1998 Mercedes-Benz SL500 (4.2L & 5.0L) Service and Repair Manual

4.2L & 5.0L V8 Article Text 1998 Mercedes-Benz SL500 For 1 Copyright © 1998 Mitchell Repair Information Company, LLC Friday, September 02, 2011 03:15PM ARTICLE BEGINNING 1997-98 ENGINES Mercedes-Benz 4.2L & 5.0L V8 1997: E420 1997-98: S420, S500, SL500 1998: CL500 * 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. ENGINE IDENTIFICATION The engine family designation is shown on the emission control information plate (attached to radiator crossmember). The 1st character identifies the model year ("V" for 1997 or "W" for 1998) while the 6th, 7th and 8th characters identify the engine displacement. ENGINE IDENTIFICATION CODES Application & Engine Size (1) Engine ID Engine Code 1997 E420 (4.2L) ............... 119.985 ........................ (2) S420 (4.2L) ............... 119.981 ........................ (2) S500 (5.0L) ............... 119.980 ........................ (2) 1998 CL500 (5.0L) .............. 119.980 ........................ (2) S420 (4.2L) ............... 119.981 ........................ (2) S500 (5.0L) ............... 119.980 ........................ (2) SL500 (5.0L) .............. 119.982 ........................ (2) (1) - The engine identification number must be used when ordering replacement parts. (2) - Information not available. ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Hydraulic valve lifters are used and valve clearance adjustment is not necessary. CAMSHAFT BASIC TIMING

4.2L & 5.0L V8 Article Text (p. 2) 1998 Mercedes-Benz SL500For 1 Copyright © 1998 Mitchell Repair Information Compan 1) Position cylinder No. 1 to 45 degrees BTDC. Remove both valve covers. Using Camshaft Pins (119 589 00 15 00), pin all camshafts. Camshaft pins are installed through camshaft bearing cap No. 1. If camshaft basic timing is okay, all camshaft pins should have been installed. 2) If any camshaft pin could not be installed, remove both top slide rails. See TOP SLIDE RAIL (TIMING CHAIN GUIDE) under REMOVAL & INSTALLATION. Remove timing chain tensioner. See CHAIN TENSIONER under REMOVAL & INSTALLATION. NOTE: To enable adjustment of camshafts, slack in timing chain (from removing timing chain tensioner) must be moved to left side of engine by rotating camshafts. 3) To start adjustment of camshaft timing, use Wrench (119 589 00 01 00) to rotate slack area in timing chain to left exhaust camshaft by rotating one at a time (in direction of engine rotation) right exhaust camshaft, right intake camshaft, then left intake camshaft. 4) When left intake camshaft is properly positioned, reposition timing chain onto left exhaust camshaft gear and install camshaft pin. Rotate left intake camshaft so camshaft pin can be installed. Reposition timing chain onto left intake camshaft. 5) Rotate right intake camshaft so camshaft pin can be installed. Reposition timing chain onto right intake camshaft. Rotate right exhaust camshaft so camshaft pin can be installed. Reposition timing chain onto right exhaust camshaft. 6) All camshaft pins should be installed and piston No. 1 should be at 45 degrees BTDC. If camshafts did not align allowing installation of camshaft pins and piston No. 1 is not at 45 BTDC, repeat procedure. VALVE TIMING NOTE: Valve timing is measured with hydraulic lifters installed. Checking 1) Measure valve timing at intake valves No. 1 and 6. Remove valve covers. Rotate crankshaft in direction of engine rotation until lobes of intake cams being tested are facing up (only base circles resting on hydraulic lifters). 2) Attach a dial indicator with tip resting vertically on cylinder No. 1 intake valve hydraulic lifter. Preload dial indicator . 12" (3 mm) and zero dial. Ensure tip moves freely. Rotate crankshaft in direction of engine rotation until dial indicator reads .08" (2 mm) valve lift. 3) With .08" (2 mm) intake valve lift (valve opening), crankshaft should indicate specification in VALVE TIMING SPECIFICATIONS table. Continue rotating crankshaft until intake valve starts closing. Crankshaft should indicate specification in VALVE TIMING SPECIFICATIONS table. Repeat steps 2) and 3) for cylinder No. 6 intake valve.

