Mercedes S-Class W-140

1991-1999 of release

Repair and operation of the car


Mercedes S-Class
+ Mercedes-Benz cars of the class S (W-140)
+ Operation manual
+ Routine maintenance
- Engine
   Check of a compression in engine cylinders
   Check of the engine by means of the vacuum gage
   Belt of the 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)
+ Cooling systems, heating
+ Power supply system and release
+ Engine electric equipment
+ Gear shifting box
+ Automatic transmission
+ Coupling
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment

79c5991e

Engine

Specifications

General parameters

Separate characteristics are provided also in the text of the Head and in case of obligation of their performance are highlighted in bold type.

Engine

Specifications were defined according to directives of the EU. All data are valid for cars in basic 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 of the issue. Code on VIN Type of an engine/fuel supply system Volume, cm3 Quantity and расп. c ditch Power, 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)//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/-
Valvate gaps
are not regulated since.
hydrocompensators are used

Capital repairs 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 conicity, mm
0.012
Admissible shift of an axis, mm
0.040

Side play in the bearing, mm

Radial
0.035
Axial
0.06 - 0.21

The sizes of the 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

Outer 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

Outer 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" guide of the 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 H6
Diameter is D a saddle
36.10-36.12/32.10-32.12

Repair values, mm

Diameter of D1 of an opening
37.20 H6 H6//33.20
Diameter is D a saddle
37.30/32.30
T size
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 compression ring
0.20-0.40
Lower compression ring
0.20-0.40
Oil scraper ring
0.20-0.45

Gaps in locks of rings, mm

Top compression ring
0.015-0.050
Lower compression ring
0.020-0.040
Oil scraper ring
0.010-0.045

Sizes and weight of rods and conrod bearings

2 — Designation
3 — the Balancing small weight
4 — M9 Bolt
5 — the Directing plug

6 — the Top insert
7 — Nizhny Novgorod an insert
8 — Adjusting ears
Arrow — the Direction of the movement


Rods

Distance of "L" between centers heads of a rod, mm
M104.94
148.995-49.005
M104.99
144.995-145.005
Width "In" lower heads 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 lower head without inserts, 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
Side play of 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,
4

Bent shaft

Diameters of conrod necks, mm / color marking of a cheek of a crank
Nominal
47.955 - 47.965 / Not marked
Nominal
1 47.945 - 47.955 / Orange
Nominal
2 47.935 - 47.945 / 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 conrod necks, mm

Nominal size
27.958 - 28.042
Repair size
to 28.300

Inserts of conrod bearings

Thickness of a wall, mm
Nominal size
Red marking
1.806 - 1.810
Yellow marking
1.810 - 1.814
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
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
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 bent shaft and radical bearings

Control sizes

Admissible conicity of radical and conrod necks of a bent shaft, mm 0.002

Admissible ovality on 54 mm of length, mm

Radical necks 0.010
Conrod necks 0.010
Tolerance of an axis of the established inserts, mm 0.02

Radius of an internal galtela, mm

Radical necks 1.9-2.1  
Conrod necks 1.9-2.1  

Repair sizes

Diameter of a radical neck, mm / Color/alphabetic marking on a forward part of a bent shaft
Nominal
57.960 - 57.965/Синий/В
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 applied on counterbalances No. No. 8 and 9, alphabetic reference - on a forward part of a bent shaft.


Width of a radical neck, mm / Color /

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 inserts of radical bearings

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

Blue tag (index 52)
Thickness of the top insert, mm
2.255-2.260
Thickness of the lower insert, mm
2.255-2.260
Yellow tag (index 54)
Thickness of the top insert, mm
2.260-2.265
Thickness of the lower insert, mm
2.260-2.265
Red tag (index 56)
Thickness of the top insert, mm
2.265-2.270
Thickness of the lower insert, 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-blue tag (index 57)
Thickness of the top insert, mm
—
Thickness of the lower insert, mm
2.263-2.268
White-yellow tag (index 58)
Thickness of the top insert, mm
—
Thickness of the lower insert, mm
2.268-2.273
White-red tag (index 60)
Thickness of the top insert, mm
—
Thickness of the lower insert, mm
2.273-2.278

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

Blue tag (index 52)
Thickness of the top insert, mm
2.375-2.380
Thickness of the lower insert, mm
2.375-2.380
Yellow tag (index 54)
Thickness of the top insert, mm
2.380-2.385
Thickness of the lower insert, mm
2.380-2.385

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

Blue tag (index 52)
Thickness of the top insert, mm
2.500-2.505
Thickness of the lower insert, mm
2.500-2.505
Nominal width of an insert, mm
19.979 - 20.000

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

Bearings No. No. 1, 5, 7
1 kerneniye
62.500-62.505
2 kerneniye
62.506-62.513
3 kerneniye
62.513-62.519
Bearings No. No. 2, 3, 4, 6
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 of X
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 of 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 of 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 the interfaced surface of the block of cylinders.

