Specifications of all engines (Mercedes-Benz S-Class W140)

Contents: General parameters ↡ Engine overhaul ↡ Tightening force of threaded…↡

General parameters

Note: Individual characteristics are also given in the text of the Chapter and, if their implementation is mandatory, are highlighted in bold.

Engine

Note: The technical data has been determined in accordance with EU directives. All data applies to vehicles in the basic version with catalytic converter. Data may differ depending on special equipment. Information on this issue is available at any Mercedes-Benz service station.

General characteristics

Model	Years of issue.	Code by VIN	Engine/fuel system type	Volume, cm³	Quantity and distribution c-row	Power, hp/kW	Torque, Nm	Max. speed, km/h	Notes
300SE 2.8	92-93	140.028	M104.944HFM	2799	R6	193/142	270	215
S280	93-94
300SE (SEL)	91-93	140.032 (033)	M104.990LH	3199	R6	231/170	315	225
S320	93-98		M104.944HFM
300SD	91-93	140.134	OM603.971	3449	R6	150/110	330	185
S350 TD	93-96
S300 TD	96-98	140.135	OM606.961	2996	R6	177/130	330	205
400SE (SEL)	91-93	140.042 (043)	M119.971LH and M119.981ME	4196	V8	279/205	400	245
S420	93-98
500SE (SEL)	91-93	140.050 (051)	M119.970LH and M119.980ME	4973	V8	320/235	470	250	Limit 270 km/h
S500	93-98
600SE (SEL)	91-93	140.056 (057)	M120.980LH and M120.982ME	5987	V12	394/290	570	250	Limit 290 km/h
S600	93-98

Nominal power, kW (hp)/at rpm)//Nominal torque, Nm (at rpm)
S280	142 (193)/5500//270/3750
S320	170 (231)/5600//315/3750
S420	205 (279)/5700//400/3900
S300	TDI 130 /4400//330/1600-3600
S500	235 (320)/5600//470/3900
S600	290 (394)/5200//570/3800
Number of cylinders/Type/Displacement, cm³/Designation
S280	6/DOHC/2799/104
S320	6/DOHC/3199/104
S420	8/OHC/4196/119
S300	TDI 6/DOHC/2996/606
S500	8/OHC/4973/119
S600	12/OHC/5987/120
Maximum speed, rpm
S280	6400
S320	6400
S420	6000
S300	TDI 5300
S500	6000
S600	6000
Compression ratio
S280	Data not provided
S320	10.0:1
S420, S500	11.0:1
S600	Data not provided
S320CDI	Data not provided
Compression pressure, bar
S280 S320	10-14
S420, S500, S600	13.5-15.5
S300	TDI 26-32
Cylinder firing order
S280, S320, S300	TDI 1-5-3-6-2-4
S420, S500	1-5-4-8-6-3-7-2
S600	1-12-5-8-3-10-6-7-2-11-4-9

Drive belt

(Generator/power steering, air conditioning), mm
S280	2170/2257
S320	2337/2440
S420, S500	2460/-
S300	TDI 6PKx2080/6PKx2120
S600	2585/-
Valve clearances	are not regulated, because. hydraulic compensators are used

Engine overhaul

M104 series engines

Camshaft Bearing Dimensions

Nominal diameter, mm
Camshaft	29.947 29.963
Cylinder head	30.000 30.021
Repair diameter, mm
Camshaft	30.434 30.450
Cylinder head	30.500 30.525.
Permissible cleanliness of bed surface, mm	0.001-0.004
Permissible taper, mm	0.012
Permissible axis displacement, mm	0.040
Bearing clearance, mm
Radial	0.035
Axial	0.06 - 0.21

Valve guide bushing dimensions

Non-ferrous metal bushings

Non-ferrous metal guide bushing (m104.990 engines of the first version)

Cylinder head hole diameters, mm
Nominal size	13.50-13.51
1st nominal size	13.53
Repair size	13.70
Outer diameter of guide bushing, mm/ Color marking
Nominal size	13.52-13.53/-
1st nominal size	13.54-13.55/ Grey-brown
Repair size	13.71-13.72/Red
Tension, mm	0.012-0.031
Inner diameter of the guide version 1, mm
Inlet valve	8.000-8.015
Exhaust valve	9.000-9.015
Inner diameter of the guide version 2, mm
Inlet valve	7.000-7.015
Exhaust valve	8.000-8.015
Length "L" of the sleeve, mm
Inlet valve	35.5
Exhaust valve	37.9
Protrusion "from" the bushing, mm
Inlet valve	10.8-11.2
Exhaust valve	8.2-8.6

Metal-ceramic bushings

Metal guide bushing for engine M104.990 (second version) and M104.944/994

Cylinder head hole diameter, mm
Nominal size	12.50-12.51
1st nominal size	12.53
Repair size	12.70
Outer diameter of guide bushing, mm/Color marking
Nominal size	12.54/-
1st nominal size	12.56-12.57/-
Repair size	12.74-12.75/-
Tension, mm	0.029-0.051
Inner diameter of guide bushing, mm
Inlet and outlet valves	7.000-7.015
Length "L" of the guide bushing, mm
Inlet and outlet valves	37.5
Protrusion "from" the guide bushing, mm
Inlet and outlet valves	10.2-10.4

Valve seat dimensions

Valve seat installation details

Inlet valve//Outlet valve
Nominal values, mm
Diameter D1 of the hole	36 H6//32 H6
Seat diameter D	36.10-36.12//32.10-32.12
Repair values, mm
Diameter D1 of the hole	37.20 H6//33.20 H6
Seat diameter D	37.30//32.30
Size "t"	5.6-5.9
Diameter D2	30//25.6

