EXIT

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 EXIT

ngine Lubrication System 18

Job No.

Engine oil and filter change .............................................. 18 - 002

Oil circuit, oil pressure, overpressure and bypass valve, oil filter .................... 18 - 005
Removal and installation of oil spray nozzles .................................. 18 - 040
Removal and installation of oil filter ......................................... 18 - 110
Modifications to oil filter ................................................. 18 - 115
Removal and installation of oil pump ........................................ 18 - 210
Replacement of oil pump chain ............................................ 18 - 212
Removal and installation of oil pressure relief valve ............................. 18 - 215
Testing oil level indicator ................................................ 18 - 220
Function of oil level indicator ............................................. 18 - 225
Removal and installation of oil level sensor ................................... 18 - 226

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 EXIT

18-002 Engine oil and filter change

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Specified viscosity class for engine oil in
accordance with SAE at prolonged outside
temperatures OF I
l w l 30

Precise use of the SAE class according to l w l 20

outside air temperatures would necessitate l w l 10

frequently changing the engine oil. The

32
temperature limits for the SAE classes should
l 0

therefore be regarded as guidelines which can l 1. - to

l 5 - 15

be exceeded for short periods. -1 - 20

See “Service Product Specifications”for

further information on specified viscosity classes
and approved engine oils.
l) SAE 40 may be used at prolonged outstde
temperatures above + 30 “C.

18.10 - 002/l
 EXIT

Oil car>acitv in liters

Model Capacity for oil and Dipstick marking
filter change
marking
I Colored
1 marking I I
Numerical marking
on handle
(color red)

6.5 (6.8 U.S. Qt.) I- I 60214’) I

I green’)
I green3)
7.5 (8.0 U.S. Qt.) I black I- I
303.96/‘97 1 126
1st version - rea colorea marung
7.5 (8.0 U.S. Qt.) I- I 60316 I

2nd verston - black colored marking

3rd version - brown colored marking
2, On engines with exhaust gas recirculation and side part on 011 sump
3) 1st version black

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Tightening torques Nm
Oil filter cover fastening nuts 25
Oil drain plug on oil sump M 12x1,5x13 30
M 14x1,5x22 25
Return pipe in oil filter cover’) 25
l) Only engtne 603 In Model 124

Special tools

117 589 02 07 00 001 589 72 21 00

18 26 35 00

Commercial tool
Engine oil extractor e.g. Deutsche Tecalimit
Am Metallwerk 11
D-4800 Bielefeld

1810 - 002/2
 EXIT

Note

On models with air-to-oil cooler (turbo engines)

the oil does not need to be drained from the air-
to-oil cooler.

Caution!
The filter element and the rubber seal on the oil
filter cover must not be confused with that of
engines 615, 616 and 617 as these are different
in size.

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Engine 602, 603
Size Ll 113 mm
L2 49 mm

Engine 615, 616, 6 17

Size Ll 131 mm
P1mci83-13
L2 55 mm

Caution!
Change engine oil only when engine at normal
operating temperature.

1 Empty oil filter before extracting or draining

the engine oil. This is done by unscrewing the
nuts (arrows) and taking off the cover.

For reasons of space, when performing this step

on engine 603 in Model 124 (up to 01186)
detach rubber gasket or sealing strip on the
component partition wall in the manner described
below, and pull up slightly.

Divided rubber gasket

Pull off retaining clip (1).

18.10 . 0020
 EXIT

One-piece rubber gasket

Remove screw (arrow).

2-part oil filter cover

(effective 02/86, engine 603 in model 124)

Unscrew return pipe (276) and take off. Unscrew

oil filter cover fastening nuts and take off cover.

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2 Extract engine oil through the dipstick guide
tube when the engine is at normal operating
temperature.

If no extractor is available:

3 Remove engine compartment cover below

(01-006).

4 Drain engine oil out of sump (arrow).

Note
The oil in the air-to-oil cooler does not need to
be drained.

18.10 - 002/4
 EXIT

5 Replace filter element.

6 Replace rubber seal (1) on the cover.

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P18-2057- 13

7 Examine restriction opening on oil pipe for

foreign bodies (arrow). If it is blocked, remove
foreign bodies by hand. Following this, blow
compressed air into restriction opening. Air must
be felt to escape at the bottom of the oil pipe. If
the restriction opening is not clear or if no air
flows out, replace oil filter cover together with oil
pipe.

P18-Olll- 13

8 Tighten nuts and return pipe to 25 Nm.

18.10 - 002/5
 EXIT

9 If the oil has been drained from the sump,

replace sealing ring of oil drain plug.

10 Tighten oil drain plug to 30 or 25 Nm,

respectively.