4.2L & 5.0L V8 Article Text (p. 3) 1998 Mercedes-Benz SL500For 1 Copyright © 1998 M 4) Attach a dial indicator so tip is resting vertically on cylinder No. 1 exhaust valve hydraulic lifter. Preload dial indicator .12" (3 mm) and zero dial. Ensure tracer pin moves freely. Rotate crankshaft in direction of engine rotation until dial indicator reads .08" (2 mm) valve lift. 5) With .08" (2 mm) exhaust valve lift (valve opening), crankshaft should indicate specification in VALVE TIMING SPECIFICATIONS table. Continue rotating crankshaft until exhaust valve starts closing. Crankshaft should indicate specification in VALVE TIMING SPECIFICATIONS table. Repeat steps 4) and 5) for cylinder No. 6 exhaust valve. 6) If valve timing is not to specification, ensure hydraulic lifters are functioning properly. Replace hydraulic lifters as necessary. If hydraulic lifters are okay, check timing chain for excessive stretching. Replace timing chain if necessary. VALVE TIMING SPECIFICATIONS Engine Crankshaft Degrees 4.2L Intake Valve Opens (1) .................................. 30 ATDC Intake Valve Closes (1) ................................. 35 ABDC Exhaust Valve Opens ...................................... 8 BBDC Exhaust Valve Closes .................................... 13 BTDC 5.0L Intake Valve Opens (1) .................................. 30 ATDC Intake Valve Closes (1) ................................. 40 ABDC Exhaust Valve Opens ..................................... 13 BBDC Exhaust Valve Closes .................................... 13 BTDC (1) - With camshaft adjuster retarded. REMOVAL & INSTALLATION * PLEASE READ THIS FIRST * NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. FUEL PRESSURE RELEASE Turn ignition off. Disconnect fuel pump(s) negative terminal (located under vehicle). If necessary, remove cover to access fuel pump(s). Start engine. Allow engine to run until it stalls. Crank engine to ensure residual fuel pressure is released. ENGINE NOTE: Procedure covers removing engine and transmission as a single unit.

4.2L & 5.0L V8 Article Text (p. 4) 1998 Mercedes-Benz SL500For 1 Copyright © 1998 Mitchell Repair Removal 1) Release fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Raise hood to vertical position. Disconnect battery terminals. Remove air filter. If vehicle is equipped with A/C, discharge A/C system and recover refrigerant. 2) Remove engine compartment covering from under vehicle. Drain and remove radiator. Loosen 2 drains located next to engine mounts. Drain engine coolant from engine. If vehicle is equipped with A/C, place a guard over A/C condenser. 3) Disconnect heater hose at intake manifold. Disconnect heater hose from rear of crankcase. Cap heater hose and engine connections to prevent contamination. 4) Remove viscous fan clutch and fan. If vehicle is equipped with A/C, remove A/C drive belt. Disconnect fuel lines. Disconnect engine wiring harness connectors. 5) Disconnect vacuum lines as necessary. Disconnect accelerator cable. Disconnect brake servo vacuum line. Using a siphon, remove power steering fluid from power steering pump reservoir. Disconnect power steering pump hydraulic lines at pump. 6) Disconnect air injection (if equipped). On E420, remove front bumper assembly and right headlight. Disconnect left engine mount cooling air duct. On CL500, S420 and S500, disconnect oil cooler line bracket. 7) On all models, disconnect oil cooler lines at air-to-oil cooler. On E420, disconnect left oil cooler line at oil sump. On all models, if vehicle is equipped with self-leveling suspension, disconnect high pressure hose at oil sump. On E420, disconnect left oil line for automatic transmission. 8) On all models, if vehicle is equipped with A/C, remove A/C compressor mounting bolts and/or nut. Secure A/C compressor aside with A/C hoses connected. Disconnect Heated Oxygen Sensor (HO2S) connector(s). Completely remove exhaust system. 9) Remove shield over starter (if equipped). Disconnect starter electrical connections. Disconnect generator electrical connections. On E420, disconnect strut located below oil sump. On all models, disconnect drive shaft from flexible coupling at transmission. Leave flexible coupling connected to transmission. 10) Loosen drive shaft center bearing bolts. Loosen large clamping nut on drive shaft. Clamping nut is located near center bearing. With clamping nut loosened, push drive shaft as far back from transmission as possible. 11) Disconnect transmission ground strap. Turn starter lockout switch locking element before disconnecting starter lockout switch connector. See Fig. 1. Using 2 screwdrivers, pry off starter lockout switch connector from transmission. 12) Remove rear engine support. Remove exhaust bracket from transmission. Disconnect shift linkage at transmission. Disconnect electrical connections from transmission. 13) Ensure all necessary electrical, vacuum and mechanical connections are disconnected. Unbolt front engine mounts. Attach chain hoist to lifting eyes of engine and take up slack. Remove engine and

