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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mercedes-Benz M-Class (W163, 1997 issue)
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 Mercedes-Benz W163
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Mercedes-Benz
W163
Introduction
Controls and receptions of safe operation
Current care and maintenance
Engine
Check the compression pressure in the cylinders
Checking the engine by means of the vacuum gauge
Replace accessory drive belt and its tension elements of the mechanism
Petrol models
Diesel models
System of cooling, heating and air conditioner
The power supply system and exhaust
Systems of an electric motor
Manual box of a gear change
The transmission automatically processed
Transmission Line
Brakes and auxiliary systems
Suspension and steering
Body
Onboard electric
 


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Engine



The following are the parameters used when performing the described procedures in this chapter. Detailed regulatory information can be found on branded service stations hundred Mercedes-Benz. Separate characteristics are resulted also in the text of the Head and in case of compulsion of their performance are highlighted in bold.


Common parameters

Designation, engine type
Petrol models
ML 230 (163.136) 111,977, in-line, 4-cylinder, DOHC, water-cooled, timing chain drive and microprocessor control
ML 320 (163.154) 112.942, V-shaped, 6-cylinder, DOHC, water-cooled, timing chain drive and microprocessor control
ML 350 (163.157) 112.970, V-shaped, 6-cylinder, DOHC, water-cooled, timing chain drive and microprocessor control
ML 430 (163.172) 113.942, V-shaped 8-cylinder, DOHC, water-cooled, timing chain drive and microprocessor control
ML 55 AMG (163.174) 113.981, V-shaped 8-cylinder, DOHC, water-cooled, timing chain drive and microprocessor control
ML 500 (163.175) 113.965, V-shaped 8-cylinder, DOHC, water-cooled, timing chain drive and microprocessor control
Diesel models
ML 270 CDI (163.113) 612,963, inline 5-cylinder, DOHC, water-cooled, chain-driven timing and turbocharger
ML 400 CDI (163.128) 628.963, V-shaped 8-cylinder, DOHC, water-cooled, chain-driven timing and turbocharger
Engine See. Specifications to the Head Controls and receptions of safe operation
Rated power output See. Specifications to the Head Controls and receptions of safe operation
Rated torque See. Specifications to the Head Controls and receptions of safe operation
Maximum engine speed See. Specifications to the Head Controls and receptions of safe operation
Compression ratio
Engines Series 111 9.0
Engines Series 112 100
Engines Series 113 No data available
Engines Series 612 No data available
Engines Series 628 No data available
Pressure compression bar
Engines Series 111
  • Nominal value
11 ÷ 15
  • The maximum allowable difference in readings between cylinders
15
Engines series 112 and 113
  • Nominal value
12 ÷ 14
  • The minimum allowable value
9.0
  • The maximum allowable difference in readings between cylinders
15
Engines series 612 and 628
  • Nominal value
29 ÷ 35
  • The minimum acceptable value (approx)
18
  • The maximum allowable difference in readings between cylinders
thirty
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
Bore
Engines Series 111 No data available
112,942 Engine 92.0
112,970 Engine No data available
113,942 Engine 89.90
113,981 Engine 97.00
113,965 Engine No data available
Engines Series 612 No data available
Engines Series 628 No data available
Drive belt, mm

Engines Series 111

  • - K / V - GUR VDA
2040
  • - K / V + GUR VDA
2055
  • + K / V - GUR VDA
2140
  • + R / V + GUR VDA
2155
Engines Series 112 No data available
Engines Series 113 No data available
Engines Series 612 (+ R / V + GUR VDA) 2271
Engines Series 628 No data available
Valve clearance Not regulated as used hydraulic lifters
Gas distribution mechanism
The codes of camshafts

Engine 111.977 (230 ML)

  • The inlet shaft
18
  • The outlet shaft
17
Engine 112.942 (ML 320) No data available
Engine 112.970 (ML 350) No data available
Engine 113.942 (430 ML) No data available
Engine 113.981 (ML 55 AMG) No data available
Engine 113.965 (ML 500) No data available
Engine 612.963 (ML 270 CDI)
  • The inlet shaft
01
  • The outlet shaft
00
Engine 628.963 (ML 400 CDI)

The left cylinder head

  • The inlet shaft
02
  • The outlet shaft
03
The right cylinder head
  • The inlet shaft
00
  • The outlet shaft
01
Timing (2 millimetrovoeotkryvanie during run-in chain)
Engine 111.977 (230 ML)

