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
'

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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