Diesel Engine Specifications (Mercedes-Benz Sprinter 903)

• 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)
• 412D (904.4) — 602 DE 29 LA (602.980)
• 210D — 602 DE 29 LA (602.980)
• 310D — 602 DE 29 LA (602.980)
• 410D — 602 DE 29 LA (602.980)

Type - Diesel with pre-chamber injection and Bosch fuel injection pump. The 602 engine has a turbocharger

Number of cylinders:

• mod. 601 - Four
• mod. 602 - Five

The order of operation of the cylinders:

• four-cylinder — 1-3-4-2
• five-cylinder — 1-2-4-5-3

Cylinder arrangement - In-line

Working volume of cylinders, cm³:

• mod. 601 - 2299
• mod. 602 — 2874

Cylinder diameter, mm — 89.00

Piston stroke, mm — 92.40

Compression ratio - 22:1

Maximum engine power at 3800 min^—1, kW (hp):

• four-cylinder - 58 (79)
• five-cylinder - 75 (102) or 90 (122)

Maximum torque, Nm:

• four-cylinder engine - 152 at 2300-3000 min^—1
• five-cylinder engine - 250 at 2000 min^—1 or 280 at 2000-3000 min^—1

Engine crankshaft main bearings:

• four-cylinder - Five plain bearings with multi-layer liners
• five-cylinder - Six plain bearings with multi-layer liners

Valve Position - Top

Camshaft location - In the cylinder head

Cooling system - Forced circulation, with coolant pump and thermostat with bypass valve

Cooling system fan - Plastic with viscous coupling drive



Radiator - Tubular

Lubrication system - Under pressure, with gear oil pump

Oil filter - Combined full-flow with bypass valve

Air filter - Dry, with paper filter element

Cylinder block

Nominal cylinder diameter, mm — 89.00

Cylinder diameter, mm:

• class A - 89,000-89,006
• class X - 89,006-89,012
• class B - 89,012-89,018

Maximum permissible wear in the longitudinal and transverse directions, mm - 0.10

Permissible values of ovality and taper, mm:

• new - 0.014
• at a wear limit of 0.07

Permissible depth of surface irregularities/deformations, mm — 0.003–0.006

Permissible pulsation/waviness - 50% of the depth of unevenness

Measurement points - Upper edge, center of cylinder bore and lower edge in transverse and longitudinal directions

Total height of cylinder block (new), mm — 234.97—235.03

Minimum height after required grinding, mm — 234.60

Permissible unevenness of joint surfaces, mm:

• in the longitudinal direction - 0.10
• in the transverse direction - 0.05

Maximum deviation from parallelism between the upper and lower mating surfaces, mm — 0.05

Permissible deformation of the surface layer, mm:

• upper surface - 0.006-0.016
• lower surface - 0.025

Crimping pressure, kPa — 150

Crankshaft

Permissible ovality of journals and liners of connecting rod bearings, mm — 0.005

Permissible taper of connecting rod bearing shells, mm — 0.010

Permissible taper of connecting rod journals, mm — 0.015

Permissible axial runout of installed bearings, mm — 0.02

Main bearing journal transition radii, mm — 2.0–3.0

The radius of transition of connecting rod journals, mm — 3.0—3.5



Permissible radial and axial runout of the rear flange of the crankshaft, mm - 0.02

Permissible runout of connecting rod journals, mm:

• necks II and IV - 0.07
• necks III - 0.101

Permissible unbalance of the crankshaft, g cm — 15

Crankshaft journal diameter, mm:

• nominal size - 57,950-57,965
• 1st repair size - 57.700-57.715
• 2nd repair size - 57.450-57.465
• 3rd repair size - 57.200-57.215
• 4th repair size - 56.950-56.965

Neck width, mm:

• nominal size - 24,520-24,500
• 1st repair size - 24.730-24.700
• 2nd repair size - 24.920-24.900
• 3rd repair size - 25,020-25,000

Diameter of connecting rod bearing shells, mm:

• nominal size - 47,950-47,965
• 1st repair size - 47.700-47.715
• 2nd repair size - 47.450-47.460
• 3rd repair size - 47.200-46.965
• 4th repair size - 46.950-46.965

Width of connecting rod bearing shells, mm:

• nominal size - 27,960-28,044
• repair dimensions - up to 28.30

Inner diameters of bearings, mm:

• indigenous - 62,500-62,519
• connecting rods - 51,600-51,619

Permissible ovality of the inner diameter of bearings, mm — 0.02

Radial clearance of bearings, mm:

• indigenous - 0.031-0.073
• connecting rods - 0.031-0.073
• maximum permissible wear - 0.080

Axial clearance of bearings, mm:

• indigenous - 0.10-0.25
• connecting rods - 0.12-0.26
• maximum permissible wear for main bearings - 0.30
• maximum permissible wear for connecting rod bearings - 0.50

Bearing shells, mm:	indigenous	connecting rod
nominal size	2,25	1,80
1st repair size	2,37	1,92
2nd repair size	2,50	2,05
3rd repair size	2,62	2,17
4th repair size	2,75	2,30

Permissible unevenness of the connecting rod bearing bore to the connecting rod bushing bore in relation to a length of 100 mm is 0.10 mm



