1976-1985 Mercedes-Benz 300D/300TD/300CD Service & Repair Manual

AR01.30-P-7162T Check/face-grind cylinder head contact surfaces 27.9.12 ENGINE 651 in MODEL 204, 212 ENGINE 648.961 in MODEL 211.023/026/223/226 ENGINE 646.961 in MODEL 211.006/206/606 ENGINE 647.961 in MODEL 211.016/216/616 ENGINE 646.951 in MODEL 211.004 a Valve setback with new valves and valve seat rings H Overall height of cylinder head without camshaft housing P01.30-0344-06 Remove/install 1 Remove cylinder head ENGINE 648.961 in MODEL AR01.30-P-5800TA 211.023/026/223/226 ENGINE 646.951 in MODEL 211.004 AR01.30-P-5800T ENGINE 646.961 in MODEL 211.006/206/606 ENGINE 647.961 in MODEL 211.016/216/616 AR01.30-P-5800TB ENGINE 651 in MODEL 204, 212 AR01.30-P-5800CD 2 Remove valves ENGINE 648.961 in MODEL AR05.30-P-3511HB 211.023/026/223/226 ENGINE 646.961 in MODEL 211.006/206/606 ENGINE 646.951 in MODEL 211.004 ENGINE 647.961 in MODEL 211.016/216/616 ENGINE 651 in MODEL 204, 212 AR05.30-P-3511CD Check 3 Check cylinder head contact surface for The camshaft case must not be flatness, porous or damaged locations; face- machined. grind if necessary The basic bores for the camshaft bearing will be changed otherwise. Only face cylinder head contact surface if porous or damaged points are present. It is not necessary to rework minor variations in the flatness in the longitudinal direction. These are compensated for again when the cylinder head is tightened. Where required, following inspection of cylinder head separating surface: Measure total height of cylinder head without camshaft case (H), note the measured value and compare with tabular value. Face grind contact surface of cylinder head Measure total height of cylinder head without camshaft case (H) again. Page 1 of 2 © Daimler AG, 11/9/16, G/01/15, ar01.30-p-7162t, Check/face-grind cylinder head contact surfaces ENGINE 651 in MODEL 204, 212 ENGINE 648.961 in MODEL 211.023/026/223/226 ENGINE 646.961 in MODEL 211.006/206/606 ENGINE 647.961 in MODEL 211.016/216/616 ENGINE 646.951 in .

Height of cylinder head (H), without camshaft *BE01.30-P-1003-02E housing 4 Measure valve setback There is no further correct valve clearance compensation available if the reference dimension for the valve setback is not reached for new valves and new valve seat rings (a). Where required, replace valve seat ring or cylinder head. Valve setback (a) with new valves and new *BE01.30-P-1001-02E valve seat rings 5 Install in the reverse order Check values for cylinder head Number Designation ENGINE ENGINE 646.951/961/962/963 648.960/961 /966, 647.961 BE01.30-P-1003-02E Height of cylinder head (H), without camshaft New mm 126,85...127,15 126,85...127,15 housing Wear limit after mm 126,65 126,65 machining For AR01.30-P-7162HB AR01.30-P-7162HB picture, see Check values for cylinder head Number Designation ENGINE 651 BE01.30-P-1003-02E Height of cylinder head (H), without camshaft New mm 134,35...134,65 housing Wear limit after mm 134,15 machining For - picture, see Check values for cylinder head Number Designation ENGINE ENGINE 646.951/961/962/963 648.960/961 /966, 647.961 BE01.30-P-1001-02E Valve setback (a) with new valves and new Exhaust valve mm 1,0...1,4 1,0...1,4 valve seat rings Intake valve mm 1,1...1,5 1,1...1,5 For picture, see – – Check values for cylinder head Number Designation ENGINE 651 BE01.30-P-1001-02E Valve setback (a) with new valves and new Exhaust valve mm 0,7...1,1 valve seat rings Intake valve mm 1,0...1,4 For picture, see – Page 2 of 2 © Daimler AG, 11/9/16, G/01/15, ar01.30-p-7162t, Check/face-grind cylinder head contact surfaces ENGINE 651 in MODEL 204, 212 ENGINE 648.961 in MODEL 211.023/026/223/226 ENGINE 646.961 in MODEL 211.006/206/606 ENGINE 647.961 in MODEL 211.016/216/616 ENGINE 646.951 in .