Piston Ring Performance

Clearances for ring fit in piston grooves, mm
Characteristic	Meaning
Upper compression ring	0.20-0.40
Lower compression ring	0.20- 0.40
Oil scraper ring	0.20- 0.45
Gaps in ring locks, mm
Upper compression ring	0.015-0.050
Lower compression ring	0.020- 0.040
Oil scraper ring	0.010- 0.045

Dimensions and weights of connecting rods and connecting rod bearings

2 - Designation; 3 - Balancing weight; 4 - Bolt M9; 5 - Guide bushing; 6 - Upper insert; 7 - Lower insert; 8 - Mounting ears; Arrow - Direction of movement

Connecting rods
Distance "L" between the centers of the connecting rod heads, mm
M104.94	148.995-49.005
M104.99	144.995-145.005
Width "B" of the lower connecting rod head, mm	21.948 - 22.000
Width "b" of the upper connecting rod head, mm	21.948 - 22.000
Diameter "D1" of the lower head without liners, mm	51.600 - 51.619
Diameter "d1" of the upper head under the bushing, mm	24.500 - 24.571
Inner diameter "d" of the connecting rod upper head bushing, mm	22.007 - 22.013
Piston pin clearance in the bushing, mm	0.013 - 0.018
Permissible twisting of connecting rod, mm	0.015
Permissible deviation from parallelism upper connecting rod head and bushing, mm	0.07
Permissible difference in connecting rod weights, g	4
Crankshaft
Connecting rod journal diameters, mm/ crank cheek color marking
Nominal	47.955 - 47.965/No marking
Nominal	1 47.945 - 47.955/Orange
Nominal	2 47.935 - 47.945/Blue
1st repair size	47.700 - 47.715/-
2nd repair size	47.450 - 47.465/-
3rd repair size	47.200 - 47.215/-
4th repair size	46.950 - 46.965/-
Width of connecting rod journals, mm
Nominal size	27.958 - 28.042
Repair size	up to 28.300
Connecting rod bearing shells
Wall thickness, mm
Nominal size
Red marking	1.806 - 1.810
Yellow marking	1.810 - 1.814
Blue marking	1.814 - 1.818
Nominal 1 (not available as a spare part)
Red marking	1.811 - 1.815
Yellow marking	1.815 - 1.819
Blue marking	1.819 - 1.823
Nominal 2 (not available as a spare part)
Red marking	1.816 - 1.820
Yellow marking	1.820 - 1.824
Blue marking	1.824 - 1.828
1st repair size (Yellow marking)	1.995 - 1.999
2nd repair size (Yellow marking)	2.060 - 2.064
3rd repair size (Yellow marking)	2.185 - 2.189
4th repair size (Yellow marking)	2.310 - 2.314

Crankshaft and main bearing dimensions

Control dimensions
Permissible taper of main and connecting rod journals of the crankshaft, mm	0.002
Permissible ovality per 54 mm of length, mm
Root necks	0.010
Connecting rod journals	0.010
Permissible deviation of the axis of installed liners, mm	0.02
Radius of inner fillet, mm
Main necks 1.9-2.1
Connecting rod journals 1.9-2.1
Repair dimensions
Main journal diameter, mm/Color/Letter marking on the front of the crankshaft
Nominal
57.960 - 57.965/Blue/B
57.955 - 57.960/Yellow/G
57.950 - 57.955/Red/R
Nominal 1
57.945 - 57.950/White/W
57.940 - 57.845/Purple/V
1st repair size	57.705 - 57.715/-/-
2nd repair size	57.450 - 57.465/-/-
3rd repair size	57.205 - 57.215/-/-
4th repair size	57.955 - 57.965/-/-

Letter marking

Note: The color marking is applied to counterweights No.8 and 9, the letter designation is on the front part of the crankshaft.

Main journal width, mm/Color/
Nominal size
24.500 - 24.533/-/0
Nominal 1
24.600 - 24.633/Red/1
1st repair size	24.700 - 24.733/-/-
2nd repair size	24.900 - 24.933/-/-
3rd repair size	25.000 - 25.033/-/-
4th repair size	-/-/-

Selection of thickness of main bearing shells

Article based on data from the website (MERCEDESMAN.ru)

Nominal size (Main bearing journal bore diameter 58.00 mm)
Blue mark (index 52)
Upper liner thickness, mm	2.255-2.260
Thickness of the lower liner, mm	2.255-2.260
Yellow mark (index 54)
Upper liner thickness, mm	2.260-2.265
Thickness of the lower liner, mm	2.260-2.265
Red mark (index 56)
Upper liner thickness, mm	2.265-2.270
Thickness of the lower liner, mm	2.265-2.270
Nominal size 1 (Main bearing journal bore diameter 58.00 mm)
White and blue mark (index 57)
Upper liner thickness, mm	—
Thickness of the lower liner, mm	2.263-2.268
White and yellow mark (index 58)
Upper liner thickness, mm	—
Thickness of the lower liner, mm	2.268-2.273
White and red mark (index 60)
Upper liner thickness, mm	—
Thickness of the lower liner, mm	2.273-2.278
1st repair size (Main bearing journal bore diameter 57.75 mm)
Blue mark (index 52)
Upper liner thickness, mm	2.375-2.380
Thickness of the lower liner, mm	2.375-2.380
Yellow mark (index 54)
Upper liner thickness, mm	2.380-2.385
Thickness of the lower liner, mm	2.380-2.385
2nd repair size (Main bearing journal bore diameter 57.50 mm)
Blue mark (index 52)
Upper liner thickness, mm	2.500-2.505
Thickness of the lower liner, mm	2.500-2.505
Nominal width of the liner, mm	19.979 - 20.000
Diameter of crankshaft main bearing beds, mm
Bearings No.1, 5, 7
1 kerning	62.500-62.505
2 kernings	62.506-62.513
3 kernings	62.513-62.519
Bearings No.2, 3, 4, 6
2 kernings	62.500-62.506
3 kernings	62.506-62.519