The permissible deviation of the parallelism of the axes of the connecting rod bearing bore to the bore of the connecting rod bushing in relation to a length of 100 mm is 0.045 mm

Permissible difference in mass of connecting rods in the engine assembly, g — 5

Connecting rod bolts:

• thread - M9x1
• thread diameter, mm - 7.4
• minimum thread diameter, mm — 7.1

Tightening torque - (30±5) Nm, then tighten by 90-100

Pistons

Nominal piston diameter, mm:

• class A - 88,970-88,976
• class X - more than 88.975-88.983
• class B - more than 88,982-88,988

Piston clearance, mm:

• new - 0.017-0.043
• maximum permissible - 0.12

Permissible difference in piston masses in the engine, g — 4 (maximum permissible — 10)

Piston pin diameter, mm — 26.995—27.000

Piston pin clearance, mm:

• in the connecting rod head bushing - 0.018-0.029
• in the piston - 0.004-0.015

Clearance in piston ring locks, mm:

• top ring - 0.20-0.40
• maximum permissible - 1.5
• middle ring - 0.20-0.40
• maximum permissible - 1.0
• lower ring - 0.20-0.40
• maximum permissible - 1.0

Vertical clearance of piston rings in piston grooves, mm:

• top ring - 0.090-0.120
• maximum permissible - 0.20
• middle ring - 0.050-0.080
• maximum permissible - 0.15
• lower ring - 0.030-0.065
• maximum permissible - 0.1

Cylinder head

Total height of the cylinder head, mm — 142.90—143.10

Maximum permissible deformation of the mating surface, mm:

• longitudinal - 0.08
• transverse - 0.00

Permissible deviation of parallelism of the upper surface to the lower one in the longitudinal direction, mm — 0.10

Permissible depth of surface layer unevenness, mm — 0.017



Depth between the edge of the valve plates and the mating surface of the cylinder head, mm:

• intake valves - +0.17 to -0.23
• exhaust valves - +0.12 to -0.28
• with milled valve seats - 1.0 mm (all valves)

Camshaft

Number of engine bearings:

• four-cylinder (601) - 5
• five-cylinder (602) - 6

Neck diameter, mm — 30.944—30.950

Inner diameter of camshaft bearings, mm:

• depth of unevenness - 0.003-0.006
• permissible ovality - 0.012

Radial clearance of camshaft bearings, mm:

• new - 0.050-0.091
• maximum permissible - 0.11

Axial clearance of camshaft bearings, mm:

• new - 0.07-0.15
• maximum permissible - 0.18

Valves

Plate diameter, mm:

• intake valves - 37.90-38.10
• exhaust valves - 34.90-35.10

Valve seat chamfer angle - 45o+15'

Rod diameter, mm:

• intake valves - 7.970-7.955
• exhaust valves - 8.960-8.945

Length, mm:

• intake valves - 106.50-106.30
• exhaust valves - 106.50-106.30

Saddle width, mm:

• intake valves - 2.5
• exhaust valves - 3.5

Designation:

• intake valves - E 601 02
• exhaust valves - A 601 02

Valve seats

Saddle width, mm:

• intake valves - 2.5
• exhaust valves - 3.5

Valve seat chamfer angle - 45o+15'

Upper compensation angle, degrees - 15

Lower compensation angle, degrees - 60

Processing - Milling or grinding

Valve seat rings

External nominal diameter of valve seat rings, mm:

• intake - 40.100-40.084
• graduation – 37,100—37,084

Width of valve seat rings, mm:

• intake - 33,400-33,600
• graduation – 30,400–30,600

Cylinder head hole diameter, mm:

• intake valves - 40,000-40,016
• exhaust valves - 37,000-37,016

Valve seat height, mm:

• inlet - 6.97-7.00
• graduation – 6.97–7.00

Upper edge of valve seat rings to mating surface of cylinder head, mm:



Publication taken from an online resource (mercedesman.ru)

• intake - 2.37-2.25
• graduation – 2.44–2.25

Valve springs

Designation: Yellow-green or purple-green

External diameter, mm — 33.20

Wire diameter, mm — 4.25

Length in free state, mm — 50.80

Length with load 72-77 kg, mm — 27.00

Maximum permissible wear, mm - 27.00 at 65 kg

Valve guide bushings

Outer diameter of intake valve guide bushings, mm:

• nominal - 14.044-14.051
• repair size - 14.214-14.222

Inner diameter of intake valve guide bushings, mm — 8.000—8.015

Cylinder head bore, mm:

• nominal - 14.030-14.035
• repair size - 14.198-14.203

Tolerance of hot fit in hole, mm:

• nominal - 0.009-0.021
• repair size - 0.011-0.024

Outer diameter of exhaust valve guide bushings, mm:

• nominal - 14.044-14.051
• repair size - 14.214-14.222

Inner diameter of exhaust valve guide bushings, mm — 9.999—9.015

Cylinder head hole diameter, mm:

• nominal - 14.030-14.035
• repair size - 14.198-14.203

Tolerance of hot fit in hole, mm:

• nominal - 0.009-0.021
• repair size - 0.011-0.024

1 Crankshaft with journals I and V (engine 601) or I and IV (engine 602) inserted into prisms when the shaft is turned.

2 Crankshaft with journals I and V (engine 601) or I and IV (engine 602) inserted into prisms when the shaft is turned.