Mercedes S-Class W-140

1991-1999 of release

Repair and car operation



Mercedes S-Class
+ Mercedes-Benz Cars of a class S (W-140)
+ Operation manual
+ Routine maintenance
- Engine
   Compression check in engine cylinders
   Engine check by means of the vacuum gage
   Belt of a streaming drive of auxiliary units
   + 6-cylinder petrol engines (M104.944 and M104.990/994)
   + 8-cylinder petrol engines (M119.970/981 and M119.971/981)
   + 12-cylinder petrol engines (M120.980/982)
   + 6-cylinder diesel engines (OM603.971)
   + 6-cylinder diesel engines (OM606.961)
+ Systems of cooling, heating
+ Power supply system and release
+ engine Electric equipment
+ gear shifting Box
+ Avtomaticheckaya transmission
+ Coupling
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment



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Engine

Specifications

General parameters

Separate characteristics are provided also in the text of Head and in case of obligation of their performance are allocated with a bold print.

Engine

Specifications were defined according to EU instructions. All data are valid for cars in base execution with the catalytic converter. Depending on elements of a special complete set data can differ from each other. On this matter you can receive references on any HUNDRED Mercedes-Benzs.

General characteristics

Model

Years вып. Code by VIN Type of engine/system of supply of fuel Volume, cm3 Quantity and расп. c ditch Capacity, hp/kW Torque, Nanometer Max. speed, km/h

Notes

300SE 2.8 92-93 140.028 M104.944HFM 2799 R6 193/142 270 215  
S280 93-94
300SE (SEL) 91-93 140.032 (033) M104.990LH 3199 R6 231/170 315 225  
S320 93-98 M104.944HFM
300SD 91-93 140.134 OM603.971 3449 R6 150/110 330 185  
S350 TD 93-96
S300 TD 96-98 140.135 OM606.961 2996 R6 177/130 330 205  
400SE (SEL) 91-93 140.042 (043) M119.971LH and
M119.981ME
4196 V8 279/205 400 245  
S420 93-98
500SE (SEL) 91-93 140.050 (051) M119.970LH and
M119.980ME
4973 V8 320/235 470 250 Ogr. 270 km/h

S500
93-98
600SE (SEL) 91-93 140.056 (057) M120.980LH and
M120.982ME
5987 V12 394/290 570 250 Ogr. 290 km/h
S600 93-98

Rated power, kW (h.p.) / at rpm)//the Nominal torque, Nanometer (at rpm)

S280
142 (193)/5500//270/3750
S320
170 (231)/5600//315/3750
S420
205 (279)/5700//400/3900
S300
TDI 130/4400//330/1600-3600
S500
235 (320)/5600//470/3900
S600
290 (394)/5200//570/3800

Number cylinders/type/worker volume, cm3/designation

S280
6/DOHC/2799/104
S320
6/DOHC/3199/104
S420
8/OHC/4196/119
S300
TDI 6/DOHC/2996/606
S500
8/OHC/4973/119
S600
12/OHC/5987/120

Maximum turns, rpm

S280
6400
S320
6400
S420
6000
S300
TDI 5300
S500
6000
S600
6000

Extent of compression

S280
Data are not provided
S320
10.0:1
S420, S500
11.0:1
S600
Data are not provided
S320CDI
Data are not provided

Pressure of a compression, bar

S280 S320
10-14
S420, S500, S600
13.5-15.5
S300
TDI 26-32

Operating procedure of cylinders

S280, S320, S300
TDI 1-5-3-6-2-4
S420, S500
1-5-4-8-6-3-7-2
S600
1-12-5-8-3-10-6-7-2-11-4-9

Driving belt

(Generator/helmsman amplifier, air conditioner), mm

S280
2170/2257
S320
2337/2440
S420, S500
2460/-
S300
TDI 6PKx2080/6PKx2120
S600
2585/-
Klapannye gaps
are not regulated, since.
hydrojacks are applied

Major maintenance of the engine

M104 series engines

Sizes of bearings of camshafts

Nominal diameter, mm

Camshaft
29.947 29.963
Head of the block of cylinders
30.000 30.021

Repair diameter, mm

Camshaft
30.434 30.450
Head of the block of cylinders
30.500 30.525.
Admissible purity of a surface of a bed, mm
0.001-0.004
Admissible konusnost, mm
0.012
Admissible shift of an axis, mm
0.040

Люфт in the bearing, mm

The radial
0.035
The axial
0.06-0.21

The sizes of directing plugs of valves

Plugs from non-ferrous metal

The directing plug from non-ferrous metal (M104.990 engines of the first version)


Diameters of openings in a head of the block of cylinders, mm

Nominal size
13.50-13.51
1st nominal size
13.53
Repair size
13.70

External diameter of the directing plug, mm / Color marking

Nominal size
13.52-13.53/-
1st nominal size
13.54-13.55/Gray-brown
Repair size
13.71-13.72/red
Tightness, mm
0.012-0.031

Internal diameter of the directing 1st version, mm

Inlet valve
8.000-8.015
Final valve
9.000-9.015

Internal diameter of the directing 2nd version, mm

Inlet valve
7.000-7.015
Final valve
8.000-8.015

Length of the "L" plug, mm

Inlet valve
35.5
Final valve
37.9

Vystupaniye "from" the plug, mm

Inlet valve
10.8-11.2
Final valve
8.2-8.6

Ceramic-metal plugs

The metal directing plug of the M104.990 engine (the second version) and M104.944/994


Diameter of an opening in a head of the block of cylinders, mm

Nominal size
12.50-12.51
1st nominal size
12.53
Repair size
12.70

External diameter of the directing plug, mm / Color marking

Nominal size
12.54/-
1st nominal size
12.56-12.57/-
Repair size
12.74-12.75/-
Tightness, mm
0.029-0.051

Internal diameter of the directing plug, mm

Inlet and final valves
7.000-7.015

Length of the "L" directing plug, mm

Inlet and final valves
37.5

Vystupaniye "from" the directing plug, mm

Inlet and final valves
10.2-10.4

Sizes of saddles of valves

Details of installation of saddles of valves


Inlet valve//Final valve

Nominal rates, mm
Diameter of D1 of an opening
36 H6//32 Н6
Diameter of the D saddle
36.10-36.12/32.10-32.12

