Mercedes G-Class 460 Workshop Manual Engines 115.973 / 616.936 / 617.931

Content

How to use this Workshop Manual 
Survey of Types and Assemblies 
Cross-country vehicle - Engines, Volume 1 

61 | Engine 115.973 
Group 01 
Installation Survey 
Illustrations, Sectional views, Exploded views 
Engine 115 - Ignition distributor side 
Engine 115 - Carburetor side 
Engine 115.973 
Longitudinal and Cross-section 
Crankcase 
Cylinder head 
Special Tools 
Workshop Equipment 
Self-made tools 
General Engine Data - Performance Diagram 
Removal and installation of engine 
Checking cylinder for leaks 
Checking compression 
Removal and installation of cylinder head 
Pressure testing cylinder head 
Refacing cylinder head parting surface 
Renewing core-hole plug in cylinder crankcase 
Knocking out and inserting steel balls for main oil ducts 
Installation and centering of intermediate flange 
Removal and installing of oil pan 
Evaluation of cylinder bores 
Measuring, boring and honing cylinder bores 
Facing cylinder crankcase parting surface 

Group 03 
Exploded views 
Removal and installation of flywheel and driven plate 
Refacing flywheel 
Static balancing of flywheel 
Renewing ring gear of flywheel 
Removal and installation of grooved ball bearing and cover ring in crankshaft 
Removal and installation of pulley and balancing disc 
Static balancing of balancing disc 
Renewing front crankshaft radial sealing ring 
Renewing rear crankshaft radial sealing ring 
Mounting of crankshaft 
Removal and installation of crankshaft sprocket 
Checking and reconditioning of crankshaft 
Removal and installation of pistons 
Reconditioning and squaring connecting rods 
Checking, renewing and tightening connecting rod bolts 

Group 05
Exploded view 
Checking and adjusting of valve clearance 
Renewing threaded bushing with valve adjusting screw 
Renewing valve stem seal 
Refacing valve seats 
Removal and Installation of Valve Springs 
Testing valve springs 
Checking and refacing valves 
Renewing valve seat rings 
Checking and renewing valve guides 
Removal and Installation of Rocker Arms 
Checking and Adjusting Camshaft Timing 
Removal and Installation of Chain Tensioner 
Renewing Timing Chain 
Removal and Installation of Tension Rail 
Removal and Installation of Slide Rails 
Removal and Installation of Helical Gear Shaft 
Removal and Installation of Intermediate Sprocket Shaft 
Removal and Installation of Intermediate Sprocket 
Removal and Installation of Camshaft 
Grinding camshaft bearing journals 

Group 07 
Illustrations, Exploded views 
Stromberg Carburetor - Design and Function Description 
General 
Float device 
Float chamber ventilation 
Idle mixture cut-off valve 
Fuel return valve 
Pulldown delay 
Idling - partial load - full load operation 
Cold start 
Acceleration 
Temperature-controlled fuel jet and heating of nozzle holder 
Starting enrichment valve 
Positive cut-off of automatic starting device 
Choke housing with supplementary air adjusting screw 
Vacuum governor (speed stabilizer) 
Supplementary vacuum sampling tube 
Troubleshooting Stromberg Carburetor 
Adjusting engine 
Adjusting Idling Speed 
Testing and adjusting starting device 
Checking and adjusting CO values on dynamometer 
Checking, removal and installation of fuel pump 
Cleaning carburettor, adjusting float level 
Removal and installation of carburettor 
Adjusting basic position of throttle valve 
Removal and installation of air piston, air piston diaphragm and metering rod 
Removal and installation of damper for air piston 
Function tests of pulldown 
Testing pulldown diaphragm for leaks 
Removal, checking and installation of pulldown diaphragm 
Renewing driver lever in starting device
Testing function of starting device (cold start) 
Checking and adjusting choke housing marking 
Checking function of idle cut-off valve, removing and installing 
Checking fuel return valve 

Group 09 
Design and function of intake air preheating 

Group 13 
Renewing and tensioning V-belt 

Group 15 
Testing ignition system with tester 
Tester - Connections 
Good display - parade 
Good display - superposition 
Contact arcing 
Jumping starting point of ignition line 
Starting point of ignition line too high but constant 
Required ignition voltage 
Required ignition voltage, accelerator shock load 
Angular cam spacing, angular ignition spacing 
Angular cam spacing 
Angular ignition spacing 
Error in opening section 
Ignition coil - starting voltage 
Ignition coil - spare voltage 
Secondary insulation 
Ignition coil - separate test 
Checking and adjusting dwell angle and firing point 
Renewing contact breaker points 
Removal and installation of ignition distributor

