Table Of Contents - Mercedes-Benz 603 Service Manual

Table of Contents

Index4
General, Technical Data5
General Technical Data6
Location Of Specific Repair Instructions7
Installation Of Crankshaft7
Special Instructions7
Vehicle Identification Number Locations9
Technical Data11
D Turbo13
Sdl Turbo14
Crankcase And Cylinder Head15
Table Of Contents16
Engine And Model Survey17
Opening Hood, Setting Vertical Warnings19
Moving Hood Into Vertical Position20
Testing Compression Pressure23
Test Values With Engine At Operating Temperature24
Tightening Torques24
Special Tools25
Checking Cylinders For Leaks28
Permissible Pressure Loss29
Commercially Available Tools29
Evaluating Cylinder Bores34
Removal And Installation Of Engine (Oil Capacity)36
Exhaust System36
Engine Oil Capacities With Oil Dipstick Code40
Self-Made Tools42
Models 124 And42
Naturally Aspirated Engines43
Turbo-Engines43
Installation Note44
Vehicles With Air Conditioning44
Vehicles With Automatic Transmission49
Crankcase Ventilation - Function54
Standard Version54
Crankcase Ventilation On Engines With Exhaust Gas Recirculation57
Pressure Control Valve58
Production Breakpoint59
Measuring, Boring And Honing Cylinder Bores60
Boring And Honing61
Maximum Permissible Wear For Cylinder Bores62
Machining Tolerances62
Introduction Of Engines Without Cylinder Sleeves63
Commercially Available Tool63
Boring, Honing And Replacement Of Cylinder Sleeves64
Items64
Dimensions For Basic Bore In Block65
Planing Crankcase Parting Surface68
Removal And Installation Of Steel Balls In Main Oil Duct70
Replacement Parts For Steel Balls71
Sealant For Replacement Of Rear Steel Ball71
Knocking Out71
Inserting71
Replacing Steel Ball With Plug72
Replacement Of Freeze Plugs In Crankcase73
Removal And Installation Of Thina Cover76
Removal And Installation Of End Cover86
Removal And Installation Of Oil Pan90
Remove, Install, 25 Nm (Item91
Oil Capacities With Oil Dipstick Code92
Model 201 (Up To93
Oil Pan With Attached Side Section95
Repair Notes For Cylinder Heads And Cylinder Head Gaskets98
Cylinder Head Gasket With Viton Sealing Ring99
Modifications In Area Of Timing Chain Case100
Production Change For Protection Against Cracks In Water Jacket100
Cylinder Head Gasket For Improved Sealing101
Improvement To Passage Supports In Water Jacket103
Reinforcements At Valve Tappet Guides And Exhaust Passages104
Combustion Chamber Recess105
Refinishing Prechamber Sealing Surface106
Cylinder Head Removed109
Cylinder Head Installed109
Removal And Installation Of Cylinder Head112
Tightening Torques And Rotation Angles For Cylinder Head Bolts123
Removal And Installation Of Prechambers126
Prechamber Survey127
Differentiation, Vertical And Angular Injection128
Differentiation, Combustion Neck Diameter129
Differentiation, Combustion Bores130
Combustion Bore Diameters (Dia. In Mm)130
Angular Injection132
Facing Cylinder Head Mating Surface134
Boring Out Camshaft Bearing Bores (Repair Stage)136
Data, Camshaft Bearings137
Pressure-Testing Cylinder Head138
Crankshaft Assembly140
Checking, Replacing And Tightening Connecting Rod Bolts142
Reconditioning And Squaririg Connecting Rods144
Note On Connecting Rod Versions146
Overheated Connecting Rods146
Connecting Rod Width146
Removal And Installation Of Pistons152
Piston Projecting Length154
Test Values154
Modifications To Pistons158
Pistons With Angular Channel162
Piston Crown162
Checking And Reconditioning Crankshaft164
Hardening169
Crack Test170
Hardness Test170
Checking Hardening Results171
Corrosion Protection171
Installation Of Crankshaft And Connecting Rod Bearings172
Association Of Crankshaft Bearing Shells And Crankcases180
Thrust Washer Sets181
Tightening Torques And Rotation Angle181
Replacing Front Crankshaft Radial Sealing Ring192
Replacing Rear Crankshaft Radial Sealing Ring195
Removal And Installation Of Crankshaft Pulley And Hub200
Checking And Correcting Adjustment Of Tdc Sensor204
Removal And Installation Of Crankshaft Sprocket210
Removal And Installation Of Flywheel And Driven Plate215
Refinishing Flywheel223
Replacing Ring Gear225
Engine Timing, Valvetrain227
Checking Camshaft Timing238
Removal And Installation Of Camshaft241
With Self-Levelling Suspension250
Removal And Installation Of Valve Springs251
Checking Valve Springs257
Replacing Of Valve Stem Seals258
Checking And Machining Valves262
Replacing Valve Seat Inserts271
Machining Valve Seats275
Removing And Installing Chain Tensioner279
Filling Chain Tensioner With Engine Oil280
Renewal Of Timing Chain283
Removal And Installation Of Tensloner Rail290
Removal And Installation Of Guide Rail293
Removal And Installation Of Guide Rail In Cylinder Head293
Removal And Installation Of Guide Rail In Timing Case297
Removal And Installation Of Pressure Oil Pump Drive299
Intake System - Air Filter, Turbocharger302
Function Of Turbocharger303
Garrett Tb 03 With Air Recirculation Valve304
Kkk-K24 With Air Recirculation Valve304
Functional Diagram Turbocharger Kkk K24305
Air Recirculation Valve307
Boost Pressure Control Valve (Kkk)308
Idle And Lower Part Load309
Upper Part Load And Full Load309
Testing Turbocharger Boost Pressure310
Removal And Installation Of Turbocharger312
Function Of Engine Overload Protectiom - Turbodiesel317
Testing Engine Overload Protection319
Removal And Installation Of Air Cleaner321
Repair Instruction324