1999 Mercedes-Benz E-Class E300TD (W210) Service & Repair Manual

3.0L 6-CYLINDER TURBO DIESEL Article Text 1999 Mercedes-Benz E300 For 1 Copyright © 1998 Mitchell Repair Information Company, LLC Tuesday, November 30, 2010 04:12AM ARTICLE BEGINNING 1999 ENGINES Mercedes-Benz 3.0L 6-Cylinder E300 Turbo Diesel * PLEASE READ THIS FIRST * NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section. NOTE: Complete service information is not available. ENGINE IDENTIFICATION The engine family designation is shown on the emission control information plate (attached to radiator crossmember). The first character identifies model year ("X" for 1999), while the sixth, seventh and eighth characters identify engine displacement. ENGINE IDENTIFICATION CODES Application (1) Engine ID Engine Code E300 Turbo Diesel (3.0L) .......... 606.962 ........ XMBXV03.0DTU (1) - The engine identification number must be used when ordering replacement parts. ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Hydraulic valve lifters are used. Valve clearance adjustment is not necessary. TROUBLE SHOOTING NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section. REMOVAL & INSTALLATION * PLEASE READ THIS FIRST * NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating

3.0L 6-CYLINDER TURBO DIESEL Article marks on major assemblies before removal. FUEL PRESSURE RELEASE Turn ignition off. Disconnect fuel pump supply line at fuel pump (located on side of injection pump) and cap fuel line. ENGINE Removal 1) Release fuel pressure. See FUEL PRESSURE RELEASE. Place hood in vertical position. Disconnect negative battery terminal. Remove air intake hose. Remove air cleaner housing. 2) Remove engine undercover. Drain engine coolant. Disconnect automatic transmission hydraulic lines. Remove radiator. Disconnect coolant hose located next to oil filter. Disconnect upper coolant hose. 3) Place a guard plate over A/C condenser. Disconnect engine wiring harness. Unbolt exhaust system at intermediate flange of turbocharger and transmission. Remove turbocharger boost pressure hoses. 4) Remove accessory drive belt. Disconnect vacuum hoses from engine. Remove power steering fluid from reservoir. Unbolt power steering lines from engine. On vehicles equipped with self-leveling suspension, disconnect hose to oil reservoir. 5) Disconnect engine oil cooler lines. Disconnect A/C compressor electrical connector. Disconnect A/C compressor from engine and set aside with hoses attached. Disconnect fuel lines at rear of engine. 6) Disconnect shift rod at selector lever. Unbolt drive shaft at transmission. Disconnect park lock interlock wire cable. Remove guard plate on right side of transmission. Disconnect transmission electrical connector on right side of transmission. 7) Using a hoist, support engine. Unbolt front engine mounts. Support transmission and remove rear engine mount. Using a hoist, remove engine from vehicle. Installation To install, reverse removal procedure. Adjust all fluid levels. If a new cylinder head gasket was installed, DO NOT pressure test cooling system until engine has obtained operating temperature. OVERHAUL CYLINDER HEAD Cylinder Head Bolts Measure cylinder head bolt length. Measure bolt length from bottom of bolt head to end of bolt threads. If bolt length is not within specification, replace bolt. See CYLINDER HEAD BOLT LENGTH SPECIFICATIONS table.

3.0L 6-CYLINDER TURBO DIESEL Article Text (p. 3) 1999 Mercedes-Benz E300For 1 Copyright © 1998 Mitchell CYLINDER HEAD BOLT LENGTH SPECIFICATIONS Application In. (mm) Bolt Length New ....................................... 4.015-4.527 (102-115) Maximum ................................... 4.094-4.606 (104-117) CYLINDER BLOCK ASSEMBLY Crankshaft Main Bearing Selection Measure crankshaft main journal diameter. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS to select main bearing size by color code. Piston Projection Depending on piston projection, install cylinder head gasket of standard thickness or use cylinder head gasket of .0728" (1.85 mm) thickness. Connecting Rod Bolts Connecting rod bolts have a stretch shank. Bolt length information is not available. Crankshaft Main Bearing Cap Bolts Measure crankshaft bearing cap bolt length. Measure bolt length from bottom of bolt head to end of bolt threads. If bolt length is not within specification, replace bolt. See CRANKSHAFT MAIN BEARING CAP BOLT LENGTH SPECIFICATIONS table. CRANKSHAFT MAIN BEARING CAP BOLT LENGTH SPECIFICATIONS Application In. (mm) Bolt Length New ..................................... 2.433-2.448 (61.8-62.2) Maximum ............................................ 2.511 (63.8) ENGINE OILING ENGINE LUBRICATION SYSTEM Crankcase Capacity Oil capacity is 8.5 qts. (8.0L) with a new filter. Oil Pressure With engine at operating temperature and idling, oil pressure should be at least 4.4 psi (.3 bar). With engine at 3000 RPM, oil pressure should be at least 44 psi (3 bar).

