Description

Mercedes-benz 108D, 110D Workshop Manual

Listen, I’ve been turning wrenches for 28 years. If you’re tearing into a Mercedes-benz Vito 108D or 110D, you don’t want some generic reprint that guesses the torque specs. You want the factory data – the one the dealer techs used. That’s what this Mercedes-benz 108D, 110D Workshop Manual is. 17 pages of OEM engine specs, direct from the German engineers. No translation errors, no aftermarket guesswork. I’ve seen guys strip cylinder head bolts using wrong values from aftermarket manuals. Don’t be that guy.

Engine Technical Data – OM 601.942 and OM 601.970

Get the numbers right before you pull a single bolt. The manual breaks down the two diesel variants side by side: the 108D with OM 601.942 (atmospheric, 58 kW/79 hp) and the 110D with OM 601.970 (turbointercooler, 72 kW/98 hp). Both are 4-cylinder inline, bore 89.9 mm, stroke 92.4 mm, indirect injection, compression ratio 22:1. The 110D puts down 23 kg·m of torque at 1500–2200 rpm, while the 108D does 15.2 kg·m at 2300 rpm. These metrics come straight from page 1 of the manual. Ignore aftermarket tables that round up or down – use the factory numbers. Also note the injection order is 1-3-4-2 on both, and idle speed is 750±20 rpm (108D) vs. 720±10 rpm (110D). If you’re chasing a rough idle, those specs are your first stop.

17 Pages of Factory Specs – What’s Included?

This is a focused engine mechanical manual. It covers the cylinder block, crankshaft, bearings, flywheel, and ring gear. You get bore diameters (origin 89–89.014 mm, max 89.05–89.064 mm), cylinder head deck height (origin 299.62 mm), main bearing clearances new 0.03–0.05 mm, lateral play new 0.10–0.25 mm, and flywheel runout limits. It’s not a full vehicle manual – you won’t find transmission, brakes, or wiring here. For transmission work, check the Manual Transmission resources separately or pair this with Mercedes-benz 200, 230, 260, 300 1994 Workshop Manual – Factory Specs for other models. But for the long block? This is the bible.

Crankshaft and Main Bearing Clearances – Critical Limits

The crankshaft section gives you five main bearing journals. New clearance must be 0.03–0.05 mm; maximum allowable is 0.08 mm. Lateral play: new 0.10–0.25 mm, wear limit 0.15 mm. The bearing shells are color-coded – yellow, red, white, violet – with thicknesses ranging from 2.225 to 2.280 mm. Bolt length for the main bearing caps: new 62 mm, max after stretching 63.8 mm. If you don’t measure and sort by color, you’ll spin a bearing. I’ve pulled engines where someone mixed up shell colors – that engine lasted about 15 miles. Use the manual’s table. Also note flywheel bolts should be replaced – the manual says “preferentemente” which means “preferably” – translate that as “mandatory” in my book.

Cylinder Block Preparation – Don’t Skip the Honing Tolerances

Bores are machined directly into the block, but sleeving is possible during repair. Deck height from the main bearing axis to cylinder head surface: 299.62 mm original. Allowable warpage between head and deck surfaces: 0.05 mm overall, 0.03 mm in longitudinal or transverse direction. Surface roughness spec on the top deck is 0.012 mm – that’s tight. Cylinder bore ovalisation limit is 0.07 mm. New bore diameter is 89.000–89.014 mm, maximum after wear is 89.050–89.064 mm. There are also letter codes (A, B, X) for piston matching. Without these numbers, you’ll end up with blow-by or oil consumption. This manual lays them out in a table you can read at the bench.

Flywheel and Clutch – Alignment and Runout Limits

Flywheel – single piece, eight bolts. Runout at friction surface and clutch mounting face: max 0.05 mm. Flatness of friction surface: 0.02 mm. Surface roughness: Ra=0.08 mm. The depth from friction surface to clutch mounting plane: 8.7–8.9 mm. Center pin protrusion of the clutch mechanism: 18.5–19.7 mm. If you resurface the flywheel, you can remove up to 1 mm. Over that and you throw off clutch geometry. The ring gear inner diameter is 275–275.396 mm. Use these figures when balancing or replacing the flywheel. Aftermarket manuals often skip the protrusion spec – then the clutch won’t release fully.

FAQ – Common Questions About This Manual

Does this manual cover the 110D turbo engine?

Yes, both 108D and 110D variants are covered with separate columns in the technical data table.

How many pages and is it a complete workshop manual?

It is 17 pages. That’s short because it’s focused on engine mechanical specs – not a full vehicle manual. You will need additional manuals for other systems like transmission, brakes, and electrical. For transmission work, Manual Transmission documentation from other sources can help. Also consider Mercedes-Benz 230 G Workshop Manual for related drivetrain knowledge.

Are torque values given in imperial units or newton-meters?

The manual uses metric units exclusively (mm, bar, kg·m). It specifies dimensions and clearances rather than listing bolt torque values. For assembly torques, you should refer to Mercedes service information for specific fasteners. However, the manual gives you the critical numbers like bolt lengths – if your main bearing cap bolts measure over 63.8 mm, scrap them. That tells you the stretch limit. Combine this manual with factory torque charts for proper reassembly.

What model years does this manual apply to?

No publication year is printed. It covers Mercedes Vito models 108D and 110D – typically early 1990s through early 2000s. Verify your engine code: OM 601.942 (108D) or OM 601.970 (110D). If you have a later or earlier variant, cross-check with Mercedes-benz Sprinter 2011 User Manual – Warranty & Service Info for related engine families.

Look, if you’re serious about rebuilding that Mercedes diesel engine, get the factory data in your hands. Access the Factory Manual now from AutoRepairManuals. It’s the only way to be sure you’re working to the same specs the engineers set. I’ve torqued more head bolts than most, and I wouldn’t trust anything else.