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A-Class W168 (1997-2004)
General information
User manual
Control Panel
Instrument panel and information display
Checking the engine oil level with a rod indicator (dipstick)
Maintenance interval indication
Heater control
Air conditioner control
Ice removal
Removal of internal fogging of glasses
Removal of external fogging of glasses
Rear window heater
Steering wheel adjustment
Seat heating
Airbags
Interior Light Switches
Interior rearview mirror
Cup holders on console and armrest
Using an outlet
Power window control
Headlight range control
Light switch
Steering column switches
Rear window wiper switch
Locking car locks
Opening and locking the tailgate
Emergency opening of the hatch of a refueling mouth
Anti-theft alarm switch with indicator light in the center console
Door mirror switches
Folding mirrors
Spare wheel vehicles
Vehicles equipped with TIREFIT tire sealant
Tire sealant TIREFIT
Bonnet opening handle
Glass washer
Location of fuses
Assignment of fuses and relays
Egnition lock
Manual Transmission
Automatic transmission
Tempomat (cruise control)
Cruise control with Speedtronic speed limiter
Car technical data
Maintenance
Car care
Starting the engine using a booster battery
Towing a car
Poddomkrachivanie car
Maintenance — list of works
Maintenance — work
Engine Compartment — Visual Inspection
Engine oil and oil filter — change
Coolant — level check
Coolant — Concentration Check
V-belt — condition check
Exhaust System — Visual Inspection
Spark plugs — removal and installation
Fuel filter — removal and installation
Air filter — filter element replacement
Transmission. main gear
Transmission — visual inspection for tightness
Suspension and steering
Steering collars — check
Ball joint caps — check
Power steering — fluid level check
Play of a support of a trailing arm of a back suspension bracket — check
Brakes, tires, wheels
Brake Fluid — Level Check
Brake Pads — Check Residual Thickness
Brake pads for drum brakes — checking the remaining thickness
Parking brake — function check, running in and adjustment
Brake Fluid — Change
Wheels and tires
Body — interior equipment
Seat Belts — Visual Check
Dust/combination filter — replacement
Drawbar — check, clean, lubricate
Electrical Equipment — Maintenance
Windshield wipers — checking the rubber bands of the brushes
Battery — electrolyte level check
Service notification and control device
Troubleshooting
Determination of engine malfunctions and their elimination
Determination of malfunctions of the engine cooling system and their elimination
Possible malfunctions of the heating system, their causes and remedies
Determination of malfunctions of the gasoline injection system and their elimination
Determination of malfunctions of the diesel engine power system and their elimination
Determination of malfunctions of the brake system and their elimination
Identifying Battery Faults and Troubleshooting
Identifying Generator Faults and Troubleshooting
List of starter malfunctions and their elimination
Determination of malfunctions of a screen wiper and their elimination
Power unit
Engine repair
Engine Specifications
General information about engines
Vehicle and engine identification
Engine — removal and installation
Cylinder head — removal and installation
Cylinder head cover — removal and installation
Ribbed belt — removal and installation
Engine — starting
Engine lubrication system
Oil — circulation
Oil pressure — check
Oil level sensor — removal and installation
Oil pan — removal and installation
Cooling and heating
Coolant circulation
Cooling liquid
Coolant — replacement
Thermostat — removal and installation
Thermostat — check
Checking the tightness of the cooling system
Water pump — removal and installation
Radiator blower fan — removal and installation
Radiator — removal and installation
Heater and air conditioner
Interior air vents — removal and installation
Heater and air conditioner switches — removal and installation
Illumination lamp on the air conditioner temperature switch
Heater fan motor — removal and installation
Additional resistance of the interior blower fan
Injection system (gasoline)
General description and precautions
The principle of operation of the fuel injection system
Fuel injectors — check
The distributive fuel highway — removal and installation
Engine control unit emergency program function
Fuel system (diesel)
Working principle of diesel engine
Glow plugs — check
Glow plugs — removal and installation
Fuel injectors — removal and installation
Fuel system
General description of the fuel system
Fuel System — Pressure Relief
Fuel pump and fuel gauge sensor
Fuel pump — removal and installation
Fuel shut-off solenoid valve — removal and installation
Air filter — removal and installation
Accelerator pedal stop — adjustment
Intake manifold — removal and installation
Intake manifold module — removal and installation
Crankshaft position sensor — removal and installation
Camshaft position sensor — removal and installation
Exhaust system
General information about the exhaust system
The principle of operation of the catalyst
Exhaust gas turbocharger
Downpipe with catalyst — removal and installation
Downpipe with main muffler — removal and installation
Lambda probe — removal and installation
Front catalyst — removal and installation
Rear catalyst and main muffler — removal and installation
Turbocharger — removal and installation
Ignition system
General description of the ignition system
Spark plugs — removal
Spark plugs — check
Spark plugs — installation
Transmission
Clutch
General description of clutch
Clutch — removal
Clutch — check
Clutch — Installation
Clutch drive — air removal and hydraulic fluid replacement
Automatic clutch
Transmission
Manual Transmission Specifications
Manual transmission — removal and installation
Gearshift mechanism — removal and installation
Clutch — removal and installation
Differential, primary and secondary shafts — removal and installation
Automatic transmission — removal and installation
Gear selection cable — removal and installation
Gear box locking mechanism when parking
Gear selector cable — adjustment
Chassis
Brake system
Brake Specifications
General description of the braking system
Disc brake pads — removal, inspection and installation
Caliper — removal and installation
Front wheel brake disc — removal and installation
Rear wheel brake disc — removal and installation
Brake disc — check
Parking brake pads — removal and installation
Parking brake — adjustment
Front parking brake cable — removal and installation
Rear parking brake cable — removal and installation
Brake shoes of a drum brake mechanism — removal and installation
Brake Fluid — Safety Precautions
Brake System — Bleeding
Brake hoses — removal and installation
Vacuum brake booster — check
Stoplight switch — removal and installation
Parking brake warning light switch
Suspension
General Suspension Information
Front suspension — device
Suspension strut — removal and installation
Suspension strut — disassembly
Shock absorber — check
Front axle beam — removal and installation
Drive shafts — removal and installation
SHRUS cuffs — removal and installation
Rear suspension — device
Rear suspension shock absorber — removal and installation
Rear suspension damper spring — removal and installation
Lower trailing arm — removal and installation
Flange on the shank of the cross beam — removal and installation
Steering
Steering — device
Airbags — precautions
Airbag unit on the steering wheel — removal and installation
Steering wheel — removal and installation
Contact spiral — removal and installation
Tie rod end — removal and installation
Steering gear cuff — removal and installation
Body
Interior (all models)
Interior trim
Internal rear-view mirror — removal and installation
Front seat — removal and installation
Armrest above the center console — removal and installation
Additional brake light cover — removal and installation
Facing the rear cross member of the ceiling — removal and installation
Central locking
The microswitch of the central lock — removal and installation
Executive element of the central lock — replacement
Central locking pump — replacement
Interior (since 1997)
Deflector pad on the driver's side — removal and installation
Deflector pad on the passenger side — removal and installation
Glove box — removal and installation
Glove box cover — removal and installation
Glove box cover — fitting
The lower cover of the instrument panel on the driver's side — removal and installation
The lower cover of the instrument panel on the passenger side — removal and installation
Center console cover — removal and installation
The front of the center console — removal and installation
The rear of the center console — removal and installation
Cover of the gear lever — removal and installation
Ashtray on the center console — removal and installation
Facing of a forward rack — removal and installation
Interior (since 2001)
Glove box — removal and installation
Glove box cover — removal and installation
The lower overlay of the instrument panel on the driver's side — removal and installation
Center console cover — removal and installation
The front of the center console — removal and installation
Ashtray on the center console — removal and installation
The rear of the center console — removal and installation
Facing of a forward rack — removal and installation
Instrument panel — removal and installation
Exterior
Body — general description and precautions
Mudguard (protection) of the bottom — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Protective bumper pads — removal and installation
Front wheel liner — removal and installation
Rear wheel arches — removal and installation
Front fender — removal and installation
Hood — removal and installation
Hood — fit
Hood lock drive rod — removal and installation
Hood lock — removal and installation
Moldings — removal and installation
External rear-view mirror — removal and installation
Glass of an external rear-view mirror — removal and installation
Facing of a cone of an external mirror — removal and installation
Outside mirror motor — removal and installation
Dimensions of A-class cars
Doors and windows
Front door — removal and installation
Door upholstery — removal and installation
Rear side door — removing and installing window handle
Front door window regulator — removal and installation
Power window motor — removal and installation
Door glass — removal and installation
External door handle — removal and installation
Door lock — removal and installation
Tailgate — removal and installation
Tailgate — Fitting
Tailgate upholstery — removal and installation
The lock and the switch of the lock of a back door — removal and installation
Gas-filled emphasis — removal and installation
Electrical equipment
Equipment and devices
General description and precautions
Additional electrical equipment — installation
Troubleshooting electrical equipment
Switches — current flow test
Relay test
Ignition Key and Remote Control — Replacing Batteries
Opening plug connections
Rear window heater — check
Sound signal — removal and installation
Fuses — Replacement
Locations of fuse blocks
Relay — removal and installation
Instrument panel — removal and installation
Steering column switches — removal and installation
Cigarette lighter — removal and installation
Air conditioner and heater switches — removal and installation
The lower block of switches on the center console — removal and installation
Switches on the back of the center console — removal and installation
Light alarm switch — removal and installation
Outside temperature sensor — removal and installation
Radio receiver — removal and installation
Speakers — removal and installation
Roof radio antenna — removal and installation
Power devices
Battery — removal and installation
Battery — check
Battery — Charging
Alternator voltage test
Generator — removal and installation
Starter — removal and installation
Traction relay — removal, installation and inspection
Windshield wipers and washers
Wiper — removal and installation
Windshield washer jets — removal and installation
Rear window washer jet — removal and installation
Windshield wiper lever — removal and installation
Front glass wiper — removal and installation
Windshield wiper motor — removal and installation
Rear window wiper brush holder — removal and installation
Rear window wiper motor — removal and installation
Washer pump motor — removal and installation
Wiper Arm Angle — Check and Adjust
Headlights and lighting
Lighting fixtures — general provisions
Headlight bulbs — replacement
Side turn signal bulbs — replacement
Rear headlights — replacing lamps
Additional brake light — bulb replacement
License plate light bulbs — replacement
Interior lighting — lamp replacement
Headlights — removal and installation
Headlight lens — removal and installation
Rear lights — removal and installation
Electrical circuits
Scheme 1. Engine control unit
Scheme 2. Engine control unit
Scheme 3. Diesel engine power system until 08/31/2000
Scheme 4. Diesel engine power system
Scheme 5. Starter, generator
Scheme 6. Data switching bus for cabin controls
Scheme 7. Automatic transmission
Diagram 8. Fuses and relays
Scheme 9. Diagnostic connector
Scheme 10. Power windows
Scheme 11. Central lock
Scheme 12. Outdoor lighting
Scheme 13. Internal lighting
Diagram 14. Special signals
Diagram 15. Windshield wiper
Scheme 16. Heater
Scheme 17. Air conditioner
Diagram 18. Airbags
Scheme 19. Instrument panel
C-Class 190 (W201) (1982-1993)
General information
Introduction to the guide
Dimensions and weights
Purchase of spare parts
Vehicle identification
Repair — general provisions
Tools and fixtures
Checking the technical condition of the car
Maintenance checks performed from the driver's seat
Maintenance checks performed with the vehicle on the ground
Maintenance checks to be carried out with the vehicle raised and the wheels spinning freely
Vehicle Exhaust System Check
Jacking up the car and placing it on stands
Car radio theft warning system
Glossary of technical terms
Operation and care
Mercedes 190: introduction
Your Mercedes 190 Owner's Manual
Main dangers
Specific Hazards
If the engine does not start
Starting the engine from a foreign battery
Wheel replacement
What are the leaks talking about?
Towing a car
Weekly checks: an introduction
Checkpoints under the hood
Engine oil level
Brake fluid level
Power steering fluid level
Coolant level
Wiper blades
Windshield washer fluid level
Tire condition and pressure
Types of tire wear
Battery Checks
Lamps and fuses
Operating materials
Choosing the oil for your car
Tire pressure
Maintenance (gasoline)
Technical service data
Maintenance interval
Location of vehicle maintenance points
Maintenance Procedures — Introduction
Regular maintenance
Engine oil and filter change
Replacing spark plugs
Throttle linkage lubrication
Checking the Fluid Level in an Automatic Transmission
Parts and hoses located under the hood / under the car — checking for leaks
Accessory drive belts — check, replace and adjust
Checking the air conditioning system
Carburetor Damper Oil Level Check — Stromberg Type Carburetor
Setting idle speed and mixture quality — checking and adjusting
Steering and Suspension Parts — Condition and Reliability Check
Drive Shafts and Drive Shaft Protectors — Checking Condition
Checking the front brake pads
Checking the rear brake pads
Parking brake — check operation
Exhaust system and fastenings — condition and reliability check
Checking the oil level in a manual transmission
Final drive oil — level check and change
Driveshaft Rubber Clutch — Condition Check
Checking the seat belts
Lubricate all hinges, locks and electrical antenna
Headlight adjustment
Windshield and headlight washer system — condition check
Check in motion
Front hub bearings — check
Clutch — test action
Backlash in the valve drive mechanism (models of release before 1984) — check and adjustment
Ignition system — checking the condition and adjusting the ignition timing
Air cleaner element — replacement
Fuel filter replacement
Automatic transmission fluid and filter — change
Clutch Driven Disc — Wear Check
Carbon Absorption Filter Replacement — Models with Gasoline Vapor Absorption System
Brake Fluid Replacement
Coolant replacement
Maintenance (diesel)
Technical service data
Types and intervals of service
Location of car service points
Diesel models: introduction
Regular maintenance
Engine oil and filter change
Throttle linkage lubrication
Checking the Fluid Level in an Automatic Transmission
Parts and hoses located under the hood / under the car — checking for leaks
Accessory drive belts — check, replace and adjust
Checking the air conditioning system
Idle speed — check and adjustment
Steering and Suspension Parts — Condition and Reliability Check
Drive Shafts and Drive Shaft Protectors — Checking Condition
Front brake pad check
Checking the rear brake pads
Parking brake — check operation
Exhaust system and fastenings — condition and reliability check
Checking the oil level in a manual transmission
Final drive oil — level check and change
Elastic Driveshaft Coupling — Condition Check
Checking the seat belts
Lubricate all hinges, locks and electrical antenna
Headlight adjustment
Windshield and headlight washer system — condition check
Check in motion
Front hub bearings — check
Clutch — test action
Air cleaner element — replacement
Fuel filter and pre-filter — replacement
Automatic transmission fluid and filter — change
Clutch Driven Disc — Wear Check
Brake Fluid Replacement
Coolant replacement
Troubleshooting
Troubleshooting: Introduction
Engine malfunctions
Cooling system malfunctions
Clutch malfunctions
Manual Transmission Faults
Automatic transmission malfunctions
Differential and cardan shaft malfunctions
Brake system malfunctions
Suspension and steering system problems
Electrical system malfunctions
Power unit
Petrol engine I4
Technical data
Basic information
Compression — checking and analyzing results
Engine and timing marks — basic information and use
Camshaft cover — removal and installation
Crankshaft pulley / vibration damper and hub — removal and installation
Camshaft drive chain cover — removal and installation
Camshaft Drive Chain — Check and Replace
Camshaft timing chain tensioner, sprockets and guides
Auxiliary shaft — removal, inspection and installation
Timing sprocket, valve lifters and camshaft
Cylinder head — removal, inspection and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Flywheel / drive faceplate — removal, inspection and installation
Crankshaft oil seals — replacement
Crankshaft centering bearing — replacement
Power unit supports — check and replace
Petrol engine V6
Technical data
Basic information
Compression — checking and analyzing results
Engine and timing marks — basic information and use
Camshaft cover — removal and installation
Crankshaft pulley / vibration damper and hub — removal and installation
Camshaft drive chain covers — removal and installation
Camshaft Drive Chain — Check and Replace
Camshaft timing chain tensioner, sprockets and guides
Asterisk of cams, pushers and camshaft — basic provisions, check and installation
Cylinder head — removal, inspection and installation
Pallet — removal and installation
Oil pump and drive chain — removal, inspection and installation
Flywheel / drive faceplate — removal, inspection and installation
Oil cuffs — replacement
Crankshaft centering bearing — replacement
Power unit supports — check and replace
Diesel engines
Technical data
General information
Compression and leak test — description and analysis of results
Valve timing marks — basic information and application
Camshaft cover — removal and installation
Pulley / damper and crankshaft hub — removal and installation
Camshaft drive chain cover — removal and installation
Camshaft Drive Chain — Check and Replace
Tensioner, sprockets and camshaft drive chain guides
Camshaft and valve lifters — removal, inspection and installation
Cylinder head — removal, inspection and installation
Oil pan — removal and installation
Oil pump and drive chain — removal, inspection and installation
Flywheel / faceplate — removal, inspection and installation
Crankshaft seals — replacement
Centering crankshaft bearing
Power unit supports
Oil cooler — removal and installation
Engine overhaul
Basic information on engine repair
Engine Repair — Basics
Powertrain Removal — Methods and Precautions
Four-cylinder gasoline engines — removal and installation
Six-cylinder gasoline engines — removal and installation
Diesel engines — removal and installation
Engine Repair — Disassembly Sequence
Technical data
Cylinder head — disassembly
Cylinder head and valves — cleaning and checking
Cylinder head — assembly
Pistons and connecting rods — removal
Crankshaft — removal
Cylinder block / crankcase — cleaning and inspection
Pistons and connecting rods — condition check
Crankshaft — condition check
Main, connecting rod bearings and bearing cap bolts — inspection and fault detection
Engine Repair — Assembly Procedure
Piston rings — installation
Crankshaft — setting and checking the clearance in the main bearings
Pistons and connecting rods — installing and checking the clearance in the bearings of the lower head of the connecting rods
Cooling and heating
Technical data
Basic information and precautions
Coolant hoses — disconnect and replace
Radiator — removal, inspection and installation
Thermostat — removal, inspection and installation
Radiator fan — removal and installation
Electric switches of the cooling system — removal and installation
Water pump — removal and installation
Heater / interior ventilation parts — removal and installation
Air Conditioning System — Basics and Precautions
Power system (carburetor)
Technical data
Basic information and precautions
Air cleaner and filter element — removal and installation
Air cleaner air temperature control system — check and replace parts
Gasoline pump — removal and installation
Fuel gauge sensor — removal and installation
Gas tank — removal and installation
Throttle cable — removal, installation and adjustment
Stromberg 175 CDT carburetor — basic information and parts replacement
Pierburg 2E-E carburetor power system — basic information and parts replacement
Carburetor — removal and installation
Intake manifold — removal and installation
Intake manifold heater — removal and installation
Injection system (gasoline)
Technical data
Basic information and precautions
Fuel injection system — depressurization
Air cleaner and filter element — removal and installation
Gasoline pump (s) — removal and installation
Fuel gauge sensor — removal and installation
Gas tank — removal and installation
Throttle cable — removal, installation and adjustment
Fuel accumulator — removal and installation
Throttle body — removal and installation
Details of the Bosch KE-Jetronic fuel injection system — removal and installation
Intake manifold — removal and installation
Injection system (diesel)
Technical data
General information and precautions
Air cleaner — removal and installation
Low pressure fuel pump — removal and installation
Fuel gauge sensor block — removal and installation
Fuel tank — removal and installation
Throttle control cable — removal, installation and adjustment
High pressure fuel pump — removal and installation
Injection timing device and high pressure fuel pump sprocket
High pressure fuel pump injection timing — check and adjustment
Injectors and high pressure fuel lines — removal and installation
Fuel thermostat — removal and installation
Electronic idle control (ELR) — removal and installation
Electronic Anti-Jerk System (ARA) — Parts Removal and Installation
Electronic diesel engine management system (EDS) — removal and installation
Engine Overload Protection System — Removal and Installation
Intake manifold — removal and installation
Exhaust system
Technical data
Exhaust system: basic information
Evaporative Emission System
Crankcase Ventilation System — Fundamentals
Exhaust manifold — removal and installation
Exhaust Gas Recirculation (EGR)
Turbocharger — removal and installation
Exhaust System — Fundamentals and Replacement Parts
Catalytic Converter — Basic Information and Precautions
Auxiliary Air System — Parts Removal and Installation
Charge and start system
Technical data
General Information and Warnings
Battery — monitoring and charging
Battery — removal and installation
Alternator/charging system — check on vehicle
Generator — removal and installation
Alternator — Replacing the Voltage Regulator Brush Holder
Engine starting system — check
Starter — removal and installation
Starter — repair
Ignition system (I4)
Technical data
Basic information about the ignition system
Checking the ignition system
High-voltage ignition coil — removal and installation
Distributor — removal and installation
Slider — removal and installation
Ignition timing — check and adjustment
Details of the ignition control system — removal and installation
Ignition system (V6)
Technical data
General provisions
Checking the ignition system
High voltage coil — removal and installation
Distributor and slider — removal and installation
Ignition timing — check and adjustment
Details of the ignition control system — removal and installation
Diesel heating system
Technical data
General provisions
Glow plug control unit — removal and installation
Glow plugs — checking, removing and installing
Coolant temperature sensor — removal and installation
Transmission
Clutch
Technical data
General provisions
Clutch — removal, inspection and installation
Release bearing and lever — removal, inspection and installation
Clutch slave cylinder — removal, disassembly and installation
Main hydraulic cylinder — removal, disassembly and installation
Bleeding the hydraulic system
Clutch pedal — removal and installation
Mechanical gearbox
Technical data
General information
Manual Transmission Oil — Drain and Fill
Details of the gear shift mechanism — removal, installation and adjustment
Oil cuffs — replacement
Switches of lanterns of a backing — check, removal and installation
Manual transmission — removal and installation
Gearbox repair — basics
Automatic gearbox
Pressure control cable — adjustment
Technical data
Basic information about automatic transmission
Gear selector — removal and installation
Shift lever rod — adjustment, removal and installation
Starter lock / reversing light switch — removal, installation and adjustment
Automatic transmission — removal and installation
Cardan shaft and axle shafts
Technical data
Basic information
Final drive — draining and filling with oil
Main gear — removal and installation
Final drive oil seals — replacement
Half shafts — removal and installation
Protective covers of semiaxes — replacement
Cardan transmission — removal and installation
Rubber driveline couplings — check and replace
Driveshaft Support Bearing — Check and Replace
Cardan joint — check and replacement
Chassis
Brake system
Technical data
Fundamentals of the braking system
Release of air from the hydraulic system
Hydraulic pipes and hoses — replacement
Front brake pads — replacement
Rear brake pads — replacement
Front brake disc — check, removal and installation
Rear brake disc — check, removal and installation
Front brake caliper — removal, repair and installation
Rear brake caliper — removal, repair and installation
Master cylinder — removal, repair and installation
Vacuum brake booster — check, removal and installation
Vacuum brake booster valve — removal, inspection and installation
Parking brake — adjustment
Parking brake pads — removal and installation
Parking brake cable — removal and installation
Stoplight switch — removal and installation
Anti-Lock Wheel System (ABS) — Basics
Details of the ABS system — removal and installation
Vacuum pump of the brake system (diesel models) — check, removal and installation
Car suspension
Technical data
Basic information
Front hub bearing — check and adjust
Front hub — removal, disassembly and installation
Front steering knuckle — removal and installation
Front suspension shock absorbers — removal, disassembly and installation
Front suspension spring — removal and installation
The lower arm of the front suspension — removal, disassembly and installation
Anti-roll bar front suspension — removal and installation
Rear hub holder — removal and installation
Rear hub bearing — replacement
Rear suspension shock absorber — removal, inspection and installation
Rear suspension spring — removal and installation
Rear suspension bars — removal and installation
Lower arm rear suspension — removal, disassembly and installation
Rear suspension anti-roll bar — removal and installation
Rear anti-roll bar link — removal and installation
Steering
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Ignition switch / steering lock — removal and installation
Steering column rubber clutch — removal and installation
Steering gear — removal, repair and installation
Steering arm — removal and installation
Lower Steering Gear Seal — Replace
Power steering pump — removal and installation
Power steering, control — air outlet
Steering shock absorber — removal and installation
Longitudinal tie rod — removal and installation
Intermediate steering lever — removal and installation
Tie rod ball joint — removal and installation
Tie rod — removal and installation
Wheel and steering angles — basics
Body
Exterior (external elements)
General information
Body and subframe maintenance
Minor body damage — restoration
Repair of serious body damage
Hood — removal and installation
Hood adjustment
Hood hinge — removal and installation
Thrust strut hood — removal and installation
Bonnet opening cable — removal and installation
Hood lock — removal and installation
Radiator grill — removal and installation
Emblem on the hood — removal and installation
Front and rear bumpers — removal and installation
Bumpers — disassembly and assembly
Interior (internal elements)
Carpet and upholstery care
Front seats — removal and installation
Rear seat — removal and installation
Seat belts — removal and installation
Central console — removal and installation
Glove box — removal and installation
Instrument panel — removal and installation
Doors, locks and windows
Trunk lid — removal and installation
Trunk lid lock — removal and installation
Interior door trim — removal and installation
Front door window regulator — removal and installation
Front door glass — removal and installation
Rear door window regulator — removal and installation
Rear door glass — removal and installation
Fixed rear door glass — removal and installation
External handle of the front door lock — removal and installation
Front door lock — removal and installation
The external handle of a back door — removal and installation
Rear door lock — removal and installation
Electromagnets of door locks (central locking system) — removal and installation
Front and rear doors — removal and installation
Windshield and rear screen — removal and installation
Door mirror glass (manual) — replacement
Door mirror assembly (with manual adjustment) — removal and installation
Door Mirror Assembly (Electrically Operated) — Replacement
Door mirror assembly (with electric drive) — removal and installation
Sunroof — general information
Vacuum pump of the central locking system — removal and installation
