Mercedes M-Class W163

since 1997 release

Repair and operation of the car



Mercedes W163
+ Mercedes-Benz cars of a class M (W163)
+ Governing bodies and methods of safe operation
+ Current leaving and service
- Engine
   Check of compression pressure in cylinders
   Check of the engine by means of the vacuum gage
   Replacement of a belt of the drive of auxiliary units and elements of the mechanism of its tension
   + Petrol models
   + Diesel models
+ Cooling systems, heating and air conditioner
+ A power supply system and production of the fulfilled gases
+ Systems of electric equipment of the engine
+ Manual box of gear shifting
+ Automatic transmission
+ Transmission line
+ Brake and auxiliary systems
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment



Engine

Specifications

The parameters used at implementation of the procedures described in the present Chapter are specified below. Detailed standard data it is possible to receive hundred Mercedes-Benzs at company car repair shops. Separate characteristics are provided also in the text of the Head and in case of obligation of their performance are highlighted in bold type.


General parameters

Designation, engine type
Petrol models
ML 230 (163.136) 111.977, line, 4-cylinder, DOHC, with water cooling, the GRM chain drive and microprocessor management
ML 320 (163.154) 112.942, V-shaped, 6-cylinder, DOHC, with water cooling, the GRM chain drive and microprocessor management
ML 350 (163.157) 112.970, V-shaped, 6-cylinder, DOHC, with water cooling, the GRM chain drive and microprocessor management
ML 430 (163.172) 113.942, V-shaped, 8-cylinder, DOHC, with water cooling, the GRM chain drive and microprocessor management
ML 55 AMG (163.174) 113.981, V-shaped, 8-cylinder, DOHC, with water cooling, the GRM chain drive and microprocessor management
ML 500 (163.175) 113.965, V-shaped, 8-cylinder, DOHC, with water cooling, the GRM chain drive and microprocessor management
Diesel models
ML 270 CDI (163.113) 612.963, line, 5-cylinder, DOHC, with water cooling, the GRM chain drive and a turbocompressor
ML 400 CDI (163.128) 628.963, V-shaped, 8-cylinder, DOHC, with water cooling, the GRM chain drive and a turbocompressor
Volume of cylinders See Specifications to the Head Governing bodies and methods of safe operation
The rated developed power See Specifications to the Head Governing bodies and methods of safe operation
Nominal torque See Specifications to the Head Governing bodies and methods of safe operation
Maximum frequency of rotation of a bent shaft See Specifications to the Head Governing bodies and methods of safe operation
Extent of compression
Series 111 engines 9.0
Series 112 engines 10.0
Series 113 engines Data are absent
Series 612 engines Data are absent
Series 628 engines Data are absent
Pressure of a compression, bar
Series 111 engines
  • Nominal rate
11 ÷ 15
  • The maximum admissible difference in indications between cylinders
1.5
Engines of a series 112 and 113
  • Nominal rate
12 ÷ 14
  • Minimum admissible value
9.0
  • The maximum admissible difference in indications between cylinders
1.5
Engines of a series 612 and 628
  • Nominal rate
29 ÷ 35
  • Minimum admissible value (approximately)
18
  • The maximum admissible difference in indications between cylinders
3.0
Operating procedure of cylinders
4-cylinder engines 1-3-4-2
5-cylinder engines 1-2-4-5-3
6-cylinder engines 1-5-3-6-2-4
8-cylinder engines 1-5-4-8-6-3-7-2
Diameter of cylinders
Series 111 engines Data are absent
Engine 112.942 92.0
Engine 112.970 Data are absent
Engine 113.942 89.90
Engine 113.981 97.00
Engine 113.965 Data are absent
Series 612 engines Data are absent
Series 628 engines Data are absent
Driving belt, mm

Series 111 engines

  • - K/B, - VDA GUR
2040
  • - K/B, + VDA GUR
2055
  • + K/B, - VDA GUR
2140
  • + K/B, + VDA GUR
2155
Series 112 engines Data are absent
Series 113 engines Data are absent
Series 612 engines (+ To/in, + GUR VDA) 2271
Series 628 engines Data are absent
Valvate gaps Are not regulated since hydrocompensators are used
Gas-distributing mechanism
Code designations of camshafts

