Mercedes-Benz 603 User manual

Mercedes-Benz
Mercedes-Benz of North America, Inc. . Montvale, NJ 07645

Q Mercedes-Benz of North America, Inc., 1991
All rights reserved. Reproduction by any means, elec-
tronic or mechanical, including photocopying, record-
ing, or by any information storage and retrieval system
or translation in whole or part is not permitted without
written authorization from the publisher.
Published by Mercedes-Benz of North America, Inc.
Printed in U.S.A.
Part number LZ S-2517-091

This service manual is the product of existing technical publications. Special care has been taken
to provide accurate information on removal, disassembly, inspection, installation, and adjustment
procedures, together with the necessary technical data for the particular job.
The material in this manual is divided according to the Mercedes-Benz Component Group System
as outlined on the GROUP INDEX page. This page will quickly direct the reader to the Major
Component Group. Each Major Component Group begins with a JOB INDEX listing all jobs within
that group.
Mercedes-Benz of North America, Inc. recommends that repairs to, and maintenance of
Mercedes-Benz automobiles be performed by trained Mercedes-Benz personnel at authorized
Mercedes-Benz dealerships.
The information contained in this special publication is ordinarily issued by Mercedes-Benz of
North America, Inc., in conjunction with supplementary service literature and special tools supplied
only to its authorized dealers. The repair and maintenance procedures outlined herein are
intended for use by trained Mercedes-Benz service and dealership personnel. This manual
can also be useful for Mercedes-Benz owners in diagnosing vehicle systems and performing
repairs. Supplementary service literature will not be provided with this publication, but may be
contained in reprints of this service manual.
Please note that this manual has been compiled from various sources, some of which cover
models other than the subject of this book. Always refer to the engine and vehicle identification
table for model and component information.
Special tools required in performing certain service jobs are identified in the manual and are
recommended for use. Any part numbers given are only used for identification and easier
differentiation between individual components, and are not intended for ordering purposes.
If your Mercedes-Benz model differs from the specifications contained in the manual you select,
consult your authorized Mercedes-Benz dealer.
All procedures, illustrations and specifications contained in this manual were based on the latest
information available at the time of publication. All rights are reserved to make production, design
and specification changes at any time, without notice and without obligation to give notice. Any
such changes will not be contained in this manual.
Caution!
The proper performance of service and repair procedures is essential for both the safety of the
mechanic and the safe and efficient operation of the vehicle. The use of incorrect service
procedures and tools may greatly increase the risk of personal injury and render the vehicle
unsafe. The procedures in this manual are described in such a manner that the service may be
performed safely and accurately.
However, it is a general assumption that the reader is familiar with basic automotive repair
procedures and Mercedes-Benz vehicles. You should not attempt to use this manual if this is not
the case.
Mercedes-Benz of North America, Inc. assumes no liability for any damage to person or property
caused by the utilization of this publication to effect maintenance or repair work on Mercedes-Benz
automobiles.
MERCEDES-BENZ OF NORTH AMERICA, INC.
Service and Parts Literature

Group Index
General, Technical Data
00
Crankcase and Cylinder head
01
Crankshaft Assembly
03
ngine Timing, Valvetrain
05
Diesel Injection System 07.1
Air Intake System - Air Filter, Turbocharger
09
elt Drive
13
Intake and Exhaust Manifolds, mission Control System
14
Electrical System, Preglow
15
ngine Lubrication System 18
ngine Cooling System 20
Engine Suspension
22
Accelerator Control
30
Fuel Tank and Lines
47
Exhaust System
49

General, technical data 00

General, technical data
00
Job No.
Instructions for use of service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
- 005
Engine and vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 010
Vehicle identification number locations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 015
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 020

