Mercedes-Benz Service Manual Engines M 110

Index

Mercedes Benz Service Manual Engines M110

00 General, technical data

• 00-005 Instructions for use of service manual
• 00-010 Engine number and vehicle identification tag location
• 00-015 Technical data

01 Crankcase and cylinder head

• 01-001 Engine and model survey
• 01-010 Checking compression
• 01-015 Checking cylinders for leaks
• 01-020 Evaluating cylinder bores
• 01-025 Measuring oil consumption
• 01-030 Removal and installation of engine (oil filling capacity)
• 01-040 Engine vent - Description of function
• 01-110 Checking, drilling and honing cylinder bores
• 01-120 Grinding crankcase mating surface
• 01-130 Knocking-out and inserting steel balls for main oil ducts
• 01-220 Installation and centering of intermediate flange
• 01-310 Complete removal and installation of oil pan
• 01-415 Removal and installation of cylinder head
• 01-416 Cylinder head measuring sensor box
• 01-418 Facing cylinder head mating surface
• 01-420 Pressure testing cylinder head
• 01-470 Removal and installation of camshaft housing
• 01-471 Association camshaft housing and camshafts
• 01-472 Facing camshaft housing
• 01-490 Cylinder head and camshaft housing illustrated table

03 Crankshaft assembly

• 03-310 Checking, replacing and tightening conrod bolts
• 03-313 Repairing and squaring connecting rods
• 03-316 Removal and installation of piston
• 03-318 Checking and reconditioning crankshaft
• 03-320 Mounting of crankshaft
• 03-324 Replacing front crankshaft radial oil seal
• 03-327 Replacing rear crankshaft radial oil seal
• 03-330 Removal and installation of radial ball bearing and closing ring in crankshaft
• 03-340 Removal and installation of pulley, vibration damper and balancing disc
• 03-344 Static balancing of balance disc
• 03-345 Checking and correcting adjustment of TDC transmitter
• 03-350 Removal and installation of crankshaft sprocket
• 03-410 Removal and installation of flywheel and driven plate
• 03-420 Machining flywheel
• 03-430 Replacing ring gear
• 03-440 Static balancing of flywheel

05 Engine timing, valvetrain

• 05-210 Checking and adjusting valve clearance
• 05-212 Replacing threaded bushing and valve adjusting screw
• 05-215 Checking and adjusting camshaft timing
• 05-220 Removal and installation of camshafts
• 05-225 Grinding camshaft bearing journals
• 05-230 Removal and installation of rocker arms
• 05-250 Removal and installation of valve springs
• 05-260 Checking valve springs
• 05-270 Replacing valve stem seals
• 05-280 Checking and machining valves
• 05-285 Inspecting, assigning and installing valve guides
• 05-290 Renewal of valve seat rings
• 05-291 Machining valve seats
• 05-310 Removal and installation of chain tensioner
• 05-320 Replacing timing chain
• 05-330 Removing and installing tensioning rail
• 05-340 Removal and installation of side rails
• 05-410 Removal and installation of helical gear shaft
• 05-412 Removal and installation of intermediate gear shaft
• 05-432 Removal and installation of intermediate wheel
• 05-440 Removal and installation of guide wheel
• 05-450 Removal and installation of distributor housing with distributor drive gear
• 05-490 Illustrated table of chain tensioner, timing chain and drive gears

