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
      Removal and installation of the engine
      Removal and installation of covers of the GRM drive
      Replacement of a gas-distributing chain
      Removal and installation of components of the GRM drive
      Installation of basic position of camshafts
      Verification of the basic provision of a balancing shaft (only series 628 engines)
      Removal and installation of the GRM components
      Removal and installation of a head(s) of cylinders
      Removal and installation of an electric motor of shutdown of inlet port (series 612 engine)
      Removal and installation of a final collector
      Replacement of a forward epiploon of a bent shaft
      Removal and installation of a back face cover, replacement of a back epiploon of a bent shaft
      Removal and installation of a damper of tortional fluctuations / pulley of a driving belt
      Removal and installation of a flywheel / driving disk
      Removal and installation of support of a suspension bracket of the power unit
      Service of the lubrication system
+ 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



Diesel models

Removal and installation of the engine

M612

Preparation for removal of the engine of a series 612

Preparation for removal of the engine of a series 612


 PERFORMANCE ORDER

  1. Illustrative material on preparation for removal of the engine is presented on illustrations to which all references which are found in the text belong.
  2. Open a cowl and prop up it in vertical position.
  3. Disconnect a negative wire from the battery.
  4. Remove overlays of heads of cylinders.
  5. Remove the lower section of a noise isolation.
  6. Empty the cooling system (see the Head of the Power supply system and production of the fulfilled gases).
  7. Remove a broad tank of the cooling system (1).
  8. Disconnect the hose (2) of a cooling path going from a thermostat casing to a radiator.
  9. Remove an air inlet (4/3).
  10. Remove a sleeve of an air inlet (4/2).
  11. Remove the electric fan (3) of the cooling system.
  12. Install the screen of protection of the К/В radiator/compressor.
  13. Take off a belt of the drive of auxiliary units (6).
  14. Pump out hydraulic liquid from the GUR tank (see the Head of the Power supply system and production of the fulfilled gases).
  15. Disconnect the line of a path of GUR (5) from a radiator.
  16. Disconnect the line of a path of GUR (13) from the steering pump, - at once to a zakuporta the open ends of a hose and the reception union.
  17. Disconnect a vacuum hose (10) from the control unit of pressurization. Also disconnect the vacuum lines (11 and 12) going to the mixing camera and the vacuum pump.
  18. Disconnect an air sleeve (19) from a turbocompressor.
  19. Pick up the phone (110/5) of air supply of pressurization to the mixing camera.
  20. Disconnect tubes of a cooling path (14 and 15) from the water pump.
  21. Disconnect a hose (16) of a cooler of fuel.
  22. Disconnect a hose (17) of a low-temperature cooler and remove the hose (18) brought to a thermostat casing.
  23. Disconnect the giving fuel tube (8) of system of a preliminary warming up.
  24. Disconnect from a fuel cooler a returnable tube (9).
  25. Disunite the engine electrical wiring socket(s).
  26. Pick up the phone (19) going from a turbocompressor (110) to an air cooler.
  27. Disconnect an electrical wiring from the К/В compressor.
  28. Otboltite K/B (21) compressor.
  29. Hang out the engine on the winch.
  30. Turn out bolts from openings under installation of a prop on a transmission case.
  31. Prop up transmission.
  32. Turn out bolts of fastening of transmission to the engine.
  33. Weaken the sprung joint of fastening of primary catalytic converter to the main three-functional catalytic converter (TWC).
  34. Release elements of fastening of a forward support of a suspension bracket of the power unit (22) to a car frame.
  35. Separate the engine from transmission and carefully take it from a motor compartment of the car.
  36. Installation is made upside-down.

