{AROS.10-P-76016 __| Replace timing chain |s2.00 ENGINES 272,273 In MODEL 212 1 exavatcamsan 3 octming cman 5 iso wnee! mange 2 ima canenan 4 Now tming can © Markings om carshaf usar 1T Markings on carat eusor & [Removing 1 [Disconnect battery ground cable |AR54.10-P-0003EW ® Note on batery (nee 109-0007 018 2 eve srk phos EAP Replace spark plugs |AP15.10-P-1560EW a Fore exhaust anda camahats 2) AROS 70 Fone ira efinde reas | | a Discomoct od ung can Anas OP TEOTSWA x '"602589009800 g -enzseo023200 g 02526056300 @ eoesee056301 ina [Draw in new timing chain (4) AROS 10-P-7601-04VA | w enaseo005600 @ -zreseeo3en00 3 tw rg can [ato 107-7607 020A 5 reneseooo0e00 a -zreseooaso00 = -zraseo000300 2 1272589016300 w -2rsavote300 ns 241 Se lp Tee Rena coi=] -aa05.10-P-1007-018 7 ‘Grank engine al eankshat im decion of ‘elation of engine to. 68" rank angle Imarkangon bet putey) ‘before ignition TOC on frst cinder (205° See "Check basic positon of camshafts with Iron cover stad a ynder head at 155" crankshaft angle before ignition TOC: Ss [ite marangs (5) on pulse wneels ot intake and exhaust careshat (1,2) onthe Inf tinder head must be tocstod catrally fn bores for camstat Hall sensors i hs not me case, tum engine at crankset larecton of engine otaton tough one fevouuton "AROS 20-P-8010EW 001580650000 2 ‘crank ngine ai eankshat ts Grecton ‘rank angle ater ignition TOC on frst of ‘otaton trough a 95° crank angiotoa 4° Spine = Insaliake camsha (7) andexhaust | []JNirings (6) paint unwarce ane marge /ARDS2-°-2802EW camsnat (2) onrartcyinderhead nine |) ign wah cota sncna one [baseposton singer hed covers. See "Check basic postion a cashes wih |AR520-P-6010-01VB ‘ron coverremoved a the yonder head ot 40" crankshaft angle ater ignition TOC a (Graangine a ankshan nthe aroaien —|TThe markings (5) on pulse wheels of ARUSZO-P-SOTOEW base postin of he camshais for an Insta ont cover on te evinder nes (05" marking onthe bat pulley) lot rotation ore engine and chock ha the 13a 66" crank angle before igrition TOC intake and exhaust camshafts (1,2) mast be Ibcated ceva bores for ears Hall a sa pr igs AP [Replace spark plugs |AP15.10-P-1580EW i Somer round ean 0 a 5419 OMEN A oaoer Ii of accent cossedby vee dang [Secure GHGS W WEEN ETON TOTRDEY [ASOOOO 0005-010 Injury causod by contusions and bums Inear he engine as tisrunting 3 (Cary out an engine test run and check laine fortes lof oy tsa wen engine w ruming. Feek ot (dung staring procedure or when warang sor "oar closed and snug. ting work clothes. Do nat touch oto etating pane {Eel Timing chain, chain tensioner Number Designation Engine | Engine m a soso TaTe Bot for timing chain vet element wm | 52 @ (reserencs vaio) wage a ~ aS \e02500008800 7 \ 02500023300 (602 580 05 63 00 \ eoaseeose301 7 ct oan tao “et cin Tt in AG 178418 GT th Ti Rc i Crvana 0zseaoseso _) \__araseoooseco 7 mas ooes0o _) \__arasesoresc0 7 ey tte! eomonnes ue Se. 2m seoor6s00 _/ \__ cor se06s0000 _/ 2 A 2041 QU th Tete, as ti cn Cras 02|AP15.10-P-1580EW ENGINE ENGINE ENGINE Shown on engine 272.983 in model 212.057 OF Sparkpiug wrench 1 Spark pug connector 3 lgniton cot connector 4 anton cable [Replace spark plugs 187, 272, 273, 276, 278 in MODEL 212 4157, 276, 278 in MODEL 218 212, 273, 276,278 in MODEL 207 3513 | Re Sparc plus xe Remove A. oancer | Rik of death cased by conta wit pas] Do nl ouch pas which conduct high JASTS HOZOODHDIA consicong ah stages ages Persons unohave decane ‘melons (9 cae posomakor) shoud ovr perm any work on We on system Broanser | lak ofinjuy Stn or aye ryuesrmay | Wea pctacve gas, plecve daling —|ASOOODZOOIE OTA Tesin va Renin oto gowng obs. |and seat gues, nessa 5 ‘Note on avoiding damage tvoug aR OOR SOTA ariamneton an ore abecs ® Notes on voiding damege to rten System Aveiro i Sc ognon 2 [Open engi hood 3 Remove gator cols ran Marl 207 exchenge 270, 278 Jaats 1-e2000cv aR Novel 212 exch ene 157,270,272 |agts 12-P-20002W aR ENGINE 276.270\m MODEL 207 laste 1220007 aR |enoame 157,276, 276im MODEL 212,218. |aRis 12-P-20036 4 ‘Detach spa ua conneclos (1) om Spark use a) ean ENGINE 272 oe2 e808 wars 12: P-010-01008 {El nataiaton: Observe correct essen of spa pug comet and gon co onmeso (13) and corres ong of fon nes) Pater |-araseseranc0 a ‘heck 5 [Ghek pak pug eonnedor creck tor samage, detmaton ana zac omaten, pais ¥ necessary 3 (Gheck wnton cal pog @)andignton ines ENGINE 272.922900004 a [il check tor eamage, deformation and ‘ack trmation, reads t necessary,7 [Remove spark plugs (R4) from the cylinder | @) inetallation: itis essential to adhere to Ihoads using sparkplug wrench (01) the Sontenng torque es nfunees the poston ofthe spark lug electrodes nthe |oyincor |An incrrecttighoning torque causes mises whic can loa to darian tothe ‘engine and catayic converter damane. Fy