Mercedes of the S-class W202

1993-2000 of release

Repair and operation of the car

Mercedes W202
+ 1.2. General information
+ 2. Maintenance
- 3. Engines
   3.1.2. Identification number
   + 3.1.3. Engine
   3.1.4. Cars with the conditioner
   3.1.5. Lower cover of a motor compartment
   3.1.6. Covers of cast openings
   3.1.7. Natyazhitel of a chain
   + 3.1.8. Cover of a head of the block of cylinders
   + 3.1.9. Head of the block of cylinders
   + 3.1.10. Camshafts
   3.1.11. Hydraulic dish-shaped pushers
   3.1.12. Maslootrazhatelny caps
   3.1.13. Valves
   3.1.14. The directing valves
   3.1.15. Saddles of valves in a head of the block of cylinders
   3.1.16. Compression
   + 3.1.17. Maple belt
   3.1.18. Diagnostics of malfunctions (DB)
   3.1.19. General comments
   3.1.20. Repair work without dismantle of the engine
   + 3.1.21. Capital repairs of the engine
   + 3.2. Diesel Engine (DE)
   3.2.3. Cars with the conditioner
   3.2.4. Lower cover of a motor compartment
   3.2.5. Covers of cast openings
   3.2.6. Natyazhitel of a chain
   + 3.2.7. Camshaft
   - 3.2.8. Head of the block of cylinders
      3.2.8.2. 2,2/2,5 l engine
   + 3.2.9. Maslootrazhatelny caps
   3.2.10. Cover of a head of the block of cylinders (2,2 / 2,5 l)
   3.2.11. Hydraulic dish-shaped pushers
   3.2.12. Valves
   3.2.13. The directing valves
   3.2.14. Saddles of valves in a head of the block of cylinders
   3.2.15. Head of the block of cylinders and motor block
   3.2.16. Compression
   3.2.17. Maple ridge belt
   3.2.18. The pulling device of a maple ridge belt
   3.2.19. Diagnostics of malfunctions (DD)
+ 4. Lubrication system
+ 5. Cooling system
+ 6. Heating, ventilation
+ 7. System of ignition
+ 8. Fuel system
+ 9. Transmission
+ 10. Running gear
+ 11. Steering
+ 12. Brake system
+ 13. Body
+ 14. Electric equipment
+ 14.2. Electrical circuitries

3.2.8.2. 2,2 / 2,5 l engine

GENERAL INFORMATION

Bolts of a head of the block of cylinders (engine of 2,5 l)

And – a bolt with a fillet of M 10х115
In – a bolt with a fillet of M 10х102
and – a universal bolt of M 8 x 50 (a chain case)
b – bolts of M 8 x 80 (for the fuel filter)

Prevention

The drawing belongs to the 2,5 l engine (22 bolts). For the 2,2 l engine with 18 bolts in a head of the block of cylinders – the same sequence of actions.

The head of the block of cylinders understands only on the cooled engine. Withdrawal of the final and soaking-up pipes remain connected. Signs of defect of sealing laying of a head of the block of cylinders same as are described for the engine of 2 l.

Removal

PERFORMANCE ORDER

1. Raise an engine cowl.
2. Disconnect a wire of "mass" of the battery (–). Prevention At the same time the anticreeping code of radio is erased.
3. Raise the car in front and remove the lower cover of a motor compartment.
4. Merge cooling liquid.
5. Unscrew a forward exhaust pipe from a final collector.
6. Unscrew an exhaust pipe from the side holder.
7. Unscrew the hydraulic coupling of the fan.
8. Weaken and take off maple a ridge belt.
	9. Disconnect hoses of depression (2, 3) from the vacuum pump (5) and a detail of the distributor (shooter). If necessary previously weaken and remove collars of fastening of hoses back.
10. Remove a hose of removal of air from the cooling system (1) and a hose of cooling liquid, previously having weakened collars of fastening of hoses.
11. Remove the hose connecting the air filter.
	12. Disconnect hoses of depression (7) and (8) from a tank of depression, the gate of the regulator of pressure and the recirculation valve of the final device.
13. Disconnect wires from temperature switches on the left side of a head of the block of cylinders and a flange of the cooling system.
14. Remove camshafts.
	15. Take the top fingers (14) the directing tires of a chain of management (15) by means of a pusher (2) and a hairpin of M6.
If there is no such tool, it is possible to take fingers by means of a chain asterisk with ten teeths (tetrahedron length = 1/2 inches) and a bolt of M6 having approximately threefold length of an asterisk, and lock-nut. For this purpose screw a lock-nut on a bolt of M6 and insert from above a bolt a pro-masonry washer. Get an asterisk on a finger, screw in M6 bolt in a carving of a finger and twirl a lock-nut before contact with an asterisk surface. The pro-masonry washer serves for improvement of contact of surfaces. Extend a finger, holding a bolt head a wrench and at the same time turning a lock-nut a wrench concerning an asterisk.
16. Also take the lower fingers of the directing tire located below a subconnecting element of cooling liquid.
	17. Unscrew a case of camshafts (10) and remove it. Dish-shaped pushers do not need to be taken out: they will not drop out, thanks to the lower ledges.
Prevention Pay attention to two adjusting sleeves (13). The ring of round section (12) at repeated installation should be replaced new.
18. Remove nozzles with fuel-supply lines.
	19. Unscrew the directing tube of the measuring instrument of level of oil (10) for the automatic transmission (if it is) from a head of the block of cylinders behind on the right.
20. Unscrew the directing tube of the masloizmeritelny probe (11) from a head of the block of cylinders.
21. Unscrew the shock-absorber (13) of the device of a tension of a ridge maple belt from a head of the block of cylinders.
	22. Disconnect fuel-supply lines (90/1) and (90/2) from the device of preliminary heating of fuel.
Prevention For simplification of the subsequent installation designate fuel-supply lines an adhesive tape. Collect the poured-out fuel by a rag.
23. Disconnect cable channel (22) from the device of preliminary heating of fuel.
	24. Unscrew electrical wires from candles of an incandescence (R9), previously having marked wires an adhesive tape.
25. Disconnect shtekkerny connections from the sensor of temperature of cooling liquid for the conditioner (B10/8), the device of indication (B11/4) and a repeated incandescence (B11/8).
26. Unscrew cable channel (1) from the heat exchanger of fuel (60).
27. Disconnect a thick hose of cooling liquid behind a head of the block of cylinders, having completely opened the fixing collar.
28. Unscrew fastening bolts, remove the fuel filter with the holder from a head of the block of cylinders and put aside together with the attached fuel-supply lines.
29. Remove the directing tire in a chain case in the same way, as well as the top tire.
	30. Unscrew two bolts of M8 of a head of the block of cylinders by means of a long face key of SW.
31. Unscrew bolts of a head of the block of cylinders in the sequence, their return numbering, i.e. from 22 to 1 (see rice. Bolts of a head of the block of cylinders (engine of 2,5 l)). At the same time at first weaken all bolts on 1/2 turns, and then completely turn out, using a face nozzle on a wrench, for example, of HAZET 2751.
32. It is better to lift a head of the block of cylinders together. Repair shops screw the holder (17) instead of an external cover of the bearing of camshafts and hang a polyspast for raising of a head of the block of cylinders.

