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602
Mercedes-Benz 602 User Manual
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Mercedes-Benz
Mercedes-Benz of North America, Inc.
.
Montvale, NJ 07645
2
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
Test Values with Engine at Operating Temperature
24
Tightening Torques
24
Special Tools
25
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
Crankcase Ventilation on Engines with Exhaust Gas Recirculation
57
Pressure Control Valve
58
Production Breakpoint
59
Measuring, Boring and Honing Cylinder Bores
60
Boring and Honing
61
Maximum Permissible Wear for Cylinder Bores
62
Machining Tolerances
62
Introduction of Engines Without Cylinder Sleeves
63
Commercially Available Tool
63
Items
64
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
Remove, Install, 25 Nm (Item
91
Oil Capacities with Oil Dipstick Code
92
Model 201 (up to
93
Oil Pan with Attached Side Section
95
Repair Notes for Cylinder Heads and Cylinder Head Gaskets
98
Cylinder Head Gasket with Viton Sealing Ring
99
Production Change for Protection against Cracks in Water Jacket
100
Modifications in Area of Timing Chain Case
100
Cylinder Head Gasket for Improved Sealing
101
Improvement to Passage Supports in Water Jacket
103
Reinforcements at Valve Tappet Guides and Exhaust Passages
104
Combustion Chamber Recess
105
Refinishing Prechamber Sealing Surface
106
Cylinder Head Removed
109
Cylinder Head Installed
109
Removal and Installation of Cylinder Head
112
Tightening Torques and Rotation Angles for Cylinder Head Bolts
123
Removal and Installation of Prechambers
126
Prechamber Survey
127
Differentiation, Vertical and Angular Injection
128
Differentiation, Combustion Neck Diameter
129
Differentiation, Combustion Bores
130
Combustion Bore Diameters (Dia. in MM)
130
Angular Injection
132
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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Mercedes-Benz 602 Specifications
General
Engine code
OM602
Engine type
diesel
Aspiration
Naturally aspirated or Turbocharged
Cylinders
5
Fuel System
Indirect injection
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