Dimensions and designations of cylinders and pistons

Cylinder/piston diameters, mm
Nominal size (89.9 mm)
Marking of tolerance group A	89.900 -89.906//89.873 - 89.879
Marking of tolerance group X	89.906 - 89.912//88.878 - 89.886
Marking of tolerance group B	89.912 - 89.918//89.885 - 89.891
1st repair size (+ 0.25 mm)
Marking of tolerance group A	90.150 - 90.156//90.123 - 90.129
Marking of tolerance group X	90.156 - 90.162//90.128 - 90.136
Marking of tolerance group B	90.162 - 90.168//90.135 - 90.141
2nd repair size (+ 0.5 mm)
Marking of tolerance group A	90.400 - 90.406//90.373 - 90.379
Marking of tolerance group X	90.406 - 90.412//90.378 - 90.386
Marking of tolerance group B	90.412 - 90.418//90.385 - 90.391

Note: Marking (except AMG engines) applied to the convex part of the piston and stamped on the mating surface of the cylinder block.

Cylinder Block Dimensions

Height, mm	282.25 -282.35
Minimum allowable height after processing1), mm	281.95
Permissible roughness of the mating surface of the cylinder block, mm
Top	0.03
Lower	0.04
1) After processing the cylinder block, a change in height of no more than 0.4 mm is allowed.

M119 series engines

Camshaft Bearing Dimensions

Diameter of bearing beds of camshafts in cylinder head, mm
Nominal size	28.000 28.021
Repair size	28.500 26.521
Camshaft bearing journal diameter, mm
Nominal	27.960 2.947
Repair	28.447 28.460
Play in camshaft bearings, mm
Radial	0.053-0.061
Axial	0.050-0.150

Valve guide bushing dimensions

Non-ferrous metal guide bushing (m104.990 engines of the first version)

Non-ferrous metal bushings (only M119.97 engines)
Cylinder head hole diameters, mm
Nominal size	13.50-13.51
1st nominal size	13.53
Repair size	13.70
Outer diameter of guide bushing, mm / color marking
Nominal size	13.51-13.53/-
1st nominal size
	13.52-13.53/Grey-green
	13.54-13.55/Grey-brown
Repair size	13.71-13.72/Red
Outer diameter of guide bushing, mm / color marking
Inner diameter of the guide, mm
Inlet and outlet valves	7.000-7.015
Outer diameter of guide bushing, mm / color marking
Length "L" of the sleeve, mm
Inlet valve	35.5
Exhaust valve	37.9
Distance "a" (inlet valve), mm	2.7-2.9
Distance "b" (intake and exhaust valves), mm	5.4-5.6
Distance "c" (intake and exhaust valves), mm	10.8-11.2
Metal-ceramic bushings (all engines of the M119 series)
Cylinder head hole diameter, mm
Nominal size	12.50-12.51
1st nominal size	12.53
Repair size	12.70
Outer diameter of guide bushing, mm/Color marking
Nominal size	12.54-12.55/-
1st nominal size	12.56-12.57/Grey
Repair size	12.74-12.75/Red
Inner diameter of guide bushing, mm
Inlet and outlet valves	7.000-7.015
Length "L" of the guide bushing, mm
Inlet and outlet valves	37.5
Distance "a", mm	—
Distance "b" (intake and exhaust valves), mm	5.4-5.6
Distance "c" (intake and exhaust valves), mm	10.2-10.4

Valve seat dimensions

Engines M119.970

Nominal dimensions
Diameter "D1" of the hole in the cylinder head, mm
Intake valves	39 H6
Exhaust valves	34 H6
Diameter "D" of the seat, mm
Intake valves	39.10-39.09
Exhaust valves	34.10-34.09
Repair dimensions
Diameter "D1" of the hole in the cylinder head, mm
Intake valves	40.20 H6
Exhaust valves	35.20 H6
Diameter "D" of the seat, mm
Intake valves	40.30
Released valves	35.30
Size "t" (intake and exhaust valves), mm	7.8-7.9
Diameter "D2", mm
Intake valves	38.47
Exhaust valves	33.47

Engines M119.971/980/982

Nominal dimensions
Diameter "D1" of the hole in the cylinder head, mm
Intake valves	36 H6
Exhaust valves	34 H6
Diameter "D" of the seat, mm
Intake valves	36.10-36.09
Exhaust valves	34.10-34.09
Repair dimensions
Diameter "D1" of the hole in the cylinder head, mm
Intake valves	37.20 H6
Exhaust valves	35.20 H6
Diameter "D" of the seat, mm
Intake valves	37.30
Exhaust valves	35.30
Size "t" (intake and exhaust valves), mm	7.8 - 7.9
Diameter "D2", mm
Intake valves	35.47
Exhaust valves	33.47

Dimensions and designations of cylinders and pistons

A - Longitudinal direction
B - Transverse direction
a — Upper travel point of the upper compression ring
b — Bottom dead center
c — Lower point of the oil scraper ring stroke
1, 2, 3 — Measurement points