spark plug to cytnder nesd Bats 10--1001-016 ($1 motor 272, 273 }-112589010900 Spank plug wrench ($1 Motor 157, 276, 278 }-278589000900 Spank plug wrench 3 Insta the reverse ode spark ae ‘Number [Designation —JENGINE 167 JeNGINE 272 [BAIS 1OPA1001-016 [Spark pug o eyindernead wn [23 23 dss ‘Number Designation [ENGINE 773 JENGINE 76 {BAIS 10PAOOT-OTG [Spark pug to Giindor hand tn [23 Fz fed sar ohine Number [Designation [ENGINE 278 BAIS 10PA001-016 [Spark pug to ojinder head Nn [23 C NO NO >) insmorece 7 \C_iiaseaoiovo _) \C_areseococece 7 Spas wanes Seng wench {Enger ak 789 2H WNCOEL 22 NONE 17 Te BR VODEL 2B ENGE 229 2762 spanrec|ARO5.20-P-6002EW | Removerinstall camshafts ENGINES 272, 273in MODEL 212 1 Camshaft suse for intake camshett 2 Auiary bearing cap of ake coment 2 Inlake camshaft 44 Aunty beating cap of exhaust coment 5 Exhaust camsnan -. 2k al m ge [Removelinatall w "The around ine onthe baton must alae | Model 272.057 be aetacnad before negrning wore onthe ‘ue! sysiem aherase pressure i be os in ‘he fuel system through openng a vehicle (dor or the rane [Remove intake camshafts i [Remove respecive camshat adusirs (1 (AROS 20-P-7201EWE 2 "Remove ausiay bearing cap (2) and nok | BARDS 20-P-1010-028 leamstan (3) [Remove exhaust camshafts 3 "Remove respecive camsha adusters (AROS 20-F-7201EWA 4 [Remove respecive cyinder head cover [Right indar head cover except model ARO’ 20-P-20126L, [bzost Fight eyinder head cover, model 212.057 |AR01 20.P-5012&1.0 Loft cyinder need cover, xcept model |AROI 20-P-5013EL ‘arz0sr Lot cyinder head cover, motel 212057 __|aRo1 20 P-5013E.D 5 "Takeoff unitary Bearing cap and | BADE 20-P-T01008 remove exhaust camstian @) é Insta nthe vere onder BS Danger! [Rak of accident caused by vehicle saring | Secure vahice to prevent ®rom moving by ASOOGDZ-0005-07A loffay tse when engine suring. Riskof [ise Injury caused by contusions and bums | Wear closed and srup-ting work clones ‘during staring procedure or when working | Do not oven Not or rotating pats near ne engno.asnisrunning 1 ‘Conduct engine test un ana heck engine forteaks ed camshatt, camshaft adjustment Number Designation Engine | Engine m 23 BSP OTA Bol, aula bearing cep tocyinder Siege 1 | Nm | 8 hoa’ stooe2 | (Sie A704 GOT wt 2h ew Remar are Come at‘ARO5.20-P-7201EWE _| Remove/install camshaft adjusters ENGINES 272, 273 in MODEL 212 ‘On intake camshafts [20.04.41 1,2 Exnaustcamsnan 11,12. Pulse wneo! or nako camsnan 2.4 Intake camara 15118. Camshaft aqustor for nako 7.8 Cantor valve of intake camshaft camhat 24 Tensionig ral 25 Colorcoding 26,27 Cap 15 Camshaft ausior for intake camshat 18 Dowel pn 19 Pia 20, Bore in camshaf adjuster 21 Dowel pin n camsnan easter 22. Filled bore for lake camshaft He [Removerinstall w “The ground ine onthe batary must alma | ‘be datacod before Degening work on he {uel sysiom athervise pressure willbe lost in ‘he fol system through opening a venice (door ort tne Type 2087 i [Remove ai fier housing [aR0@10-P-EOEWS Sa NR rage an teen[Remove chan tanson 1 installation: install new chain {tensioner The prevusy msiaed chan {tensioner must not be rensalad because |durng removals pressure pis pressod nto ne-end postion ‘The ust pn Ich revons vs rturn stoke. Ths wou loversteich the timing chan on resting. \aR05 10-P-7800EW [Removal on right eylinder ead "Remove camshant ecto for ight exaust ‘camenst (9) (AROS 20 P-TAOTEWA [Remove cap 2) ‘Detach center vive (7) [i opserve loosening direction | installation: The center vaive (7) may ony be ightoned when cha tensioner ‘eremoved, horse ths can lead fo mafunctoning of camsnan adjustment "ARO520P-7201-08VA 5a05.20-P-1000.028 [Remove igh eyindor Read cover Excaph model 772087 [Type 2120057 TAROT 20-P-SOT2EL (ani 20-P-501261 (ark tena chain lave to ho comshait [agustor (15) using corr codes (25) Tiengine positioned at 40° crankshaft angle later giten TOC [i nstatition: Check postion of ntsko ‘camshaft (3) asad on coor coding (25) "Remove tensioning rl 24) (AROS 10-P-SF2TEW [Remove center valve (7) and pulse wheel ln FBichack dowel pin (1) and pin (19) \dewal pin (18) or pin (19) sheared of then Ines must be removed fom camshat ‘adjuster (15) |@ installation: Aways replace pulse whee! (14) Wha tightening center vai (1) tare JS ask tat dow pin (18) oF pm (19) may sar oat puso whoo! (11), [i] installation: Lubricate center valve (7) at contae surface with pulse whe! (1) Before lassen, [HE nstallation: Align doe in (18) on puso wheel (11) wih bore (20) a camshat laguster (5) [Lt oming chan ana pao camsnan ‘aster (15) from intake cama) Nowaras the Fork [il installation: Lubricate contact surfaces {io ntako camsnar (3) and casa [adjuster (15) fore mounting cams ‘aaser (1) instattation: ign coter coding (25) on [cama aajster (75) and tering chan