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
+ Cooling systems, heating and air conditioner
- Power supply system and production of the fulfilled gases
   + Power supply system of petrol engines
   - Power supply system of diesel engines
      General information
      Checks of system of injection of fuel
      Service of components of an inlet air path
      Service of components of the drive of a butterfly valve
      Depletion of the fuel tank
      Removal and installation of the sensor of a reserve of fuel
      Removal of air from a contour of low pressure of a fuel path, - on the example of the series 612 engine
      Removal and installation of the preliminary fuel pump
      Removal and installation of the fuel pump of high pressure (FPHP)
      Removal and installation of the fuel distributive highway and nozzles
      Removal and installation of the sensor of pressure in the fuel highway
      Removal and installation of the electric locking valve, - model 163.113
      Removal and installation of the valve regulator of pressure of fuel
      Removal and installation of valvate assembly on models 163.128
      Removal and installation of a cooler of fuel on models 163.113
      Removal and installation of the module of management of fuel injection
      Removal and installation of the fuel tank
   + Systems of release and decrease in toxicity 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



Service of components of an inlet air path

Model 163.113

Replacement of the filtering air cleaner element

Details of installation of components of an inlet air path of the models equipped with the series 612 engine


 PERFORMANCE ORDER

  1. Illustrative material on replacement of the filtering air cleaner element on models 163.113 (the series 612 engine) is presented on an illustration to which all references which are found in the text belong.
  2. Remove panels of finishing of a cover of a head of cylinders.
  3. Disconnect an electrical wiring from the MAF (B2/5) sensor.
  4. Disconnect from the air cleaner an air sleeve (4/2).
  5. Remove an air inlet (4/3).
  6. Turn out fixing bolts and remove the top section of a casing of the air cleaner (4/1).
  7. Take the filtering element (4/4).
  8. In case of need remove the lower section of a casing of the air cleaner (4/5), - pay attention on enclosed from below (from the engine) washers.
  9. Installation is made upside-down, - do not forget to replace the failed fixing collars.
  10. In conclusion drop the indication of the indicator of extent of pollution of the filtering element (shooter).

Removal and installation of the sensor of temperature of the soaked-up air (IAT)

Details of installation of the IAT sensor on models 163.113 (the series 612 engine)


 PERFORMANCE ORDER

  1. Details of installation of the IAT sensor on models 163.113 (the series 612 engine) are shown on an illustration to which all references which are found in the text belong.
  2. Cut a tape bandage (1) of fixing of the holder (3).
  3. Disunite the contact socket of an electrical wiring (2) IAT (B17) sensors.
  4. Squeeze together fixing brackets (arrows) and release the sensor (B17) from the holder (3).
  5. Remove a sealing ring (4) which at assembly is subject to replacement without fail.
  6. Installation is made upside-down.

Installation of the sensor has to be made at the disunited contact socket, otherwise the probability of damage of fixing brackets (arrow) as a result of their pulling is not excluded!

  1. In conclusion make cleaning of memory of system of onboard self-diagnostics (see the Head Sistemy of electric equipment of the engine).

Removal and installation of a turbocompressor

Details of installation of a turbocompressor on models 163.113 (the series 612 engine)


 PERFORMANCE ORDER

  1. Details of installation of a turbocompressor on models 163.113 (the series 612 engine) are shown on an illustration to which all references which are found in the text belong.
  2. Remove the lower section of sound insulation.
  3. Remove the air cleaner (see above).
  4. Remove an air sleeve (4/2).
  5. Disconnect from a turbocompressor (110) an air duct (110/6).
  6. Disconnect from the vacuum block (110/10) a hose (4).
  7. Otboltite the maslopodayushchy line (110/3) from a turbocompressor and the block of the engine, - at an otpuskaniye of a nipple nut hold a turbocompressor from a provorachivaniye.
  8. Remove primary catalytic converter (120/1).
  9. Otboltite from an engine case a basic arm (3).
  10. Remove a turbocompressor (110) assembled with an arm (3) and maslootvodyashchy lines (110/4).
  11. Disconnect a basic arm (3) and the maslootvodyashchy line (110/4) from a turbocompressor (110), - prepare for collecting the spilled oil.
  12. Installation is made upside-down. Do not forget to replace all sealing elements. You make tightening of nipple nuts of oil pipelines only after installation of a turbocompressor.
  13. In conclusion check the level of motive oil, in case of need make the corresponding adjustment (see the Head of the Power supply system and production of the fulfilled gases).