Engines of the M119.960/970/972/974 series

Piston//cylinder diameters, mm
Nominal size (96.5 mm)
Designation 0 (index 52)	96.483-96.493// 96.498-96.503
Designation 0+ (Index 53)	96.488-96.498// 96.503-96.508
Designation 1 (Index 54)	96.493-96.503// 96.508-96.513
Designation 1+ (Index 55)	96.498-96.508// 96.513-96.518
Designation 2 (Index 56)	96.503-96.513// 96.518-96.523
1st repair size (+0.5 mm)
Designation 0	96.983-96.993//96.998-97.003
Designation 1	96.993-97.003//97.008-97.013
Designation 2	97.003-97.013//97.018-97.023
2nd repair (+1.0 mm)
Designation 0	97.483-97.493//97.498-97.503
Designation 1	97.493-97.503//97.508-97.513
Designation 2	97.503-97.513//97.518-97.523

Engines of the M119.980/982/970/972/974 series

Piston//cylinder diameters, mm
Nominal size (96.5 mm)
Designation A (index 52)	96.482-96.495// 96.500-96.508
Designation B (index 54)	96.491-96.504// 96.508-96.516
Designation C (index 56)	96.499-96.512// 96.516-96 524
1st repair (+0.5 mm)
Designation A	96.982-96.995//97.000-97.008
Designation B	96.991-97.004//97.008-97.016
Designation	From 96.999-97.012//97.016-97.024
2nd repair (+1.0 mm)
Designation A	97.482-97.495//97.000-97.508
Designation B	97.491-97.504//97.508-97.516
Designation C	97.499-97.512//97.516-97.524

Engines M119.971/975/981/985 (digital designation)

Piston//cylinder diameters, mm
Nominal size (92.0 mm)
Designation 0 (index 52)	91.983-91.993// 91.998-91.003
Designation 0+ (index 53)	91.988-91.998// 92.003-92.008
Designation 1 (index 54)	91.993-92.003// 92.008-92.013
Designation 1+ (index 55)	91.998-92.008// 92.013-92.018
Designation 2 (index 56)	92.003-92:013// 92.018-92.023
1st repair (+0.5 mm)
Designation 0	92.483-92.493//92.498-92.503
Designation 1	92.493-92.503//92.508-92.513
Designation 2	92.503-92.513//92.518-92.523
2nd repair (+1.0 mm)
Designation 0	92.983-92.993//92.998-93.003
Designation 1	92.993-93.003//93.008-93.013
Designation 2	93.003-93.013//93.018-93.023

Engines M119.971/975/981/985 (letter designation)

Piston//cylinder diameters, mm
Nominal size (96.5 mm)
Designation A (index 52)	91.982-91.995// 92.000-92.008
Designation B (index 54)	91.991-92.004// 92.008-92.016
Designation C (index 56)	91.999-92.012// 92.016-92.024
1st repair (+0.5 mm)
Designation A	92.482-92.495//92.500-92.508
Designation B	92.491-92.504//92.508-92.516
Designation C	92.499-92.512//92.516-92.524
2nd repair (+1.0 mm)
Designation A	92.982-92.995//93.000-93.008
Designation B	92.991-93.004//93.008-93.016
Designation C	92.999-93.012//93.016-93.024

Connecting rod dimensions

Connecting rods

Distance "L" between the centers of the connecting rod heads, mm	154.450-154.550// 148.950-149.050
Width "B" of the lower connecting rod head, mm	24.857-24.890//24.857-24.890
Width "b" of the upper connecting rod head, mm	27.900-28.000//21.900-22.100
Diameter "D" of the lower head without liners, mm	51.600-51.619//51.600-51.619
Diameter "d1" of the upper head under the bushing, mm	26.007-26.013//24.007-24.013
Inner diameter "d" of the upper head bushing connecting rod, mm	29.000-29.021//27.000-27.210
Piston pin clearance in the bushing, mm	0.007-0.018

Dimensions of crankshaft, main and connecting rod bearings

Motors with mounting bearing

Crankshaft journal diameter, mm
Nominal
Blue marking	63.965
Yellow marking	63.960
Red marking	63.955
1st repair	63.700
2nd repair size	63.450
3rd repair size	63.200
4th repair size	62.950
Width of main journal with mounting bearing, mm
Nominal size	27.021
Maximum permissible size	27.50
Crankshaft journal diameter, mm
Nominal	47.955
1st repair	47.705
2nd repair size	47.455
3rd repair size	47.205
4th repair size	46.955
Main journal width, mm
Nominal size	50.100
Maximum permissible size	50.30
Diameter of holes for main bearings, mm
Blue marking	68.486
Yellow marking	68.492
Red marking	68.500
Diameter of holes for connecting rod bearings, mm	51.619
Permissible ovality and taper of the main bearings and connecting rod journals of the crankshaft, mm	0.01
Radial clearance in main bearings, mm
New shaft	0.021 - 0.045
Maximum permissible value	0.09
Radial clearance in connecting rod bearings, mm
New shaft	0.030 - 0.055
Maximum permissible value	0.080
Crankshaft axial clearance, mm
New shaft	0.10 - 0.22
Maximum permissible value	0.30
Axial clearance of connecting rods, mm
New shaft	0.22 - 0.38
Maximum permissible value	0.50

Correspondence of color and dot marking of main bearing shells and cylinder block

Parameters	Marking
Dot marking on the cylinder block	1 point	2 points	3 points
Colour coding on bearing caps/block casting	Blue	Yellow	Red
Color coding of upper liners	Blue	Yellow	Red
Color coding of lower liners	Blue	Yellow	Red