Repair values, mm

Diameter of D1 of an opening
37.20 H6//33.20 Н6
Diameter of the D saddle
37.30/32.30
Size "t"
5.6-5.9
Diameter of D2
30/25.6

Performance data of piston rings

Gaps of landing of rings in flutes of pistons, mm

Characteristic

Value

Top kompressionny ring
0.20-0.40
Bottom kompressionny ring
0.20-0.40
Maslosjemnoye ring
0.20-0.45

Gaps in locks of rings, mm

Top kompressionny ring
0.015-0.050
Bottom kompressionny ring
0.020-0.040
Maslosjemnoye ring
0.010-0.045

Sizes and weight of rods and shatunny bearings

2 — Designation
3 — Balancing грузик
4 — Bolt М9
5 — the Directing plug

6 — the Top loose leaf
7 — Nizhny the loose leaf
8 — Adjusting ears
Arrow — the movement Direction


Rods

Distance of "L" between centers heads of a rod, mm
М104.94
148.995-49.005
М104.99
144.995-145.005
Width "In" the bottom head of a rod, mm
21.948-22.000
Width of "b" of the top head of a rod, mm
21.948-22.000
Diameter of "D1" of the bottom head without loose leaves, mm
51.600-51.619
Diameter of "d1" of the top head under the plug, mm
24.500-24.571
Internal diameter of "d" of the plug of the top head of a rod, mm
22.007-22.013
Люфт a piston finger in the plug, mm
0.013-0.018
Admissible twisting of a rod, mm
0.015
Tolerance from parallelism
top head of a rod and plug, mm
0.07
Admissible difference of scales of rods, g
4

Cranked shaft

Diameters of shatunny necks, mm / color marking of a cheek of a crank
The nominal
47.955-47.965/not marked
The nominal
1 47.945 - 47.955/orange
The nominal
2 47.935 - 47.945/dark blue
1st repair size
47.700-47.715/-
2nd repair size
47.450-47.465/-
3rd repair size
47.200-47.215/-
4th repair size
46.950-46.965/-

Width of shatunny necks, mm

Nominal size
27.958-28.042
Repair size
to 28.300

Loose leaves of shatunny bearings

Thickness of a wall, mm
Nominal size
Red marking
1.806-1.810
Yellow marking
1.810-1.814
Dark blue marking
1.814-1.818
Nominal 1 (it is not delivered as the spare part)
Red marking
1.811-1.815
Yellow marking
1.815-1.819
Dark blue marking
1.819-1.823
Nominal 2 (it is not delivered as the spare part)
Red marking
1.816-1.820
Yellow marking
1.820-1.824
Dark blue marking
1.824-1.828
1st repair size (Yellow marking)
1.995-1.999
2nd repair size (Yellow marking)
2.060-2.064
3rd repair size (Yellow marking)
2.185-2.189
4th repair size (Yellow marking)
2.310-2.314

Sizes of a cranked shaft and radical bearings

Control sizes

Admissible konusnost of radical and shatunny necks of a cranked shaft, mm 0.002

Admissible ovality on 54 mm of length, mm

Radical necks 0.010
Shatunnye of a neck 0.010
Tolerance of an axis of the established loose leaves, mm 0.02

Radius internal galtel, mm

Radical necks 1.9-2.1  
Shatunnye of a neck 1.9-2.1  

Repair sizes

Diameter of a radical neck, mm / Color/alphabetic marking on a forward part of a cranked shaft
The nominal
57.960-57.965/Siny/in
57.955-57.960/Zhelty/G
57.950-57.955/Krasny/R
Nominal 1
57.945-57.950/Bely/W
57.940-57.845/Purpurny/V
1st repair size 57.705-57.715/-/-
2nd repair size 57.450-57.465/-/-
3rd repair size 57.205-57.215/-/-
4th repair size 57.955-57.965/-/-

Alphabetic marking

Color marking is put on No. No. 8 and 9 counterbalances, an alphabetic reference - on a forward part of a cranked shaft.


Width of a radical neck, mm /

Nominal size
24.500-24.533/-/0
Nominal 1
24.600-24.633/Krasny/1
1st repair size 24.700-24.733/-/-
2nd repair size 24.900-24.933/-/-
3rd repair size 25.000-25.033/-/-
4th repair size -/-/-

Selection of thickness of loose leaves of radical bearings

The nominal size (Diameter of an opening under a neck of the radical bearing of 58.00 mm)

Dark blue label (index 52)
Thickness of the top loose leaf, mm
2.255-2.260
Thickness of the bottom loose leaf, mm
2.255-2.260
Yellow label (index 54)
Thickness of the top loose leaf, mm
2.260-2.265
Thickness of the bottom loose leaf, mm
2.260-2.265
Red label (index 56)
Thickness of the top loose leaf, mm
2.265-2.270
Thickness of the bottom loose leaf, mm
2.265-2.270

The nominal size 1 (Diameter of an opening under a neck of the radical bearing of 58.00 mm)

White-dark blue label (index 57)
Thickness of the top loose leaf, mm
Thickness of the bottom loose leaf, mm
2.263-2.268
White and yellow label (index 58)
Thickness of the top loose leaf, mm
Thickness of the bottom loose leaf, mm
2.268-2.273
White-red label (index 60)
Thickness of the top loose leaf, mm
Thickness of the bottom loose leaf, mm
2.273-2.278

The 1st repair size (Diameter of an opening under a neck of the radical bearing of 57.75 mm)

Dark blue label (index 52)
Thickness of the top loose leaf, mm
2.375-2.380
Thickness of the bottom loose leaf, mm
2.375-2.380
Yellow label (index 54)
Thickness of the top loose leaf, mm
2.380-2.385
Thickness of the bottom loose leaf, mm
2.380-2.385

The 2nd repair size (Diameter of an opening under a neck of the radical bearing of 57.50 mm)