AR05.00-P-2010CD Check hydraulic valve clearance compensating elements 23.4.12 ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221 2 Compensating element 3 Cam 4 Roller-type cam follower 5 Tool P05.00-2063-11 Remove/install 1 Check engine oil level, correct if necessary The engine oil level must lie between "Min" and "Max". Engine damage can occur otherwise. Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working Do not touch hot or rotating parts. near the engine as it is running 2 Start engine and bring to operating Coolant temperature 60 to 80°C. temperature 3 Remove cylinder head cover AR01.20-P-5014CD Checking 4.1 Rotate engine at crankshaft using a Except code (B03) ECO start-stop function counterholder in direction of engine rotation until the cam (3) on the compensation element (2) to be tested is on its base circle The engine must not be turned back. The timing chain can skip and cause engine damage otherwise. *651589004000 Counterholder 4.2 Rotate engine at crankshaft using a suitable With code (B03) ECO start/stop function tool in direction of engine rotation until the cam (3) on the compensation element (2) to be tested is on its base circle The engine must not be turned back. The timing chain can skip and cause engine damage otherwise. 5 Press down compensation element (2) over Do not use a steel tool. Press cam follower (4) by hand using the compensation element (2) downwards using appropriate tool (5) normal force of the hand. If a number of compensation elements (2) drop, check oil ducts and oil feed bores for the compensation elements (2) for fouling; blow out oil ducts with compressed air in the direction of flow of the oil if necessary. If a compensation element (2) drops much more than other compensation elements (2), replace the compensation element (2) in question See: Remove/install compensation element (2). AR05.00-P-2011CD 6 Install in the reverse order Page 1 of 2 © Daimler AG, 11/9/16, G/01/15, ar05.00-p-2010cd, Check hydraulic valve clearance compensating elements ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221

651 589 00 40 00 Counterholder Page 2 of 2 © Daimler AG, 11/9/16, G/01/15, ar05.00-p-2010cd, Check hydraulic valve clearance compensating elements ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221

SM07.16-P-0005B Check injectors 22.7.10 ENGINES 651 in MODELS 204, 207, 212 1 Date of manufacture P07.16-3645-04 Operation no. of operation texts or standard texts and flat rates Category Op. no. Operation text Time Acc. no. Code P 024762 Connect and disconnect Diagnosis Assistance System (DAS) P 025059 Read out and erase fault memory (with DAS connected) P 026748 Perform control unit adaptation (with DAS connected) P 026872 Perform quick test P 026873 Check (all) injectors P 026874 Replace injectors (all) (after check) List of affected vehicles Model 204 from SM07.16-P-0005-01BAA WDC2049021F405147 to WDD2042821F471917 Model 207 from SM07.16-P-0005-01BAB WDD2073031F008596 to WDD2073032F039959 Model 212 from SM07.16-P-0005-01BAC WDD2120021A001295 to WDD2122031A167495 Checking 1 Check manufacture date (1) for all If the manufacture date (1) for the injectors is injectors up to 09316, continue with operation step 2. If the manufacture date (1) for the injectors is as from 09317, end measure . Remove/install 2 Remove/install/replace injectors AR07.16-P-1000CD Part delivery is executed solely on the basis of a TIPS case. The logistics Centers (LCs) will not ship any more injectors without instruction to do so by the Technical Workshop Support. It is not possible to order the injectors through the usual order channels. 3 Clear fault memory Parts ordering notes Part no. Designation Quantity Small parts such as stop nuts, sealing rings, cable ties, fluid etc. are no shown in the parts listing. The required small parts are taken into account in the cost framework A 651 070 20 87 Injector parts kit 1 Page 1 of 1 © Daimler AG, 11/9/16, G/01/15, sm07.16-p-0005b, Check injectors ENGINES 651 in MODELS 204, 207, 212