Electrical equipment
Equipment and devices
Technical data
Basic information and precautions
Troubleshooting in electrical circuits — basic information
Fuses and Relays — Fundamentals
Central mounting: block — removal and installation
Steering column switch block — removal and installation
Instrument panel and central console switches — removal and installation
Switches of a plafond of internal lighting — removal and installation
Instrument panel — removal and installation
Instrument panel parts — removal and installation
Speedometer cable — removal and installation
Lamps (Outdoor Lighting Devices) — Replacement
Interior lighting lamps — replacement
Outdoor lighting devices — removal and installation
Headlight glass — removal and installation
Headlight adjustment
Headlight Beam Leveling System — Description
Wiper blades and arms — removal and installation
Wiper motor and linkage — removal and installation
Wiper motor — removal and installation
Windshield washer system — removal, installation and adjustment
Sound signals — removal and installation
Audio equipment — removal and installation
Front and rear speakers — removal and installation
Radio antenna — removal and installation
Parts of the constant speed motion system — removal and installation
Intruder Alarm System — General
Airbags — basic information and precautions
Details of the security system — removal and installation
Electrical circuits
Symbol designations on diagrams, grounding points and fuses
Scheme of starting the engine and charging the battery
Radiator Motor, Magnetic Clutch and Downshift
Typical engine management system
Light indicators and instruments (typical scheme)
Outdoor lighting devices — clearance, rear, fog and headlights
Exterior Lighting (continued) — turn signals, hazard lights, brake lights and taillights
Typical interior lighting and windshield wiper
Headlight/glass washer and wiper, rear window defroster, heater fan
Horn, cigarette lighter, sunroof and power windows
C-Class W202 (1993-2000)
General information
User manual
Driver's seat and instrument panel
Periodic care and maintenance
Car keys
Opening and closing doors
Seats — adjustment
Seat belts
Airbag
Safety instructions
Blokada zapłonu
Light rotary switch
Light range adjustment
Combination switch
Rear view mirrors
Sun visors
Automatic lighter
Interior lighting
Sliding sunroof
Rear window heating
Power windows
Engine Hood — Opening and Closing
Ventilation unit, air conditioner
Some tips for buying a car
Broken numbers
Buying an old car
Vehicle durability
On the parallelism of the bridges of the car and the trailer
Preparing your car for winter
Driving a car
Parking brake
Starting off and shifting gears
Installing the gear selector
Driving mode select switch
Vehicle traffic control
Cruise control
Oil and fuel consumption
Starting the engine from the auxiliary battery
Towing a car
Jacking and lifting the car
Car care
Car body wash
Care of painted surfaces
Care of plastic parts
Care of glass and rubber seals
Caring for alloy wheels
Seat belts
Underbody corrosion protection
Preservation of the engine compartment
Seat upholstery care
Maintenance
Maintenance interval
After 12 months or 15,000 km
Additionally every 60,000 km
Every 2 years
Every 3-4 years
Maintenance work
Engine and exhaust system
Engine oil change
Checking the condition of the V-belt
Replacing spark plugs
Checking electrical connections
Throttle control system lubrication
Checking the coolant level
Air conditioning: Checking the refrigerant level
Replacing the fuel filter / coarse filter
Replacing the air filter element
Check of system of release of the fulfilled gases
Gearbox / final drive
Visual tightness control
Checking the oil level in the differential
Check of disks of hinges of a cardan shaft
Checking the rubber cuffs of the axle shafts
Front axle / steering
Checking the hinges of the front axle
Steering wheel free play check
Tightening the fixing bolts on the steering gear
Checking the oil level in the steering gear
Brakes / tires
Checking the thickness of the friction linings of the brake pads
Checking the brake fluid level
Check of a signal lantern of level of a brake liquid
Visual inspection of brake lines
Brake Fluid Replacement
Checking the tread pattern of a tire (tire)
Checking the valve of the pneumatic tube or tire
Checking the pressure in inflated tires
Body / interior lighting
Replacing the dust filter attachment
Hood grease
Checking the seat belts
Sunroof Lubrication
Tools used for maintenance
Power unit
Gasoline engines
Specifications of gasoline engines
Engine identification number
Removing the engine
Engine installation
Engine ventilation
Removing the engine (vehicles with air conditioning)
The lower cover of the engine compartment — removal and installation
Cast hole caps (6-cylinder engine)
Chain tensioner — removal and installation
Cylinder head cover (4-cylinder engine)
Cylinder head cover (6-cylinder engine)
Cylinder head (4-cylinder engine)
Cylinder head (2.2 liter engine)
Cylinder head (6-cylinder engine)
Camshafts (4-cylinder engine)
Camshafts — Basic Position Adjustment (4 Cylinders)
Camshafts (6-cylinder engine)
Hydraulic Poppet Pushers
Oil seals — removal and installation
Valves — removal and installation
Directional valves
Valve seats in the cylinder head
Cylinder compression check
V-belt (4-cylinder engine)
V-belt (6-cylinder engine)
Diagnostics of malfunctions of gasoline engines
General notes on engine overhaul
Repair work without dismantling the engine
Engine overhaul
Engine Overhaul Alternatives
Dismantling the engine
Engine disassembly sequence
Diesel engines
Specifications of diesel engines
Removal and installation of the engine
Engine ventilation
Removing the engine (vehicles with air conditioning)
The lower cover of the engine compartment — removal and installation
Chain tensioner — removal and installation
Camshaft (2.0 L engine)
Camshaft (2.2/2.5L engine)
Cylinder head (2.0L engine)
Cylinder head (2.2/2.5L engine)
Oil-reflecting caps (2.0 L engine)
Oil-reflecting caps (2.2/2.5 L engine)
Cylinder head cover (2.2 / 2.5L)
Hydraulic Poppet Pushers
Valves — removal and installation
Directional valves
Valve seats in the cylinder head
Cylinder head and engine block
Cylinder compression check
V-ribbed belt — removal and installation
Tensioning device of the wedge ribbed belt
Diagnostics of malfunctions of diesel engines
Lubrication system
Lubrication system — general description
Engine oil specification
Scope of oils / viscosity class
Oil consumption
Oil circuit (diesel)
Oil pressure relief valve — removal and installation
Oil pan (gasoline engine) — removal and installation
Oil pan (diesel 2.0) — removal and installation
Oil pan (diesel 2.2 / 2.5) — removal and installation
Oil level indicator — removal and installation
Oil/coolant heat exchanger
Diagnosis of malfunctions in the oil circuit
Cooling system
Coolant circulation circuit
Coolant (gasoline engines)
Coolant (diesel engines)
Coolant (vehicles with air conditioning)
Antifreeze for radiator
Coolant thermostat (thermostat)
Checking the cooling system
Hydraulic fan clutch — removal and installation
Liquid cooling pump — removal and installation
Radiator — removal and installation
Fan shroud — removal and installation
Diagnosis of malfunctions of the cooling system
Diagnosis of malfunctions of the liquid level indication system
Engine overheating
Heating and ventilation
General information about heating and ventilation
Air conditioning — general description
Additional resistance — removal and installation
Heating fan — removal and installation
Heating service device — removal and installation
Diagnosis of malfunctions of the heating system
Air conditioning: not only pluses, but also minuses
Air Conditioner Service Rules
Ignition system
General description of the ignition system
Safety precautions when repairing an electronic ignition system
Ignition coils — removal and installation
Spark plugs — removal, installation, check
The index of the caloric number
Checking the diesel preheating device
Incandescent lamp — check
Heating control relay
Glow plugs — removal, inspection and installation
Coolant temperature sensor
Intake air temperature sensor — removal, inspection and installation
Self-diagnostics of the diesel heating device
Fuel system
Safety precautions and refueling
Fuel tank — design description
Fuel level sensor — removal and installation
Fuel pump — removal and installation
Fuel filter — removal and installation
Air filter — removal and installation
Cross pipe of the air filter — removal and installation
Inlet gas pipeline — removal and installation
Throttle cable/throttle lever (petrol)
Gas control cable (gasoline) — removal and installation
Diesel engine fuel circuit
Pre-heating of diesel fuel
Fuel thermostat — removal and installation
Hydraulic valve housing — removal and installation
Throttle cable/throttle lever (diesel)
Gas control cable (diesel) — removal and installation
Injection system (gasoline)
PMS and HFM engine management systems
How the PMS system works
How the HFM system works
Self-diagnosis of the state of the ignition and fuel injection system
Air mass meter — removal and installation
Coolant temperature sensor — removal, inspection and installation
Intake air sensor — removal, inspection and installation
Vacuum piping system
Fuel distributor with valve injectors
Valve injectors — removal and installation
Oxygen sensor (lambda probe) — removal and installation
Diagnostics of malfunctions of system of injection of gasoline
What you need to know the owner of a car with an injection engine
Repair and replacement of the turbocharger
Injection system (diesel)
Injection systems with exhaust gas recirculation
Checking / setting the start of fuel supply by the pump
Nozzles — removal and installation
Technical data of the diesel injection and power supply system
Diagnostics of malfunctions of the injection system and power supply
Exhaust system
Design and description of the exhaust system
Exhaust system (gasoline) — removal and installation
Exhaust system (diesel) — removal and installation
Main and middle mufflers
Vehicles with catalytic converter
Diesel car exhaust aftertreatment device
Three in one — or how to save the catalyst
Transmission
Clutch
Clutch design and description
Checking the thickness of the clutch disc in the mounted state
Clutch — removal, inspection and installation
Clutch Release Bearing
Bleeding air from the clutch control system
Clutch slip
Diagnosis of malfunctions of the clutch system
Car gearbox
Gearbox design
Gearbox — removal, installation and adjustment
Automatic transmission
Towing vehicles equipped with automatic
Checking the oil level in an automatic transmission
Transmission oil and filter — change
Control pressure cable
Gearshift rod
Features of the operation of an automatic transmission
Chassis
Suspension, wheels and tires
Front suspension design
Shock absorbers — removal and installation
Inspection and disposal of shock absorbers
Front springs — removal and installation
Setting the clearance in the front bearings
Anti-roll bar — removal and installation
Rear suspension design
Rear shock absorbers — removal and installation
Rear springs — removal and installation
Half shafts — removal and installation
Removal of axle shafts / replacement of rubber cuffs
Why you need a shock absorber
Types of shock absorbers
Additional protection of spherical joints of steering rods
Secret bolts to secure the outer elements
Wheel specifications
Wheel and tire maintenance
Tire Fault Diagnosis
Steering
Steering design and description
Steering wheel airbag unit
Steering wheel — removal and installation
Steering trapezoid — removal, inspection and installation
Steering trapezoid cuffs — removal and installation
Power steering pump — removal and installation
Wheel alignment installation
Power steering — easy and effortless
Steering System Maintenance
Diagnosis of malfunctions of the steering system
Brake system
Construction and description of the brake system
Anti-lock braking system — ABS
Optional equipment — ASR system
Brake system technical data
Front brake pads — removal and installation
Rear disc brake pads — removal and installation
Checking the thickness of the brake discs and their lateral runout
Caliper — removal and installation
Front brake disc — removal and installation
Rear brake disc — removal and installation
Brake fluid
Removal of air from the brake system
Brake pipes / hoses
Replacement of brake lines
Parking brake pads — removal and installation
Parking brake adjustment
Stoplight switch — removal and installation
Brake fault diagnosis
Body
Exterior (external elements)
General information about the body and safety
Outside mirror / mirror glass — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
The inner wing of the car — removal and installation
Car fender — removal and installation
Radiator grille / Mercedes emblem — removal and installation
Engine hood pull — removal and installation
Covering under the windshield — removal and installation
Air supply unit for interior heating
Water collector — removal and installation
Paintwork — damage repair
Body metal corrosion
Body care products
Search and elimination of squeaks and vibrations
Purpose and types of sunroof
Interior (internal elements)
Glove box — removal and installation
Protective cover for shift knob
Front ashtray — removal and installation
Center console — removal and installation
Heating service panel — removal and installation
A-pillar inner lining — removal and installation
C-pillar inner lining — removal and installation
Front seat — removal and installation
Rear seat — removal and installation
Central locking
Covering under the dashboard — removal and installation
Doors and windows
Front door — removal and installation
Rear door — removal and installation
Front door handle — removal and installation
Rear door handle — removal and installation
Door lock — removal and installation
Interior door trim — removal and installation
Front power window — removal and installation
Front window glass — adjustment
Rear power window — removal and installation
Front door glass — removal and installation
Power window motor — removal and installation
Electrical equipment
Equipment and devices
General description of electrical equipment
Measuring instruments
Measurement technique
Electrical checks
Sound signal — removal and installation
Fuse Replacement
Dashboard — removal and installation
Incandescent lamps on the instrument panel — removal and installation
Light switch — removal and installation
Radio receiver — removal and installation
Antenna — removal and installation
Automatic Antenna Telescope — Removal and Installation
Speakers — removal and installation
Rubber wiper blades — removal and installation
Diagnosis of malfunctions of wiper blades
Windshield washer jets
Wash nozzles for headlights
Windshield wiper and its engine — removal and installation
Protect your car yourself
Anti-theft «immunodeficiency»
Checking the functioning of signaling devices / outdoor lighting
Power devices
Battery — removal and installation
Maintenance-free batteries
Checking the battery
Battery self-discharge
Charging the battery
Storage of the battery
Diagnostics of battery malfunctions
Generator — Description and Safety
Generator — removal and installation
Checking the alternator charging voltage
Replacing and checking the carbon brushes of the generator / voltage regulator
Diagnostics of malfunctions of the generator
Starter — general description
Starter — removal and installation
Starter Troubleshooting
Traction relay — removal, inspection and installation
The main malfunctions of the starter and generator
Lighting system
Lighting system — description and table of lamps
Low beam, high beam and fog lamps
Lamp in the front turn signal lamp
Lamp in the tail light
Lamp in the license plate light
Plafond in the cabin — removal and installation
Turn signal lamp — removal and installation
Headlight — removal and installation
Headlight adjustment
Rear light — removal and installation
Why do headlights dim
Extending the life of halogen lamps
About the correct headlight adjustment
Electrical circuits
Use of wiring diagrams
Abbreviations in wiring diagrams
Electrical equipment — starter, generator, battery (BD 111 HFM / PMS)
Outdoor lighting (BD, DD)
Interior lighting (BD, DD)
Dashboard (BD 111 HRM / PMS / 104 HFM)
Dashboard (DD 601 / 604 / 605)
Wiring diagram of starter, generator, battery (DD 601 / 604 / 605)
C-Class W203 (2000-2007)
General information
Introduction to guide
Vehicle identification numbers
Purchase of spare parts
Vehicle maintenance technology
Workplace tools and equipment
Jacking and towing a car
Starting the Engine with the Auxiliary Battery
Automotive chemicals, oils and lubricants
Vehicle troubleshooting
User manual
Vehicle Specifications
Main organs and control / control panels
Locks, keys and locks. Single lock
Vehicle theft protection
Facilitate getting in and out of the car
Seat and headrest adjustment
Security systems
Steering wheel, mirrors
Memory for seats, steering wheel and exterior mirrors
Dashboard
Multifunction steering wheel, universal display
Headlight and wiper switches
Automatic heater and air conditioner, ventilation, independent heater
Rear window heater
Power windows, sunroof
Salon equipment
Vehicle control and assistance systems
Warning lights, warning lights and fault messages
First aid kit, fire extinguisher, tools, warning triangle and spare wheel compartment
Maintenance
General description of current maintenance
Maintenance Specifications
Scheduled maintenance due indicator
Maintenance Schedule
General setup information
Checking fluid levels, leak control
Checking tire condition and pressure. Wheel designation. Wheel rotation and replacement
Changing the engine oil and oil filter
Brake system checks, parking brake adjustment
Fuel system check
Checking the condition and replacing the engine compartment hoses, localizing leaks
Checking the condition of the ribbed belts of the serpentine drive of auxiliary units
Checking the functioning of the cooling system and frost resistance of the coolant
Check of a condition of system of release of the fulfilled gases
Checking the automatic transmission oil level
Visual control of the gearbox for oil leaks
Checking the condition of suspension and steering components
Check of a condition of protective covers of power shafts
Checking the fluid level of the power steering system
Checking the fluid level of the clearance control system
Checking the air conditioning system
Cleaning the sunroof sliding panel mechanism
Visual inspection of the seat belt and airbag unit
Checking the headlights and horn
Checking the condition, adjusting and replacing the wiper blades
Battery check, care and charging
Replacing the Battery of the Tele-Aid Emergency Call System
Replacing the Cabin Air Filter Element / Charcoal Air Cleaning Filter
Checking, cleaning and lubricating the hitch
Brake Fluid Replacement
Checking the flexible coupling of the cardan shaft
Checking and replacing spark plugs, the condition of high-voltage wires
Replacing the Engine Air Filter Element
Fuel filter replacement
Power unit
Gasoline engines
Specifications of gasoline and diesel engines
Checking compression in the engine cylinders
Checking the engine with a vacuum gauge
Removal and installation of a cover of an impellent compartment from the bottom
Design of 4-cylinder petrol engines
Removal and installation of a head of cylinders (I4)
Removal and installation of a cover of a head of cylinders (I4)
Removal and installation of the chain tensioner (I4)
Replacing timing chains and installing valve timing (I4)
Checking the phase setting of the camshafts (I4)
Removal and installation of the V-belt (I4)
Design of 6-cylinder petrol engines
Removal and installation of a head of cylinders (V6)
Replacing timing chains and installing valve timing (V6)
Removal and installation of the V-belt (V6)
Engine lubrication system
Oil pressure check
Removal and installation of the oil level sensor
Diesel engines
Diesel engine design
Removal and installation of the top cover of the engine
Setting the piston of the first cylinder to the TDC position
Removal and installation of a cover of a head of cylinders
Removal and installation of a head of cylinders
Removing and installing the front cover
Removal and installation of the upper chain guide
Replacing timing chains and installing valve timing
Removal and installation of camshafts
Removal and installation of an intermediate asterisk
Removal and installation of the chain tensioner
Removing and installing the V-belt
Oil filter design
Cooling system
Cooling and Heating Specifications
General description of the cooling system
Antifreeze — antifreeze
Coolant replacement
Removal and replacement of cooling system hoses
Removal and installation of the thermostat
Thermostat check
Checking the pressure cooling system
Removal and installation of the pump of a cooling liquid
Removal and installation of the fan (models with manual transmission)
Removing and installing the radiator (models with manual transmission)
Ventilation and heating
Design of ventilation, heating and air conditioning systems
Removal and installation of ventilation deflectors
Removal and installation of damper drive motors
Removal and installation of the block of management of a heater and the conditioner
Removal and installation of the electric motor of the fan of a heater or the conditioner
Removal and installation of an electronic regulator of the fan of a heater or the conditioner
Removal and installation of sensors of the conditioner
Supply system
Power System and Exhaust Specifications
Gasoline and diesel engine power system
Depressurizing the fuel system
Removal and installation of the fuel pump and the gauge of a stock of fuel
Removal and installation of the air filter
Injection system (gasoline)
Safety precautions when working with the injection system
Functioning of the control and injection system
General check of the injection system
Removal and installation of an air mass meter
Checking the injectors
Removal and installation of the fuel distributive highway and injectors
Idle speed / ignition timing / CO concentration check
Injection system (diesel)
Elements of the fuel injection system of a diesel engine
Functional diagram of fuel injection control
Arrangement of elements of the Common Rail injection control system
General Description of the Diesel Engine Injection System
Removal and installation of nozzles
Bleeding air from the low pressure fuel circuit
Fuel Injection System Checks
Exhaust system
Exhaust system — general information
Removal and installation of the exhaust system
Checking the tightness of the exhaust system
Emission control systems — general information
Catalytic converter
Turbocharger — General Information and Precautions
Belt driven intake air compressor
Intercooler — general information
Ignition and control system
Ignition and engine management specifications
Diagnostics of malfunctions of the ignition system and engine management
The design of the ignition system and engine management
Removal and installation of ignition coils
Ignition and injection control system checks
Troubleshooting and Preliminary Checks
Checking and adjusting the ignition timing
Spark Plugs — Condition Detection
Diesel engine preheating system
Checking diesel glow plugs
Removal and installation of glow plugs
Diagnostics of electronic control systems and diagnostic equipment
Diagnostics of electronic control systems for engine, injection, ignition and auxiliary brake systems
Personal computer interface controller with OBD II on-board self-diagnosis system
Diagnostics of the electronic system of the automatic air conditioner (AC)
Using an oscilloscope to observe signals in control circuits
Charge and launch systems
General description of charge and launch systems
Battery — Basics and Purchasing
Checking and charging the battery
Replacing the battery
Storage of the battery
Charging system — general information and safety measures
Checking the charging system
Generator — removal, check and installation
Removal and installation of the voltage regulator and replacement of brushes
Engine starting system — general information and precautions
Removal and installation of a starter
Removal and installation of the traction relay of a starter
Checking the engine start system
Transmission
Mechanical gearbox
Construction and description of the manual gearbox
Manual transmission specifications
Removal and installation of a mechanical box
Adjustment of the manual transmission control drive
Automatic gearbox
Automatic transmission design
Automatic transmission specifications
Elements of the hydraulic control of the automated gearbox Sequentronic
Elements of electronic control and signals of the control unit of the automated transmission Sequentronic
Design of automatic transmission 722.6
Troubleshooting — general information
Electronic control unit tasks and control signals
Removal and installation of AT with torque converter
Electrohydraulic control unit AT
Disassembly and assembly of the electro-hydraulic control unit
Dismantling and assembly of a plate of a gear change
Transmission housing and torque converter
Multi-disc brakes B2, B3 and gear lock when «Parking»
Disassembly and assembly of the rear hollow shaft with rear freewheel
Removal and installation of multi-disc brake B1 and oil pump
Disassembly and assembly of the oil pump
Disassembly and assembly of the multi-disc brake B1
Disassembly and assembly of the B2 multi-disc brake
Disassembly and assembly of the output shaft with the central and rear planetary gears
Removal and installation of multi-plate clutches K1, K2 and K3
Disassembly and assembly of clutch K1
Disassembly and assembly of the drive shaft with the K2 clutch and the front planetary gear set
Disassembly and assembly of clutch K3
Parking lock mechanism
Removal and installation of the gear selector lever
Clutch and drive shafts
Specification of clutch and drive shafts
Clutch design and description
Clutch — removal, inspection and installation
Bleeding air from the clutch actuator, changing the hydraulic fluid
Removal and installation of cardan shaft
The design and description of the drive shafts of the wheels
Removal and installation of drive shafts of wheels
Disassembly of drive shafts and replacement of protective covers
Differential
Disassembly and assembly of the differential
Disassembly and assembly of the final drive gearbox and adjustment of gear clearances
Determining the thickness of the shim and installing it in the gearbox housing
Checking and adjusting the flange clearance
Dismantling and assembly of differential with automatic blocking
Chassis
Brake system
Construction and description of the brake system
Brake Specifications
Replacing the front disc brake pads
Removal and installation of the front caliper
Replacing the rear brake pads
Removal and installation of a back support
Removal and installation of a brake disk
Checking the brake disc
Dual Master Cylinder
Replacing parking brake pads
Removal and installation of a cable of a drive of a parking brake
Removal and installation of the brake light switch
Removal of air from the brake system
Removal and installation of a brake hose
Checking the brake booster
Car suspension
General description of the suspension and steering
Suspension and steering specifications
Design and description of the front wheel suspension
Removal and installation of a forward amortization rack
Front suspension strut repair
Front wheel bearing clearance adjustment
Design and description of the rear wheel suspension
Removal and installation of the rear shock absorber
Removal and installation of a back spring
Vehicle wheel alignment — general information
Conditions for checking wheel alignment
Front wheel adjustment
Rear wheel adjustment
Checking the clearance of the car body
Steering
Steering and airbags — general information
Safety precautions when working on the airbag
Removal and installation of the block of an airbag on a steering wheel
Removal and installation of a steering wheel
Removal and installation of a tip of steering draft
Removal and installation of a protective cover of the steering mechanism
Body
Exterior (external elements)
General information and safety measures when carrying out body work
Cleaning and care of the body and bottom
Repair of minor damage to body panels
Repair of significant damage to the body
Damage to the windscreen as a result of falling stones
Replacing wiper blades
Removal and installation of a windshield washer jet
Removal and installation of the rear window jet
Removal and installation of the windshield wiper arm
Removal and installation of the rear wiper arm
Removal and installation of a water collector
Removal and installation of a cowl
Removal and installation of facing of a cowl
Hood adjustment
Removal and installation of the lock of a cowl
Disconnecting the drive cable from the hood latch
Removal and installation of the spoiler grille
Removal and installation of a bumper
Removal and installation of a back bumper
Removal and installation of a forward wing
Removal and installation of a protective strip on a wing
Removal and installation of a protective level on a bumper
Removal and installation of a protective strip on a door
Removal and installation of the front wing locker
Removal and installation of the rear part of the wing locker
Removal and installation of a forward door
Checking and adjusting the door
Removal and installation of a forward facing of a door
Removal and installation of a triangular overlay
Removal and installation of the external door handle
Removal and installation of facing of an external rear-view mirror
Removal and installation of an external mirror
Removal and installation of mirror glass
Removing and installing the trunk lid
Removal and installation of facing of a cover of a luggage carrier
Removal and installation of a latch of the lock of a luggage carrier
Removal and installation of the lock of a door of a back
Removal and installation of the mechanism of the lock of a door of a back
Removal and installation of the cylinder of the lock of a luggage carrier and doors of a back
Removal and installation of a door of a back
Tailgate adjustment
Removal and installation of facing of a door of a back
Removal and installation of the rear spoiler — removal and installation
Removal and installation of a plug of a cargo compartment
Specification and body size
Interior (internal elements)
Notes on work with interior equipment
Removal and installation of the expansion clamp
Removal and installation of a cover under the panel of devices
Removal and installation of the lower part of the instrument panel
Removal and installation of a ware box
Removal and installation of a cover under a ware box
Removal and installation of the center console
Removal and installation of a cover of the top part of the central console
Removal and installation of an internal mirror
Removal and installation of facing in a cargo compartment
Removal and installation of a forward seat
Removal and installation of a back seat
Removal and installation of the shelf
Removal and installation of facing of racks A and B
Removal and installation of facing of a rack C
Electrical equipment
Equipment and devices
General description of onboard electrical equipment