11 Add engine oil.

12 Run engine and examine for signs of leaks

13 Check oil level approx. 2 minutes after

turning off engine at normal operating
temperature.

14 Install engine compartment covering (Ol-

006).

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18.10 - 00216
 EXIT

1 e-005 Oil circuit, oil pressure, overpressure and bypass valve, oil filter

A 14 185 203 275 52

I; I

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18 240 P160116-55

Oil circuit diagram engine 602.91

14 011 spray nozzle 203 Valve tappet
18 Timing dewe 240 Oil pump
52 Oil pressure gauge 275 011 filter
185 Camshaft A Injection pump

18.10 - 00511
 EXIT

185 203 275

P18-0108-55
18 240 238

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Oil circuit diagram engine 602.91 with exhaust gas recirculation
1 InjectIon pump 275 Oil filter
18 Tlmtng device 296 Oil pressure switch
185 Camshaft 351 Oil level sensor
203 Valve tappet A Unfiltered 011 to air-to-oil cooler
238 Oil spray nozzle B Unfiltered 011 from air-to-oil cooler
240 011 pump

Note
Engine 602.91 with exhaust gas recirculation and manual transmission in combination with air
conditioning.

1810 - 00512
 I..

EXIT

1 m5 203 275

1’8 240 238 P18-0041- 55

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Oil circuit diagram engines 602.96, 603.96197 (Turbo)
1 InjectIon pump 296 011 pressure switch
18 Timing device 351 Oil level sensor
185 Camshaft A Unfiltered 011 to air-to-oil cooler
203 Valve tappet B Unfiltered 011 from air-to-oil cooler
238 011 spray nozzle a To exhaust gas turbocharger
240 011 pump b From exhaust gas turbocharger
275 Oil filter

18.10 - 005/3
 EXIT

Dipstick

Effective 051’84 the Min and Max markings on a a

engine 601 are made of plastic.

42a Max marking

42b Min marking
42c Round handle
A - B Filling range

Production breakpoint: 05/84

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On engine 602 a dipstick with black handle
was fitted to achieve standardization with
engine 603.

42a Max marking

42b Min marking
42c Handle shaped
like a bottle
opener
A - I3 Filling range

Production breakpoint: 01186

18.10 - 005/4
 EXIT

Effective 01187 a dipstick with green handle

(previously black) is fitted to engine 602.96
(Turbo).

Production breakpoint: 01/87

Model Engine Engine End No. Vehicle ldent End No.
manual automatic
transmission transmission A F
* *
201.128 1602.961 I- 000405 I
* not regtstered

Engine 602.91 is fitted with a dipstick with a

brown handle.

Production breakpoint: 0387

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” not registered

Effective 03/90 the oil level sensor position on

engine 602.91 is lowered, which results in a
change to the dipstick.

Dipstick marking
Color: red
Marking on handle 60214

Size: A - 6 previously 28 mm, now 24 mm

a previously 516 mm, now
516 mm

POl-0182-15

18.10 - 00515
 EXIT

Production breakpoint:03/90
I I
Model Engine Engine End No. Vehicle ldent End No.
manual automatic
I I transmission transmission

201.122 1602.911 1089320 0 17352 558126 723643

On engine 603.970 the dipstick is

marked on handle with the number 60316.

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POl-0064-14

a 512 mm
A - B Ftlltng range

Dipstick marking

Round handle

l) 1 st version color marking “red”

2nd version color marking “black”
3rd version color marking “brown”
*) Only on engines with exhaust gas reclrculatlon and side part on 011 sump
3) 1 st version color marking “black”

Note
The dipsticks must not be interchanged.

18.10 - 00516
. . . . . . . . EXIT

Oil pressure and oil pressure indicator

Specified oil pressure at normal operating

temperature

idle speed 3000 rpm

Oil pressure 2 0.3 bar L 3 bar

Voltage exists at the gauge in the instrument

cluster when ignition is switched on. In the
pressure sensor on the oil filter housing (arrow)
ground is switched to the gauge. Any change in
oil pressure results in different electrical
resistances in the pressure sensor and hus in a
different reading in the gauge.

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Resistances of pressure sensor as a
function of oil pressure

bar gauge pressure 0 1 2 3

Resistance approx. Q 10 69 129 184

Oil overpressure valve

The oil is drawn through the suction strainer to

the suction chamber (B) from the lowest point in
the sump. From here, the oil flows through the
gears to the pressure chamber (A) and on into
the main oil gallery to the filter.

From an oil pressure of 5.8 bar gauge pressure, a-

the piston (252) is pushed against the compres-
sion spring (251) and opens the relief bore
(arrows) to the suction chamber (8).

