Car engine repair Mercedes Sprinter I (903)

General description of engines
Diesel engines with a capacity of 2.3 and 2.9 liters, designated as 601 and 602, were previously installed on other Mercedes-Benz vehicles, with the only difference...

Dismantling the power unit
Figure 14. Dismantling the power unit To dismantle the power unit, a lifting hoist or hand winch is required. The power unit is removed forward after removing all the...

Installation of the power unit
The installation of the power unit on the vehicle is carried out in the reverse order of removal, taking into account the following: check for damage and, if necessary,...

Disassembling the engine
All diesel engines are very demanding in terms of cleanliness of maintenance and repair. When performing any work on these engines, make sure that no foreign objects get...

Cylinder head — general description
The cylinder head is cast from aluminum alloy. It has channels for the circulation of coolant, oil, air required for fuel combustion, and exhaust gases. The cylinder...

Removal and installation the cylinder head
The cylinder head may only be removed when the engine is cold. The cylinder head is removed together with the exhaust manifold, while the intake manifold must be...

Disassembling the cylinder head
The operations for replacing the cylinder head are described below. If it is intended to carry out only valve repairs, then the description of other types of work can be...

Cylinder head repair
All cylinder head components should be checked for wear. The mating surface of the cylinder head must be thoroughly cleaned (sometimes there are stuck fragments of the...

Pistons and connecting rods — removal
Figure 47. Piston with combustion chamber (1) made on it The pistons are made of a special aluminum alloy. Each piston has a star-shaped combustion chamber 1 (figure 47)...

Measuring cylinder liners
To measure the cylinder liners in the middle and lower parts, you need a special indicator for measuring cylinders (nutromer). You will not be able to perform the...

Checking pistons and connecting rods
Figure 58. Measuring vertical clearances in piston ring grooves using a feeler gauge Figure 59. Measuring gaps in piston ring locks located in engine cylinders Conduct a...

Assembly of pistons and connecting rods
Figure 54. Piston and connecting rod after disassembly: 1 - piston rings; 2 - piston pin retaining rings; 3 — piston; 4 - piston pin; 5 — connecting rod; 6 - bearing...

Installing pistons with connecting rods into cylinders
When installing pistons with connecting rods into engine cylinders, the following operations must be performed: lubricate the inner surfaces of the cylinders; place the...

Camshaft Drive Mechanism Cover
Figure 43. Camshaft drive mechanism cover and its attachments: 1 — generator mounting bolt, 45 Nm; 2 - alternating current generator; 3 — bolt, 25 Nm; 4 - washer; 5 —...

General Description — Cylinder Block
Figure 65. Parts installed on the cylinder block: 1 — connecting nipple; 2 - threaded nozzle; 3 - connecting nipple for draining coolant, on the right side; 4, 5 -...

Removal and installation cylinder block plugs
Figure 67. Front of the cylinder block: 1 - spring tension pin; 2 - chain guide support pin; 3 - steel ball with a diameter of 17 mm; 4 - oil spray nozzle; 5 — cylinder...

Measuring the working clearance in pistons
To determine the working clearance of the pistons, it is necessary to measure their diameters and record the results. To determine the clearance, measure the cylinder...

Changes in the design of the cylinder block introduced as a result of modernization
Figure 71. Location of oil spray nozzles of the piston cooling system Below are some of the changes made to the 601 and 602 engine family design in case you are...

Crankshaft and Flywheel — General Information
The crankshaft is designed to convert the reciprocating motion of the pistons into rotary motion. For additional rigidity, each crankpin is located between two main...

Removal the crankshaft
To remove the crankshaft, you need to remove the engine from the car. The removal process must be carried out as follows: disconnect the gearbox from the engine. When...

Checking the crankshaft
The crankshaft inspection must be performed in the following order: conduct a thorough inspection of the crankshaft for wear and deformation, measure the journals of the...

Installing the crankshaft
The crankshaft installation must be performed in the following order: wipe the crankshaft main bearing seats and insert the liners with holes and grooves for supplying...

Flywheel or drive disc (automatic transmission models)
The engine is equipped with a combined flywheel with a torsional vibration damper (damper). The purpose of such a flywheel design is to smooth out and prevent the...

Belt pulley and torsional vibration damper of the crankshaft
Figure 76. Crankshaft and its mating parts using the example of engine 602 (similar parts are used on the 601 engine): 1 - bolt for fastening the chain drive sprocket to...

Rear crankshaft oil seal and its holder
Figure 65. Parts installed on the cylinder block: 1 — connecting nipple; 2 - threaded nozzle; 3 - connecting nipple for draining coolant, on the right side; 4, 5 -...

Front crankshaft oil seal
Figure 44. Camshaft drive mechanism cover with individual parts indicated (the details of the lid are shown below): 1 — support pin of the generator drive belt...

Camshaft Drive Mechanism — General Description
Figure 95 a. Timing chain tensioner mechanism: 1 - cork; 2 - plug gasket; 3 - ball; 4 — spring seat; 5 - pressure spring; 6 - finger; 7 - relief valve; 8 - sealing ring;...

Removal and installation the camshaft drive chain tensioner
The chain tensioner is located on the side, on the right side of the cylinder head. The force in the chain tensioner is created by the force of the spring and the...

Dismantling and installation of the camshaft drive chain
The camshaft and fuel pump are driven by a double-row drive chain. The camshaft and fuel pump drive sprockets have twice as many teeth as the crankshaft drive sprocket....

Removal and installation the chain tension shoe
Figure 96. Camshaft drive mechanism assembly: 1 - crankshaft sprocket; 2 - chain tension shoe; 3 - chain tensioner; 4 — camshaft drive sprocket; 5 - chain tensioner; 6 —...

Dismantling and installation of drive chain dampers
Figure 95 b. Other parts of the camshaft drive mechanism: 1 - double row drive chain; 2 - landing pin; 3 - camshaft thrust washer; 4 — camshaft; 5 - chain tensioner...

Removal and installation the crankshaft sprocket
Removal and installation of the crankshaft sprocket must be carried out in the following order: remove all components and parts that impede access to the end of the...

Removal and installation the camshaft
Figure 108. Numerical identifier indicating the corresponding modification or size group of the camshaft (top). Correct direction of rotation of the crankshaft (bottom)...

Gas distribution mechanism
Figure 102. Location of marks when the piston of the first cylinder is at TDC The valve timing cannot be adjusted. This is why it is necessary to follow all the...

Hydraulic valve lifter compensators — device
Figure 114. Hydraulic valve lifter: 1 — rocker arm; 2 - retaining ring; 3 - washer; 4 — cap; 5 - push rod; 6 - guide bushing; 7 - ball guide channel; 8 - ball with a...

Checking the serviceability of hydraulic tappets
The noise of hydraulic tappets is almost inaudible due to the fact that they are in constant contact with the camshaft. If noise occurs from the camshaft area, the...

Removal and installation of hydraulic tappets
Figure 116. Valve with hydraulic tappet (cross section): 1 - pressure pin (rod); 2 - retaining ring; 3, 5 - pressure springs; 4 - ball; 6 - guide bushing; 7 - ball guide...

Diesel Engine Specifications
208D (901.3) — 601.943 208D (902.3) — 601.943 308D (903.3) — 601.943 408D (904.3) — 601.943 212D (901.4) — 602 DE 29 LA (602.980) 312D (903.4) — 602 DE 29 LA (602.980)...

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Vito 1 (1996-2003)