Repair of a gasoline engine 2.0 l car Mercedes Vito 1

Removal and installation the engine
Removal 1. Remove the engine with the accessories attached. Unscrew the axle shaft mounting bolts and push them to the sides. 2. Disconnect the hydraulic pipes from the...

Air filter
Removal 1. Turn off the ignition. 2. Disconnect the air intake pipe 1 from the air filter cover 2 (see figure 2.2). Figure 2.2. Air filter: 1. Air intake pipe, 2. Air...

Cylinder head cover
Removal 1. Turn off the ignition. 2. Remove the air filter. 3. Disconnect the crankcase ventilation tube 4 (see figure 2.3). Figure 2.3. Cylinder head cover: 1. Cylinder...

Intake manifold
Removal 1. Remove the idle speed drive MZZ (see figure 2.4a). Figure 2.4 a. Intake manifold: 1. Air intake pipe, 2. Oil filler pipe, 3. Intermediate flange, 4. Fuel...

Exhaust manifold
Removal 1. Remove the front part of the exhaust system 5 (see figure 2.5). Figure 2.5. Exhaust manifold: 1. Gasket, 2. Exhaust manifold, 3, 4. Nut, 5. Front part of the...

Exhaust gas system
Removal 1. Remove the bottom protective cover. 2. Remove the flange 1 of the front and rear 2 parts of the exhaust system (see figure 2.6). Figure 2.6. Exhaust pipe: 1....

Front cylinder head cover
Removal 1. Remove the air filter. 2. Remove the cylinder head cover 7 (see figure 2.7). Figure 2.7. Front cylinder head cover: 1. Thermostat housing, 2. Bolt with gasket...

Cylinder head
Removal 1. Remove the chain guide 1 from the cylinder head (see figure 2.8). Figure 2.8. Cylinder head: 1. Chain drive guide, 2. Intake manifold, 3. Cooling system pipe,...

Chain drive cover
Removal 1. Remove the subframe together with the engine. 2. Remove the oil filter element 5 (see figure 2.9a). Figure 2.9a. Removing the chain drive cover: 1. Front...

Chain drive tensioner
Removal 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 lever
Removal 1. Remove cover 1 from the cylinder head (see figure 2.12). Figure 2.12. Sliding lever of chain drive: 1. Lid, 2. Chain tensioner, 3. Bolt with gasket, 4....

Chain drive tensioner lever
Removal 1. Remove the cylinder head 1 (see figure 2.13). Figure 2.13. Chain drive tension lever: 1. Cylinder head, 2. Chain drive cover, 3. Tension lever, 4. Guide pin....

Chain tensioner
Removal 1. Remove the cylinder head 1 (see figure 2.14). Figure 2.14. Chain tensioner: 1. Cylinder head, 2. Chain drive cover, 3. Chain tensioner, 4. Guide pin. 2....

Drive chain
Replacement 1. Remove the sliding lever 8 from the cylinder head (see figure 2.15). Figure 2.15. Drive chain: 1. Old chain, 2. New chain, 3. Outer plate, 4. Intermediate...

Camshafts
Removal 1. Remove the sliding lever 3 (see figure 2.24). Figure 2.24. Camshafts: 1. Exhaust camshaft pulley, 2. Drive chain, 3. Sliding lever, 4. Intake camshaft pulley,...

Crankshaft Groove Pulley
Removal 1. Remove the alternator drive belt. 2. Set the piston of the first cylinder to TDC. Key 7 should be facing up. 3. Lock the flywheel with the locking device 18...

Crankshaft rear oil seal cover
Removal 1. Remove the flywheel. 2. Check for leaks. 3. Unscrew bolts 1 and 5 (see figure 2.31). Figure 2.31. Crankshaft rear oil seal cover: 1. Bolt with gasket, 2....

Rear crankshaft oil seal
Replacement 1. Remove the flywheel 1 (see figure 2.32) Figure 2.32. Rear crankshaft oil seal: 1. Flywheel, 2. Seal, 3a, 3b, 3c. Additional tool. 2. Using a screwdriver,...

Crankshaft toothed pulley
Removal 1. Remove the engine together with the attached parts. 2. Remove the oil pump 8 (see figure 2.33). Figure 2.33. Crankshaft toothed pulley: 1. Crankshaft toothed...

Hydraulic compensators — removal, inspection, installation
Removal 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
Removal 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 installed on the...

Valves — removal and installation
Removal 1. Remove the cylinder head cover. 2. Remove all hydraulic compensators using a magnetized puller. 3. Remove the cylinder head (unscrewing the mounting bolts)...

Replacing valve seals
1. Remove the cylinder head. 2. Remove the camshafts. 3. Remove all hydraulic valve lifters. 4. Remove the spark plugs. 5. Set the first piston to TDC and lock the...

Lapping valve seats
1. Remove the valves. 2. Grind the valve seats. Measure the valve seat width and adjust if necessary (angles a and P) (see figure 2.49). Figure 2.49. Valve seat angles....

Pistons — Removal and Installation
Removal 1. Remove the engine. 2. Remove the cylinder head. 3. Remove the oil pan. 4. Remove the connecting rod caps 5 (see figure 2.51). Mark connecting rod 4 and cover...

Piston rings
Removal 1. Remove the piston. 2. Measure the gaps between the piston rings and the groove in the piston (see figure 2.52). Figure 2.52. Measuring the gaps between the...

Checking and replacing connecting rods
Removal 1. Remove the pistons. Examination 2. Check the connecting rods for blue color, scoring and recesses (notches). A connecting rod with blue color, scoring and...

Cylinder block
Wipe the cylinder surface thoroughly and take measurements in positions 1, 2, 3 (see figure 2.56). The cylinder dimensions are given in Table 2.4. Figure 2.56. Checking...

Flywheel — removal and installation
Removal 1. Remove the gearbox. 2. Remove the clutch. 3. Lock the flywheel rotation with the lock. 4. Unscrew bolts 1 using key 6 (see figure 2.57). Figure 2.57....

Crankshaft ball bearing
Removal 1. Remove the gearbox. 2. Remove the clutch. 3. Remove the radial bearing 2 (see figure 2.60). Remove cover 3 together with bearing 2. Figure 2.60. Crankshaft...

Replacing the crankshaft
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...

Checking the axial clearance in the crankshaft main bearings
1. Measure the main bearing journal width and select the required thickness of the end clearance adjusters. Adjusters of the same thickness must be installed on both...

Checking the radial clearance in the crankshaft main bearings
1. Install the support covers without liners. You need to start from the center so that all the lids can be installed in the same position. All lids have identification...

Checking the radial clearance in the connecting rod bearings
1. Install the bearing shell into the connecting rod cap and connecting rod. Tighten the connecting rod cap mounting bolts to a torque of 42 Nm + 90°. 2. Measure the...

Tightening torques of engine components and parts 111.948

Technical characteristics of petrol engines 111.948 and 111.978
General information on petrol engines 111.948 and 111.978 Valve timing system for petrol engines 111.948 and 111.978 Cylinder block for petrol engines 111.948 and...

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Vito 1 (1996-2003)