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Old 02-24-2004, 01:10 AM
kamil's Avatar
Rutgers University
Join Date: Feb 2004
Location: North Jersey
Posts: 1,310
Hey...first time post and I found FEW answers during my search through this site


I am doing my first Valve Adjustment tomorrow. The car starts perfect but I need to do it since it has been over 15k miles...

I had two questions and I found few different answers...

what size feeler gauge do I use for intake and exhaust valves (mm or inches)

when I turn the engine over, can I just push the car so the engine turns ? (i have automatic)

can I turn the engine with the powersteering pulley? if so then how do I turn it and in which direction

The reason why I am asking these questions is because I spent hours on this site reading and I found MANY different answers.. maybe you can help me clarify a few things...

thank you very much

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Old 02-24-2004, 03:08 AM
dmorrison's Avatar
Registered User
Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,694
First go to this site

Go to job number 05-210

This is the Mercedes service manual for the 300D (617 engine). You car is a 240D (616 engine) the valve clearance requirements for your 616 engine are

Intake cold 0.10mm at 20degrees C
Intake hot 0.15mm at 60degrees C

Exhaust cold 0.30mm at 20 degrees C
Exhaust hot 0.35mm at 60 degrees C

Your intake vs exhaust valves are the same as 1-4 cylinders in the diagram for the 617 engine. Just ignore the #5 cylinder in the diagram.

You don't have to use the Mercedes wrenches. Some folks are successful with regular wrenches.

You cannot rotate the engine by pushing the car in gear with an automatic.

You can use the power steering pump bolt but go slowly. Dont' put a lot of force on the unit. rotate slowly and allow the compressed air to enter and exit the cylinders. Or remove your glow plugs.
If your on the drivers side of the car and you put a wrench on the power steering bolt you will pull it towards you.
Look at the fan blades and make them move in the right direction.

Go to the site above and read about your car. Remember you have the 616 engine and the site is for a 617 engine.

When your making a title for your post. Be more specific about your needs. I would have made the title
"Info for a valve adjustment on a 616"
"Questions on how to adjust valves on a 1983 240D"

Get more specific and it allows the members to focus on posts that they can help you with. Otherwise we may just skip your post.


Always include the car, engine and any specifics about your vehicle. Ie-1983 240D AC system

If you had your Email on your post I would have sent you the 240D job 05-210 ( pdf format) for the 616 engine.
1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car
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Old 02-24-2004, 08:05 AM
Registered User
Join Date: Sep 2001
Location: central Texas
Posts: 17,277
Dave's answer was very good... but he probably has not run into a power steering pulley which needed to come off on a car which had been turned using that nut..... TCane had that situation from the PO of the car... and it was a real bear... it took several heatings with an oxy-acet torch and then still a big hammer.... not fun.... it is a tapered shaft that pulley is on....
The Factory shop manual specifies that the crank bolt should be used to rotate the engine...
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Old 02-24-2004, 09:45 AM
Posts: n/a

Welcome to the forum.

We need to know the year and model before we can tell you the exact lash settings. "Name and town. Name and town." (Just a Foxnews joke."

I know a lot of people turn the engine by the P/S pump, but I won't do it. It's not that tough to do from the crankshaft bolt, you just have to dig through your tool box awhile to find the right extension length and socket combo.

The five cylinders are much more challenging to get at the crank bolt, but once you get set up it's no big deal.

Hope this helps,
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Old 02-24-2004, 11:30 AM
kamil's Avatar
Rutgers University
Join Date: Feb 2004
Location: North Jersey
Posts: 1,310
thank you very much gentlemen...

PS. my car is a 1983 240d

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