Removal and installation of an intermediate cooler of a path of pressurization of air

Details of installation of an intermediate cooler of a path of pressurization of air on models 163.113 (the series 612 engine)


 PERFORMANCE ORDER

  1. Details of installation of an intermediate cooler of a path of pressurization of air on models 163.113 (the series 612 engine) are shown on an illustration to which all references which are found in the text belong.
  2. Open a cowl and record it in vertical position.
  3. Remove block headlights (1) with slips (2).
  4. Remove a forward cross beam of a frame (3).
  5. Disunite the contact socket of an electrical wiring (4) IAT (B17) sensors.
  6. Release fixing collars (5 and 6) and disconnect from the cooler heat exchanger (110/2) air sleeves (7 and 8).
  7. Turn out fixing bolts (9) and remove a cooler (110/2).
  8. Installation is made upside-down.

Removal and installation of the air distributor

Details of installation of the air distributor on models 163.113 (the series 612 engine)

1 — the Panel of finishing of a cover of a head of cylinders
2 — the Panel of finishing of the air distributor
3 — the Line of supply of fuel
4 — the Final fuel-supply line
5 — the Mixing camera
6 — a fuel Cooler
7 — Nizhny Novgorod a basic arm of the air distributor
8 — the Top basic arm of the air distributor

9 — EGR Cooler
10 — the Basic arm of a cooler of EGR on the air distributor pipeline
12 — the Air duct
13 — the Connecting branch pipe
21 — the Fuel highway
70 — the Full-line fuel filter
110/1 — the air distributor Pipeline


 PERFORMANCE ORDER

  1. Details of installation of the air distributor of a path of pressurization of air on models 163.113 (the series 612 engine) are shown on an illustration to which all references which are found in the text belong.
  2. Open a cowl and record it in vertical position.
  3. Remove panels of finishing of the power unit (1 and 2).
  4. Remove the lower section of a noise isolation.
  5. Disconnect a negative wire from the battery.
  6. Empty the cooling system (see the Head of the Power supply system and production of the fulfilled gases).
  7. Remove a cooler of fuel (6).
  8. Remove the fuel highway (21) (see the Section Removal and installation of the fuel distributive highway and nozzles).
  9. Remove basic arms of the fuel highway.
  10. Otboltite top basic arm (8) of the air distributor (110/1).
  11. Pump out oil from the GUR tank and disconnect from the last a hydraulic hose, - at once to a zakuporta the open ends of a hose and the union.
  12. Disconnect vacuum lines.
  13. Remove an overflow hose of a radiator.
  14. Remove the air duct connected to the mixing camera (5) (12).
  15. Remove the mixing camera (5).
  16. Remove a connecting branch pipe (13).
  17. Remove a thermostat casing (see the Head of the Cooling system, heating and the air conditioner).
  18. Remove a basic arm (10) of fastening on the EGR system tube air distributor pipeline.
  19. Release a plait of the electrical wiring laid along the distributive pipeline (110/1) from clamps, - disunite contact sockets of sensors of level of oil (V40), CKP (L5), pressure of pressurization (B28), the terminal switch of locking of inlet port (S99) and electric motor of a starter (M1).
  20. Turn out fixing bolts and remove the pipeline of the air distributor (110/1) from the lower basic arm (7).
  21. Installation is made upside-down, - do not forget to replace sealing elements and the failed components.
  22. In conclusion make cleaning of memory of the module of onboard self-diagnostics (see the Head Sistemy of electric equipment of the engine).

