4 - The ott ntter neck must be
removed In order to take out the engine .
• Disconnect the oil pipes from the
oil filter housing.
• Remove the pipe clamp from the
oil sump.
Remove
the oil filler neck. Fig. 1.4
shows the location.
Remove the transmission
mounting from
the crossmember (1
bolt).
Slacken the engine mounting
supports from the engine mounting.
Unscrew the crossmember underneath the transmission and also underneath
the
engine. Figs. 1.5 and 1.6 show where the items are attached. Check once more
that the unit is supported.
12
Lift the engine/transmission assembly towards the front of the vehicle, turning it
slightly to allow the gearchange to clear the engine compartment. If the unit is
resting
on a jack, remove the jack at the same time. Helpers will be required to
guide the power unit. Finally lower the assembly to the ground. Remove the
transmission
If required.
Fig. 1.6 - The attachment of the engine
crossmember.
The Installation Is a reversal of the removal
procedure, but the following points should
be noted:
• Check the engine mountings and the
oil and fuel pipes (hoses) for damage and
replace parts as necessary.
• If a manual transmission Is fitted, take
the opportunity to check the
clu1ch release
bearing and replace If necessary.
• Do not connect or refit any of the
disconnected parts until the engine and transmission are refitted to their
mountings and the engine
Is free from the ropes or chains.
• Remove the engine mounts If their conditions require it. Keep oil or grease away
from the rubber parts.
• Connect the propeller shaft in accordance with the Instructions In Section 4.
• Refill the cooling system with anti-freeze of the correct strength for the
temperatures to be expected. If the original anti/freeze is used, check 1st strength
before filling It in.
• Check the air cleaner element before re-use. Dirty elements should be replaced,
mainly If overhaul work has been undertaken on the engine.
Check the oil levels In engine and transmission and correct If necessary, If no
other operations have been carried out on the units.
• After starting the engine and allowing It to warm up, check the cooling system for
leaks. Drive
the vehicle a few miles to check for exhaust pipe ratt1e .
1.2. Engine -Dismantl ing
Diesel eng ines are sensitive to dirt or other contamination. It Is therefor essential to
make sure that no foreign matter can enter the pipes, connections, etc. during the
dismantling operations.
Dismantling of the engine will be made much easier, If a swivelling engine stand Is
available. Otherwise place the engine/transmission on a work bench, supporting is
adequately to prevent if from tanlng over.
Before commencing dismantling, block up the inlet and exhaust openings
and give the
exterior of the engine a thorough cleaning to remove
all loose dirt and oil. Pay
particular attention to an Joint surfaces, brushing these to remove loose debris which
might otherwise find
1st way Into the Interior of the engine.
Many of the parts are made of Aluminium alloy and must
be treated accordingly. Only
use plastic or rubber mallets to separate parts, If necessary.
As a complete strip-down
of the engine Is in most cases not necessary, and many of
the operations can
be carried out with the engine fitted, you will find in the following text
13

• If a power-assisted steering is fitted, remove the drive belt and unscrew the belt
pulley from the pump shaft. Unscrew the complete steering pump and remove it
together with the connected hoses.
Disconnect the fuel pipe from the pre-filter. Close the open connections In suitable
manner to prevent entry of dirt.
• Remove the vacuum hose from the vacuum pump at the location shown In Fig.
1.3.
Fig. 1 .3- DlsconnKt the vacuum hose for
the brake servo unit from the vacuum
pump (exhauster pump).
• Unscrew the gear change lever
knob, remove the rubber gaiter
and withdraw the lever after
removing the clamp bolt. During
later Installation tighten the clamp
bolt until the gap is 1.5 mm .
Slacken the heater hose behind
the thermostat housing and
withdraw.
• Remove the starter motor.
Fig . 1.5 - The attachment of
crossmember underneath the vehicle.
• Use a hand crane or suitable holst
and with ropes
or chains attach the
power unit, utilising the lifting eyes.
Also place a mobile jack underneath
the engine/transmission unit
to
support it from below. Before
removing any of the engine and
transmission mountings ensure that
the weight of the assembly is well
supported.
Disconnect the throttle control.
Fig. 1.4 - The ott ntter neck must be
removed In order to take out the engine .
• Disconnect the oil pipes from the
oil filter housing.
• Remove the pipe clamp from the
oil sump.
