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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mercedes-Benz M-Class (W163, 1997 issue)

general info. full specifications. diagnostics. hints. tips. tricks
Mercedes-Benz W163
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Mercedes-Benz
W163
Introduction
Controls and receptions of safe operation
Current care and maintenance
Engine
System of cooling, heating and air conditioner
The power supply system and exhaust
The power supply system of petrol engines
The power supply system of diesel engines
Exhaust systems and reduce emissions
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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The power supply system and exhaust



Separate characteristics are resulted also in the text of the Head and in case of compulsion of their performance are highlighted in bold.

Power system

general information

Grades used fuel See. Specifications to the Head Controls and receptions of safe operation
The fuel tank See. Specifications to the Head Current leaving and service
Type of injection
Petrol models Electronic microprocessor-injection system (SPFI)
  • M111
HFM-SFI
  • M112 / 113
ME-SFI
Diesel models CDI
The principle of measurement of air flow Hot-film sensor (MAF)
Diesel injection
Type Pump
ML 270 CDI Bosch, EDC 15C, Common rail
ML 400 CDI No data available
The procedure for fuel injection
ML 270 CDI 1-2-4-5-3
ML 400 CDI 1-5-4-8-6-3-7-2
Adjusting data
Idling speed, min -1

Petrol models

  • ML 230
600 ÷ 900, adjustment shall not be
  • ML 320
600 ÷ 850, adjustment shall not be
  • ML 350
No data available
  • ML 430
550 ÷ 800, adjustment shall not be
  • ML 55 AMG
No data available
  • ML 500
No data available
Diesel models
  • ML 270 CDI
640 ÷ 840
  • ML 400 CDI
No data available
Limitation of revolutions without load (diesel models), min -1
ML 270 CDI 4500 ÷ 4900 (less than 1 second when checking the transparency of exhaust gases)
ML 400 CDI No data available
CO content at idle speed, oil temperature of 60 ?� C (all petrol models) Not more than 0.5%, adjustment can not be
The content of the National Assembly at idle, ppm (particles) (all petrol models) 100
The content of CO 2 in the idle (all petrol models) 14.5-16%
The content of O 2 at idle (all petrol models) 0.1-0.5%
The content of CO in the 2200-2800 rev / min (all petrol models) 0.3%
The lambda value in the 2200-2800 rev / min (all petrol models) 0.97-1.03
The opacity of the exhaust gases (diesel models)
EU limit Not more than 73%
Homology value 56%
Efforts of a tightening of carving connections, Nanometer
Power system

