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Sprinter (1995-2000, diesel) Vito 1 (1996-2003) Vito 2 (2003-2014, diesel) Vario 814D (1996-2003, diesel)
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Measuring the working clearance in pistons (Mercedes-Benz Sprinter 903)

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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 liner diameters as described below.

Figure 55. Cylinder liner hole measurement locations: A - measurement in the longitudinal axis of…

Figure 55. Cylinder liner hole measurement locations: A - measurement in the longitudinal axis of the engine; B - measurement in the transverse axis of the engine; a - the upper stopping point of the upper piston ring; b — lower piston stopping point; c — lower stopping point of the oil scraper ring; 1, 2, 3 — measurement points


Using a bore gauge, measure the cylinder diameter as shown in the figure 55.

Measurements are taken in the longitudinal and transverse axes of the engine cylinder block and at equal cylinder depths. All six results are carefully recorded. The difference in the measurement results obtained at the top and bottom of the cylinder indicates its taper. The difference in the results obtained from measurements in the longitudinal axis and from measurements in the transverse axis indicates the ovality of the cylinder bores. At none of the 6 measurement points should the cylinder diameter deviate from the specified value by more than 0.12 mm.

Each engine is equipped with replaceable cylinder liners, which should be pressed into the cylinder block at a service station. The mating surface of the cylinder block should be checked for deformations similar to the mating surface of the cylinder head. Take measurements in the longitudinal, transverse and diagonal directions under a ruler installed on the mating surface of the cylinder block. A feeler gauge thicker than 0.10 mm should not pass under the ruler at any point on the surface.
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Mercedes Sprinter / Engine repair
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Removal and installation cylinder block plugs
General Description — Cylinder Block
Camshaft Drive Mechanism Cover
Installing pistons with connecting rods into cylinders
Assembly of pistons and connecting rods
Changes in the design of the cylinder block introduced as a result of modernization
Crankshaft and Flywheel — General Information
Removal the crankshaft
Checking the crankshaft
Installing the crankshaft
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Vario 814D (1996-2003, diesel) 
  • General information
  • Maintenance
  • Power unit
  • Engines 602.984/985
  • Engines 904.908/914/923/936
  • Transmission
  • Clutch
  • Manual gearbox 711.613
  • Manual gearbox 710.64/66
  • Manual gearbox 715.051
  • Automatic gearbox 723.345
  • Power take-off box
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body and electrical equipment
  • Interior (internal elements)
  • Exterior (external elements)
  • Heater and air conditioner
  • Electrical diagrams
Vito 2 (2003-2014, diesel) 
  • General information
  • User manual
  • Maintenance
  • Diesel engine OM646
  • Engine repair
  • Cooling and lubrication system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Car gearbox
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Body elements
  • Electrical equipment
  • Equipment and devices
  • Security systems
  • Electrical circuits
Vito 1 (1996-2003) 
  • General information
  • User manual
  • Maintenance
  • Petrol engines 2.0 l
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and control system
  • Petrol engines 2.8 l
  • Engine repair
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  • Diesel engines 2.3 l
  • Engine repair
  • Cooling system
  • Lubrication system
  • Turbocharging and recycling
  • Power and control system
  • Diesel engines 2.2 l
  • Engine repair
  • Cooling system
  • Lubrication system
  • Turbocharging and recycling
  • Power and control system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Chassis
  • Front suspension and wheels
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Electrical equipment
  • Equipment and devices
  • Heater and air conditioner
  • Electrical circuits
Sprinter (1995-2000, diesel) 
  • General information
  • Introduction to the guide
  • Maintenance
  • Power unit
  • Engine repair
  • Lubrication system
  • Cooling system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Front axle
  • Rear axle and cardan
  • Chassis
  • Car suspension
  • Steering
  • Brake system
  • Tires and wheels
  • Electrical equipment
  • Equipment and devices
  • Headlights and lighting
  • Power devices
  • Electrical circuits
 
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