Checking, correcting setting of TDC sensor - RA03001203450X(03-3450)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Preceding work:

Poly-V belt removed (13-3420) .

Radiator removed (20-4200) .

Fig 1: Checking Setting Of TDC Sensor

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

CHECKING SETTING OF TDC SENSOR

Tensioning roller, tensioning device	remove, install (step 1).
Spark plugs on cylinder 1 and 7	remove, install.
TDC sensors (L1/1 and L1/2)	remove, install (step 3).
Piston of cylinder 1 and 7	set to 10° before TDC (step 4).
Dial gauge holder (02) 363 589 02 21 00 with threaded sleeve (04)	fit on valve cover of cylinder 1 and 7 (step 5).
Dial gauge (01) with extension (03) (300 mm)	clamp in dial gauge holder (02) 363 589 02 21 00 with 4 mm preload (step 6).
Crankshaft	rotate in direction of rotation of engine with wrench socket 001 589 65 09 00 and set TDC at cylinder 1 and 7 with dial gauge (01).
Large pointer of dial gauge (01)	set to "0".
Crankshaft	rotate with wrench socket 001 589 65 09 00 in direction of rotation of engine until dial gauge has moved back by the value in table "piston travel" (20° after TDC cylinder 1 and 7).
Fixing device 119 589 00 21 00	insert into adjusting slide (step 10).
Fixing device 119 589 00 21 00	must engage in measuring pin on vibration damper.

CORRECTING SETTING OF TDC SENSORS

Nuts of adjusting slide	slacken (step 11).
Adjusting slide	move until fixing device 119 589 00 21 00 engages at vibration damper (step 11).
Nuts of adjusting slide	tighten (step 12).

PISTON TRAVEL AT CRANKSHAFT SETTING 20° AFTER TDC CYLINDER 1, OR 20° AFTER TDC CYLINDER 7

Measurement through spark plug hole or vertically on piston

2.33 mm

Special tools

Fig 2: Identifying Special Tools (119 589 00 21 00 03)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Special Tools (001 589 65 09 00 03 07 32)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Special Tools (119 589 02 09 00 15)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Special Tools (001 589 53 21 00 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shop-made tool

Threaded sleeve (M8 to M6 reduction) for attaching dial gauge holder 363 589 02 21 00 to cylinder head cover.

Fig 6: Identifying Threaded Sleeve Length

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

NOTE: The TDC sensors (L1/2) and (L1/1) with adjusting slides (3) and (7) are attached to the timing case cover.

The measuring pin (arrow) on the vibration damper must be centered below the TDC sensors (L1/2) and (L1/1) at 20° after TDC at cylinder 1° and at 20° after TDC at cylinder 7 (TDC pointer reading 80°).

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

if the crankshaft or the vibration damper is replaced.
if the timing case cover is replaced.
if parts are added to part engines.

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

Fig 7: Locating TDC Sensors And Adjusting Slides

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Checking setting of TDC sensors (L1/1) and (L1/2)

Unscrew bolt (1), remove tensioning pulley (8) of poly V-belt.
Tightening torque 38 Nm.
Unscrew spark plugs at cylinder 1 and 7.
Tightening torque 25 Nm.

Fig 8: Locating Tensioning Pulley Of Poly V-Belt And Bolt
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew TDC sensors (L1/2) and L1/1) and remove from adjusting slides (3) and (7).

Fig 9: Locating TDC Sensors And Adjusting Slides
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Set pistons of cylinders 1 and 7 to 10° before TDC (reading 50° CKA on vibration damper for cylinder 7).
Attach dial gauge holder (02) 363 589 02 21 00 with threaded sleeve (04) (shop-made) to cylinder head cover of cylinders 1 and 7.
Unscrew cylinder head cover bolt for this step and install dial gauge holder (02) with threaded sleeve (04).

Fig 10: Identifying Right Bank Of Cylinders
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Clamp dial gauge (01) with extension (03) (300 mm) into dial gauge holder (02) with 4 mm preload.
Rotate crankshaft in direction of rotation of engine with socket wrench 001 589 65 09 00 and set TDC at cylinders 1 and 7 with dial gauge (01).
Turn scale of dial gauge until the large pointer of gauge (01) is at "0".

Fig 11: Identifying Crankshaft Direction With Dial Gauge
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Turn on crankshaft in direction of rotation of engine until the dial gauge has moved back by the respective amount (piston travel).
Insert fixing device (4) 119 589 00 21 00 into the adjusting slide (3) (right bank of cylinders) or (7) (left bank of cylinders).
The slot of the fixing device (4) must engage in the measuring pin (arrow) on the vibration damper (6).

If the fixing device (4) does not engage at the vibration damper (6), correct the setting of the TDC sensors.

Fig 12: Locating Vibration Damper, Fixing Device And TDC Sensor
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Correcting setting of TDC sensors (L1/1) and (L1/2)
Slacken nut (5) or (9) and move adjusting slide (3) or (7) until fixing device (4) engages in the measuring pin (arrow) at the vibration damper (6).
Tighten nut (5) or (9).
Install in the reverse order, beginning at step 3.

Fig 13: Correcting Setting Of TDC Sensors (L1/1) And (L1/2)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.