Electrical Equipment Specifications
Diagnostics of malfunctions of onboard electrical equipment
Checking the wiper motor
Checking the heated rear window
Relays and fuses — location and replacement
Replacing the battery of the ignition key / remote control
Removal and installation of the windshield wiper motor
Removal and installation of the electric motor of a cleaner of back glass
Removal and installation of the water tank and pump motor
Removal and installation of the rain sensor
Removal and installation of a sound signal
Removal and installation of parking sensors
Removal and installation of the sensor of temperature of external air
Removal and installation of the dashboard
Removal and installation of the steering column switch
Removal and installation of the switch of a forward plafond on a ceiling
Removal and installation of a group of switches to the left of the control panel
Removal and installation of the switch of the central console
Removal and installation of switches in doors
Removal and installation of door switches of internal lighting
Removing and installing parking assistant warning signs
Removal and installation of the cigarette lighter
Removal and installation of the radio receiver
Removing and installing the loudspeaker
CAN digital data bus
Single lock — general information
Installation of additional electrical and electronic devices
Purpose and location of electrical connectors
Lighting system
Replacement of incandescent lamps of outdoor lighting devices
Replacement of incandescent lamps for interior lighting devices
Removal and installation of the daylight sensor
Removal and installation of a headlight
Removal and installation of a fog lamp
Removal and installation of a diffuser of a fog lamp
Removal and installation of a back lantern
Electrical diagrams (2000)
Designations and abbreviations on electrical equipment diagrams
Power distribution wiring diagram
Ground wiring
Charging system wiring diagram
Starting system wiring diagram
Cooling fan wiring diagram
Tempostat wiring diagram
Wiring diagram of the engine management system 2.3 l
Wiring diagram for automatic air conditioner
On-board computer wiring diagram
Wiring diagram of the diagnostic connector DLC
Wiring diagram of the anti-lock braking system (ABS)
CAN bus wiring diagram
Wiring diagram of the anti-theft system
Wiring diagram of outdoor lighting devices
Wiring diagram xenon headlights
Wiring diagram for headlights with DRL
Headlight wiring diagram (without xenon)
Dashboard wiring diagram
Wiring diagram for interior lighting when opening doors
Wiring diagram for instrument lighting
Wiring diagram of the Parktronic system (PTS)
Wiring diagram of a single lock
Wiring diagram glass heater
Wiring diagram for reversing lights
Wiring diagram for automatic dimming inside rearview mirror
Wiring diagram for the electric drive for adjusting the exterior rear-view mirrors
Rear head restraint wiring diagram
Convertible Top/Moon Roof Wiring Diagram
Trunk lid latch release circuit diagram
Seat heating wiring diagram
Klaxon wiring diagram
Electrical wiring diagram for driver's seat adjustment
Electrical wiring diagram for passenger seat adjustment
Wiring diagram of the electric drive of window regulators
Wiring diagram of a radio receiver with amplifier and data bus D2B
Wiring diagram of a radio receiver with an amplifier and without a D2B data bus
Wiring diagram of a radio receiver without an amplifier and with a D2B data bus
Wiring diagram of a radio receiver without amplifier and without D2B data bus
SRS Supplementary Safety System Wiring Diagram
Automatic transmission wiring diagram
Electrical circuit of the transmission shift lock
Wiring diagram for windshield wiper/washer
The wiring diagram of the cleaners / washers of the lenses of the block headlights
Electrical diagrams (since 2001)
Designations and abbreviations on electrical equipment diagrams
Wiring diagram of the petrol engine control system 111
Wiring diagram of the petrol engine control system 112
Wiring diagram of the petrol engine control system 271
Wiring diagram of the diesel engine control system
Fuel pump wiring diagram
Wiring diagram of the ignition lock control unit
Wiring diagram of the SAM module
Dashboard wiring diagram
Wiring diagram for automatic heater
Wiring diagram for automatic air conditioner
Wiring diagram of the automatic transmission control unit
Wiring diagram of the control unit of an automated gearbox
Wiring diagram of the AT selector control unit
Wiring diagram speed-sensitive power steering
Wiring diagram of anti-skid system ESP
Brake light wiring diagram
Wiring diagram of the wheel pressure control unit
Wiring diagram of the Distronic system
Wiring diagram of the Comand system
D2B bus wiring diagram
Cell phone wiring diagram
Wiring diagram CD changer
E-Class W123 (1976-1985)
General information
Introduction to the guide
Preface to the car repair manual
Passport data of the car
Lifting and towing a car
General requirements for car repair
Vehicle specifications and dimensions
Power unit
Engine device
General information about engines
Design and specification of the cylinder head
Design and specification of valves
The design and specification of the cylinder block
The design and specification of the crank mechanism
The design and specification of the gas distribution mechanism
Design and specification of the engine lubrication system
Design and specification of the cooling system
Design and specification of the power system
Design and specification of carburetor engines
Design and Specification of the Fuel Injection System
Design and specification of the ignition system
Repair M102 engines
Checking and adjusting clearances in the valve drive mechanism on engines M102.920 and M102.939
Checking clearances in the valve drive mechanism on engines M102.980 and M102.982
Complex operations without removing the engine from the car
Complex operations only on the engine removed from the vehicle
Removing accessories
Timing mechanism of 4-cylinder engines
Camshaft Drive Chain Replacement
Removal and installation of a head of cylinders
Dismantling and assembly of a head of cylinders
Removing the power unit
Installing the power unit
Engine disassembly
Checking the technical condition and repair of the engine
Repair M110 and M123 engines
Checking and adjusting the clearances in the valve drive mechanism on the M123 and M110 engines
Removal of engines M110 and M123
Removing the cylinder head
Removing the camshaft
Disassembly of the cylinder head
Replacing the camshaft chain
Removing the intermediate sprocket and shaft
Removing the flywheel (drive disk)
Replacing the front crankshaft oil seal
Removing the oil pump
Removing rods and pistons
Removing the crankshaft and main bearings
Oil filter replacement
Engine mount replacement
Description and maintenance of the crankcase ventilation system
General instructions for the inspection and restoration of the engine
Inspection and restoration of the crankshaft and its bearings
Inspection and restoration of connecting rods and bearings
Inspection and restoration of pistons and piston rings
Inspection and restoration of cylinders in the block
Inspection and restoration of parts of the distribution mechanism
Inspection and restoration of the flywheel (drive disk) and flywheel ring gear
Inspection and restoration of the oil pump
Cleaning of deposits, lapping of valves and restoration of the cylinder head
Engine Assembly
Installation of the crankshaft and its bearings
Installation of connecting rods and bearings
Oil pump installation
Installing the flywheel (drive disk)
Installing an intermediate sprocket and shaft
Cylinder head assembly
Installing the camshaft
Installing the cylinder head
Removal and installation of the inlet pipeline and a final collector
Cooling and lubrication (M102)
Lubrication system design
Removal and installation of the oil pump
Oil pressure check
Cooling system design
Coolant drain
Filling and bleeding the cooling system
Removal and installation of the water pump
Removing, installing and adjusting the tension of the alternator drive V-belt
Removal and installation of a multi-ribbed accessory drive belt
Setting and adjusting the belt tension
Cooling (M110 and M123)
Cooling system — general information
Draining the cooling system
Flushing the cooling system
Filling the cooling system
Removal, inspection, cleaning and installation of the radiator
Removal, check and installation of the thermostat
Removal and installation of the water pump
Water pump repair
Checking, replacing and adjusting the water pump and alternator drive belt
Cooling Fan Clutch Check
Ignition system
Breaker contact adjustment
Replacing breaker contacts
Installing the ignition distributor
Setting the ignition timing with a stroboscope
Setting the ignition timing with a warning lamp
Features of the contactless ignition system device
The principle of operation of the contactless ignition system
Removal and installation of the sensor-distributor
Replacement of the contactless sensor-distributor of ignition
Checking the sensor-distributor ignition
Removal and installation of the TDC sensor
Setting the ignition timing
Power system «Stromberg»
Features of the device carburetor Stromberg 175 CDT
Operating principle
Adjusting and checking the carburetor
Removal and installation of the electromagnetic shut-off valve
Removal and installation of the fuel pump
Power system «Solex 4A1»
The main parts of the Solex 4A1 carburetor
Engine idle adjustment
Carburetor cleaning
Removal and installation of the carburetor
Replacing the needle valve and setting the fuel level in the float chamber
Checking and adjusting the automatic starter
Adjustment of the throttle actuator of the 1st chamber
Checking the optional trigger
Checking and adjusting the accelerator pump
Checking the solenoid shut-off valves
Removal and installation of the case of a bimetallic spring of the automatic starting device
Removal and installation of the fuel pump
Valve timing (V6)
Fuel injection «K-Jetronic»
Description of the K-Jetronic fuel injection system
Air flow meter
Fuel dispenser-distributor
Nozzles — general description
Checking the injection system
Engine idle adjustment
Possible malfunctions of the L-Jetronic system, their causes and methods of elimination
Fuel injection «L-Jetronic»
Description of L-Jetronic fuel injection system
Checking the injectors
Engine idle adjustment
Checking the auxiliary fuel supply valve
Thermal valve check
Checking the thermoelectric switch
Checking the thermal time switch
Possible malfunctions of the L-Jetronic system, their causes and methods of elimination
Transmission
Clutch
Clutch design and specifications
Removal and installation of clutch
Removal and installation of the clutch slave cylinder
Removal and installation of the clutch master cylinder
Removal of air from the hydraulic clutch
Clutch malfunctions and methods for their elimination
Mechanical gearbox
Mechanical transmission design and specifications
Removal and installation of a transmission
Gearbox disassembly
Disassembly of the input and intermediate shafts
Dismantling and assembly of a secondary shaft
Dismantling and assembly of a cover of the mechanism of a gear change
Gearbox Assembly
Assembly of a four-speed gearbox
Assembling a five-speed gearbox
Assembly of a four-speed and five-speed gearbox
Adjustment of the gear shift actuator (from the lever on the body floor tunnel)
Automatic gearbox
Design and technical characteristics of automatic transmission
Changing the oil and oil filter, checking the oil level
Removal and installation of automatic transmission
Removal and installation of the transformer
Flushing the transformer
Flushing the oil cooler
Control pressure rod adjustment
Adjustment of draft of a choice of transfers
Checking shift points
Checking and adjusting the modulating pressure
Operating pressure test
Checking the pressure in the centrifugal regulator
Starter Interlock Switch Adjustment
Cardan and rear axle
Design and technical characteristics of the cardan and bridge
Removal and installation of cardan transmission
Replacing the intermediate support of the input shaft
Replacing the flexible coupling and centering sleeves
Rear axle and shaft design
Removal and installation of a shaft of a drive of back wheels
Replacement of a protective cover of a shaft of a drive of a back wheel
Removal and installation of the rear axle
Replacing the rear axle drive gear oil seal
Replacement of an epiploon of a shaft of a drive of a back wheel
Replacing the rear suspension bracket of the rear axle
Chassis
Front suspension
Design and technical characteristics of the front suspension
Removal and installation of front suspension springs
Check, removal and installation of shock absorbers
Removal and installation of a bar of the forward stabilizer of cross-section stability
Removal and installation of the front suspension assembly
Removal, installation and adjustment of a nave and bearings of forward wheels
Removal, dismantling and installation of a rotary fist
Removal and installation of the upper suspension arm
Removal and installation of the lower arm of a forward suspension bracket
Removal and installation of auxiliary draft of a forward suspension bracket
Checking and adjusting the angles of the front wheels
Rear suspension
Design and technical characteristics of the rear suspension
Removal, check and installation of shock-absorbers
Removal and installation of the rear anti-roll bar
Removal and installation of a spring of a back suspension bracket
Removal and installation of the rear suspension assembly
Removal and installation of the diagonal arm of a back suspension bracket
Removal, installation and adjustment of the hub and rear wheel bearings
Replacing the front rear suspension mount
Automatic Body Position Control System
Steering
Steering design and specifications
Removal and installation of a steering wheel
Removal, dismantling and installation of a steering column
Removal and installation of the coupling and the deformable shaft of the steering column
Removal and installation of the lock of blocking of a steering column
Removal, dismantling and installation of the steering gear without power steering
Removal, disassembly and installation of the pendulum lever
Removal and installation of transverse and longitudinal steering rods
Checking and replacing the tie rod joints
Removal and installation of the mechanism of a steering with the hydraulic booster
Removing air from the hydraulic steering system
Removal and installation of the power steering pump
Checking and adjusting the angles of the front wheels
Brake system
Design and technical characteristics of the brake system
Checking and replacing disc brake pads
Removal, disassembly and installation of the brake caliper
Inspection, removal and installation of the brake disc
Removal, dismantling and installation of the main brake cylinder
Bleeding air from master cylinder
Bleeding the brake system
Brake Fluid Replacement
Flexible hoses — check and replace
Steel brake lines — check and replace
Vacuum brake booster — removal and installation
Removal and installation of the brake light switch
Removing and installing the brake pedal
Parking brake — general description
Parking brake adjustment
Checking and replacing parking brake pads
Body
Exterior (external elements)
Body and its equipment — general description
Removal and installation of a cowl
Removal and installation of a cable of a drive of the lock of a cowl
Removing and installing the trunk lid
Removal and installation of the trunk lid lock
Outside rear view mirror
Removal and installation of the hatch of a jellied mouth of a fuel tank
Removal and installation of bumpers
Removal, adjustment and installation of windshield washer jets
Interior (internal elements)
Removal and installation of seats
Removal and installation of the instrument panel
Removal and installation of a ware box and its cover
Removal and installation of the center console
Removal and installation of a back ware box (models with a body a sedan)
Removal and installation of the electric motor of a heater
Removal and installation of a heater
Removal and installation of a heater radiator
Maintenance of the air conditioning system
Doors, locks and windows
Removal and installation of a back door (models with a body the station wagon)
Removal and installation of glass of a door of a back (models with a body the station wagon)
Removal and installation of gas-filled stops of the tailgate (models with a station wagon)
Removal and installation of the panel of an internal upholstery of a door
Removal and installation of a mechanical window regulator of a door
Removal and installation of an electric window regulator
Removal and installation of lowering glass of a forward door
Removal and installation of lowering glass of a back door
Removal and installation of fixed rear door glass
Removal and installation of a door
Removal and installation of the limiter of opening of a door
Removal and installation of the external handle of a forward door
Removal and installation of the external handle of a back door
Removal and installation of the lock of a forward door
Removal and installation of the lock of a back door
Sunroof adjustment
Removal and installation of a windshield and back glass
Removal and installation of glass of a back lateral window
Removal and installation of a window regulator of a back lateral window
Central locking system
Electrical equipment
Equipment and devices
Design and technical characteristics of electrical equipment
Fuses and relays
Removal and installation of the combined switch
Removal and installation of the door switch of illumination of salon
Removal and installation of the light switch
Removal and installation of switches of the panel of devices and the console
Removal and installation of a combination of devices
Removal and installation of a flexible speedometer drive shaft
Removal and installation of indicators of a combination of devices
Headlight / fog light adjustment
Removal and installation of headlights and their lamps
Lamp replacement
Replacing the windshield wiper blades
Removal and installation of the lever of a cleaner of a windscreen
Removal and installation of drafts of a drive of a screen wiper
Removal and installation of a drive of a cleaner of a headlight
Windshield washer
Power devices
Removing and installing the battery
Adding electrolyte to the battery
Charging the battery
Generator Maintenance and Special Precautions
Removal and installation of the generator
Checking the alternator and voltage regulator on the car
Removal, inspection and installation of generator brushes
Removal and installation of a starter
Starter repair
Electrical circuits
Wiring diagram model «250» with engine 123.026
The wiring diagram of the model «280E» with the engine 123.033
Wiring diagram of the model «280E» (engine 123.033) and «280CE» (engine 123.053)
Wiring diagram model «280TE» with engine 123.093
Wiring diagram model «280TE» with engine 123.093, starting from chassis no. 007 619
Models «280» with engine 123.030
E-Class W124 (1984-1995)
General information
Governing bodies
Controls and control devices
Instrument cluster
Control lights
Heating and ventilation
Examples of temperature control and air distribution
Independent heating system
Air conditioning system
Automatic air conditioning system
Car keys
Closing and blocking the door locks
Rear door child lock
Manual adjustment of the position of the front seat
Electric front seat position adjustment
Steering wheel adjustment
Adjusting the position of the lower part of the backrest of the front seat
Front seat armrest
Rear seat armrest
Rear seat headrest
Head restraint adjustment
Rear window heater
Seat belts
Airbag
Steering column lock / ignition lock
Light switch
Headlight corrector
Multifunction steering column switch
Rear view mirrors
Cigarette lighter in salon
Sun visors
Interior lighting
Sunroof
Control of electric windows
Parking brake
Vehicle identification
Main vehicle dimensions
Car control dimensions
Driving and operation
Starting and stopping the engine
Driving Instructions
Manual Transmission
Automatic transmission
Automatic transmission mode switch
Cruise control system
Four wheel drive (4 MATIC)
Opening and closing the hood
Exhaust gas exhaust system
If the engine does not start
Wheel replacement
Checking the tightness of connections
Towing a car
Weekly care
Weekly checkpoints
Coolant level
Brake fluid level
Fluid level in the power steering system
Washer fluid level
Rechargeable battery — care
Tires and tire pressure check
Wiper blades
Bulbs and fuses
Maintenance (gasoline)
Engine compartment and service intervals
Maintenance Specifications
Primary and secondary maintenance activities
Maintenance every 9,000 km
Maintenance every 18,000 km
Maintenance every 58,000 km
Maintenance every 118,000 km or 1 time in 4 years
Maintenance every 12 months
Maintenance every 3 years
Maintenance (diesel)
Maintenance Specifications
Engine compartment and service intervals
Primary and secondary maintenance activities
Maintenance every 9,000 km
Maintenance every 58,000 km
Maintenance every 12 months
Maintenance every 3 years
Troubleshooting
Engine Diagnostics and Troubleshooting
Diagnosing and Troubleshooting the Cooling System
Diagnostics of malfunctions of fuel and exhaust system
Clutch Diagnostics and Troubleshooting
Diagnostics of malfunctions of a manual transmission
Diagnostics of malfunctions of an automatic transmission
Diagnosis of malfunctions of the differential and cardan shaft
Diagnostics and troubleshooting of the brake system
Suspension and steering fault diagnosis
Diagnostics of malfunctions of electrical equipment
Power unit
I4 petrol engine
Engine Specifications
General engine data
Repair operations on the engine installed in the car
Compression (compression) pressure check
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover — removal and installation
Crankshaft pulley/vibration damper and hub
Drive chain cover — removal and installation
Checking and replacing the drive chain
Drive chain tensioner
Camshaft sprocket — removal, inspection and installation
Crankshaft sprocket — removal, inspection and installation
Lower Drive Chain Guide for Single Chain Models
Lower Drive Chain Guide for Dual Chain Models
Upper chain guide
Tensioner Shoe for Single Chain Drive Models
Tensioner Shoe for Dual Chain Drive Models
Intermediate shaft — removal, inspection and installation
Valve drive, tappets and camshaft
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Flywheel / drive plate — removal, inspection and installation
Replacement of sealing rings of a cranked shaft
Replacing the bearing at the end of the crankshaft
Checking and replacing the support of the power unit
V6 petrol engine (SOHC)
Engine Specifications
General engine data
Repair operations on the engine installed in the car
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover — removal and installation
Crankshaft pulley/vibration damper and hub
Drive chain covers — removal and installation
Lower drive chain cover — removal and installation
Drive chain — check and replace
Drive chain tensioner
Camshaft and crankshaft sprockets
Damper and drive chain tensioner shoe
Valve drive, tappets and camshaft
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Replacing the oil pump drive chain
Replacement of O-rings
V6 petrol engine (DOHC)
Engine Specifications
General engine data
Repair operations on the engine installed in the car
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover — removal and installation
Crankshaft pulley/vibration damper and hub
Drive chain covers — removal and installation
Upper Timing Chain Cover (Models with HFM Fuel Injection System)
Lower drive chain cover — removal and installation
Checking and replacing the drive chain
Drive chain tensioner
Camshaft and crankshaft sprocket
Chain guides — removal, inspection and installation
Tensioner shoe — removal, inspection and installation
Camshaft adjustment mechanism
Camshafts and tappets — removal, inspection and installation
Checking and adjusting the position of the camshafts
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump chain and drive — removal, inspection and installation
Replacement of O-rings
Oil cooler — removal and installation
Diesel engines
Engine Specifications
General engine data
Repair operations on the engine installed in the car
Compression (compression) pressure check
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover — removal and installation
Crankshaft pulley/vibration damper and hub
Drive chain cover — removal and installation
Drive chain — check and replace
Drive chain tensioner
Camshaft and crankshaft sprocket
Chain guides — removal, inspection and installation
Camshafts and tappets
Checking hydraulic tappets
Camshafts — installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump and drive chain — removal and installation
Replacement of sealing rings of a cranked shaft
Engine overhaul
Specifications and overhaul dimensions of engines
General techniques for disassembling the cylinder head
Recommendations for removing the engine
Removal and installation of 4-cylinder petrol engines
Removal and installation of 6-cylinder petrol engines
Removal and installation of diesel engines
Engine disassembly sequence
Dismantling of a head of the block of cylinders
Cleaning and inspection of the cylinder head
Valves — checking and lapping
Cylinder head assembly
Removing pistons with connecting rods
Removing the crankshaft
Engine block
Pistons and connecting rods — removal and installation
Crankshaft — check
Inspection of main and connecting rod bearings
Engine assembly sequence during overhaul
Installation of piston rings
Choice of crankshaft bearings
Checking the operating clearance of the main bearings
Installing the crankshaft
Installing pistons with connecting rods
Starting the engine after a major overhaul
Cooling system
Specifications of the cooling system
General information about the cooling system
Coolant hoses
Radiator — removal, inspection and installation
Thermostat — removal, inspection and installation
Radiator fan — removal and installation
Fan with electromagnetic clutch — removal and installation
Electrical sensors — removal and installation
Water pump — removal and installation
Water pump (models with six-cylinder petrol engines)
Water Pump (Diesel Models)
Heating and ventilation
Heating and ventilation system — general information
Elements of the heating system — removal and installation
Heater radiator — removal and installation
Heater control panel — removal and installation
Heater fan motor — removal and installation
Internal temperature sensor — removal and installation
Heater radiator temperature sensors — removal and installation
Air and wire distribution switch
Air flow regulator — removal and installation
Air conditioning system — general information
Fuel system (carburetor)
Fuel system specification
General information about carburetors
Air filter and filter element — removal and installation
Air intake temperature control unit
Fuel pump — removal and installation
Accelerator cable — removal and installation
Carburetor STROMBERG 175 CDT
Replacing elements of the STROMBERG 175 CDT carburetor
Carburetor PIERBURG 2E-E
Replacing carburetor elements PIERBURG 2E-E
Removal and installation of the carburetor
Intake manifold — removal and installation
Intake manifold heater — removal and installation
Injection system «Bosch CIS-E»
Technical characteristics of the fuel injection system Bosch CIS-E (KE-Jetronic)
General information about the Bosch CIS-E (KE-Jetronic) fuel injection system
Accelerator cable — removal, installation and adjustment
Air filter — removal and installation
Air filter housing — removal and installation
Fuel filter — removal and installation
Pressure accumulator — removal and installation
Fuel level sensor — removal and installation
Fuel pump — removal and installation
Fuel tank — removal and installation
Throttle body — removal and installation
Intake manifold — removal and installation
Elements of the KE-Jetronic fuel injection system
Fuel distributor — removal and installation
Air flow sensor — removal and installation
Air pump (models with six-cylinder engines)
Engine cold start valve — removal and installation
Coolant temperature sensor — removal and installation
Throttle position switch
Electronic Control Unit (ECU)
Fuel injectors — removal and installation
Pressure regulator — removal and installation
Additional air device
Lambda sensor — removal and installation
Relieve pressure in the fuel system
Idle speed adjustment and CO content in exhaust gases
Injection system «Bosch HFM»
Technical characteristics of the Bosch HFM fuel injection system
General information about the Bosch HFM fuel injection system
Accelerator cable — removal, installation and adjustment
Air filter — removal and installation
Air filter housing — removal and installation
Throttle body — removal and installation
Intake manifold — removal and installation
Air flow meter — removal and installation
Coolant temperature sensor — removal and installation
Lambda sensor — removal and installation
Electronic Control Unit (ECU)
Fuel injectors and fuel line
Fuel pressure regulator — removal and installation
Relieve pressure in the fuel system
Idle speed adjustment and CO content in exhaust gases
Diesel fuel system
Technical characteristics of the diesel fuel system
General information about the diesel fuel system
Air filter — removal and installation
Intake manifold — removal and installation
Accelerator cable — removal, installation and adjustment
High pressure fuel pump — removal and installation
Priming fuel pump — removal and installation
Injection timing mechanism, fuel pump sprocket
High pressure fuel pump injection timing
Fuel injectors — removal and installation
Electronic Idle Speed Control System (ELR)
Electronic anti-knock system ARA
Electronic diesel engine management system
Motor overload protection system
Fuel thermostat — removal and installation
Supply system
Turbocharger technical data
General information about the power system
Evaporative Emission System
Crankcase ventilation system
Exhaust manifold — removal and installation
Exhaust gas re-burning (EGR) system
Turbocharger — removal and installation
Exhaust system — removal and installation
Catalytic converter
Starting and charging system
Technical characteristics of the starting and charging system
General information about the starting and charging system
Battery Care Rules
Battery check
Accumulator charging
Battery — removal and installation
Charging system
Generator — removal and installation
Replacing the voltage regulator unit and brush holder
Engine start system
Starter — removal and installation
Ignition system (I4)
Specifications of the ignition system of 4-cylinder engines
EZL ignition system
TFZ ignition system
Checking the ignition system
Ignition coil — removal and installation
Ignition distributor — removal and installation
Distributor rotor — removal and installation
Ignition advance angle
Elements of the ignition control system — removal and installation
Ignition system (V6)
Ignition system specifications for 6-cylinder engines
General information about the ignition system
Checking the ignition system
Ignition coil — removal and installation
Ignition distributor and distributor rotor
Checking and adjusting the ignition timing