Remove
the oil filler neck. Fig. 1.4
shows the location.
Remove the transmission
mounting from
the crossmember (1
bolt).
Slacken the engine mounting
supports from the engine mounting.
Unscrew the crossmember underneath the transmission and also underneath
the
engine. Figs. 1.5 and 1.6 show where the items are attached. Check once more
that the unit is supported.
12
Lift the engine/transmission assembly towards the front of the vehicle, turning it
slightly to allow the gearchange to clear the engine compartment. If the unit is
resting
on a jack, remove the jack at the same time. Helpers will be required to
guide the power unit. Finally lower the assembly to the ground. Remove the
transmission
If required.
Fig. 1.6 - The attachment of the engine
crossmember.
The Installation Is a reversal of the removal
procedure, but the following points should
be noted:
• Check the engine mountings and the
oil and fuel pipes (hoses) for damage and
replace parts as necessary.
• If a manual transmission Is fitted, take
the opportunity to check the
clu1ch release
bearing and replace If necessary.
• Do not connect or refit any of the
disconnected parts until the engine and transmission are refitted to their
mountings and the engine
Is free from the ropes or chains.
• Remove the engine mounts If their conditions require it. Keep oil or grease away
from the rubber parts.
• Connect the propeller shaft in accordance with the Instructions In Section 4.
• Refill the cooling system with anti-freeze of the correct strength for the
temperatures to be expected. If the original anti/freeze is used, check 1st strength
before filling It in.
• Check the air cleaner element before re-use. Dirty elements should be replaced,
mainly If overhaul work has been undertaken on the engine.
Check the oil levels In engine and transmission and correct If necessary, If no
other operations have been carried out on the units.
• After starting the engine and allowing It to warm up, check the cooling system for
leaks. Drive
the vehicle a few miles to check for exhaust pipe ratt1e .
1.2. Engine -Dismantl ing
Diesel eng ines are sensitive to dirt or other contamination. It Is therefor essential to
make sure that no foreign matter can enter the pipes, connections, etc. during the
dismantling operations.
Dismantling of the engine will be made much easier, If a swivelling engine stand Is
available. Otherwise place the engine/transmission on a work bench, supporting is
adequately to prevent if from tanlng over.
Before commencing dismantling, block up the inlet and exhaust openings
and give the
exterior of the engine a thorough cleaning to remove
all loose dirt and oil. Pay
particular attention to an Joint surfaces, brushing these to remove loose debris which
might otherwise find
1st way Into the Interior of the engine.
Many of the parts are made of Aluminium alloy and must
be treated accordingly. Only
use plastic or rubber mallets to separate parts, If necessary.
As a complete strip-down
of the engine Is in most cases not necessary, and many of
the operations can
be carried out with the engine fitted, you will find in the following text
13

II
II,
I)
a description of individual operations which can be carried out with the engine fitted
and removed. Combining these, will give you the complete dismantling
of the engine.
Engine -Overhaul
1.3 .
1.3.0. Cylinder Head and
Valves- Technical Data
Cylinder Head:
Cylinder head height:
-616 engine
Max. Distortion of Cylinder Head Faces:
-Longitudinal direction:
-Across the face:
Max. deviation
of faces between upper and
lower sealing faces (parallel
to each other)
142.
9- 143.1 mm
84.8- 85.00 mm (min. 84.00 mm)
0.08 mm
O.OOmm
0.10
mm
Depth of valve head faces and cylinder head sealing face -Except 616:
-Inlet valves +0 .17 to 0.23 mm
-Exhaust valves +0 .12 to 0.28 mm
-With re-cut valve seats 1.0
mm -all valves
Depth of valve head faces and cylinder head sealing face -616:
-Inlet valves +0.03 to 0.43 mm
-Exhaust valves - 0. 38 to 0.78 mm
-With re-cut valve seats 1.5 mm -all valves
Valves
Valve Head Diameter (0 " in Fig. 1.22):
-Inlet valves
616 engine
-Exhaust valves
616 engine
Valve seat angle
Valve Stem Diameter
(01" in Fig.1.22):
-Inlet valves
-Exhaust valves
-616 engine
Valve Length ("L" in Fig. 1.22):
-Inlet valves
-Exhaust valves
616
engine- Inlet valves
616 engine -Exhaust valves
Valve Seat Width:
-Inlet valves
-Exhaust valves
Valve Identification:
- Inlet valves
-Exhaust valves
14
37 . 90-38 . 10 mm
39 .70 -39.90 mm
34 . 90-35 . 10 mm
34 .10 -34.30 mm
45" + 15' (616 engine = 30")
7. 970-7 .955 mm
8.960- 8.945 mm
9. 920- 9.940 mm
106. 50-106 .30 mm
106. 50- 106.30 mm
131 .