The intake valves

  • Opening
20.0 ?� ATDC
  • Closing
29.5 ?� after BDC
The exhaust valves
  • Opening
19.5 ?� before the BDC
  • Closing
14.0 ?� before TDC
Engine 112.942 (ML 320)
The left cylinder head
The intake valves
  • Opening
24.9 ?� ATDC
  • Closing
25.9 ?� after BDC
The exhaust valves
  • Opening
31.5 ?� before the BDC
  • Closing
12.1 ?� before TDC
The right cylinder head
The intake valves
  • Opening
26.5 ?� ATDC
  • Closing
27.5 ?� after BDC
The exhaust valves
  • Opening
29.9 ?� before the BDC
  • Closing
10.5 ?� before TDC
Engine 112.970 (ML 350) No data available
Engine 113.942 (430 ML)
The left cylinder head

The intake valves

  • Opening
31.9 ?� ATDC
  • Closing
28.2 ?� after BDC
The exhaust valves
  • Opening
24.1 ?� before the BDC
  • Closing
9.1 ?� before TDC
The right cylinder head

The intake valves

  • Opening
33.5 ?� ATDC
  • Closing
29.8 ?� after BDC
The exhaust valves
  • Opening
22.5 ?� before the BDC
  • Closing
7.5 ?� before TDC
Engine 113.981 (ML 55 AMG)
The left and right cylinder heads

The intake valves

  • Opening
25 ?� ATDC
  • Closing
39 ?� after BDC
The exhaust valves
  • Opening
35 ?� before BDC
  • Closing
15 ?� before TDC
Engine 113.965 (ML 500)
The left cylinder head

The intake valves

  • Opening
30.9 ?� ATDC
  • Closing
25.7 ?� after BDC
The exhaust valves
  • Opening
23.2 ?� before the BDC
  • Closing
9.1 ?� before TDC
The right cylinder head

The intake valves

  • Opening
32.5 ?� ATDC
  • Closing
27.3 ?� after BDC
The exhaust valves
  • Opening
21.6 ?� before the BDC
  • Closing
7.5 ?� before TDC
Engine 612.963 (ML 270 CDI)
The intake valves
  • Opening
19 ?� ATDC
  • Closing
7 ?� after BDC
The exhaust valves
  • Opening
9 ?� before BDC
  • Closing
22 ?� before TDC
Engine 628.963 (ML 400 CDI) No data available
Additional parameters for the engine 111.977 (ML 230)
The maximum allowable radial play vibration damper, mm 0.6
Maximum permissible axial play of the vibration damper, mm 0.6
The diameter of the camshaft bearing, mm
Nominal value 28.00 ÷ 28.02
Workshop value 28.50 ÷ 28.52
The diameter of the bearing journals of the camshaft, mm
Nominal value 27.95 ÷ 27.96
Workshop value 28.45 ÷ 28.46
The axial clearance of camshafts, mm 0.05 ÷ 0.15
Efforts of a tightening of carving connections, Nanometer



These are listed in order of presentation (succession of sections).

M111
Tension wheel nut to the tensioner assembly accessory drive belt 25
Bolts damper tensioner accessory drive belt 25
Bolts tensioner 25
Bolt steering pump to timing cover 20
Bolts of fastening of transmission to the engine