3.0L 6-CYLINDER TURBO DIESEL Article Text (p. 4) 1999 Mercedes-Benz E300For 1 Copyright © 1998 Mitchell TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor-To-Bracket Bolt ............................ 17 (23) Camshaft Bearing Cap Bolts ................................ 11 (15) Camshaft Gear Nut ......................................... 13 (18) Chain Tensioner ........................................... 59 (80) Connecting Rod Bearing Cap Bolt First Step .............................................. 30 (40) Second Step ................................................. (1) Crankshaft Bearing Cap Bolts Step 1 .................................................. 41 (55) Step 2 ...................................................... (1) Crankshaft Pulley Bolts ................................... 18 (25) Cylinder Head Bolts Step 1 .................................................. 11 (15) Step 2 .................................................. 26 (35) Step 3 (After 10 Minute Wait) ............................... (1) Step 4 ...................................................... (1) Cylinder Head Bolts-To-Timing Cover ....................... 18 (25) Drive Plate Bolts Step 1 .................................................. 33 (45) Step 2 ...................................................... (1) Engine Mount-To-Axle Carrier Bolts ........................ 30 (40) Oil Pan Bolts 8-mm .................................................... 18 (25) 10-mm ....................................................... (2) Prechamber Threaded Ring ................................. 96 (130) Power Steering Pump Return Line ....................................... 26-33 (35-45) Supply Line ....................................... 33-37 (45-50) Steering Coupling Bolt .................................... 15 (20) Transmission Housing-To-Oil Pan ........................... 30 (40) Vibration Damper Center Bolt ............................ 148 (200) INCH Lbs. (N.m) End Cover Bolts ........................................... 89 (89) Timing Cover-To-Crankcase Bolts 6-mm .................................................... 89 (10) 8-mm ........................................................ (2) Oil Pan Bolts 6-mm .................................................... 89 (10) Valve Cover Bolts ......................................... 89 (10) (1) - Tighten an additional 90 degrees. (2) - Information not available.

3.0L 6-CYLINDER TURBO DIESEL Article Text (p. 5) 1999 Mercedes-Benz E300For 1 Copyright © 1998 Mitchell ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Application Specification Displacement ................................. 183.1 Cu. In. (3.0L) Bore .............................................. 3.43" (87.0 mm) Stroke ............................................ 3.31" (84.0 mm) Compression Ratio ............................................ 22:1 Fuel System ....................... Electronic Diesel Control (EDC) CYLINDER BLOCK CYLINDER BLOCK Application In. (mm) Height New ................................. 9.250-9.253 (234.97-235.03) Minimum .......................................... 9.236 (234.60) Cylinder Sleeve Bore Standard .......................................... 3.4252 (87.0) Group "A" ......................... 3.4252-3.4254 (87.000-87.006) Group "X" ......................... 3.4254-3.4256 (87.006-87.012) Group "B" ......................... 3.4256-3.4258 (87.012-87.018) Wear Limit Longitudinal & Transverse Direction .......................................... .007 (.20) Shape Difference New (Maximum) ................................... .00055 (.014) Limit ............................................ .00196 (.05) Out-Of-Roundness Maximum ........................................... .0027 (.07) Cylinder Bore Diameter For Liner ................ 3.5433-3.5446 (90.000-90.035) Diameter For Liner Collar ............. 3.564-3.568 (90.55-90.65) Liner Collar Seat Depth ..................... .039-.047 (1.0-1.2) Piston Projection New Crankcase .......................... .0309-.0399 (.785-1.015) Machined Crankcase ..................... .0387-.0478 (.985-1.215) Crankshaft Main Bearing Bore Diameter ................................ 2.460-2.461 (62.50-62.52) Crankshaft Main Bearing Bore Width At Fit Bearing .................. .9440-.9448 (23.98-24.00) CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

1999 Mercedes-Benz E-Class E300TD (W210) Service & Repair Manual

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