30-131 . 70 mm
130. 8-131.20 mm
2.5
mm (616 = 1.3 to 1.6 mm)
3.5 mm (616 = 2.
5-2 .9 mm)
E
601 02 (616 = E 616 02)
A 601 02 (616 =A 616 05)
Val ve Seats
Valve seat width:
-Inlet valves
-Exhaust valves
Valve seat angles
Upper correction angle
Lower correction angle
2.5
mm (616 = 1.3 to 1.6 mm)
3.5 mm (616 = 2.
5- 2.9 mm)
45"- 15' (616 = 30")
15"(616=60.)
60" (616 = N/A)
Valve Seat
Inserts (only 601 and 602 given)
Insert outer diameter \D" In Fig. 1.20):
_ Inlet
valves- Std. 40. 100-40 .084 mm
_ Exhaust valves- Std. 37. 100- 37.084 mm
Insert inner diameter (0 1" In Fig. 1.20):
-Inlet
valves- Std. 33. 400- 33.600 mm
-Exhaust valves -Std. 30. 500- 30.600 mm
Basic bore In cylinder head (D2" In Fig. 1.20):
-Inlet
valves- Std.
-Exhaust valves -Std.
Valve seat height, all valves
40.000- 40.016 mm
37. 000- 37.016 mm
6.
97 -7.00 mm
Upper edge of valve seat r1ngs to cylinder head face:
-Inlet valves 2.37 -2. 25 mm
-Exhaust valves 2. 44- 2. 25 mm
Valve
Springs- Except 616 engine
Colour code
Outer diameter
Wire diameter
Free length
Length under load
of 72 to 77 kg
-Wear limit
yellow-green or purple-green
33.20 mm
4.
25 mm
50 .80 mm
27. 00 mm
27. 00 mm at 65 kg
Valve
Springs -616 engine
Colour code green/green
or
VloleVgreen
30. 20- 30 .5 mm
3. 80 mm
50. 50mm
yellow/yellow or
Outer diameter
Wire diameter
Free length
length under load of 46.3 to 53 kg
Length under load of 58.9 kg
-Wearllmlt
Valve
Guides- Except 618
Inlet valve Guides:
-Outer diameter
-Std .
-Outer
diameter- Repair size
Inner diameter
Baste bore
In cylinder head:
-Std.
-Repair size
violet/yellow
30. 0-30 .7 mm
3. 90 mm
51 . 20mm
29. 90 mm, min.
41.70 kg
14. 044-14 . 051 mm
14 .214 - 14 .222 mm
8.000 - 8.015 mm
14 . 030-14 .035 mm
14 . 198-14 . 203mm
26. 00 mm
53. 00 kg
15

II
II,
I)
a description of individual operations which can be carried out with the engine fitted
and removed. Combining these, will give you the complete dismantling
of the engine.
Engine -Overhaul
1.3 .
1.3.0. Cylinder Head and
Valves- Technical Data
Cylinder Head:
Cylinder head height:
-616 engine
Max. Distortion of Cylinder Head Faces:
-Longitudinal direction:
-Across the face:
Max. deviation
of faces between upper and
lower sealing faces (parallel
to each other)
142.