with leach other Algn dowel pn (21) in camshaft “adustee (15) wh tad ore (22) mnt [camshat (3) [Removal on left evinder heed "Remove camshaft custo for exhaust ‘camenst (2) (AROS 20 72OTEWA 2 [Remove cap 7) 8 ‘Detach center valve (8) TH opserve loosening direction ‘@ installation: ngntening of center vane (&) may ony take place tora removes chan ‘eesionee Waltunetons ot camsnat ladsiment cn ooo herwoe, [ay (AROS20-P-720%- OVA ["BA0S 20-P-1000-024 [Remove oyindor head cover Except model 212.057 [Type 212087 TAROT 20-P-5O79EL (an0% 20-P-5019E1D Mark rena chain lave to carchaft [aster (1) using coir codes (25) [lenge positioned at 40° cranksnant angie anor giton TDC. [H nstaiation: Check postion of intake ‘cama () based on coor coding (25), [Remove conor vale (6) and pulse whosl G2) SSNS Rage mate EB check dowel pin (18) and pen (10). a \dowel pin (18) orn (19) sheared of thon Ines mast be removed fom camshat laduser (18), © instalation: Always replace puse wneot (12) Won tightening contr vale 8) tore Isa isk hat dow pin (18) oF pm 18) may ser of at pulse whee (12) [i] instaniation: Lubricate center vatve (8) at ‘contac surface wth pulse wheel (12) before ‘sesoruy[TD nstaiiation: Aign dowel pin (18) for se whee (12) wh tad bore 20) 9 [camshaft adjuster (1) 7 [Gifting chain and detach camshat |) inatalaton: Lubricate contac surfs [aduster (16 forwards rom the intake |i intake camshaf (4) and camshaft [cams (4) ‘agjusor (16) etore tho mounting camsnan ladusor (1), [Hi instatition: ign color casing (25) on [camshaft adjster (16) and trang chan with ‘eachother Align dowel pn 21) ncamshat adjuster (16 th ied bore 22) n nike Sa 2 ican ns eS a Checking Bomoer Rik of accent causodby voice dan | secre ano wo preven aM Tog by [ASOODOZ00OSOTA Srey Sites eagas vowing, Rak | fay cacoy curs and Sure ie sea an sma wat hines (dunng staring procedure or when wering | Do not euch ht or rotating pats Inear he engnieas tsrunting 19 ‘Conduct engine test un and check engine forleaks. el camshaft, camshaft adjustment Number Designation Engine | Engine mm 23 sO OTA Center valve for puse whet sm [45 “5 ‘camsnan aguster to caste Sin 6,4 Gen ats D9 Ties Rere ce Cras‘ARO1.30-P-S700EWL __| Removefinstall front cover on cylinder head 2310 | ENGINES 272, 273 in MODEL 212 Front cover at let cylinder head 1 Polev-bet 7 Frontcover Loft exhaust camshaft Hall sensor 2 Poy bal tonsioning device Ta ols Left intake camshaft solenoid 3. Coolant thermostat housing To Prying igs ‘Yeai6. Le exhaust camshaft solenoid 4 Oifiternousing 5 Powe stoxng expansion reservar 1864 Lom intake camshat Hal sensor 8 cam 2H [Removelinstall a Information on preventing damage 0 (Av5400-P-0007-078 ‘Slecronic components ds to slectrastaic echorgs 7 Tur koy in igion lock fo positon "0" 2 [Remove bottom engine compartmont (ARG 2O-P-TTOSEW pancing 3 [Dratn coolant at radiator (aR20.00--TA2EWS ® |Notes on coolant \AH20.00-N-2080-018 4 [Remove lft engine inlake airduct and Font | Sex Remove a ilar housing. TARO9 10-P-1750EWS [engine cover 5 ‘Remove poh-V bet (7) and pol-V bet (ART3.20-P-O00TEWS: tensioning device 2) a "Remove coolant hermasiai housing G) (ARZO TO-P-RAGOEW r [Remove of fier housing () (aR18.20-P-3671EW 2 "Remove expansion reser (5) [ARa6.25-P-1000E WL a ‘Disconnect lactnicel comectors one ‘nts camshat Hat sensor (86/4) an let lexhaustcomshat Hal sno (2) 10 [isconnec lactical enacts on let take carnshat solenoid (V40'4) and lt [onaustcamshat solenas (¥40%) a [Dotan cap (6) @ "Remove bos (7a) Tom Wont cover (7) BADTSOP-TOOEOTO 3 ‘Carefully loosen front cover (7) on iting lugs |[T) Pay attention to ited sleeves in area of (7b) and detach rom the Font outer threaded connections (arto¥s) [7] installation: Apply sealant tothe front lover). a Notes on sestnt pt for front cover to |aeo1 20-P-1000-02v ‘orincer nese {si} 112580002500 Loctte seatan 5970 "ROO 45-2-1013-018 ‘lean (Glen sealing surfaces on cyindar had. on |@) Do not use any sharp-edged ioas or AROTOO-P-ODEOOTA leyinr eas cover and on rontcover(7) | abrasva paper ass wil darmage tho ‘Sealing strfaces. Loctte 7200 00.45-2-1030-048 [loaning spray, Loc 7083 (150m) _|"BROO.45-2-1086-048 (2a A 7 0418 GT wt 3p Tee Renan ot ceeded Cras a15 [Detach tet incke camshaft Hal sansor [hen replacing the front cover (7) (644) and lt exhaust camshat (86:6) om ont caver (7) ea [BAS 10-P-1002-09E 6 [Detach it intake camshaf solencid (Y401) | When replacing the font cover (7) ‘and et exhaust eamsnaft solenoid (Y4016) ‘fom front eave) & Bats 10-P-1003-09 7 instal nthe reverse onder al ‘Checking Bs Dengert [Risk of accident caused by vehicle staring | Secure vehicio to prevent om moving by /ASOOGD-Z-0005-07A ‘of by tsa wen engine s runing. Reekot | sat near he engno.as ts running Injury caused by contusions and bums” | Wear