Group 18 
Checking oil pressure 
Removal and installation of oil filter element 
Disassembly and assembly of oil filter 
Removal and installation of oil pump 

Group 20 
Schematic coolant circuit diagram, exploded view 
Removal and installation of water pump 
Reconditioning water pump 
Sealing water pump 
Removal and installation of water pump housing 

62 | Diesel Engine 616 and 617 
Group 01 
Installation survey 
Illustrations, Sectional views 
Exploded views 
Special tools 
Self-made tools 
Workshop equipment 
General engine data - Performance diagram 
Removal and installation of engine 
Checking cylinder for leaks 
Checking compression 
Removal and installation of cylinder head cover
Removal of cylinder head 
Installing cylinder head 
Pressure testing cylinder head 
Refacing cylinder head parting surface 
Renewing core-hole plug in cylinder crankcase 
Knocking out and inserting steel balls for main oil ducts 
Installation and centering of intermediate flange 
Removal and installation of oil pan 
Evaluation of cylinder bores 
Measuring cylinder bores 
Renewing, boring and honing cylinder liners 
Refacing cylinder crankcase parting surface 
Removal and installation of precombustion chambers 

Group 03 
Exploded views 
Removal and installation of flywheel and driven plate 
Refacing flywheel 
Static balancing of flywheel 
Renewing ring gear of flywheel 
Removal and installation of grooved ball bearing and cover ring in crankshaft 
Removal and installation of pulley, vibration damper and balancing disk 
Static balancing of balancing disk 
Renewing front crankshaft radial sealing ring 
Renewing rear crankshaft radial sealing ring 
Mounting Crankshaft 
Removal and installation of crankshaft sprocket 
Checking and reconditioning of crankshaft 
Removal and installation of pistons 
Reconditioning and squaring connecting rods 
Checking, renewing and tightening connecting rod bolts 

Group 05 
Exploded views 
Checking and adjusting valve clearance 
Renewing valve stem seals 
Refacing valve seats 
Removal and installation of valve springs 
Testing valve springs 
Checking and refacing valves 
Checking and renewing valve guides 
Removal and installation of rocker arms with rocker arm bearing brackets 
Renewing rocker arms and rocker arm bearing brackets 
Checking and adjusting camshaft timing 
Removal and installation of chain tensioner 
Renewing timing chain 
Removal and installation of tension rail 
Removal and installation of slide rails 
Removal and installation of helical gear shaft 
Removal and installation of intermediate sprocket shaft 
Removal and installation of camshaft 
Grinding camshaft bearing journals 
Removal and installation of idler gear 

Group 07 
Exploded views 
Test values for injection pump and governor
Test values for injection pump and governor 
Adjusting idle speed and idle speed advance 
Checking and Adjusting Nominal Speed at No Load 
Checking Fuel Pump and Overflow Valve 
Removing and Installing Fuel Pump 
Checking Key-operated Starter for Leaks 
Checking Injection Pump for Start of Delivery 
Adjusting Injection Pump to Start of Delivery (After Checking Start of Delivery) 
Checking Injection Pump for Start of Delivery Deviation (After Checking Start of Delivery of 
Cylinder 1) 
Reversing Injection Pump (after Adjusting Start of Delivery) 
Venting Injection System 
Removal and Installation of Injection Pump 
Renewing Pipe Connection, Delivery Valve or Copper Sealing Ring of Injection Pump 
Renewing Vacuum Control Unit at Injection Pump 
Removal and Installation of Injection Timing Device 
Removal and Installation of Injection Nozzle 
Checking Injection Nozzles 
Disassembling, Cleaning, Reassembling and Adjusting Injection Nozzles 

Group 09 
Exploded Views 
Removal and installation of air cleaner 

Group 13 
Notes on renewing and tensioning V-belts 

Group 14 
Exploded Views 
Removal and installation of intake manifold and exhaust manifold 

Group 15 
Function of the preglow system 
Glow Plugs - Complaints - Causes 
Checking preglow system 
Removal and installation of glow plugs 

Group 18 
Exploded Views 
Removal and installation, checking of thermostat in oil filter 
Removal and installation of oil filter 
Removal and installation of oil pressure relief valve on oil pump 
Removal and installation of oil pump 

Group 20 
Exploded Views 
Coolant Circuit 
Removal, installation and sealing water pump 
Removal and installation of water pump housing 
Reconditioning water pump 
Function and Venting of Thermostat 
Removal and installation of thermostat 
Checking radiator cap 
Draining and filling coolant - Antifreeze table 
Cleaning cooling system 
Removal and installation of radiator