Assembly note

Whenever performing repairs on the engine, make sure the seal is replaced.

NOTES ON ASSEMBLY

'85 MODELS ONWARD ENGINE TYPE M 44.05/06/07/08

TORQUING PROCEDURE, CRANKCASE UPPER HALF - COMPENSATING-SHAFT COVER

Note:

When aligning crankcase upper half and compensating-shaft cover, proceed as follows:

1.Tighten all hex bolts by hand

2.Install bearing housing with 0-ring lightly oiled but without mounting bolts.

3.Tightening torque for M6 bolts: 10 Nm (7 ftlb) Tightening torque for M8 bolts in 2 stages.

1st stage 15 Nm (11 ftlb) 2nd stage 20 Nm (14 ftlb)

Torquing sequence: see illustration.

13 - 44h Disassembling and Assembling Compensating Shaft Drive

NOTES ON ASSEMBLY '87 MODELS ONWARD

ENGINE TYPE M 44.40/05/06/07/08

TORQUING PROCEDURE, UPPER CRANKCASE HALF/COMPENSATING SHAFT COVER BOLTS (with integrated bearing bridge)

Note:

It is imperative to align upper half of crankcase and compensating-shaft cover as follows:

1.Tighten all hex bolts by hand.

2.Place bearing housing in position with 0-ring lightly oiled, but without mounting bolts.

Torquing sequence: see illustration

1st stage No. 1 + 2 Tightening torque for M8 bolts 15 Nm (11 ftlb) 2nd stage No. 3...16 Tightening torque for M6 bolts 10 Nm (7 ftlb)

M8 bolts 20 Nm (14 ftlb)

3rd stage No. 17 + 18 Tightening torque for M8 bolts 33 Nm (24 ftlb)

No.

Description

Qty.

Note When: Removing Installing

Special Instructions

1

Nut M 10

1

2

Washer A 10.5

1

3

Roller or roller with slot

1

Check

4

Nut

1

5

Washer A 10.5

1

6

Tensioning roller for compensating shaft belt

1

Check

7

Compensating shaft belt

1

Handle with care, When installing do not twist belt make sure or turn; side of belt with store separately color coded tooth faces out

M 10x35

1

Hold with Same as for Special Tool 9200 removal when unscrewing

9

Washer

1

Position correctly

10

Collar

1

Position correctly

M 10x35

1

No.

Description

Qty.

Instal1ing

12

Washer

1

Position correctly

13

Collar

1

Position correctly

14

Balance shaft drive gear

1

Check movement on seat of balance shaft

15

Woodruff key

1

16

Balance shaft drive gear

1

Check movement on seat of balance shaft

17

Woodruff key

1

Torque: 8 Nm

M6xl6 - 8.8

4

M6x2.5 - 10.9

4

Torque: 13 Nm

Use from Mod. 87

19

Washer A 6.4

4

20

Pulley

1

M16xl.5x60

1

Torque: 210 Nm

Gear for balance shaft drive

1

Position correctly, pay attention to surve, see Page 13-49

Balance Shaft Drive

944

Engine / Crankshaft, Pistons

Note when:

No.

Description

Qty.

Removing Installing

24

Gear for camshaft

1

Belt collar faces

drive

compensating shaft

drive gear

25

Woodruff key

1

26

Thrust washer

1

27

Seal

1

Replace

ASSEMBLY NOTES ON SECURING THE PULLEY

The pulley (A) without recess must only be installed for old crankshafts without extended journal for accommodation of the servo pump drive. Pulley (B) with recess for crankshaft with extended journal can also be used on old crankshafts.

Disassembling and Assembling Compensating Shaft Drive

INSTALLING DRIVE GEARS OF BALANCE SHAFTS (Since 1 984 Models)

Note:

Groove code "U" is omitted on drive gears.

Installing Drive Gear of Upper Balance Shaft

1. Woodruff key groove of balance shaft faces up.

Insert woodruff key.

Apply thin coat of Optimoly HT on bearing surface for drive gear.

