Remove/install hydraulic valve clearance compensation elements

AR05.00-P-2011M

Remove/install hydraulic valve clearance compensation elements

15.1.01

 

Remove/install

1.1

Remove air cleaner

Model 220

AR09.10-P-1050M

Model 463

AR09.10-P-1050GD

2.1

Remove the hot film mass air flow sensor on the left or on the right with the air intake tubes

Model 220

AR07.07-P-1454M

Model 463

AR07.07-P-1454GD

2.2

Detach the intake air distribution pipe

Model Series 163

AR09.10-P-1250CD

3

Unscrew the charge air intake pipe at the cylinder head cover and press it to the side

Model 220

Model 463

Model 163 charge air intake pipe on the right

4.1

Remove fender liner in left front fender

Model 163 charge air intake pipe on the left

AR88.10-P-1300GH

5.1

Detach the charge air intake pipe at the cylinder head cover (1) and the turbocharger and press to the side

Model 163 charge air intake pipe on the left

6

Remove the cover of the injectors on the left or on the right

Danger!

Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.

Fire, sparks, open flames or smoking forbidden.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

7

Remove the injectors (Y76) on the left or on the right

 Installation: Replace the injector seal and screws of the clamping claws. Clean the injectors and the injector recesses on the cylinder head. Pay attention to maximum cleanliness while cleaning!

AR07.16-P-1000M



Notes on injectors

AH07.16-P-1000-01A

8

Remove the cylinder head cover (1) on the left or on the right

Model 163, 220

AR01.20-P-5014M

Model 463

AR01.20-P-5014GA

9.1

Remove fan shroud (2).

 Only the compensation elements of the cylinder head on the right.

Model 220

AR20.40-P-6800MB

Model 463

AR20.40-P-6800GD

10.1

Remove throttle valve adjusting motor with upper charge air pipes

 Only the compensation elements of the cylinder head on the right.

Model 220, 463

AR09.41-P-1314M

10.2

Remove charge air cross pipe

 Only the compensation elements of the cylinder head on the right.

Model Series 163

AR09.41-P-1510CD

11.1

Remove the vacuum pump (6)

 Only the compensation elements of the cylinder head on the right.

Model 163, 220

AR43.05-P-1320HB

Model 463

AR43.05-P-1320GA

12

Position piston of cylinder 1 to ignition TDC

 Rotate the engine at the crankshaft in the running direction.

Model 220, 463:

Rotate the engine from below through the opening in the transmission housing at the torque converter.

The scribe marks (arrows) of the camshaft bearing caps (4) must align with the scribe marks on the camshafts (3a, 3b). The scribe marks (B) on the camshaft sprockets (7, 8) must be (as per the diagram) opposite to each other.

13

Remove camshafts (3a, 3b)

AR05.20-P-6992M

14

Pull out compensation element (5)

 The compensation elements can also be removed with the camshaft case (10). A lug prevents the compensation elements from dropping out.

 Do not use a magnet!

The friction surface of the compensating element would otherwise be magnetized. This may cause minute iron swarf to gather which can result in damage to the compensating element and cam.

 Installation: Reinstall the compensation elements (5) that are not replaced at the same position. Oil compensation elements (5).



*WH58.30-Z-1041-02A

15

Install in the reverse order

Danger!

Risk of accident as vehicle may start off by itself with the engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns

Secure vehicle to prevent it from moving off by itself.
Wear closed and close-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

16

Run engine and inspect for oil leaks

Danger!

Risk of explosion from fuel igniting. Risk of injury if eyes or skin are struck by escaping fuel stream

Keep all ignition sources out of hazardous area.

Do not carry out any work on the system when it is pressurized.

AS07.16-Z-0001-01A

17

Run engine and inspect fuel system for leaks

18

Connect STAR DIAGNOSIS and read fault memory

 During repairs, for example, delete the errors stored in the diagnostic trouble code memory by separating the connectors.

*WH58.30-Z-1048-13A



AD00.00-P-2000-04A

Number

Designation

WH58.30-Z-1041-02A

Rubber suction cup, dia. 30 mm

WH58.30-Z-1048-13A

STAR DIAGNOSIS diagnosis system, Compact Passenger Car

6511 1801 00