Dark blue label (index 52)
Thickness of the top loose leaf, mm
2.500-2.505
Thickness of the bottom loose leaf, mm
2.500-2.505
Nominal width of the loose leaf, mm
19.979-20.000

Diameter of beds of radical bearings of a cranked shaft, mm

No. No. 1, 5, 7 bearings
1 kerneniye
62.500-62.505
2 kerneniye
62.506-62.513
3 kerneniye
62.513-62.519
No. No. 2, 3, 4, 6 bearings
2 kerneniye
62.500-62.506
3 kerneniye
62.506-62.519

Sizes and designations of cylinders and pistons

Diameters of cylinders//pistons, mm

Nominal size (89.9 mm)
Marking of group of the admission of A
89.900-89.906/89.873-89.879
Marking of group of the admission by the X-th
89.906-89.912/88.878-89.886
Marking of group of the admission In
89.912-89.918/89.885-89.891
1st repair size (+ 0.25 mm)
Marking of group of the admission of A
90.150-90.156/90.123-90.129
Marking of group of the admission X
90.156-90.162/90.128-90.136
Marking of group of the admission In
90.162-90.168/90.135-90.141
2nd repair size (+ 0.5 mm)
Marking of group of the admission of A
90.400-90.406/90.373-90.379
Marking of group of the admission X
90.406-90.412/90.378-90.386
Marking of group of the admission of B
90.412-90.418/90.385-90.391

Marking (except AMG engines) is put on a convex part of the piston and beaten out on an interfaced surface of the block of cylinders.

Sizes of the block of cylinders

Height, mm
282.25-282.35
Minimum admissible height after обработки1), mm
281.95

Admissible roughness of an interfaced surface of the block of cylinders, mm

The top
0.03
The bottom
0.04
1) After processing of the block of cylinders height change no more than on 0.4 mm is allowed.

M119 series engines

Sizes of bearings of camshafts

Diameter of beds of bearings of camshafts in a head of the block of cylinders, mm

Nominal size
28.000 28.021
Repair size
28.500 26.521

Diameter of a neck of the bearing of a camshaft, mm

The nominal
27.960 2.947
The repair
28.447 28.460

Люфт in bearings of a camshaft, mm

The radial
0.053-0.061
The axial
0.050-0.150

The sizes of directing plugs of valves

The directing plug from non-ferrous metal (M104.990 engines of the first version)


Plugs from non-ferrous metal (only M119.97 engines)

Diameters of openings in a head of the block of cylinders, mm
Nominal size
13.50-13.51
1st nominal size
13.53
Repair size
13.70
External diameter of the directing plug, mm / color marking
Nominal size
13.51-13.53/-
1st nominal size
 
13.52-13.53/gray-green
 
13.54-13.55/gray-brown
Repair size
13.71-13.72/red
External diameter of the directing plug, mm / color marking
Internal diameter directing, mm
Inlet and final valves
7.000-7.015
External diameter of the directing plug, mm / color marking
Length of the "L" plug, mm
Inlet valve
35.5
Final valve
37.9
Distance "and" (inlet valve), mm
2.7-2.9
«b» distance (inlet and final valves), mm
5.4-5.6
Distance "with" (inlet and final valves), mm
10.8-11.2

Ceramic-metal plugs (all engines of the M119 series)

Diameter of an opening in a head of the block of cylinders, mm
Nominal size
12.50-12.51
1st nominal size
12.53
Repair size
12.70
External diameter of the directing plug, mm / Color marking
Nominal size
12.54-12.55/-
1st nominal size
12.56-12.57/grey
Repair size
12.74-12.75/red
Internal diameter of the directing plug, mm
Inlet and final valves
7.000-7.015
Length of the "L" directing plug, mm
Inlet and final valves
37.5
Distance "and", mm
«b» distance (inlet and final valves), mm
5.4-5.6
Distance "with" (inlet and final valves), mm
10.2-10.4

Sizes of saddles of valves


M119.970 engines

Nominal sizes

Diameter of "D1" of an opening in a head of the block of cylinders, mm
Inlet valves
39 Н6
Final valve
34 Н6
Diameter of the "D" saddle, mm
Inlet valves
39.10-39.09
Final valves
34.10-34.09

Repair sizes

Diameter of "D1" of an opening in a head of the block of cylinders, mm
Inlet valves
40.20 Н6
Final valves
35.20 Н6
Diameter of the "D" saddle, mm
Inlet valves
40.30
Vypusenye valves
35.30
Size "t" (inlet and final valves), mm
7.8-7.9
Diameter of "D2", mm
Inlet valves
38.47
Final valves
33.47

M119.971/980/982 engines

Nominal sizes

Diameter of "D1" of an opening in a head of the block of cylinders, mm
Inlet valves
36 Н6
Final valves
34 Н6
Diameter of the "D" saddle, mm
Inlet valves
36.10-36.09
Final valves
34.10-34.09

Repair sizes

Diameter of "D1" of an opening in a head of the block of cylinders, mm
Inlet valves
37.20 Н6
Final valves
35.20 Н6
Diameter of the "D" saddle, mm
Inlet valves
37.30
Final valves
35.30
Size "t" (inlet and final valves), mm
7.8-7.9
Diameter of "D2", mm
Inlet valves
35.47
Final valves
33.47

Sizes and designations of cylinders and pistons

A — the Longitudinal direction
B — the Cross-section direction
and — the Top point of a course of the top kompressionny ring

b — the Bottom dead point
with — the Bottom point of a course of a maslosjemny ring
1, 2, 3 — Points of measurements

M119.960/970/972/974 series engines

Diameters of pistons//cylinders, mm

Nominal size (96.5 mm)
Designation 0 (index 52)
96.483-96.493/96.498-96.503
Designation 0 + (Index 53)
96.488-96.498/96.503-96.508
Designation 1 (Index 54)
96.493-96.503/96.508-96.513
Designation 1 + (Index 55)
96.498-96.508/96.513-96.518
Designation 2 (Index 56)
96.503-96.513/96.518-96.523
1st repair size (+0.5 mm)
Designation 0
96.983-96.993/96.998-97.003
Designation 1
96.993-97.003/97.008-97.013
Designation 2
97.003-97.013/97.018-97.023
The 2nd repair (+1.0 mm)
Designation 0
97.483-97.493/97.498-97.503
Designation 1
97.493-97.503/97.508-97.513
Designation 2
97.503-97.513/97.518-97.523