3. Install collar that its locating tab protrudes into unmarked groove of drive gear. Code "0" can be seen in large bore of collar. Install bolt and washer. Coat threads of bolt with Loctite 574.

2. Push drive gear with groove code "0" on woodruff key.

13 - 50 Installing Drive Gears of Balance Shafts III, 1983 - Printed in Germany

(Since 1984 Models)

\43-if4UTA)

4. Tighten bolt while holding with Special Tool 9200.

Tightening torque: 45 Nm.

Installing Drive Gear of Lower Balance Shaft

2. Push drive gear without a groove code on woodruff key.

3. Install collar that its locating tab protrudes into groove "0" of drive gear. Code "0" can be seen in square opening of collar.

Install bolt and washer.

Coat threads of bolt with Loctite 574.

Printed in Germany - III, 1983 Installing Drive Gears of Balance Shafts 13 - 47

(since 1984 models)

MACHINING CYLINDER BORES IN UPPER CRANKCASE SECTION

The upper crankcase section is an aluminum alloy product and contains minute particles of pure silicium.

In order to have an usable cylinder surface finish, the cylinder bores have to be machined in a manner that the silicium particles protrude out of the aluminum and therefore pistons and piston rings only have contact with the silicium.

If it is necessary to machine cylinder bores, they can be restored with a SUNNEN CK -10 / CV - 616 cylinder repairing machine for installation of oversize pistons.

Standard size 100.00 mm

Oversize 1 100.50 mm

Oversize 2 101.00 mm

Single cylinder bores can be machined as required, since pertinent oversize pistons weigh the same as standard pistons.

Prior to machining cylinder bores it is recommended to check the stocks on hand for pertinent tolerance groups and, if necessary, to hone the bore for a certain piston size which is available. There could be problems in supplying pistons of certain tolerance groups depending on circumstances.

The following procedures are necessary.

Rough turning to 0.1 mm before finished size. Dressing to 0.02 mm before finished size. Polishing to finished size. Lapping with Sunnen silicium mixture.

PROCEDURES

It is absolutely necessary to bolt the upper and lower crankcase sections together with help of the bearing studs prior to machining.

Tightening Procedures

Torque in Nm

Threads

3 steps: step 1

20

M 12 x 1.5

step 2

40

step 3

75

2 steps: step 1

20

M 10

step 2

50

10

M 6

20

M 8

TOOLS

Machine

Grinding attachment Grinding oil Felt inserts Silicium mixture Storage box for felt inserts Stone holder set for felt inserts instead of honing stones Stone holder set for honing stones for 3 different stones (types)

Felt holder seat instead of guide shoe Roughing stone set Dressing stone set Polishing stone set

CK-10 with filter CV-616 with filter CK-3000 or CK-2600 MB-30 or MAN-845 C30-F 85 1 set AN-30 AN-35

CK-3035 A 1 set

CK-3035 A 3 set

CK-3130 A 1 set

C30-J 55 ++ shorten to 70 mm length C30-J 84 ++ shorten to 70 mm length C30-C 03 - 81

13-54

Machining Cylinder Bores

Printed in Germany

Honing Procedures

Perform all honing and lapping jobs without the upper dressing guide shoe.

The protrusion of the bronze bar on main guide shoe no. 3 has to be eliminated; flush with guide shoe base.

Setting Up Machine

Roughing adjustment table described in column 1.

Dressing adjustment table described in column 2.

Polishing adjustment table described in column 3.

Lapping — uncovering the silicium crystals.

1. Set up machine as described in column 4 of test sheet.

2. Thoroughly remove all abrasive residue from previous honing jobs with filtered honing oil.

3. Wipe cylinder bores dry and apply a thin coat of thoroughly mixed silicium mixture. Note:

If the silicium mixture is too consistent, it can be diluted by adding fresh honing oil and mixing thoroughly.