At the same time, the oil flows over two flat

faces fitted to the collar (a) into the damping
chamber (C). This oil counteracts the piston
movements produced by the pulsating oil
pressure and results in a damping of the piston.

249 Screw plug

250 Guide pm

18.10 - 005/7
 EXIT

ypass valve

As the filter element becomes increasingly

fouled, the lubrication points of the engine are
supplied with less and less oil and the pressure
in the oil filter rises. Once the filter element is so
severely fouled that the oil pressure is 2 bar
above the pressure of the oil delivered by the
pump, the bypass valve (285) opens. As a result,
unfiltered oil flows directly from the sump to the
lubrication point, bypassing the filter element.

275 Oil filter housing

283 Spnng plate
285 Bypass valve
286 Return check valve seat
287 Return check valve cone
290 8 mm 0 ball
b To the beanng points

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C Finely flltered 011 to sump

Oil filter element

The full-flow and bypass-flow filter elements are
combined in a cartridge.

During the inspection (800 - 1000 miles) the

break-in oil filter element (A) should be replaced
by the combination oil filter element (B).

The combination oil filter element (B) must be

replaced every 7500 miles.

P1K?os6-13

Caution!
The filter element and the rubber seal on the oil
filter cover must not be interchanged with those
of engines 615, 616 and 617 as they are
different in size.

Engine 602, 603

Size Ll 113 mm
L2 49 mm

Engine 615, 616, 617

Size Ll 131 mm
L2 55 mm Plaam3-13

18.10 - 00518
 ................................................................................................. .. .................................... .......
EXIT

Oil filter (without air-to-oil cooler

connections)

The oil flows from the inlet passage (a) through

the return check valve (286, 287) into the oil
filter housing and flows direct to the oil filter
element (280). It flows through the filter element
and then through the riser pipe (281) and the
passage (b) to the main oil gallery and on to the
main bearings. The finely filtered oil flows
through the return pipe (276) and the passage
(c) to the oil pan.
A rubber seal is fitted in the oil filter element
(280) to separate the full flow and bypass flow.

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271 M 8 nut
272 M 8 stud
273 Cover 280a
274 0-nng 281
275 011 filter houslng
276 Return pipe
277 Check valve
278 0-nng
279 0-rrng
280 011 filter element
280a Full-flow filter
281 Rtser pipe 282- \
282 Locking ring
283 Spring plate
284 Spring
285 Bypass valve cone
286 Return check valve
289
seat I-- _I__

287 Return check valve

cone
r----- 288
288 Compression spnng P18-0085-37

289 Spring plate

18.10 - 00519
 EXIT

Note
When changing the oil filter element, unscrew
the cover (273) and raise it slightly. As a result,
the return pipe (276) attached to the cover
clears an opening which connects the passages
(b) and (c) to each other. The oil in the filter
flows back along passage (c) into the oil pan.

The return pipe on engines 601, 602 and in

engine 603 - 1st version is press-fitted. On
engine 603 in model 124 - 2nd version, this
return pipe can be unscrewed when changing oil
to more easily remove the oil filter cover.

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Oil filter (with air-to-oil cooler connections)

A thermostat (295) for controlling the oil circuit

through the air-to-oil cooler is fitted in the oil
filter.

Start of opening approx. 110 “C oil temperature.

Fully open at approx. 125 “C oil temperature.

When the thermostat is fully open, only a slight

quantity of oil flows directly to the oil filter
element.

18.10 - 005/10
 EXIT

274a-
271 M 8 nut
272 M 8 stud 271
273 Cover
274 0-nrlg
274a Seal (only engine 603 273
In model 124) 274
275 011 filter housing
275 -
276 Return pipe
277 Check valve 276 -
278 O-ring
280
279 0-nng
280 011 filter element
280a Full-flow filter part
281 Rrser pope
282 Lockrng nng 280a--
283 Spring plate
281~
284 Spring
285 Bypass valve cone
286 Return check valve
seat
287 Return check valve 277
cone
278
288 Compressron spnng
289 Spring plate

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295 Thermostat
296 Spring
295
A Unfiltered 011 to air-to-or1 285
cooler - 296
B Unfiltered oil from air- 279
to-oil cooler
a To 011 filter 289
b To bearing points 288
287
C To 011 pan Pl a-0099-37

The air-to-oil cooler lines at the oil filter

housing are sealed by O-rings (265).

264 Air-to-oil cooler lanes

265 O-ring
266 2screwsM6x16
275 011 filter housing P18-01~15

18.10 - 005/11
 EXIT

Air-to-oil cooler (engines 602, 603 with

exhaust gas circulation and engines with
turbocharger)
The air-to-oil cooler is attached to the left
wheelhouse behind the bumper.