Engines with thrust half rings

Crankshaft journal diameter//thickness of thrust half rings, mm
Nominal size
Blue marking	63.960-63.965//2.20
Yellow marking	63.955-63.960//2.25
Red marking	63.950-63.955//2.30
1st nominal size	63.945-63.950 63.940-63.945 63.935-63.940
Crankshaft journal width, mm	27.000-27.033
Crankshaft journal diameter, mm	47.955-47.965
Crankshaft journal width, mm	50.000/50.100
Diameter of holes for main bearings, mm
Blue marking	68.480-68.486
Yellow marking	68.986-68.492
Red marking	68.492-68.500
Diameter of holes for connecting rods bearings, mm	51.600-51.619
Permissible ovality and taper of the main bearings and connecting rod journals of the crankshaft, mm	0.01
Radial clearance in main bearings, mm
New shaft	0.021 - 0.045
Maximum permissible value	0.09
Radial clearance in connecting rod bearings, mm
New shaft	0.030 - 0.055
Maximum permissible value	0.080
Crankshaft axial clearance, mm
New shaft	0.10 - 0.22
Maximum permissible value	0.30
Axial clearance of connecting rods, mm
New shaft	0.22 - 0.38
Maximum permissible value	0.50

Correspondence of color and dot marking of main bearing shells and cylinder block

Parameters	Marking
Dot marking on the cylinder block	1 point	2 points	3 points
Colour coding on bearing caps/block casting	Blue	Yellow	Red
Color coding of upper liners	Blue	Yellow	Red
Color coding of lower liners	Blue	Yellow	Red

M120 series engines

Camshaft Code Designations

Engines of the M120.980 series to No.010 822
Right intake camshaft	29
Left intake camshaft	30
Right exhaust camshaft	27
Left exhaust camshaft	28
Engines of the M120.980 series with No.010 823 and M120.982
Right intake camshaft	33
Left intake camshaft	34
Right exhaust camshaft	31
Left exhaust camshaft	32

Dimensions and installation details of valve guide bushings

Valve guide bushing installation details

Non-ferrous metal bushings
Inner diameter of guide bushing, mm
Inlet valve	7.000 - 7.015
Exhaust valve	8.000 - 8.015
Length of guide bushing "L", mm	37.5
Cylinder head tension	0.029 - 0.051
Retaining ring	Not installed
Distance "a"	2.7 - 2.9
Distance "b"	5.4 - 5.6
Distance "c"	8.2 - 8.6
Metallized bushings
Inner diameter of guide bushing, mm
Inlet valve	7.000 - 7.015
Exhaust valve	7.000 - 7.015
Length of guide bushing "L", mm	37.5
Cylinder head tension	0.029 - 0.051
Retaining ring	Installed
Distance "a"	—
Distance "b"	—
Distance "c"	10.2 - 10.4

Dimensions and designations of cylinders and pistons

Cylinder/piston diameters, mm
Nominal size (89 mm)
Group 1) 0	89.000 - 89.008//88.978 - 88.988
Group 1	89.008 - 89.016//88.988 - 88.998
Group 2	89.016 - 89.024//88.998 - 89.008
1st repair size (+ 0.352) mm)
Group 0	89.350 - 89.358 // 89.328 - 89.338
Group 1	89.358 - 89.366 // 89.338 - 89.348
Group 2	89.361 - 89.374 // 89.348 - 89.358
2nd repair size (+0.72) mm)
Group 0	89.700 - 89.708 // 89.678 - 89.688
Group 1	89.708 - 89.710 // 89.688 - 89.698
Group 2	89.716 - 89.724 // 89.698 - 89.708
1) The group number on new engines is stamped on the mating surface of the cylinder block of the next cylinder
2) The group number is painted on the piston skirt and is also stamped on the side of the piston skirt

Connecting rod dimensions

Size "l", mm	153.95 - 154.05
Width of lower connecting rod head "B", mm	21.948 - 22.000
Width of the upper connecting rod head "b", mm	19.90 - 20.10
Connecting rod lower head hole diameter "D1", mm	51.600 - 51.619
Upper connecting rod head bore diameter "d1", mm	24.500 - 24.521
Inner diameter of the connecting rod upper head bushing "d", mm	22.007 - 22.013
Clearance of piston pin fit in connecting rod bushing, mm	0.013 - 0.018
Permissible difference in weights of assembled connecting rods, g	4

Dimensions of crankshaft, main and connecting rod bearings

Diameter of crankshaft main journal//thickness of thrust bearing lining, mm
Nominal size	57.960//2.15 57.955//2.20 57.950//2.25
1st nominal size	57.945//2.35 57.940//2.40 57.935
1st repair size	57.700
2nd repair size	57.450
3rd repair size	57.200
Diameter of connecting rod journals, mm
Nominal size	47.955
1st repair size	47.705
2nd repair size	47.455
3rd repair size	47.205
Width of connecting rod journals, mm	24.225
Main bearing bed diameter, mm	62.500
Diameter of connecting rod bearing beds, mm	61.600
Inner diameter of main bearings bearings, mm	23.500
Width of connecting rod journal, mm	22.000
Permissible ovality and taper of bearing beds	0.02
Radial clearance, mm
Main bearings	0.026 - 0.050
Connecting rod bearings	0.020 - 0.058
Crankshaft axial clearance, mm	0.100 - 0.254
Axial clearance of connecting rods, mm	0.225 - 0.391

Correspondence of color and dot marking of main bearing shells and cylinder block

Parameters	Meaning
Dot marking on the cylinder block	1 point	2 points	3 points	—	—
Colour coding on bearing caps	Blue	Yellow	Red	—	—
Color marking on the crankshaft	Blue	Yellow	Red	White	Violet
Color coding of upper liners	Blue	Yellow	Red	—	—
Color coding of lower liners	Blue	Yellow	Red	White	Violet
Letter marking on main bearing journals	IN	G	R	W	V
Actual diameter numbers on main journals	35-39	40-44	45-49	50-54	55-60