Instructions for use of servic
00-005
Complete Service Manual coverage for late
model year Mercedes-Benz vehicles requires
four individual manuals:
Service Manual, Engine
Service Manual, Chassis and Body
Service Manual, Automatic Climate Control
Electrical Troubleshooting Manual
Throughout these manuals, the vehicles are
identified by their chassis and engine numbers.
These numbers are made up of the first six digits
of the respective serial number. For the actual
location of chassis and engine numbers, see
page 00-015/l. In cases where the repair
instructions apply to all versions, only the first
three digits of the respective number are
referenced.
For example, chassis 124 applies to all 124
models. However, chassis 124.128 would apply
only to model 3000 2.5 Turbo.
Location of specific repair instructions
First locate the Group No. in the Group Index.
Individual groups are separated by an easily
visible dividing page, which is followed by the job
index page. The exact job required is found in
the job index. The initial page of a typical job
description appears as follows:
03-320 Installation of Crankshaft
Job Title appears on
same line as Group
No.
03.9-320/l
Technical data, tightening torques and tools are
listed at the beginning of each job.
All dimensions are in metric units unless
otherwise indicated. Any part numbers given are
only used for identification and differentiation
between individual components, and are not
intended for ordering purposes.
Special Instructions
AWarning Appears throughout service instructions indicating the possiblity of personal injury
if procedures are not followed.
Caution! Indicates possible equipment or vehicle damage if procedures are not followed.
Note Provides helpful information for the described procedure.
Installation note Provides detailed information during assembly.

00
ngine and vehicle identification
Model
I
Sales designation
I
Engine
201.126 190 D 2.5 602.911
126.125 300 SDL Turbo (Federal) 603.961
126.125 300 SDL Turbo (California) 603.961
201.126 190 D 2.5 602.911
201.128 190 D 2.5 Turbo (Federal) 602.961
124.133 300 D Turbo 603.960
124.193 300TD Turbo 603.960
126.125 300 SDL Turbo 603.961
201.126
I
190 D 2.5
(Federal)
I
602.911
201.126
I
190 D 2.5
(Federal)
I
602.911
124.128 300 D 2.5 Turbo (Federal) 602.962
126.135 350 SDL Turbo (Federal) 603.970
124.128 300 D 2.5 Turbo (Federal) 602.962
126.134 350 SD Turbo (Federal) 603.970
126.135 350 SDL Turbo (Federal) 603.970
00 - 010/l

hick identification number locations
00
Model 201
When ordering spare parts, please
specify chassrs and engine numbers.
Model 124
When ordering spare parts, please
specify chassis and engine numbers.
1 Certrfication Tag (left door pillar)
2 Identification Tag (left windshield post)
3 Vehicle Identificatron No.
4 Engine No.
5 Body No. and Paintwork No.
6 InformatIon Tag
California version
Vacuum line routing for emission
control system
7 Emrsslon Control Tag
1 Certification Tag (left door pillar)
2 Identification Tag (left window post)
3 Vehicle Idenkficatron No.
4 Engine No.
5 Body No. and Paintwork No.
6 lnformatron Tag
California version
Vacuum line routing for emission
control system
7 Emission Control Tag
8 Emrssron Control Tag
Catalyst Information
00 - 015/l

Vehicle identification number locations
Model 124 f
When ordering spare parts, please
specify chassrs and engine numbers.
1 Certrfication Tag (left door prllar)
2 ldentrftcatron Tag (left wrndshreld post)
3 Vehicle ldentifrcatron No.
4 Engine No.
5 Body No. and Paintwork No.
6 lnformatron Tag
Caltfornia version
Vacuum line routing for emrssron
control system
7 Emrssron Control Tag
Model 126
When ordenng spare parts, please
specrfy chassis and engine numbers.
Certification Tag (left door pillar)
ldentlficatron Tag (left wrndow post)
Vehicle ldentrfication No.
Engrne No.
Body No. and PaMwork No.
Emrssron Control Tag
lnformatron Tag
California version
Vacuum lrne routing
for emrssron control system

Technical data
Diesel engines
axlmum spee
G(multi-component, 6 (multi-component,
pump, thermosta pump, thermosta
with bypass line, fan with bypass line, fan
with visco fan clutch, with visco fan clutch,
4600 t 50
120/4600
pump, thermosta pump, thermosta
with bypass line, fan
with bypass line, fan
with visco fan clutch,
00 - 020/l