4.2L & 5.0L V8 Article Text (p. 5) 1998 Merce transmission by repositioning engine hoist several times. Installation To install, reverse removal procedure. Adjust all fluid levels. Fig. 1: Identifying Starter Lockout Switch Connector Locking Element Courtesy of Mercedes-Benz of North America. BELT TENSIONER Removal & Installation Loosen belt tensioner adjustment bolt (accessible from top front of engine). Remove belt. Remove bolt from center front of belt tensioner (accessible from front of engine). Pull belt tensioner forward, removing belt tensioner. To install, reverse removal procedure. Tighten bolt to specification. See TORQUE SPECIFICATIONS. INTAKE MANIFOLD NOTE: Removal and installation procedure is not available. EXHAUST MANIFOLD Removal & Installation (Right Side) Disconnect negative battery cable. Disconnect dipstick guide tube from exhaust manifold. Disconnect exhaust manifold from exhaust pipe. Remove exhaust manifold retaining bolts. Raise engine slightly to assist in removal of exhaust manifold. Remove exhaust manifold. To install, reverse removal procedure. Install NEW exhaust manifold gasket with metal side facing cylinder head. Removal & Installation (Left Side)

4.2L & 5.0L V8 Article Text (p. 6) 1998 Mercedes-Benz SL500For 1 Copy Disconnect negative battery cable. Remove radiator shroud. Disconnect left engine mount. Disconnect exhaust manifold from exhaust pipe. Remove exhaust manifold retaining bolts. Raise engine slightly to assist in removal of exhaust manifold. Remove exhaust manifold. To install, reverse removal procedure. Install new exhaust manifold gasket with metal side facing cylinder head. CYLINDER HEAD Removal 1) Raise hood to vertical position. Release fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect battery ground cable. Drain engine coolant from engine. Remove accessory drive belt. 2) Rotate crankshaft to 45 degrees Before Top Dead Center (BTDC). Remove intake manifold. Disconnect power steering pump with reservoir and position aside. 3) Remove crankcase ventilation lines. Remove engine wiring harness over right cylinder head valve cover. Disconnect brake servo vacuum line at intake manifold. 4) Remove covers over both distributors. Remove both distributor caps with wires. Remove distributor rotor and driver. Remove protective cover with seal. 5) Disconnect left front cylinder head cover oil line. Remove left cylinder head bracket cover (located on end of cylinder head). Remove left front cylinder head cover (located on end of cylinder head). 6) Disconnect camshaft adjuster electrical connector from right cylinder head. Remove right cylinder head bracket cover (located on end of cylinder head). Remove right front cylinder head cover (located on end of cylinder head). 7) Mark all 4 camshaft gears with colored dots to identify timing chain position. Remove timing chain tensioner. See CHAIN TENSIONER. Remove camshaft sprockets. 8) Disconnect fuel lines from fuel rail. Remove covers over spark plugs and ignition coils. Disconnect spark plug wires. Remove valve cover bolts with washers. Note different lengths of valve cover bolts during removal. 9) Remove valve covers with seals. Disconnect right cylinder head dipstick guide tube. Disconnect exhaust manifolds at exhaust manifold flange. 10) Remove first and fourth intake camshaft bearing caps. Attach Lifting Eyes (104 589 00 40 00) to intake camshaft bearing cap locations No. 1 and 4. 11) Remove 3 bolt and washer assemblies from front of cylinder head. Note different lengths of valve cover bolts during removal. Identify location of bolt and washer assemblies for reassembly. 12) With engine cold, remove cylinder head bolts in reverse order of installation. On CL500, E420, S420 and S500, cylinder head bolt No. 10 for either head (last in tightening sequence, first in removal) cannot be removed with cylinder head installed. Loosen and

