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Removal and installation of the camshaft - ra05006010220x(0220)

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Engines 601, 602 (except 602.98), 603 

Operation no. of operation texts and work units or standard texts and flat rates 05-6292

Fig 1: Identifying Camshaft Remove/Install Components
G05438389Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Turbo engine: 
Boost air pipe remove, install.
Engine 601 in model 202 
Air cleaner cross pipe remove, install.
Cylinder head cover (125) remove, install, 10 Nm.
Engine position on ignition TDC of No. 1 cylinder.
IMPORTANT The engine must not be turned by the camshaft timing gear bolt.
Chain tensioner (224) remove, install, replace sealing ring (237) (05-310 ).
With self-levelling suspension: 
Drive of the pressure oil pump (400) remove, install (05-437).
Camshaft timing gear (188) mark at timing chain (210). Remove, install camshaft timing gear. Different bolts (190) and washers (189). Hexagon bolt, 65 Nm, bihexagonal head bolt, 25 Nm/90° angle of rotation.
IMPORTANT When assembling the camshaft timing gear ensure that the straight pin (187) is not pushed out rearwards.
Camshaft bearing cap (80, 81, 82) remove, install, note sequence, hexagon bolts (84) and washers (84a), 25 Nm.
IMPORTANT Note slackening and tightening diagram!
Camshaft (185) remove, install. Check for ease of movement.
Lock washer (186) check.
Valve tappet (203) remove, install, check.
After installation allow engine to run, check for leaks.
DATA

Permitted eccentricity of center bearing pins and camshaft gear seat when locating the camshaft in the outer bearing positions Bearing position/engine 601 602 603
Camshaft timing gear seat 0.025 0.025 0.025
2nd and 4th bearing position 0.030 - -
3rd bearing position 0.050 - -
2nd and 5th bearing position - 0.030 -
3rd and 4th bearing position - 0.050 -
2nd and 6th bearing position - - 0.030
3rd and 5th bearing position - - 0.045
4th bearing position - - 0.060
Scleroscope hardness of cam 70-82 70-82 70-82

Camshaft code numbers 

The code number is stamped on the flange next to the TDC notch (arrow).

TDC marking (arrow) and code number

Fig 2: Locating TDC Marking And Code Number
G05438390Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Engine Thread for sprocket wheel Camshaft code number
601 M10 05, 06, 08(1)
M11 10, 12(1), 13(2)
602, 603 M10 07, 09(1)
M11 11, 13(1) 16(3)
(1) Repair camshaft with 0.5 μ larger bearing dia.
(2) Engine 601.913 in model 202
(3) Engine 602.982 in model 210

Washer for camshaft timing gear bolt 

A modified washer with larger outer diameter (c) has been installed since 12/86 to prevent the camshaft timing gear bolt from loosening.

Fig 3: Identifying Washer For Camshaft Timing Gear Bolt
G05438391Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Camshaft timing gear bolt 

As of 11/88 the camshaft timing gear bolt has been changed from a M10 hexagon bolt to a M11 12-point necked down bolt on all engines.

Tightening torques 

Hexagon bolt (A) 65 Nm 12-point necked down bolt (B) Pre-torque 25 Nm Tightening angle 90°

IMPORTANT Note modified plain washer!

Fig 4: Identifying Bolt Dimension
G05438392Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Use the plain washer (A) for the hexagon bolt, and plain washer (B) for the 12-point necked down bolt.

Fig 5: Identifying Plain Washer Dimension
G05438393Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Use carrier (A) for previous hexagon bolt, carrier (B) for bihexagon necked down bolt.

Fig 6: Identifying Carrier Dimension
G05438394Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TIGHTENING TORQUES AND TIGHTENING ANGLES

  Nm
Hexagon bolts on cylinder head cover 10
Hexagon bolts on camshaft timing gear 65
12-point bolt on camshaft timing gear initial torque 25
  tightening angle 90°
Hexagon bolts on camshaft bearing cap 25

Special tools 

Fig 7: Identifying (001 589 66 21 00)
G05438395Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Identifying (001 589 72 21 00)
G05438396Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TOOLS AND TESTERS

Designation e.g. Make Order no.
Rubber suction cup, dia. 30 mm Hazet Postfach 100461 42804 Remscheid 795-3

Removal 

Turbo engine: 

  1. Remove boost air pipe.

    Engine 601 in model 202 

  2. Remove air cleaner cross pipe.
  3. Remove cylinder head cover.
  4. Position engine on ignition TDC of no. 1 cylinder (arrow).

