Checking and correcting setting of TDC sensor - RA03001193450X(03-3450)

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Operation no. of operation texts and work units or standard texts and flat rates

03-1101, 1122

Fig 1: Checking And Correcting Setting Of TDC Sensor Using Special Tools (116 589 17 2100)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Ground cable of battery	disconnect, connect.
Poly V-belt tensioning device	remove, install (13-3450) .
Right cylinder head cover	remove, install (01-0500) .
Piston of no. 1 cylinder	set to 10° before TDC.
Spark plug at no. 1 cylinder	remove, install (25 Nm)
Measuring pin 116 589 17 21 00	screw into spark plug thread of No. 1 cylinder, unscrew (step 6).
TDC sensor	remove, install (step 7).

CHECKING SETTING OF TDC SENSOR

Dial gauge (01)	clamp tight in measuring pin with 4 mm preload, special tool 116 589 17 21 00 (step 8).
Crankshaft	turn in direction of rotation of engine and set TDC with dial gauge (01) (step 8).
Large point of dial gauge	set to "0" (step 8).
Engine	rotate with wrench socket in direction of rotation of engine until dial gauge has moved back by the value, see table "Data" (20° after TDC), special tool 001 589 65 09 00.
Fixing device	insert into adjusting slide, special tool 119 589 00 21 00 (step 10).
Fixing device	must engage in measuring cam on vibration damper, special tool 119 589 00 21 00 (step 10).

CORRECTING SETTING OF TDC SENSOR

Nut of adjusting slide	slacken (step 11).
Adjusting slide	move until fixing device locks in place in measuring cam on vibration damper, special tool 119 589 00 21 00 (step 11).
Nut of adjusting slide	tighten (step 12).

PISTON TRAVEL AT CRANKSHAFT SETTING OF 20° AFTER TDC

Engine	119.960	119.970/974	119.971
Measurement through spark plug bore	3.25 mm	3.28 mm	2.99 mm
Vertical to piston	3.27 mm	3.30 mm	3.01 mm

Special tools

Fig 2: Identifying Special Tools (116 589 17 21 00 03)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Special Tools (119 589 00 21 00 03)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Special Tools (001 589 65 09 00 03 07 32)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Special Tools (102 589 02 09 00 15)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOL

Dial gauge A 1 DIN 878

e.g.

Mahr
D-7300 Esslingen
Order no. 311 000

NOTE: The TDC sensor (2) with bracket is attached to the timing case cover.

The measuring cam (1) on the vibration damper must be positioned in the middle below the TDC sensor (2) when the crankshaft is in the position 20° after TDC.

Fig 6: Identifying TDC Sensor With Bracket To Timing Case Cover

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

The setting of the TDC sensor must be checked and corrected:

When replacing the crankshaft of the vibration damper.
When replacing the timing case cover.
When fitting parts to basic engines.

With the cylinder head removed, attach the dial gauge holder to the crankcase and position dial gauge pin on the piston crown.

Disconnect ground cable at battery.
Remove poly V-belt tensioning device (13-3450) .
Remove right cylinder head cover (01-0500) .
Position piston of No. 1 cylinder to 10° before TDC.
Unscrew spark plug of No. 1 cylinder.
Screw measuring pin (arrow), special tool 116 589 17 21 00, into spark plug bore at No. 1 cylinder.

Fig 7: Locating Screw Measuring Pin
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew hexagon nut (arrow) and withdraw TDC sensor (2).

Fig 8: Locating TDC Sensor Hexagon Nut
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Checking
Clamp dial gauge (01) tight into measuring pin, special tool 116 589 17 21 00, with 4 mm preload.
Rotate crankshaft in direction of rotation of engine and set TDC precisely with the dial gauge (01). Turn scale of dial gauge until large pointer of gauge (01) is set to "0".

Fig 9: Identifying Dial Gauge Installed In Measuring Pin
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rotate crankshaft further in direction of rotation until the dial gauge has moved back by the relevant value (piston travel).
Position fixing device (4) 119 589 00 21 00 into the setting slide (3).
The groove of the fixing device (4) must engage in the measuring cam (1) on the vibration damper.

If the fixing device (4) does not engage, correct position of setting slide (3).

Fig 10: Identifying Fixing Device (119 589 00 21 00) & Setting Slide
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Correcting
Slacken nut (arrow) of setting slide and move it until the fixing device (4), special tool 119 589 00 21 00, engages in the measuring cam (1).
Screw on setting slide (3) and remove fixing device (4).

Fig 11: Locating Setting Slide And Vibration Damper
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert TDC sensor (2) and screw on (arrow).
Remove dial gauge and measuring pin.
Install in the reverse order beginning from step 5.

Fig 12: Locating TDC Sensor And Screw
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.