Elements of the ignition control system — removal and installation
Preheating
Technical characteristics of the preheating system
General information about the preheating system
Glow plug control unit — removal and installation
Glow plugs — removal, inspection and installation
Coolant temperature sensor — removal and installation
Transmission
Clutch
Clutch Specification
General clutch information
Clutch assembly — removal, inspection and installation
Release bearing — removal, inspection and installation
Clutch release lever — removal, inspection and installation
Clutch slave cylinder — removal and installation
Clutch master cylinder — removal, repair and installation
Clutch Master Cylinder Pusher Adjustment
Bleeding the hydraulic clutch system
Clutch pedal — removal and installation
Mechanical gearbox
Technical characteristics of a manual transmission
General Information Manual Transmission
Changing the oil in the gearbox
Gearshift mechanism — removal and installation
Replacement of O-rings
Reversing light switch — removal, inspection and installation
Removal and installation of a transmission
Gearbox repair
Automatic gearbox
Technical characteristics of the automatic transmission
General information about automatic transmission
Selector lever — removal and installation
Draft of a choice of transfers — removal and installation
Pressure Control Cable Adjustment
Switches of blocking of a starter and lanterns of a backing
Removal and installation of an automatic transmission
Automatic transmission repair
Drive shafts
Technical characteristics of drive shafts
General information about drive shafts
Changing the oil in the rear final drive
Removal and installation of the rear final drive
Replacement of sealing rings of the rear final drive
Drive shafts — removal and installation
Replacing the protective covers of the CV joints of the drive shaft
Cardan shaft — removal and installation
Rubber flexible coupling of propeller shaft
Central propeller shaft bearing
Universal joint for cardan shaft
Chassis
Brake system
Technical characteristics of the brake system
General information about the brake system
Bleeding the hydraulic brake system
Brake lines and hoses
Replacing the front brake pads
Replacing the rear brake pads
Front brake disc — removal, inspection and installation
Rear brake disc — removal, inspection and installation
Front brake caliper
Caliper repair
Rear brake caliper — removal and installation
Master brake cylinder — removal and installation
Vacuum brake booster — removal, inspection and installation
One-way brake booster valve
Parking brake adjustment
Parking brake pads — removal and installation
Parking brake pedal — removal and installation
Parking brake cables — removal and installation
Stoplight switch — removal and installation
Anti-lock braking system (ABS)
Elements of the anti-lock braking system — removal and installation
Models with Vehicle Speed Control (ASR)
Vacuum pump on diesel models
Car suspension
Technical characteristics of the suspension and steering
General information about suspension and steering
Front hub bearing — check and adjust
Front wheel hub — removal and installation
Swivel fist — removal and installation
Front suspension shock absorber — removal and installation
Front suspension spring — removal and installation
Lower arm front suspension — removal and installation
Front stabilizer bar
Fastener of a back nave — removal and installation
Replacing the rear hub bearing
Rear suspension shock absorber — removal and installation
Shock absorber (models without self-levelling rear suspension)
Rear suspension spring — removal and installation
Rear suspension arms — removal and installation
Lower arm rear suspension — removal and installation
Stabilizer bar of the rear suspension
Connecting earring of the stabilizer of cross-section stability
Self-levelling rear suspension system on Wagon models
Self-levelling rear suspension elements
Steering
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Steering column lock / ignition lock — removal and installation
Contact group of the ignition switch — removal and installation
Steering shaft rubber clutch — removal and installation
Steering gear — removal and installation
Steering gear bipod — removal and installation
Replacement of the lower sealing ring of the steering gear
Power steering pump — removal and installation
Bleeding the power steering system
Steering shock absorber — removal and installation
Central tie rod — removal and installation
Intermediate steering lever — removal and installation
Tie rod — removal and installation
Wheel alignment
Body
Exterior (external elements)
Tightening torques for threaded connections
General information about the body
Car body care
Caring for upholstery and rugs
Repair of minor body damage
Repair of severe damage to the body
Front bumper — removal and installation
Rear bumper — removal and installation
Hood — removal, installation and adjustment
Hood opening cable — removal and installation
Hood lock — removal and installation
Exterior mirrors
Exterior body parts
Interior (internal elements)
Front and rear seats — removal and installation
Front seat belt tension mechanism
Seat belt elements
Front seat belt on Coupe models
Seat belt height adjustment mechanism
Front seat belt buckle
Rear seat side belt on Sedan models
Rear seat side seat belt on Wagon models
Central seat belt for rear seat
Interior decoration — removal and installation
Center console — removal and installation
Instrument panel — removal and installation
Doors, locks and windows
Doors — removal and installation
Door upholstery — removal and installation
Door handles and locks
Door glass and power windows
Trunk lid — removal and installation
Trunk lid lock — removal and installation
Rear door — removal and installation
Rear door lock — removal and installation
Elements of the central lock — removal and installation
Windshield and rear window
Car sunroof
Electrical equipment
Equipment and devices
Technical characteristics of electrical equipment
General information about electrical equipment
Electrical circuits
Faulty electrical circuit detection
Fuses and relays
Instrument cluster — removal and installation
Elements of the instrument cluster
Speedometer drive cable — removal and installation
Cigarette lighter backlight — removal and installation
Sound signal — removal and installation
Wiper arm — removal and installation
Wiper drive — removal and installation
Rear door wiper — removal and installation
Elements of the windshield and headlight washer system
Sound reproducing equipment
Loudspeakers — removal and installation
Elements of the cruise control system — removal and installation
Airbag
Airbag elements — removal and installation
Switches
Multifunction steering column switches
Headlight beam corrector — removal and installation
Light switch — removal and installation
Center console front switches
Center console rear switches
Power sunroof switch — removal and installation
Parking brake warning light switch
Seat adjustment switch
Rear Power Window Switches
Interior lighting switch — removal and installation
Trunk Light Switch — Removal and Installation
Headlights and lighting
External lighting bulbs — general information
Headlights — removal and installation
Front position lamp
Front fog lamp
Front direction indicator
Side turn signal — removal and installation
Rear lights — removal and installation
License plate light
Interior lighting bulbs — general information
Front interior lighting
Rear interior lighting
Trunk light lamp
Instrument cluster lights
Duffel box lighting lamp
Heater control panel illumination lamp
Switch illumination lamps
External lighting devices
Headlight adjustment
Electrical circuits
General information, wiring diagram of the charging and starting system
Wiring diagram of the engine management system
Wiring diagram of the instrument cluster and sensors
Wiring diagram for external lighting
Interior lighting, wipers and washers
Washers, heated glass, fan, horn, cigarette lighter
Mirrors, radio, central locking, seat belt mechanism
Heating system, electric windows
E-Class W210 (1996-2002)
General information
Vehicle description
Repair manual structure
Maintenance and control
Working symbols
General description of the body
Lightweight body concept
Appearance of the E-class model
Mercedes-Benz E-class models
Model range of E-class cars
T-model station wagon
Correct position in the car
Seating
Airbags
Luggage capacity
Dimensions of Mercedes E-class cars
Engines — general information
Diesel 4-cylinder engines: E220D, E200CDI and E220CDI
Common rail direct injection
Diesel 5-cylinder engines: E250D and E290TD
Diesel 6-cylinder engine E300D
Diesel 6-cylinder engine E320CDI
Petrol 4-cylinder in-line engines E200, E230
Gasoline 6-cylinder in-line and V-shaped engines E240, E280, E320
Petrol 8-cylinder V-shaped engines E420, E430, E50AMG, E55AMG
Manual Transmission
Automatic transmission
Driving and cornering safety
Improved driving dynamics
Brake system
Passive safety system
Side impact protection
Forward collision protection
Technical data and vehicle characteristics
Working conditions and tools
Workplace of an auto mechanic
Purchase of spare parts
Essential car repair tool
Special tool for car repair
Safety precautions when repairing a car
Jacking up the car
Mechanic's working methods
Car delivery for repair
Car care
Car interior cleaning
Car body wash
Car cleanliness check
Place for car wash
If you wash your car yourself
Engine wash
Lubrication of moving body parts
Windshield wiper and washer
Pouring washer fluid into the windshield washer
Wiper blade replacement
Windshield washer jets
Removing the windshield wiper arm
Removal and installation of the windshield wiper gearmotor
Windshield wiper motor terminals
Removing the rear window wiper arm (T-model)
Removal and installation of the rear window wiper motor reducer (T-model)
Possible malfunctions of the wiper blade system, their causes and solutions
Possible malfunctions of the wiper, their causes and solutions
Paintwork care
Repairing damaged paintwork
Mercedes E-class maintenance plan
Diesel engines
Engine repair
Four-cylinder diesel engines
Five-cylinder diesel engines
Six-cylinder diesel engines
Turning the crankshaft of the engine
Hydraulic pushers — check and adjustment
Possible malfunctions of the hydraulic pusher, their causes and solutions
Camshaft drive chain
Cylinder compression check
Checking the accessory drive belt
Accessory drive belt replacement
Cylinder head gasket
Possible malfunctions of the cylinder head, their causes and solutions
Possible engine malfunctions, their causes and remedies
Knocking in the engine
Lubrication system
Lubrication system — general description
Oil pump
Oil pressure
Engine oil
Automatic oil level control
Checking the operation of the oil level sensor
Checking the condition of the engine oil
Changing the oil and oil filter
Filling volumes of the lubrication system
Checking the tightness of the oil system
Possible malfunctions of the lubrication system, their causes and remedies
Cooling system
Cooling system — general information
Overpressure and radiator fan
Cooling liquid
Checking the cooling system for leaks
Coolant level gauge
Checking the level and topping up the coolant
Coolant replacement
Refueling volumes of the cooling system
Possible malfunctions of the hydraulic pusher thermostat and their causes
Possible malfunctions of the cooling system, their causes and solutions
Thermostat — removal and inspection
Fan — Health Check
Replacing the cooling system hoses
Radiator — removal and installation
Air filter — removal and installation
Injection system
Diesel injection system — general information
Basic elements of the electronic diesel system (EDS)
Engine operating modes
Idle system
Soft Shift System (ARA)
Variable length intake manifold
Nozzles — general description
Turbocharger — description and maintenance
Possible malfunctions of the turbocharger, their causes and solutions
Engine shutdown
Maintenance of the injection system
Removing nozzles
Disassembly of nozzles
Accelerator pedal drive
Possible malfunctions of the diesel engine power system, their causes and remedies
Supply system
Fuel tank
Fuel pump
Fuel system heat exchanger
Fuel filter — removal and installation
Fuel supply system
Fuel — specifications and description
Draining fuel from the fuel tank
Removal of pipelines and hoses of the fuel supply system
Fuel pump malfunctions
Preheating device
Exhaust system
Exhaust System — General Description
Service life of the exhaust system
Reducing the toxicity of exhaust gases
Checking the condition of the exhaust system
Exhaust system replacement
Silencer replacement
Gasoline engines
Engine repair
Gasoline engines — general information
Hydraulic pushers — check and adjustment
Possible malfunctions of hydraulic pushers, their causes and solutions
Cylinder compression check
Accessory drive belt
Removal and installation of the engine (4-cylinder in-line engine)
Removal and installation of a cover of a head of the block of cylinders
Possible engine malfunctions, their causes and remedies
Lubrication system
Lubrication system — general description
Oil circulation
Oil pressure — check
Engine oil -classification and selection
Crankcase ventilation
Engine oil consumption
Oil level control system
Checking the condition of the engine oil
Changing the oil and oil filter
Possible malfunctions of the lubrication system, their causes and remedies
Cooling system
Coolant circulation
Overpressure in the cooling system
Features of the cooling system of 6- and 8-cylinder engines
Additional electric fan
Checking the tightness of the cooling system
Cooling liquid
Thermostat — removal, installation and inspection
Removal and installation of a radiator (for engines of 2.0 and 2.3 l)
Possible malfunctions of the cooling system, their causes and solutions
Control system
Engine management systems — general description
Safety measures when working on the engine management system
Operation of the engine management system
Removal and installation of ignition coils
Removal and installation of the fuel distributor
Removal and installation of fuel injectors
Checking the technical condition of fuel injectors
Possible malfunctions of the injection system, their causes and remedies
Power and exhaust system
Power System — General Description
Fuel tank ventilation system
Draining fuel from the fuel tank
Dismantling of fuel lines and hoses of the power system
Removal and installation of the fuel level sensor
Removal and installation of the fuel pump
Removal and installation of the air filter
Exhaust gas exhaust system
Catalytic converter
Check of system of release of the fulfilled gases
Removal and installation of system of release of the fulfilled gases
Transmission
Clutch
Torque transmission
Hydraulic clutch
Clutch wear
Clutch test
Clutch jerking
Clutch Wear Check
Visual inspection of the hydraulic clutch
Pumping the clutch hydraulic drive
Clutch repair
Possible clutch malfunctions, their causes and solutions
Mechanical gearbox
Manual Gearbox — General Description
Adjustment of the mechanism of a gear change
Checking the oil level in the gearbox
Mechanical transmission leak test
Automatic gearbox
Automatic transmission — general description
The principle of operation of the automatic transmission
Torque Converter — General Description
Selector lever positions
Checking the automatic box
Possible malfunctions of the automatic transmission, their causes and remedies
Drive shafts
Cardan shaft — general description
Removing the cardan shaft
Purpose of the differential
Checking the oil level in the differential
Rear wheel drive shafts — general description
Noises in the rear wheel drive shafts
Check of a condition of dirt-protective covers of shafts of a drive of back wheels
Removal and installation of a shaft of a drive of a back wheel
Disassembly of the drive shaft and replacement of mudguards
Matic all-wheel drive system
Chassis
Car suspension
General Suspension Information
Front suspension — design description
Rear suspension — design description
Station wagon T-model chassis
Clearance regulation
Wheel alignment check
Checking the condition of shock absorbers
Checking mudguards and play of tie rod ends
Checking mudguards and ball joint play
Checking wheel bearing play
Setting the front hub bearing clearance
Removing the front shock absorbers
Checking the removed shock absorbers
Removing the front wheel suspension spring
Removing the rear wheel suspension shock absorber (without clearance adjuster)
Removing the rear suspension spring
Steering
Steering — general description
Power steering
Steering play check
Checking the level of hydraulic booster fluid
Checking the tightness of the hydraulic booster
Checking the mudguards of the steering rack
Replacement of tie rod ends
Checking mudguards of steering rods
Possible malfunctions of a steering, their reasons and ways of elimination
Tires and wheels
The structure of the multilayer tire
Mercedes E-class wheels
Information on the bus
Important information about tires
Tire pressure check
Wheel replacement
Tire condition check
Wheel imbalance
Possible tire failures, their causes and solutions
Brake system
Brake system — general description
Service brake system
Anti-Lock Braking System (ABS)
Traction control (ASR)
Electronic throttle control
BAS system (Brake-Assist)
Electronic Stability Program (ESP)
Operation of ABS/ASR/BAS/ESP systems
Brake check
Parking brake system
Checking the brake fluid level
Checking the brake system for leaks and damage
Checking the brake booster
Checking the lining thickness
Checking the condition of the brake discs
Replacing the front brake pads
Replacing the rear brake pads
Removing the brake caliper
Removing the brake disc
Removing the brake hose
Removal of brake pipelines
Bleeding the brake system
Brake Fluid Replacement
Parking brake adjustment
Removing the parking brake pads
Replacing the parking brake cables
Possible malfunctions of the brake system, their causes and remedies
Body
Exterior (external elements)
Car body — general description
Installing the hood in a vertical position
Removing the hood
Hood adjustment
Removal of facing of a radiator
Removal of the Mercedes emblem
Bonnet release cable replacement
Wing removal
Removing fender liner
Removing the side pads
Front and rear bumpers
Removing the outside rear-view mirror
Interior (internal elements)
Car interior — general description
Instrument cluster and switches in the cabin
Troubleshooting power windows
Window lifter repair on the road
Power window switches
Removing the power window switch
Central locking with pneumatic drive
Troubleshooting in the central locking system
Adjustment of rear-view mirrors
Checking the electric drive for adjusting the rear view
Rear view mirror disassembly
Cigarette lighter — replacement
Checking the rear window heater
Removing the radio
Removing the speakers
Replacement of interior lighting lamps
Replacing the rest of the lamps in the cabin
Removing the front seats
Removing the rear seat
Removing the rear head restraints
Seat heating
Checking the seat belts
Removing the glove box
Removing the lining of the gear lever on the center console
Removing the ashtray
Removing the center console
Removal of facing of the block of management of a heater
Removal of an upholstery of an average rack
Removing the upholstery of the rear pillar
Removing the rear shelf
Removing the upholstery under the dashboard
Removing the upholstery in the area of the pedal assembly
Doors and windows
Removing the trunk lid
Trunk lid adjustment
Doors — general information
Removing the front door
Front door adjustment
Removing the rear door
Rear door adjustment
Removing the door upholstery
Removing the door glass
Removing the outer door handle
Removing the door lock
Windshield and rear window
Sunroof
Heating and ventilation
Heating and ventilation — general description
Elements of automatic heating system (HAU)
Checking the operation of the heating and ventilation system
Replacing the cabin air filter
Supply air fan
Fan Troubleshooting
Removing the fan motor
Possible malfunctions of the heating system, their causes and remedies
Air conditioning — general description
The principle of operation of the air conditioner
Electrical equipment
Equipment and devices
Electrical equipment — general information
Control devices — general description
Checking control devices
Instrument Cluster — General Description
Removing the instrument cluster
Tempomat (cruise control)
Airbag system and seat belt pretensioners
Wires and fuses
Color coding of wires
Relay and fuse mounting block
Fuses — types and location
Fuse replacement
Relay — assignment and troubleshooting
Combi Relay — Location
Power devices
Battery — general description
Starter — design description
Generator — design description
Checking the electrolyte level in the battery, maintaining contacts
Checking the battery charge
Battery voltage measurement
Starting the engine from an external power source
Charging the battery
Removing the battery
Faulty Consumer Detection
Checking the voltage regulator
Possible battery malfunctions, their causes and solutions
Removing the generator
Removal and installation of a starter
Possible starter malfunctions, their causes and remedies
Lighting and signaling
Headlights — general description
Permanent monitoring of lighting devices
Replacing headlight bulbs
Fog Light Bulb Replacement
Removing headlights
Approximate headlight adjustment
Headlight adjustment
Fog lamp adjustment
Replacing the lamp in the rear light
Removing the rear light
Replacement of a lamp in an additional signal of braking
Replacing the license plate lamp
Sound and light alarm — general description
Checking sound and light signaling devices
Replacing the front direction indicators
Replacing turn signal repeaters
If the turn signal relay is faulty
Checking and removing brake signals
Removing the sound signal
Checking the beep
Possible malfunctions of the sound signal, their causes and solutions
Possible malfunctions of the brake signal, their causes and solutions
Possible malfunctions of the alarm and direction indicators, their causes and remedies
Electrical circuits
Wiring Diagrams — General Description
Symbols on electrical diagrams
Scheme 1. Starter and generator (engines 104, 111, 604, 605, 606)
Diagram 2 Front axle speed signal (GES) (104, 111, 602, 604, 605, 606 engines)
Diagram 3. Rear axle speed signal (GES) (engines 104, 111, 602, 604, 605, 606)
Diagram 4. Rear axle speed signal (GES) (engines 104, 111, 604, 605, 606)
Diagram 5. Automatic transmission (AG) (engines 104, 111, 119, 604, 605)
Diagram 6. Relay module (K40) (motors 602, 604, 605, 606)
Diagram 7. Electronic Throttle Control (EFP) / Cruise Control (TMP) / Idle Speed Control (LLR) (104 Engines)
Scheme 8. Diesel engine injection system with injection pump (EVE) of the distributor type and electronic control (engine 602)
Scheme 9. The injection system of a diesel engine with high pressure fuel pump (EVE) of a distributive type and electronic control (engine 604)
Scheme 10. Diesel injection system with in-line injection pump (EVE) and electronic control (engine 605)
Scheme 11. Diesel engine injection system with in-line injection pump (EVE) and electronic control (engine 606)
Diagram 12. Engine with CAN data bus
Diagram 13. Adaptive Suspension Adjustment System (ADS)
Scheme 14. Anti-dazzle device of the internal rear-view mirror
Diagram 15. Sound signal
Scheme 16. Parktronik parking system (PTS)
Scheme 17. Illumination of a cosmetic mirror
Diagram 18. Fuse and relay box (F1)
Diagram 19 — Sliding/Lifting Sunroof (SHD) Drive
Scheme 20. Windshield wiper
Scheme 21. Internal lighting
Diagram 22. Infrared remote control
Scheme 23. Trailer connector
Scheme 24. Central blocking
Scheme 25. Outdoor lighting
Scheme 26. Automation of the heating system (HAU)
Scheme 27. Fuse box in the rear of the car (F4)
Diagram 28 and 29. E320 petrol engine control system
Diagram 30. ABS system, models with traction control
Scheme 31. Headlights with xenon lamps
G-Class W463 (1999-XXXX)
General information
Introduction to the guide
Information about this guide
Mercedes-Benz G-class cars — abstract
Vehicle identification numbers
Purchase of spare parts
Jacking with a regular jack when changing wheels
Car hanging
Transportation of the emergency vehicle
Starting the engine from an auxiliary power source
Vehicle troubleshooting
Controls and instruments
Vehicle specifications and dimensions
Instrument panel and center console — general information
Instrument cluster, meters, control lamps and indicator lights
Controls and interior equipment
Replacing wiper blades
Automated air conditioning system (Tematic)
Activation / deactivation of the service mode of the TELE AID emergency call system
Driving and operation
Running in the first 1500 kilometers
Getting Started and Shifting the Automatic Transmission
Transfer case switch
Differential lock
Speed control systems (Tempostat / Speedtronic)
Parktronic System (PTS)
Emergency Brake Assist (BAS)
Anti-Lock Brake System (ABS)
Traction control system (4-ETS)
Electronic anti-skid system (ESP)
Maintenance
Routine care and maintenance — general information
Maintenance Specifications
Active Scheduled Maintenance Alert System (ASSYST)
Schedule of ongoing maintenance
General information about settings
Checking fluid levels, leak control
Checking the condition of tires and their pressure, designation of tires and wheel rims, wheel rotation
Changing the engine oil and oil filter
Checking the brake system
Checking the power system, replacing the fuel filter
Checking the condition and replacing the engine compartment hoses, localizing leaks
Checking the condition of the multi-ribbed accessory drive belts
Checking the cooling system and coolant, changing the fluid
Check of a condition of system of release of the fulfilled gases
Changing the filter and automatic transmission fluid
Visual check of tightness of automatic transmission
Checking the Condition of Suspension and Steering Components
Checking the condition of the anthers of the drive shafts
Checking the air conditioning system
Lubrication of door stops and lock cylinders
Visual inspection of seat belts and airbag modules
Checking the headlights and horn
Checking the condition and replacing the wiper blades
Cabin filter replacement
Changing the Differential Lock Fluid
Brake Fluid Replacement
Checking and replacing spark plugs, checking the condition of high-voltage wires
Replacing Glow Plugs (Diesel Models)
Power unit
Engine repair
Engine Specifications
Compression pressure check, cylinder condition assessment
Checking the engine with a vacuum gauge
Replacement of the auxiliary drive belt and elements of its tensioning mechanism
Engine Oil Pressure Check
Oil consumption calculation
Checking and adjusting the basic position of the camshafts
Checking the basic position of the balancing shaft (only engines M112 and 628)
Checking the condition of the timing chain on the M628 engine
Checking the correct setting of the ignition timing on gasoline models
Removal and installation of the power unit
Removal and installation of suspension mounts of the power unit
Cooling system
Cooling, heating and ventilation specifications
Antifreeze — antifreeze
Coolant Replacement — General Notes
Checking the cooling system cover, replacing hoses
Thermostat check
Removal and installation of the thermostat
Removal and installation of a radiator of system of cooling
Removal and installation of a broad tank
Removing and installing the cooling fan assembly
Removal and installation of the water pump
Removal and installation of a low-temperature cooler (M612)
Removal and installation of a heater of the block of the engine
Removal and installation of additional heater STH
Removal and installation of circulation pump for auxiliary heater STH
Heating and ventilation
General information and security measures
Removal and installation of the control panel for heating / ventilation / air conditioning systems
Removal and installation of the heater / air conditioner fan and its control module
Removal and installation of the heater heat exchanger
Removal and installation of the circulation pump of a heater
Removal and installation of back ventilating guards
Checking the refrigerant level in the working path of the A/C system
Removal and installation of sensors of system K/V
Removing and Installing the Auxiliary Fan Assembly
Removal and installation of an electric motor of a drive of a ventilating damper
Removal and installation of a stepper electric motor for the drive of the damper for switching modes of air circulation
Removal and installation of the mixing damper drive electric motor
Removal and installation of the evaporator of the K / V system and its casing
Removal and installation of the compressor of system K/V
Removal and installation of the condenser of system K/V
Removal and installation of the expansion valve
Removal and installation of the receiver-drier
Power system (gasoline)
Power system specifications
General information and security measures
Checking and adjusting idle speed / ignition timing / CO concentration
Relieving pressure in the fuel system of a gasoline engine
The principle of operation of the control system and injection of a gasoline engine
General inspection of the petrol engine injection system
Checking the injectors
Removal and installation of components of an inlet air path
Servicing throttle actuator components
Emptying the fuel tank
Removal and installation of the fuel pump
Removal and installation of the gauge of a stock of fuel
Removal and installation of the fuel distributive highway and injectors
Removal and installation of the fuel tank
Removing and installing fuel injection control module (ECM ME-SFI)
Fuel system (diesel)
General information about the power supply system of diesel engines
Fuel Injection System Checks
Servicing Air Inlet Components
Bleeding air from the low pressure circuit of the fuel path
Removal and installation of the preliminary fuel pump
Removal and installation of the high pressure fuel pump (TNVD)
Removal and installation of the fuel distributive highway and nozzles
Removal and installation of the pressure sensor in the fuel line
Removal and installation of the fuel pressure regulator valve
Removal and installation of valve assembly
Removal and installation of a fuel cooler
Removal and installation of a low-temperature cooler
Removal and installation of the fuel injection control module
Exhaust system
Systems of release and decrease in toxicity of the fulfilled gases
Tightening force of threaded connections, Nm
Removal and installation of system of release of the fulfilled gases
Removal and installation of exhaust manifolds
Removal and installation of lambda probes
Removal and installation of the air pump
Removal and installation of the valve of a purge of a coal adsorber (EVAP)
Removal and installation of a coal adsorber (EVAP)
Removal and installation of the EGR valve
Removing and installing the EGR cooler
Removal and installation of EGR positioners
Removal and installation of the gauge of temperature of a cooling liquid (CDI)
Ignition and control system
Engine Electrical System Specifications
Basic Information and Safety Precautions
Ignition and injection control system checks
Troubleshooting — General Information and Preliminary Checks