Sizes of the block of cylinders

Height, mm
282.25 - 282.35
Minimum admissible height after obrabotki1), mm
281.95

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

Top
0.03
Lower
0.04
1) After processing of the block of cylinders change of height 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 the camshaft, mm

Nominal
27.960 2.947
Repair
28.447 28.460

Side play in bearings of the camshaft, mm

Radial
0.053-0.061
Axial
0.050-0.150

The sizes of the 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
Outer diameter of the directing plug, mm / color marking
Nominal size
13.51-13.53/-
1st nominal size
 
13.52-13.53/is gray-green
 
13.54-13.55/is gray-brown
Repair size
13.71-13.72 / Red
Outer diameter of the directing plug, mm / color marking
Internal diameter of a guide, mm
Inlet and final valves
7.000-7.015
Outer 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
Distance of "b" (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
Outer 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" guide of the plug, mm
Inlet and final valves
37.5
Distance "and", mm
—
Distance of "b" (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 H6
Final valve
34 H6
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 H6
Final valves
35.20 H6
Diameter of the "D" saddle, mm
Inlet valves
40.30
Vypuseny valves
35.30
T size (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 H6
Final valves
34 H6
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 H6
Final valves
35.20 H6
Diameter of the "D" saddle, mm
Inlet valves
37.30
Final valves
35.30
T size (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 direction
and — the Top point of the course of the top compression ring

b — the Lower dead point
with — the Lower point of the course of an oil scraper ring
1, 2, 3 — Points of measurements

Engines of the M119.960/970/972/974 series

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

Engines of the M119.980/982/970/972/974 series

Diameters of pistons//cylinders, mm

Nominal size (96.5 mm)
Designation A (index 52)
96.482-96.495/96.500-96.508
Designation B (index 54)
96.491-96.504/96.508-96.516
Designation C (index 56)
96.499-96.512/96.516-96 524
The 1st repair (+0.5 mm)
Designation A
96.982-96.995/97.000-97.008
Designation B
96.991-97.004/97.008-97.016
Designation
With 96.999-97.012//97.016-97.024
The 2nd repair (+1.0 mm)
Designation A
97.482-97.495/97.000-97.508
Designation B
97.491-97.504/97.508-97.516
Designation C
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)
Designation A (index 52)
91.982-91.995/92.000-92.008
Designation B (index 54)
91.991-92.004/92.008-92.016
Designation C (index 56)
91.999-92.012/92.016-92.024
The 1st repair (+0.5 mm)
Designation A
92.482-92.495/92.500-92.508
Designation B
92.491-92.504/92.508-92.516
Designation C
92.499-92.512/92.516-92.524
The 2nd repair (+1.0 mm)
Designation A
92.982-92.995/93.000-93.008
Designation B
92.991-93.004/93.008-93.016
Designation C
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" lower heads 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" lower head without inserts, 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
Side play of a piston finger in the plug, mm
0.007-0.018

Sizes of a bent shaft, radical and conrod bearings

Engines with the adjusting bearing

Diameter of a neck of a bent shaft, mm

Nominal
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
Extreme admissible size
27.50

Diameter of a neck of a bent shaft, mm

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
Extreme admissible size
50.30

Diameter of openings under radical bearings, mm

Blue marking
68.486
Yellow marking
68.492
Red marking
68.500
Diameter of openings under conrod bearings, mm
51.619
Admissible ovality and conicity of radical
and conrod necks of a bent shaft, mm
0.01

Radial gap in radical bearings, mm

New shaft
0.021 - 0.045
Maximum permissible value
0.09

Radial gap in conrod bearings, mm

New shaft
0.030 - 0.055
Maximum permissible value
0.080

Axial side play of a bent shaft, mm

New shaft
0.10 - 0.22
Maximum permissible value
0.30

Axial side play of rods, mm

New shaft
0.22 - 0.38
Maximum permissible value
0.50

Compliance of color and pointed marking of inserts of radical bearings and block of cylinders

Parameters

Marking

Pointed marking on the block of cylinders 1 point 2 points 3 points
Color marking on covers подшип-ников / casting of the block Blue Yellow Red
Color marking of the top inserts Blue Yellow Red
Color marking of the lower inserts Blue Yellow Red