closed and snu-fiting work cloths dung staring procedure or when werkirg | Do not ouch ht or rotating pats 18 (Conduct engne test un and check engine ‘ortoaks el cytinder head Number Designation Engine | Engine m Ect oro s10 Bl, font cover to cyinder head ve nm | @ ° [i Position sensor Number Designation Engine | Engine a | ars BAS OPHRE Bol. camshat Hall sensor to ron over on eyinger head nm | 8 8 SORE Bol, camshaft solonod wo front cover Nm |e 8 to cylinder hoad| \412580.0025 00 _/ Senseo Repair materials ‘Number [Besignaton (Grderauribor FELTIOTE Loctite sealant 5970 "A003 989 98 20 awernEaA Locate T200 Honko! Loette Deuschiand GmbH lArcoolastrasse 17 11025 hanson Germany Tei "40 200288-0 Fax +49 009101078 van Loctte de mE REO (Gearing spray, Loctite 7053 (150m) [Aoot 86717110 Sin 6403. nt bp Sn Rem nc cd‘AR01a0-#-57008WR__|Removensal font over on eynder need as10_ | ENGINES 272,219 in MODEL212 Front cover at right cylinder head 1 Aieshutof valve 4 Pring igs Y32__ Air pump suitchovor valve 2 Brocket ‘Y405_ightintake camshaft solenad 2a Bots [BOIS Rightiniake camshaft Hallsensor ——-Y4SI7 ‘Right axhaust comshaf solenodd 3 Hose 86/7 Right exhaust camshaft Hall sensor 4 Fromeover 4a Screw 5 Bots 8 Bracket 62 Bots 62 Serew 125. Lowemperature circu shutof valve He [Removerinsall ® Information on preventing damage (Ave OOF 007-07 llecvonie components due to lectrostate \ascharge 7 "Tur ky in ignition lock a pasion “OP 2 [Remove bottom engine compartment (ARG 20-P-FT05EW lpancang 3 [Remove tort engine evar Tit he tort engine cover upward and ‘outofe mountings z [Remove igh engne niske ar Gack ‘See "Remove ar iter hound” [ARO TOF RENE 5 [Remove a shutoff va (1) al the ight | Except modal 212 057 (ARIA 20-P-7200EW lepncer neat 6 'Romove bots (2a) and st bracket (2) tor | Excopt model 212.057 ‘font angie cover wth ai pump swsichover valve (¥32) one Se [Do not detach tines atthe air pump |swichover vave (¥32), "BA01 30-P-1000-010 z [Remove hose capt model 212 0578 [Remeve bots (6) en place low-temperature | Modal 212057 erent shut vate (¥125) tone Soo wh ines comected i 3001 301019.010 2 [Remove bls (6) loosen Bal (Syed | ode 212057 ‘wo noe me Sd i aap 301018-010 @ Disconnected comacs on wR ‘face comshat slenod (¥40') and aah evhaus came slena (49/7) w Disconnect elecical comectrs on ght [tac camshat Hat sensor (2) and att [emaus cams Hal senso (B07) 2 'Romove bots (4,7 pecs) rom rot ova | @)isttaton: Check satng of he seal ia) ore ot ape guide tie theo pan evo of eae. = aap1301006-010 it ano 45-P1006-010 8 Garey issen ont cover ening Was | [pay tention to ited seoves in area ot (4b) and cetac rem the font laser treadedconmezbons avons) {El netaation: Ay secanto ont cover . a Notes on salt path arnt ove to |ano1 90-1000-02¥ yn nead 5 11250002500 Lotte satan 5070 oR00 45-2-1019.018 a ‘dean “4 Glan saing sures on ont coor (on | De nt us any sharp-adged ts or (AROTOOP-OO60GTA {nner need cover ond on crnor need "| aorasn paper 05 Ps wt damage ho seaing suracea Lotte 7200 anon 492-030-040 oering sory, Loci 7063 (150m) | aR0048-2-1040-040 6 tac ign wake cana Hal sensor |e repiacng the ron cover (4 (0) and ngntexnavat camenan ak Sensor (B07 tom wont cover) is oats 10 s002-096 ® Datac igh tae crise sree? | Wa eae We Won Ge AT (740) ana nit exnaust amen sero {4} rom fon cover. 5 aats.1021000-006 7 int ne rovers oder s ‘checking Avenger Risk of accident ca.zedby veice daring [Secure vide opreven Ram marng by (ASODOOZIOIEOTA toy teak when engne's rng Rieke (scat nr caused ty corisons and bums’ |Wen closed and sap ting work thes ‘rg starng procedure o when woxing Dena tueh Rat olan pars Ieare engne es nisrunnng 10 [Conduct engne est un ang check enane fereats Ployinder nese Nmber Deelonaton Engine | Engine m2 Tuormeesmeeio | Bol, Fon covertocynder head we wn | ° twormeamscio | Bot ewichovervae racket fo cyinder head MG nm | 9 ° Tworerswiee1o | Bol. NT Oru cadet ie bacet onder head wn] orajeder head font cover TaorecmcIo | Bo, shor vave bracket fo yin ead wn] on pan oan L8G wh ape en econ ee Crvana 0Number Designation Engine 272 | Engine 273, Biase Mounting bol for of dostek guide tube nm [8 8 il Position sensor Number Designation Engine | Engine a | ars BAS OPRRE Bol, camshat Hall sensor to front over on cyngor head nm | 8 3 SORE Bo, camhaf sclonod fo front cover Nm |e 8 fo cylinder hoad| co 4112589 00 25 00 Sancta Repair materials ‘Number [Besignanon [order aumibor SMELT Locite soalant 5970 'A.003 989 98 20 awerTEAA Locate T200 HonkolLoette Deuschiand GmbH larcoolastrasse 17 12025 nano Germany Tei "40 200288-0 Fax + 49 009101078 {ww Loctite de mare (Gearing spray, Loci 7083 (10m) [Aoot 086 717110, (Seine 4670418 Get wt sp Tea Rene coerencndr head Cras RR BUSTA as ateomie tel‘AR01.20-P.210081"S ___[Removesinstall centrifuge ENGINES 272,273 mn MODEL 212 1 Crankease vetlation hose 2 Gonintuge cover [ar0 ba Sew 2 Gasket, 22 Rada shat seal 23 Donel ane 3 Coniige Sa Saw ae |Removeinsia i [Remove a RorTousing [ROTOR TRONS 2 Dec nose teenie ever @) 5 |Remove uke between vest wes Engine 27 563 Hinton: Ensue mat oor ses are sented corectyonbunnead. 