OM603 series engines

Connecting rod dimensions

1 - Connecting rod; 2 - Connecting rod cover; 3 - Bushing; 4 - Guide grooves; 5 - Connecting rod bolt; 6 - Balancing weights; 7 - Identification field (turbocharged models); 8 - Grooves for installing liners; 9 - Oil channel (turbocharged models); 10 - Oil channel (non-turbocharged models); 11 - Identification field (non-turbocharged models); b - Width of the upper connecting rod head; B - Width of the lower connecting rod head; d - Inner diameter of the connecting rod upper head bushing; d1 - Outer diameter of the connecting rod upper head bushing; D1 - Connecting rod lower head bore diameter; L - distance between the centers of the holes of the connecting rod heads

Size "L", mm	144.97 - 145.03
Width of the lower head of the connecting rod "B", mm	21.948 - 22.000
Connecting rod lower head bore diameter "D1"	51.600 - 51.614
Maximum permissible ovality and taper of the hole, mm	0.02
Inner diameter of the connecting rod upper head bushing "d", mm	28.018 - 28.024
Outer diameter of the bushing, mm	30.575 - 30.600
Connecting rod upper head bore diameter (under the bushing) "d1", mm	30-500 - 30-525
Clearance of piston pin seat in connecting rod bushing, mm	0.007 - 0.018

Cylinder dimensions

Cylinder diameter, mm
Nominal	89.0
Size group A	89.000 - 89.006
Size group X	89.007 - 89.012
Size group B	89.013 - 89.018
Permissible deviation of cylinder diameter in longitudinal and transverse directions, mm	0.20
Permissible taper, mm	0.007
Permissible ovality, mm	0.07
Wear limit, mm	0.05

Dimensions of holes in the cylinder block for installing liners

D, D1 — Diameters for sleeve flanges
D2 — Diameter under the sleeve
T — Length of the sleeve
T1 — Sleeve seating depth

Diameter "D2" for the sleeve in the block cylinders, mm	91.500 - 91.535
Diameter "D1" under the sleeve collar in cylinder block, mm	92.00 - 92.20
Diameter "D" under the sleeve collar in cylinder block, mm	94.15 - 94.25
Length of sleeve "T", mm	231.0 - 231.2
Landing depth of the sleeve "T1", mm	1.0 - 1.2
Chamfer width "M", mm	35

Dimensions of crankshaft, main and connecting rod bearings

Main journal diameter, mm
Nominal size	57.940 - 57.965
1st repair size	57.700 - 57.715
2nd repair size	57.450 - 57.465
3rd repair size	57.200 - 57.215
4th repair size	56.950 - 56.965
Main journal diameter, mm
Nominal size	47.940 - 47.965
1st repair size	47.700 - 47.715
2nd repair size	47.450 - 47.465
3rd repair size	47.200 - 47.215
4th repair size	46.950 - 46.964
Installation width of main journals, mm
Nominal size	24.500 - 24.533
1st repair size	24.600 - 24.633
2nd repair size	24.700 - 24.733
3rd repair size	24.900 - 24.933
4th repair size	25.000 - 25.033
Crankshaft hole diameter, mm	62.500 - 62.519
Width of the hole for the crankshaft with the liners installed, mm	19.979 - 20.000
Permissible ovality and taper of main bearing shell beds, mm	0.02
Main bearing working clearances, mm
New	0.03 - 0.05
Acceptable	0.08
Crankshaft axial clearance, mm
New	0.10 - 0.25
Acceptable	0.3
Radial runout of crankshaft, mm	0.020 - 0.065
Standard crankshaft liners for bearing caps with diameter	58 mm
Repair diameter (color - blue), mm	52
Repair diameter (color yellow), mm	54
Repair diameter (color yellow), mm	54
Insert thickness, mm	2.260 - 2.265
Repair diameter (color - red), mm	56
Insert thickness, mm	2.265 - 2.270
Repair diameter (color white), mm	57
Insert thickness, mm	2.270 - 2.275
Repair diameter (color purple), mm	58
Insert thickness, mm	2.275 - 2.280

OM606 series engines

Valve sizes

1 — Timing marks for bringing the engine to the TDC position of the end of the compression stroke of the piston of the first cylinder

2 - Locking the intake camshaft with a rod

3 - Make sure the 1.5mm holes in the sprockets are aligned correctly

4 — Disposable bolts are used to secure the camshaft sprockets and must be replaced
5 - Assembling the chain tensioner

6 — When removing/installing the high-pressure fuel pump, the crankshaft should be set to the position 14°+05° after TDC of the piston of the first cylinder

7 — The fuel injection pump sprocket bolt has a left-hand thread.

8 - Locking tool

Valve plate diameter "D", mm
Inlet	25.90 - 26.10
Outlet	28.90 - 29.10
Height of the cylindrical part (belt) valve plates "h", mm	1.0 - 1.2
Valve seat chamfer angle	45° 15'
Valve stem diameter "D1", mm
Inlet	6.955 - 6.97
Outlet	5.955 - 5.97
Full length of valve "L", mm
Inlet	105.5 - 105.9
Outlet	105.2 - 105.9
Width of the working chamfer of the valve seat, mm	1.9
Offset of valve seat axis relative to stem, mm	0.03
Marking on the end of the valve stem
Inlet	A 606 13
Outlet	E 606 11