Oil capacity:
Engine 602.91 0.4 liters
Engines 602.96 1 0.9 liters
Engine 603.96197 0.65 liters

The air-to-oil cooler is shielded by a cover plate.

When changing the oil, it is not necessary to

drain the oil in the air-to-oil cooler.

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Cover for air-to-oil cooler, shown on model 124

Lubrication of exhaust gas turbocharger

The oil supply of the turbocharger comes from

an oil passage in the crankcase and from an oil
feed line (A) connected at that point.
The oil return line (6) is likewise located on the
right side of the crankcase and is connected
directly above the oil pan.

Oil return
Part of the oil from the cylinder head returns to
the oil pan through the timing chain case.
Because of the installation position tilted 15” to
the right, the cylinder heads and crankcase are
fitted with two and three return passages
(arrows), respectively, for improving the oil
return.

Engine601
011 return In cylinder head

18.10 - OOW12
 EXIT

Engines 602 and 603

P182104-13
011 return In cylmder head

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Engines 602 and 603
Pie-2105-13
Oil return in crankcase

18.10 - 00913
 EXIT

emoval and installation of oil spray nozzles

Preceding work:
011 pan removed (01-310).

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P18-0101-15

Hex. bolt (238a) ........................ unbolt, bolt in, 10 Nm.

Oil spray nozzle (238) .................... take off, fit on.

Note
To remove, position crankshaft so that the oil
spray nozzle is accessible; do not tilt oil spray
nozzle and do not grasp at the nozzle neck.
Cover over oil feed bores. Replace oil spray
nozzles which have a sharply out-of-round
nozzle bore or formation of flash at the nozzle
outlet. Blow through oil spray nozzle with
compressed air in flow direction of oil. Do not
use any hard objects for cleaning. Position oil
spray nozzle vertical to the mating surface on
the crankcase and press into place.

18 10 - 04011
 EXIT

Caution!
The oil spray nozzles of the naturally aspirated
engines (with exhaust gas recirculation and
engine 603.970) must not be confused with
those of the turbo engines, which have a
different spray direction.

Tightening torques Nm
Hex. bolt of oil spray nozzle 10

Special tool

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001 589 72 21 00
\ 00

Note
Since 1 l/88 die-cast oil spray nozzles have been
fitted to the naturally aspirated and turbo engines
(previously white heart malleable cast iron).

Production breakpoint: 1 l/88

. not registered

18.10 - 04012
 EXIT

18-110 Removal and installation of oil filter

Preceding work:
Naturally asplrated engtne:air filter removed (09-400).

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PlB-o114-57

Hex. nuts (271) ........................ on oil filter cover (273) unbolt, bolt on,
25 Nm.
Oil filter cover (273) ..................... remove, refit.
Gasket (274) and seals (9) ................ remove, insert. Replace gasket and seals.

Engine 603
Return pipe (276) ....................... on oil filter cover, unscrew, screw in, 25 Nm.
Replace seals (9).
Oil filter element (280) .................... withdraw, insert.
Bracket or clips ........................ for starter cable, heater return and vacuum line
to oil filter housing, detach, attach.

18.10 - 110/l
 EXIT

Engine with exhaust gas recirculation

Pipe(l) . . . . . . . . . . . . . . . . . . . . . . s ...... between EGR valve and intake manifold or
charge air distribution pipe, detach from oil filter
housing, attach.
Oil delivery line (2) ................ ...... unbolt, reinstall.
Electrical connection .............. ...... detach from oil pressure sensor (296) attach.
With air-to-oil cooler
Connection line . . . . . . . . . . , . . . ...... detach from oil filter housing, attach.
Replace seal.
Hex. socket screws (291) . . . . . . . . ...... on flange of oil filter housing (275) unscrew,
screw in, 25 Nm.
Oil filter housing (275) . . . . take off from crankcase together with gasket
(270), attach. Replace gasket.
Caution!
Seal bores when cleaning sealing surfaces on
crankcase.

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Tightening torques Nm
Oil filter cover hex. nut 25
Return pipe 25

Special tool

001 589 72 21 00

\ 00 /

Removal and installation

1 Unscrew hex. nuts (arrows) on oil filter

cover.

Installation instruction
Tightening torque 25 Nm.

2 Take off oil filter cover together with seal.

Installation instruction
Replace seal of oil filter cover.
Check clear passage of return pipe.

18.10 - 11012
 EXIT

Engine 603
3 Unbolt return pipe (276) and remove,
25 Nm.

Installation instruction
Replace seals.
Check that the passage of return pipe is clear.

4 Withdraw oil filter element.

Installation instruction
Replace oil filter element.