M119.980/982/970/972/974 series engines

Diameters of pistons//cylinders, mm

Nominal size (96.5 mm)
A designation (index 52)
96.482-96.495/96.500-96.508
Designation In (an index 54)
96.491-96.504/96.508-96.516
Designation With (an index 56)
96.499-96.512/96.516-96 524
The 1st repair (+0.5 mm)
A designation
96.982-96.995/97.000-97.008
Designation In
96.991-97.004/97.008-97.016
Designation
With 96.999-97.012//97.016-97.024
The 2nd repair (+1.0 mm)
A designation
97.482-97.495/97.000-97.508
Designation In
97.491-97.504/97.508-97.516
Designation With
97.499-97.512/97.516-97.524

M119.971/975/981/985 engines (digital designation)

Diameters of pistons//cylinders, mm

Nominal size (92.0 mm)
Designation 0 (index 52)
91.983-91.993/91.998-91.003
Designation 0 + (index 53)
91.988-91.998/92.003-92.008
Designation 1 (index 54)
91.993-92.003/92.008-92.013
Designation 1 + (index 55)
91.998-92.008/92.013-92.018
Designation 2 (index 56)
92.003-92:013/92.018-92.023
The 1st repair (+0.5 mm)
Designation 0
92.483-92.493/92.498-92.503
Designation 1
92.493-92.503/92.508-92.513
Designation 2
92.503-92.513/92.518-92.523
The 2nd repair (+1.0 mm)
Designation 0
92.983-92.993/92.998-93.003
Designation 1
92.993-93.003/93.008-93.013
Designation 2
93.003-93.013/93.018-93.023

M119.971/975/981/985 engines (alphabetic reference)

Diameters of pistons//cylinders, mm

Nominal size (96.5 mm)
A designation (index 52)
91.982-91.995/92.000-92.008
Designation In (an index 54)
91.991-92.004/92.008-92.016
Designation With (an index 56)
91.999-92.012/92.016-92.024
The 1st repair (+0.5 mm)
A designation
92.482-92.495/92.500-92.508
Designation In
92.491-92.504/92.508-92.516
Designation With
92.499-92.512/92.516-92.524
The 2nd repair (+1.0 mm)
A designation
92.982-92.995/93.000-93.008
Designation In
92.991-93.004/93.008-93.016
Designation With
92.999-93.012/93.016-93.024

Sizes of rods


Rods
Distance of "L" between centers heads of a rod, mm
154.450-154.550/148.950-149.050
Width "In" the bottom head of a rod, mm
24.857-24.890/24.857-24.890
Width of "b" of the top head of a rod, mm
27.900-28.000/21.900-22.100
Diameter of the "D" bottom head without loose leaves, mm
51.600-51.619/51.600-51.619
Diameter of "d1" of the top head under the plug, mm
26.007-26.013/24.007-24.013
Internal diameter of "d" of the plug of the top head
rod, mm
29.000-29.021/27.000-27.210
Люфт a piston finger in the plug, mm
0.007-0.018

Sizes of a cranked shaft, radical and shatunny bearings

Engines with the adjusting bearing

Diameter of a neck of a cranked shaft, mm

The nominal
Dark blue marking
63.965
Yellow marking
63.960
Red marking
63.955
The 1st repair
63.700
2nd repair size
63.450
3rd repair size
63.200
4th repair size
62.950

Width of a radical neck with the adjusting bearing, mm

Nominal size
27.021
Limiting admissible size
27.50

Diameter of a neck of a cranked shaft, mm

The nominal
47.955
The 1st repair
47.705
2nd repair size
47.455
3rd repair size
47.205
4th repair size
46.955

Width of a radical neck, mm

Nominal size
50.100
Limiting admissible size
50.30

Diameter of openings under radical bearings, mm

Dark blue marking
68.486
Yellow marking
68.492
Red marking
68.500
Diameter of openings under shatunny bearings, mm
51.619
Admissible ovality and konusnost of the radical
and shatunny necks of a cranked shaft, mm
0.01

Radial gap in radical bearings, mm

New shaft
0.021-0.045
Maximum permissible value
0.09

Radial gap in shatunny bearings, mm

New shaft
0.030-0.055
Maximum permissible value
0.080

Axial люфт cranked shaft, mm

New shaft
0.10-0.22
Maximum permissible value
0.30

Axial люфт rods, mm

New shaft
0.22-0.38
Maximum permissible value
0.50

Compliance of color and dot marking of loose leaves of radical bearings and block of cylinders

Parameters

Marking

Dot marking on the block of cylinders 1 point 2 points 3 points
Color marking on covers подшип-ников / block molding The dark blue The yellow The red
Color marking of the top loose leaves The dark blue The yellow The red
Color marking of the bottom loose leaves The dark blue The yellow The red

Engines with persistent half rings

Diameter of a neck of a cranked shaft/thickness of persistent half rings, mm

Nominal size
Dark blue marking
63.960-63.965/2.20
Yellow marking
63.955-63.960/2.25
Red marking
63.950-63.955/2.30
1st nominal size
63.945-63.950
63.940-63.945
63.935-63.940
Width of a neck of a cranked shaft, mm
27.000-27.033
Diameter of a neck of a cranked shaft, mm
47.955-47.965
Width of a neck of a cranked shaft, mm
50.000/50.100
Diameter of openings under radical bearings, mm
Dark blue marking
68.480-68.486
Yellow marking
68.986-68.492
Red marking
68.492-68.500
Diameter of openings under the shatunny
bearings, mm
51.600-51.619
Admissible ovality and konusnost of the radical
and shatunny necks of a cranked shaft, mm
0.01
Radial gap in radical bearings, mm
New shaft
0.021-0.045
Maximum permissible value
0.09
Radial gap in shatunny bearings, mm
New shaft
0.030-0.055
Maximum permissible value
0.080
Axial люфт cranked shaft, mm
New shaft
0.10-0.22
Maximum permissible value
0.30
Axial люфт rods, mm
New shaft
0.22-0.38
Maximum permissible value
0.50

