Mercedes M-Class W163

since 1997 of release

Repair and car operation



Mercedes W163
+ Mercedes-Benz Cars of a class M (W163)
+ Governing bodies and receptions of safe operation
+ Current leaving and service
+ Engine
+ Systems of cooling, 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 a drive of a butterfly valve
      Oporozhneniye of a fuel tank
      Removal and installation of the sensor of a stock of fuel
      Air removal from a contour of low pressure of a fuel path, - on an example of the engine of a series 612
      Removal and installation of the preliminary fuel pump
      Removal and installation of the fuel pump of a high pressure (TNVD)
      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, - models 163.113
      Removal and installation of the valve regulator of pressure of fuel
      Removal and installation of klapanny 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 by fuel injection
      Removal and installation of a 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
+ Avtomaticheckaya transmission
+ Transmission line
+ Brake and auxiliary systems
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment


Service of components of an inlet air path

Models 163.113

Replacement of a filtering element of an air purifier

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


 PERFORMANCE ORDER

  1. The illustrative material on replacement of a filtering element of an air purifier on models 163.113 (the series 612 engine) is presented on an illustration which all references meeting in the text concern.
  2. Remove panels of furnish of a cover of a head of cylinders.
  3. Disconnect electroconducting from the MAF sensor (B2/5).
  4. Disconnect from an air purifier 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 an air purifier (4/1).
  7. Take filtering element (4/4).
  8. In case of need remove the bottom section of a casing of an air purifier (4/5), - pay attention on enclosed from below (from the engine) of a washer.
  9. Installation is made upside-down, - do not forget to replace the failed fixing collars.
  10. In summary dump the indication of the indicator of extent of pollution of a filtering element (shooter).

Removal and installation of the sensor of temperature of 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 which all references meeting in the text concern.
  2. Cut a tape bandage (1) fixing of the holder (3).
  3. Disunite the contact socket of electroconducting (2) IAT sensors (В17).
  4. Compress together fixing brackets (arrows) and liberate the sensor (В17) 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 should be made at the disunited contact socket, the probability of damage of fixing brackets (arrow) as a result of their pulling otherwise is not excluded!

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

Removal and turbokompressor installation

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


 PERFORMANCE ORDER

  1. Details of installation of a turbokompressor on models 163.113 (the series 612 engine) are shown on an illustration which all references meeting in the text concern.
  2. Remove the bottom section of sound insulation.
  3. Remove an air purifier (see above).
  4. Remove an air sleeve (4/2).
  5. Disconnect from a turbokompressor (110) air line (110/6).
  6. Disconnect from the vacuum block (110/10) a hose (4).
  7. To Otboltita the maslopodayushchy line (110/3) from a turbokompressor and the engine block, - at an otpuskaniye of a shtutserny nut hold a turbokompressor from a provorachivaniye.
  8. Remove the primary catalytic converter (120/1).
  9. To Otboltita from an engine case a basic arm (3).
  10. Remove a turbokompressor (110) assembled with an arm (3) and maslootvodyashchy lines (110/4).
  11. Disconnect from a turbokompressor (110) basic arm (3) and the maslootvodyashchy line (110/4), - prepare for collecting spilled oil.
  12. Installation is made upside-down. Do not forget to replace all sealing elements. A tightening of shtutserny nuts of oil pipelines make only after turbokompressor installation.
  13. In summary check level of impellent oil, in case of need make the corresponding adjustment (see. 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 which all references meeting in the text concern.
  2. Open a cowl and fix it in vertical situation.
  3. Remove block headlights (1) with slips (2).
  4. Remove a forward cross-section beam of a frame (3).
  5. Disunite the contact socket of electroconducting (4) IAT sensors (В17).
  6. Release fixing collars (5 and 6) and disconnect from the heat exchanger of a cooler (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 air distributor installation

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

1 — the Panel of furnish of a cover of a head of cylinders
2 — the Panel of furnish of the air distributor
3 — the Line of supply of fuel
4 — Final топливопровод
5 — the Mixing chamber
6 — a fuel Cooler
7 — Nizhny 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 line
13 — the Connecting branch pipe
21 — the Fuel highway
70 — Polnopotochny the 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 which all references meeting in the text concern.
  2. Open a cowl and fix it in vertical situation.
  3. Remove panels of furnish of the power unit (1 and 2).
  4. Remove the bottom section of a noise isolation.
  5. Disconnect a negative wire from the battery.
  6. Empty cooling system (see. Head of the Power supply system and production of the fulfilled gases).
  7. Remove a fuel (6) cooler.
  8. Remove the fuel highway (21) (see. Section Removal and installation of the fuel distributive highway and nozzles).
  9. Remove basic arms of the fuel highway.
  10. To Otboltita top basic arm (8) air distributor (110/1).
  11. Pump out oil from the GUR tank and disconnect from the last a hydraulic hose, - at once закупорьте the open ends of a hose and the union.
  12. Disconnect vacuum lines.
  13. Remove perelivny a radiator hose.
  14. Remove the air line connected to the mixing chamber (5) (12).
  15. Remove the mixing chamber (5).
  16. Remove a connecting branch pipe (13).
  17. Remove a thermostat casing (see. Head of System of cooling, heating and air conditioner).
  18. Remove a basic arm (10) fastenings on the pipeline of the air distributor of a tube of EGR system.
  19. Liberate from clamps a plait of the electroconducting laid along the distributive pipeline (110/1), - disunite contact sockets of sensors of level of oil (В40), CKP (L5), pressure of pressurization (В28), the terminal switch of locking of inlet port (S99) and the electromotor of a starter (М1).
  20. Turn out fixing bolts and remove the air distributor (110/1) pipeline from the bottom basic arm (7).
  21. Installation is made upside-down, - do not forget to replace sealing elements and the failed components.
  22. In summary make cleaning of memory of the module of onboard self-diagnostics (see. Head of System of electric equipment of the engine).