Valve guide bushing dimensions

Valve guide bushing installation details

Cylinder head hole diameter, mm
Nominal	12.50 - 12.51
1st nominal	12.53
1st repair	12.70
Outer diameter of guide bushing, mm
Nominal	12.54 - 12.55
1st nominal (color: gray)	12.56 - 12.57
1st repair (color: red)	12.74 - 12.75
Inner diameter of guide bushing, mm
Inlet valve	6.000 - 6.015
Exhaust valve	6.000 - 6.015 (up to 11.94) 7.000 - 7.015 (since 11.94)
Length of guide bushing "L", mm	37.5
Preload in the block head cylinders, mm	0.029 - 0.051
Size "a"	—
Size "b"	—
Size "c"	10.2 - 10.04

Valve seat dimensions

Milling and grinding of valve seats

Valve seat installation details

Inner diameter of guide bushing, mm
Valve seat chamfer width "b", mm
Inlet valve	1.0 - 1.5
Exhaust valve	0.8 - 1.5
Valve seat chamfer angle b	45° 15'
Correction angle in
Inlet valve	15° 15'
Exhaust valve	25° 15'
Maximum valve seat ovality, mm	0.03
Distance from the end of the valve stem to the camshaft bearing "T", mm	23.7 - 24.2
Depth of hole "C" for valve seat in cylinder head, mm
Standard ring
Inlet valve	7.94 - 8.04
Exhaust valve	7.924 - 8.02
Repair ring
Inlet valve	8.14 - 8:24
Exhaust valve	8.12 - 8.23
Radius "R", mm
Inlet valve	0.2 - 0.4
Exhaust valve	0.2 - 0.4
Diameter "D2" of the hole for the valve seat, mm
Nominal size
Inlet valve	30.060 - 30.070
Exhaust valve	28.000 - 28.013
Repair size
Inlet valve	30.250 - 30.266
Exhaust valve	28.250 - 28.263
Valve overlap, mm
Inlet valve	0.2 - 0.4
Exhaust valve	0.2 - 0.4
Valve seat height "H", mm
Nominal size
Inlet valve	5.6
Exhaust valve	5.6
1st repair size
Inlet valve	5.6
Exhaust valve	5.6
Outer diameter "D" of valve seat, mm
Nominal size
Inlet valve	30.000 - 30.013
Exhaust valve	27.97 - 28.07
1st repair size
Inlet valve	30.31 - 30.32
Exhaust valve	28.31 - 28.32

Connecting rod dimensions

Distance between connecting rod centers heads "L", mm 1	48.7 - 149.3
Width of the top "b" and bottom "B" connecting rod heads, mm	21.48 - 22.00
Diameter "D1" of the lower head connecting rod, mm	51.600 - 51.614
Permissible ovality and taper of the lower connecting rod head hole, mm	0.02
Permissible twist of connecting rod per 100 mm of length, mm	0.1
Permissible difference in deviation from parallelism between heads connecting rod per 100 mm of connecting rod length, mm	0.045
Inner diameter of the upper bushing connecting rod head "d", mm	28-018 - 28.024
Outer diameter of the bushing, mm	30.575 - 30.600
Diameter under the bushing in the upper head of the connecting rod "d1", mm	30.500 - 30.525
Piston pin clearance in the bushing upper connecting rod head, mm	0.007- 0.008
Maximum protrusion (Rz) of the bushing connecting rod outward, µm	5
Maximum allowable difference in connecting rod weight, g	2

Dimensions of holes in the cylinder block for installing liners, mm

Extracting the cartridge case

Diameter "D2" for the liner in the cylinder flare, mm	9.000 - 90.535
Diameter "D1" under the flange of the sleeve in the cylinder block, mm	90.55 - 90.65
Diameter "D" under the liner flange in the cylinder block, mm	92.65 - 92.75
Length of sleeve "T", mm	231.0-231.2
Landing depth of the sleeve "T1", mm	1.0 - 1.2

Cylinder dimensions

Diameter, mm
Nominal	87.0
Size group A	87.000 - 87.006
Size group X	87.007 - 87.012
Size group B	87.013 - 87.018
Permissible cylinder limit in longitudinal and transverse directions, mm	0.20
Permissible taper of cylinders new block, mm	0.000 - 0.014
Wear limit, mm	0.05
Permissible cylinder ovality, mm	0.07

Crankshaft dimensions

Hole diameter under crankshaft, mm	62.500 - 62.519
Crankshaft bore width with inserts installed, mm	19.979 - 20.000
Permissible ovality and taper bed liners of the main bearings crankshaft bearings, mm	0.02
Working clearance in main bearings, mm
New	0.03 - 0.05
Maximum permissible	0.08
Crankshaft axial clearance, mm
New	0.10 - 0.25
Maximum permissible	0.3
Radial runout of crankshaft, mm	0.020 - 0.065
Nominal crankshaft liners for 58mm diameter bearing caps
Repair diameter (color - blue), mm	52
Insert thickness, mm	2.255 - 2.260
Repair diameter (color - yellow), mm	54
Insert thickness, mm	2.260 - 2.265
Insert thickness, mm	2.265 - 2.270
Repair diameter (color - white), mm	57
Insert thickness, mm	2.270 - 2.275
Repair diameter (color - purple), mm	58
Insert thickness, mm	2.275 - 2.280
1st repair size crankshaft liners for bearing caps with a diameter of 57.70 mm
Insert thickness, mm	2.37
2nd repair size crankshaft liners for bearing caps with a diameter of 57.40 mm
Insert thickness, mm	2.50
3rd repair size crankshaft liners for bearing caps with a diameter of 57.20 mm
Insert thickness, mm	2.62
4th repair size crankshaft liners for bearing caps with a diameter of 56.90 mm
Insert thickness, mm	2.75