4 rsrew bas Ga # each) andremeve | [Hincpt engine chat Hows ctw an sone ever) ancrent 9p £5 natlaion: Cocks!) ac ha senting ing) west oe! caoge “nctopace cong cover 2) recesses he ted pins (2 determine te instalaton ston osc ove s axon 20-10-01. 5 [Remove bolt (3a) and remove the centrifuge |[1) Len-nand thread 5 aaonanp 100201. z ink fe vrs aoe a ‘Checking s Danger! [Risk of accident caused by vehid staring |Secure vahide io prevent # fom moving by [AS00002 0005010 off tat wen gine 8 eving Riker [is ‘ry causa by cotasons and bums |Woar cased and snug ing work ates. {umng Seria procedure owen woxing_|Donot une orroatra ba “ona erga ring 7 ‘ary ot an engin a chock eng clea a [Gheocenone of el BeAP Enge ol end Mer cone perso P o101ew crankcase vention cynder headcover Number Designation Engine | Engine mle moras | pot canton cover iocyinir acini Saget Nm | 6 6 eons over sn AG 78418 GH wt 2 tbe Rem eneSiage2 | 90 % orzo zo Bol, centiuge to camshaft sprocket ‘Stage1 im [8 6 Siage2 | 80 % i 6 Ge 2892 hen Rel ie Cras 2a[AROS 20-9-6010-01VB Inspect basic postion of cars L Shown without pulse wheels on the camshaft adjusters 1 Crank tre engine at ne cranksnan in umm the deco of angie rotation (artow) to 40" crank angle ater ignition the. Li The 40° marking (1) on the bet ploy must be aligned wih the pestoning edge (2) on the tming case The marangs (3) onthe camshatt adjusters face upare, and the markings 4) align wn te contact Stacas onthe eyindor heed covers CEE en SE, mt ennsns® Soosstes[AROS 20-9-7201-05VA | Loek tho ener backash compensation ‘® The tooth lanks (1, 2) are held against each other by spring pressure and should nat be: skewed, otnenise he camshaft aster willbe ireparebiy camaged 1 Insertthe drt, diameter Sm) into the bore () of he cover pale and lock the tooth Ranks (1, 2} win each oer. Push the drift (3) through tothe end of tooth flank (2). To allow the ait (3) tobe nsertad more easty, align the tocth tanks with eachother (ithe direction of the artows) Shown on camshaft adjuster, engine 273.985 Shown on camshaft adjuster, engine 272.988[AROS 20.-7201.06VA [Loosen the centr vas el Camshatt, camshaft adjustment Number Designation Engine | Engine m a as Center vane fer pulse wheat nm [145 us ‘camsan aust to camsran [Tl counternolseamsnats athe rar wih @ Tone sersvdrver busing sutabe toto Uunfaston and fasten the contr valves. Boforeinstling, the conta vees must be hericated ‘wit of on the contact surfaces win he pulse wheels, ‘Center valves of right cylinder head 1 Loosen the conte valves in the rection or tne aro, 2 Tighten the contr valves against he crcton ofthe arrow. Center valves of eft evlinder hess 3 Loosen he center valves nthe dvection ofthe crow. 4 Tighton th contr vatos against he aracton of ho arrow. nt A 7318 GT, 5 20972 Lenehan aes[AROS 20-9-6010-01VB Inspect basic postion of cars L Shown without pulse wheels on the camshaft adjusters 1 Crank tre engine at ne cranksnan in umm the deco of angie rotation (artow) to 40" crank angle ater ignition the. Li The 40° marking (1) on the bet ploy must be aligned wih the pestoning edge (2) on the tming case The marangs (3) onthe camshatt adjusters face upare, and the markings 4) align wn te contact Stacas onthe eyindor heed covers CEE en SE, mt ennsns® Soosstes‘AR01.20-.50126L ___|Removerintall right eylinder hes cover [2310 | ENGINES — 272, 273 (except 272.983) in MODEL 212 1 rocket 5 Ragntconvel une racket Na NE:SFI Me] cont unt ta Scr 3 Goin cae Yea" Airpurp sienover vate 2 Reshutot vave + Gfinder need cover 3 Fronteover 3 Feodauet LLetconnecor 4 Corer 8 Resonance nse manos R —_Rignteonector 3) Letconot unt brecket fo. Engine ting eve ae Removetnatal T ] ® Inimaten on prevening damage 0 (ana OOP-D007-OTA Jaecronc consonens duet decresaic cna x "um ky mignon eek poston “0 | Remove a er housing [aoe TO E-TOEWS 3 Reve bots (ta) end rancve mack () | PaADT a0 P1006-010 foront engoe cover star pump. suachovervae (32), 4 [Remove ight ee shui vave @). [ARIA 9OPOOEW | 5 Remove tot caver (onthe wai cyindr TAROT 90-P-STOOEWR. sao Remove aon cos tight der haad RSE MEW T [Remove cover (4) on centrifuge: ARO} 20-P-2100EWS 3 Disconnect gh cornodt al MEST Imejoonrolunt NSO) 2 ‘Dein ME-SF [Me] onal uni WIT) |LL1bo not asconoctotconodtar a ermal nt rcs (1S andy © | eS te} ott nt) wo Remove right cont unt act 60 | [PanoT o-P-002-07— 1 Detach ground ie (rom cinder nad fst PADI 30PTOTO-OIO cove) @ Remove eed duet) rom resonance ae | a rants oP Ianto (2), stn heed cover (7) and ‘ear gt ein iting aye (10) an lacs to low ace Fa jens se9-s002018 5 veasierson.018_| 5 Toosen bos for oyinde ead cover yn [Engine 272 TAROT 20-P-54-0BVA ‘overs orc Yomonng pocadue id ‘emove nem Engine 273 laro120"-soreoasx | franotso-s004010 | 2a 4118 GT mh hg Rent bend co ema“ catetaty eyo eye hese cove?) |) To avod daring seg sures do fem prc ed [notpounain he omy eel une ‘ser nas cove 7 ond he cynder rosa Winston: Aopy sina compoune to corned cov Ch a ‘ows on scale panto onnserness [Engine 272 Ler 20-1000.00v a Engine 273 |n01 20-1000. 