M10x40

Plated yellow 55
With synthetic coating Dacromet / chrome 40
M10x90
Plated with yellow 45
With synthetic coating Dacromet / chrome 40
Bolts front cylinder head cover
M6 10
M8 25
Bolts timing cover
To the engine block (M8) 25
To the cylinder head
  • Step 1
18
  • Step 2
To hold 90 ?�
Bolts of asterisks of camshafts to the flanges
  • Step 1
20
  • Step 2
To hold up to 60 ?�
Nuts of fastening of asterisks of camshafts to the flanges 65
Chain guide bolts to the cylinder head 10
Plug chain tensioner 40
Chain tensioner in the timing cover 80
Central bolt knob to the camshaft
  • Step 1
5
  • Step 2
To hold 90 ?�
Bolts of fastening of covers of bearings of camshafts 21
Cylinder head bolts
M12
  • Step 1
55
  • Step 2
To hold a 90 ?� angle
  • Step 3
To hold a 90 ?� angle
To cover timing
  • Step 1
18
  • Step 2
To hold 90 ?�
Bolts and nuts intake manifold to the cylinder head 20
Bolts of fastening the rear end of the engine cover 10
The central bolt of vibration damper (Class 10.9) 300
Bolts flywheel / drive disc to the crankshaft
Step 1 40/45
Step 2 To hold 90 ?�
Nuts of fastening pads Front Mount power unit
To the frame of the car 35
To support arm 65
Bolts / nuts cushion back support suspension of the power unit
By the transmission housing 35
By crossmember 35
Nuts of fastening of the crossbeam to the vehicle frame 35
Sump bolts
The cylinder block
  • M6
10
  • M8
25
  • M10
-
Transmission to the dome 40
Bolts of fastening of the oil pump
Hexagonal 25
TORX 18
M112 / 113
Self-tapping bolt tensioner to cover timing
  • The thread does not cut
35
  • The thread is cut
25
Bolts damper tensioner accessory drive belt
Tensioner 25
To the water pump 35
Bolts tensioner 25
The socket assembly connected to the fuel pipe feeding fuel line 38
Flanged reception pipe exhaust system with exhaust manifold 20
Bolts starter against the crankcase 42
Bolts pads front support to the subframe 35
M8 bolts fastening the torque converter to the drive disk 42
AT bolts to the engine
M10x40 and M10x90 40
M12 -
Mounts hydraulic lines to the steering pump

Pressure line

  • M14x1.5
-
  • M16x1.5
45
Return line 2
Tighten the screws on the compressor K / V to the support bracket 20
Bolts timing cover to the block and the cylinder head 20
Bolt M8x78 mounting idler belt K / B and auxiliary units to cover timing 68
Bolts of fastening of the water pump
Self-tapping

M6

  • The thread does not cut
14
  • The thread is cut
10
M8
  • The thread does not cut
35
  • The thread is cut
25
Standard (M7) 10
Fixing water pump pulley 10
Thermostat housing bolts (M6) 10
Bolts steering pump

Self-tapping

  • The thread does not cut
35
  • The thread is cut
20
Standard 25
Bolts intake manifold to the cylinder heads (M8) 20
Chain tensioner in the timing cover 80
Bolt stars camshafts

(M12x45)

  • Step 1
50
  • Step 2
To hold a 90 ?� angle
The Hall sensor of a camshaft in the cylinder head 8
Bolts camshaft bearing bridge to the cylinder heads

M7x45

  • Step 1
15
  • Step 2
-
M7x84
  • Step 1
10
  • Step 2
To hold a 90 ?� angle
Bolts of asterisks of camshafts

(M12x45)

Step 1 50
Step 2 To hold a 90 ?� angle
Cylinder head bolts

To the engine block (inside TORX)

  • Step 1
10
  • Step 2
thirty
  • Step 3
To hold a 90 ?� angle
  • Step 4
To hold a 90 ?� angle
To cover timing 20
Bolts cylinder head covers 10
Nut connecting pipe to the EGR valve 40
Flanged reception pipe exhaust system with exhaust manifold 20
Nuts of fastening of a final collector 16
Wheel bolts 150
Bolts of fastening of the end cap of the engine 10
The central bolt of vibration damper
Step 1 200
Step 2 To hold at an angle of 95 ?�
Bolts disk drive to the crankshaft
Step 1 45
Step 2 To hold a 90 ?� angle
Bolts / nuts cushion back support suspension of the power unit
By the transmission housing 35
By crossmember 35
Nuts of fastening of the crossbeam to the vehicle frame 35
Bolts left and right side supports the suspension of the power unit to the crankcase
Step 1 20
Step 2 To hold a 90 ?� angle
Bolts airbags Front Mount power unit
The subframe 35
To support arm 65
The cover casing of the oil filter 25
Bolts of the oil filter housing assembly 70
Fixing liquid heat exchanger oil filter eleven
Drain plug oil pan (M14) thirty
Self-tapping screws the lower section of the sump to the top
The thread does not cut 14
The thread is cut 10
Bolts of fastening of the top section of the oil pan to the cylinder block
M6 9
M8 20
Bolts oil level sensor to the upper section of the oil pan 10
Bolts lubricators 15
Oil pump bolts (M8x30) 20
M612
  • Tighten the screws on the trim panel of the cylinder head cover
10
  • Tighten the screws on the trim panel diffusers
10
  • Bolts support bracket sleeves supercharge air distribution
20
Mounts steering pump pressure line
M14x1.5 -
M16x1.5 45
Hollow screw couplings oil return line to the radiator thirty
Bolts compressor K / V to cover timing 20
Bolts to the engine AT
M10x40 and M10x90 40
M12 -
Bolts front cylinder head cover 14
The cylinder head bolts to the timing cover (M8) 20
Bolts timing cover to the crankcase
M6 -
M8 20
Sump bolts