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5 Remove brackets (a, b) for starter cable and
heater return pipe along with clip (c) for the
vacuum line from the oil filter housing.

Engine with exhaust gas recirculation

Remove pipe (1) between EGR valve and intake
manifold or charge air distribution pipe from the
oil filter housing.

18.10 - 110/3
 EXIT

6 Detach electrical connection at oil pressure

sensor (arrow).

With air-to-oil cooler

7 Unscrew hex. socket screws (266) and 275
I
remove connection line (264) from the oil filter
housing (275).

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Installation instruction
Replace seal (265).

8 Unscrew hex. socket screws at the flange of

the oil filter housing.

9 Remove oil filter housing together with

gasket from the crankcase and seal connection
bore in the crankcase.

Installation instruction
Clean mating surfaces and replace gasket.
P18-0100-15

18.10 - 11014
 EXIT

18-115 Modifications to oil filter

271
272
273
Engine 603.960 in model 124.1331.93, Mode
274
Year 1987
275
The oil filter housing has a thermostat (295)
276
between the engine and the oil cooler for
280
controlling the oil cooling.

Start of opening: approx. 11 OC oil temperature.

Fully opened: approx. 125C oil temperature. 280
281
With the thermostat fully opened, a small
quantity of oil will continue to flow to the oil filter
element. - 277
278

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The oil cooler lines on the oil filter are sealed by 282
O-rings (previously screw connections with 283
284
conical seal). - 295
285
- 296
279
286 ~ 289

287 - 288

271 Nut, M 8 286 Valve seat return

272 Stud, M 8 flow check valve
273 Cover 287 Valve cone return
274 O-ring flow check valve
275 Housfng 288 CompressIon sprtng
276 Return tube 289 Spnng seat
277 Check valve 295 Thermostat
278 0-nng 296 Spring
279 0-ring a Supply from 011 pump
280 011 filter element b To bearrngs
280a Full flow filter section c Return to 011 pan
281 Rser A Unfiltered 011
282 Retalnrng nng to 011 cooler
283 Spnng seat B Unfiltered 011
284 Spnng from oil cooler
285 Valve cone bypass va

Oil filter cover with removable oil return pipe

(only engine 603 in model 124)
The oil filter cover has been modified. The return
pipe (276) can be removed. This facrlitates the
011 change.

18.10 . 115 1
 EXIT

Elimination of thread on hole for

initial filling
The tapped hole with M 10 x 1 screw plug at
the hole for initial filling (arrow) has been
modified into a fit hole with ball (8 mm dia.).

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Production breakpoint: 04186

not reglstered

Modification of shape of gasket between oil

filter housing and crankcase
The new gasket is pierced only in the area of the
supply and return lines. This achieves improved
sealing.

A 1 st version
P18-0107-13
B 2nd veraon

Production breakpoint: 07/87

* not reglstered

18.10 - 115/2
 .................................. ............. ....................................................
EXIT

18-210 Removal and installation of oil pump

Preceding work:
011 sump removed (Ol -310A).
Front axle houslng removed (Ol -3108).

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Pla411937

Engines 602 and 603

Support (265) . . . . . . . . . . . . . . . . . . . . . . . . . . unbolt from oil pump pickup, screw on, hex. bolt
(266, 267), 10 Nm.
Oil pump (240) ......................... detach, attach, hex. socket screws (260),
25 Nm.

18.10 - 210/l
 EXIT

Notes
Modification to shape of oil deflector plate
The vibration properties have been improved by
modifying the shape of the oil deflector plate
(arrow).

A 1st version
B 2nd veraon P18-0115-15

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Production breakpoint:04187

t not reglstered

Production modification of oil pump chain

An oil pump chain with open sleeves is fitted to
reduce wear.

Production breakooint: 06/88

Vehicle ldent End No.

* not registered

18.10 - 210/2
 EXIT

Oil pump, engine 603.96

Since 01 90 oil pumps with relief groove for
preventing noise have been fitted to these
engines.

Production breakpoint: 01190

Model Engine Engine End No. Vehicle ldent End No.
manual automatic
transmission transmission A F
124.133 603.960 025426 025426 * *
124.193 I I
* not regIstered

Oil pump chain

Engines 602 and 603
Since 03,90 oil pump chains made by the

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manufacturer Daido have been installed.

Production breakpoint: 03/90

Engine End No. Vehicle ldent End No.

l
not registered

Hex. bolt of sprocket wheel 25

Hex. socket screws of oil pump 25
Hex. bolts of intake manifold bracket (engine 602, 603) 25

18.10 - 210/3
 EXIT

Special tools

001 589 72 21 00
00
/

Removal and installation

1 Unbolt hex. bolt (259) and remove sprocket

wheel from chain.