4.2L & 5.0L V8 Article Text (p. 7) 1998 Merc secure left cylinder head bolt No. 10 in raised position. 13) On all models, attach hoist to lifting eyes mounted on cylinder head. Remove cylinder head bolts. Using hoist, remove cylinder head. CAUTION: Check cylinder head bolts for excessive stretching. Failure to replace stretched bolts may result in bolts breaking. Installation 1) To install, reverse removal procedure. Install new cylinder head gasket. Ensure head gasket is correctly positioned. Check length of cylinder head bolts. Cylinder head bolts stretch permanently when installed. 2) Measure from bottom of bolt head to bottom of bolt. Check cylinder head bolt length. Maximum cylinder head bolt length is 6.41" (162.7 mm). If length exceeds 6.41" (162.7 mm), replace all cylinder head bolts. 3) Oil threads and bolt head contact surface of cylinder head bolts. With engine cold, tighten cylinder head bolts to specification in proper sequence. See Fig. 2. Ensure bolt and washer assemblies (located on front of cylinder head) are installed in proper location because bolts are different sizes. See TORQUE SPECIFICATIONS. Ensure paint marks on timing chain and camshaft sprockets are aligned. To complete installation, reverse removal procedure. Fig. 2: Installing Cylinder Head Bolts Courtesy of Mercedes-Benz of North America. FRONT CRANKSHAFT OIL SEAL Removal With engine removed from vehicle, remove all accessory drive

4.2L & 5.0L V8 Article Text (p. 8) 1998 Merce belts. Mark for installation alignment reference, and remove vibration damper, pulley and hub. Using a seal remover, remove oil seal. NOTE: DO NOT use grease when installing oil seal. Grease will prevent oil from flowing back into engine. Installation Check hub for grooves. If hub is grooved, install oil seal with a .12" (3 mm) offset. Using engine oil, lubricate sealing lip of oil seal and install seal. DO NOT use grease. To complete installation, reverse removal procedure. REAR CRANKSHAFT OIL SEAL NOTE: DO NOT remove rear cover from engine when replacing rear crankshaft oil seal unless absolutely necessary. Removal 1) Rear crankshaft oil seal is located in an end cover bolted to cylinder block. Disconnect negative battery cable. Separate engine from transmission. Remove drive plate. Cover crankshaft journal with a rag. 2) Using a screwdriver, carefully remove rear seal. DO NOT damage crankshaft journal. Check sealing surface of crankshaft for damage. Check mounting hole for burrs. Remove burrs as necessary. NOTE: DO NOT use grease when installing oil seal. Grease will prevent oil from flowing back into engine. Installation 1) Check crankshaft for grooves. If crankshaft is grooved, during installation use a repair size oil seal. The repair size oil seal has a sealing lip that is .07" (1.75 mm) offset to the inside. 2) Install inner part of Seal Installer (117 589 00 43 00) onto crankshaft flange. Apply engine oil to new seal. DO NOT use grease. Place new rear seal over inner part of seal installer. Attach outer part of Seal Installer (117 589 00 43 00) to inner part of seal installer. Press new rear seal into mounting hole. CAUTION: Ensure oil seal dust lip does not rest against crankshaft, or oil leaks may occur due to pumping action. 3) Measure stretch bolts for drive plate. Measure shaft diameter between bottom of bolt head and top of threads. If shaft diameter is not within specification, replace stretch bolt. 4) Measure bolt length from bottom of bolt head to end of bolt threads. If bolt length is not within specification, replace stretch bolt. See DRIVE PLATE BOLT SPECIFICATIONS table. To complete installation, reverse removal procedure. CAUTION: Check drive plate bolts for excessive stretching. Failure to replace stretched bolts may result in bolts breaking.