9- 143.1 mm
84.8- 85.00 mm (min. 84.00 mm)
0.08 mm
O.OOmm
0.10
mm
Depth of valve head faces and cylinder head sealing face -Except 616:
-Inlet valves +0 .17 to 0.23 mm
-Exhaust valves +0 .12 to 0.28 mm
-With re-cut valve seats 1.0
mm -all valves
Depth of valve head faces and cylinder head sealing face -616:
-Inlet valves +0.03 to 0.43 mm
-Exhaust valves - 0. 38 to 0.78 mm
-With re-cut valve seats 1.5 mm -all valves
Valves
Valve Head Diameter (0 " in Fig. 1.22):
-Inlet valves
616 engine
-Exhaust valves
616 engine
Valve seat angle
Valve Stem Diameter
(01" in Fig.1.22):
-Inlet valves
-Exhaust valves
-616 engine
Valve Length ("L" in Fig. 1.22):
-Inlet valves
-Exhaust valves
616
engine- Inlet valves
616 engine -Exhaust valves
Valve Seat Width:
-Inlet valves
-Exhaust valves
Valve Identification:
- Inlet valves
-Exhaust valves
14
37 . 90-38 . 10 mm
39 .70 -39.90 mm
34 . 90-35 . 10 mm
34 .10 -34.30 mm
45" + 15' (616 engine = 30")
7. 970-7 .955 mm
8.960- 8.945 mm
9. 920- 9.940 mm
106. 50-106 .30 mm
106. 50- 106.30 mm
131 .
30-131 . 70 mm
130. 8-131.20 mm
2.5
mm (616 = 1.3 to 1.6 mm)
3.5 mm (616 = 2.
5-2 .9 mm)
E
601 02 (616 = E 616 02)
A 601 02 (616 =A 616 05)
Val ve Seats
Valve seat width:
-Inlet valves
-Exhaust valves
Valve seat angles
Upper correction angle
Lower correction angle
2.5
mm (616 = 1.3 to 1.6 mm)
3.5 mm (616 = 2.
5- 2.9 mm)
45"- 15' (616 = 30")
15"(616=60.)
60" (616 = N/A)
Valve Seat
Inserts (only 601 and 602 given)
Insert outer diameter \D" In Fig. 1.20):
_ Inlet
valves- Std. 40. 100-40 .084 mm
_ Exhaust valves- Std. 37. 100- 37.084 mm
Insert inner diameter (0 1" In Fig. 1.20):
-Inlet
valves- Std. 33. 400- 33.600 mm
-Exhaust valves -Std. 30. 500- 30.600 mm
Basic bore In cylinder head (D2" In Fig. 1.20):
-Inlet
valves- Std.
-Exhaust valves -Std.
Valve seat height, all valves
40.000- 40.016 mm
37. 000- 37.016 mm
6.
97 -7.00 mm
Upper edge of valve seat r1ngs to cylinder head face:
-Inlet valves 2.37 -2. 25 mm
-Exhaust valves 2. 44- 2. 25 mm
Valve
Springs- Except 616 engine
Colour code
Outer diameter
Wire diameter
Free length
Length under load
of 72 to 77 kg
-Wear limit
yellow-green or purple-green
33.20 mm
4.
25 mm
50 .80 mm
27. 00 mm
27. 00 mm at 65 kg
Valve
Springs -616 engine
Colour code green/green
or
VloleVgreen
30. 20- 30 .5 mm
3. 80 mm
50. 50mm
yellow/yellow or
Outer diameter
Wire diameter
Free length
length under load of 46.3 to 53 kg
Length under load of 58.9 kg
-Wearllmlt
Valve
Guides- Except 618
Inlet valve Guides:
-Outer diameter
-Std .
-Outer
diameter- Repair size
Inner diameter
Baste bore
In cylinder head:
-Std.
-Repair size
violet/yellow
30. 0-30 .7 mm
3. 90 mm
51 . 20mm
29. 90 mm, min.
41.70 kg
14. 044-14 . 051 mm
14 .214 - 14 .222 mm
8.000 - 8.015 mm
14 . 030-14 .035 mm
14 . 198-14 . 203mm
26. 00 mm
53. 00 kg
15

I .
I!
Exhaust Valve Guides:
-Outer diameter- Std.
-Outer diameter -Repair size
-Inner diameter
Basic bore in
cylinder head:
-Std.
-Repair size
Interference
frt of valve guides -All guides:
- Std.
-Repair size
Valve Guides- 616
Inlet Valve/Exhaust Valve Guides:
-Length:
Inlet valves
Exhaust valves
Outer diameter- Std., all guides
Outer diameter -Repair size, all guides
Inner diameter, all guides
Max. inner diameter
Basic bore in cylinder head:
Std.
Repair size
Interference fit of valve guides -All guides:
Std.