Engines with persistent half rings

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

Nominal size
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 bent shaft, mm
27.000-27.033
Diameter of a neck of a bent shaft, mm
47.955-47.965
Width of a neck of a bent shaft, mm
50.000/50.100
Diameter of openings under radical bearings, mm
Blue marking
68.480-68.486
Yellow marking
68.986-68.492
Red marking
68.492-68.500
Diameter of openings under conrod
bearings, mm
51.600-51.619
Admissible ovality and conicity of radical
and conrod necks of a bent shaft, mm
0.01
Radial gap in radical bearings, mm
New shaft
0.021 - 0.045
Maximum permissible value
0.09
Radial gap in conrod bearings, mm
New shaft
0.030 - 0.055
Maximum permissible value
0.080
Axial side play of a bent shaft, mm
New shaft
0.10 - 0.22
Maximum permissible value
0.30
Axial side play of rods, mm
New shaft
0.22 - 0.38
Maximum permissible value
0.50

Compliance of color and pointed marking of inserts of radical bearings and block of cylinders

Parameters

Marking

Pointed marking on the block of cylinders 1 point 2 points 3 points
Color marking on covers подшип-ников / casting of the block Blue Yellow Red
Color marking of the top inserts Blue Yellow Red
Color marking of the lower inserts Blue Yellow Red

M120 series engines

Code designations of camshafts

Engines of the M120.980 series 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 M120.982

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

The sizes and details of installation of the directing plugs of valves

Details of installation of the 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 L plug, mm
37.5
Tightness in a head of the block of cylinders
0.029 - 0.051
Lock ring
It is not established
Distance of "a"
2.7 - 2.9
Distance of "b"
5.4 - 5.6
Distance "with"
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 L plug, mm
37.5
Tightness in a head of the block of cylinders
0.029 - 0.051
Lock ring
It is established
Distance of "a"
—
Distance of "b"
—
Distance "with"
10.2 - 10.4

Sizes and designations of cylinders and pistons

Diameters of cylinders//pistons, mm

Nominal size (89 mm)

Gruppa1) 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) Number of group on new engines is beaten out on the interfaced surface of the block of cylinders, the following cylinder
2) Number of group is put on a piston skirt with paint and, besides, is beaten out sideways on a piston skirt

Sizes of rods

L size, mm
153.95 - 154.05
Width of the lower conrod head "In", mm
21.948 - 22.000
Width of the top conrod head of "b", mm
19.90 - 20:10
Diameter of an opening of the lower 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,
4

Sizes of a bent shaft, radical and conrod bearings

Diameter of a radical neck of a bent 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 conrod necks, mm

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

Radial gap, mm

Radical bearings
0.026 - 0.050
Conrod bearings
0.020 - 0.058
Axial side play of a bent shaft, mm
0.100 - 0.254
Axial side play of rods, mm
0.225 - 0.391

Compliance of color and pointed marking of inserts of radical bearings and block of cylinders

Parameters

Value

Pointed marking on the block of cylinders
1 point
2 points
3 points
—
—
Color marking on covers of bearings
Blue
Yellow
Red
—
—
Color marking on a bent shaft
Blue
Yellow
Red
White
Violet
Color marking of the top inserts
Blue
Yellow
Red
—
—
Color marking of the lower inserts
Blue
Yellow
Red
White
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 — the Conrod cover
3 — the Plug
4 — the Directing grooves
5 — the Conrod bolt
6 — Balancing small weights
7 — the Identification field (models with a turbo-supercharging)
8 — Grooves for installation of inserts
9 — the Oil channel (models with a turbo-supercharging)

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


L size, mm
144.97 - 145.03
Width of the lower head of a rod "In", mm
21.948 - 22.000
Diameter of an opening of the lower head of a rod of "D1"
51.600 - 51.614
Maximum admissible ovality and conicity 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
Outer 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
Side play of landing of a piston finger in the plug of a rod, mm
0.007 - 0.018

Sizes of cylinders

Diameter of cylinders, mm

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 directions, mm
0.20
Admissible conicity, 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 — sleeve Length
T1 — the 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 "D" under fillet sleeves
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 bent shaft, radical and conrod 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 bent shaft, mm
62.500 - 62.519
Opening width under a bent shaft at the established inserts, mm
19.979 - 20.000
Admissible ovality and conicity of beds of inserts of radical bearings, mm
0.02