4.2L & 5.0L V8 Article Text (p. 9) 1998 Mercedes-Benz S DRIVE PLATE BOLT SPECIFICATIONS Application In. (mm) Shaft Diameter Standard ...................................... .38-.40 (9.6-10.0) Minimum ................................................ .37 (9.3) Bolt Length Standard ..................................... .90-.91 (22.8-23.2) Maximum ............................................... .93 (23.5) REAR COVER NOTE: DO NOT remove rear cover from engine unless absolutely necessary. Removal 1) With engine removed from vehicle, separate engine from transmission. Remove drive plate. Remove rear cover bolts. Identify rear cover bolts during removal, as lengths may be different. 2) Using two 8-mm tapped holes in rear cover, insert bolts and press rear cover from engine. DO NOT damage oil pan gasket when pressing rear cover from engine. NOTE: Proper installation is critical, as the rear cover seals a main oil gallery. DO NOT use grease when installing oil seal. Grease will prevent oil from flowing back into engine. Installation 1) Carefully clean sealing surface on engine and rear cover. DO NOT damage sealing surfaces, or rear cover may leak. Apply sealant to sealing surface of rear cover. DO NOT let any sealant get into oil gallery in rear cover. See Fig. 3. 2) Apply engine oil between dust lip and sealing lip of rear crankshaft oil seal. Install inner part of Seal Installer (117 589 00 43 00) onto crankshaft flange. Install rear cover (with seal) over inner part of seal installer. Use care to not damage oil pan gasket when installing rear cover. 3) Install rear cover bolts. Pay attention to rear cover bolt length, as bolt length may be different depending on bolt location. Evenly tighten rear cover bolts to specification. See TORQUE SPECIFICATIONS. Remove inner part of seal installer. To complete installation, reverse removal procedure.

4.2L & 5.0L V8 Article Text (p. 10) 1998 Mercedes-Benz SL500For 1 Copyright © 1998 Mitchell Repair Information Comp Fig. 3: Identifying Rear Cover Oil Gallery Courtesy of Mercedes-Benz of North America. TIMING CHAIN NOTE: Removal and installation procedure is not available. CHAIN TENSIONER Removal & Installation 1) Raise hood to vertical position. Disconnect negative battery cable. Position cylinder No. 1 to 45 degrees BTDC. Remove right valve cover. Using a Camshaft Pin (119 589 00 15 00), pin exhaust camshaft. Camshaft pin is installed through camshaft bearing cap No. 1. 2) Pinning camshaft prevents camshaft from turning when chain tensioner is removed. Loosen accessory drive belt. Remove belt from air pump. Remove air pump. Remove chain tensioner. Ensure gasket is removed when removing chain tensioner. To install, reverse removal procedure. TOP SLIDE RAIL (TIMING CHAIN GUIDE) NOTE: Removing top slide rail requires Release Tool (119 589 01 63 03) and Pusher (119 589 01 63 00). Front part of slide rail must be removed (unlocked) before removing bottom part of slide rail from cylinder head. Removal & Installation 1) Remove valve cover to access top slide rail being removed. Insert Release Tool (119 589 01 63 03) between bottom and top part of slide rail. Insert release tool from camshaft side of slide rail.

1998 Mercedes-Benz SL500 (4.2L & 5.0L) Service and Repair Manual

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