Compliance of color and dot marking of loose leaves of radical bearings and block of cylinders

Parameters

Marking

Dot marking on the block of cylinders 1 point 2 points 3 points
Color marking on covers подшип-ников / block molding The dark blue The yellow The red
Color marking of the top loose leaves The dark blue The yellow The red
Color marking of the bottom loose leaves The dark blue The yellow The red

M120 series engines

Code designations of camshafts

M120.980 series engines on No. 010 822

Right inlet camshaft
29
Left inlet camshaft
30
Right final camshaft
27
Left final camshaft
28

Engines of the M120.980 series with No. 010 823 and М120.982

Right inlet camshaft
33
Left inlet camshaft
34
Right final camshaft
31
Left final camshaft
32

The sizes and details of installation of directing plugs of valves

Details of installation of directing plugs of valves


Plugs from non-ferrous metal

Internal diameter of the directing plug, mm
Inlet valve
7.000-7.015
Final valve
8.000-8.015
Length of the directing plug "L", mm
37.5
Tightness in a head of the block of cylinders
0.029-0.051
Lock ring
It is not established
«a» distance
2.7-2.9
«b» distance
5.4-5.6
«c» distance
8.2-8.6

The metallized plugs

Internal diameter of the directing plug, mm
Inlet valve
7.000-7.015
Final valve
7.000-7.015
Length of the directing plug "L", mm
37.5
Tightness in a head of the block of cylinders
0.029-0.051
Lock ring
It is established
«a» distance
«b» distance
«c» distance
10.2-10.4

Sizes and designations of cylinders and pistons

Diameters of cylinders//pistons, mm

Nominal size (89 mm)

Группа1) 0
89.000-89.008/88.978-88.988
Group 1
89.008-89.016/88.988-88.998
Group 2
89.016-89.024/88.998-89.008

1st repair size (+ 0.352) mm)

Group 0
89.350-89.358/89.328-89.338
Group 1
89.358-89.366/89.338-89.348
Group 2
89.361-89.374/89.348-89.358

2nd repair size (+0.72) mm)

Group 0
89.700-89.708/89.678-89.688
Group 1
89.708-89.710/89.688-89.698
Group 2
89.716-89.724/89.698-89.708
1) Group number on new engines is beaten out on an interfaced surface of the block of cylinders, the following cylinder
2) Number of group is put on a piston skirt with paint and besides beaten out sideways on a piston skirt

Sizes of rods

Size "l", mm
153.95-154.05
Width of the bottom shatunny head "In", mm
21.948-22.000
Width of the top shatunny head of "b", mm
19.90-20.10
Diameter of an opening of the bottom head of a rod of "D1", mm
51.600-51.619
Diameter of an opening of the top head of a rod of "d1", mm
24.500-24.521
Internal diameter of the plug of the top head of a rod of "d", mm
22.007-22.013
Gap of landing of a piston finger in the plug of a rod, mm
0.013-0.018
Admissible difference of scales of rods assembled, g
4

Sizes of a cranked shaft, radical and shatunny bearings

Diameter of a radical neck of a cranked shaft/thickness of persistent laying of the adjusting bearing, mm

Nominal size
57.960/2.15
57.955/2.20
57.950/2.25
1st nominal size
57.945/2.35
57.940/2.40
57.935
1st repair size
57.700
2nd repair size
57.450
3rd repair size
57.200

Diameter of shatunny necks, mm

Nominal size
47.955
1st repair size
47.705
2nd repair size
47.455
3rd repair size
47.205
Width of shatunny necks, mm
24.225
Diameter of beds of radical bearings, mm
62.500
Diameter of beds of shatunny bearings, mm
61.600
Internal diameter of the radical
bearings, mm
23.500
Width of a shatunny neck, mm
22.000
Admissible ovality and konusnost of beds of bearings
0.02

Radial gap, mm

Radical bearings
0.026-0.050
Shatunnye bearings
0.020-0.058
Axial люфт cranked shaft, mm
0.100-0.254
Axial люфт rods, mm
0.225-0.391

Compliance of color and dot marking of loose leaves of radical bearings and block of cylinders

Parameters

Value

Dot marking on the block of cylinders
1 point
2 points
3 points
Color marking on covers of bearings
The dark blue
The yellow
The red
Color marking on a cranked shaft
The dark blue
The yellow
The red
The white
The violet
Color marking of the top loose leaves
The dark blue
The yellow
The red
Color marking of the bottom loose leaves
The dark blue
The yellow
The red
The white
The violet
Alphabetic marking on necks of radical bearings
In
G
R
W
V
The valid numbers of diameters on radical necks
35-39
40-44
45-49
50-54
55-60

OM603 series engines

Sizes of rods

1 — the Rod
2 — Shatunnaya a cover
3 — the Plug
4 — Directing grooves
5 — Shatunny a bolt
6 — Balancing грузики
7 — the Identification field (models with a turbo-supercharging)
8 — Grooves for installation of loose leaves
9 — the Oil channel (models with a turbo-supercharging)

10 — the Oil channel (models without a turbo-supercharging)
11 — the Identification field (models without a turbo-supercharging)
b — Width of the top head of a rod
B — Width of the bottom head of a rod
d — Internal diameter of the plug of the top head of a rod
d1 — External diameter of the plug of the top head of a rod
D1 — Diameter of an opening of the bottom head of a rod
L — distance between centers openings of heads of a rod


Size "L", mm
144.97-145.03
Width of the bottom head of a rod "In", mm
21.948-22.000
Diameter of an opening of the bottom head of a rod of "D1"
51.600-51.614
Maximum admissible ovality and konusnost of an opening, mm
0.02
Internal diameter of the plug of the top head of a rod of "d", mm
28.018-28.024
External diameter of the plug, mm
30.575-30.600
Diameter of an opening of the top head of a rod (under the plug) «d1», mm
30-500-30-525
Люфт landings of a piston finger in the plug of a rod, mm
0.007-0.018