Tightening force of threaded connections, Nm

Cylinder Head Bolt Tightening Sequence for Petrol Engine Models

Cylinder Head Bolt Tightening Sequence for Diesel Models

Cylinder head bolts
Petrol models (length to base heads no more than 162.7 mm)	55NCHm, +90°, +90°
S300 TDI up to 01.89 (length to the base of the heads no more than 83.6, 105.6 and 118.6 mm)	25Nm, +40Nm, wait 10 min, +90°, +90°
S300 TDI after 01.89 (length to base heads no more than 82, 104 and 117 mm)	15Nm, +35Nm, +90°, wait 10 min, +90° (M8 25Nm)
Main bearing cap bolts
S280, S320 (length to base of head no more than 63.8 mm)	55NCHm, +90°, -100°
S420, S500	25NHz, +50NHz
S300 TDI	M11: 55LFm, +90°, M12: 90LFm
S600	M8: 30NCHm, M10: 50NCHm
Connecting rod bearing cap bolts
S280, S320 (length to base of head no more than 52.9 mm)	30+90°
S420, S500, S600	45NCHm, +90°, -100°
S300 TDI	40Nm, +90°, -100°
Flywheel/Drive Disc Bolts S280, S320, S420 (diameter of non-threaded part no more than 8.1 mm for flywheel, 8.0 mm for the drive disk)	30 Nm, +90°
S300 TDI	40Nm, +90°, -100°
S500, S600	35NCHm, +90°, -100°
Clutch basket on the flywheel	25
Crankshaft pulley
S280, S320, S420, S500, S600	400
S300 TDI	200NCHm, +90°
Camshaft Sprocket Bolts
S280, S320	Torx: 22, Hexagonal: 18, Torx with flange: 20Nm+90°-100°
S420, S500	18
S300 TDI	25NCHm, +90°
S600	20Nm, +90°, -100°
Camshaft bed cover
S280, S320, S600	21
S420, S500	12
S300 TDI	25
Camshaft rocker cover
S280, S320, S420, S500, S600	9
S300 TDI	10
Candles
S280, S320, S420, S500	25-30
S600	25
S300 TDI	20
Injector clamps	30
Fuel injection pump flange	20
Nozzle Sprayer to Holder	80
Lambda probe	50-60
Knock sensor	20
M series engines	104.94/99
Bolts and nuts for fastening the intake manifold to the cylinder head	25
Cylinder head cover mounting bolts	10
Timing chain cover to cylinder block mounting bolts
M6	9
M8	21
Tensioner mounting bolt to cylinder block	75
Bolt for fastening the fittings to the control plunger
1st version	7
2nd version	5Nm + 90°
Regulator nut M20	65
Drain plug	25
Bolts securing the oil pan to the cylinder block
M6	10
M8	25
M10	40
Oil lines to the sump	10
Oil pump sprocket to pump	32
Oil pump cover mounting bolts M6	10
Oil filter for cylinder block	25
Oil filter cover	20
Oil pressure sensor to oil filter housing	20

Engines of the M119.97/98 series

Cylinder head cover mounting bolt	9
Intake manifold mounting bolts	28
Intake manifold top mounting bolt pipeline to the bottom	25
Exhaust pipe to exhaust manifold	20
Exhaust manifold mounting bolts	30
Thermostat housing cover mounting bolts	10
Coolant pump mounting bolts	21

M120.980/982 series engines

Intake manifold mounting bolt	28
Intermediate flange mounting bolt	28
Exhaust manifold mounting nuts	30
Front cover mounting bolt M8	25
Timing chain cover to cylinder block
M6	9
M8	21
Air Pump/Generator Bracket Mounting Bolt	25
Timing chain tensioner plug	40
Timing chain tensioner housing in timing chain cover	80
Nut for fastening flange to sprocket	65
Bolt for fastening the fittings to the plunger	5Nm + 90°
Camshaft cover mounting bolt	21°
Oil deflector mounting bolts	9
Bolts securing the oil pan to the cylinder block
M6	10
M8	21
M12	40
Drain plug M12	40
Oil deflector to sump mounting bolt M12	9
Oil pump sprocket	28
M6 bolts for fastening the fan clutch and the coolant pump pulley	10
M6 bolts for fastening the cooling system pump	21

Engines of the OM603.971 series

Spring lever on the cylinder head	21
Tension roller mounting bolt	30
Tensioner lever pin	100
Tensioner shock absorber to the cylinder head	25
Tensioner shock absorber to the tension lever	20
Timing belt cover to head mounting bolts cylinder block
Head cover mounting bolts cylinder block	10
Drive chain cover mounting bolt Timing belt to cylinder head	25
Timing chain tensioner	80
Bolt M12 crankshaft bearing	90
Pallet mounting bolts
M6	10
M8	25
Oil level sensor mounting bolt	10
Oil pump sprocket mounting bolt	32
Oil pump cover fastening nut	25
Bolt securing the oil filter housing to the cylinder block	25
Coolant pump pulley mounting bolt	15
Cooling system pump mounting bolt to housing	10
Coolant pump housing mounting bolt to cylinder block	10

Engines of the OM606.961 series

Cylinder head cover mounting bolt	10
Prechamber threaded ring in the cylinder head	130
Distribution housing mounting bolt shafts to the cylinder head	15
Camshaft cover mounting bolt	15
Timing chain cover mounting bolt to the cylinder head	25
Timing chain cover mounting bolt to the cylinder block	10
Timing chain tensioner	80
Rear hub	320
Front caliper to holder	35
Rear Caliper to Holder (TDI)	115
Caliper holder to the fist
Front wheels	115
Rear wheels
Until 07.93	115
After 08.93	50
Tie rod end nuts
S280, S320, S300 TDI	50
S420, S500, S600	55
Wheels
S280, S320, S420, S500, S600	150
S300 TD	I 110