Repair of a gasoline engine 2.0 l car Mercedes Vito 1
Removal and installation of the engine Removing 1. Remove the engine with attached accessories. Unscrew the bolts securing the axle shafts and push them out to the sides. 2. Disconnect the hydraulic tubes...
Air filter Removing 1. Turn off the ignition. 2. Disconnect the air inlet pipe 1 from the air filter cover 2 (see fig. 2.2). Pic. 2.2. Air filter: 1. Air inlet pipe, 2. Air filter...
Cylinder head cover Removing 1. Turn off the ignition. 2. Remove the air filter. 3. Disconnect the crankcase ventilation tube 4 (see fig. 2.3). Pic. 2.3. Cylinder head cover: 1. Cylinder...
Intake manifold Removing 1. Remove the idling drive MZZ (see fig. 2.4a). Pic. 2.4 a. Intake manifold: 1. Air inlet pipe, 2. Oil filler pipe, 3. Intermediate flange, 4. Fuel lines, 5....
An exhaust manifold Removing 1. Remove the front part of the exhaust system 5 (see fig. 2.5). Pic. 2.5. An exhaust manifold: 1. Gasket, 2. Exhaust manifold, 3, 4. Nut, 5. Front exhaust...
Exhaust gas exhaust system Removing 1. Remove the lower protective cover. 2. Remove the flange 1 of the front and rear of the 2 parts of the exhaust system (see fig. 2.6). Pic. 2.6. Outlet pipe:...
Front cylinder head cover Removing 1. Remove the air filter. 2. Remove the cylinder head cover 7 (see fig. 2.7). Pic. 2.7. Front cylinder head cover: 1. Thermostat housing, 2. Bolt with gasket M8...
Cylinder head Removing 1. Remove the chain drive guide 1 from the cylinder head (see fig.2.8). Pic. 2.8. Cylinder head: 1. Chain guide, 2. intake manifold, 3. Pipe of the cooling...
Chain cover Removing 1. Remove the subframe along with the engine. 2. Remove the oil filter element 5 (see fig. 2.9a). Pic. 2.9a. Removing the chain drive cover: 1. Front cylinder...
Chain drive tensioner Removing 1. Disconnect the negative cable from the battery. 2. Remove the generator and secure it to the side without disconnecting the wiring. 3. Remove tensioner 13...
Sliding chain drive arm Removing 1. Remove cover 1 from the cylinder head (see fig. 2.12). Pic. 2.12. Chain Drive Sliding Arm: 1. Cover, 2. Chain tensioner, 3. Bolt with gasket, 4. Sliding...
Drive chain Replacement 1. Remove the sliding lever 8 from the cylinder head (see fig. 2.15). Pic. 2.15. Drive chain: 1. Old chain, 2. New chain, 3. Outer plate, 4. Intermediate...
Crankshaft groove pulley Removing 1. Remove the alternator drive belt. 2. Set the piston of the first cylinder to TDC. Key 7 should be facing up. 3. Block the flywheel with the blocking device...
Cover of a back epiploon of a cranked shaft Removing 1. Remove the flywheel. 2. Check for leaks. 3. Remove bolts 1 and 5 (see fig. 2.31). Pic. 2.31. Crankshaft rear oil seal cover: 1. Bolt with gasket, 2. Oil...
Rear crankshaft oil seal Replacement 1. Remove flywheel 1 (see fig. 2.32) Pic. 2.32. Rear crankshaft oil seal: 1. Flywheel, 2. Oil seal, 3a, 3b, 3c. Additional tool. 2. Use a screwdriver to...
Crankshaft pulley Removing 1. Remove the engine with attached parts. 2. Remove the oil pump 8 (see fig. 2.33). Pic. 2.33. Crankshaft Toothed Pulley: 1. crankshaft pulley, 2. Key, 3. Oil...
Hydraulic lifters — removal, inspection, installation Removing 1. Warm up the engine to an operating temperature of 80°C. Check the engine oil level and correct it. 2. Remove the cylinder head cover 1 and, rotating the...
Valve springs and valve stem retainers Removing 1. Insert adapter 1 into the spark plug hole and apply air pressure to the combustion chamber (minimum 5 bar), only if the cylinder head is mounted on the...
Valves — removal and installation Removing 1. Remove the cylinder head cover. 2. Remove all hydraulic lifters using a magnetized puller. 3. Remove the cylinder head (loosening the fixing screws) and...
Replacing valve seals 1. Remove the cylinder head. 2. Remove camshafts. 3. Remove all valve lifters. 4. Remove the spark plugs. 5. Set the first piston to TDC and block the crankshaft with...
Lapping of valve seats 1. Remove valves. 2. Lap in the valve seats. Measure the width of the valve seats, correct if necessary (angles a and p) (see fig. 2.49). Pic. 2.49. Valve seat angles....
Pistons — removal and installation Removing 1. Remove the engine. 2. Remove the cylinder head. 3. Remove the oil pan. 4. Remove connecting rod caps 5 (see fig. 2.51). Mark connecting rod 4 and cap 5...
Piston rings Removing 1. Remove the piston. 2. Measure the gaps between the piston rings and the groove in the piston (see fig. 2.52). Pic. 2.52. Measuring the clearance between...
Checking and replacing connecting rods Removing 1. Remove the pistons. Examination 2. Check connecting rods for blue, nicks and gouges (notches). Connecting rod with blue color, notches and dimples (notches)...
Cylinder block Wipe the surface of the cylinders thoroughly and take measurements in positions 1, 2, 3 (see fig.2.56). The dimensions of the cylinders are given in table 2.4. Pic....
Flywheel — removal and installation Removing 1. Remove the gearbox. 2. Remove the clutch. 3. Block the rotation of the flywheel with the lock. 4. Remove bolts 1 using wrench 6 (see fig.2.57). Pic. 2.57....
Crankshaft ball bearing Removing 1. Remove the gearbox. 2. Remove the clutch. 3. Remove radial bearing 2 (see fig.2.60). Remove cover 3 together with bearing 2. Pic. 2.60. Crankshaft ball...
Crankshaft replacement 1. Remove the engine. 2. Remove the cylinder head. 3. Remove the camshaft chain drive cover. 4. Remove the cover from the rear oil seal. 5. Remove the pistons. 6. Remove...
Specifications for petrol engines 111.948 and 111.978 General information for petrol engines 111.948 and 111.978 Gas distribution system for petrol engines 111.948 and 111.978 Cylinder block for petrol engines 111.948 and...