00 Technical data
Gasoline engines
Model
i 126.125 1126.125 1 126.134 I.135
4-cycle diesel, MB 4-cycle diesel, MB
4-cycle diesel, MB
arranqemen
Bore/stroke mm
I
87.0184.0
I
87.Oi84.0
I
89.0192.4
Total effective
piston
displacement cc
2996 2996
Compression
ratio
Engine output
(SAE)kW/rpm
net bhp/rpm
11 O/4600 1071’4600
14814600 143) 4600
Maximum torque
Nmirpm
net lb-ft./rpm
27312400
20112400
265/2400
195/2400
3 1 o/2000
22812000
Crankshaft
bearings 7 (multi-component, 7 (multi-component, 7 (multi-component, anti-friction bearings) anti-friction bearings) anti-friction bearings)
Valve
arrangement
Overhead Overhead Overhead
Camshaft
arrangment 1 overhead camshaft 1 overhead camshaft 1 overhead camshaft
Cooling Coolant circulating
pump, thermostat
with bypass line, fan
with visco fan clutch,
finned tube radiator
Coolant circulating
pump, thermostat
with bypass line, fan
with visco fan clutch,
finned tube radiator
Coolant circulating
pump, thermostat
with bypass line, fan
with visco fan clutch,
finned tube radiator
Lubrication Pressure lubrication Pressure lubrication
via gear type pump via gear type pump
Combination full flow Combination full flow
1 and bypass filter 1 and bypass filter
Pressure lubrication
via gear type pump
Combination full flow
and bypass filter
Oil filter
Air cleaner Dry paper cartridge Dry paper cartridge Dry paper cartridge
00 - 02012

Technical data
cm
Filling capacities
Model 201.126
I
201.128
(Federal)
124.128
(Federal)
I
124.133,
I
126.125
124.193
(Federal)
Sales designation 190 D 2.5 190 D 2.5
Turbo
300 D 2.5
Turbo
300 D Turbo 300 SDL Turbo
300 TD Turbo
Engine 602.911
-r-m ~
602.961
602.962
I
603.960
I ~~~
603.961
Fuel tank/reserve
aoorox. I
7019.0
I
7019.0
I
90112.5
72/l 0.0
8.2
I
9.2
I
9.2
Engine oil initial filling
approx. I
During oil and filter
change approx. I
Marks on dipstick
max./min. approx. I
Oil-to-air cooler with
hoses
Cooling system with
heater
approx. I
7.0
I
8.0
I
8.0
6.Oi4.0
I
6.5i4.5
I
6.514.5
5.513.5
6.0/4.0
0.7
I
1.1
I
0.65
8.08.0
9.0 10.0 12.5
Filling capacities (continued)
~350 SDL Turbo
603.970
90/l 2.5
603.961 Engine
Fuel tan k/reserve
approx. I 90/l
2.5
Engine oil initial filling
approx. I
During oil and filter
change approx. I
Marks on dipstick
max./min. approx. I
Oil-to-air cooler with
hoses
8.0 7.5
6.514.5 6.514.5
0.65 0.65
Cooling system with
heater
aoorox. I
00 - 02013

00
Technical data
Electrical system
Model
201.128
(Federal)
124.128
(Federal)
124.133,
124.193 126.125
(Federal)
201.126
190 02.5
Turbo
300 D 2.5
Turbo
300 0Turbo
300 TD Turbo
Sales designation
300 SDL Turbo
602.962 Engine
602.911 602.961 603.960 603.961
Battery
Voltage
Capacity 12v 62 Ah
(M.Y. 1986)
92 Ah (from
M. Y. 1987)
12 v
92 Ah
12v12v
92 Ah
12v
92 Ah
12V
2.2 kW
12v
1.5 kW
Starter Bosch 12 v
2.2 kW
14V70A 14V70A 14v 80A 14V70A 14V70A
Alternator
Electrical system
Model
I
126.125
(California)
126.134.1.135
(Federal)
Sales designation 300SDL Turbo 350 SD Turbo
350 SDL Turbo
603.970
Battery
Voltage
Capacity 12v
62 Ah
12v
62 Ah
Starter Bosch 12 v 12v
2.2 kW 1.7 kW
Alternator
I
14V70A
I
14v 80A
00 - 020/4

