Name: Mercedes-Benz 201.024
Brand: Mercedes-Benz
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General,

technical

data

Group Index4
General, Technical5
Special Instructions7
Location of Specific Repair Instructions7
Engine and Vehicle Identification8
Gasoline Engines10
Filling Capacities11
Electrical System11
Crankcase and Cylinder Head12
Table of Contents13
Engine and Model Survey14
Overview - Engines, Models, Output and Compression Ratio15
Removal and Installation of Bottom Engine Compartment Cover16
Testing Compression Pressure17
Special Tools18
Testing Cylinder Leaktightness21
Commercial Tool24
Illuminating Cylinders24
- Removal and Installation of Englne25
- Viscosity Grades for Engine Oils According to SAE27
- Oil Capacity in Liters27
- Tightening Torques28
- Shoe-Made Tools28
- Englne 102.985 (CFI System)42
Crankcase Ventilation - Function42
Measuring, Boring and Honing Cylinders43
- Identification of Tolerance Stages44
- Standard Implementation44
- Measuring45
Facing Crankcase Parting Surface46
Removal and Installation of Steel Balls in Main Oil Gallery48
Replacing Core Plug in Crankcase51
Removal and Installation of Tlmlng Case Cover54
Removal and Installation of End Cover62
Removal and Installation of Oil Pan64
Oil Capacity in Litres65
Repair Instructions for Crankcase70
Removal and Installation of Cylinder Head Cover76
Reconditioning Spark Plug Thread in Cylinder Head81
Removal and Installation of Cylinder Head85
Matching Measuring Sensors to Cylinder Head95
Facing Cylinder Head Mating Face98
- Valve Clearance to Cylinder Head Mating Face99
- Facing99
Enlarging Camshaft Bearing Bores (Repair Size)100
Pressure-Testing Cylinder Head103
- Crankshaft Assembly105
- Checking, Replacing and Torquing Conrod Bolts106
- Reconditlonlng and Checking Angles of Bearing Bores109
- Removal and Installation of Pistons115
  - Matching Pistons and Cylinders116
  - Test Data118
- Checking and Reconditioning Crankshaft126
  - Checking, Grinding129
  - Crack Test132
  - Explanatory Notes Regarding Diagram132
  - Hardening132
  - Hardness Test132
  - Corrosion Protection133
  - Inspection of Hardening133
  - Installation of Crankshafts Bearings134
  - Matching Crankshaft Bearing Shells to Crankcase139
  - Matching Crankshaft Bearings, Installing Crankshaft142
  - Matching Conrod Bearings and Installing146
- Replacing Front Crankshaft Radial Seal148
- Replacing Rear Crankshaft Radial Seal153
  - Removal and Installation of Grooved Ball Bearlng in Crankshaft157
  - Removal and Installation of Vibration Damper or Hub and Belt Pulley159
- Checking and Correcting Setting of TDC Pulse Generator164
- Removal and Installation of Crankshaft Gear171
- Removal and Installation of Flywheel or Flex Plate175
- Remachining Flywheel180
- Replacing Ring Gear on Flywheel182
- Checking and Replacement of Hydraulic Valve Clearance186
- Hydraulic Valve Clearance Compensation188
- Inspection Specification of Washer and Ball Socket195
- Checking and Adjusting Camsbft Timing202
- Removal and Installation of Camshaft210
- Rocker Arms and Rocker Shafts230
- Bearing Suppoft230
- Removal and Installation of Valve Springs232
- Cylinder Headl Installed236
- Checking Valve Springs238
- Replacement of Valve Stem Seals240
- Distinguishing Features241
- Checking and Machining Valves244
- Checking and Machining247
- Checking and Replacing Valve Guides248
- Cylinder Head Clamping Fixture250
- Valve Guides250
- Broach Base Bore in Cylinder Head251
- Inserting Valve Guide252
- Guide Sleeve - Valve Seat Allocation to Enaine252
- Replacing Valve Seat Ring253
- Machining Valve Seats257
- Valve Distance to Cylinder Head Parting Surface259
- Removal and Installation of Chain Tensioner263
- Replacement of Timing Chain268
- Installation of Oil Spray Nozzle Retroactively275
- Removal and Installation of Tensioner Blade281
- Removal and Installation of Guide Rails286
- Guide Rail in Cylinder Crankcase291
- Temoval and Installation of Idler Gear Shaft297
- Removal and Installation of Oil Pressure Pump Drive301

Mercedes-Benz 201.024 User Manual

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Mercedes-Benz 201.024 Specifications

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Brand	Mercedes-Benz
Model	201.024
Category	Engine
Language	English