Checking and adjusting the ignition timing
Spark plugs — condition check
Removal and installation of ignition coils
Removal and installation of the crankshaft position sensor (CKP)
Removing and installing the camshaft Hall sensor
Removal and installation of knock sensors (KS)
Diesel engine preheating system
Checking diesel glow plugs
Removal and installation of glow plugs
Diagnostics of electronic control systems and diagnostic equipment
Personal computer interface controller with OBD II on-board self-diagnosis system
Using an oscilloscope to monitor the performance of a control system
Charging and starting system
General information about the charging and starting system
Battery — general information, maintenance recommendations
Charging system — general information and safety measures
Checking the charging system
Removal and installation of the generator
Engine starting system — general information and precautions
Removal and installation of a starter
Transmission
Automatic gearbox
General information about automatic transmission
Automatic transmission specifications
Troubleshooting — general information
General principles of functioning of the transmission control system, control signals
Adjustment of a drive of switching AT
Removal and installation of the electrohydraulic block of management of switchings
Removal and installation of AT with torque converter
Removal and installation of the selector module (ESM)
Removal and installation of the AT output speed sensor
Removal and installation of ATF cooler
Flushing the ATF cooler and oil lines
Removal and installation of the electronic transmission control module (TCM / ETC)
Transfer case
Transmission Line Specifications
Basic principles of organizing permanent all-wheel drive
Lubrication of articulated joints and sliding joints of cardan shafts
Removing air from the hydraulic path of the differential lock drive
Changing the oil in the transfer case
Removing and installing the transfer box control module
Removal and installation of a vacuum receiver of a control system of blocking of differentials
Removal and installation of the vacuum pump of a drive of blocking of differentials
Removal and installation of the transfer box servomotor
Disconnection and connection of cardan shafts on the transfer case
Removal and installation of the transfer case
Removal and installation of bearings of a suspension bracket of a distributing box
Transfer case design
Replacing the transfer case seals
Removal and installation of the executive cylinder of a drive of blocking of interaxal differential
Removing and installing the front cover
Removing and installing intermediate flange bearing cover
Disassembly and assembly of the bearing cover
Removal and installation of an intermediate flange cover
Removal and installation of an intermediate flange
Removal and installation of center differential
Disassembly and assembly of the center differential
Removal and installation of input and intermediate shafts
Disassembly of the input (drive) shaft
Dismantling the intermediate shaft
Removal and installation of components of the mechanism of inclusion of blocking of interaxal differential
Removal and installation of components of the mechanism for switching modes of the transfer case
Axles front and rear
General information about bridges
Checking and adjusting the level / changing the oil in axle assemblies
Checking the packing with grease of the hinged casings of the front axle swivel assemblies
Checking and adjusting the backlash of the wheel bearing of the front axle
Checking the concentricity of the fit of the connecting flanges of the final drive gears
Replacement of epiploons of leading gear wheels of the main transfers
Removal and installation of main gears
Removal, installation and adjustment of the actuating cylinders and components of the drive mechanism for blocking cross-axle differentials
Dismantling and assembling the slave cylinder of the differential lock drive
Removal and installation of naves of forward wheels
Disassembly and assembly of the front wheel hubs
Removal and installation of drive shafts of the forward bridge
Swivel Bearing Adjustment
Disassembly and assembly of the hinged casing of the front axle
Disassembly and assembly of the drive shaft
Removal and installation of semiaxes
Disassembly and assembly of the axle shaft
Removal and installation of assemblies of cross-axle differentials with driven gears of main gears
Disassembly and assembly of cross-axle differentials
Checking the correct engagement of the final drive gears
Chassis
Brake system
General information about the brake system and safety measures
Brake Specifications
Checking the brake system for leaks
Check of serviceability of functioning of the vacuum amplifier of brakes
Removal and installation of the brake fluid reservoir and brake master cylinder (GTZ)
Removal and installation of the vacuum brake booster and diaphragm stroke sensor BAS
Removal and installation of the vacuum pump (diesel engines)
Removal and installation of control modules ABS / EBV / ESP
Removal and installation of hydromodulator ABS / 4-ETS
Removal and installation of ABS wheel sensors
Removal and installation of ABS wheel sensor rotors
Removing and installing the foot brake pedal
Removal and installation of the lever of a cocking of a parking brake with a bearing bracket
Replacement of brake hoses
Checking the condition and replacing the brake pads
Replacing parking brake shoes
Removal and installation of brake calipers
Fixed type caliper repair
Check, removal and installation of brake disks
Removal and installation of components of a cable drive of a parking brake
Parking brake actuator adjustment
Bleeding the brake system
Front suspension
General information about suspension and steering
Suspension and steering specifications
General information about the front suspension
Removing and installing the front axle assembly
Removing, checking and installing front shock absorbers
Removal and installation of front suspension springs
Removal and installation of the front anti-roll bar
Removal and installation of longitudinal suspension arms
Replacing the rubber bushing of the trailing arm
Vehicle wheel alignment — general information
Adjustment of a convergence of forward wheels
Determination of the required amount of run-out
Checking and adjusting the limit angles of rotation of the front wheels
Checking the wheelbase
Rear suspension
General information about the rear suspension
Removal and installation of the rear axle assembly
Removing, checking and installing rear shock absorbers
Removal and installation of front suspension springs
Removal and installation of the rear anti-roll bar
Removal and installation of longitudinal suspension arms
Steering
General steering information
Steering pump head check
Checking and adjusting the hydraulic limiter
Steering shaft adjustment
Assessment of the condition of the components of the steering gear
Removal and installation of a steering wheel
Removal and installation of a contact cable drum of a steering wheel
Removal and installation of the steering wheel angle sensor
Removal and installation of the mechanism of an electronic lock of a steering column
Removal and installation of a steering column with the electric drive of adjustment
Removal and installation of the steering pump
Removal and installation of the power steering fluid cooling line
Removal and installation of the steering mechanism
Steering gear design
Body
Exterior (external elements)
Specifications of the body and its elements
Removing and installing wiper arms
Removing the front wiper drive
Removal and installation of a cowl
Removal and installation of the lock of a cowl
Removal and installation of a drive cable of release of a latch of the lock of a cowl
Removal and installation of a forward lattice
Removal and installation of covers of block headlights
Removal and installation of an anther of an impellent compartment of a complete set AMG
Removal and installation of side steps
Removal and installation of bumpers
Removal and installation of door rear-view mirrors
Removal and installation of the glass washer fluid reservoir
Removal and installation of the spare wheel holder
Removal and installation of wheel arch protection lockers
Removing and installing A-pillar exterior trim panels
Removal and installation of front fenders
Interior (internal elements)
Removal and installation of the lower covers of the panel of devices
Removal and installation of deflectors of air ducts of the panel of devices
Removal and installation of a ware box
Removal and installation of the handle of the panel of devices
Removal and installation of a forward ashtray
Removal and installation of the left lower section of finishing of the panel of devices
Removal and installation of knee support
Removal and installation of an end cover of a steering column
Removal and installation of the facing panel of the console section of the instrument panel
Removal and installation of the center console
Removal and installation of a combination of devices
Removal and installation of the instrument panel
Removal and installation of a saloon rear-view mirror
Removal and installation of trim panels body pillars
Removal and installation of trim panels
Removal and installation of a ceiling upholstery (Universal models)
Removal and installation of carpet floor panels
Removal and installation of front seat assemblies
Removal and installation of rear seat assemblies
Removal and installation of seat backs
Removing and installing seat cushions
Doors, locks and windows
Removal, installation and adjustment of doors
Removal and installation of a gas-filled emphasis of a door of a back (Universal model)
Removal and installation of external door handles
Removal and installation of internal door handles
Removal and installation of door locks
Removal and installation of latches and locking wedges of a folding board
Removal and installation of an internal upholstery of door assemblies
Removal and installation of regulators of door windows
Removal and installation of window frames door assemblies
Removal and installation of body glazing elements
Removal and installation of the panel of an upholstery of a cover of the top hatch
Removal and installation of a cover of the top hatch
Removal and installation of a cable of a drive of the top hatch
Removal and installation of a frame of the top hatch
Removal and installation of a sealing element of the top hatch and elements of its fastening
Removal and installation of a drainage trench of the top hatch
Removal, installation and adjustment of the wind deflector of the upper hatch
Electrical equipment
Equipment and devices
Onboard Electrical Specifications
General information and precautions
Search for the causes of electrical equipment failures
Fuses — general information
Circuit breakers — general information
Relay — general information and function check
CAN digital data bus
Disconnecting and connecting wiring of mounting blocks and control modules
Removal and installation of fuse and relay mounting blocks
Removing and installing control modules
Removal and installation of electromotors of a drive of screen wipers
Removal and installation of single lock activators
Removal and installation of electromotors of a drive of adjustment of forward seats
Removal and installation of sensors
Removal and installation of frontal airbag modules
Switches in salon
Removal and installation of steering column switches
Group of switches on the left side of the instrument panel
Removal and installation of the switch handle and actuators for adjusting the position of the block headlights
Removing and installing the assembly of the upper groups of switches of the console part of the instrument panel
Removal and installation of the panel of switches of blocking of differentials
Removal and installation of the panel of switches of the electric drive of windows of a driver's door
Removal and installation of the panel of the ceiling console
Headlights and lighting
Removal and installation of block headlights, replacement of lamps, adjustment of the direction of optical axes
Removal and installation of the back combined lanterns
Removal and installation of direction indicators
Removal and installation of a stoplight of the top level
Removal and installation of fog lights
Replacement of interior lighting lamps
Audio system and navigation
Removal and installation of the radio receiver
Removing and installing CD changer / TV tuner
Removal and installation of antenna amplifiers
Removal and installation of antenna nodes
Removal and installation of the antenna divider
Removing and installing loudspeakers
Removing and installing the Handsfree mobile phone transceiver
Removing and installing the mobile phone interface
Removing and installing the cell phone holder
Electrical circuits
List of symbols on electrical diagrams
ME-SFI control system for petrol engines 112.945 and 113.962
Diesel CDI control system 628.962
Powertrain Control Module (ETC) (all models)
Electronic AT Selector Lever Module (All Models)
Transfer case (all models)
Front differential lock (all models from 09/01/01)
Starting system (all models of release 01.09.01)
Engine cooling system (all petrol models produced 06/01/99)
Anti-lock brake system (ABS) (all models)
Steering column (all models)
Fuse mounting block F1 (all models from 09/01/01)
Fuse mounting block F2 (all models from 09/01/01)
Pre-fuse mounting block F32 (all models from 09/01/01)
Cabin fuse box F34 (all models)
Relay mounting block K40 (petrol models)
Electronic Ignition Switch (EIS) (all models from 11/25/02)
Diagnostic connector DLC (all models from 09/01/01)
Instrument cluster without ASSYST (all models from 09/01/01)
Instrument Cluster with ASSYST (Petrol Models)
Alarm system (petrol models)
Driver's door control module (all models)
Right Front Door Control Module (All Models)
Left Rear Door Control Module (All Models)
Single lock (petrol models)
13-pin hitch harness connector (petrol models, code E43)
Windscreen wipers (petrol models)
Headlight cleaners (petrol models)
Air conditioning system (AAC) (petrol models from 09/01/01)
Additional security systems (petrol models)
Steering column contact cable reel (all models)
Cigarette lighter (all models)
Power outlets (all models)
Overhead console (all models from 09/01/01)
Rear reading lamps (G 500)
Electric seat adjustment front (ESV) (all models from 09/01/01)
Anti-theft system (ATA) (petrol models, code FZ5)
M-Class W163 (1997-2005)
General information
Introduction to the guide
Mercedes-Benz M class cars (W163) — abstract
Vehicle identification numbers
Purchase of spare parts
Jacking and towing a car
Starting the engine from an auxiliary power source
Vehicle troubleshooting
General information and vehicle specification
Controls and instruments
Single lock for car access
Unlocking and locking the doors
Access to luggage compartment
Access to the fuel tank filler neck
Access to the underhood space
Access to the storage box of the right front seat
Anti-theft system
Elements of security systems — general information
Rules for the use of passive safety equipment for the driver and passengers
Seat adjustment
Supplemental Security System (SRS)
Risk of carbon monoxide (CO) poisoning
Instrument panel and center console
Instrument cluster, meters and control lamps and indicator lights
Controls and interior equipment
Luggage compartment equipment
Replacing wiper blades
Automated air conditioning system (climate control)
COMMAND system, radio, telephone and radio station
Driving and operation
Running in the car for the first 1500 km
Operating techniques and auxiliary systems
Breaking in a new car
Features of operation of vehicles equipped with a three-function catalytic converter
Car parking
Getting started and shifting gears
Speed control systems (Tempostat / Speedtronic)
Parktronic System (PTS)
Emergency Brake Assist (BAS)
Anti-Lock Brake System (ABS)
Traction control system (4-ETS)
Electronic anti-skid system (ESP)
Electronic brake force distribution (EBV)
Maintenance
Recommended lubricants and fluids
Active Scheduled Maintenance Alert System (ASSYST)
Schedule of ongoing maintenance
General information about settings
Checking fluid levels, leak control
Checking the condition of tires and their pressure, designation of tires and wheel rims, wheel rotation
Changing the engine oil and oil filter
Checking the brake system
Checking the power system, replacing the fuel filter
Checking the condition and replacing the engine compartment hoses, localizing leaks
Checking the condition of the multi-ribbed accessory drive belts
Checking the cooling system and frost resistance of the coolant, changing the fluid
Check of a condition of system of release of the fulfilled gases
Replacing and checking the ATF level, replacing the AT filter
Visual check of tightness of automatic transmission
Checking the Condition of Suspension and Steering Components
Checking the condition of the anthers of the drive shafts
Checking the air conditioning system
Lubrication of door stops and lock cylinders
Visual inspection of the seat belt and airbag unit
Checking the headlights and horn
Checking the condition and replacing the wiper blades
Cabin filter replacement
Brake Fluid Replacement
Checking and replacing spark plugs, checking the condition of high-voltage wires
Power unit
Gasoline engines
Engine Specifications
Checking the compression pressure in the cylinders
Checking the engine with a vacuum gauge
Replacement of the auxiliary drive belt and elements of its tensioning mechanism
Removal and installation of the engine
Removing and installing timing covers
Replacing the gas distribution chain
Removal and installation of timing drive components
Setting the basic position of the camshafts
Checking the Basic Position of the Balance Shaft (112 Series Engines Only)
Removal and installation of timing components
Removal and installation of a head of cylinders
Removal and installation of the inlet pipeline
Removal and installation of a final collector
Removal and installation of the end cover, replacement of the crankshaft rear oil seal
Removing and installing vibration damper / drive belt pulley
Removal and installation of the flywheel / drive plate
Removal and installation of suspension mounts of the power unit
Maintenance of the lubrication system
Diesel engines
Removal and installation of the engine
Removing and installing timing covers
Replacing the gas distribution chain
Removal and installation of timing drive components
Setting the basic position of the camshafts
Checking the Basic Position of the Balance Shaft (628 Series Engines Only)
Removal and installation of timing components
Removal and installation of a head of cylinders
Removal and installation of the electric motor for shutting off the intake port (612 series engine)
Removal and installation of a final collector
Replacing the front crankshaft oil seal
Removal and installation of the rear end cap, replacement of the crankshaft rear oil seal
Removing and installing vibration damper / drive belt pulley
Removal and installation of the flywheel / drive plate
Maintenance of the lubrication system
Cooling system
Cooling, Heating and Air Conditioning Specifications
Antifreeze — antifreeze
Coolant Replacement — General Notes
Replacing the cooling system hoses
Check of serviceability of functioning of the thermostat
Removal and installation of the thermostat
Removal and installation of a radiator of system of cooling
Removing and installing the cooling fan assembly
Removal and installation of the water pump
Heating and ventilation
General information and security measures
Removal and installation of the control panel for heating / ventilation / air conditioning systems
Removal and installation of the heater / air conditioner fan and its resistive assembly
Removal and installation of the heater heat exchanger
Removal and installation of a stepper electric motor for the drive of the damper for switching modes of air circulation
Removal and installation of the mixing damper drive electric motor
Quick check of serviceability of functioning of the air conditioning system
Removing and Installing the Auxiliary Fan Assembly
Removal and installation of the suction fan of the cabin air temperature sensor
Removal and installation of the sensor of temperature of external air
Removal and installation of the evaporator temperature sensor
Removing the air conditioner evaporator cover
Removal and installation of the air conditioner evaporator
Removal and installation of the air conditioner condenser
Removal and installation of the expansion valve
Removal and installation of the receiver-drier
Removal and installation of the air conditioning control module
Power system (gasoline)
Checking and adjusting idle speed / ignition timing / CO concentration
Relieving pressure in the fuel system of a gasoline engine
The principle of operation of the control system and injection of a gasoline engine
General inspection of the petrol engine injection system
Checking the injectors
Removal and installation of components of an inlet air path
Servicing throttle actuator components
Emptying the fuel tank
Removal and installation of assembly of the fuel pump with the gauge of a stock of fuel
Removal and installation of the shut-off fuel valve (only American models)
Removal and installation of the fuel distributive highway and injectors
Removal and installation of the fuel line from the filter to the fuel line
Removal and installation of the fuel tank
Fuel system (diesel)
Diesel engine power system — general information
Fuel Injection System Checks
Servicing Air Inlet Components
Servicing Throttle Actuator Components
Removal and installation of the gauge of a stock of fuel
Bleeding air from the low pressure circuit of the fuel path
Removal and installation of the preliminary fuel pump
Removal and installation of the high pressure fuel pump (TNVD)
Removal and installation of the fuel distributive highway and nozzles
Removal and installation of the pressure sensor in the fuel line
Removal and installation of the electric shut-off valve
Removal and installation of the fuel pressure regulator valve
Removal and installation of valve assembly on models 163.128
Removal and installation of a cooler of fuel on models 163.113
Removal and installation of the fuel injection control module
Replacing parking brake shoes
Bleeding the brake system
Removal and installation of the pedal assembly and sensor-switch of brake lights
Removal and installation of a pedal of a cocking of a parking brake
Removal and installation of the cable assembly of the parking brake actuator
Parking brake actuator adjustment
Removal and installation of ABS / ETS / ESP wheel sensors
Exhaust system
Systems of release and decrease in toxicity of the fulfilled gases
Removal and installation of system of release of the fulfilled gases
Replacing the front sections of the exhaust system on gasoline models
Removal and installation of catalytic converters on diesel models
Removal and installation of lambda probes
Removal and installation of the EGR valve — М112/113
Removing and installing the EGR cooler — diesel models
Removal and installation of the air pump — M112/113
Removal and installation of a carbon adsorber — gasoline models
Removal and installation of the expansion tank for the accumulation of fuel vapors
Ignition and control system
Engine Electrical System Specifications
Basic Information and Safety Precautions
Ignition and injection control system checks
Troubleshooting — General Information and Preliminary Checks
Checking and adjusting the ignition timing
Spark plugs — condition check
Removal and installation of ignition coils — gasoline models
Removal and installation of the crankshaft position sensor (CKP)
Removal and installation of the camshaft position sensor (CMP)
Removing and installing the camshaft Hall sensor
Removal and installation of knock sensors (KS) — gasoline engines
Diesel engine preheating system
Checking glow plugs
Removal and installation of glow plugs
Removal and installation of the coolant temperature sensor (ECT)
Diagnostics of electronic control systems and diagnostic equipment
Personal computer interface controller with OBD II on-board self-diagnosis system
Using an oscilloscope to monitor the performance of a control system
Charging and starting system
Charge and launch systems — general information
Battery — general information, maintenance recommendations
Charging system — general information and safety measures
Checking the charge system
Removal and installation of the generator
Removal and installation of a drive pulley of the generator
Removal and installation of the voltage regulator
Engine starting system — general information and precautions
Removal and installation of a starter
Transmission
Mechanical gearbox
Manual Transmission Specifications
Adjustment of the shift drive manual transmission 717.461
Removal and installation of the shift lever RKPP 717.461
Features of the design of the rod-cable drive for switching RKPP 716.644
Removal and installation of the shift lever RKPP 716.644
Removal and installation of mechanical transmission
Automatic gearbox
Specifications of automatic transmission
Troubleshooting — general information
General principles of operation of the transmission system, control signals
Adjustment of a drive of switching of automatic transmission
Removal and installation of the electrohydraulic block of management of switchings
Removal and installation of AT with torque converter
Removal and installation of the selector module
Removal and installation of a cable of blocking of the electronic switch of ignition (EIS)
Clutch
Transmission Line Specifications
Description of the clutch design
Evaluation of the degree of wear of the clutch disc
Removal, installation and clutch check
Removal and installation of the master cylinder
Removal and installation of the clutch slave cylinder
Removal of air from the hydraulic path of the clutch drive
Drive shafts and cardan
Removal and installation of the front propeller shaft
Removal and installation of the rear propeller shaft
Removal and installation of the intermediate bearing of a back cranked shaft
Removal and installation of the steering knuckle, replacement of the ball joint
Removal and installation of the front drive shaft flange and double-row angular contact ball bearing of the front hub
Removal and installation of the rear hub assembly, replacement of the ball joint
Removal and installation of the rear drive shaft flange and double-row angular contact ball bearing of the rear hub
Removal and installation of power shafts
Replacement of anthers of hinge assemblies of power shafts
Transfer case
Removing and installing the transfer box control module
Removal and installation of the transfer case
Replacing the oil seal of the input shaft of the transfer case
Replacing the output flange seal of the rear propeller shaft
Replacing the front output shaft seal
Removal and installation of the servomotor for switching modes of the transfer case
Removal and installation of the assembly of the planetary gearbox of the center differential of the transfer case
Removal and installation of assembly of bearing assembly of a distributing box
Removal and installation of the oil pump of a distributing box
Removal and installation of the transfer case switching mechanism
Removal and installation of a reduction gear wheel of a distributing box
Replacing the side differential seals
Replacement of epiploons of driving gears of differentials
Removal and installation of differentials
Chassis
Brake system
Specifications for braking and auxiliary systems
General information and security measures
Checking the brake system for leaks
Check of serviceability of functioning of the vacuum amplifier of brakes
Non-return valve check
Removal and installation of the main brake cylinder
Removal and installation of the vacuum brake booster and diaphragm stroke sensor BAS
Removal and installation of hydromodulator ETS/ESP
Removal and installation of hydraulic lines laid between the GTZ and the ETS / ESP hydraulic modulator
Wear assessment and replacement of brake pads
Replacement of brake hoses
Removal and installation of a support
Removal and installation of a brake disk
Front suspension
Suspension and steering specifications
Removing and installing the front axle assembly
Removing, checking and installing front shock absorbers
Removal and installation of a torsion bar
Removal and installation of torsion springs
Removal and installation of the lower transverse arm, replacement of the front axle bushing
Removal and installation of the upper transverse arm
Check of a condition of spherical support of a rotary fist
Rear suspension
Removal and installation of the rear axle assembly
Removal, disassembly and installation of rear racks
Removal and installation of a torsion bar
Removal and installation of the lower transverse arm
Removal and installation of the upper transverse arm
Remove and install longitudinal brace
Steering
Filling and «pumping» the steering pump
Steering pump head check
Replacing the hose clamp of the power steering fluid cooling path
Assessment of the condition of the steering rod joints and anthers of the rack and pinion housing
Removal and installation of the steering pump
Replacement of anthers of a crankcase of the steering mechanism
Removal and installation of tie rod ends
Removal installation of input knot of the steering mechanism
Removal and installation of the steering mechanism
Dismantling the mechanical steering column adjuster
Removal and installation of a steering wheel and a spiral contact drum of a steering column
Removal and installation of the cylinder of the lock of ignition
Removal and installation of the lock of blocking of a steering column
Removal and installation and shirts of the steering column
Suspension geometry
Checking the geometric parameters of the installation of bridges
Checking and adjusting ride height
Vehicle wheel alignment — general information
Checking and adjusting camber and runout
Checking and adjusting convergence
Checking the amount of divergence of the front wheels in a turn
Body
Exterior (external elements)
Body specifications and dimensions
Removal and installation of levers of screen wipers
Removing the front wiper drive
Removal and installation of retractable telescopic headlight washer nozzles
Removal, installation and adjustment of a cowl
Bonnet hinge replacement
Removing and installing the Mercedes emblem
Removal, installation and service of components of the lock of a cowl
Removal and installation of a gas-filled stop for fixing the hood in the open position
Removing and installing washer fluid reservoir
Removal and installation of a forward bumper
Removal and installation of the upper front transverse beam of the frame
Removal and installation of panels of the bottom protection of an impellent compartment
Removal and installation of a back bumper
Removal and installation of the external holder of a spare wheel
Removal and installation of wheel arch protection lockers
Interior (internal elements)
Removal and installation of the lower covers of the panel of devices
Removal and installation of deflectors of air ducts of the panel of devices
Removal and installation of the central (console) section of the instrument panel