AR27.00-P-0100AC Check oil level in automatic transmission and correct if necessary. 2.11.10 TRANSMISSION 722.6 93 Cap 93a Locking pin A Range at 25 °C (77 °F) B Range at 80 °C (180 °F) P27.50-0274-06 Modification notes 6.8.08 Value changed: Filling capacity, Specifications for *BF27.00-P-1001-01C Operating Fluids Value changed: Filling capacity, Transmission *BF27.00-P-1001-01C 722.600/601/604/605/606/607/608/609/611/61 3/614/616/617/618/619/629/634/639/660/661/ 662/664/665/689/695/696/699 Transmission 722.602/603/615 Transmissions 722.610/638 Transmission 722.620/621 in model 129 Transmission 722.620/621 in model 140, transmission 722.622/623/624/625/626/627/628/ 630/631/632/633/635/636/ 663/666/669 Transmission 722.637 in model 461.302/331/332/342/345 Transmission 722.637 in model 463.322/323 Transmission 722.640/644 Transmission 722.642 Transmission 722.648 Transmission 722.649 Transmission 722.667/668/672/676/690 Transmission 722.671/675/677 Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working Do not touch hot or rotating parts. near the engine as it is running The vehicle must be positioned horizontally on its wheels, otherwise measurement errors will occur. Check and pour in transmission oil when cold (approx. 25 °C) 1 Remove engine cover. Only if required 2 Remove locking pin (93a) and take plug (93) To do so, break off the plate of the off oil filler pipe locking pin (93a) using a suitable tool and remove the pin remaining in the cap (93) by pressing downwards. 3 Fill with transmission oil After a complete refill and after changing the transmission oil, pour in approx. 5 liters of transmission oil before starting the engine. Insufficient and excessive quantities of oil can result in malfunctions and transmission damage. Page 1 of 5 © Daimler AG, 11/9/16, G/01/15, ar27.00-p-0100ac, Check oil level in automatic transmission and correct if necessary. TRANSMISSION 722.6

*BF27.00-P-1001-01C *126589126300 *140589496300 4 Start engine and allow it to idle briefly in gear range "P" 5 Fill with remaining quantity of transmission Only with complete refill oil *BF27.00-P-1001-01C 6 Actuate service brake and briefly shift through gear ranges several times with vehicle stationary and engine running at idle speed, then reengage gear range "P" 7 Insert oil dipstick all the way into oil filler When cold, the transmission oil level pipe, pull it out again and read off must be between the "min" and "max" transmission oil level marking in the range (A). *140589152100 8 Correct transmission oil level If necessary Insufficient and excessive quantities of oil can result in malfunctions and transmission damage. *210589007100 *140589496300 *126589126300 9 Check transmission oil level again After pouring in transmission oil. Only perform steps 10 to 14 if shifting Precise checking is only possible at a problems occur. transmission oil temperature > 80 °C . 10 Connect Star Diagnosis and check Operate the service brake when doing transmission oil temperature in gear range so. "R" or "D" 11 Start engine and allow it to idle in gear range "P" 12 Insert oil dipstick all the way into oil filler The transmission oil level must be pipe, pull it out again and read off between the "min" and "max" marking in the transmission oil level range (B). *140589152100 13 Correct transmission oil level If necessary Insufficient and excessive quantities of oil can result in malfunctions and transmission damage. *210589007100 *140589496300 *126589126300 14 Check transmission oil level again After pouring in transmission oil. 15 Mount cap (93) on oil filler pipe and press in new locking pin (93a) until it latches 16 Perform engine test run and, with engine running, check transmission for leaks and that it is functioning correctly Automatic transmission Number Designation Transmission Transmission Transmissions 722.602/603/615 722.610/638 722.600/601/604/605/ 606/607/608/609/611/ 613/614/616/617/618/ 619/629/634/639/660/ 661/662/664/665/689/ 695/696/699 BF27.00-P-1001-01C Filling Initial charge Liters 7.5 (+0.5) 7.0 (+0.5) 8.0 capacity during oil change Liters - - - Specifications for Operating Sheet BB00.40-P-0236-14A BB00.40-P-0236-14A BB00.40-P-0236-14A Fluids Sheet - - - Page 2 of 5 © Daimler AG, 11/9/16, G/01/15, ar27.00-p-0100ac, Check oil level in automatic transmission and correct if necessary. TRANSMISSION 722.6