Camshaft- Except 616 Engine
Camshaft Bearings:
- 4 cal. engine
- 5 cal. engine
Journal diameter
Camshaft Bearing Clearance:
-New condition
- Wearllmit
Camshaft End Float:
-New condition
- Wearlimit
Camshaft- 616 Engine
Camshaft bearing running clearance
Camshaft end noat
14. 044-14 . 051 mm
14. 214 -14. 222 mm
9. 000- 9. 015 mm
14 . 030- 14.035 mm
14 .198 -14. 203 mm
0 . 009- 0.021 mm
0.011 - 0. 024 mm
60 .0 or 61 .0 mm
48.5- 40 .5 mm
14 . 03- 14 . 04 mm
14 . 23- 14 . 24 mm
10.00 - 10 . 015 mm
10 . 025 mm
14. 000- 14. 020 mm
14 . 200-14 .220 mm
0.01 - 0 . 04 mm
5
6
30 . 944- 30 . 950 mm
0. 050 - 0.091 mm
0.11 mm
0. 07 - 0 .15 mm
0.18 mm
0. 025- 0. 066 mm (max. 0. 11 mm)
0. 05 - 0.128 mm (max. 0 . 18 mm)
1.3 .0.1. Cylinder Head -Removal and Installation
The following information should be noted when work is carried out on a cylinder head:
16
The cylinder head is made of light-alloy. Engine coolant, engine oil, the air
required to Ignite the fuel and the exhaust gases are directed through the cylinder
head. Glow plugs, injectors, pre-combustion chambers and valve tappets are fitted
to the cylinder head. Also in the cylinder heads you will find the camshaft.
The exhaust manifold and the Inlet manifold are bolted to the outside of the head.
The fuel enters the head on one side and exits on the other side,
I. e. the head is of
the well-known "crossnow" type.
• The cylinder head Is fitted with various sender units, sensors and switching
valves, responsible for certain functions of the temperature control.
• As the cylinder head Is made of light alloy, It Is prone to distortion If, for example,
the order
of slackening or tightening of the cylinder head bolts Is not observed. For
the same reason never remove the cylinder head from a hot engine.
• A cylinder head cannot be checked In frtted position. Sometimes the cylinder head
gasket will "blow", aflowing air Into the cooling system. A quick check is possible
after opening the coolant reservoir cap (engine fa irly cold). Allow the engine to
warm-up and observe the coolant. Visible air bubbles point in most cases
to a "blown" gasket. Further evidence Is white exhaust smoke, oil in the coolant or
coolant in the eng ine oil. The latter can be checked at the oil dipstick. A white,
grey emulsion on the dipstick Is more or less a confirmation of a damaged cylinder
gasket.
• If you are convinced that water has entered the engine and you want to get home
or to the nearest garage, unscrew the injectors and crank the engine with the
starter motor for a while to eject the water. Refit the injectors, start the engine and
drive to your destination without switching off the engine. This is the only method
to avoid serious engine damage (bent connecting rods for example).
The cylinder head must only be removed when the engine Is cold. The head Is
removed together with the exhaust manifold, but the Inlet manifold must be separated
from the cylinder head before the head can be lifted off. New cylinder head gaskets
are wrapped In plastic und must only be unwrapped just before the gasket Is frtted.
The cylinder head can be removed with the engine frtted and these operations are
described below, but note that operations may vary, depending on the equipment frtted:
•
•
•
Fig . 1.7 -Remove the two hoses
shown
by the arrows after
slackening the hose clamps.
Remove the driver's seat,
disconnect the battery earth
cable and remove the
eng in e
bonnet.
• Drain the cooling system
(Section 1.8.1.) und remove the
radiator.
• un up the radiator grill and
lock It In the raised position.
• Disconnect the air intake
hose
and the coolant hose
shown in Fig. 1.7.
Remove the vlsco-clutch from the front end of the engine. Do not store the clutch
assembly In vertical position.
Remove the
oil fifler elbow (Fig. 1.4).
Cut the cable binder securing the engine cable harness.
1
Remove the single poly V-belt from the front of the engine. To do this, refer to Fig.
1
.8 and slacken the nanged nut. Insert a drift of 12 mm diameter and 180 mm In
:th Into the spring-loaded lever and push the tensioning device towards the left.
e eve the tension from the securing screw until the tensioning spring can be
pushed In direction Inlet manifold. Now remove the bolt (3) securing the mounting
17

I .
I!