Petrol models

Bolt actuator electronic throttle actuator to the inlet pipeline (except the ML 55 AMG) 9
Securing supply fuel pipe to the fuel distribution manifold
Models with engine series 111 24
Models with engines of series 112 and 113 38
Union nut-mounting ring assembly fuel pump / gauge of a stock of fuel in the fuel tank 65
Clamp locking fuel valve 20
Bolts fuel line to the cylinder head 25
Self-locking bolts to the frame of the rear subframe 200
Self-locking bolts to the propeller shaft coupling flange of the rear differential 50
Bolts mounting tapes fixing the fuel tank 20
Bolts longitudinal strips processing by a mounting tapes 20
Bolts mounting bracket fixing additional fuel tank (model 163.174) 20
Bolts body assembly to the frame 65
Hollow bolts fuel pipe to the fuel filter 27
Diesel models
Tighten the screws on the trim panel of the cylinder head cover 10
Tighten the screws on the trim panel diffusers 10
Union nut-mounting ring assembly gauge of a stock of fuel in the fuel tank 65
Bolts mounting tapes fixing the fuel tank 20
Bolts longitudinal strips processing by a mounting tapes 20
Self-locking bolts to the frame of the rear subframe 200
Self-locking bolts to the propeller shaft coupling flange of the rear differential 50
Flanged mounting the exhaust manifold to the turbocharger thirty
Mounting the turbocharger to the front of the catalytic converter (model 163.113) thirty
Bolt oil return line of the turbocharger 9
Bolt oil supply line to the turbocharger thirty
Bolt oil supply line to the cylinder head
  • Models 163,113
22
  • Models 163,128
10
Bolts turbocharger thirty
Bolts turbocharger support bracket to the crankcase (models 163.113) 20
Bolt Sleeve tract charge air (M7) 16
Bolt support bracket tract charge air hose (models 163.113) 20
Bolt cooling line to the upper arm tract charge air 9
Bolt servo actuator overlapping inlet port (models 163.113) 9
Nut terminals 30 (only models 163.128) 14
Nut terminals 50 (only models 163.128) 6
Bolts starter (model 163.128) 42
Bolt fuel pump prior to the top of the cylinder head cover (model 163.113) / pump (model 163.128) 9
Flare nuts pressure line to the fuel pump and the fuel line (model 163.113) / valve assembly (model 163.128) 20
Screws injector mounting clips
  • Step 1
7
  • Step 2
To hold a 90 ?� angle
Bolt the support bracket to the pump (model 163.113) 9
Pump bolts to the cylinder head (model 163.128) 14
Bolts fuel line to the cylinder head
  • Models 163,113
14
  • Models 163,128
20
Hollow bolt leak oil line to the fuel line (model 163.113) / valve block (model 163.128) 20
Nuts of fastening pressure lines to the fuel line / nozzle
  • Latest
20
  • Used
25
Mounting of the pressure sensor in the fuel distribution manifold
  • Models 163.113 (a highway)
20
  • Models 163.128 (a valve block)
35
Bolt shut-off the fuel valve (model 163.113) 8
Bolt valve, fuel pressure regulator to the line (model 163.113) / valve assembly (model 163.128)
  • Step 1
3
  • Step 2
5
Mounting manifold to the air (only model 163.128) 12
Bolt locking clamp pressure line to the sleeve of the diffuser (model 163.128) 8
Couplings pressure lines nozzles 42
Exhaust systems and reduce emissions
Petrol models
Bolts flange connection on the receiving pipe (s) of the exhaust system with the exhaust manifold (s) 20
The nut bracket fixing exhaust pipe package AMG (except models 163.174) 55
Screw the support bracket of the suspension of the exhaust system to the transmission housing (model 163.174) 20
Locking nuts reception pipe exhaust system (model 163.174) 29
Lambda sensors in exhaust gas / exhaust manifold 55
Bolt the EGR valve on the cylinder head (except models 163.136) 20
Bolting securing EGR pipe to the valve EGR (except models 163.136) 40
Bolts for flange mounting EGR pipe to the intake manifold (except models 163.136)
In addition to the models 163,136 and 163,157 9
Models 163,157 8
Bolts air pump support bracket (except models 163.136) 12
Diesel models
Bolts flange connection on the receiving pipe (s) of the exhaust system with the exhaust manifold (s) 20
The nut bracket fixing exhaust pipe package AMG (except models 163.174) 55
Nut suspension support bracket to the threaded mounting plate of the middle section of the exhaust system and to the transmission housing 20
Bolt mounting bracket joint front and rear sections of the exhaust system 55
Mounting the turbocharger to the front of the catalytic converter thirty
Bolt the support bracket of the catalytic converter to the crankcase 20
Nuts of fastening the rear transverse beam to the frame of the power unit (model 163.128) 40
Bolts positioners (activators) EGR to EGR nipples on the cylinder head (163.128 models only) 15
Bolt EGR pipe to the cooler EGR (163.128 models only) 15
Bolts support bracket positioners EGR (163.128 models only) 15
Bolts EGR cooler EGR positioner and the top of the diffuser (models 163.128) 15

General information and safety measures

Gasoline engines

The composition of the fuel system are: installed in the rear of the car (under the rear bench seat) fuel tank to the adsorption on activated carbon, fuel, electric fuel pump, and the electronic system of sequential injection, controlled by the control unit.

Fuel is displayed to the driver on the instrument panel. In the gasoline engine gasoline vapors are collected in the absorber and fed into the combustion chambers of the engine.

