what are the procedure to have less problems while putting it back together?
Are there any way to fix chain and IP at point when first piston is on firing?


The motor was overheated.

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Not really sure what you are asking, also what car are you working on?

i have van Mb 308d.
I have to exchange parts red marked on attached picture.

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You have to replace the pistons and cylinder liners??? If you're replacing pistons, there's no need to touch the IP or remove the chain from the IP sprocket. If you're replacing cylinder liners, the crank has to come out which means the chain and IP have to come off the block. There's no way to keep things indexed. You will have to set IP timing when installing the IP. Setting initial IP timing is an easy task compared to resleeving the block.

Is it worth your time and money to do that work? It might be cheaper and definitely easier to find a replacement engine.

Sixto
87 300D

Thank You.
Ok, i understand about indexing: I will open it, then will see. Maybe the damage is not so big.

The OM601 has an aluminum cylinder head which usually takes the brunt of overheating. Most likely you need a new cylinder head and no need to touch the block. Good luck!

Sixto
87 300D

Make marks on the chain in reference to camshaft sprocket and crank sprocket when tearing down the engine at 15 ATDC. Find a port on the injection pump driver's side that allows you screw in a bolt that will fix the pump's camshaft in place.

The adjusting bolt for the pump will also serve as a reference when re-installing.

However, if you are tearing down an engine, you will need access to a service manual and will / should replace parts that affect timing. You will want to time the injection pump after the rebuild.

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You have to pull a 601/2/3 cam at #1 TDC otherwise you risk damaging the cam. I suppose from that point you can rotate the engine to 15*ATDC but it'll be a bear to work on the pistons without turning the crank. You might face a lot more work than if you just retime the IP when the engine's back together. No need to loosen the IP from the block, though.

Sixto
87 300D

The engine has 210 000 Km, so...

I have problems with understanding of technical terms. Until now i had not used English for
this purpose. But i know that understanding of Yours comments can spare me lot of troubles. Just another thing : is it better to take engine out from van?

Find a port on the injection pump driver's side that allows you screw in a bolt that will fix the pump's camshaft in place.

1. Can i get some picture of this port?
2. Here, to be sure, i understand that IP timing is different from om616. There i had
set IP at 24* BTDC?

The first question is why you think the engine needs work. You mentioned it overheated. Is there oil in the cooling system? Exhaust smoke? Reduced power? Engine will not turn? Are you able to check compression?

Your plan to fix the engine should be based on what you believe is the problem. I wouldn't remove the engine to replace a cylinder head gasket in a passenger car. I don't know how the engine is situated in a van, though.

Sixto
87 300D

You have to pull a 601/2/3 cam at #1 TDC otherwise you risk damaging the cam.

In what situation can i damage the cam?

Fuel delivery timing is the same as in the 616 but MB provided a separate reference for installation timing that is unrelated to fuel delivery timing in the newer engine. There reference mark is at 14*ATDC but this is only to verify IP position. 14*ATDC has nothing to do with actual fuel delivery.

This picture shows a 602 pump with the locking tool installed -



There is a plug, a short bolt with a 17mm head, that covers the RIV port when the tool is not installed. Do not turn the engine or IP when the tool is installed! The tool prevents the IP internals from turning by engaging this tang -



The tang is centered in the RIV port when the engine is at 14-15*ATDC, assuming the IP is properly timed.

Sixto
87 300D

There is a specific sequence for loosening the cam towers, the upper half of the bearings retaining the cam. The sequence accounts for the pressure on the cam by the valves that are open when the engine is at #1 TDC. Randomly removing cam towers can cause the cam to bend. I suppose in an unsuitable situation such as if the crankshaft is stuck I would release each cam tower bolt a quarter turn at a time until all are loose. That should minimize the risk of bending the cam.

Sixto
87 300D

Thank you for yours fast answer.

The temperature has raised to almost 100 degrees Celsius. While i was not in the van: cleaning parking place. It has happen after test ride. I had heard that engine has changed sound but it was to late. Next day a went on a ride again and it stopped when i was driving into hill. I have parked and wait for some minutes. the i could make it run again.
But i could not get home, because it stopped after 100 m again.

I have pressure clock and sort of adapter which i have used on om616 . I will check
if i can use it also on om601.