Sizes of cylinders

Diameter of cylinders, mm

The nominal
89.0
Dimensional group A
89.000-89.006
Dimensional group X
89.007-89.012
Dimensional group B
89.013-89.018
Tolerance of diameter of the cylinder in the longitudinal and cross-section directions, mm
0.20
Admissible konusnost, mm
0.007
Admissible ovality, mm
0.07
Limit of wear, mm
0.05

The sizes of openings in the block of cylinders under installation of sleeves

D, D1 — Diameters under sleeve fillets
D2 — Diameter under a sleeve
T — Length of a sleeve
Т1 — Landing depth of a sleeve


Diameter of "D2" under a sleeve in the block
cylinders, mm
91.500-91.535
Diameter of "D1" under a sleeve fillet
in the block of cylinders, mm
92.00-92.20
Diameter of "D" sleeves under a fillet
in the block of cylinders, mm
94.15-94.25
Length of a sleeve of "T", mm
231.0-231.2
Landing depth of a sleeve of "T1", mm
1.0-1.2
Width of a facet of "M", mm
35

Sizes of a cranked shaft, radical and shatunny bearings

Diameter of a radical neck, mm

Nominal size
57.940-57.965
1st repair size
57.700-57.715
2nd repair size
57.450-57.465
3rd repair size
57.200-57.215
4th repair size
56.950-56.965

Diameter of a radical neck, mm

Nominal size
47.940-47.965
1st repair size
47.700-47.715
2nd repair size
47.450-47.465
3rd repair size
47.200-47.215
4th repair size
46.950-46.964

Adjusting width of radical necks, mm

Nominal size
24.500-24.533
1st repair size
24.600-24.633
2nd repair size
24.700-24.733
3rd repair size
24.900-24.933
4th repair size
25.000-25.033
Diameter of an opening under a cranked shaft, mm
62.500-62.519
Width of an opening under a cranked shaft at the established loose leaves, mm
19.979-20.000
Admissible ovality and konusnost of beds of loose leaves of radical bearings, mm
0.02

Working gaps of radical bearings, mm

The new
0.03-0.05
The admissible
0.08

Axial люфт cranked shaft, mm

The new
0.10-0.25
The admissible
0.3
Radial palpation of a cranked shaft, mm
0.020-0.065
Standard loose leaves of a cranked shaft for covers of bearings in diameter
58 mm
Repair diameter (color - dark blue), mm
52
Repair diameter (color yellow), mm
54
Repair diameter (color yellow), mm
54
Thickness of the loose leaf, mm
2.260-2.265
Repair diameter (color - red), mm
56
Thickness of the loose leaf, mm
2.265-2.270
Repair diameter (color white), mm
57
Thickness of the loose leaf, mm
2.270-2.275
Repair diameter (color purple), mm
58
Thickness of the loose leaf, mm
2.275-2.280

OM606 series engines

Sizes of valves

1 — Adjusting labels for engine reduction in the provision VMT of the end of a step of compression of the piston of the first cylinder
2 — Blocking of an inlet camshaft by means of a core
3 — Make sure of correctness of combination of 1.5-millimetric openings in asterisks
4 — For fastening of asterisks of camshafts the disposable bolts which are subject to replacement without fail are used
5 — Assembly of a natyazhitel of a chain
6 — At TNVD removal/installation the cranked shaft should be brought into situation 14 ° + 05 ° after VMT of the piston of the first cylinder
7 — the Bolt of an asterisk of TNVD has the left cutting.
8 — the Lock tool

Diameter of a plate of the valve "D", mm

The inlet
25.90-26.10
The final
28.90-29.10
Height of a cylindrical part (corbel)
plates of the valve "h", mm
1.0-1.2
Corner of a facet of a saddle of the valve
45 ° 15'

Diameter of a core of the D1 valve, mm

The inlet
6.955-6.97
The final
5.955-5.97

The full is long the valve "L", mm

The inlet
105.5-105.9
The final
105.2-105.9
Width of a working facet of a saddle of the valve, mm
1.9
Shift of an axis of a saddle of the valve concerning a core, mm
0.03

Designation on the end of a core of the valve

The inlet
A 606 13
The final
E 606 11

The sizes of directing plugs of valves

Details of installation of directing plugs of valves


Diameter of an opening in a head of the block of cylinders, mm

The nominal
12.50-12.51
The 1st nominal
12.53
The 1st repair
12.70

External diameter of the directing plug, mm

The nominal
12.54-12.55
The 1st nominal (color: gray)
12.56-12.57
The 1st repair (color: red)
12.74-12.75

Internal diameter of the directing plug, mm

Inlet valve
6.000-6.015
Final valve
6.000-6.015 (till 11.94)
7.000-7.015 (from 11.94)
Length of the directing plug "L", mm
37.5
Landing tightness in a block head
cylinders, mm
0.029-0.051
Size "a"
Size "b"
Size "s"
10.2-10.04

Sizes of saddles of valves

Frezerovka and polishing of saddles of valves



Details of installation of a saddle of the valve


Internal diameter of the directing plug, mm

Width of a facet of a saddle of the valve "b", mm
Inlet valve
1.0-1.5
Final valve
0.8-1.5
Corner of a facet of a saddle of the valve
45 ° 15'
Adjustment corner in
Inlet valve
15 ° 15'
Final valve
25 ° 15'
Limiting ovality of a saddle of the valve, mm
0.03
Distance from an end face of a core of the valve to the bearing of a camshaft of "T", mm
23.7-24.2

Depth of an opening "With" under a valve saddle in a head of the block of cylinders, mm

Standard ring
Inlet valve
7.94-8.04
Final valve
7.924-8.02
Repair ring
Inlet valve
8.14-8:24
Final valve
8.12-8.23