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Installation instruction
Tightening torque 25 Nm.

249 011 overpressure valve screw plug

260 Hex. socket screws P18-2094-13

Installation instruction
Tightening torque 25 Nm. Install sprocket wheel
so that the curvature is facing the oil pump
(arrows).

18.10 - 21014
 EXIT

Engines 602 and 603

2 Unbolt hex. bolt (266) at the support (265) of
the oil pump prckup.

Installation instruction
Tightening torque 25 Nm.

3 Unscrew hex. socket screws (260) of the oil

pump (240a) and remove oil pump.

Installation instruction
Tightening torque 25 Nm. P1&2101-13

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Engine 602.96 and 603.970
4 Unscrew other hex. socket screws (260) and
remove oil deflector plate (239).

Installation instruction
Tightening torque 25 Nm.

Engme 602.96
240a 011 pump
249 011 overpressure
valve screw plug

5 Installation is performed in the reverse order. I I I

Engine 603.97

18.10 - 210/5
 EXIT

Preceding work:
011 sump removed (Ol -3lOA).
Front axle houslng removed (01-3108).

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P1&012&57

Bolt (259) ............................ loosen, tighten, 25 Nm (step 1).

Rivet link pin .......................... grind open (step 2).
Oil pump drive gear (257) ................. replace (steps 3, 4).
New oil pump chain to old oil pump chain ...... link, fit on (steps 5, 6).
Rivet link (263a) ........................ insert from behind into oil pump chain (step 7).
Plate (263b) ........................... insert into rivet tool, press on (steps 10 - 12).
Oil pump chain rivet link pins ............... rivet individually, approx. 30 Nm (step 14).

18.10 - 212/l
 EXIT

Special tools

000 589 58 43 00 001 589 72 21 00 103 589 01 63 00

05 \ 00 05

Removal and installation

Note
The oil pump drive gear should be replaced
together with the oil pump chain.

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1 Loosen bolt (259). Tightening torque 25 Nm.

2 Grind open both rivet link pins (arrows) at

a double link of the oil pump chain. Press out
ground open double link.

3 Remove bolt (259) together with washer

(258).

4 Insert new oil pump drive gear with the

curved face pointing toward oil pump.

Pl&2031-13

18.10 - 212/2
 EXIT

5 Attach new oil pump chain with rivet link to

the old oil pump chain.

6 Fit on new oil pump chain linked to old oil

pump chain by slowly turning the crankshaft in
direction of rotation of engine.

7 Detach old oil pump chain. Insert rivet link

from behind into the new oil pump chain.

8 Insert thrust piece (03) into the riveting tool

as shown in the drawing and tighten with the
screw (arrow).

Note

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The number 2 is stamped on the side of the
thrust piece (03).

POS-2285-13

9 Insert moving jaw (02) with the figure 2 into

the riveting tool as shown in drawing.

Po5-2286-13

10 Insert plate (arrow) into the moving jaw (02)

(magnetic adhesion).

POS-2123-13

18.10 - 21213
 EXIT

11 Fit web (arrow) onto both rollers at rivet link.

Note
The rivet heads of the rivet link pins must be
guided into the groove (C).

12 Screw in spindle (04) until firm resistance is

felt.

Note
During installation, ensure that the pins of the

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rivet link are guided into the holes of the plate.

13 Remove riveting tool and switch over the

moving jaw (02) to the riveting profile (D).

PO5-2125-13

14 Position riveting tool exactly in center of rivet

link pin.
Rivet pins of the rivet link individually by
tightening the spindle (04) to approx. 30 Nm.

15 Check riveting; re-rivet, if necessary.

16 Install in reverse order.

I I Pm-2128-13

18.10 - 21214
 EXIT

18-215 emoval and installation of oil pressure relief valve

Precedmg work:
Ott pan removed (01-310).

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P18-0121-57

Screw plug (249) . . . . . . . . . . . . . . . . . . . . . . . Caution!

The screw plug is spring-tensioned. Unbolt,
install, 50 Nm.
Replace seal.
Guide pin (250), compression spring (251) and
piston (252) . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, install.

Special tool

001 589 66 21 00
\ 00

18.10 . 2150
 EXIT

18-220 Testing oil level indicator

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1 Instrument cluster
5 lgnltlon lock
351 011 level sensor Pl8-0036-36
a Electrows
b Fuse 8 A

Problems

A. Indicator lamp shows a steady light

when engine running and oil level
correct.

8. Indicator lamp does not light up when

key is in position “2”.

C. Indicator lamp does not light up when

engine running, oil temperature
* + 60 “C and oil level below “min”.