Removal and installation of the main glove box
Removal, installation and adjustment of a cover of the main ware box (models of release on 08/31/99)
Removal and installation of the lower and upper main sections of the instrument panel
Removal and installation of a cover of a console ware box
Removal, disassembly and installation of the center console
Removal and installation of a facing cover of the lever of the selector (on an example of models of release on 31.08.01)
Removal and installation of trim panels body pillars
Removing and installing front footwell trim panels
Removal and installation of overlays of door thresholds
Removal and installation of carpet floor panels
Removal and installation of front seat assemblies
Removal and installation of a back seat
Removal and installation of seat backs
Removal and installation of a folding armrest of a separate back seat
Doors and locks
Removal and installation of doors
Removal and installation of limiters of opening of lateral doors
Removal and installation of tailgate hinges
Removal and installation of a gas-filled sliding stop of the tailgate
Removal and installation of external door handles
Removal and installation of panels of an internal upholstery of door assemblies
Removal and installation of door locks
Removal and installation of door rear-view mirrors
Electrical equipment
Equipment and devices
Fuse and Relay Specifications
General information and precautions
Search for the causes of electrical equipment failures
Fuses — general information
Circuit breakers — general information
Relay — general information and function check
CAN digital data bus
Removal and installation of mounting blocks
Removing and installing control modules
Removing and installing the CAN bus adapter
Removal and installation of a combination of devices
Replacing the Turn-Push Temperature Selector Lamp
Removal and installation of onboard power outlets
Removal and installation of group of switches of the central console
Removal and installation of individual switches of the electric drive of regulators of window regulators of back doors
Removal and installation of switches of the electric drive of adjustment of forward seats
Removal and installation of the steering column switch assembly
Removing and installing the overhead console assembly
Removal and installation of the switch of management of functioning of the electric drive of the top hatch
Removal and installation of the trip computer assembly (if equipped)
Removal and installation of frontal airbag modules
Removal and installation of side airbag modules
Drive motors
Removal and installation of groups of electromotors of a drive of adjustment of a forward seat
Removal and installation of electromotors of a drive of regulators of door window regulators
Removal and installation of electric motors for adjusting the position of door mirrors
Removal and installation of an electric motor of a drive of the top hatch
Removal and installation of electric motors of the drive for adjusting the direction of the optical axes of the headlights
Removal and installation of electromotors of a drive of screen wipers
Removal and installation of electric motors of activators of locks of a door of a back and a cover of a hatch of a jellied mouth of a fuel tank
Removal and installation of electric motors for the drive of exhaust vents
Lighting and signaling
Removal and installation of klaxon horns
Removal and installation of block headlights, replacement of lamps
Removal, installation and replacement of fog lamps
Removal and installation of rear lights, replacement of lamps
Removal and installation of the central brake light of the upper level
Removal and installation of license plate lights
Replacing interior lamps
Removal and installation of the sensor of temperature of external air
Removal and installation of the rain sensor (if equipped)
Audio system
Removal and installation of the radio receiver
Removal and installation of door loudspeakers
Removal and installation of the AM/FM amplifier
Removal and installation of the antenna divider
Removing and installing the CD changer (if equipped)
Removing and installing the subwoofer (if equipped)
Electrical circuits
Abbreviations and designations used on electrical diagrams
Manual air conditioning system with cooling fan control module (ML 430)
Manual air conditioning system without cooling fan control module (ML 430)
Anti-Lock Brake System (ABS) (ML 430)
Brake Boost System (ML 430)
Cooling fan (ML 430)
Anti-theft system with additional siren (ML 430)
Anti-theft system without additional siren (ML 430)
General Activity Module (AAM) (ML 430)
Extended Activity Module (EAM) (ML 430)
Processor data lines (ML 430)
Tempostat or cruise control (ML 430)
Heated windows (ML 430)
Engine management system (ML 430)
Engine management system (ML 320)
Engine management system (ML 500)
Reversing lights (ML 430)
Trip computer (ML 430)
Heated driver's seat (ML 430)
Outdoor lighting (ML 430)
Headlight adjustment (ML 430)
Klaxon (ML 430)
Headlights (xenon) (ML 430)
Headlights (not xenon) (ML 430)
Instrument cluster (ML 430)
Interior lighting when opening doors (ML 430)
Instrument lighting (ML 430)
Driver seat adjustment (with memory function) (ML 430)
Front passenger seat adjustment (with memory function) (ML 430)
Power Distribution (ML 430)
Electric door locks (ML 430)
Power door mirrors (ML 430)
Power driver's seat (ML 430)
Heated front passenger seat (ML 430)
Power front passenger seat (ML 430)
Motorized two-panel sunroof (ML 430)
Motorized one-panel sunroof (ML 430)
Power windows (ML 430)
Power rear windows (ML 430)
Charging system (ML 430)
Headlight washers (ML 430)
Radio (basic, with emergency call system) (ML 430)
Radio (basic, without emergency call system) (ML 430)
Radio (upgraded, with emergency call system) (ML 430)
Radio (upgraded, without emergency call system) (ML 430)
AT shift lock (ML 430)
Starting system (ML 430)
All wheel drive (4WD) (ML 430)
Supplementary Restraint System (SRS) (with seat position memory function) (ML 430)
Supplementary Restraint System (SRS) (without seat position memory function) (ML 430)
Automatic transmission (AT) (ML 430)
Windshield wipers/washers (ML 430)
Rear window wipers/washers (ML 430)
S-Class W116 (1972-1980, petrol)
General information
Introduction to guide
General provisions: introduction
Vehicle designation
General repair instructions
Working conditions and tools
Proper vehicle lifting
Maintenance and care
General vehicle specifications
Power unit
8-cylinder V8 engine
Removal and installation of the engine
Cylinder head: removal and installation
Engine disassembly and assembly
Disassembly of the cylinder head
Cylinder head repair
Camshaft drive cover: removal and installation
Pistons and connecting rods — removal
Pistons and connecting rods — Cylinder measurement
Checking pistons and connecting rods
Assembly of pistons and connecting rods
Installation of pistons and connecting rods
Cylinder block
Crankshaft and drive plates
Checking the parts of the crankshaft
Installing the crankshaft
Box drive discs
Damper and crankshaft pulley
Rear crankshaft oil seal and cover
Front crankshaft oil seal
Camshaft drive
Removal and installation of a chain of a drive
Removal and installation of the tensioner shoe
Removal and installation of chain guides
Removal and installation of an asterisk of a drive of the distributor of ignition
Removal and installation of camshafts (without removing the engine)
Engine mounts
Exhaust system
Engine Specifications
Tightening torques for threaded connections
6-cylinder I6 engine
Removing the engine
Engine installation
Engine disassembly and assembly
Removing the cylinder head
Disassembly of the cylinder head
Cylinder head repair
Pistons and connecting rods — removal
Measuring cylinders, checking pistons and connecting rods
Assembly of pistons and connecting rods
Installation of pistons and connecting rods
Cylinder block
Removing the crankshaft
Crankshaft and Flywheel: Parts Check
Installing the crankshaft
Flywheel or drive discs (automatic transmission)
Damper and crankshaft pulley
Rear oil seal
Front oil seal
Camshaft drive
Removal and installation of the chain tensioner
Removal and installation of a chain of a drive
Removal and installation of the tensioner shoe
Removal and installation of chain guides
Removal and installation of the guide sprocket
Removal and installation of rocker arms
Removal and installation of the camshaft housing
Removal and installation of camshafts
Checking the valve timing
Valve timing adjustment
Valve clearance adjustment for 6 and 8 cylinder engines
Engine Mount
Cooling and lubrication system
Engine lubrication system — general information
Removal and installation of the oil pump
Oil filter
Removal and installation of an oil crankcase
Engine cooling system — general information
Draining and filling the cooling system
Cooling liquid
Radiator and fan
Removal and installation of the pump of a cooling liquid
Thermostat — general information
Adjusting the tension of the coolant pump drive belts
Specifications for lubrication and cooling systems
Power system (carburetor)
Dual carburetor Solex 4A 1 — device
The principle of operation of the carburetor
Disassembly and assembly of the carburetor
Checking the carburetor
Air filter
Fuel pump
Power system specifications
Fuel injection system
The device and functions of the main elements of the power system
Adjustment of idling and CO content in exhaust gases
Removal and installation of individual components of the fuel injection system
Check of knots of system of injection of fuel
Injection system specifications
Ignition system
Ignition system — brief description
Safety rules when working with the ignition system
Ignition distributor
Ignition timing adjustment
Spark plug
Ignition coil
Transistor ignition system for fuel injected engines
Speed limiter
Ignition System Specifications
Transmission
Clutch and cardan
Clutch — general information and removal
Clutch repair
Clutch installation
Clutch Release Drive
Checking the wear of the lining of the clutch disc (assembly)
Removal and installation of the master cylinder
Removal and installation of the working cylinder
Clutch and Suspension Pedal Free Play Check
Hydraulic pumping
Disassembly and assembly of the synchronizer of a mechanical gearbox
Removal and installation of cardan transmission
Removal and installation of the bearing of an intermediate support of cardan transfer
Adjustment of a convergence of forward wheels
Clutch Specifications
Tightening torques for threaded connections
Car gearbox
Removal and installation of a manual transmission
Disassembly and assembly of a manual transmission
Removal and installation of a cover of the mechanism of inclusion of transfers of a manual gearbox
Removal and installation of a forward cover of a mechanical transmission
Removal and installation of a back cover of a mechanical transmission
Removal and installation of transfer of a backing of mechanical KP
Removal and installation of mechanical gearbox gears
Disassembly and assembly of the driven shaft of a mechanical gearbox
Disassembly and assembly of the intermediate shaft of a mechanical gearbox
Adjustment of a drive of a gear change of a mechanical KP
Manual transmissions of the first releases
Automatic transmission — general information
Removal and installation of an automatic transmission
Gearbox Specifications
Tightening torques for threaded connections
Chassis
Front suspension
Removal and installation of the shock absorber
Removal and installation of a spring of a forward suspension bracket
Removal and installation of a forward suspension bracket
Adjusting the axial clearance of the wheel bearings
Removal and installation of the hub
Hub bearing replacement
Removal and installation of a rotary pin
Replacement of ball joints
Adjustment of the camber and the longitudinal angle of inclination of the axis of rotation
Determining the rotation angle difference
Front Suspension Specifications
Tightening torques for threaded connections
Wheel specifications and wheel alignment
Rear suspension
Removal and installation of the main transfer (differential)
Replacing the drive gear oil seal
Replacement of epiploons in covers of bearings of the main transfer
Removal and installation of semiaxes in gathering
Removal and installation of a nave of a back wheel and adjustment of bearings of a nave
Adjustment of bearings of a nave of a back wheel
Removal and installation of the rear suspension shock absorber
Checking the position of the car on the rear suspension
Replacing the brake pads of the rear wheels
Parking brake adjustment
Rear Suspension Specifications
Tightening torques for threaded connections
Steering
Steering — removal and installation
Steering gear
Power steering — removal
Power steering pump
Steering Specifications
Tightening torques for threaded connections
Brake system
Brake system — general information
Replacing the brake pads of the front wheels
Removal and installation of the front caliper
Front caliper overhaul
Removal and installation of a brake disk of forward brakes
Rear caliper overhaul
Removal and installation of brake disks of back wheels
Master brake cylinder
Removal and installation of parking brake pads
Brake booster
Removing air from the hydraulic brake system
Brake Specifications
Tightening torques for threaded connections
Electrical equipment
Power devices
Electrical equipment — general information
Accumulator battery
Safety precautions when working on the generator
Checking the generator on the car
Removal and installation of the generator
Generator repair
Check, removal and installation of a starter
Disassembly and assembly of the starter
Electrical specifications
Electrical circuits
The electrical circuit of the car «Mercedes 280 S»
The electrical circuit of the car «Mercedes 280 SE»
The electrical circuit of the car «Mercedes 350 SE»
Wiring diagram of the car «Mercedes 450 SE / 450 SEL»
S-Class W126 (1979-1991, petrol)
Power unit
Engine repair
Vehicle identification
Removal and installation of the engine
Engine disassembly
Engine assembly
Disassembly of the cylinder head
Inspection of cylinder head parts
Installing the valve guide
Cylinder head assembly
Checking pistons and connecting rods
Cylinder block (crankcase)
Crankshaft and flywheel
Camshaft and drive mechanism — general information
Checking the camshafts
Checking the valve timing
Valve timing adjustment
Rocker arm — removal and installation
Checking and replacing the hydraulic valve clearance compensator
Chain tensioner — removal and installation
Engine Specifications
Vehicle dimensions and filling capacities
Tightening torques for threaded connections
Cylinder head cover for six-cylinder engine
Cylinder head of six-cylinder engine
Ignition system
General information about the ignition system
The operation of the transistorized ignition system
Safety Precautions for Transistor Ignition System
Checking the ignition system
Checking the ignition coil
Checking the ignition wires
Checking and adjusting the ignition timing
Ignition distributor — general information
Ignition distributor — removal and installation
Spark plugs — description and marking
Checking the distributor cap
Checking electrical connections
Checking spark plugs
Diagnostics of malfunctions of system of ignition
Lubrication system
Purpose and properties of motor oils
The device and principle of operation of the lubrication system
Oil pressure relief valve — removal and installation
Oil pump — removal and installation
Oil filter — design description
Replacing the oil filter on a type 110 engine with air conditioning
Oil sump — removal and installation
Oil temperature thermostat — removal and installation
Oil cooler — removal and installation
Engine oil change
Diagnostics of malfunctions of the lubrication system
Lubrication circuit for eight-cylinder engines
Cooling system
The device and principle of operation of the cooling system
Removal and installation of the pump of a cooling liquid
Coolant Pump Repair
Thermostat — removal, installation and inspection
Drive belts — replacement and tension
Radiator — removal and installation
Fan motor — removal and installation
Checking the coolant level
Checking antifreeze
Visual check of the system for leaks
Coolant replacement
Table of malfunctions of the cooling system
Specifications of the engine cooling and lubrication system
Details of the cooling system of eight-cylinder engines
Fuel system
Solex 4A-1 carburetor — design description
Idle speed and CO content adjustment
Checking the idle shut-off valves
Air filter — removal and installation
Changing the air filter element
Checking the vacuum regulator
Air Piston Damper Oil Level Check
Tempomat adjustment
Checking the idle shutoff valve
Checking the earth connection on the carburetor
Idle Shutoff Valve Relay Test
Idle shutoff valve — removal and installation
Adjusting the warm engine speed and the CO content in the exhaust gases
Thermal Delay Valve / Pull-down Valve Check
Automatic start device — removal and installation
Fuel tank — general information
Fuel pump — check
Fuel pump — removal and installation
Carburetor Troubleshooting
Engine Power System Specifications
Fuel injection system
The principle of operation of the fuel injection system
Inspection, testing and adjustment of the fuel injection system
Checking the tightness of the injection system connections
Checking and adjusting idle speed and CO content
Throttle link adjustment
Full Throttle Limiter Adjustment
Removal, installation and check of a nozzle of start of the cold engine
Removal, installation and check of the thermal time switch
Checking the additional air damper
Checking and adjusting the air flow meter damper
Checking the cold start valve
Tempomat adjustment
Checking the Temperature Sensor
Fuel pump check
Removal and installation of the fuel pump
Diagnosis of malfunctions of the injection system
Transmission
Clutch and cardan
Description of the clutch design
Removal, check and installation of coupling
Bleeding the hydraulic clutch
Air removal with a special installation
Removal and installation of release bearing
Clutch master cylinder — removal and installation
Checking the thickness of the driven disk
Clutch Troubleshooting
Removal and installation of cardan shaft
Removal and installation of the intermediate bearing of the cardan shaft
Cardan Shaft Specifications
Tightening torques for threaded connections
Cardan shaft details
Mechanical gearbox
Removal and installation of a transmission
Gearshift device cover
Removal and installation of a forward cover of a transmission
Removal and installation of a back cover of a transmission
Reverse gear — removal and installation
Gear Lever Adjustment
Checking the oil level in a manual transmission
Manual Transmission Specifications
Tightening torques for threaded connections
Cross section of a 5-speed manual transmission
Automatic gearbox
Automatic Gearbox — Description
Automatic transmission — removal and installation
Checking the oil level in an automatic transmission
Changing the oil / cleaning the screen in the oil sump
Towing vehicles with automatic transmission
Automatic transmission specifications
Tightening torques for threaded connections
Chassis
Front suspension
Description of the design of the front suspension
Front shock absorber — removal and installation
Shock absorber check
Front coil springs — removal and installation
Removing, installing and checking the front wheel bearings
Adjusting the axial clearance of wheel bearings
Front and rear wheel suspension specifications
Tightening torques for threaded connections
Front suspension — design description
Camber and kingpin axle tilt
Rear suspension
Description of the design of the rear suspension
Rear coil springs — removal and installation
Rear shock absorber — removal and installation
The middle part of the rear axle (differential) with axle shafts
Rear axle maintenance
Rear Axle — Design Description
Steering
General description of steering
Removal and installation of a steering wheel
Removal and installation of tie rod ends
Anther swivel connecting and steering rods
Power steering — removal and installation
Removal and installation of the pump of the amplifier of a steering
Power Steering Fluid Replacement
Removal and installation of swivel connecting rod
Anthers of joints of connecting / steering rods — check
Steering gear play — check
Checking the oil level
Steering clamp bolts — tightening
Power steering hydraulic pump drive belt
Wheel alignment
Steering Specifications
Tightening torques for threaded connections
Brake system
General description of the braking system
Replacing the rear and front disc brake pads
Replacing the front brake disc
Replacing the rear brake disc
Brake fluid — general information
Bleeding the brake system
Brake pipes and hoses — replacement
Hand brake — design description
Servo Cylinder — Operation Check
Replacing the front brake cable
Replacing the rear brake cable
Handbrake brake pads
Handbrake adjustment
Anti-lock braking system (ABS system)
Checking the Low Brake Fluid Level Indicator
Checking the thickness of the brake pads
Checking the thickness of the brake discs
Visual inspection of brake pipes
Brake Fluid Replacement
Checking the handbrake
Diagnostics of malfunctions of the brake system
Brake Specifications
Tightening torques for threaded connections
Anti-lock braking system — design description
Electrical equipment
Power devices
Measuring devices
Measurement technique
Battery — removal and installation
Battery charge
Checking the battery
Battery maintenance
Diagnostics of battery malfunctions
Alternator — Design Description
Alternator — removal and installation
Replacing the alternator drive belt
Replacement of carbon brushes of the generator
Voltage regulator — check
Diagnosing faults in the alternator
Starter — design description
Starter — removal and installation
Diagnostics of malfunctions in a starter
Engine Electrical Specifications
Bosch generator — design description
Bosch starter — design description
Electrical circuits
Scheme of electrical equipment with a 6-cylinder carburetor engine
Explanations for the wiring diagram with a 6-cylinder carburetor engine
Wiring diagram for an 8-cylinder injection engine
Explanation of the wiring diagram with an 8-cylinder injection engine
S-Class W140 (1991-1998)
User manual
Controls and instruments
Vehicle identification numbers
Purchase of spare parts
Jacking and towing a car
Starting the engine from an auxiliary power source
Vehicle troubleshooting
Main vehicle specifications
Remote control and special functions
Unlocking the driver's door with the key
Access to luggage compartment
Access to the fuel tank filler neck
Access to the underhood space
Access to the main glove box and glasses compartment
Anti-theft system
Elements of security systems
Rules for the use of passive safety equipment for the driver and passengers
Seat adjustment
Supplemental Security System (SRS)
Danger of carbon monoxide (CO) poisoning
Dashboard — general information
Instrument cluster, meters and control lamps and indicator lights
Controls and interior equipment
Luggage compartment equipment
Replacement of brushes of cleaners of headlights and a windshield
Top rack installation
Automated air conditioning system (climate control)
Independent heater
Driving and operation
Basic cautions
Breaking in a new car
Car parking
Getting started and shifting gears
Speed control systems (tempostat) and Speedtronic
Parktronic System (PTS)
Emergency Brake Assist (BAS)
Anti-Lock Brake System (ABS)
Traction Control (ASR)
Electronic anti-skid system (ESP)
Automatic damping suspension system
Tips for driving in adverse weather conditions
Vehicle operation in winter conditions
Trailer towing
Maintenance
Ongoing maintenance — general information
Maintenance Specifications
Active Scheduled Maintenance Alert System (ASSYST)
Schedule of ongoing maintenance
General setup information
Checking fluid levels, leak control
Checking the condition of tires and their pressure, designation of tires and wheel rims, wheel rotation
Changing the engine oil and oil filter
Checking the brake system
Checking the fuel system, replacing the fuel filter
Checking the condition and replacing the engine compartment hoses, localizing leaks
Checking the condition of the ribbed belts of the serpentine drive of auxiliary units
Checking the functioning of the cooling system and frost resistance of the coolant, changing the fluid
Check of a condition of system of release of the fulfilled gases
Checking the ATF level, replacing the AT filter
Visual check of tightness of automatic transmission
Checking the Condition of Suspension and Steering Components
Check of a condition of protective covers of power shafts
Checking the air conditioning system
Lubrication of door stops and lock cylinders
Visual inspection of the seat belt and airbag unit
Checking the headlights and horn
Check of a condition, adjustment and replacement of brushes of screen wipers
Battery check, care and charging
Cabin filter replacement
Brake Fluid Replacement
Checking and replacing spark plugs, checking the condition of high-voltage wires
Power unit
Petrol engine V6
Specifications of all engines
Checking compression in the engine cylinders
Checking the engine with a vacuum gauge
Serpentine accessory drive belt
Removal and installation of the engine
Cylinder head cover — installation details
Removal and installation of the inlet pipeline with the resonator
Exhaust Manifold — Installation Details
Removal and installation of a head of the block of cylinders
Removing and installing the timing chain cover
Timing drive — general information, component maintenance
Crankshaft sprocket — installation details
Removal and installation of the camshaft adjuster
Removal and installation of camshafts
Replacing valve guides
Valve seat replacement
Removal and installation of pistons
Replacing piston rings
Checking the condition of the connecting rods
Checking the condition of the crankshaft
Maintenance of the cylinder block
Removal and installation of the pallet crankcase of the engine
Oil Pump — Installation Details
Oil level switch — installation details, test data
Petrol engine V8
Removal and installation of the engine
Cylinder Head Covers — Installation Details
Removal and installation of the inlet pipeline
Removal and installation of a final collector
Removal and installation of heads of the block of cylinders
Removing and installing timing chain covers
Timing Chain Replacement
Checking the valve timing
Timing drive — general information, component maintenance
Removal and installation of the valve timing regulator
Removal and installation of camshafts
Checking and adjusting the control position of the camshafts
Removal and installation of valves
Replacing valve guides
Replacing valve seat rings
Removal and installation of pistons
Designation and dimensions of pistons
Checking the condition of the connecting rods
Checking the condition of the crankshaft
Petrol engine V12
Removal and installation of the engine
Air Cleaner — Installation Details
Cylinder head covers — removal and installation
Removal and installation of the inlet pipeline
Removal and installation of a final collector
EGR Valve — Installation Details
Air supply pump — removal and installation
Removal and installation of the upper front covers
Cylinder heads — removal and installation
Removing and installing the timing chain cover
Timing Chain Replacement
Timing drive — general information, component maintenance
Timing chain tensioner — removal and installation
Camshaft adjuster — removal and installation
Removal and installation of camshafts
Checking the valve timing
Checking and adjusting the position of the camshafts
Replacing valve guides
Removal and installation of pistons
Removal and installation of the crankshaft
Removal and installation of the pallet crankcase of the engine
Oil Level Switch — Installation Details
Oil pump — design and installation details
Diesel engine OM603
Removal and installation of the engine
Air Cleaner — Installation Details
Replacing the alternator drive belt
Removing and installing alternator drive belt tensioner
Exhaust Manifold — Installation Details
Timing chain cover — removal and installation
Camshaft — removal and installation
Removal and installation of a head of the block of cylinders
Checking the control position of the camshaft
Timing Chain Replacement
Timing drive — general information, component maintenance
Timing Chain Tensioner — Installation Details
Removal and installation of pistons
Check of a condition and replacement of rods
Measurement of cylinder diameters
Removal and installation of cylinder liners
Checking the condition of the crankshaft
Removal and installation of an asterisk of a cranked shaft
Oil Level Switch — Installation Details
Replacing the oil pump drive chain
Removal and installation of the oil pump
Removal and installation of the oil filter housing
Diesel engine OM606
Cylinder head cover — installation details
Removal and installation of prechambers
Removal and installation of the camshaft housing
Removal and installation of camshafts
Checking the control position of the camshafts
Removal and installation of a head of the block of cylinders
Removing and installing the timing chain cover
Timing Chain Tensioner — Installation Details
Timing drive — general information, component maintenance
Checking the condition of the valves
Removal, condition check and installation of directing plugs of valves
Valve seat replacement
Removal and installation of pistons
Removal and installation of piston rings
Removal, condition check and installation of connecting rods
Measurement of cylinder diameters
Checking the condition of the crankshaft, replacing oil seals
Removal and installation of the pallet crankcase of the engine
Removal and installation of the oil pump
Oil Level Switch — Installation Details
Removal and installation of the oil filter housing
Oil Cooler Fan — Installation Details
Cooling system
Cooling and heating systems — general information
Cooling and Heating Specifications
Antifreeze — antifreeze
Coolant Replacement — General Notes
Removal and replacement of cooling system hoses
Check of serviceability of functioning of the thermostat
Removal and installation of the thermostat
Removal and installation of a radiator of system of cooling
Removal and installation of the water pump
Ventilation, heating and air conditioning systems
Fan Shroud and Fan Assembly — Installation Details
Air conditioning system — information and precautions
Location of the main elements of the automatic air conditioning system
Power supply and injection system
Power System and Exhaust Specifications
Power supply and fuel injection system of a gasoline engine — general information
Safety precautions and cleanliness when working with the fuel system
Relieving pressure in the fuel system of a gasoline engine
Checking and adjusting the idle speed / ignition timing / CO concentration
Diesel fuel injection system — general information
Fuel Injection System Checks (Diesel)
Emission control systems — general information
Exhaust system — general information
Catalytic converter (petrol models)
Control system HFM-SFI
Removal and installation of the fuel distributive highway with injectors
Removal and installation of injectors — removal and installation
Replacing the Airflow Measurement Sensor