Removal and installation of the electromotor of the actuation mechanism of a perekryvaniye of inlet port

Details of installation of the electromotor of the actuation mechanism of a perekryvaniye of inlet port on models 163.113 (the series 612 engine)


 PERFORMANCE ORDER

  1. Details of installation of the electromotor of a drive of a perekryvaniye of inlet port on models 163.113 (the series 612 engine) are shown on an illustration which all references meeting in the text concern.
  2. On models from AT remove the air distributor (see above).
  3. On models from RKPP remove 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 from RKPP disunite the contact socket of electroconducting (4) electromotors (М55).
  7. Remove the electromotor (М55) from air distributor (5) assembly.
  8. Installation is made upside-down. Track correctness of landing of all positioning a zaslonok, check smoothness of their course. Do not forget to replace sealing elements.
  9. In summary make cleaning of memory of the module of onboard self-diagnostics (see. Head of System of electric equipment of the engine).

Models 163.128

Replacement of a filtering element of an air purifier

Design of an air purifier of models 163.128 (series 628 engine)


 PERFORMANCE ORDER

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

Removal and installation of the sensor of temperature of 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 which all references meeting in the text concern.
  2. Open a cowl.
  3. Remove the sleeve of the soaking-up fan of the engine laid ahead of an air purifier.
  4. Disunite the contact socket of electroconducting (1) sensor (В17), at the same time fixing fixing brackets (arrows) of the last.

Removal and installation of turbokompressor

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

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


 PERFORMANCE ORDER

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

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

  1. Installation is made upside-down. Do not forget to replace all sealing elements. A tightening of shtutserny nuts of oil pipelines make only after turbokompressor installation.
  2. In summary check level of impellent oil, in case of need make the corresponding adjustment (see. 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 which all references meeting in the text concern.
  2. Open a cowl and fix it in vertical situation.
  3. Remove both block headlights.
  4. Remove the top forward cross-section beam of a frame.
  5. Disconnect from the right side of a cooler (1) 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 air distributor installation

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 which all references meeting in the text concern.
  2. Remove the fuel filter (1) assembled with a basic arm.
  3. Remove the klapanny 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 lines (5), - only for the bottom section (6), - air lines (5) act in film assembled with the top sections of the air distributor (7).
  7. Disconnect from the vacuum pump the line (8), remove and shift aside an arm (9).
  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) fastenings of a cooler of EGR.
  12. Disconnect from the line (15) hoses of an okhladitelny path (14).
  13. Remove and take aside the line of an okhladitelny path (15).
  14. Remove basic arms (16) left and right pozitsioner 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 — Shlangovy a 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 which all references meeting in the text concern.

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 electroconducting from the sensor of pressure of pressurization.
  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 bottom sleeves of a path of pressurization of air

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

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

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

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

Details of installation of the bottom sleeves of a path of pressurization of air on models 163.128 (the series 628 engine) are shown on illustrations which all references meeting in the text concern.

Left sleeve

 PERFORMANCE ORDER

  1. Remove the bottom 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) turbokompressor (6).
  5. Turn out the bottom screw of a plate (5) on an air sleeve (2).
  6. Disconnect a sleeve (2) from a flange (4) turbokompressor (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 bottom section of a noise isolation.
  3. Remove protective covers of electric lines (6 and 7) a starter (М1), - No. No. 30 and 50 plugs.
  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 turbokompressor (4).
  6. Turn out the bottom screw of a plate (5) on an air sleeve (1).
  7. Disconnect a sleeve (2) air lines (1).
  8. Remove basic arms (3) from the bottom section of the pallet of a case and from an air line (1).
  9. Remove the top arm (shooter) of an air line from an engine case.
  10. Take aside a starter and the ATF lines and disconnect an air sleeve from an inlet flange of a turbokompressor.
  11. Pass a sleeve forward and take it from an impellent compartment.
  12. Installation is made upside-down, - do not forget to replace a sealing ring.

Removal and installation of bypass air lines

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

1 — Bypass an air line

2 — Basic arms of lines of an okhladitelny path

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

1 — Bypass an air line
3 — the Sensor

4 — the Air sleeve

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

1 — Bypass air lines
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 lines on models 163.128 (the series 628 engine) are shown on illustrations which all references meeting in the text concern.
  2. Remove panels of furnish of the power unit.
  3. Disconnect electroconducting from the sensor (3).
  4. Liberate lines of an okhladitelny path from an arm (2).
  5. Disconnect an air sleeve (4) from a bypass sleeve (1).
  6. Separate from an air sleeve the GUR (6) line.
  7. Separate EGR tube (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 — Pozitsioner of a butterfly valve with the top air sleeves
5 — the Screw
6 — the Screw

7 — the Screw
8 — the Vacuum block of a perekryvaniye of inlet port
9 — Draught
10 — the Sealing ring
11 — the Sealing ring


 PERFORMANCE ORDER

  1. Details of installation of intermediate air lines on models 163.128 (the series 628 engine) are shown on an illustration which all references meeting in the text concern.
  2. Lift a cover of the power unit.
  3. Remove bypass air lines (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) vacuum blocks of a perekryvaniye 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).