    IMPORTANT Do not turn engine by the camshaft timing gear bolt. Do not turn engine backwards.

    Fig 9: Identifying Timing Marks
    G05438397Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. Remove chain tensioner (05-310 ).

    With self-levelling suspension 

  6. Remove pressure oil pump (05-437).
  7. Align camshaft timing gear and timing chain.
    Fig 10: Aligning Marks On Camshaft Timing Gear And Timing Chain
    G05438398Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. Unscrew hexagon bolt or 12-point head bolt on camshaft timing gear, while holding the camshaft with a mandrel.
  9. Remove camshaft timing gear and allow timing chain to sag.
    NOTE: The timing chain is prevented from twisting when the timing case cover is assembled.
    Fig 11: Removing Camshaft Timing Gear And Allow Timing Chain
    G05438399Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    IMPORTANT Note different bolt and washer.

    IMPORTANT

  10. It is absolutely essential to observe the following sequence during removal and installation  in order to avoid damage to the camshaft:

    Engine 601 

    Unscrew both hexagon bolts on camshaft bearing caps 1, 3 and 5 (light arrows).

    Fig 12: Locating Camshaft Bearing Caps Bolts - Engine 601
    G05438400Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Slacken both hexagon bolts on camshaft bearing caps 2 and 4 alternately in increments of one turn respectively until counter pressure is reduced (dark arrows).

    Engine 602 

    Unscrew both hexagon bolts on camshaft bearing caps 1, 2 and 6 (light arrows).

    Slacken both hexagon bolts on camshaft bearing caps 3, 4 and 5 in increments of one turn respectively, until counter pressure is reduced (dark arrows).

    Fig 13: Locating Camshaft Bearing Caps Bolts - Engine 602
    G05438401Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Engine 603 

    Unscrew both hexagon bolts on camshaft bearing caps 1, 5 and 6 (light arrows).

    Slacken both hexagon bolts on camshaft bearing caps 2, 3, 4 and 7 in increments of one turn respectively, until counter pressure is reduced (dark arrows).

  11. Remove camshaft upwards.
    Fig 14: Locating Camshaft Bearing Caps Bolts - Engine 603
    G05438402Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  12. Remove lock washer for axial location (arrow) and check condition.
    Fig 15: Locating Lock Washer
    G05438403Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  13. Pull out valve tappet with rubber suction cup.
  14. Check condition of valve tappet (visual check), replace, if required.

    IMPORTANT Install valve tappet in the same position again.

    Fig 16: Pulling Out Valve Tappet With Rubber Suction Cup
    G05438404Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Installation 

  15. Insert lock washer for axial fixing (arrow) in cylinder head.
    Fig 17: Locating Lock Washer
    G05438403Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  16. Lubricate camshaft and place on the cylinder head so that the TDC marking (arrow) points vertically upwards.
  17. Install camshaft bearing caps. Note marking on bearing caps.
    Fig 18: Locating TDC Marking And Code Number
    G05438390Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Assemble camshaft bearing cap bolts (dark arrows) and tighten up alternately in increments of one turn respectively in accordance with tightening diagram, see work step  10.

    Engine 601; camshaft bearing caps 2 and 4

    Engine 602; camshaft bearing caps 3, 4 and 5

    Engine 603; camshaft bearing caps 2, 3, 4 and 7

    The remaining camshaft bearing caps (light arrows) can then be assembled at random.

    Tightening torque 25 Nm.

  18. Install camshaft sprocket according to marking and tighten. Check straight pin to ensure it is correctly fitted.

    Tightening torques and tightening angle

    Hexagon bolt 65 Nm,

    12-point head bolt 25 Nm, 90°

  19. Install chain tensioner (05-310 ).
    Fig 19: Aligning Marks On Camshaft Timing Gear And Timing Chain
    G05438398Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    If car fitted with level control: 

  20. Install pressurized oil pump (05-437).
  21. Position engine to ignition TDC of cylinder 1 and check markings (arrows).
  22. Install cylinder head cover. Tightening torque 10 Nm.
    Fig 20: Locating Marks
    G05438408Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Turbo engine: 

  23. Install boost air pipe.

    Engine 601 in model 202 

  24. Install air cleaner cross pipe.

    After installation: 

  25. Run engine and check for leaks.
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