4. Holders with felt inserts are now placed in the grinding attachment instead of guide shoe and honing stones.

Adjusting to the cylinder diameter is made with a gage as for the guide rails and honing stones.

5. Soak felt inserts in filtered honing oil and coat with silicium mixture.

6. Stop grinding oil feed; cylinders are lapped without grinding oil!

Machining Cylinders

Guide grinding attachment into bore. Turn feed wheel anticlockwise until felt inserts rest on walls. Start machine and keep turning handwheel anticlockwise until needle of load instrument reaches approx. 20 to 30 %.

Now set scale of feed wheel to 20.

The machine stops on its own after about 80 seconds. The cylinder surface will now be dull and without gloss.

First coat felt inserts with new silicium mixture before going on to the next cylinder. Note:

If holder with felt inserts are not being used, they must be kept in the storage box to avoid contact with dirt.

Never reuse old silicium mixture.

Machining Cylinder Bores with SUNNEN 10/CV 616 Machine

1 .Roughing to Dia.

2. Dressing to Dia.

3.Polishing to Dia.

4.Lapping

Cylinder dia. Standard: 100.00 mm

Cylinder dia. Oversize 1 : 100.50 mm

100.40 mm

100.48 mm

100.50 mm

100.50 mm

Cylinder dia. Oversize 2 : 101.00 mm

Cylinder length 145 mm

Honing head type

CK-3000 or CK-2600

ditto

ditto

ditto

Travel scale for stone length

70 mm

70 mm

70 mm

70 mm

Adjustment on scale

160 mm

160 mm

160 mm

125 mm

Speed (rpm)

125 CK/CV

125 CK/CV

125 CK/CV

185 CK/ 230 CV

Strokes per minute

49 CK/57 CV

49 CK/57CV

49 CK/57 CV

73 CK/80CV

Feed

5

4

3

2

Stone protrusion top

21 mm

21 mm

21 mm

2 mm

Roughing stone

C 30 - J 55

Dressing stone

C 30 - J 84

Polishing stone

C 30-C03-81

Felt insert

C 30-F 85

Display (%)

30-40

30-40

20-30

Adjustment on feed wheel

0.07 mm/ 10 lines

0.03 mm/ 10 lines

0.01 mm/ 10 lines

approx. 20 lines

80 seconds running time

Surface finish (Rt.)

approx. 7 - 8 my

approx.2my

approx 0.6-0.8 my

approx. 1 -2 my

13-56 Machining Cylinder Bores

VI, 1985 - Printed in Germany

A chamfer of 0.5 mm x 30° has to be machined on the upper cylinder wall of machined cylinder bores after finishing the honing procedures.

Clean upper and lower crankcase sections thoroughly to remove abrasion residue and silicium paste prior to assembling.

TOOLS

No.

Description

Special Tool

Remarks

1

Belt tightness tester

9201

2

Adjusting gauge for roller

9207

with slot

CHECKING AND ADJUSTING TIGHTNESS OF CAMSHAFT DRIVE BELT

Note

The tightness of the drive belt must only be checked and adjusted on a cold engine (room temperature).

Checking

1. Turn crankshaft clockwise slowly until TDC mark on camshaft sprocket is aligned with cast mark in console for the distributor cap.

Note

Check drive belt for wear and damage at same time while turning.

2. TDC mark on flywheel and cast boss on clutch housing must also be aligned.

3. Turn engine on crankshaft anticlockwise approx. 10° on crankshaft, which is equal to about 1.5 teeth toward mark on the camshaft sprocket.

4. Prepare Special Tool 9201 for checking. Pull out lockpin on special tool and push out test pin opposite the lockpin completely. Align drag needle with gage needle.

5. Slide special tool on to drive belt. Press in test point (arrow) slowly until lockpin is felt to engage and read displayed value from the dial gage.

Note

Always line up the drag needle and gage needle after engagment of the lockpin to exclude incorrect display (by turning anticlockwise).

Adjusting Value:

Scale Value:

Control Value: for operation up to about 3,000 km 2.4 to 4.3

Correct drive belt tightness if necessary.