Removal and installation of a diaphragm fuel pressure regulator
Removal and installation of the air pump
Removal and installation of the crankshaft position sensor (CKP)
Removal and installation of a lambda probe
Removal and installation of knock sensors
Control system LH-SFI
Removal and installation of the fuel distributive highway with injectors
Air flow meter — installation details
Diaphragm Fuel Pressure Regulator
Lambda probes — installation details
Exhaust Gas Recirculation (EGR) Valve Installation Details
Knock sensor installation details
Control systems ME-SFI
Location of ME-SFI Fuel Injection and Ignition Control System Components
Removal and installation of the fuel distributive highway with injectors
Details of the installation of the diaphragm fuel pressure regulator
Installation details of the airflow meter
Installation details of the lambda probe (oxygen sensor)
Crankshaft Position (CKP) Sensor Installation Details
Knock sensor installation details
Diesel control system
Functional diagrams of fuel injection systems (diesel engines of the OM603 series)
Removal and installation of the high pressure fuel pump (OM603)
Installation details of the fuel injection timing regulator (OM603)
Removal and installation of a turbocharger (OM603)
Location of components of the electronic engine control system (OM606 diesel engines)
Installation details of glow plugs (OM606)
High pressure fuel pump (TNVD) (OM606)
Installation details of fuel injection timing regulator (OM606)
Intercooler (Compressed Air Radiator) — Installation Details (OM606)
Compressed air pipes — wiring diagram (OM606)
Turbocharger installation details (OM606)
Turbocharging system — general information
Intercooler — general information
Ignition system
The main elements of the microprocessor control system
Ignition and injection control system checks
Troubleshooting — General Information and Preliminary Checks
Checking and adjusting the ignition timing
Spark plugs — condition check
Self-diagnosis of electronic control systems OBD
Diagnostics of the electronic system of the automatic air conditioner (AC)
Using an oscilloscope to observe control system signals
Ignition coil installation details
Removal, installation and adjustment of the camshaft position sensor (CMP)
Ignition distributor installation details
Engine Electrical System Specifications
Charge and launch system
Charge and launch systems — general information
Battery — basic information, disconnection and purchase of a new battery
Checking and charging the battery
Storage of the battery
Charging system — general information and safety measures
Checking the charging system
Generator Installation Details
Engine starting system — general information and precautions
Checking the engine start system
Transmission
Mechanical gearbox 717.438
Manual transmission specifications
Removal and installation of a transmission
Details of installation of a forward cover of a transmission
Removal and installation of a back cover of a transmission
Removal and installation of the vehicle speed sensor (VSS)
Removal and installation of the intermediate crankcase
Checking the clearance of the drive and intermediate shafts
Disassembly and assembly of the driven shaft
Removal and installation of driving and driven gears
Replacement of ball bearings for manual transmission from No. 6141001
Replacing the tapered roller bearings of the gearbox up to No. 6141000
Details of the installation of the elements of the gear shift mechanism
Mechanical gearbox 717.454
RKPP installation details 717.454
Removal and installation of the vehicle speed sensor (VSS)
Removal and installation of a forward cover of a transmission
Removal and installation of a back cover of a transmission
Removal and installation of the intermediate crankcase
Replacement of an epiploon of a back cover of a transmission
Removal and installation of gearbox shafts
Disassembly and assembly of the intermediate shaft
Gearbox Dimensional Check
Replacing tapered roller bearings of intermediate shaft
Replacement of intermediate shaft ball bearings
Adjustment of the mechanism of a gear change
Automatic gearbox 722.5
Automatic transmission — general information
Automatic transmission specifications
Troubleshooting — general information
Removal and installation of automatic transmission
Removal, condition check and installation of the hydrotransformer
Removal and installation of the centrifugal regulator
Removal and installation of the sensor switch of blocking of a starter
Installation details of the AT vacuum unit
Removal, maintenance and installation of the secondary pump (AT up to No. 3652931)
Removal and installation of a forward cover with the secondary pump
Removal and installation of the piston LB3
Removal and installation of a back cover of transmission
Dismantling and assembly of AT valve assembly
Disassembly and assembly of transmission
Setting and checking clearance in multi-disc brake B3
Brake clearance measurement B1
Overdrive clutch
Removal, installation and inspection of components of the brake BS overdrive and clutch KS
Disassembly and assembly of the freewheel
Disassembly and assembly of planetary mechanisms
Disassembly and assembly of clutch K1
Clutch K2 — disassembly, assembly and inspection
Gear selector lever
Automatic gearbox 722.6
Removal and installation of AT with torque converter
Removal and installation of the electrohydraulic control unit AT (transmission installed)
Disassembly and assembly of the electro-hydraulic control unit
Disassembly and assembly of the shift plate
Disassembly and assembly of the transmission housing and torque converter
Disassembly and assembly of multi-disc brakes B2, B3 and transmission lock gear in the «P» position
Disassembly and assembly of the rear hollow shaft with rear freewheel
Removing and installing multi-disc brake B1 and oil pump
Disassembly and assembly of the oil pump
Disassembly and assembly of the multi-disc brake B1
Disassembly and assembly of the B2 multi-disc brake
Disassembly and assembly of the output shaft with the central and rear blocks of planetary gears
Removal and installation of multi-plate clutches K1, K2 and K3
Disassembly and assembly of clutch K1
Disassembly and assembly of the drive shaft with the K2 clutch and the front planetary gear set
Disassembly and assembly of clutch K3
Removal and installation of the mechanism of blocking of transmission in position «P»
Removal and installation of the gear selector lever
Clutch and drive shafts
Clutch and differential specifications
Clutch — general information
Removal and installation of clutch
Removal and installation of the clutch master cylinder
Removal and installation of the clutch slave cylinder
Removal and installation of cardan shaft
Drive shafts — general information
Removal and installation of the drive shaft flange and angular contact ball bearing
Removal, check and installation of a power shaft
Removal and installation of CV joints of drive shafts and their protective covers
Differential
Dismantling, assembling and checking the differential
Disassembly and assembly of the final drive gearbox and adjustment of gear clearances
Determining the thickness of the shim and installing it in the gearbox housing
Checking and adjusting the flange clearance
Disassembly and assembly of the final drive gearbox and adjustment of gear clearances (models up to 05/31/94)
Dismantling and assembly of differential with automatic blocking
Auto-Lock Differential Cylinder Replacement (Models Before 5/31/94)
Chassis
Brake system
General information and security measures
Brake Specifications
Location of ASR/ETS traction control components
Component Location of the Emergency Brake Assist (BAS)
Location of ESP system components
Dismantling and assembly of the main brake cylinder of the Tandem type (models 140.028/032/033/135)
Removal, installation and check of serviceability of functioning of the servo drive of the vacuum booster of brakes
Removal and installation of a brake caliper
Checking the thickness of the brake disc and brake pads
Removal and installation of parking brake pads
Removal and installation of a forward cable of a drive of a parking brake
Parking brake adjustment
ABS Wheel Sensors — Installation Details
Steering
Suspension and steering specifications
Safety Precautions When Repairing Suspension and Steering
Vehicle wheel alignment angles, ground clearance
Removal and installation of the steering mechanism
Removal and installation of the steering pump (with engines 104, 119, 120 and 606)
Dismantling and assembly of the pump of the amplifier of a steering
Disassembly and assembly of the electronically adjustable steering column
Removal and installation of the lower steering shaft
Removal and installation of a drive of telescopic adjustment of a steering column
Removal and installation of an emphasis of a pipe
Disassembly and assembly of the inner tube
Installing the Top Pipe Bracket
Removal and installation of the blocking cylinder
Contact spring — removal, inspection and installation
Removal and installation of average steering draft
Removal and installation of the pendulum lever of a steering drive
Removal and installation of transverse steering draft
Front suspension
Removal and installation of a forward suspension bracket
Front wheel bearing clearance adjustment
Removal and installation of the lower ball joint
Checking the condition of the upper ball joint
Upper wishbone replacement
Lower wishbone replacement
Removal, check and installation of a nave of a forward wheel
Removal and installation of assembly of a rotary fist
Removal and installation of a helical spring
Removal and installation of the stabilizer bar
Removal and installation of the shock absorber
Front Suspension Adjuster — Installation Details
Rear suspension
The design of the rear suspension of the car
Design and installation details of the hub assembly
Removal and installation of a helical spring
Anti-roll bar — installation details
Removal and installation of the shock absorber
Removal and installation of a back amortization rack
Checking the hydraulic pump
Removal and installation of the rear suspension hydraulic pressure accumulator
Removal and installation of the rear suspension clearance control unit
Damping Valves — Installation Details
Removal and installation of the clearance adjustment valve
Rear suspension adjuster
Body
Exterior (external elements)
Body specifications and dimensions
Safety measures during body work
Bumpers — installation details
Combination Relay — Installation Details
Front doors — removal, installation and adjustment
Rear doors — installation details
Hood adjustment
Block headlights — installation details
Rear Combination Lights — Installation Details
Removal and installation of the air conditioning compressor speed sensor (models after 08/31/95)
Checking and adjusting the position of the headlights
Tailgate adjustment
Front fenders and wheel arch lockers — installation details
Decorative grille — installation details
Emblem «Mercedes»
Removal and installation of external rear-view mirrors
Front direction indicators — installation details
Reversing Lights — Installation Details
Interior (internal elements)
Removal and installation of the instrument panel
Removal and installation of the combined steering column switch
Headlight Switch — Installation Details
Removal and installation of a combination of devices
Control lamps and signal indicators of the instrument panel
Instrument Cluster Gauges — Layout and Installation Details
Removal and installation of the block of management of the automatic conditioner
Removal and installation of the button control panel of the conditioner
Replacement of control lamps of the button control panel of the conditioner
Checking the pneumatic tilt adjuster of the optical axes of the headlights
Center Console Switches — Installation Details
Removal and installation of the center console
Loudspeakers — installation details
Removal and installation of panels of an internal upholstery of doors
Removal and installation of seats
Removal and installation of head restraints
Instrument panel duct deflectors — installation details
Glove box cover — installation details
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Electrical Equipment Specifications
Diagnosis of malfunctions of on-board electrical equipment — general information
Checking the wiper motor
Checking the heated rear window
Replacing incandescent lamps
Electrical fuses
Installation of electrical and electronic appliances
Location of the main electrical elements of the electrical system of the car body
Electrical circuits
Symbols on circuit diagrams
Engine management system for 3.2L models
Engine management system for 4.2 and 5.0 l models
Launch system
Charge system
Automatic transmission
AT shift blocking system
Electronic power steering system
Electronic suspension
Anti-Lock Brake System (ABS) for models equipped with Anti Traction Control (ASR)
Anti-lock brake system (ABS) for models equipped with an anti-skid system (ESP)
Tempostat wiring diagram
Engine cooling system fan
Instrument cluster
Instrument illumination
Exterior lighting fixtures on Sedan models with conventional headlights
Exterior lighting fixtures on Sedan models with xenon headlights
Outdoor lighting fixtures
Standard type headlights
Xenon headlights
Daytime Running Lights (DRL)
Reversing lights on Sedan models
Reversing lights on Coupe models
Interior lighting when opening doors
Automatic day/night switching of the interior rear-view mirror
Parktronic system
Klaxon wiring diagram
Rear window heating
Windshield wipers/washers
Headlight cleaners and washers
Washer fluid heating
Automatic air conditioning system in the cabin
Automatic air conditioning system in the rear
Anti-theft alarm
Single lock
Door closing system
Trunk lid latch release drive
Electric window lifter drive
Power driver's seat adjustment
Power front passenger seat adjustment
Power rear seat adjustment solid construction
Electric adjustment of the four-seater rear seat of a separate design
Electric rear window blind
Electric convertible top/roof hatch
Heated front seats
Heated rear seats
Power rear headrests (Coupe)
Seat belt comfort selector (Sedan)
Seat Belt Extension (Coupe)
Supplemental Security System (SRS)
Power Antenna Motor (Except models with built-in cellular phone and Bose audio system)
Antenna motor (models with built-in cellular phone)
Power antenna motor (models with Bose audio system)
Processor data lines
Memory position of adjustable rear-view mirrors and telescopic steering column
Seat position memory
Radio wiring diagram
S-Class W220 (1998-2005)
General information
Introduction to guide
Mercedes-Benz S-class cars (W220) — abstract
Vehicle identification numbers
Purchase of spare parts
Service technology, tools and equipment of the workplace
Jacking and towing a car
Starting the engine from an auxiliary power source
Vehicle readiness checks
Automotive chemicals, oils and lubricants
Vehicle troubleshooting
User manual
Vehicle specifications and dimensions
Main organs and control/control panels
Locks, keys and locks. Smart card. Single lock
Theft protection
Assistance in getting in and out of the vehicle
Front and rear seat adjustment
Security systems
Steering wheel, mirrors
Seat position memory
Dashboard
Multifunction steering wheel, multi-information display
Headlight and wiper switches
Automatic air conditioner. Ventilation. Independent heater
Power windows, sunroof
Salon equipment
Vehicle control and assistance systems
Warning and indicator lamps and messages on the multi-information display
First aid kit, fire extinguisher, warning triangle and spare wheel compartment
Messages and inscriptions in foreign languages
Maintenance
Overview of ongoing maintenance
Maintenance Specifications
Active Scheduled Maintenance Alert System (ASSYST)
Schedule of ongoing maintenance
General setup information
Checking fluid levels, leak control
Check the condition of the tires and the pressure in them. Designation of tires and disks of wheels. Wheel rotation and replacement
Changing the engine oil and oil filter
Checking the brake system
Fuel system check
Checking the condition and replacing the engine compartment hoses, localizing leaks
Checking the condition of the ribbed belts of the serpentine drive of auxiliary units
Checking the functioning of the cooling system and frost resistance. Fluid replacement
Check of a condition of system of release of the fulfilled gases
Checking the automatic transmission oil level
Visual check of tightness of automatic transmission
Checking the condition of suspension and steering components
Check of a condition of protective covers of power shafts
Checking the fluid level of the power steering system
Checking the air conditioning system
Lubrication of door stops and lock cylinder
Visual inspection of the seat belt and airbag unit
Checking the headlights and horn
Check of a condition, adjustment and replacement of brushes of screen wipers
Battery check, care and charging
Replacing the Cabin Air Filter Element/Charcoal Air Cleaning Filter
Brake Fluid Replacement
Checking and replacing spark plugs. Checking the condition of high-voltage wires
Power unit
Engine repair
Engine Specifications
Checking compression in the engine cylinders
Checking the engine with a vacuum gauge
Serpentine accessory drive belt
Gas distribution mechanism and engine elements
Replacing timing chains and installing valve timing
Location of the main sensors of the gasoline engine
Cooling and heating systems
General parameters of cooling and heating systems
General description of the cooling system
Antifreeze — antifreeze
Coolant Replacement — General Notes
Removal and replacement of cooling system hoses
Removing and checking the thermostat
Ventilation, heating and air conditioning systems
Air conditioning system — general information and precautions
Location of the main electrical components of the air conditioning system
Power and exhaust systems
General description of power and exhaust systems
Description of the design of the power supply and fuel injection system
Relieving pressure in the fuel system of a gasoline engine
Power distribution control — description and principle of organization of the cylinder shutdown function
Air blower
Checking and adjusting the idle speed / ignition timing / CO concentration
Diesel fuel injection system
Diesel injection system checks
Diesel turbocharger — general information, removal and installation
Diesel intercooler — general information
Emission control systems — general information
Exhaust gas exhaust system
Catalytic converter
Ignition and control system
Engine Electrical Specifications
The main elements of the microprocessor control system
Ignition and injection control system checks
Troubleshooting — General Information and Preliminary Checks
Checking and adjusting the ignition timing
Spark plugs — condition check
Self-diagnosis of electronic control systems of the second generation OBD II
Personal computer interface controller with OBD II on-board self-diagnosis system
Using an oscilloscope to observe signals in control circuits
CAN digital data bus
Charge and launch systems
Charge and launch systems — general information
Battery — basic information and how to buy a new one
Checking and charging the battery
Storage of the battery
Charging system — general information and safety measures
Checking the charging system
Engine starting system — general information and precautions
Checking the engine start system
Transmission
Automatic gearbox
General description of automatic transmission
Electronic control unit tasks and control signals
Troubleshooting — general information
Removal and installation of AT with torque converter
Electrohydraulic control unit AT (AT installed)
Disassembly and assembly of the electro-hydraulic control unit
Dismantling and assembly of a plate of a gear change
Transmission housing and torque converter
Multi-disc brakes B2, B3 and gear lock in «Park»
Disassembly and assembly of the rear hollow shaft with rear freewheel
Removing and installing multi-disc brake B1 and oil pump
Disassembly and assembly of the oil pump
Disassembly and assembly of the multi-disc brake B1
Disassembly and assembly of the B2 multi-disc brake
Disassembly and assembly of the output shaft with the central and rear planetary gears
Removal and installation of multi-plate clutches K1, K2 and K3
Disassembly and assembly of clutch K1
Disassembly and assembly of the drive shaft with the K2 clutch and the front planetary gear set
Disassembly and assembly of clutch K3
Parking lock mechanism — removal and installation
Removal and installation of the gear selector lever
Drive shafts
Drive shaft and differential specifications
Removal and installation of cardan shaft
Removal and installation of the drive shaft flange and angular contact ball bearing
Drive shaft — removal, inspection and installation
Removal and installation of SHRUS and protective covers of power shafts
Disassembly and assembly of the differential
Disassembly and assembly of the final drive gearbox and adjustment of gear clearances
Determining the thickness of the shim and installing it in the gearbox housing
Checking and adjusting the flange clearance
Dismantling and assembly of differential with automatic blocking
Chassis
Brake system
Basic information about the brake system
Brake Specifications
Component location of the BAS brake booster
Location of ESP system components
Dual Master Cylinder
Vacuum booster — removal, inspection and installation
Brake caliper — removal and installation
Checking the thickness of the brake disc and brake pads
Removal and installation of brake pads
Removal and installation of a forward cable of a drive of a parking brake
Parking brake adjustment
Anti-lock braking system ABS, anti-skid system
Front suspension
Suspension and steering specifications
Suspension Safety Precautions
Removal and installation of a forward suspension bracket
Front wheel bearing clearance adjustment
Front wheel hub — removal, inspection and installation
Front steering knuckle — removal and installation
Front stabilizer bar
Pneumatic shock absorber strut — removal and installation
Rear suspension
Rear suspension design
Rear wheel hub
Stabilizer bar
Rear shock absorber — removal and installation
Rear pneumatic suspension strut
Elements of the controlled air suspension system
Steering
Vehicle wheel alignment — general information
Conditions for checking wheel alignment
Front wheel adjustment
Rear wheel adjustment
Checking the clearance of the car body
Removal and installation of the steering mechanism
Power steering pump — removal and installation
Dismantling and assembly of the pump of the amplifier of a steering
Disassembly and assembly of the electronically adjustable steering column
Removal and installation of the lower steering shaft
Removal and installation of the drive for telescopic adjustment of the steering column
Removal and installation of an emphasis of a pipe
Disassembly and assembly of the inner tube
Installing the Top Pipe Bracket
Removal and installation of the blocking cylinder
Contact spring — removal, inspection and installation
Body
Body elements
Control dimensions of the car body
Safety measures during body work
Car cleaning and care
Repair of minor damage to body panels
Repair of significant damage to the body
Replacing wiper blades
Orthopedic seats
Heated seats
Replacing the cabin air filter
Electrical system sensors
Fire extinguishing system
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Onboard Electrical Specifications
Diagnosis of malfunctions of on-board electrical equipment — general information
Checking the wiper motor
Checking the heated rear window
Replacing incandescent lamps
Backup light function
Electrical fuses
Installation of electrical and electronic appliances
Elements of a single castle
Location of the main electrical elements of the electrical system of the car body
Anti-theft alarm
Electrical circuits
Designations and purposes of electrical wiring, leads and terminals
Power distribution
Grounding points
Charge system
Launch system
M112 engine management system
Left front signal processing and control unit (SAM)
Rear signal processing and control unit (SAM)
Right front signal processing and control unit (SAM)
CAN data bus
Diagnostic connector DLC
Automatic air conditioning system
Automatic transmission
Transmission shift locks
Anti-Lock Braking System (ABS)
Electronic suspension
Anti-theft system (ATA)
Tempostat (speed control system)
Distronic system
Parktronic system
Dashboard
Navigation system
Airbag (SRS)
Window heating (condensate removal)
Modular box fan
Cooling system fan
Reversing lights
Outdoor Lighting
Headlights
Interior lighting
Driver's seat memory
Rear view mirror memory
Passenger seat memory
Steering column position memory
Seat belt comfort adjustment, Sedan
Single lock
Power mirrors
Rear head restraints
Power rear seats
Electric drive of the folding roof/upper hatch
Electric release of the latch of the luggage compartment lid lock
Electric window lifter drive
Electric rear sunblind
Klaxon wiring diagram
Radio wiring diagram
Wipers / washers for glass / headlight lenses
Mercedes Sprinter (1995-2000, diesel)
General information
Introduction to the guide
Description and characteristics of Mercedes Sprinter
Vehicle identification
Disconnecting the battery
General rules for repair work
Working conditions and tools
Maintenance
Maintenance and care — general information
Checking the engine oil level
Checking the brake fluid level
Stop lamp test
Lighting test
Tire pressure check
Checking the liquid level in the cooling system
Air filter filter element
Checking the fluid level in the power steering
Other maintenance work
Lubricants, sealants
Methods of working with threaded connections, bolts, nuts
Car maintenance card
Tightening torques for threaded connections, N·m
Power unit
Engine repair
General description of engines
Dismantling the power unit
Installation of the power unit
Engine disassembly
Cylinder head — general description
Removal and installation of a head of the block of cylinders
Dismantling of a head of the block of cylinders
Cylinder head repair
Pistons and connecting rods — removal
Cylinder Liner Measurement
Checking pistons and connecting rods
Assembly of pistons and connecting rods
Installation of pistons with connecting rods in cylinders
Cover of the mechanism of a drive of a camshaft
General Description — Cylinder Block
Removal and installation of plugs of the block of cylinders
Piston clearance measurement
Changes in the design of the cylinder block, made as a result of modernization
Crankshaft and flywheel — general information
Removing the crankshaft
Checking the crankshaft
Installing the crankshaft
Flywheel or drive plate (models with automatic transmission)
Belt pulley and crankshaft vibration damper
Rear oil seal of the crankshaft and its holder
Forward cuff of a cranked shaft
Camshaft Drive Mechanism — General Description
Removal and installation of the camshaft drive chain tensioner
Removal and installation of the camshaft drive chain
Removal and installation of the chain tensioning shoe
Dismantling and installation of drive chain dampers
Removal and installation of an asterisk of a cranked shaft
Removal and installation of a camshaft
Gas distribution mechanism
Hydraulic valve lifters — device
Checking the health of hydraulic pushers
Removal and installation of hydropushers
Diesel engine specifications
Lubrication system
Purpose of the engine lubrication system
Checking the oil level
Engine oil consumption
Engine oil selection and replacement
Reasons for the formation of sediment in the oil
Service oil change
Self-changing engine oil
Brief description of the lubrication system
Removal and installation of the oil pump
Removal and installation of an oil crankcase
Removal and installation of the oil filter
Oil cooler — removal and installation
Oil dipstick
Turbo diesel engine oil lines
Lubrication system specifications
Cooling system
Cooling system — design description
Coolant replacement
Antifreeze — general information
Radiator — general description
Radiator check
Removal and installation of a radiator
Coolant Pump — Design Description
Removal and installation of the pump of a cooling liquid
Drive belt — removal and installation
Viscous fan clutch
Thermostat — design description
Thermostat malfunctions
Thermostat check
Checking the cooling system
Checking the coolant level sensor
Engine overheating
Coolant Density Check
Coolant hoses
Cooling system specifications
Power and exhaust system
General Description of the Diesel Fuel Injection System
Precautions when working on the injection system
Removal and installation of injection pump
Checking the moment of setting the start of injection
Nozzles and nozzle bodies — troubleshooting
Removal and installation of nozzles
Repair and cleaning of nozzles
Removal and installation of the mixing chamber
Removal and installation of the fuel filter
Removal and installation of the air filter
Turbocharger — general description
Possible malfunctions of the turbocharger
General instructions for the operation of the turbocharger
Removal and installation of a turbocharger
General description of glow plugs
Removal and installation of glow plugs
Possible malfunctions of glow plugs
Removal and installation of an inlet collector
Removal and installation of system of release of the fulfilled gases
Recommendations for the repair of the exhaust system
Idle adjustment
Specifications of diesel engine power system
Transmission
Clutch
General description of clutch
Clutch Maintenance
Removing the clutch
Clutch repair
Clutch installation
Removal and installation of the clutch release fork and clutch release bearing
Removal and installation of the master cylinder
Removal and installation of the working cylinder
Checking the driven disk for wear (in installed condition)
Pumping the clutch hydraulic drive
Possible clutch malfunctions
Mechanical gearbox
Manual transmission — general description
Removal and installation of a transmission
Gearbox repair
Replacing the cuff of the primary (leading) shaft of the gearbox
Rear cuff replacement
Removal and installation of the gear lever
Checking the oil level in the gearbox and changing the oil
Manual transmission specifications
Automatic gearbox
Automatic transmission — general description
Starting the engine of a car with automatic towing gearbox
Towing a car with an automatic transmission
Checking the automatic transmission
Removal and installation of an automatic transmission
The level of the working fluid and its replacement
Removal and installation of the automatic transmission housing
Start blocker — general information
Automatic transmission specifications
Front axle
General description of the front axle
Front axle device
Removing the front axle
Installing the front axle
Removing the lower transverse arm
Installation of the transverse arm
Ball joint replacement
Replacement of silent blocks of transverse levers
Removal and installation of a rotary fist
Wheel bearing axial play adjustment
Removal and installation of a forward nave
Hub bearing replacement
Front Axle and Suspension Specifications
Rear axle and cardan
Rear Axle and Cardan Shaft — General Description
Removal and installation of the rear axle (for models without ABS)
Removal and installation of the rear axle (for models with ABS)