00sx wi [+112589002500 oct seat 5970 |-oR00 45-2 1015014 co ‘Clean seaing sarisaes al cynderheed and |B) not use any sha aageatons ov AROTOOPODEO.IA Stevindor headcover) shranvs panera ta Somage be Seno suracre oct F220 ron 457-1098-060 Geerna sry, tote 7069 (150m) __ RIN Z-1085.6A i ita be overs or a recking A denger Rik of accdoot caused by vic dang [Socio ote to provank fam movngby ASOOOOZOOIETTA {roy sor won onjn suring. Riko [Ret ay saad by eetesone ond bur | Wear lose and rug ting work athe. {urn sarig procedure or amen woxing [Do not touch er rttng pare ‘ear he engee essing ” ‘Conduct nan est un and check eine ‘cost watts ng, evince eas Number Desionation none | Engine mm BworzepsteI9 | Bok eynder nea caver o ender haes MT Sag91 wm] 2 See? eo SurmrTacIo | Bok avichovervave Wecket 9 inread WO nn] o ° awsome | Bot, gourd ie to cyinder had cover we wmf o ° contrat umber Designation Engine | Engine me SSORETBINIA | Got con untbraeetio resonance ake nants wn e 3 engine wiring harness Number Designation Engine | Engine mom AETERIBTEIE | Bo. feed Getto resonance ake mando wn |e a SASI#RIAREIE | Bo. eed aut Gndar nea over nw fe 3 SASISRIODE | Bat eed dic loge ing ee we fe a nha 9 Gere at esta Reina ned om com(\a12sa0 002500) ‘Syaegie Repair materials ‘Number [Designanon [Grderaumibor aR EZ TTA Loctite saalant 5970 [A003 989 98 20 aMEZ TOR Locate T200 Henkel Lostte Deusctiand Grmor larcootastrasse 17 12025 nano Germany Tei va0 200288-0 Fax * 40 200101078 ww Loctite de wmET ROR [A00 086 717110, (Gearing spray, Loci 7083 (1am) (2 AG 0418 wt 2b sta Retna tend oe|ARO1.20-P-5073EL ENGINE 272, 273 | Removerinstall ett cylinder head cover (except 272.983) in MODEL 212 [23.0 apes et | ee Cote ss swe, 100 1 o8merreusing © Food aut 30 Cylinder head cover 2 Bower stoxcngexparsion reson TF pp. ‘a Heat shies 3 Front cover 8 Fun tence 11 Engi iting aye 4 Pugotine 9 Ground cable 12 Rubber mount 5 Ob separator Se Removelinsiall A engeet "lak of death couse by vile sipping or |Algn vehiebolwoen coumns oven Im |ASOOGDZ 0070.01 “epoing of the itt plato fang poston ow suppor plates eee It ‘Spot ports specied ty vehie imansfague Z “Turn Key in igtion bea pasion z "Remove botiom engine comoeriment (ARS ZO POSE ning 3 [ran cool at adator [AR20 OO PTAEWS ® Notes on oolnt [Ar20.00-42080-01A 4 Remove ar for nousing [ARO 10.P-11506WS: 5 "Remove po} bot and poy.V ba TaR13 20. O00TEWS {ansening devi z "Remove coon hermosa (ARO TOR AOE 7 "Remove os filer howsrg (1) [ARI@20.P3471EW ® ‘Remove expansion exerci [aR 25-5-1000EW ® [Remove fort cover) ate yinder sad TAROL30-F-5700EWL ry [Detach te purge ine (at seperton pint (crow), uncip rm bracket on Separator () and fod ine et) 2nd Dace tothe ade 7 "Redice fol presse St aoves Vahe ROTATE Biengine272 "enor oo. 1004-018 g 119550046200 @ [Detach fel ne (7) al fol sno @) | [L cath escaping ul wih an absorbet ‘oa! LL sea connections mmacitly win stop dius ts |eno703-P-001-018 129560000100 a "Remove ion cals on ok inde ad lana 12° 200960 “4 [Remove of separator 6) [AROL20-F47S0EWS 5 [Detach ground ine (tom cinder ead [Ral PaA01 30. 100%-010 cover) we [Remove kit vearengna Ming ya 7) "SADT SOP TODSOTO (2a AG 0418 GT wt 2h te Reel der-Bar6.16-P-1002-018 = 7 "Remove fede dl (6 om ender Fears weec002 018 ‘ve ® [Detach rot ribbor mount (eater [a "BAP TOTTO ‘stefan oor bend ove (0) @ Rave hen sii (108) is "BAD SEPDATOTO 2 Remove wasn pam gna 279 (ARES 05 P-T=D0ED a Loosen ots cyinder had ener (O)n [Enon 272 TARO 20-5014 0BVA ‘rece oso Soronngprosedu ane ‘crow em Engne 273 lao 20 -sove-0asx "aot a0 1004-010 z yor eyindor neat enero) Fom | o goa aang sau sues ao Src eae each retpeand nt pn ta Seaeon ror ad cover 1 ands ender Seed Winton: Aor salto ender ead ee (10) a Notes on sonlat pain foroyeternesd [Engin 272 Lot 309-1000.08v a Engine 273 [not 20-1000 08sx w Loctite sealant 5070 112589002500 R00 45-2-1019-018 ‘lean (Clean sealing suraces at cyinder had and lat eye head cover (10) | Do not use any sharp-edged tools or abrasive paper as this wil damage tne Sealing surfaces, Loctite 7200, Cleaning spray, Loctite 7063 (150m) 'AROT 00-P-SO50-OTA R00 45-2-1020-048 -BRO0 45-7-1046-048 2 ia neers oder a Checking Bower