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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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Disassembling the engine (Mercedes-Benz Sprinter 903)

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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 into them. It is best to seal the fuel line connections and other exposed openings on the engine with adhesive tape.

Before starting work, it is necessary to thoroughly clean and wash the engine, having previously covered all openings with a clean rag to prevent foreign objects from getting inside the engine.

Engine disassembly is discussed in detail in the following subsections. Therefore, the following describes the work that can be performed both on the engine installed in the vehicle and on the engine removed from the vehicle. In the event that a complete disassembly of the engine is required, it will only be necessary to combine individual types of work in the specified sequence.

When disassembling the engine, all moving mating parts should be marked before dismantling them so that in case of their subsequent use, these parts can be installed in their original position. This is especially important when removing pistons, valves, covers and bearing shells. They should be laid out in such a way as to avoid confusion during subsequent assembly.

Never mark bearings and seals with sharp objects ("scribers") or by stamping numbers. Many engine parts are made of aluminum alloy and therefore require very careful handling. If you have to use a hammer to remove certain parts, the hammer should be rubber, plastic or coated with a synthetic material.



[Material taken from a web resource Mercedesman.ru]

Since complete disassembly of the engine is required only in rare cases, and most work can be performed on the engine installed in the vehicle, individual work is described in the relevant sections. In case of major engine repairs, it is necessary to combine individual stages of work from these sections.

The following description applies to all types of engines, since they differ in most cases only in the number of cylinders. The text provides separate references to the design differences of a specific engine.
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The article has been verified: Levin Kirill Glebovich
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Mercedes Sprinter / Engine repair
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Installation of the power unit
Dismantling the power unit
General description of engines
Cylinder head — general description
Removal and installation the cylinder head
Disassembling the cylinder head
Cylinder head repair
Pistons and connecting rods — removal
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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
  • Lubrication system
  • Cooling system
  • Power and control system
  • 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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