Engine 111.977 (ML 230)

  • Inlet shaft
18
  • Final shaft
17
Engine 112.942 (ML 320) Data are absent
Engine 112.970 (ML 350) Data are absent
Engine 113.942 (ML 430) Data are absent
Engine 113.981 (ML 55 AMG) Data are absent
Engine 113.965 (ML 500) Data are absent
Engine 612.963 (ML 270 CDI)
  • Inlet shaft
01
  • Final shaft
00
Engine 628.963 (ML 400 CDI)

Left head of cylinders

  • Inlet shaft
02
  • Final shaft
03
Right head of cylinders
  • Inlet shaft
00
  • Final shaft
01
Gas distribution phases (a 2-millimetrovoyeotkryvaniye at the earned extra chain)
Engine 111.977 (ML 230)

Inlet valves

  • Opening
20.0 ° after VMT
  • Closing
29.5 ° after NMT
Final valves
  • Opening
19.5 ° before NMT
  • Closing
14.0 ° before VMT
Engine 112.942 (ML 320)
Left head of cylinders
Inlet valves
  • Opening
24.9 ° after VMT
  • Closing
25.9 ° after NMT
Final valves
  • Opening
31.5 ° before NMT
  • Closing
12.1 ° before VMT
Right head of cylinders
Inlet valves
  • Opening
26.5 ° after VMT
  • Closing
27.5 ° after NMT
Final valves
  • Opening
29.9 ° before NMT
  • Closing
10.5 ° before VMT
Engine 112.970 (ML 350) Data are absent
Engine 113.942 (ML 430)
Left head of cylinders

Inlet valves

  • Opening
31.9 ° after VMT
  • Closing
28.2 ° after NMT
Final valves
  • Opening
24.1 ° before NMT
  • Closing
9.1 ° before VMT
Right head of cylinders

Inlet valves

  • Opening
33.5 ° after VMT
  • Closing
29.8 ° after NMT
Final valves
  • Opening
22.5 ° before NMT
  • Closing
7.5 ° before VMT
Engine 113.981 (ML 55 AMG)
Left and right heads of cylinders

Inlet valves

  • Opening
25 ° after VMT
  • Closing
39 ° after NMT
Final valves
  • Opening
35 ° before NMT
  • Closing
15 ° before VMT
Engine 113.965 (ML 500)
Left head of cylinders

Inlet valves

  • Opening
30.9 ° after VMT
  • Closing
25.7 ° after NMT
Final valves
  • Opening
23.2 ° before NMT
  • Closing
9.1 ° before VMT
Right head of cylinders

Inlet valves

  • Opening
32.5 ° after VMT
  • Closing
27.3 ° after NMT
Final valves
  • Opening
21.6 ° before NMT
  • Closing
7.5 ° before VMT
Engine 612.963 (ML 270 CDI)
Inlet valves
  • Opening
19 ° after VMT
  • Closing
7 ° after NMT
Final valves
  • Opening
9 ° before NMT
  • Closing
22 ° before VMT
Engine 628.963 (ML 400 CDI) Data are absent
Additional parameters for engines 111.977 (ML 230)
Limit admissible radial side play of a damper of tortional fluctuations, mm 0.6
Limit admissible axial side play of a damper of tortional fluctuations, mm 0.6
Diameter of bearings of camshafts, mm
Nominal rate 28.00 ÷ 28.02
Repair value 28.50 ÷ 28.52
Diameter of bearing necks of camshafts, mm
Nominal rate 27.95 ÷ 27.96
Repair value 28.45 ÷ 28.46
Axial side play of camshafts, mm 0.05 ÷ 0.15
Efforts of tightening of threaded connections, Nanometer



Data are provided in a material statement order (consistently according to Sections).