Working gaps of radical bearings, mm

New
0.03 - 0.05
Admissible
0.08

Axial side play of a bent shaft, mm

New
0.10 - 0.25
Admissible
0.3
Radial beating of a bent shaft, mm
0.020 - 0.065
Standard inserts of a bent shaft for covers of bearings diameter
58 mm
Repair diameter (color - blue), mm
52
Repair diameter (color yellow), mm
54
Repair diameter (color yellow), mm
54
Thickness of an insert, mm
2.260 - 2.265
Repair diameter (color - red), mm
56
Thickness of an insert, mm
2.265 - 2.270
Repair diameter (color white), mm
57
Thickness of an insert, mm
2.270 - 2.275
Repair diameter (color purple), mm
58
Thickness of an insert, mm
2.275 - 2.280

OM606 series engines

Sizes of valves

1 — Adjusting tags for reduction of the engine in the provision of VMT of the end of a step of compression of the piston of the first cylinder
2 — Blocking of the inlet camshaft by means of a core
3 — Make sure of correctness of combination of 1.5-millimeter 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 the TNVD removal/installation the bent shaft should be given to 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 D valve, mm

Inlet
25.90 - 26.10
Final
28.90 - 29.10
Height of a cylindrical part (corbel)
plates of the h valve, mm
1.0 - 1.2
Valve saddle facet corner
45 ° 15'

Diameter of a core of the D1 valve, mm

Inlet
6.955 - 6.97
Final
5.955 - 5.97

Full is long the L valve, mm

Inlet
105.5 - 105.9
Final
105.2 - 105.9
Width of a working facet of a saddle of the valve, mm
1.9
Valve saddle axis shift concerning a core, mm
0.03

Designation on the end of a core of the valve

Inlet
A 606 13
Final
E 606 11

The sizes of the directing plugs of valves

Details of installation of the directing plugs of valves


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

Nominal
12.50 - 12.51
The 1st nominal
12:53
The 1st repair
12.70

Outer diameter of the directing plug, mm

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 L plug, mm
37.5
Landing tightness in a block head
cylinders, mm
0.029 - 0.051
And size
—
B size
—
With the size
10.2 - 10:04

Sizes of saddles of valves

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

Opening depth "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 "H", mm

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

Outer 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 — the Conrod cover
3 — the Plug
4 — the Directing grooves
5 — the Conrod bolt
6 — Balancing small weights
7 — the Identification field (models with a turbo-supercharging)
8 — Grooves for installation of inserts
9 — the Oil channel (models with a turbo-supercharging)

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


Distance between centers conrod
heads of "L", mm 1
48.7 - 149.3
Width of top "b" and lower "In"
heads of a rod, mm
21.48 - 22.00
Diameter of "D1" of the lower head
rod, mm
51.600 - 51.614
Admissible ovality and conicity of an opening of the lower 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,
2

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

Extraction of a sleeve


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 "D" under a fillet sleeves in the block of cylinders, mm
92.65 - 92.75
Length of a sleeve of "T", mm
231.0-231.2
Landing depth of a sleeve of "T1", mm
1.0 - 1.2

Sizes of cylinders

A — the Longitudinal direction
B — the Cross direction
and — the Top point of the course of the top compression ring

b — the Lower dead point
with — the Lower point of the course of an oil scraper ring
1, 2, 3 — Points of measurements

Diameter, mm

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 longitudinal
and cross directions, mm
0.20
Admissible conicity 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 bent shaft

Diameter of an opening
under a bent shaft, mm
62.500 - 62.519
Opening width under a bent shaft
at the established inserts, mm
19.979 - 20.000
Admissible ovality and conicity
beds of inserts radical
bearings of a bent shaft, mm
0.02
Working gap in radical bearings, mm
New
0.03 - 0.05
Maximum permissible
0.08
Axial side play of a bent shaft, mm
New
0.10 - 0.25
Maximum permissible
0.3
Radial beating of a bent shaft, mm
0.020 - 0.065
Nominal inserts of a bent shaft for covers of bearings with a diameter of 58 mm
Repair diameter (color - blue), mm
52
Thickness of an insert, mm
2.255 - 2.260
Repair diameter (color - yellow), mm
54
Thickness of an insert, mm
2.260 - 2.265
Thickness of an insert, mm
2.265 - 2.270
Repair diameter (color - white), mm
57
Thickness of an insert, mm
2.270 - 2.275
Repair diameter (color - purple), mm
58
Thickness of an insert, mm
2.275 - 2.280
Inserts of the 1st repair size of a bent shaft for covers of bearings with a diameter of 57.70 mm
Thickness of an insert, mm
2.37
Inserts of the 2nd repair size of a bent shaft for covers of bearings with a diameter of 57.40 mm
Thickness of an insert, mm
2.50
Inserts of the 3rd repair size of a bent shaft for covers of bearings with a diameter of 57.20 mm
Thickness of an insert, mm
2.62
Inserts of the 4th repair size of a bent shaft for covers of bearings with a diameter of 56.90 mm
Thickness of an insert, mm
2.75