Removal and installation of an electric motor of the actuation mechanism of an overshoot of inlet port

Details of installation of an electric motor of the actuation mechanism of an overshoot of inlet port on models 163.113 (the series 612 engine)


 PERFORMANCE ORDER

  1. Details of installation of an electric motor of the drive of an overshoot of inlet port on models 163.113 (the series 612 engine) are shown on an illustration to which all references which are found in the text belong.
  2. On models remove the air distributor from AT (see above).
  3. On models remove from RKPP the left forward wheel and a loker of protection of a wheel arch.
  4. Turn out bolts (1).
  5. Release a clamp and carefully remove a support (3) from a spherical head (2).
  6. On models with RKPP disunite the contact socket of an electrical wiring (4) electric motors (M55).
  7. Remove an electric motor (M55) from assembly of the air distributor (5).
  8. Installation is made upside-down. Track correctness of landing of all positioning gates, check smoothness of their course. Do not forget to replace sealing elements.
  9. In conclusion make cleaning of memory of the module of onboard self-diagnostics (see the Head Sistemy of electric equipment of the engine).

Model 163.128

Replacement of the filtering air cleaner element

Design of the air cleaner of models 163.128 (series 628 engine)


 PERFORMANCE ORDER

  1. Illustrative material on replacement of the filtering air cleaner element on models 628 (the series 628 engine) is presented on an illustration to which all references which are found in the text belong.
  2. Throw off brackets of six clamps (arrow) of fastening of a cover of the air cleaner (1).
  3. Uncover (1) and take the filtering element which is subject to replacement from an air cleaner casing.
  4. Installation is made upside-down, - track correctness of landing of a cover.

Removal and installation of the sensor of temperature of the soaked-up air (IAT)

Details of installation of the IAT sensor on models 163.128 (the series 628 engine)

2 — the Sealing ring


 PERFORMANCE ORDER

  1. Details of installation of the IAT sensor on models 163.128 (the series 628 engine) are shown on an illustration to which all references which are found in the text belong.
  2. Open a cowl.
  3. Remove the sleeve of soaking-up engine fan laid ahead of the air cleaner.
  4. Disunite the contact socket of an electrical wiring (1) of the sensor (B17) which is at the same time fixing fixing brackets (arrows) of the last.

Removal and installation of turbocompressors

Details of installation of the right turbocompressor on models 163.128 (the series 628 engine)

Details of installation of the left turbocompressor on models 163.128 (the series 628 engine)


 PERFORMANCE ORDER

  1. Details of installation of turbocompressors on models 163.128 (the series 628 engine) are shown on illustrations to which all references which are found in the text belong.
  2. Remove forward wheels and loker of protection of wheel arches.
  3. Remove entrance air ducts both (right/left) pressurization of air of paths (see below).
  4. Remove the lower air ducts both (right and left) paths of pressurization of air (see below).
  5. Give a nut (1) on a basic arm of the maslopodayushchy line (110/3).
  6. Turn out a bolt (2) and disconnect the maslopodayushchy line (110/3) from a head of cylinders.
  7. Disconnect the maslopodayushchy line (110/3) from the left turbocompressor (110).
  8. Turn out bolts (3) and disconnect the maslovozvratny line (110/4) from a turbocompressor and a case of the engine.
  9. Release a collar of fastening of primary catalytic converter to the right turbocompressor (110).
  10. Completely weaken and take away the left three-functional catalytic converter (TWC) back.
  11. Turn out a bolt (4) on a basic arm (5).
  12. Disconnect from a turbocompressor (110) an electrical wiring of the regulator of pressure of pressurization (7).
  13. Turn out fixing bolts (6) and remove a turbocompressor (110) from a final collector of the engine.

Regulators of pressure of pressurization (Y100 and Y100/1) are replaced only complete with the corresponding turbocompressor!

  1. Installation is made upside-down. Do not forget to replace all sealing elements. You make tightening of nipple nuts of oil pipelines only after installation of a turbocompressor.
  2. In conclusion check the level of motive oil, in case of need make the corresponding adjustment (see the Head of the Power supply system and production of the fulfilled gases).