M111
Nut of fastening of a tension roller to assembly of a natyazhitel of a belt of the drive of auxiliary units 25
Bolts of fastening of a damper of a natyazhitel of a belt of the drive of auxiliary units 25
Bolts of fastening of a natyazhitel 25
Bolt of fastening of the steering pump to a GRM drive cover 20
Bolts of fastening of transmission to the engine

M10x40

With electroplated coating of yellow color 55  
With a synthetic covering of Dacromet/chromeplated 40  
M10x90
With electroplated coating of yellow color 45
With a synthetic covering of Dacromet/chromeplated 40
Bolts of fastening of a forward cover of a head of cylinders
M6 10
M8 25
Bolts of fastening of a cover of the GRM drive
To the block of the engine (M8) 25
To a head of cylinders
  • Stage 1
18
  • Stage 2
To hold on on 90 °
Bolts of fastening of asterisks of camshafts to flanges
  • Stage 1
20
  • Stage 2
To hold on on 60 °
Nuts of fastening of asterisks of camshafts to flanges 65
Bolts of fastening of the directing chain on a head of cylinders 10
Cap of a natyazhitel of a chain 40
Natyazhitel of a chain in a GRM drive cover 80
The central bolt of fastening of the regulator to the camshaft
  • Stage 1
5
  • Stage 2
To hold on on 90 °
Bolts of fastening of covers of bearings of camshafts 21
Bolts of fastening of a head of cylinders
M12
  • Stage 1
55
  • Stage 2
To hold on on a corner 90 °
  • Stage 3
To hold on on a corner 90 °
To a GRM drive cover
  • Stage 1
18
  • Stage 2
To hold on on 90 °
Bolts and nuts of fastening of the inlet pipeline to a head of cylinders 20
Bolts of fastening of a back face cover of the engine 10
Central bolt of fastening of a damper of tortional fluctuations (class of durability 10.9) 300
Bolts of fastening of a flywheel / a driving disk to a bent shaft
Stage 1 40/45
Stage 2 To hold on on 90 °
Nuts of fastening of pillows of forward support of a suspension bracket of the power unit
To a car frame 35
To a support arm 65
Bolts/nut of fastening of a pillow of a back support of a suspension bracket of the power unit
To a transmission case 35
To a cross beam 35
Nuts of fastening of a cross beam to a car frame 35
Bolts of fastening of the pallet of a case
To the block of cylinders
  • M6
10
  • M8
25
  • M10
-
To a transmission dome 40
Bolts of fastening of the oil pump
Six-sided 25
TORX 18
 
M112/113
Self-cut bolt of fastening of a natyazhitel to a GRM drive cover
  • The carving is not cut
35
  • The carving is cut
25
Bolts of fastening of a damper of a natyazhitel of a belt of the drive of auxiliary units
To a natyazhitel 25
To the water pump 35
Bolts of fastening of a natyazhitel 25
Nipple knot of connection of the giving fuel pipe to the fuel highway 38
Flange connection of a reception pipe of system of production of the fulfilled gases with a final collector 20
Bolts of fastening of a starter to an engine case 42
Bolts of fastening of pillows of forward support to a stretcher 35
Bolts of M8 of fastening of the hydrotransformer to a driving disk 42
Bolts of fastening of AT to the engine
M10x40 and M10x90 40
M12 -
Knots of fastening of hydraulic lines to the steering pump

Pressure head line

  • M14x1.5
-
  • M16x1.5
45
Returnable line 2
Screws of fastening of the K/V compressor to a basic arm 20
Bolts of fastening of a cover of the GRM drive to the block and a head of cylinders 20
Bolt of M8x78 of fastening of the directing pulley of a belt of the K/V drive and auxiliary units to a GRM drive cover 68
Bolts of fastening of the water pump
Self-cut

M6

  • The carving is not cut
14
  • The carving is cut
10
M8
  • The carving is not cut
35
  • The carving is cut
25
Standard (M7) 10
Fastening of a pulley of the drive of the water pump 10
Bolts of fastening of a casing of the thermostat (M6) 10
Bolts of fastening of the steering pump

Self-cut

  • The carving is not cut
35
  • The carving is cut
20
Standard 25
Bolts of fastening of the inlet pipeline to heads of cylinders (M8) 20
Natyazhitel of a chain in a GRM drive cover 80
Bolt of fastening of asterisks of camshafts

(M12x45)

