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Engine
603
Service manual
Mercedes-Benz 603 Service Manual
Diesel engines
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Table Of Contents
325
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of
325
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325
Contents
Table of Contents
Bookmarks
Table of Contents
Index
General, Technical Data
General Technical Data
Location of Specific Repair Instructions
Installation of Crankshaft
Special Instructions
Vehicle Identification Number Locations
Technical Data
D Turbo
SDL Turbo
Crankcase and Cylinder Head
Table of Contents
Crankcase and Cylinder Head
Engine and Model Survey
Opening Hood, Setting Vertical Warnings
Moving Hood into Vertical Position
Testing Compression Pressure
Test Values with Engine at Operating Temperature
Tightening Torques
Special Tools
Checking Cylinders for Leaks
Permissible Pressure Loss
Commercially Available Tools
Evaluating Cylinder Bores
Exhaust System
Removal and Installation of Engine (Oil Capacity)
Engine Oil Capacities with Oil Dipstick Code
Self-Made Tools
Models 124 and
Naturally Aspirated Engines
Turbo-Engines
Installation Note
Vehicles with Air Conditioning
Vehicles with Automatic Transmission
Standard Version
Crankcase Ventilation - Function
Crankcase Ventilation on Engines with Exhaust Gas Recirculation
Pressure Control Valve
Production Breakpoint
Measuring, Boring and Honing Cylinder Bores
Boring and Honing
Maximum Permissible Wear for Cylinder Bores
Machining Tolerances
Introduction of Engines Without Cylinder Sleeves
Commercially Available Tool
Items
Boring, Honing and Replacement of Cylinder Sleeves
Items
Dimensions for Basic Bore in Block
Planing Crankcase Parting Surface
Removal and Installation of Steel Balls in Main Oil Duct
Replacement Parts for Steel Balls
Sealant for Replacement of Rear Steel Ball
Knocking out
Inserting
Replacing Steel Ball with Plug
Replacement of Freeze Plugs in Crankcase
Removal and Installation of Thina Cover
Removal and Installation of End Cover
Removal and Installation of Oil Pan
Remove, Install, 25 Nm (Item
Oil Capacities with Oil Dipstick Code
Model 201 (up to
Oil Pan with Attached Side Section
Repair Notes for Cylinder Heads and Cylinder Head Gaskets
Cylinder Head Gasket with Viton Sealing Ring
Production Change for Protection against Cracks in Water Jacket
Modifications in Area of Timing Chain Case
Cylinder Head Gasket for Improved Sealing
Improvement to Passage Supports in Water Jacket
Reinforcements at Valve Tappet Guides and Exhaust Passages
Combustion Chamber Recess
Refinishing Prechamber Sealing Surface
Cylinder Head Removed
Cylinder Head Installed
Removal and Installation of Cylinder Head
Tightening Torques and Rotation Angles for Cylinder Head Bolts
Removal and Installation of Prechambers
Prechamber Survey
Differentiation, Vertical and Angular Injection
Differentiation, Combustion Neck Diameter
Differentiation, Combustion Bores
Combustion Bore Diameters (Dia. in MM)
Angular Injection
Facing Cylinder Head Mating Surface
Boring out Camshaft Bearing Bores (Repair Stage)
Data, Camshaft Bearings
Pressure-Testing Cylinder Head
Crankshaft Assembly
Crankshaft Assembly
Checking, Replacing and Tightening Connecting Rod Bolts
Reconditioning and Squaririg Connecting Rods
Note on Connecting Rod Versions
Overheated Connecting Rods
Connecting Rod Width
Removal and Installation of Pistons
Piston Projecting Length
Test Values
Modifications to Pistons
Pistons with Angular Channel
Piston Crown
Checking and Reconditioning Crankshaft
Hardening
Crack Test
Hardness Test
Checking Hardening Results
Corrosion Protection
Installation of Crankshaft and Connecting Rod Bearings
Association of Crankshaft Bearing Shells and Crankcases
Thrust Washer Sets
Tightening Torques and Rotation Angle
Replacing Front Crankshaft Radial Sealing Ring
Replacing Rear Crankshaft Radial Sealing Ring
Removal and Installation of Crankshaft Pulley and Hub
Checking and Correcting Adjustment of TDC Sensor
Removal and Installation of Crankshaft Sprocket
Removal and Installation of Flywheel and Driven Plate
Refinishing Flywheel
Replacing Ring Gear
Engine Timing, Valvetrain
Checking Camshaft Timing
Removal and Installation of Camshaft
With Self-Levelling Suspension
Removal and Installation of Valve Springs
Checking Valve Springs
Replacing of Valve Stem Seals
Checking and Machining Valves
Replacing Valve Seat Inserts
Machining Valve Seats
Removing and Installing Chain Tensioner
Filling Chain Tensioner with Engine Oil
Renewal of Timing Chain
Removal and Installation of Tensloner Rail
Removal and Installation of Guide Rail
Removal and Installation of Guide Rail in Cylinder Head
Removal and Installation of Guide Rail in Timing Case
Removal and Installation of Pressure Oil Pump Drive
Intake System - Air Filter, Turbocharger
Function of Turbocharger
Garrett TB 03 with Air Recirculation Valve
KKK-K24 with Air Recirculation Valve
Functional Diagram Turbocharger KKK K24
Air Recirculation Valve
Boost Pressure Control Valve (KKK)
Idle and Lower Part Load
Upper Part Load and Full Load
Testing Turbocharger Boost Pressure
Removal and Installation of Turbocharger
Function of Engine Overload Protectiom - Turbodiesel
Testing Engine Overload Protection
Removal and Installation of Air Cleaner
Repair Instruction
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General, Technical Data
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Crankcase and Cylinder Head
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Mercedes-Benz
Mercedes-Benz of North America, Inc.
Montvale, NJ 07645
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