Mercedes W124

since 1985-1995 of release

Repair and car operation



W124 Mercedes
+ Governing bodies and control devices
+ MAINTENANCE
+ 2. Maintenance (diesel engines)
+ ENGINE
+ 4. Repair of 6-cylinder petrol SOHC engines
+ 5. Repair of 6-cylinder petrol DOHC engines
+ 6. Repair of the diesel engine established in the car
- 7. Major maintenance of engines
   7.2. General information
   7.3. Recommendations about engine removal
   7.4. Removal and installation of 4-cylinder petrol engines
   7.5. Removal and installation of 6-cylinder petrol engines
   7.6. Removal and installation of diesel engines
   7.7. Sequence of dismantling of the engine
   + 7.8. Analysis of a head of the block of cylinders
   + 7.9. Assembly of a head of the block of cylinders
   7.10. Removal of pistons with rods
   7.11. Removal of a cranked shaft
   7.12. Block of cylinders of the engine
   7.13. Pistons and rods
   7.14. Cranked shaft
   7.15. Survey of radical and shatunny bearings
   7.16. Engine balance of assembly at major maintenance
   7.17. Installation of piston rings
   7.18. Installation of a cranked shaft
   7.19. Check of a working gap of radical bearings
   7.20. Installation of a cranked shaft
   + 7.21. Installation of pistons with rods
   7.22. Engine start after major maintenance
+ COOLING SYSTEM
+ FUEL SYSTEM
+ 10. System of injection of BOSCH CIS-E fuel (KE-JETRONIC)
+ 11. System of injection of BOSCH HFM fuel
+ 12. Fuel system of diesel engines
+ 13. Fuel system of diesel engines
+ SYSTEMS OF START, IGNITION
+ 15. System of ignition of 4-cylinder petrol engines
+ 16. System of ignition of four-cylinder petrol engines
+ PRESTARTING HEATING
+ TRANSMISSION
+ 19. Mechanical transmission
+ 20. Automatic transmission
+ POWER SHAFTS
+ BRAKE SYSTEM
+ SUSPENSION BRACKET
+ BODY
+ ELECTRIC EQUIPMENT
+ CHECK OF MALFUNCTIONS






7. Major maintenance of engines

7.1. Technical characteristics

Head of the block of cylinders

Maximum not planeness of the bottom surface:
– 4th cylinder petrol engines:
   • parallel to an axis
0,15 mm
   • perpendicular to an axis
0,05 mm
– other engines:
   • parallel to an axis
0,08 mm
   • perpendicular to an axis
0 mm
Minimum admissible height of a head of the block of cylinders after machining:
– 4th cylinder petrol engines
97,8 mm
– 6 cylinder petrol SOHC engines
89,5 mm
– 6 cylinder petrol DOHC engines
135,5 mm
– diesel engines
142,4 mm
Size of a vystupaniye of the vortical chamber on diesel engines
7,6-8,1 mm
The minimum vystupaniye of valves for the bottom plane of laying of a head of the block of cylinders at installation of new valves and saddles of valves:
– 4th cylinder petrol engines:
   • inlet valve
1,7 mm
   • final valve
0,5 mm
– 6 cylinder petrol SOHC engines
Engines of 2,6 l
Engines of 3,0 l
   • inlet valve
1,0 mm
1,3 mm
   • final valve
0,8 mm
1,4 mm
– 6 cylinder petrol DOHC engines
There are no data
– diesel engines:
   • inlet valve
0,1-0,5 mm
   • final valve
0,1-0,5 mm
The minimum vystupaniye of valves for the bottom plane of laying of a head of the block of cylinders at installation of mechanically processed saddles of valves and the ground-in valves:
– 4th cylinder petrol engines:
   • inlet valve
2,6 mm
   • final valve
1,4 mm
– 6 cylinder petrol SOHC engines
Engines of 2,6 l
Engines of 3,0 l
   • inlet valve
1,7 mm
2,0 mm
   • final valve
1,5 mm
2,1 mm
– 6 cylinder petrol DOHC engines
There are no data
– diesel engines:
   • inlet valve
0,7 mm
   • final valve
0,7 mm

Valves

Diameter of a plate of the valve:
4th cylinder petrol engines:
– inlet valve:
   • engines of 2,0 l
42,90-43,10 mm
   • engines of 2,3 l
45,10-46,19 mm
– final valve
38,90-39,10 mm
6 cylinder petrol SOHC engines:
– engines of 2,6 l
   • inlet valve
40,0 mm
   • final valve
35,0 mm
– engines of 3,0 l
   • inlet valve
43,0 mm
   • final valve
39,0 mm
6 cylinder petrol DOHC engines
There are no data
Diesel engines:
– inlet valve
37,90-38,10 mm
– final valve
34,90-35,10 mm
Diameter of a core of the valve:
– 4th cylinder petrol engines and 6 cylinder petrol SOHC engines:
   • inlet valve
7,955-7,970 mm
   • final valve
8,938-8,960 mm
– 6 cylinder petrol DOHC engines
There are no data
– diesel engines:
   • inlet valve
7,955-7,970 mm
   • final valve
8,945-8,960 mm