Exhaust Valve Guides:
-Outer diameter- Std.
-Outer diameter -Repair size
-Inner diameter
Basic bore in
cylinder head:
-Std.
-Repair size
Interference
frt of valve guides -All guides:
- Std.
-Repair size
Valve Guides- 616
Inlet Valve/Exhaust Valve Guides:
-Length:
Inlet valves
Exhaust valves
Outer diameter- Std., all guides
Outer diameter -Repair size, all guides
Inner diameter, all guides
Max. inner diameter
Basic bore in cylinder head:
Std.
Repair size
Interference fit of valve guides -All guides:
Std.
Camshaft- Except 616 Engine
Camshaft Bearings:
- 4 cal. engine
- 5 cal. engine
Journal diameter
Camshaft Bearing Clearance:
-New condition
- Wearllmit
Camshaft End Float:
-New condition
- Wearlimit
Camshaft- 616 Engine
Camshaft bearing running clearance
Camshaft end noat
14. 044-14 . 051 mm
14. 214 -14. 222 mm
9. 000- 9. 015 mm
14 . 030- 14.035 mm
14 .198 -14. 203 mm
0 . 009- 0.021 mm
0.011 - 0. 024 mm
60 .0 or 61 .0 mm
48.5- 40 .5 mm
14 . 03- 14 . 04 mm
14 . 23- 14 . 24 mm
10.00 - 10 . 015 mm
10 . 025 mm
14. 000- 14. 020 mm
14 . 200-14 .220 mm
0.01 - 0 . 04 mm
5
6
30 . 944- 30 . 950 mm
0. 050 - 0.091 mm
0.11 mm
0. 07 - 0 .15 mm
0.18 mm
0. 025- 0. 066 mm (max. 0. 11 mm)
0. 05 - 0.128 mm (max. 0 . 18 mm)
1.3 .0.1. Cylinder Head -Removal and Installation
The following information should be noted when work is carried out on a cylinder head:
16
The cylinder head is made of light-alloy. Engine coolant, engine oil, the air
required to Ignite the fuel and the exhaust gases are directed through the cylinder
head. Glow plugs, injectors, pre-combustion chambers and valve tappets are fitted
to the cylinder head. Also in the cylinder heads you will find the camshaft.
The exhaust manifold and the Inlet manifold are bolted to the outside of the head.
The fuel enters the head on one side and exits on the other side,
I. e. the head is of
the well-known "crossnow" type.
• The cylinder head Is fitted with various sender units, sensors and switching
valves, responsible for certain functions of the temperature control.
• As the cylinder head Is made of light alloy, It Is prone to distortion If, for example,
the order
of slackening or tightening of the cylinder head bolts Is not observed. For
the same reason never remove the cylinder head from a hot engine.
• A cylinder head cannot be checked In frtted position. Sometimes the cylinder head
gasket will "blow", aflowing air Into the cooling system. A quick check is possible
after opening the coolant reservoir cap (engine fa irly cold). Allow the engine to
warm-up and observe the coolant. Visible air bubbles point in most cases
to a "blown" gasket. Further evidence Is white exhaust smoke, oil in the coolant or
coolant in the eng ine oil. The latter can be checked at the oil dipstick. A white,
grey emulsion on the dipstick Is more or less a confirmation of a damaged cylinder
gasket.
• If you are convinced that water has entered the engine and you want to get home
or to the nearest garage, unscrew the injectors and crank the engine with the
starter motor for a while to eject the water. Refit the injectors, start the engine and
drive to your destination without switching off the engine. This is the only method
to avoid serious engine damage (bent connecting rods for example).
The cylinder head must only be removed when the engine Is cold. The head Is
removed together with the exhaust manifold, but the Inlet manifold must be separated
from the cylinder head before the head can be lifted off. New cylinder head gaskets
are wrapped In plastic und must only be unwrapped just before the gasket Is frtted.
The cylinder head can be removed with the engine frtted and these operations are
described below, but note that operations may vary, depending on the equipment frtted:
•
•
•
Fig . 1.7 -Remove the two hoses
shown
by the arrows after
slackening the hose clamps.
Remove the driver's seat,
disconnect the battery earth
cable and remove the
eng in e
bonnet.
• Drain the cooling system
(Section 1.8.1.) und remove the
radiator.
• un up the radiator grill and
lock It In the raised position.