Rsk of accident cased vce sang | Seowe vee even fom mongty /ASOOODZONSOTA Sith kevanenenprseronng Rater (cat ny caus by cts and Eurs [ier close and sping work ties tig sing pects or wen wring (Goat loucnse cr esing ae now beatae anche 2 Sond ene text sn nd check nine forteaKs. ed injectors, injection valves, lines Designation m Engine | Engine Barapa {Union ni faa ine ofl dstibutor im | 20 Fa ‘morane aie Protective cp an service vave Plante tm 2 - eta im | 18 - el cytinder head Number Designation Engine | Engine mm am eee) Bol, ground inet front cover Ne nm | 8 ° morsop-0cero Bol, cylinder head cover to cylinder hood MT Siaget tim | 12 12 Stage? | 80 % morose Bol, ting eye to eyinaer heed ue 1m | 20 20 niet 7.8 Gn a Bp Rent dco7 [Rotate engine st center bo forerankshett |] The trust pin 1a for chain tensioner indirection of engine rotation by 290° (1) yi on pushed out and tensions tne rank angio {ming cain, a instal end cover) ® Insta alerator (ARIS a0-P-SO2EW B danger [Rak of accident caused by vehicle saring | Secure vehicle fo prevent ®from moving by "ASOD OD-Z-0005-018 loffoy tse when engine s rung. Fiske [iso Injury caused by contusions and bums” | Wear closed and sniping work cloths, ‘dung staring procedure or when werking Do not ouen ot or rotating pats. hear ine engnie as srunning 10 ‘cary out an engine test un eno check lengne fortes Fl Timing chain, chain tensioner Number Designation Engine | Engine m 23 os op Rae ‘Chain tensionaron timing caso MZ2x15 Nm | 70, 70 ‘aso sane “Torque on unlock chain tensioner wm | 70 70 00% 680 65 0900‘Ros.10--0127EW __|Removenstal tensioning ral ENGINES 272.279 In MODEL 212 ta Tensioning rt ae [Removelinstall r "Remove conshaf easier Cans easter wiake carhatt (ARTS Z0P-TOOTEWE Camshet ads of exaust camshaft [ARDS 20.7201 EWA z ‘Remove ensionng ra bat TARO 30-Ps000-04V 116508203300 116560013400 UH netaiation: Aopyselatto ersionna ‘a bots before ance ced 112580002500 Loci sesan 5070 ano 45-2. 1042.016 z ‘altensoning al ia) upwards and tof ‘ming case z Insal e evers oder (aieseo002500 7 sveseo20sn00 7 ineseoorsa00 7 7 es Repair materiale mer [Desigion Order amber ODEN —— |Locte sealant 6970 [Ao 89 98 20 Sa 678413 GT ws hr Rent it cormmor osni810 Bol, fiter housing rubber mount to Ne im | 8 8 ‘eyindernead cover moreso Bot, neat shield to yinder head M6 nm | 8 ° Fl engine wiring harness Number Designation Engine | Engine om a poses Bol, fed cut to cylinder ad cover nm | a sagopa Bor, feed uct to engine ing eve nm [8 8 +110 590 04 69 00 129599 00 91 00 112 589 0025 00 Premes test Satstame pe a Repair materials Number Designation (Gre umber SMELIOTE Lociteseelnt 70 [A003 269 08 20 ET TROR Loctte 7200, Konkel Loctite Deuschiard GmbH \Arabolastasse 17 21825 Nanchen ‘Germany Tet "49 099206-0 Fax 49209101078 ww Loctite de BWETISOR [Geaning spray, Lose 7053 (130m) (R00: 998.71 7110 (2a AG 0418 GT wt 2h Ste Reena indrhed Cras‘ARO5.10-P-7800EW __|Removerinstall chain tensioner [e111 | ENGINES 272, 273 in MODEL 212 1 Chain tensiner 1a Pressurepin 2 Timing case cover 3 cp 4 Latex omaha Bi Removing 7 Rotate agi at canna caer bara EE ron SaneSt000 rectonotcngre rien toa <0 Stanko neato ton TOC z Remove atemnator [ARTS PSOE 3 Remove chan eine (fom bing Ge ‘oe z install 4 Sérow nw chain iensensr() wo tno | i] Replace chain tensioner). The ace cove 2) and tharos We resetoed_|ponoesy sigs chon erssror 1) mst ‘ors fete ransales sce on rel dtesur ol (a), ts besseo othe en poston apa nessun soe othe Pressr bt (prevents satu stoke Fins wa ovete te tre chon rerstlng = aos 0.108018 5 Remove ea @) 6 Tur engine tent bo on the Sanka Ts unioas te chon tensioner) ‘un eseroet ots aganetareton ot ‘none retaton ow) a ‘oterteangint exist arse at [oor a sual 5 anos 0 1000.08‘AR05.10.-7601-01VA | Separet ming chan \eonswo 05605) onsesensson_) \aansonesesco 7) aoneesosescn 1 Cover evor tring case rooess wit a sean cet. Te timing case recess must be secured agains! pats alin down Pits hat have fen ito the timing {ase ese must be removed 2 Blassembie me cna separating toot (01) and ine ] pressure serew (02) together 9 ZA Fitthe chain separating too! (01) at the ting chain (1) lEnsure that the [Pi pressure pin (03) es atthe pin (aan) of bmg 4 Bi screw intne pressure serew (02) and separate the timeng 5 Remove tne EF] pressure screw (02) and take oft tne SF] chain (1) chan separating tot (0), [io not tet te pins that nave been pushed out fall ito the tmong care recess|ARO5.10.