6. Turn the tensioning roller anticlockwise while tightening.

Turn the tensioning roller clockwise while loosening.

7. Tighten mounting nuts with specified torque while counterholding.

8. Turn engine clockwise two complete turns and align TDC mark on camshaft sprocket with cast mark in console for distributor cap. Turn engine anticlockwise approx. 10 crankshaft degrees from this position.

9. Recheck tightness of drive belt and, if necessary, correct.

Note

Sliding shoes must have complete contact on surface of drive belt. The special tool must not be turned nor moved on the belt while checking.

15-4 Checking and Adjusting Tightness of Camshaft Drive Belt

Printed in Germany

INSTALLING CAMSHAFT DRIVE BELT AND ADJUSTING TIMING

1. Turn engine crankshaft to TDC for cylinder no. 1. TDC marks on flywheel and cast clutch housing must be aligned.

2. Align mark on camshaft sprocket with mark on rear drive belt cover.

3. Install drive belt according to following procedures:

Place belt on sprocket of crankshaft (1), tensioning roller (2), water pump pulley (3) and camshaft sprocket (4), preloading belt slightly by hand each time so that belt can be pushed on to camshaft sprocket.

4. Tighten drive belt; see page 15-3.

Installing Camshaft Drive Belt and Adjusting Timing

REMOVING AND INSTALLING CYLINDER HEAD Removing

The cylinder head can be taken off without removing the engine.

1. Disconnect battery ground wire.

2. Unscrew cap on coolant expansion tank.

3. Remove splash guard.

4. Unscrew coolant drain plug on radiator and drain coolant.

5. Remove poly-rib belt.

6. Remove drive belt cover.

7. Turn engine to TDC in cylinder no. 1.

7. Turn engine to TDC in cylinder no. 1.

8. Remove distributor cap, unscrew distributor rotor and remove protective cap.

9. Remove mount for distributor cap.

10. Relax belt tension and pull camshaft belt off of camshaft sprocket.

11. Unscrew 2 mounting bolts on rear drive belt cover.

12. Unscrew fuel lines.

14. Unscrew aluminum plugs, coolant line and bolts (with attached washers) and remove camshaft housing from cylinder head.

Note

Make sure that hydraulic valve tappets do not fall out and are not mixed up.

15. Remove air cleaner assembly.

13. Remove plastic cover on fuel collection tube, pull off wire plugs on fuel injectors and lay wire harness aside.

16. Unscrew bolt of intake brace.

17. Remove intake distributor by dismantling holder on oil dipstick tube, hose on brake booster, hose on intake distributor, retaining clamp on accelerator cable and mounting bolts of intake distributor/cylinder head.

18. Unscrew bolts of exhaust manifold/catalytic converter pipe flange.

19. Unscrew hose clamp on heater regulating valve and two screws on neck for coolant circuit.

20. Unscrew mounting nuts for cylinder head. Note

Order for unscrewing mounting nuts is crosswise from outside to inside.

21. Take off cylinder head.

Installing

1. Install cylinder head gasket in correct position.

A. Preloading Cylinder Head Gasket 1st step 20 Nm

2nd step 50 Nm

3rd step 90 Nm

3. Mount camshaft housing.

Tightening torque for socket head bolts: 20 Nm.

Tightening torque for aluminum plugs: 40 Nm.

4. Install drive belt, see page 15-5.

5. Adjust polyrib belt, see page 13 -1.

2. Mount cylinder head.

Tightening order: see figure. Note

Never use a lubricant for installation of cylinder head nuts and washers. Only give the threads of studs a light coat of engine oil. The washers must not turn when tightening cylinder head nuts! If necessary, check this with paint stripes. In the repair sector the washers can be reused after roughening the bearing surface for the cylinder head with a rough sandpaper.

15-10 Removing and Installing Cylinder Head

V, 1985 - Printed in Germany

Engine, Cylinder Head, Valve Drive

+1 0

Post a comment