• Disconnect the air intake
hose
and the coolant hose
shown in Fig. 1.7.
Remove the vlsco-clutch from the front end of the engine. Do not store the clutch
assembly In vertical position.
Remove the
oil fifler elbow (Fig. 1.4).
Cut the cable binder securing the engine cable harness.
1
Remove the single poly V-belt from the front of the engine. To do this, refer to Fig.
1
.8 and slacken the nanged nut. Insert a drift of 12 mm diameter and 180 mm In
:th Into the spring-loaded lever and push the tensioning device towards the left.
e eve the tension from the securing screw until the tensioning spring can be
pushed In direction Inlet manifold. Now remove the bolt (3) securing the mounting
17

I I'
I
II
shock absorber (see also Fig. 1.9) and remove the tensioning device. Push down
on the tensioning pulley to loosen and remove the belt.
Fig. 1 .8- Releasing the tenalon of the drive
belt at the front end of the engine.
Tensioning spring
2 Damper
3 Bracket for tensioner
If a power-assisted steering is frtted,
remove the pulley for the drive belt.
• Disconnect all coolant, fuel and
vacuum hoses and the electrical
cables connected to the cylinder head
or any other unit on the cylinder head
which cannot be removed together
with the cylinder head (also see
below).
Fig. 1.1 - Unscrew the demper for the belt
tensioning device from tM cylinder heed end .
• Separate the throttle control linkage at
the ball joint connection.
• Disconnect the vacuum pipes from the
exhauster (vacuum) pump.
One hose and
one union nut must be removed.
• Use suitable clamps and clamp-off the
fuel hoses and disconnect the fuel hoses at
the fuel pre-filter
or remove the fuel filter
bracket and Ue it up with a piece of wire.
• In the case of a four cylinder engine
remove
the Injection pipes of cylinder Nos. 1, 2 and 3 together with the pipe
bracket and remove the Injection pipe of No. 4 cylinder without the bracket. On a
five-cylinder engine, the Injection pipes of Nos. 4 and 5 cylinder are held together
by means of a plastic clip. Also withdraw the leak-off hose at the Injector of the No .
1 cylinder. Close off the hose end in suitable manner (a bolt of suitable diameter
can be pushed into the hose end.
Remove the damper for the engine speed regulation from the Inlet manifold. This
is the Item shown in Fig. 1.1
0.
Fig. 1.10 -The damper for the engine speed
regulation Is
attached to the manifold.
• Disconnect the vacuum hose from
the thermo valve.
18
Disconnect the electrical leads from
the glow plugs.
Remove the securing clip for the
heater assembly feed pipe with a
wire hook. Remove the connectors
from the oil filter and on the other
end.
Disconnect the exhaust pipe flange
•
from the exhaust manifold and unscrew the exhaust pipe support bracket from the
transmission.
Remove the Inlet (Intake) manifold.
Fig. 1.11- Removal of an Injector.
Remove the cylinder head cover. Six
screws must be removed. Two are
located on each long side of the cover
and two on
the timing side of the
engine. If an automatic transmission Is
frtted, there Is a regulating rod frtted
across the cylinder head cover, which
must
be separated on one side at the
ball joint. A stlcldng cylinder head G 1
cover must not be freed by tapping It
with a hammer. If difficult to remove, try to unstlck It by pushing It by hand to one
side.
Use a plastic mallet, lf necessary.
• Unscrew the Injectors (Fig. 1.11) and remove the washers underneath.
• Rotate the engine until the piston of No . 1 cylinder Is at top dead centre In the
firing position., I.e. the
·cr mark must be opposite the adjusting pin, as shown In
Fig. 1.12. A 27 mm socket can be applied to the crankshaft pulley to rotate the
crankshaft.
large tube.
Fig. 1.12 -Dead centre position of
the engine.
Never attempt to rotate the
crankshaft by applying a socket to
the camshaft liming wheel bolt.
The crankshaft must be rotated In
the direction of rotation.
• Remove the chain tensloner
as described
In Section 1.3.5.0.
The chain tensloner plug must be
unscrewed by applying a spanner
to the hexagon. The plug Is
located above the water pump and
the thermostat cover, next to
the
Mark the camshaft sprocket and the timing chain at opposite points, as shown In
Fig. 1.13, using a spot of paint.
