Mercedes-Benz 603 Manuals

Manuals and User Guides for Mercedes-Benz 603. We have 1 Mercedes-Benz 603 manual available for free PDF download: Service Manual

Mercedes-Benz 603 Service Manual

Mercedes-Benz 603 Service Manual (325 pages)

Diesel Engines

Brand: Mercedes-Benz | Category: Engine | Size: 10 MB

Table of Contents

Index
4
General, Technical Data
5
General Technical Data
6
Location of Specific Repair Instructions
7
Installation of Crankshaft
7
Special Instructions
7
Vehicle Identification Number Locations
9
Technical Data
11
D Turbo
13
SDL Turbo
14
Crankcase and Cylinder Head
15
Table of Contents
16
Crankcase and Cylinder Head
16
Engine and Model Survey
17
Opening Hood, Setting Vertical Warnings
19
Moving Hood into Vertical Position
20
Testing Compression Pressure
23
Checking Cylinders for Leaks
28
- Permissible Pressure Loss
  29
- Commercially Available Tools
  29
Evaluating Cylinder Bores
34
Exhaust System
36
Removal and Installation of Engine (Oil Capacity)
36
- Engine Oil Capacities with Oil Dipstick Code
  40
- Self-Made Tools
  42
- Models 124 and
  42
- Naturally Aspirated Engines
  43
- Turbo-Engines
  43
- Installation Note
  44
- Vehicles with Air Conditioning
  44
- Vehicles with Automatic Transmission
  49
- Standard Version
  54
Crankcase Ventilation - Function
54
Measuring, Boring and Honing Cylinder Bores
60
Boring, Honing and Replacement of Cylinder Sleeves
64
- Items
  65
- Dimensions for Basic Bore in Block
  65
Planing Crankcase Parting Surface
68
Removal and Installation of Steel Balls in Main Oil Duct
70
- Replacement Parts for Steel Balls
  71
- Sealant for Replacement of Rear Steel Ball
  71
- Knocking out
  71
- Inserting
  71
- Replacing Steel Ball with Plug
  72
Replacement of Freeze Plugs in Crankcase
73
Removal and Installation of Thina Cover
76
Removal and Installation of End Cover
86
Removal and Installation of Oil Pan
90
Repair Notes for Cylinder Heads and Cylinder Head Gaskets
98
Refinishing Prechamber Sealing Surface
106
- Cylinder Head Removed
  109
- Cylinder Head Installed
  109
Removal and Installation of Cylinder Head
112
Facing Cylinder Head Mating Surface
134
Boring out Camshaft Bearing Bores (Repair Stage)
136
Data, Camshaft Bearings
137
Pressure-Testing Cylinder Head
138
- Crankshaft Assembly
  140
- Crankshaft Assembly
  141
- Checking, Replacing and Tightening Connecting Rod Bolts
  142
- Reconditioning and Squaririg Connecting Rods
  144
- Note on Connecting Rod Versions
  146
- Overheated Connecting Rods
  146
- Connecting Rod Width
  146
- Removal and Installation of Pistons
  152
- Piston Projecting Length
  154
- Test Values
  154
- Modifications to Pistons
  158
- Pistons with Angular Channel
  162
- Piston Crown
  162
- Checking and Reconditioning Crankshaft
  164
- Hardening
  169
- Crack Test
  170
- Hardness Test
  170
- Checking Hardening Results
  171
- Corrosion Protection
  171
- Installation of Crankshaft and Connecting Rod Bearings
  172
- Association of Crankshaft Bearing Shells and Crankcases
  180
- Thrust Washer Sets
  181
- Tightening Torques and Rotation Angle
  181
- Replacing Front Crankshaft Radial Sealing Ring
  192
- Replacing Rear Crankshaft Radial Sealing Ring
  195
- Removal and Installation of Crankshaft Pulley and Hub
  200
- Checking and Correcting Adjustment of TDC Sensor
  204
- Removal and Installation of Crankshaft Sprocket
  210
- Removal and Installation of Flywheel and Driven Plate
  215
- Refinishing Flywheel
  223
- Replacing Ring Gear
  225
- Engine Timing, Valvetrain
  227
- Checking Camshaft Timing
  238
- Removal and Installation of Camshaft
  241
- With Self-Levelling Suspension
  250
- Removal and Installation of Valve Springs
  251
- Checking Valve Springs
  257
- Replacing of Valve Stem Seals
  258
- Checking and Machining Valves
  262
- Replacing Valve Seat Inserts
  271
- Machining Valve Seats
  275
- Removing and Installing Chain Tensioner
  279
- Filling Chain Tensioner with Engine Oil
  280
- Renewal of Timing Chain
  283
- Removal and Installation of Tensloner Rail
  290
- Removal and Installation of Guide Rail
  293
- Removal and Installation of Guide Rail in Cylinder Head
  293
- Removal and Installation of Guide Rail in Timing Case
  297
- Removal and Installation of Pressure Oil Pump Drive
  299
- Intake System - Air Filter, Turbocharger
  302
- Function of Turbocharger
  303
- Garrett TB 03 with Air Recirculation Valve
  304
- KKK-K24 with Air Recirculation Valve
  304
- Functional Diagram Turbocharger KKK K24
  305
- Air Recirculation Valve
  307
- Boost Pressure Control Valve (KKK)
  308
- Idle and Lower Part Load
  309
- Upper Part Load and Full Load
  309
- Testing Turbocharger Boost Pressure
  310
- Removal and Installation of Turbocharger
  312
- Function of Engine Overload Protectiom - Turbodiesel
  317
- Testing Engine Overload Protection
  319
- Removal and Installation of Air Cleaner
  321
- Repair Instruction
  324

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