  • Stage 1
50
  • Stage 2
To hold on on a corner 90 °
Hall's sensor of the camshaft in a head of cylinders 8
Bolts of fastening of bridges of bearings of camshafts to heads of cylinders

M7x45

  • Stage 1
15
  • Stage 2
-
M7x84
  • Stage 1
10
  • Stage 2
To hold on on a corner 90 °
Bolts of fastening of asterisks of camshafts

(M12x45)

Stage 1 50
Stage 2 To hold on on a corner 90 °
Bolts of fastening of a head of cylinders

To the engine block (internal TORX)

  • Stage 1
10
  • Stage 2
30
  • Stage 3
To hold on on a corner 90 °
  • Stage 4
To hold on on a corner 90 °
To a GRM drive cover 20
Bolts of fastening of covers of heads of cylinders 10
Nut of fastening of a connecting tube to the EGR valve 40
Flange connection of a reception pipe of system of production of the fulfilled gases with a final collector 20
Nuts of fastening of a final collector 16
Wheel bolts 150
Bolts of fastening of a face cover of the engine 10
Central bolt of fastening of a damper of tortional fluctuations
Stage 1 200
Stage 2 To hold on on a corner 95 °
Bolts of fastening of a driving disk to a bent shaft
Stage 1 45
Stage 2 To hold on on a corner 90 °
Bolts/nut of fastening of a pillow of a back support of a suspension bracket of the power unit
To a transmission case 35
To a cross beam 35
Nuts of fastening of a cross beam to a car frame 35
Bolts of fastening of the left and right side support of a suspension bracket of the power unit to an engine case
Stage 1 20
Stage 2 To hold on on a corner 90 °
Bolts of fastening of pillows of forward support of a suspension bracket of the power unit
To a stretcher 35
To a support arm 65
Cover of a casing of an oil filter 25
Bolts of fastening of a casing of assembly of an oil filter 70
Fastening of the liquid heat exchanger of an oil filter 11
Drain stopper of the pallet of a case (M14) 30
Self-cut bolts of fastening of the lower section of the pallet of a case to top
The carving is not cut 14
The carving is cut 10
Bolts of fastening of the top section of the pallet of a case to the block of cylinders
M6 9
M8 20
Bolts of fastening of the sensor of level of oil to the top section of the pallet of a case 10
Bolts of fastening of masloraspylitel 15
Bolts of fastening of the oil pump (M8x30) 20
M612
  • Screws of fastening of the finishing panel of a cover of a head of cylinders
10
  • Screws of fastening of the finishing panel of the air distributor
10
  • Bolts of a basic arm of a sleeve of distribution of air of pressurization
20
Knots of fastening of the pressure head line of the steering pump
M14x1.5 -
M16x1.5 45
Hollow bolt of nipple connection of the maslootvodyashchy line to a radiator 30
Bolts of fastening of the K/V compressor to a GRM drive cover 20
Fastening bolts to the AT engine
M10x40 and M10x90 40
M12 -
Bolts of fastening of a forward cover of a head of cylinders 14
Bolts of fastening of a head of cylinders to a cover of the GRM (M8) drive 20
Bolts of fastening of a cover of the GRM drive to an engine case
M6 -
M8 20
Bolts of fastening of the pallet of a case