Efforts of tightening of threaded connections, Nanometer

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

Order of 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)
55nchm, +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)
25nchm, +40nchm to wait for 10 min., +90 °, +90 °
S300 TDI after 01.89 g (length to the basis
heads no more than 82, 104 and 117 mm)
15nchm, +35nchm, +90 ° to wait for 10 min., +90 ° (M8 25nchm)

Bolts of covers of radical bearings

S280, S320 (length to the head basis
no more than 63.8 mm)
55nchm, +90 °, -100 °
S420, S500
25nchm, +50nchm
S300 TDI
M11: 55nchm, +90 °, M12: 90nchm
S600
M8: 30nchm, M10: 50nchm

Bolts of covers of conrod bearings

S280, S320 (length to the head basis
no more than 52.9 mm)
30+90 °
S420, S500, S600
45nchm, +90 °, -100 °
S300 TDI
40nchm, +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 Nanometer, +90 °
S300 TDI
40nchm, +90 °, -100 °
S500, S600
35nchm, +90 °, -100 °
Coupling basket on a flywheel
25

Crankshaft pulley

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

Bolts of asterisks of cam-shafts

S280, S320
Torx: 22,
Six-sided: 18,
Torx with a fillet: 20 Of Nanometer +90 ° -100 °
S420, S500
18
S300 TDI
25nchm, +90 °
S600
20nchm, +90 °, -100 °

Cam-shaft bed cover

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 the GRM drive to the block of cylinders

M6
9
M8
21
Bolt of fastening of the tension device to the block of cylinders
75

Bolt of fastening of fittings to a control plunger

1st version
7
2nd version
5 Of Nanometer + 90 °
M20 regulator nut
65
Drain stopper
25

Bolts of fastening of the pallet to the block of cylinders

M6
10
M8
25
M10
40
Oil pipelines to the pallet
10
Asterisk of the oil pump to the pump
32
Bolts of fastening of a cover of the M6 oil pump
10
Oil filter to the block of cylinders
25
Cover of an oil filter
20
The oil pressure sensor to the case of an oil filter
20

Engines of the M119.97/98 series

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 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 the cooling system
21

Engines of the M120.980/982 series

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 a forward cover of M8
25
GRM drive chain cover to the block of cylinders
M6
9
M8
21
Bolt of fastening of the air pump / arm of the generator
25
Stopper of a natyazhitel of a chain of the GRM drive
40
The case of a natyazhitel of a chain of the GRM drive in a GRM drive chain cover
80
Nut of fastening of a flange to an asterisk
65
Bolt of fastening of fittings to a plunger
5 Of Nanometer + 90 °
Bolt of fastening of a cover of the camshaft
21 °
Bolts of fastening of a maslootrazhatel
9
Bolts of fastening of the pallet to the block of cylinders
M6
10
M8
21
M12
40
Drain stopper of M12
40
Bolt of fastening of a maslootrazhatel to the pallet M12
9
Asterisk of the oil pump
28
Bolts of M6 of fastening of the coupling of the fan and pulley of the pump of the cooling system
10
Bolts of M6 of fastening of the pump of the cooling system
21

Engines of the OM603.971 series

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 the drive
GRM to a head of the block of cylinders
25
Natyazhitel of a GRM drive chain
80
Bolt of M12 of the bearing of a bent shaft
90
Bolts of fastening of the pallet
M6
10
M8
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 an oil filter to the block of cylinders
25
Bolt of fastening of a pulley of the pump of the cooling system
15
Bolt of fastening of the pump of the cooling system to the case
10
Bolt of fastening of a pump housing of the cooling system to the block of cylinders
10

Engines of the OM606.961 series

Bolt of fastening of a cover of a head of the block of cylinders
10
Carving ring of the precamera
in a head of the block of cylinders
130
Bolt of fastening of the case distributive
shaft to a head of the block of cylinders
15
Bolt of fastening of a cover of the camshaft
15
Bolt of fastening of a cover of a chain of the GRM drive
to a head of the block of cylinders
25
Bolt of fastening of a cover of a chain of the GRM drive
to the block of cylinders
10
Natyazhitel of a GRM drive chain
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