Radius of "R", mm

Inlet valve
0.2-0.4
Final valve
0.2-0.4

Diameter of "D2" of an opening under a saddle of the valve, mm

Nominal size
Inlet valve
30.060-30.070
Final valve
28.000-28.013
Repair size
Inlet valve
30.250-30.266
Final valve
28.250-28.263

Overlapping of valves, mm

Inlet valve
0.2-0.4
Final valve
0.2-0.4

Height of a saddle of the valve "N", mm

Nominal size
Inlet valve
5.6
Final valve
5.6
1st repair size
Inlet valve
5.6
Final valve
5.6

External diameter of the "D" saddle of the valve, mm

Nominal size
Inlet valve
30.000-30.013
Final valve
27.97-28.07
1st repair size
Inlet valve
30.31-30.32
Final valve
28.31-28.32

Sizes of rods

1 — the Rod
2 — Shatunnaya a cover
3 — the Plug
4 — Directing grooves
5 — Shatunny a bolt
6 — Balancing грузики
7 — the Identification field (models with a turbo-supercharging)
8 — Grooves for installation of loose leaves
9 — the Oil channel (models with a turbo-supercharging)

10 — the Oil channel (models without a turbo-supercharging)
11 — the Identification field (models without a turbo-supercharging)
b — Width of the top head of a rod
B — Width of the bottom head of a rod
d — Internal diameter of the plug of the top head of a rod
d1 — External diameter of the plug of the top head of a rod
D1 — Diameter of an opening of the bottom head of a rod
L — distance between centers openings of heads of a rod


Distance between centers shatunny
heads of "L", mm 1
48.7-149.3
Width of top «b» and bottom "In"
heads of a rod, mm
21.48-22.00
Diameter of "D1" of the bottom head
rod, mm
51.600-51.614
Admissible ovality and konusnost of an opening of the bottom head of a rod, mm
0.02
Admissible twisting of a rod
on 100 mm of length, mm
0.1
Admissible difference in a deviation
from parallelism between heads
rod on 100 mm of length of a rod, mm
0.045
Internal diameter of the plug top
heads of a rod of "d", mm
28-018-28.024
External diameter of the plug, mm
30.575-30.600
Diameter under the plug in a verkhneygolovka of a rod of "d1", mm
30.500-30.525
Gap of a piston finger in the plug
top head of a rod, mm
0.007-0.008
Maximum vystupaniye (Rz) of the plug
rod outside, micron
5
Maximum admissible difference of weight of rods, g
2

The sizes of openings in the block of cylinders under installation of sleeves, mm

Sleeve extraction


Diameter of "D2" under a sleeve in a patch of light of cylinders, mm
9.000-90.535
Diameter of "D1" under a sleeve fillet in the block of cylinders, mm
90.55-90.65
Diameter of "D" sleeves under a fillet in the block of cylinders, mm
92.65-92.75
Length of a sleeve of "T", mm
231.0-231.2
Landing depth of the sleeve «Т1», mm
1.0-1.2

Sizes of cylinders

A — the Longitudinal direction
B — the Cross-section direction
and — the Top point of a course of the top kompressionny ring

b — the Bottom dead point
with — the Bottom point of a course of a maslosjemny ring
1, 2, 3 — Points of measurements

Diameter, mm

The nominal
87.0
Dimensional group A
87.000-87.006
Dimensional group X
87.007-87.012
Dimensional group B
87.013-87.018
Admissible limit of the cylinder in the longitudinal
and cross-section directions, mm
0.20
Admissible konusnost of cylinders
new block, mm
0.000-0.014
Limit of wear, mm
0.05
Admissible ovality of cylinders, mm
0.07

Sizes of a cranked shaft

Diameter of an opening
under a cranked shaft, mm
62.500-62.519
Width of an opening under a cranked shaft
at the established loose leaves, mm
19.979-20.000
Admissible ovality and konusnost
beds of loose leaves radical
bearings of a cranked shaft, mm
0.02
Working gap in radical bearings, mm
The new
0.03-0.05
Maximum permissible
0.08
Axial люфт cranked shaft, mm
The new
0.10-0.25
Maximum permissible
0.3
Radial palpation of a cranked shaft, mm
0.020-0.065
Nominal loose leaves of a cranked shaft for covers of bearings in diameter of 58 mm
Repair diameter (color - dark blue), mm
52
Thickness of the loose leaf, mm
2.255-2.260
Repair diameter (color - yellow), mm
54
Thickness of the loose leaf, mm
2.260-2.265
Thickness of the loose leaf, mm
2.265-2.270
Repair diameter (color - white), mm
57
Thickness of the loose leaf, mm
2.270-2.275
Repair diameter (color - purple), mm
58
Thickness of the loose leaf, mm
2.275-2.280
Loose leaves of the 1st repair size of a cranked shaft for covers of bearings in diameter of 57.70 mm
Thickness of the loose leaf, mm
2.37
Loose leaves of the 2nd repair size of a cranked shaft for covers of bearings in diameter of 57.40 mm
Thickness of the loose leaf, mm
2.50
Loose leaves of the 3rd repair size of a cranked shaft for covers of bearings in diameter of 57.20 mm
Thickness of the loose leaf, mm
2.62
Loose leaves of the 4th repair size of a cranked shaft for covers of bearings in diameter of 56.90 mm
Thickness of the loose leaf, mm
2.75

Efforts of a tightening of carving connections, Nanometer

Order of a tightening of bolts of a head of the block of cylinders on models with petrol engines

Order of a tightening of bolts of a head of the block of cylinders on models with diesel engines


Bolts of a head of cylinders

Petrol models (length to the basis
heads no more than 162.7 mm)
55НЧм, +90 °, +90 °
S300 TDI to 01.89 g (length to the basis of heads no more than 83.6, 105.6 and 118.6 mm)
25НЧм, +40НЧм to wait for 10 mines, +90 °, +90 °
S300 TDI after 01.89 g (length to the basis
heads no more than 82, 104 and 117 mm)
15НЧм, +35НЧм, +90 ° to wait for 10 mines, +90 ° (М8 25НЧм)