To the engine block

  • M6
9
  • M8
20
  • M10
-
To a cover of the GRM (M6) drive 9
Side bolts 9
Drain stopper of the pallet of a case (M14) 30
Central bolt of a damper of tortional fluctuations
Class of durability 8.8
  • Stage 1
200
  • Stage 2
To hold on on a corner 90 °
Class of durability 10.9
  • Stage 1
325
  • Stage 2
To hold on on a corner 90 °
Bolts of fastening of the K/V compressor to a GRM drive cover 20
Bolts of fastening of covers of bearings of camshafts to a head of cylinders 9
Bolt of fastening of an asterisk of the final camshaft 18
Bolt of fastening of an intermediate asterisk of TNVD 40
Bolt of fastening of a natyazhitel of a gas-distributing chain to a GRM drive cover 80
Bolts of fastening of a head of cylinders
To a cover of the GRM (M8) drive 20
To the block of the engine (M12)
  • Stage 1
60
  • Stage 2
To hold on on a corner 90 °
  • Stage 3
To hold on on a corner 90 °
Nut of the TNVD pressure head line / fuel distributive highway 20
Knot of connection of the forward catalytic converter to a turbocompressor 30
Bolt of fastening of the line of removal of oil of a turbocompressor 9
Bolts of fastening of a basic arm to a turbocompressor 30
Bolts of a distributive sleeve of a path of pressurization of air
  • M5
-
  • M7
16
Collars of an air path 3
Bolt of fastening of a basic arm to a distributive sleeve of a path of pressurization of air 20
Bolt of fastening of a basic arm to an assembly bracket of the engine 40
Bolts of fastening of an electric motor of shutdown of inlet port to a sleeve of distribution of air of a path of pressurization 9
Nuts of fastening of a final collector on a head of cylinders 30
Bolts of fastening of a back face cover of the engine 9
Bolts of fastening of a flywheel / a driving disk to a bent shaft
  • Stage 1
45
  • Stage 2
To hold on on a corner 90 °
Cover of a casing of an oil filter 25
Fastening of the liquid heat exchanger of an oil filter 15
Bolts of fastening of the pallet of a case

To the engine block

  • M6
9
  • M8
20
  • M10
-
To a transmission case 40
To a cover of the GRM (M6) drive 9
Bolts of fastening of the sensor of level of oil to the case pallet 14
Bolts of fastening of the oil pump 18
M628
Natyazhitel of a belt of the drive of auxiliary units in an engine case 30
Knot of connection of the forward catalytic converter to a turbocompressor 15
Bolts of fastening of the hydrotransformer to a driving disk (M8) 42
Cap nuts / hollow bolts of nipple lines of a path of cooling of ATF 35
Knots of fastening of the pressure head line of the steering pump
M14x1.5 -
M16x1.5 45
Hollow bolt of nipple connection of the maslootvodyashchy line to a radiator 30
Bolt of fastening of the refrigerator line to the K/V compressor 20
Fastening bolts to the AT engine
M10x40 and M10x90 40
M12 -
Bolts of fastening of a forward cover of a head of cylinders 14
Pins of riveted links of a gas-distributing chain (approximate value) 28
Bolts of fastening of covers of bearings of camshafts to a head of cylinders 9
Bolt of fastening of an asterisk of the final camshaft 18
Bolt of fastening of an intermediate asterisk of TNVD 40
Bolt of fastening of a natyazhitel of a gas-distributing chain to a GRM drive cover 80
Bolts of fastening of a cover of the centrifuge to an engine case 8
Bolts of fastening of heads of cylinders
To a cover of the GRM (M8) drive 20
To the engine block
Stage 1 20
Stage 2 60
Stage 3 To hold on on a corner 90 °
Stage 4 To hold on on a corner 90 °
Stage 5 To hold on on a corner 90 °
Bolt of fastening of the line of removal of oil to a turbocompressor 9
Bolts of fastening of a basic arm to a turbocompressor 30
Nuts of fastening of a final collector on a head of cylinders 30
Bolts of fastening of a back face cover of the engine 9
Drain stopper of the pallet of a case (M14) 32
Bolts of fastening of the pallet of a case

To the engine block

M6 19
M8 20
M10 -
To a transmission case 40
To a cover of the GRM (M6) drive 9
Central bolt of a damper of tortional fluctuations
Stage 1 275
Stage 2 To hold on on a corner 90 °
Bolts of fastening of a driving disk to a bent shaft
Stage 1 45
Stage 2 To hold on on a corner 90 °
Cover of a casing of an oil filter 25
Fastening of the liquid heat exchanger of an oil filter 15
Fastening of the ventilating line to the left inlet pipeline 11
Self-cut bolts of fastening of the lower section of the pallet of a case to top
The carving is not cut 12
The carving is cut 8
Bolts of fastening of the top section of the pallet of a case to the block of the engine (M6) 8
Bolts of fastening of the oil pump (TORX) 8
Fastening screws to assembly of the oil pump of a cover with an oil tube 10