Test data
Resistance at max. oil level <lC?

Resistance at min. oil level

Battery voltage approx. 12 V

Commercial tool
Multimeter e.g. Sun, DMM-5

18.10 - 220/l
 EXIT

Testing

A. Indicator lamp shows a steady light

when engine running and oil level correct

Test oil level sensor by detaching connector.

Measure resistance between oil level sensor
and ground.

Readout: < 1 Q

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Test cable by removing Spin connector from
instrument cluster. Measure resistance
between contact 5 of Spin connector and
contact of oil level sensor plug.

Readout: < 1 Q

Yes I No

Replace gauge.

End of test

18.10 - 220,'2
 EXIT

8. Indicator lamp does not light up when

key is in position “2” (check function)

Test operation of bulb.

Result: bulb functions properly.

Yes I No

Remove instrument cluster. Measure voltage

with multimeter at contacts 6 and 9 of the 15
pin connector.

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Readout: approx. 12 V

Yes No

P20-0076-13

End of test

18.10 - 22013
 EXIT

C. Indicator lamp does not light up when

engine running, oil temperature
* + 60 OC and oil level below “min”

Test operation of bulb.

Result: bulb functioning.

st oil level sensor by detaching connector.

st resistance between oil level sensor and

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P18-0075-13

Instrument cluster.
Measure voltage between contacts 6 and 9 of
the 1 Spin connector. r I I
Readout: approx. 12 V

Yes

Replace wiring harness.

B V

P20-0076-13

Replace gauge.

End of test

18.10 - 220/4
 EXIT

Wiring Diagrams Models 124, 126 and 201

Model 124

II---e14 e l e3pl p2e4 p3 e5 e6 e7 612 ell 613 62 h2 e6 hl p6 Al

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0,?5 br/ gn J
L- 0,75 br/ bl
t I
X27

b d S42
P18-0136-57

Wiring diagram engine oil level indicator, coolant level indicator, windshield washer level indicator (see
Wiring Diagrams Volume 3 and Volume 4 for further information)
Al Instrument cluster B5 Oil pressure gauge sensor
et Left turn srgnal Indicator lamp s41 Coolant level rndrcator lamp switch
e2 Rrght turn signal rndrcator lamp S42 WIndshIeld washer rndrcator lamp switch
e3 Htgh beam rndrcator lamp s43 Oil level indicator lamp switch
e4 Fuel reserve warnrng lamp w2 Ground, front right (next to lamp unit)
e5 Battery charge rndrcator lamp X27 Connector, starter wtnng harness
e6 Brake pad wear rndrcator lamp a Main ground (behind instrument cluster) Wl
e7 Brake fluid and parking brake Indicator lamp b Fuse 7 terminal 15
e8 Instrument lrghtrng C Fuse 5 terminal 15
ell Coolant level rndrcator lamp d Lamp rndrcator unrt
e12 011 level Indicator lamp Preglow time relay terminal La
e13 WindshIeld washer level lndrcator lamp
el4 Exterror lamp failure rndrcator lamp
e16 Preglow rndrcator lamp
ht Warnrng buzzer
Pl Coolant temperature gauge
P2 Fuel gauge
Oil pressure gauge
Electronrc clock

18.10 - 220/5
 EXIT

Model 201

el e3 pl p2 e4 e5 e6 e7 e12 ell e13 62 h2 p3 e0 hl

58d 58

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1 x5/2
.
Y
0

If Ib td s41 S42 s43 85

Plao138.57

Wiring diagram engine oil level indicator, coolant level indicator, windshield washer level indicator (see
Wiring Diagrams Volume 5 for further information)
Al Instrument cluster BS 011 pressure gauge sensor
el Left turn signal rndtcator lamp s41 Coolant level lndtcator lamp switch
e2 Right turn srgnal tndtcator lamp S42 Windscreen washer Indicator lamp switch
e3 High beam Indicator lamp s43 011 level Indicator lamp switch
e4 Fuel reserve warning lamp Wl Main ground (behind Instrument cluster)
e5 Battery charge lndrcator lamp x5/2 Connector, Interior/starter 4-pole
e6 Brake pad wear Indicator lamp a Main ground (behind Instrument cluster) Wl
e7 Brake fluid and parklng brake Indicator lamp b Electrical center connector contact 15 terminal 15
e8 Instrument ltghtrng unprotected
elf Coolant level lndrcator lamp C Electncal center connector D contact 2
e12 011 level Indicator lamp terminal 15 fuse 8
e13 Windshield washer level Indicator lamp d Electrical center connector D contact 8 alternator
e16 Preglow Indicator lamp terminal 61
hl Warning buzzer Preglow time relay
h2 Audible turn slgnal Indicator
Pl Coolant temperature gauge
P2 Fuel gauge
P3 Oil pressure gauge
~6 Electronic clock

18.10 - 22018
 EXIT

18-225 Function of oil level indicator

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1 Instrument cluster
5 lgnltlon lock
351 Oil level sensor Pm-0030-36
a Electrows
b Fuse 8A

General

The electrical oil level indicator monitors the

engine oil level in the sump when the engine
is running and engine oil temperature is above
+ 60 “C. When the ignition is switched on, the
indicator lamp lights up with a weak light (check
function) and goes out as soon as the engine is
started.