°-7601-08VA | Drawing in timing chain (eons 008600) asses) 1 Cover evor tring case rooess wit a sean cet. Te timing case recess must be secured agains! pats alin down Pits hat have fen ito the timing {ase ese must be removed 2. Comect he new tming chan 2) and the ofd tang onan (1) tn 2 te sssembiy nk (01) [HIP iets oo ottne [Pl assemeiy link (01) nthe direction cpposit fo that in whicn the urang chan sera stherse it coud gt jammed onthe Side ras and come of when the tng ena 'sorawn, 3 Remove the rags tom the timing case ress lomnarse, toy coud get pulled into te uming caso recess wren iv engine cranked 4 Tum te cxanksnat slowly in ne engne’sdrecton of otaton {actow) and dram nthe new ming Shan (2) unl the ends oF the now ting hain (2) ean be connected [EAs tne now tming chain (2) Being drawn in (arrows, pul cut the end ofthe old tang can (1) every it Becomes roe 5 Cover over ting case recess wih a clean loth [il Tne timing case recess must be secured aganst parts fang down Pars that have fan no the ming cae races ‘must be rernoved 6B cetach the assert lnk (01), and separate theo tiring ain (1) rom te new Uming chain (2) |The assembly ink (1) must be rernoved. The assembly ln only an aid for assembly ands not sural for engine operation|ARO5.10.9-7601-02VA | Rivatng he ting chain Eel Timing chain, chain tensioner Number Designation Engine | Engine m a Bo for met slemantin ming ehae Nm | 32 2 (ceeronoe vaua) A Co eorse0009800 7 \ are se0003000 _/ \_areseoooesco __) \__zreseaoresoo _/ (Carr se00165.00 lvinen carrying out work on te tming case recess, safeguard this wth @ lean cloth to prevent lems doppng down Parts whi have fallen ino te bmi case recess, must Be removed Press the riveted ink ito the press-fit center plate 1 Brice me assembiy isan (F11) in BFlme nvet press toot (01) ana tx in place with ‘he mourting sero 2 Biptscetne assembiy insert (012) in. Zine svt press tot (01) 3 Insrt the rvtod nk (1), the centring fork (03) and he pross-ft center plate (2) into the ands ofthe tng chai (4), and pres the pins of tha cortrng fark (03) no the holes of ne press contr plate (2) and conor he press contr plate (2) [insert riveted lnk (1) from the rear4 screw in the pressure screw (02) at the rivet press tool (01), and press the fated (toe res camer pt al neyo ater [Enoure that ing mvetad ink (1) and tne [F nvet pase too (01) are aianect Whe screwing in tne [flprossure sere (02) ensure thet he pins ofthe rated ink (1) are pressed ito the holes of the press contr nate (2), ad that the centring fork (03) {hat hes been squeazed out doesnot fab inte tha tng eaeerocas= 5 remove the pressure scrow (02) an tako othe ret pass tal (1) Prete the outer plate onthe riveted ink 6 BlPiece tne assembly insert (F401) in line rwet press too (01) and Nx in place with tne mounting sorew 7 Brace tne assomby ison (0103) in Zine evet press too 0%). 8 Insert the outer plate (3) nto the Flassembiy insert (03). [tkme outor plato 1s nett magneneaty. 9 Piece the rivet press tool (01) n such a way that the spacer webs of he fszembly meer (Fa) bee on the ros ofthe tng chan (2) [Blensure that tne veted ink (1) and tne outer plate (3) are shgned 10° Serewinine resistance White turing the Bl pressure screw (02), ensure thatthe pins ofthe riveted link (1) safe prossed nto te cuter plato (3), pressure screw 02) ato El et pross tol (Ot) unt hero's slid 11 Remove rivet press to! (0) Rivet timing ehain 12 som me assomay nsert (2) on te noted section (arom), 1Pace th ret pros tool (01) nthe center of rtod Ek (1) pin [Blrivet the ps of he rveted ink 1) neal Tighten the pressure screw (02) atthe [Eleivet press tool (01) [Elrintening txque of tre [Zlpressure screw 02) reference value 32 Nm 15 WlRemove rivet press tol (01) 16 Fi inspect riveting (arrows), ro-rvet necessary 2c 71,74 078206 Rtg trata Cras 02‘AR0520-P-60106 __| check basle postion of camshafts [21200 | ENGINES 772,273 in MODEL 212 1 Marking on tet puiley 2 postioning edge on tming case cover 3 Pulse wneot marange a8 od f a si E ene No sera cnconars | ee a ‘Checking I 3 [Tum cued reas ey Ti The 305° marking (7) on bet pulley must Rastesamacaie [Caprese apame Saiesenie cere near ne, apminmemmrnren ra Lael gl (ots ecelnoin prea ci eget tine Se eae essen & peers iz Sr ‘Romo Ss a ae aT ee crt spear a [oa a eiste career to oe mienpiiiu we ie arrow. (eee eitors Sree uate Fi Position sensor aoe cance sm aoe a (3 SaaS — | em reyes o racaae =) a seats gg nr tra comet(00158085 0000 7‘AR0520-P-60106 __| check basle postion of camshafts [21200 | ENGINES 772,273 in MODEL 212 1 Marking on tet puiley 2 postioning edge on tming case cover 3 Pulse wneot marange a8 od f a si E ene No sera cnconars | ee a ‘Checking I 3 [Tum cued reas ey Ti The 305° marking (7) on bet pulley must Rastesamacaie [Caprese apame Saiesenie cere near ne, apminmemmrnren ra Lael gl (ots ecelnoin prea ci eget tine Se eae essen & peers iz Sr ‘Romo Ss a ae aT ee crt spear a [oa a eiste career to oe mienpiiiu we ie arrow. (eee eitors Sree uate Fi Position sensor aoe cance sm aoe a (3 SaaS — | em reyes o racaae =) a seats gg nr tra comet001 58065 0800 —_/