M628

Preparation for removal of the engine of a series 628

Preparation for removal of the engine of a series 628


 PERFORMANCE ORDER

  1. Illustrative material on preparation for removal of the engine is presented on illustrations to which all references which are found in the text belong.
  2. Open a cowl and prop up it in vertical position.
  3. Disconnect a negative wire from the battery.
  4. Lift a cover of the power unit.
  5. In the conditions of a workshop of car service make a discharge of the air conditioning system.
  6. Remove the left and right block headlights (see the Head Kuzov).
  7. Remove the top cross beam of a frame (see the Head Kuzov).
  8. Remove the tank of liquid of washing of glasses (see the Head Kuzov).
  9. Remove assembly of the air cleaner (18).
  10. Previously having pumped out hydraulic liquid, remove the tank (21) of the steering pump from a basic plate of a sleeve of distribution of the soaked-up air.
  11. Remove the left forward wheel.
  12. Remove a loker of protection of a wheel arch.
  13. Working through a wheel arch, separate the refrigerator line (13) from the К/В compressor.
  14. Also through an arch disconnect fuel lines (14).
  15. Remove the lower section of a noise isolation.
  16. Empty the cooling system (see the Head of the Power supply system and production of the fulfilled gases).
  17. Disconnect from a cooler (11) air hoses (9 and 10) of the right and left turbocompressors, and a sleeve of air of pressurization (12).
  18. Release collars of fastening of primary catalytic converter on the left and right turbocompressors.
  19. Turn out bolts of fastening of a dome of transmission to the engine (except lower).
  20. Give nuts of the left and right support of a suspension bracket of the power unit.
  21. Uncover (30) service windows and turn out bolts of fastening of the converter of rotation to the driving disk of start of the engine equipped with a gear wreath.
  22. Separate from a transmission case the left and right drainage hoses (28 and 29).
  23. Disconnect from a radiator (1) ventilating (5) and the giving (4 and 6) hoses.
  24. Disconnect from a radiator of the line of a path of cooling of ATF (2 and 3).
  25. Disconnect from a radiator of the line of a path of cooling of GUR liquid (7 and 8).
  26. Remove the electric fan of the cooling system (see the Head of the Cooling system, heating and the air conditioner).
  27. Install the screen of protection of the К/В radiator/compressor.
  28. Disconnect hoses (15 and 17) of a low-temperature cooler.
  29. Disconnect a returnable hose of a heater (16).
  30. Disunite contact sockets of an electrical wiring of MAF sensors (B2/6 and B2/7).
  31. Remove the air distributor (20) with an inlet sleeve of the air cleaner (24).
  32. Remove a broad tank of the cooling system (19).
  33. Remove the giving heat exchanger hose at the left on a partition of a motive compartment.
  34. Remove the circulation pulser of the cooling system (an additional complete set) from a board of the rechargeable battery and, without disconnecting hoses, take him aside.
  35. Release fixture and pick up the jellied phone (27) ATF from a cover of a head of cylinders.
  36. Separate the vacuum line of inlet port of the locking valve (23) and a ventilating hose of the cooling system from the assembly block of safety locks and the relay.
  37. Disconnect the vacuum line of inlet port of the locking valve (23) from the servo-driver of the brake amplifier.
  38. Disconnect the refrigerator line (26) from the K/V compressor.
  39. Disconnect the pressure head line (25) from the steering pump.
  40. Disconnect a driving cable from the position sensor (22).
  41. Remove the position sensor (22) from a partition.
  42. Disunite the engine electrical wiring socket(s).
  43. Hang out the engine on the winch, having completely unloaded forward support of a suspension bracket of the power unit.
  44. Prop up transmission.
  45. Turn out the lower bolts of fastening of a dome of transmission to the engine.
  46. Having delayed the engine forward, separate it from transmission, then carefully take from a motor compartment.
  47. Installation is made upside-down.
  48. Fill in fresh cooling liquid in the cooling system, in conditions HUNDRED make К/В system charging. Check the ATF level, in case of need make the corresponding adjustment (see the Head of the Power supply system and production of the fulfilled gases).
  49. In conclusion connect the reader STAR DIAGNOSIS to the diagnostic DLC socket and carry out a survey of the processor memory on existence of codes of malfunctions (DTC). Having executed necessary corrections, clear memory of system.