A significant impact on fuel consumption has a style of driving. Below are a few tips for the wise management of the gas pedal:

  • After starting the engine once started, even if it takes place in the cold;
  • When the vehicle is stopped for more than 40 seconds, turn off the engine;
  • Move always on the highest possible transmission;
  • When driving long distances as far as possible to maintain a uniform speed. Avoid driving at high speed. Operate the vehicle with caution. Without need do not brake;
  • Do not carry unnecessary burden is not a car. If the trunk is not in use, remove it from the roof;
  • Check the air pressure in the tires. Avoid excessive pressure drop.

Diesel engines

The composition of the fuel system are: installed in the rear of the car (under the rear bench seat) fuel tank, fuel filter, fuel injectors, fuel pipes and hoses, fuel reserve sensor located inside the tank and the engine electronic control unit.

Fuel is supplied through a special pump filter. In the filter accumulates dirt and the water contained in the fuel.

The motor controlled by an electronic system, a control system similar to petrol engines. The system controls the operation of the engine, analyzing information from a large number of sensors.

On diesel models, no accelerator cable. Instead, the pedal position sensor is installed it.

Fuel shut-off valve when the ignition is absent. In order to stop the engine when the ignition, the engine control unit sends a signal to pump control unit which, in turn, stops the supply of fuel to the injectors.

The fuel system is designed in such a way as to prevent "choke" the absence of air in the fuel tank. The control unit continuously checks the fuel level in the tank, processing information from the sensor supply of fuel in the tank. In the fall of fuel supply to a certain level the control unit activates the warning lamp in the instrument cluster, and then forcibly causes the fuel supply passes, thereby limiting the maximum speed. This continues until the fuel level in the tank does not exceed the allowable mark.

Fuel system Diesel engines are very reliable. When using cleaner fuels and performing regular maintenance, it must function properly until the end of life of the vehicle. After a very high mileage internal components can wear out nozzles, and will need to be repaired. Since the pump - nozzle have a complex construction, repair is recommended to a specialist workshop.

Security measures and rules of observance of cleanliness at work with fuel system

When working on the fuel system, observe the following safety precautions and cleanliness:

  • Do not go near the place of work with open fire, do not smoke and do not include any heating appliances! Keep a fire extinguisher at the ready;
  • Watch for normal ventilation of the workplace, - fuel vapors are poisonous;
  • The fuel system is pressurized. With the opening of the fuel can escape under pressure - use protective glasses. Spilled fuel collect rags;
  • When working with the components of the power supply system of the diesel engine, observe special precautionary measures. In particular it concerns the injectors. Keep in mind that the fuel pressure at the outlet of the nozzles is about 1,100 atmospheres, - do not expose any part of the body under the stream of fuel;
  • Hose connections are secured using tape or clamps. Clamps must always be replaced by the band clamps or final design. To install the belt clamps Special tools are available (for example, HAZET 796-5);
  • Links and adjacent space before opening thoroughly clean;
  • The removed components install on a clean surface and cover with polyethylene, paper or lint-free cloth;
  • Carefully cover the exposed ends of the connectors choke or clog them suitable plugs;
  • On-site only clean parts - Replacement Parts unwrap just before installation. Do not use the stored unpackaged items;
  • Avoid the use of compressed air at an open fuel system, if possible, try not to move the car;
  • Do not use sealants containing silicone - trapped in the engine silicone particles do not burn, and can cause failure of the oxygen sensor.

Safety precautions when removing the fuel tank

  • Before removing the tank, drain the fuel or the fuel pump out specially provided for this pump;
  • The fuel tank is removed from the underside of the vehicle. Before removing the clamps securing the tank, move it to the bottom of the jack and the pad;
  • The empty tank is explosive and can not be reclaimed as such. Before disposing of the tank should be cut into pieces. Make sure that when it did not have the spark. To do this, turn in the fuel tank to a specialized company;
  • After installation of the tank in place, start the engine and check the tightness of all connections.




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The power supply system of petrol engines

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