Disassembly of the rear axle
Removal and installation of drive axle shafts
Disassembly of the drive shaft
Cuff drive gear
Checking the oil level in the rear axle housing and changing the oil
Cardan shaft — removal and installation
Rear Axle and Suspension Specifications
Chassis
Car suspension
Front wheel alignment
Ball joint maintenance
Checking the mudguards of the ball bearings
Checking shock absorbers
Front and rear suspension — general information
Replacing the front spring
Removal and installation of the front anti-roll bar
Rear spring mount
Removal and installation of rear springs
Rear shock absorbers — removal and installation
Rear stabilizer bar
Steering
Steering — general information
Power steering fluid reservoir
Removing the steering gear
Replacement of tie rod ends and protective covers
Steering play check
Checking the play in the tie rod joints
Checking the protective covers of the steering mechanism
Filling fluid in the power steering system
Bleeding the hydraulic booster system
Checking the tightness of the hydraulic booster system
Power steering pump drive V-belt, belt replacement
Removal and installation of the hydraulic booster pump
Front wheel alignment
Possible malfunctions of a steering and ways of their elimination
Brake system
Brake system — general information
Brake system design
Brake system maintenance — general information
General description of the various elements of the brake system
Checking the brake fluid level
Brake Fluid Replacement
Brake check
Checking the tightness and serviceability of the brake system
Checking the brake pads
Floating caliper front disc brakes — general information
Replacing the front brake pads
Removal and installation of the front brake caliper
Front brake caliper repair
Replacing the rear brake pads
Installing and removing the rear caliper
Rear brake caliper repair
Removal and installation of a forward brake disk
Removing the rear brake disc
Installing the rear brake disc
Master brake cylinder — general information
Removal and installation of the main brake cylinder
Repair of the main brake cylinder
Parking brake — general information
Removal and installation of parking brake pads
Parking brake shoe adjustment
Parking brake cable adjustment
Replacing the front parking brake cable
Replacing the rear parking brake cables
Vacuum brake booster — general information
Removal and installation of the vacuum amplifier of brakes
Bleeding the brakes
Anti-Lock Braking System (ABS)
Vacuum pump — removal and installation
Brake Specifications
Tires and wheels
Tires and wheels — general information
Tire size
Speed and age designation of tires
Wheel swap
Tire pressure check
Extended tire life
Wheel replacement
Tire condition check
Electrical equipment
Equipment and devices
Electrical system — general information
Description of devices for measuring voltage, current and resistance
Checking the wipers
Replacing the wiper arm
Removal and installation of wiper blades
Removal and installation of the electric motor and wiper arms
Instrument cluster
Coolant temperature gauge
Fuel level indicator
Other appliances
Pilot lamps
Windshield washer
Fuses — description and replacement
Headlights and lighting
Checking lamps
Replacing outdoor lamps
Headlight housing replacement
Replacing the front direction indicators
Headlight adjustment
Headlight range adjustment
Headlight cleaners
Rear lights
Rear lights of a different design
Direction indicators and alarms
Side turn signal repeaters
License plate light
Power devices
Battery — general information
Description of battery characteristics
Checking and servicing the battery
Faulty Consumer Detection
Alternator — general information
Alternator Circuit Precautions
Checking the generator without dismantling
Removal and installation of the generator — removal and installation
Replacement of brushes and generator voltage regulator
Dismantling and repair of the generator
Starter — general information
Starter check
Removal and installation of a starter — removal and installation
Starter repair
Possible starter malfunctions
Electrical circuits
Scheme 1. Diesel engine fuel injection system with exhaust gas recirculation system
Scheme 2. Diesel engine control system with injection pump of distribution type
Scheme 3. Diesel engine control system with injection pump of distribution type
Scheme 4. Diesel engine control system 602.980 with injection pump of distribution type
Scheme 5. Rear window heater
Scheme 6. Power supply and engine start systems for 601.943 releases until April 1998
Scheme 7. Systems of power supply and engine start 602.980 release from February 1998
Diagram 8. Manual transmission power take-off (engines 601 and 602)
Scheme 9. Instrument cluster with electronic tachometer
Scheme 10. Anti-theft system EDW
Scheme 11. Outdoor lighting system
Scheme 12. Direction indicators, emergency light signaling
Scheme 13. Interior lighting system
Scheme 14. Interior lighting system
Diagram 15. Electric windows
Scheme 16. Interior lighting system when opening doors
Scheme 17. Interior heating system
Scheme 18. Electric drive of rear-view mirrors
Diagram 19 ABS/ABD or ABS/ETS systems
Diagram 20. Sound signal
Mercedes Vito 1 (1996-2003)
General information
User manual
Dashboard
Instrumentation, signal and indicator lights
Combination switch
Emergency light signaling
Rear fog lamp/ fog lamp
Wiper operation switch
Watches — general information
Total and daily mileage counter
Tempomat — general information
Egnition lock
Heating and ventilation
Air recirculation mode
Setting the heating and ventilation operating modes
Rear window heating
Heated seats
Air conditioning — general information
Engine residual heat utilization mode
Central locking
Central locking switch
Start blocking device (immobilizer)
Anti-theft system
Seat and head restraint adjustment
Steering wheel adjustment
Airbags
Additional heating
Hood — general information
Fuel grades
Engine starting
Manual Transmission
Automatic transmission
Program switch positions
Brake systems
Anti-lock braking system ABS
Automatic Brake and Differential Control (ABD)
Electronic Rise Control (ENR)
Maintenance
Scheduled vehicle maintenance
Checking the drive belts
Replacing the alternator drive belt
Cooling system
Changing engine oil and oil filter
Replacing spark plugs (only on engines 111.948 and 104.900)
Fuel filter replacement
Replacing the air filter element
Checking the operation of indicator and signal lamps, signal, multifunction switch, wipers and washer
Changing the oil in a manual transmission
Changing the oil in an automatic transmission
Steering check
Checking the brake system
Tire pressure check
Front crankshaft oil seal
Petrol engines 2.0 l
Engine repair
Removal and installation of the engine
Air filter
Cylinder head cover
Intake manifold
An exhaust manifold
Exhaust gas exhaust system
Front cylinder head cover
Cylinder head
Chain cover
Chain drive tensioner
Sliding chain drive arm
Chain tension lever
Chain damper
Drive chain
Camshafts
Crankshaft groove pulley
Cover of a back epiploon of a cranked shaft
Rear crankshaft oil seal
Crankshaft pulley
Hydraulic lifters — removal, inspection, installation
Valve springs and valve stem retainers
Valves — removal and installation
Replacing valve seals
Lapping of valve seats
Pistons — removal and installation
Piston rings
Checking and replacing connecting rods
Cylinder block
Flywheel — removal and installation
Crankshaft ball bearing
Crankshaft replacement
Checking the axial clearance in the main bearings of the crankshaft
Checking the radial clearance in the main bearings of the crankshaft
Checking the radial clearance in the connecting rod bearings
The moments of an inhaling of elements and details of the engine 111.948
Specifications for petrol engines 111.948 and 111.978
Lubrication system
Lubrication system — device
Pallet — removal and installation
Oil level indicator guide pipe
Oil pump
Replacing the oil pump drive chain
Oil level sensor
Pressure reducing valve
Oil pressure sensor
Oil pressure check
Cooling system
Fan — removal and installation
Radiator — removal and installation
Coolant pump
Thermostat — removal and installation
Oil radiator
Coolant temperature sensors
Air conditioner condenser
Coolant level sensor
Fan thermal switch
Power and control system
Engine management system
Ignition coils
Replacing spark plugs
Idling drive
Idle speed controller
Control element of the «Tempomat» device
Inlet air temperature sensor
Oxygen sensor
Crankshaft position sensor
Diaphragm Fuel Pressure Regulator
Fuel distributor with injectors
Generator — removal and installation
Starter — removal and installation
Petrol engines 2.8 l
Engine repair
Removing the engine from the subframe
Removing the engine from the transmission
Air filter
Cylinder head cover
Intake manifold
An exhaust manifold
Exhaust gas exhaust system
Cylinder head
Upper Timing Cover
Lower Timing Cover
Chain tensioner
Drive chain replacement
Checking the basic position of the camshafts
Camshafts
Valves — removal and installation
Replacing valve seals
Crankshaft groove pulley
Replacing the front crankshaft oil seal
Replacement of a back epiploon of a cranked shaft
Flywheel / Drive Disc
Tightening torques for elements and engine parts 104.900
Lubrication system
Engine sump
Oil level indicator guide pipe
Oil filter housing
Oil pump
Oil pressure sensors
Oil radiator
Cooling system
Cooling system fan
Radiator of the cooling system
Coolant pump
Thermostat housing
Thermostat — removal and installation
Coolant temperature sensors
Circulation pump
Power and control system
Ignition coils
Replacing spark plugs
Lambda probe (oxygen sensor)
Diaphragm Fuel Pressure Regulator
Throttle body
Exhaust gas recirculation (EGR) valve
Exhaust Gas Recirculation (EGR) Shutoff Valve
Air quantity test valve
Mass Air flow measurement sensor
Inlet air temperature sensor
Engine crankshaft speed sensor
Camshaft speed sensor
Knock sensors
Checking engine compression
Nozzles — removal and installation
Generator — removal and installation
Starter — removal and installation
Diesel engines 2.3 l
Engine repair
Removal and installation of the engine
Cylinder head cover
Intake manifold
An exhaust manifold
Crankshaft groove pulley
Timing chain cover
Cylinder head
Anterior chamber — removal and installation
Camshaft
Timing Chain Sliding Lever
Timing chain tensioner
Checking the hydraulic compensator
Front crankshaft oil seal
Rear crankshaft oil seal
Flywheel — removal and installation
Technical characteristics of diesel engines OM 601.942 and OM 601.970
Cooling system
Fan — removal and installation
Radiator — removal and installation
System pump
Thermostat — removal and installation
Coolant level sensor
Fan thermal switch
Lubrication system
Engine oil pan
Oil filter housing
Oil radiator
Oil level sensor
Oil pressure sensor
Oil pressure check
Turbocharging and recycling
Vacuum converter of the exhaust gas recirculation system
Exhaust gas recirculation valve
Turbocharging — removal and installation
Turbocharger radiator
Turbo radiator fan
Distribution pipes for compressed air
Power and control system
Inlet and compressed air pressure sensor
Electronic Fuel Injection Control Temperature Sensor
Air mass meter
Electronic fuel injection control unit
Mixing chamber
Transmission overload valve
Vehicle speed sensor
Checking engine compression
High pressure fuel pump (TNVD)
High pressure fuel pump microswitch
Nozzles — removal and installation
Glow plugs
Pre-glow relay
Preglow temperature sensor
Checking and Adjusting the Start of Injection (Digital Tester Method)
Checking and adjusting idle speed
Generator — removal and installation
Starter — removal and installation
The moments of an inhaling of elements and details of the engine 601.970
Diesel engines 2.2 l
Engine repair
Removal and installation of the engine
Cylinder head cover decorative panel
Cylinder head cover
Mixing chamber with exhaust gas recirculation valve
Intake manifold
An exhaust manifold
Crankshaft groove pulley
Front cylinder head cover
Timing chain cover
Timing Chain Sliding Lever
Timing chain tensioner
Timing chain tensioner
Timing chain replacement
Camshafts
Checking the basic position of the camshafts
Cylinder head
Pistons — removal and installation
Crankshaft
Front crankshaft oil seal
Rear crankshaft oil seal
Cooling system
Fan — removal and installation
Radiator — removal and installation
Coolant pump
Thermostat housing
Lubrication system
Pallet — removal and installation
Oil pump — removal and installation
Oil radiator
Oil level sensor
Turbocharging and recycling
Exhaust pressure chamber
EGR Vacuum Converter
Exhaust gas recirculation valve
Removal and installation of turbocharging
Intercooler (compressed air cooling radiator)
Intercooler fan
Compressed air distribution pipes
Compressed air temperature sensor
Compressed air pressure sensor
Electronic fuel injection control system
Power and control system
CDI electronic fuel injection control unit
Fuel Injection Coolant Temperature Sensor CD1
Air mass meter
High pressure fuel pump intermediate gear
High pressure fuel pump
Vacuum pump
Fuel cut-off valve
Fuel pressure sensor in the distributor
Fuel pressure control valve
Fuel distributor
Crankshaft position sensor
Camshaft speed sensor
Nozzles — removal and installation
Glow plugs
Pre-glow relay
Checking engine compression
Generator — removal and installation
Starter — removal and installation
The moments of an inhaling of elements and details of the engine 611.980
Transmission
Clutch
Removal and installation of clutch
Clutch Release Lever
Clutch slave cylinder (only on vehicles with engines 111.948 and 601.970)
Clutch Master Cylinder
Clutch hydraulic lines (vehicles with engine 611.980)
Mechanical gearbox
Removal and installation of a transmission
Disassembly and assembly of the gearbox
Reversing light switch
Bearing caps
Clutch housing
Gearbox housing
Transmission shaft seals
Drive shaft
Driven shaft
Reverse gear shaft
Disassembly and assembly of the differential
Reverse gear lock
Gear Lever Adjustment
Gear shift cables
Specifications for manual transmissions
Automatic gearbox
Removal and installation of automatic transmission
Changing the transmission fluid and automatic transmission oil filter
Automatic transmission tray
Automatic transmission control unit
Electro-hydraulic control unit
Electromagnetic gearshift valves
Program switch of automatic transmission modes (cars with engines 111.601 and 611.980)
Inductive GTR Turbine Speed Sensor
Inductive speed sensor of the driven shaft, automatic transmission
GTR radial oil seal
Epiploon of a flange of the left semiaxis
Right axle flange oil seal (vehicles with engine 104.900)
Rear cover of automatic transmission (on vehicles with engine 104.900)
Gear selector lever position sensor (vehicles with engines 111, 601.970 and 611.980)
Oil cooler automatic transmission (vehicles with engine 104.900)
Oil cooler fan automatic transmission (vehicles with engine 104.900)
Gear shift cable
The moments of fastening of elements of transmission
Specifications for automatic transmission
Chassis
Front suspension and wheels
Removal and installation of a forward suspension bracket
Stabilizer bar
Lower Suspension Arm
Wheel hub
Rounded fist
Half shaft — removal and installation
Central drive shaft with bearing
Left gearbox flange
Moments of fastening of suspension elements
Rear suspension
Removal and installation of a back suspension bracket
Lower Suspension Arm
Anti-roll bar (vehicles 638.244 from 1.4.97 with rear air suspension)
Air suspension control unit
Removing the shock absorber
Air chamber (vehicles 638.0/1 and 638.2 with rear air suspension)
Checking and adjusting the vehicle level
Compressor — removal and installation
Lift height sensor (vehicles 638.0/1 and 638.2 with rear air suspension)
Lift height sensor adjustment lever
Camber and longitudinal inclination of the kingpin of the front wheels
Front wheel alignment
The collapse and convergence of the rear wheels
Steering
Steering wheel (vehicles with airbags)
Steering gear
Steering shaft
Ignition Lock Cylinder
Egnition lock
Power steering pump
Power steering pump pressure test
Support of fastening of the pump of the amplifier of a steering
Spherical bearing
Driver's airbag
Passenger airbag
Airbag control unit
The moments of fastening of elements of a steering
Brake system
Brake systems — general information
Master brake cylinder
Vacuum brake booster
Front brake caliper
Brake disc (ventilated) front brake
Front brake pads
Rear brake caliper
Brake disc of the rear brake mechanism
Rear brake pads
Parking brake drive mechanism
Brake pads parking brake system
Parking brake adjustment
Front parking brake cable
Rear parking brake cables
Location of ABS/ABD system components, ABS/ABD circuit diagram and picture of ABS/ABD control unit wiring connector
Hydraulic block ABS/ABD or ABD/ETS
ABS wheel speed sensors
Tightening torque of brake system components
Body
Exterior (external elements)
Radiator grille
Front bumper
Rear bumper
Hood — removal and installation
Front doors
Side door adjustment
Rear door adjustment
Mounting distances of the hood, doors and covers
Basic dimensions for checking the relative position of body points
Interior (internal elements)
Dashboard central cover
Dashboard
Dashboard
Electrical equipment
Equipment and devices
Headlights — removal and installation
Headlight bulbs
Rear lights
Fog light switch
Wiper drive
Windshield wiper linkage
Parktronic sensors
Relay and fuse box (right side of dashboard)
Heater and air conditioner
Heater body
Heater fan drive
Additional heater control unit
Ignition sensor
Temperature and overheat sensors
Engine Residual Heat Recovery Switch
Engine Residual Heat Recovery Control Unit
Air conditioning compressor
Air conditioner condenser
Air conditioner evaporator
Outdoor temperature sensor
Cabin air temperature sensor
Air conditioning pressure sensor
Air conditioning control unit
Air conditioner switch
Exhaust air temperature sensor
Electrical circuits
How to read and use wiring diagrams
Engine management system 111.948 and 111.978
Fuel injection and ignition control system HFM-SFI/MFI engine 104.900
Diesel injection system CDI engine 611.980
Diesel fuel injection system with in-line injection pump (IFI) and electronic control
Starting and charging system for engines 111.948 and 111.978
Starting and charging system for engine 104.900 on model 638.244
Starting and charging system for engine 104.900 on model 638.294
Engine starting and charging system 611.980 on model 638.094/194/294
Engine starting and charging system 601.970 on models 638.074/174/274 (up to 1.05.98)
Engine starting and charging system 601.970 on models 638.074/174/274 (from 23.04.98)
Manual transmission 503.018/06 (5-speed)
Automatic transmission 503.020 (up to 1.05.98)
Automatic transmission 503.020 (from 23.04.98)
Automatic transmission 503.020 with engines 111.948 and 601.970 (from 23.04.98)
Automatic transmission 503.020/04 on vehicles with engine 104.900
Direction indicators and alarms
Outdoor lighting on models (with DLR system) 638.014
Outdoor lighting on models 638.244 (up to 1.05.98)
Outdoor lighting on models 638.094/194/294
Engine cooling fan 111.948 and 601.970
Engine cooling fan 104.900 on model 638.244
Engine cooling fan 611.980 on models 638.094/194/294
Engine cooling fan 611.980 and 111.950/980 on models 638.094/194/294
Heating system on models 638.014-274 (up to 1.05.98)
Heating system on models 638.014-274 (from 04/23/98)
ABS/ABD or ABS/ETS on models 638.014-274 (before 1.05.98)
ABS/ASR on models 638.094/194/294 with engine 611.980 (from 1.02.00)
Mercedes Vito 2 (2003-2014, diesel)
General information
User manual
Technical terms used in the manual
General overview — driver's workplace
Car key
Ignition switch positions
Seat adjustment
Steering wheel adjustment
Rear view mirrors
Seat belts
Starting the engine with a manual transmission
Starting the engine with automatic transmission
Parking brake
External lighting control
Windscreen wiper
Parking and locking the car
Traffic safety systems
Theft protection
Multifunction display (standard)
Multifunction Display (High-Line)
Features of using some functions
Speed control systems TEMPOMAT and SPEEDTRONIC
Electronic Vehicle Leveling (ENR)
PARKTRONIC system (PTS)
Options for organizing the luggage compartment
Self Help — Where to look?
Emergency opening and closing
Sliding/tilting sunroof/panoramic sliding roof
Manual disengagement of the gearbox lock when parked
Lamp replacement
Spare wheel removal
Electrical fuses
Front towing eye
Rear towing eye
Tires and wheels
Vehicle Specifications
Maintenance
Maintenance intervals between services
Maintenance work
Changing engine oil and oil filter
Cooling system — checking, adjusting the concentration of antifreeze with anti-corrosion additives
Hydraulic brake drive
Car windshield washer
Replacing the air filter element
Checking the V-ribbed belt for wear and damage
Belt replacement
Fuel filter replacement
Replacing the filter element of the dust filter of the heating-ventilation system
Tire pressure: adjustment
Checking the thickness of the friction linings of the brake pads and the condition of the brake discs
Removal, installation and adjustment of parking brake pads
Checking tightness and condition
Removal and installation of spherical tips of steering drafts
ASSYST Service Computer — Reading Update
Changing the oil and oil filter in an automatic transmission 722.680/682/683
Additional work at each maintenance
Tow hitch with removable ball stud and automatic locking
Additional work at every second maintenance
Additional work carried out every 2 years
Additional work carried out after 180,000 km
Additional work carried out every 10 years or after 300,000 km of run
Diesel engine OM646
Engine repair
General information
Vehicle Equipment Option Codes
Engine Specifications
Removal and installation of the power unit
Components and assemblies in the front of the engine
Removal and installation of the cylinder head (cylinder head)
Checking the relative position of the camshafts
Checking the relative position of the crankshaft and camshaft system
Cylinder head repair
Removal and installation of valves
Valve seats
Valve guide bushings
Processing the cylinder head for the installation of valve guides
Checking the hydraulic gap compensators in the valve drive
Disassembly and repair of the lower part of the engine
Removal and installation of the crankshaft
Connecting rod and piston group of parts (SHPG) — composition
Crank mechanism (KShM) — composition
Checking and repairing connecting rods
Connection of pistons with connecting rods and installation in the cylinder block
Measuring the piston protrusion above the parting plane of a new cylinder block
Front cylinder block cover
Installation of a back cover of the block of cylinders
Oil pump installation
Flywheel Installation
Cooling and lubrication system
Lubrication system — general information
Oil pump
Oil sump pan
Oil filter and heat exchanger
Oil supply and return lines
Coolant circulation pump and thermostat
Cooling radiator
Cooling system fan
Connecting hoses and branch pipes
Power and exhaust system
Functional diagram of the air supply system
Turbocharger — purpose, control
Removing and installing turbocharger
Removal and installation of an intercooler
Elements of the air supply system
Low pressure circuit
High pressure circuit
High pressure fuel pump
HPFP drive
High pressure fuel manifold (TKVD)
High pressure fuel lines
Pressure control valve in TKVD
Fuel injectors
The union of fastening of a tube of a high pressure to a fuel atomizer
Exhaust gas exhaust system
Transmission
Clutch
Clutch mechanism
Clutch mechanism control
The principle of operation of the hydraulic clutch release
Automatic clutch release system
Clutch release drive with pedal
Checking clutch parts during repair
Removing the coaxial clutch slave cylinder
Removal and installation of the clutch pedal
Clutch pedal bracket
Car gearbox
Gearbox designation and specifications
Rear axle main gear reducer
Manual gearbox type 716.6
Hydraulic control box
Mechanical gear shift
Disassembly and assembly of semi-automatic gearbox 716.6
Disassembly and assembly of the front of the gearbox housing
Clutch release position sensor
Pressure sensor in the hydraulic drive of the gearbox control
Internal shift mechanism
Gearbox mechanical elements
Tri-cone synchronizing mechanism
Double cone synchronizing mechanism
Single cone synchronizing mechanism
Intermediate shaft
Main shaft and input shaft
Components of the final drive of the rear axle
Removal and installation of the rear final drive
Removal and installation of cardan shaft
Removal and installation of drive shafts of rear axle wheels
Removing the inner CV joint of the drive shaft from the rear axle final drive gearbox
Removing the outer CV joint from the drive shaft
Removing the inner CV joint from the drive shaft
CV joint boot replacement
Front axle reducer
Chassis
Front suspension
Front wheel suspension
Front suspension arm
Front arm and steering knuckle
Mounting the steering knuckle to the shock absorber strut
Stabilizer bar
Fastening of the stabilizer bar of transverse stability
Shock absorber strut
General information on checking wheel alignment
Checking and adjusting the convergence of the front wheels
Checking and adjusting camber and caster
Rear suspension
Rear suspension
Rear suspension with metal springs
Rear air suspension
Air suspension compressor
Rear air suspension lines
Rear stabilizer
Removal and installation of the rear shock absorber
Checking the condition of the rear shock absorber
Removal and installation of rear suspension arms
Removal and installation of the bearing of a back nave
Removal and installation of reactive draft of a back reducer
Replacement of an epiploon of a back reducer
Checking and adjusting the convergence of the rear wheels
Rear wheel camber check
Removal and installation of the steering mechanism
Steering
Hydraulic power steering (GUR
Steering column
Steering wheel
Removal and installation of a steering wheel
Removing the rotating contact joint
Setting the middle position of the rotating contact joint (VKS)
Removal and installation of the steering wheel angle sensor
Removal and installation of a tip of steering draft
Removal and installation of steering draft
Gear gap adjustment in rack and pinion
Brake system
Elements of the brake system
Removal and installation of a pedal of brakes
Removal and installation of the main brake cylinder (GTZ)
Removing and installing the vacuum brake booster
Body
Body elements
Car body Vito Viano
Removal and installation of a cowl
Removal and installation of mudguards
Removal and installation of a radiator grille
Removal and installation of a forward bumper
Removal and installation of the top lining of a bumper
Removal and installation of a basic traverse of the forward panel
Removal and installation of an external rear-view mirror
Removal and installation of a forward wing
Removal and installation of the hatch of a fuel tank
Removal and installation of rear bumper corners
Disassembly and assembly of the rear bumper
Removal and installation of the bumper amplifier
Removal and installation of lateral fastening of a bumper
Removal and installation of a step of a lateral door
Removal and installation of front passenger seats
Removal and installation of top rails
Coupling device
Control data for clearances when installing removable body elements
Electrical equipment
Equipment and devices
Vehicle control system
Operating principle of CAN·multiplex network
The principle of signal generation in a multiplex network
Block diagram of the multiplex networks of the Vito Viano
List of multiplex network components
Communication between data buses
Instrument cluster (A1)
Front Universal Switching Unit
Functions of the SAM block
Engine management system
Functions performed by the control system in various modes
Fuel injection control
Managing the amount of fuel injected
Fuel injection pressure control
Controlling the amount of fuel injected in engine start mode
Driving injection control
Idle injection control
Fuel pre-injection control function
Main injection control function
Final injection stage
Glow plug preheat function
Postheating
Boost pressure control function
Air-Fuel Ratio Definitions
Exhaust gas recirculation (EGR) control
Air supply cut-off control
A/C Compressor Shutdown Control Function
Fuel supply system
Functional diagram of motor control
Elements of the engine management system
Electronic Engine Control Unit (CDI ECU)
Accelerator pedal position sensor (B37)
Crankshaft position sensor (L5)
Camshaft Position Sensor (B6/1)
Coolant temperature sensor (B11/4)
Fuel temperature sensor (B50)
Inlet air mass sensor (B2/5) combined with inlet air temperature sensor (B2/5b1)
Charge air temperature sensor (B17/9)
Boost pressure sensor (B5/1)
Fuel pressure sensor in TKVD (B4/6)
Oil Condition Sensor (B40)
Inlet oxygen sensor on the converter (G3/2)
Air filter outlet pressure sensor (B28/5)
Actuators of the CDI control system
Glow plugs (R9)
HP pressure control valve (Y74)
Exhaust Gas Recirculation (EGR) Valve Actuator
Electronic Stability Program (ESP)
Systems interaction
Location of ABS components (for vehicles not equipped with ESP)
Wheel speed sensors
Lateral acceleration sensor
Angular rate (yaw) sensor
Steering angle sensor
Hydraulic brake force control unit
Functioning of the ESP system
Brake Assist System (BAS): functional description
Monitoring system for maintenance and vehicle condition (ASSYST)
Tire pressure monitoring system
Security systems
Passive safety system
Block diagram of the passive safety system
Elements of the security system
Precautions when servicing components containing elements of a passive safety system
Driver's airbag
Side airbags
Seat belt pretensioner
OTU design
Upper side airbags
Electrical circuits
Use of electrical diagrams
Relay and fuse box
Power supply to fuse box F34
Power supply to fuse box F35
Power supply to the fuse box located in the frame of the right seat
Power supply to fuse blocks F4 and F5
Electronic ignition control unit
Electrical wiring couplings
Starter and generator (for engines OM 646.982 and 646.983, up to 28.02.2005)
Starter and alternator (for engines OM 646.980 and 646.981, from 01.03.2005)
Electronic control unit for the CDI system (for engines OM 646.982 and 646.983)
Electronic control unit for the CDI system (for engines OM 646.980 and 646.981)
Fuel supply system
Automatic transmission
Gear selector control unit
Brake control (with ESP stability control system (VVZ configuration code))
Brake control (without ESP stability control system)
Stability Program ESP up to No. 195056
Stability Program ESP from No. 195057
Multifunction steering wheel
Rear window heating
Power rear vent window
Right sliding door control unit
Rear wiper
Power window driver's door
Power window regulator, front passenger door
Front left door control unit
Front right door control unit
Central locking
Anti-theft alarm
Outdoor Lighting
Internal sockets
License plate lighting up to No. 094908
License plate lighting from No. 094909
Direction indicators and alarms
Stop signal
Interior lighting
Illuminated controls
Sound signal
Rear wiper
Car windshield washers
Heater diagram
Passive safety system until 31.08.2005
Passive safety system from 01.09.2005
List of electrical equipment items

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