07-2 Carburetor, fuel pump, throttle linkage

• 07_2-090 Layout and function Solex carburetor 4 A 1
• 07_2-092 Technical modifications (revisions) of model years
• 07_2-100 Adjusting idle speed
• 07_2-101 Synchronizing idle speed systems
• 07_2-102 Checking idle speed shutoff valves for function
• 07_2-104 Removal and installation of idle speed shutoff valves
• 07_2-110 Regulation of engine
• 07_2-125 Adjusting choke
• 07_2-128 Testing starting device (choke) for function (cold start)
• 07_2-130 Testing and adjusting TN choke for function
• 07_2-132 Adjusting choke rod
• 07_2-134 Testing pulldown diaphragm for leaks
• 07_2-138 Removal and installation of TN choke
• 07_2-140 Removal and installation of choke
• 07_2-142 Checking and correcting choke housing mark
• 07_2-145 Checking choke cover-stepped heater
• 07_2-147 Subsequent installation of choke cover-stepped heater
• 07_2-150 Adjusting accelerating pump
• 07_2-152 Checking suction valve and delivery valves of accelerating pump for leaks
• 07_2-154 Removal and installation of accelerating pump diaphragm
• 07_2-156 Subsequent installation of vapor bubble draw-off for accelerating pump (USA 1975/76 only)
• 07_2-170 Checking and correcting air valve adjustment of stage II
• 07_2-172 Checking and correcting jet needle adjustment of stage II
• 07_2-174 Removal and installation of restoring spring for air valve of stage II
• 07_2-175 Subsequent installation of modified adjusting pin for air valve preload of stage II
• 07_2-176 Subsequent installation of bypass bores of stage II
• 07_2-180 Adjusting float level
• 07_2-182 Checking float chamber external venting system
• 07_2-186 Checking fuel return valve
• 07_2-190 Checking fuel return valve
• 07_2-192 Removal and installation of carburetor cover
• 07_2-194 Removal and installation of carburetor
• 07_2-210 Checking fuel pump
• 07_2-212 Removal and installation of fuel pump
• 07_2-300 Adjustment of regulating linkage
• 07_2-310 Removal and installation of engine longitudinal regulating shaft
• 07_2-320 Removal and installation of front wall regulating shaft
• 07_2-330 Removal and installation of accelerator pedal

07-3 Mechanical gasoline injection system (CIS)

• 07_3-100 Adjustment of idle speed
• 07_3-105 Checking and adjusting on-off ratio
• 07_3-110 Checking and regulating engine
• 07_3-120 Checking fuel pressures and for internal leaks
• 07_3-125 Checking choke system
• 07_3-130 Checking delivery capacity of fuel pump
• 07_3-135 Checking injection valves
• 07_3-140 Checking decel shutoff
• 07_3-145 Checking idle speed stabilization on engines with refrigerant compressor
• 07_3-150 Checking idle speed stabilization on engines with refrigerant compressor
• 07_3-160 Checking fuel distributor for constant delivery
• 07_3-165 Checking fuel pump relay with electronic rpm regulation (breakaway)
• 07_3-199 Survey mixture preparation
• 07_3-200 Removal and installation of mixture controller
• 07_3-205 Replacement of fuel distributor
• 07_3-210 Reconditioning of system pressure regulator and pressure compensating valve
• 07_3-215 Removal and installation of injection valves
• 07_3-220 Replacement of air flow sensor
• 07_3-225 Removal and installation of mixture controller with air guide housing
• 07_3-230 Removal and installation of throttle valve housing
• 07_3-242 Subsequent installation of safety switch on air flow sensor
• 07_3-245 Replacement, centering and zero position of air flow sensor plate
• 07_3-270 Removal and installation of fuel reservoir
• 07_3-275 Removal and installation of fuel filter
• 07_3-280 Removal and installation of fuel pump
• 07_3-281 Replacement of holder for fuel pump, fuel filter and fuel reservoir
• 07_3-282 Conversion of fuel pump assembly
• 07_3-283 Subsequent installation of separate check valve on fuel pump
• 07_3-500 Operation

07-5 Ignition system

• 07_5-500 Checking and adjusting closing angle (dwell angle) and firing point
• 07_5-503 Removing, preventing formation of layer on breaker points (breaker-controlled transistorized ignition)
• 07_5-505 Renewing contact breakers (breaker points)
• 07_5-510 Removal and installation of ignition distributor
• 07_5-519 General description of breaker controlled transistorized ignition (J) (USA)
• 07_5-520 Testing breaker-controlled transistorized ignition (J) (USA)