Springs of valves

Length of a spring in a free condition:
4th cylinder petrol engines
49 mm
6 cylinder petrol SOHC engines
There are no data
6 cylinder petrol DOHC engines:
– with two springs:
   • external spring
46,8 mm
   • internal spring
47,6 mm
– with one spring
47,3 mm
Diesel engines:
– with it is yellow / green or it is violet / green color marking
50,8 mm
– with is yellow/become blue or is violet/become blue color marking
50,0 mm

Block of cylinders

Diameter of cylinders:
4th cylinder petrol engines:
– engines of 2,0 l:
   • standard 0
88,998-89,008 mm
   • standard 1
89,009-89,018 mm
   • standard 2
89,019-89,028 mm
   • standard And
89,000-89,006 mm
   • standard X
89,007-89,012 mm
   • standard In
89,013-89,018 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
– engines of 2,3 l:
   • standard 0
95,498-95,508 mm
   • standard 1
95,509-95,518 mm
   • standard 2
95,519-95,528 mm
   • standard And
95,500-95,506 mm
   • standard X
95,507-95,512 mm
   • standard In
95,513-95,518 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
6 cylinder petrol SOHC engines:
– engines of 2,6 l:
   • standard 0
82,898-82,908 mm
   • standard 1
82,908-82,918 mm
   • standard 2
82,918-82,928 mm
   • standard And
82,900-82,906 mm
   • standard X
82,906-82,912 mm
   • standard In
82,912-82,918 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
– engines of 3,0 l:
   • standard 0
88,948-88,508 mm
   • standard 1
88,508-88,518 mm
   • standard 2
88,518-88,528 mm
   • standard And
88,500-88,506 mm
   • standard X
88,506-88,512 mm
   • standard In
88,512-88,518 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
6 cylinder petrol DOHC engines:
– engines of 3,0 l:
   • standard And
88,500-88,506 mm
   • standard X
88,506-88,512 mm
   • standard In
88,512-88,518 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
– l engines 2,8 and 3,2:
   • standard And
88,900-88,906 mm
   • standard X
88,906-88,912 mm
   • standard In
88,912-88,918 mm
   • increased by +0,25 mm
The sizes as are higher than +0,250 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
– diesel engines:
   • standard And
87,000-87,006 mm
   • standard X
87,006-87,012 mm
   • standard In
87,012-87,018 mm
   • increased by +0,7 mm
The sizes as are higher than +0,700 mm
   • maximum ovality of the cylinder:
– petrol engines
0,05 mm
– diesel engines
0,07 mm
Maximum konusnost of the cylinder:
– petrol engines
0,05 mm
– diesel engines
0,07 mm
Minimum height of the block of cylinders of the engine:
– 4th cylinder petrol engines
292,35 mm
– 6 cylinder petrol engines
281,95 mm
– diesel engines
299,62 mm
Maximum not planeness of the top plane of the block of cylinders of the engine:
– 4th cylinder petrol engines
There are no data
– 6 cylinder petrol engines:
   • parallel to an axis
0,100 mm
   • perpendicular to an axis
0,05 mm
– diesel engines
0,03 mm

Pistons

Diameter of the piston:
4th cylinder petrol engines:
– engines of 2,0 l:
   • standard 0
88,968-88,982 mm
   • standard 1
88,978-88,992 mm
   • standard 2
88,988-89,002 mm
   • standard And
88,973-88,979 mm
   • standard X
88,978-88,986 mm
   • standard In
88,985-88,991 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
– engines of 2,3 l:
   • standard 0
95,469-95,481 mm
   • standard 1
95,479-95,491 mm
   • standard 2
95,489-95,501 mm
   • standard And
95,473-95,479 mm
   • standard X
95,478-95,486 mm
   • standard In
95,485-95,491 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
6 cylinder petrol SOHC engines:
– engines of 2,6 l:
   • standard 0
82,868-82,882 mm
   • standard 1
82,878-82,892 mm
   • standard 2
82,888-82,902 mm
   • standard And
82,873-82,879 mm
   • standard X
82,878-82,886 mm
   • standard In
82,885-82,891 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
– engines of 3,0 l:
   • standard 0
88,469-88,481 mm
   • standard 1
88,479-88,491 mm
   • standard 2
88,489-88,501 mm
   • standard And
88,473-88,479 mm
   • standard X
88,478-88,486 mm
   • standard In
88,485-88,491 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
6 cylinder petrol DOHC engines:
– engines of 3,0 l:
   • standard And
88,473-88,479 mm
   • standard X
88,478-88,486 mm
   • standard In
88,485-88,491мм
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
   • increased by +1,0 mm
The sizes as are higher than +1,000 mm
– l engines 2,8 and 3,2:
   • standard And
88,478-88,879 mm
   • standard X
88,878-88,886 mm
   • standard In
88,885-88,891 mm
   • increased by +0,25 mm
The sizes as are higher than +0,250 mm
   • increased by +0,5 mm
The sizes as are higher than +0,500 mm
Vystupaniye of the piston from the block of cylinders of diesel engines:
– the minimum
0,735 mm
– the maximum
0,965 mm