Removal and installation of an intermediate cooler of a path of pressurization of air

Details of installation of an intermediate cooler of a path of pressurization of air on models 163.128 (the series 628 engine)


 PERFORMANCE ORDER

  1. Details of installation of an intermediate cooler of a path of pressurization of air on models 163.128 (the series 628 engine) are shown on an illustration to which all references which are found in the text belong.
  2. Open a cowl and record it in vertical position.
  3. Remove both block headlights.
  4. Remove the top forward cross beam of a frame.
  5. Disconnect from the right side of a cooler (1) an air sleeve (2).
  6. Turn out screws of fastening of connecting plates (3) at the left on the heat exchanger of a cooler (1).
  7. Turn out fixing screws (shooters) and remove a cooler (1).
  8. Installation is made upside-down, - do not forget to replace sealing elements.

Removal and installation of the air distributor

Details of installation of the air distributor on models 163.128 (the series 628 engine)

Details of installation of the air distributor on models 163.128 (the series 628 engine)


 PERFORMANCE ORDER

  1. Details of installation of the air distributor of a path of pressurization of air on models 163.128 (the series 628 engine) are shown on illustrations to which all references which are found in the text belong.
  2. Remove the fuel filter (1) assembled with a basic arm.
  3. Remove the valvate block (2).
  4. Remove overlays (3) covers of heads of cylinders and disconnect maslootvodyashchy tubes from nozzles.
  5. Remove fuel highways (4).
  6. Remove bypass air ducts (5), - only for the lower section (6), - air ducts (5) are removed assembled with the top sections of the air distributor (7).
  7. Disconnect the line (8) from the vacuum pump, remove and shift an arm (9) aside.
  8. Disconnect the vacuum line (10) of the locking valve of inlet port.
  9. Remove a tape bandage (11) fixings of the transport pipeline.
  10. Turn out bolts (12).
  11. Turn out bolts (13) of fastening of a cooler of EGR.
  12. Disconnect from the line (15) hoses of a cooling path (14).
  13. Remove and take aside the line of a cooling path (15).
  14. Remove basic arms (16) of the left and right positioners of EGR.
  15. Turn out fixing bolts (17) and remove the top sections of the air distributor (7) assembled with bypass sleeves (5).
  16. Installation is made upside-down, - do not forget to replace sealing elements and the failed components.

Removal and installation of inlet sleeves of a path of pressurization of air

Details of installation of the left inlet sleeve of a path of pressurization of air on models 163.128 (the series 628 engine)

Details of installation of the right inlet sleeve of a path of pressurization of air on models 163.128 (the series 628 engine)

1 — the Inlet sleeve
2 — the Bolt
3 — the Hose collar

4 — the Bolt
5 — the Cover

Details of installation of inlet sleeves of a path of pressurization of air on models 163.128 (the series 628 engine) are shown on illustrations to which all references which are found in the text belong.

Left sleeve

 PERFORMANCE ORDER

  1. Remove the left forward wheel and a loker of protection of a wheel arch.
  2. Disconnect an inlet sleeve from the air distributor.
  3. Turn out bolts (2) flanges (3).
  4. Turn out a bolt (5) on a cover of a head of cylinders.
  5. Release a collar (4) and remove an inlet sleeve (1).
  6. Installation is made upside-down.

Right sleeve

 PERFORMANCE ORDER

  1. Disconnect an inlet sleeve from the air distributor.
  2. Disconnect an electrical wiring from the pressurization pressure sensor.
  3. Turn out a bolt (2) on a cover of a head of cylinders.
  4. Release a collar (3) and remove an inlet sleeve (1).
  5. Installation is made upside-down.

Removal and installation of the lower sleeves of a path of pressurization of air

Details of installation of the left lower sleeve of a path of pressurization of air on models 163.128 (the series 628 engine)

Details of installation of the left lower sleeve of a path of pressurization of air on models 163.128 (the series 628 engine)

Details of installation of the right lower sleeve of a path of pressurization of air on models 163.128 (the series 628 engine)

Details of installation of the right lower sleeve of a path of pressurization of air on models 163.128 (the series 628 engine)

Details of installation of the lower sleeves of a path of pressurization of air on models 163.128 (the series 628 engine) are shown on illustrations to which all references which are found in the text belong.