Bolts of covers of radical bearings

S280, S320 (length to the head basis
no more than 63.8 mm)
55НЧм, +90 °,-100 °
S420, S500
25НЧм, +50НЧм
S300 TDI
М11: 55НЧм, +90 °, М12: 90НЧм
S600
М8: 30НЧм, М10: 50НЧм

Bolts of covers of shatunny bearings

S280, S320 (length to the head basis
no more than 52.9 mm)
30+90 °
S420, S500, S600
45НЧм, +90 °,-100 °
S300 TDI
40НЧм, +90 °,-100 °
Flywheel bolts / driving disk
S280, S320, S420 (diameter of not carving part
no more than 8.1 mm for a flywheel, 8.0 mm
for a driving disk)
30 Nanometers, +90 °
S300 TDI
40НЧм, +90 °,-100 °
S500, S600
35НЧм, +90 °,-100 °
Coupling basket on a flywheel
25

Crankshaft pulley

S280, S320, S420, S500, S600
400
S300 TDI
200НЧм, +90 °

Bolts of asterisks of cam-shafts

S280, S320
Torx: 22,
The six-sided: 18,
Torx with a fillet: 20ì¼+90 °-100 °
S420, S500
18
S300 TDI
25НЧм, +90 °
S600
20НЧм, +90 °,-100 °

Cover of a bed of a cam-shaft

S280, S320, S600
21
S420, S500
12
S300 TDI
25

Cover of rockers of a cam-shaft

S280, S320, S420, S500, S600
9
S300 TDI
10

Candles

S280, S320, S420, S500
25-30
S600
25
S300 TDI
20
Clips of nozzles
30
TNVD flange
20
Nozzle spray to the holder
80
Lambda probe
50-60
Detonation sensor
20
Series M engines
104.94/99
Bolts and nuts of fastening of the inlet pipeline to a head of the block of cylinders
25
Bolts of fastening of a cover of a head of the block of cylinders
10

Bolts of fastening of a cover of a chain of a drive of GRM to the block of cylinders

М6
9
М8
21
Bolt of fastening of the tension device to the block of cylinders
75

Bolt of fastening of fittings to a control plunzher

1st version
7
2nd version
5Нм + 90 °
Nut of regulator М20
65
Drain stopper
25

Bolts of fastening of the pallet to the block of cylinders

М6
10
М8
25
М10
40
Oil pipelines to the pallet
10
Asterisk of the oil pump to the pump
32
Bolts of fastening of a cover of the oil pump M6
10
The oil filter to the block of cylinders
25
Cover of the oil filter
20
The sensor of pressure of oil to the case of the oil filter
20

M119.97/98 series engines

Bolt of fastening of a cover of a head of the block of cylinders
9
Bolts of fastening of the inlet pipeline
28
Bolt of fastening of the top part of the inlet
the pipeline to the lower part
25
Exhaust pipe to a final collector
20
Bolts of fastening of a final collector
30
Bolts of fastening of a cover of the case of the thermostat
10
Bolts of fastening of the pump of system of cooling
21

M120.980/982 series engines

Bolt of fastening of the inlet pipeline
28
Bolt of fastening of an intermediate flange
28
Nuts of fastening of a final collector
30
Bolt of fastening of forward cover М8
25
Cover of a chain of a drive of GRM to the block of cylinders
М6
9
М8
21
Bolt of fastening of an air pump / arm of the generator
25
Stopper of a natyazhitel of a chain of a drive of GRM
40
The case of a natyazhitel of a chain of a drive of GRM in a cover of a chain of a drive of GRM
80
Nut of fastening of a flange to an asterisk
65
Bolt of fastening of fittings to a plunzher
5Нм + 90 °
Bolt of fastening of a cover of a camshaft
21 °
Bolts of fastening of a maslootrazhatel
9
Bolts of fastening of the pallet to the block of cylinders
М6
10
М8
21
М12
40
Drain stopper М12
40
Bolt of fastening of a maslootrazhatel to the pallet M12
9
Asterisk of the oil pump
28
Bolts М6 of fastening of the coupling of the fan and pulley of the pump of system of cooling
10
Bolts М6 of fastening of the pump of system of cooling
21

Om603.971 series engines

The spring lever on a head of the block of cylinders
21
Bolt of fastening of a tension roller
30
Finger of the tension lever
100
Shock-absorber of the tension device
to a head of the block of cylinders
25
Shock-absorber of the tension device
to the tension lever
20
Bolts of fastening of a cover of GRM to a head
block of cylinders
Bolts of fastening of a cover of a head
block of cylinders
10
Bolt of fastening of a cover of a chain of a drive
GRM to a head of the block of cylinders
25
Natyazhitel of a chain of a drive of GRM
80
Bolt М12 of the bearing of a cranked shaft
90
Bolts of fastening of the pallet
М6
10
М8
25
Bolt of fastening of the sensor of level of oil
10
Bolt of fastening of an asterisk of the oil pump
32
Nut of fastening of a cover of the oil pump
25
Bolt of fastening of the case of the oil filter to the block of cylinders
25
Bolt of fastening of a pulley of the pump of system of cooling
15
Bolt of fastening of the pump of system of cooling to the case
10
Bolt of fastening of the case of the pump of system of cooling to the block of cylinders
10

Om606.961 series engines

Bolt of fastening of a cover of a head of the block of cylinders
10
Carving ring of the prechamber
in a head of the block of cylinders
130
Bolt of fastening of the case the distributive
shaft to a head of the block of cylinders
15
Bolt of fastening of a cover of a camshaft
15
Bolt of fastening of a cover of a chain of a drive of GRM
to a head of the block of cylinders
25
Bolt of fastening of a cover of a chain of a drive of GRM
to the block of cylinders
10
Natyazhitel of a chain of a drive of GRM
80
Back nave
320
Forward support to the holder
35
Back support to the holder (TDI)
115
The holder of a support to a fist
Forward wheels
115
Back wheels
To 07.93 g
115
After 08.93 g
50
Nuts of tips of steering drafts
S280, S320, S300 TDI
50
S420, S500, S600
55
Wheels
S280, S320, S420, S500, S600
150
S300 TD
I 110