09 Air filter

• 09-400 Removal and installation of air cleaner
• 09-400a Functional description of intake air preheating system
• 09-405 Removal and installation of thermostat for intake air preheater
• 09-410 Removal and installation of air filter
• 09-415 Removal and installation of intake pipe

13 Belt drive

• 13-335 Instructions for renewing and tensioning V-belts
• 13-340 Renewal and tensioning of V-belt

14 Intake and exhaust manifold, emission control system

• 14-001 Functional characteristics
• 14-050 Operation
• 14-050a Operation
• 14-050b Operation
• 14-100 Test program
• 14-100a Test program
• 14-100b Test program
• 14-150 Wiring diagrams
• 14-200 Removal and installation of catalyst
• 14-200a Removal and installation of catalyst
• 14-200b Removal and installation of catalyst
• 14-250 Removal and installation of air pump
• 14-250a Removal and installation of air pump
• 14-300 Removal and installation of anti-backfire valve
• 14-450 Removal and installation of intake manifold, replacement of gasket
• 14-455 Renewing intake manifold (intake manifold removed)
• 14-470 Removal and installation of exhaust manifold
• 14-472 Survey exhaust manifold
• 14-475 Testing EGR
• 14-500 Operation of EGR

15 Electrical system, engine

• 15-501 Testing and adjusting firing point
• 15-510 Removal and installation of ignition distributor
• 15-528 Notes concerning jobs on breakerless transistorized ignition system TSZ 4 and TSZ 8 u
• 15-530 General description of breakerless transistorized coil ignition system TSZ 4 and TSZ 8 u
• 15-531 Notes concerning use of test instruments on breakerless transistorized ignition system without pre-resistors TSZ 8 u
• 15-562 Testing breakerless transistorized ignition

18 Engine lubrication system

• 18-005 Oil circuit, oil pressure, pressure relief valves and oil filter
• 18-020 Additional installation of oil pressure relief valve in main oil duct
• 18-030 Removal and installation of outer oil return line
• 18-120 Checking thermostat in oil filter
• 18-125 Removal and installation of thermostat in oil filter upper section
• 18-210 Removal and installation of oil pump

20 Engine cooling system

• 20-005 Coolant circuit and engine cooling
• 20-010 Draining and filling coolant - Anti-freeze table
• 20-015 Cleaning cooling system
• 20-210 Removal and installation of water pump
• 20-310 Temperature controlled visco-fan clutch
• 20-330 Magnetic fan clutch
• 20-420 Removal and installation of radiator
• 20-425 Repairing radiator
• 20-430 Testing radiator or expansion tank closing cap

22 Engine suspension

• 22-211 Removal and installation of front engine mount
• 22-212 Removal and installation of rear engine mount
• 22-240 Removal and installation of engine shock absorber

30 Accelerator control

• 30-300 Adjustment of regulating linkage
• 30-310 Removal and installation of engine longitudinal regulating shaft
• 30-320 Removal, installation and adjustment of chassis regulating shaft
• 30-330 Removal and installation of accelerator pedal
• 30-335 Lubrication of regulating linkage and regulating shafts

47 Fuel system

• 47-700 Removal and installation of fuel tank
• 47-700a Removal and installation of fuel tank
• 47-705 Removal and installation of fuel expansion tank
• 47-705a Removal and installation of fuel expansion tank (model 114)
• 47-710 Removal and installation of immersion tube transmitter
• 47-710a Removal and installation of immersion tube transmitter
• 47-715 Functional description of immersion tube transmitter
• 47-715a Functional description of immersion tube transmitter for fuel gauge
• 47-720 Functional description of positive and negative venting of fuel tank
• 47-720a Functional description of fuel tank positive and negative venting system (model 114)
• 47-800 Fuel evaporation control system (AUS) (J) (USA)
• 47-800a Fuel evaporation system (J) (USA)
• 47-850 Fuel cooler (J) (USA)

49 Exhaust system

• 49-100 Removal and installation of exhaust system