Cranked shaft

Axial люфт:
– 4th cylinder petrol engines
0,300 mm
– 6 cylinder petrol SOHC engines
0,100-0,240 mm
– 6 cylinder petrol DOHC engines
0,100-0,250 mm
– diesel engines
0,300 mm
Thickness of persistent half rings for adjustment axial люфта a cranked shaft
2,15, 2,20, 2,25, 2,35, 2,40 mm
Diameters of radical necks of a cranked shaft:
– 4th cylinder petrol engines:
   • the nominal dark blue
57,960-57,965 mm
   • the nominal yellow
57,955-57,960 mm
   • the nominal red
57,950-57,955 mm
   • the nominal 1 dark blue
57,945-57,950 mm
   • the nominal 1 yellow
57,940-57,945 mm
   • the nominal 1 red
57,935-57,940 mm
   • reduced 1
57,705-57,715 mm
   • reduced 2
57,455-57,465 mm
   • reduced 3
57,205-57,215 mm
   • reduced 4
56,955-56,965 mm
– 6 cylinder petrol SOHC engines
There are no data
– 6 cylinder petrol DOHC engines:
   • the nominal dark blue
57,960-57,965 mm
   • the nominal yellow
57,955-57,960 mm
   • the nominal red
57,950-57,955 mm
   • the nominal 1 white
57,945-57,950 mm
   • the nominal 1 violet
57,940-57,945 mm
   • reduced 1
57,705-57,715 mm
   • reduced 2
57,455-57,465 mm
   • reduced 3
57,205-57,215 mm
   • reduced 4
56,955-56,965 mm
– diesel engines:
   • the nominal
57,959-57,965 mm
   • reduced 1
57,700-57,715 mm
   • reduced 2
57,450-57,465 mm
   • reduced 3
57,200-57,215 mm
   • reduced 4
56,959-56,965 mm
Diameters of shatunny necks of a cranked shaft:
– 4th cylinder petrol engines:
   • the nominal
47,955-47,965 mm
   • reduced 1
47,705-47,715 mm
   • reduced 2
47,455-47,465 mm
   • reduced 3
47,205-47,215 mm
   • reduced 4
46,955-46,965 mm
– 6 cylinder petrol DOHC engines:
   • the nominal
47,955-47,965 mm
   • nominal 1
47,945-47,955 mm
   • reduced 1
47,700-47,715 mm
   • reduced 2
47,450-47,465 mm
   • reduced 3
47,200-47,215 mm
   • reduced 4
46,950-46,955 mm
– diesel engines:
   • the nominal
47,950-47,965 mm
   • reduced 1
47,700-47,715 mm
   • reduced 2
47,450-47,650 mm
   • reduced 3
47,200-47,215 mm
   • reduced 4
46,950-46,965 mm
Working gap of radical bearings:
– 4th cylinder petrol engines
0,070 mm
– 6 cylinder petrol SOHC engines
0,030-0,050 mm
– 6 cylinder petrol DOHC engines
0,030-0,045 mm
– diesel engines
0,080 mm
Working gap of shatunny bearings:
– 4th cylinder petrol engines
0,070 mm
– 6 cylinder petrol SOHC engines
0,030-0,060 mm
– 6 cylinder petrol DOHC engines
0,020-0,050 mm
– diesel engines
0,080 mm

Piston rings

Gap in the lock of piston rings:
– 4th cylinder petrol engines:
   • the kompressionny ring is more true
0,30-1,00 mm
   • average kompressionny ring
0,25-0,80 mm
   • maslosjemny ring
0,25-0,80 mm
– 6 cylinder petrol engines:
   • the kompressionny ring is more true
0,15-0,50 mm
   • average kompressionny ring
0,20-0,40 mm
   • maslosjemny ring
0,10-0,45 mm
– diesel engines:
   • the kompressionny ring is more true
0,09-0,20 mm
   • average kompressionny ring
0,15-0,15 mm
   • maslosjemny ring
0,03-0,10 mm

Bolts of fastening of a cover of the radical bearing

Maximum length:
– 6 cylinder petrol DOHC engines
63,8 mm

Bolts of fastening of a cover of the shatunny bearing

Minimum diameter:
– 4th cylinder petrol engines
8,0 mm
Maximum length:
– all engines except the 4th cylinder petrol engines
52,9 mm

Tightening moments

4th cylinder petrol engines
Look technical characteristics in chapter 2А
6 cylinder petrol SOHC engines
Look technical characteristics in chapter 2В
6 cylinder petrol DOHC engines
Look technical characteristics in chapter 2С
Diesel engines
Look technical characteristics in chapter 2D