Crankcase and Cylinder Head 01

01
Crankcase and cylinder head
Job No.
Engine and model survey ................................................
01 - 001
Removal and installation of noise capsule at bottom of engine compartment ............
01 - 006
Opening hood, setting vertical warnings ......................................01
- 008
Testing compression pressure
.............................................
- 010
Checking cylinders for leaks
...............................................
- 015
Evaluating cylinder bores
................................................. - 020
Removal and installation of engine (oil capacity)
................................. - 030
Crankcase ventilation - Function
............................................
- 040
Measuring, boring and honing cylinder bores
................................... - 110
Boring, honing and replacement of cylinder sleeves
..............................
- 115
Planing crankcase parting surface
........................................... - 120
Removal and Installation of steel balls in main oil duct
............................ - 130
Replacement of freeze plugs in crankcase
.....................................
- 140
Removal and installation of timing cover
...................................... -210
Removal and installation of end cover ........................................ - 222
Removal and installation of oil pan .......................................... - 310
Repair notes for cylinder heads and cylinder head gaskets
......................... - 400
Refinishing prechamber sealing surface
....................................... - 410
Removal and installation of cylinder head
.....................................
- 415
Removal and installation of prechambers ......................................
- 417
Facing cylinder head mating surface
.........................................
- 418
Boring out camshaft bearing bores (repair stage)
................................ - 419
Pressure-testing cylinder head
............................................. - 420
01/l

01-001
Engine and r?lodel suwey
output
(SAE)
Kw(hp)/rpm
Torque (SAE)
Nm/rpm
(net lb.-fthpm)
No.
Cyl.
Displacement
(cm?
Bore I
Stroke
Engine
version
Vehrcle
model Sales
&
desrgnation
190 D 2.5
I
22.0
84.0 187.0
201.126
165 12800
(12212800)
22812400
(16812400)
223 / 2400
(164 / 2400)
265 12400
(195 / 2400)
6914600
(93 14600)
92 14600
(12314600)
90 14600
(120/4600)
2497
602.911
84.0 187.0
602.961
Federal 5
201.128
84.0 187.0
602.962
Federal 5
124.128
2996
84.0 187.0
107/4600
(14314600)
603.960
124.133
124.193
6
300 TD
Turbo
87.0 / 84.0 110/4600
(148 /4600)
273 /2400
(201 / 2400)
603.961
Federal
126.125 6
2996
87.0 184.0 107 /4600
(143/4600) 265
12400
(195 12400)
603.961 126.125
6
2996
California
603.970
Federal
310 12000
(228 12000)
6
89.0 192.4 100/4000
(133/4000)
350 SD Turbo
22.0
350 SDLTurbo
126.134
126.135
1.10 - 001/l

Model 201
Noise capsule at bottom of engine compartment, front (1) Noise capsule at bottom of engine compartment, rear (2)
Noise capsule, front and rear (1, 2)
. . . . . . . . . .
Remove sheet metal screws (arrows), reinstall
and remove capsule, install.
Note
Install engine compartment capsule so that
edges of side part of capsule engage in bottom
part of capsule.
01.10 - 006/2

01-008
Opening hood, setting vertical, warnings
AWarning
There is risk of injury whenever the engine is
running and the hood is open.
Opening hood
1 To unlock the hood, pull the lever (533) on
the left below the instrument panel in the
direction of the arrow. The hood opens to the
safety hook stop.
Model126
Model 124
01.10 - 008/l

2 Close hood by pushing down forcibly.
Model201
Model 124, 126, 201
3 Pull the handle (535) extending from the
grille as far as the stop and open hood (it may
be necessary to lift the hood slightly to release
the handle).
Note
Do not attempt to lift the hood with handle (535).
The windshield wiper arm must not be pivoted
forward when the hood is lifted.
Moving hood into vertical position
Model 124 (production up to August 1988)
4 Push lock lever (537) on the left hood
support (536) in direction of arrow. Lift hood
slightly upward to keep the lock lever (537) from
reengaging again.
Repeat the preceding at the right hood support
and set the hood in a vertical position.
5 To close the hood, push in lock lever at the
right hood support, and close the hood by
pushing down forcibly.
1.10 - 00812