Automatic transmission Number Designation Transmission Transmission 722.620/621 722.620/621 in model 129 in model 140, transmission 722.622/623/ 624/625/626/627/628/ 630/631/632/633/635/ 636/663/666/669 BF27.00-P-1001-01C Filling Initial charge Liters 8.2 (+0.5) 8.6 (+0.5) capacity during oil change Liters - - Specifications for Operating Sheet BB00.40-P-0236-14A BB00.40-P-0236-14A Fluids Sheet - - Automatic transmission Number Designation Transmission Transmission 722.637 in 722.637 in model model 461.302/331/332/ 463.322/323 342/345 BF27.00-P-1001-01C Filling Initial charge Liters 7.9 7.9 capacity during oil change Liters - - Specifications for Operating Sheet BB00.40-P-0236-14A BB00.40-P-0236-14A Fluids Sheet - - Automatic transmission Number Designation Transmissions Transmission Transmission 722.640/644 722.642 722.643 BF27.00-P-1001-01C Filling Initial charge Liters 7.5 7.3 (+0.5) 8,7 capacity during oil change Liters - - - Specifications for Operating Sheet BB00.40-P-0236-14A BB00.40-P-0236-14A BB00.40-P-0236-14A Fluids Sheet - - - Automatic transmission Number Designation Transmission Transmission Transmission 722.648 722.649 722.667/668/672 /676/690 Page 3 of 5 © Daimler AG, 11/9/16, G/01/15, ar27.00-p-0100ac, Check oil level in automatic transmission and correct if necessary. TRANSMISSION 722.6

BF27.00-P-1001-01C Filling Initial charge Liters 8 8,0 9 capacity during oil change Liters 5 6.5 - Specifications for Operating Sheet BB00.40-P-0236-14A BB00.40-P-0236-14A BB00.40-P-0236-14A Fluids Sheet - - - Automatic transmission Number Designation Transmission Transmission Transmission 722.673 722.674 722.641 in model in model in model 163 163 170 BF27.00-P-1001-01C Filling Initial charge Liters 7.6 to 8.0 8.8 to 9.2 7.3 to 7.7 capacity during oil change Liters - - - Specifications for Operating Sheet BB00.40-P-0236-14A BB00.40-P-0236-14A BB00.40-P-0236-14A Fluids Sheet - - - Automatic transmission Number Designation Transmission Transmission Transmission 722.612/697/ 722.621 722.645 698 in model in model in model 202 463 202 BF27.00-P-1001-01C Filling Initial charge Liters 7.3 to 7.7 8.5 to 8.9 8.8 to 9.2 capacity during oil change Liters - - - Specifications for Operating Sheet BB00.40-P-0236-14A BB00.40-P-0236-14A BB00.40-P-0236-14A Fluids Sheet - - - Automatic transmission Number Designation Transmission Transmission Transmission 722.646 722.671/675/677 722.694 BF27.00-P-1001-01C Filling Initial charge Liters 8.3 8.5 to 8.9 7.3 capacity during oil change Liters - - - Specifications for Operating Sheet BB00.40-P-0236-14A BB00.40-P-0236-14A BB00.40-P-0236-14A Fluids Page 4 of 5 © Daimler AG, 11/9/16, G/01/15, ar27.00-p-0100ac, Check oil level in automatic transmission and correct if necessary. TRANSMISSION 722.6

Sheet - - - 126 589 12 63 00 140 589 15 21 00 140 589 49 63 00 210 589 00 71 00 Funnel Dipstick Filling pipe Hand pump Page 5 of 5 © Daimler AG, 11/9/16, G/01/15, ar27.00-p-0100ac, Check oil level in automatic transmission and correct if necessary. TRANSMISSION 722.6

1976-1985 Mercedes-Benz 300D/300TD/300CD Service & Repair Manual

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