18.10 - 225/l
 EXIT

Oil level sensor

The engine 011 level in the oil level sensor (351)

is equalized to the oil level in the sump (27)
through an outlet bore (b). The float (358) with
permanent magnet (359) senses the actual 27
engine oil level. The electronics in the instrument
cluster sends a permanent signal to the oil level
357
sensor. If the engine oil level is in the “Min”
358
range of the dipstick, the Reed contact (360) of
359
the float (358) is opened and the permanent
signal to the oil level sensor interrupted. The 360
indicator lamp lights up with a bright light (fault 361
signal). The Reed contact (360) is interrupted 352
shortly before the oil level has reached the
“Min” marking on the dipstick. If the cable from
the oil level sensor to the instrument cluster is
interrupted, the permanent signal to the oil level P18-0079-15

sensor is also interrupted and the indicator lamp

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shows a bright light (fault signal).
352 Blmetal snap plate
3 6 5 O-ring
b Outlet bore 4 mm 0

Avoiding incorrect readings

As the engine oil is viscous below a temperature

of + 60 “C and only flows back to the sump
slowly, this could result in incorrect signals of the
indicator lamp. In this case, the bimetal snap 27

plate (352) closes the outlet bore (b) and the

float (358) only registers the oil level in the oil
357
level sensor (351). This eliminates the possibility
358
of an incorrect signal at low engine oil tempera-
359
tures. Once the oil temperature climbs above
+ 60 OC, the bimetal snap plate opens and 360
clears the outlet bore (b). Consequently, the float 361
(358) senses the actual engine oil level in the 352

sump (27). The bimetal snap plate closes at an

engine oil temperature of approx. + 30 “C.

P18-0079-15

359 Permanent magnet

365 O-ring

18.10 - 2252
 EXIT

If the engine oil is drained during an oil change,

the oil also flows out of the oil level sensor.
Because the fresh engine oil added is colder
than + 60 “C, the bimetal snap plate closes the
outlet bore (b) i.e. there is no engine oil in the oil
level sensor and the indicator lamp would signal
insufficient engine oil although the engine oil
level is sufficient. In order to avoid this, the oil
level sensor is filled through the vent bore (a).
When driving through sharp corners, the engine
oil is pushed against the outer walls of the oil
pan. Particularly when negotiating left turns, the
engine oil level around the oil level sensor drops
and the sensor runs dry. The float (358) briefly
interrupts the Reed contact (360) and the
indicator lamp would show a bright light. The
electronics in the instrument cluster prevent the
indicator lamp from lighting up until after the

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Weed contact (360) has been interrupted for
60 s. This avoids any incorrect signal when
negotiating sharp corners.

18 10 - 2251'3
 ............................... ................................................. EXIT

emoval and installation of oil level sensor

Preceding work:
Engine 011 dralned.
Engine compartment cladding bottom removed (01-006).

A. Engine 602,603

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Pl&0112 57

Plug (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . for oil level sensor, disconnect, plug in.

Bolts (20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt in, 10 Nm. Remove and install oil
level sensor (351). Replace O-ring (365).

18.10 - 226 1
 EXIT

Modifications

A larger diameter O-ring made of Viton is fitted

for sealing the oil level sensor at the sump.
Color: green (previously black).
Diameter 3.15 mm (previously 3 mm).

Production breakpoint: 09/86

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201.126 1602.911 / 027261 006588 * *

l
not registered

The seal of the oil level sensor at the sump has

been improved by modifications in size of the
O-ring.

New O-ring:

Previous Present
Size version version
mm mm

dl 40,20 37,20
d2 3,15 3,20
POl-0187-U

18.10 - 22612
 EXIT

Production breakpoint: 06/87

Model Engine End No. Vehicle ldent End No.
manual automatic
transmission transmission A F
124.133 603.960 - 013429 * *
124.193 I I
126.125 013103 * *
I 603.g61 I-
*

* not reglstered

Tightening torques Nm
Oil level sensor bolts 10

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Special tool

16.10 - 2260