To the engine block

  • M6
9
  • M8
20
  • M10
-
To cover the timing (M6) 9
Side bolts 9
Drain plug oil pan (M14) thirty
Central bolt of vibration damper
Strength class 8.8
  • Step 1
200
  • Step 2
To hold a 90 ?� angle
Class 10.9
  • Step 1
325
  • Step 2
To hold a 90 ?� angle
Bolts compressor K / V to cover timing 20
Bolts of fastening of covers of bearings of camshafts to the cylinder head 9
Bolt exhaust camshaft sprocket 18
Bolt pump idler sprocket 40
Bolt tensioning gas distribution chain to cover timing 80
Cylinder head bolts
To cover the timing (M8) 20
To the engine block (M12)
  • Step 1
60
  • Step 2
To hold a 90 ?� angle
  • Step 3
To hold a 90 ?� angle
Nut pressure line fuel pump / fuel distribution pipe 20
The node connecting the front of the catalytic converter to the turbocharger thirty
Bolt oil return line of the turbocharger 9
Bolts support bracket to the turbocharger thirty
Bolts distribution charge air hoses tract
  • M5
-
  • M7
16
Yokes air path 3
Bolt the support bracket to the distribution arm of the charge air tract 20
Bolt the support bracket to the mounting bracket Engine 40
Bolts motor off the inlet port to the sleeve of the air distribution path of boost 9
Nuts of fastening of the exhaust manifold to the cylinder head thirty
Bolts of fastening the rear end of the engine cover 9
Bolts flywheel / drive disc to the crankshaft
  • Step 1
45
  • Step 2
To hold a 90 ?� angle
The cover casing of the oil filter 25
Fixing liquid heat exchanger oil filter 15
Sump bolts

To the engine block

  • M6
9
  • M8
20
  • M10
-
By the transmission housing 40
To cover the timing (M6) 9
Bolts oil level sensor to the sump 14
Bolts of fastening of the oil pump 18
M628
Tensioner accessory drive belt in the crankcase thirty
The node connecting the front of the catalytic converter to the turbocharger 15
Bolts torque converter to the drive disk (M8) 42
Union nuts / bolts hollow choke lines tract cooling ATF 35
Mounts steering pump pressure line
M14x1.5 -
M16x1.5 45
Hollow screw couplings oil return line to the radiator thirty
Bolt refrigeration lines to the compressor K / V 20
Bolts to the engine AT
M10x40 and M10x90 40
M12 -
Bolts front cylinder head cover 14
The pins riveted links the gas distribution chain (approximate value) 28
Bolts of fastening of covers of bearings of camshafts to the cylinder head 9
Bolt exhaust camshaft sprocket 18
Bolt pump idler sprocket 40
Bolt tensioning gas distribution chain to cover timing 80
Cover bolts centrifuge to the crankcase 8
Bolts cylinder head
To cover the timing (M8) 20
To the engine block
Step 1 20
Step 2 60
Step 3 To hold a 90 ?� angle
Step 4 To hold a 90 ?� angle
Step 5 To hold a 90 ?� angle
Bolt oil return line of the turbocharger 9
Bolts support bracket to the turbocharger thirty
Nuts of fastening of the exhaust manifold to the cylinder head thirty
Bolts of fastening the rear end of the engine cover 9
Drain plug oil pan (M14) 32
Sump bolts

To the engine block

M6 19
M8 20
M10 -
By the transmission housing 40
To cover the timing (M6) 9
Central bolt of vibration damper
Step 1 275
Step 2 To hold a 90 ?� angle
Bolts disk drive to the crankshaft
Step 1 45
Step 2 To hold a 90 ?� angle
The cover casing of the oil filter 25
Fixing liquid heat exchanger oil filter 15
Fixing the vent line to the left of the inlet pipeline eleven
Self-tapping screws the lower section of the sump to the top
The thread does not cut 12
The thread is cut 8
Bolts of fastening of the top section of the oil pan to the engine block (M6) 8
Oil pump bolts (TORX) 8
Fixing screws to assemble the oil pump cover with the oil pipe 10




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