Left sleeve

 PERFORMANCE ORDER

  1. Remove the lower section of a noise isolation.
  2. Remove a sleeve of a path of pressurization of air (3).
  3. Turn out bolts (1).
  4. Release the top screw of a connecting plate (5) on an inlet flange (4) turbocompressors (6).
  5. Turn out the lower screw of a plate (5) on an air sleeve (2).
  6. Disconnect a sleeve (2) from a flange (4) turbocompressors (6) and remove it from the engine, having lowered down.
  7. Installation is made upside-down, - do not forget to replace a sealing ring.

Right sleeve

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery.
  2. Remove the lower section of a noise isolation.
  3. Remove protective covers of electric lines (6 and 7) of a starter (M1), - plugs No. No. 30 and 50.
  4. Turn out bolts of fastening of a starter to a transmission dome.
  5. Release the top screw of a connecting plate (5) on an inlet flange of a turbocompressor (4).
  6. Turn out the lower screw of a plate (5) on an air sleeve (1).
  7. Disconnect a sleeve (2) air ducts (1).
  8. Remove basic arms (3) from the lower section of the pallet of a case and from an air duct (1).
  9. Remove the top arm (shooter) of an air duct from an engine case.
  10. Take aside a starter and the ATF lines and disconnect an air sleeve from an inlet flange of a turbocompressor.
  11. Pass a sleeve forward and take it from a motive compartment.
  12. Installation is made upside-down, - do not forget to replace a sealing ring.

Removal and installation of bypass air ducts

Details of installation of bypass air ducts on models 163.128 (the series 628 engine)

1 — Bypass an air duct

2 — Basic arms of lines of a cooling path

Details of installation of bypass air ducts on models 163.128 (the series 628 engine)

1 — Bypass an air duct
3 — the Sensor

4 — the Air sleeve

Details of installation of bypass air ducts on models 163.128 (the series 628 engine)

1 — Bypass air ducts
5 — the Right connecting branch pipe
6 — Hydraulic a tench of GUR

7 — the Left connecting branch pipe
8 — the EGR Line


 PERFORMANCE ORDER

  1. Details of installation of bypass air ducts on models 163.128 (the series 628 engine) are shown on illustrations to which all references which are found in the text belong.
  2. Remove panels of finishing of the power unit.
  3. Disconnect an electrical wiring from the sensor (3).
  4. Release lines of a cooling path from an arm (2).
  5. Disconnect an air sleeve (4) from a bypass sleeve (1).
  6. Separate the GUR (6) line from an air sleeve.
  7. Separate a tube of EGR (8) from a connecting flange of a head of cylinders (shooter).
  8. Disconnect bypass sleeves from connecting branch pipes (5 and 7) and remove them from the engine.
  9. Installation is made upside-down, - do not forget to replace sealing elements.

Removal and installation of intermediate connecting branch pipes

Details of installation of intermediate connecting branch pipes of an air path of the engine of a series 628

1 — the Right connecting branch pipe
2 — the Left connecting branch pipe
3 — the Fuel filter
4 — the Positioner of a butterfly valve with the top air sleeves
5 — the Screw
6 — the Screw

7 — the Screw
8 — the Vacuum block of an overshoot of inlet port
9 — Draft
10 — the Sealing ring
11 — the Sealing ring


 PERFORMANCE ORDER

  1. Details of installation of intermediate air ducts on models 163.128 (the series 628 engine) are shown on an illustration to which all references which are found in the text belong.
  2. Lift a cover of the power unit.
  3. Remove bypass air ducts (see above).
  4. Remove the fuel filter (3).
  5. Turn out screws (5) and remove the right connecting branch pipe (1).
  6. Disconnect draft (9) of the vacuum block of an overshoot of inlet port (8).
  7. Turn out the screw (7) and take aside the vacuum block (8).
  8. Turn out screws (6) and remove the left connecting branch pipe (2).
  9. Installation is made upside-down, - do not forget to replace sealing rings (10 and 11).