Fig. 1 .1 3- Mark the chain and sprocket
With • spot of paint before removal of
the sprocket.
Unscrew the camshaft sprocket
bolt. To counterhold the
camshaft against rotation, Insert
a strong screwdriver blade or
steel bolt Into one of the holes
of the camshaft sprocket.
Remove the camshaft sprocket
from the shan without
19

I I'
I
II
shock absorber (see also Fig. 1.9) and remove the tensioning device. Push down
on the tensioning pulley to loosen and remove the belt.
Fig. 1 .8- Releasing the tenalon of the drive
belt at the front end of the engine.
Tensioning spring
2 Damper
3 Bracket for tensioner
If a power-assisted steering is frtted,
remove the pulley for the drive belt.
• Disconnect all coolant, fuel and
vacuum hoses and the electrical
cables connected to the cylinder head
or any other unit on the cylinder head
which cannot be removed together
with the cylinder head (also see
below).
Fig. 1.1 - Unscrew the demper for the belt
tensioning device from tM cylinder heed end .
• Separate the throttle control linkage at
the ball joint connection.
• Disconnect the vacuum pipes from the
exhauster (vacuum) pump.
One hose and
one union nut must be removed.
• Use suitable clamps and clamp-off the
fuel hoses and disconnect the fuel hoses at
the fuel pre-filter
or remove the fuel filter
bracket and Ue it up with a piece of wire.
• In the case of a four cylinder engine
remove
the Injection pipes of cylinder Nos. 1, 2 and 3 together with the pipe
bracket and remove the Injection pipe of No. 4 cylinder without the bracket. On a
five-cylinder engine, the Injection pipes of Nos. 4 and 5 cylinder are held together
by means of a plastic clip. Also withdraw the leak-off hose at the Injector of the No .
1 cylinder. Close off the hose end in suitable manner (a bolt of suitable diameter
can be pushed into the hose end.
Remove the damper for the engine speed regulation from the Inlet manifold. This
is the Item shown in Fig. 1.1
0.
Fig. 1.10 -The damper for the engine speed
regulation Is
attached to the manifold.
• Disconnect the vacuum hose from
the thermo valve.
18
Disconnect the electrical leads from
the glow plugs.
Remove the securing clip for the
heater assembly feed pipe with a
wire hook. Remove the connectors
from the oil filter and on the other
end.
Disconnect the exhaust pipe flange
•
from the exhaust manifold and unscrew the exhaust pipe support bracket from the
transmission.
Remove the Inlet (Intake) manifold.
Fig. 1.11- Removal of an Injector.
Remove the cylinder head cover. Six
screws must be removed. Two are
located on each long side of the cover
and two on
the timing side of the
engine. If an automatic transmission Is
frtted, there Is a regulating rod frtted
across the cylinder head cover, which
must
be separated on one side at the
ball joint. A stlcldng cylinder head G 1
cover must not be freed by tapping It
with a hammer. If difficult to remove, try to unstlck It by pushing It by hand to one
side.
Use a plastic mallet, lf necessary.
• Unscrew the Injectors (Fig. 1.11) and remove the washers underneath.
• Rotate the engine until the piston of No . 1 cylinder Is at top dead centre In the
firing position., I.e. the
·cr mark must be opposite the adjusting pin, as shown In
Fig. 1.12. A 27 mm socket can be applied to the crankshaft pulley to rotate the
crankshaft.
large tube.
Fig. 1.12 -Dead centre position of
the engine.
Never attempt to rotate the
crankshaft by applying a socket to
the camshaft liming wheel bolt.
The crankshaft must be rotated In
the direction of rotation.
• Remove the chain tensloner
as described
In Section 1.3.5.0.
The chain tensloner plug must be
unscrewed by applying a spanner
to the hexagon. The plug Is
located above the water pump and
the thermostat cover, next to
the
Mark the camshaft sprocket and the timing chain at opposite points, as shown In
Fig. 1.13, using a spot of paint.
Fig. 1 .1 3- Mark the chain and sprocket
With • spot of paint before removal of
the sprocket.
Unscrew the camshaft sprocket
bolt. To counterhold the
camshaft against rotation, Insert
a strong screwdriver blade or
steel bolt Into one of the holes
of the camshaft sprocket.
Remove the camshaft sprocket
from the shan without
19