Installation

PERFORMANCE ORDER

1. Before installation clear a head of the block of cylinders a scraper of the sealant remains. Track that they did not get to openings.
2. Blow the carving openings cleared of oil and water compressed air. If there is no compressed air, then absorb liquid in deaf openings the rag which is wrapped up around the small screw-driver.
3. Check a head of the block of cylinders and the block of cylinders for lack of cracks and planeness by means of a steel ruler.
4. Surely replace sealing laying of a head of the block of cylinders (20).
5. Impose new sealing laying without sealant so that it did not close an opening.
6. Establish a head of the block of cylinders (21). Prevention Align a head of the block of cylinders by means of the fixing sleeves (19) on the motor block.
	7. Measure length (L) bolts of a head of the block of cylinders. If the maximum length is exceeded (see the table Bolts of a head of the block of cylinders), then just in case replace a bolt.
8. Oil engine a carving of bolts of a head of the block of cylinders, and also the place of their prileganiye to it, twist bolts and tighten manually (see rice. Bolts of a head of the block of cylinders (engine of 2,5 l)). Prevention Bolts of a head of the block of cylinders are mounted without pro-masonry washers. Carefully tighten bolts of a head of the block of cylinders. Previously check the accuracy of a dynamometer key. Tighten bolts of a head of the block of cylinders in the sequence with 1 on 22 and, respectively, with 1 on 18, in 4 stages. Prevention Bolts of a head of the block of cylinders at each stage drag on in the sequence from 1 to 22 or from 1 to the 18th. 1 stage: a dynamometer key with m 15 N.' moment. 2 stage: a dynamometer key with m 35 N.' moment. 3 stage: Rozhkov a wrench tighten bolts in the same direction on 90 °. Prevention In this place make a 10-minute pause for the draft of bolts. Then tighten bolts further, without weakening. 4 stage: turn bolts in the same direction on 90 ° Rozhkov a wrench. Prevention When tightening bolts estimate an angle of rotation. Arrange the wrench handle along the engine and tighten a bolt by one effort until the handle of a key becomes across the engine (1/4 turns, 90 °).
9. Establish 2 bolts of M8 (a) in front of a head of the block of cylinders with spring washers and tighten a long face key of SW6 with the moment 25 N. of m.
10. Install the fuel filter with the holder and twirl with the moment 25 N. of m, bolts (b).

	11. Install the lower directing tire of a chain of management in a case of a chain and implant persistent fingers. At the same time install the directing tire so that elements of installation of the top persistent finger (A) and lower finger (V) were from above.
12. Put on a thick hose of cooling liquid a back branch pipe of cooling liquid and record it a collar.
13. Connect electrical wires to glow plugs and sensors of temperature of cooling liquid.
14. Screw cable channel on system of preliminary warming up of fuel.
15. Connect with the moment 25 N. of m the shock-absorber of the device of a tension of a maple ridge belt to a head of the block of cylinders.
16. Screw the directing pipe of the masloizmeritelny probe in the engine and in the automatic transmission on a head of the block of cylinders.
17. Establish nozzles.
	18. Establish a case of camshafts with dish-shaped pushers and center two unloading plugs (13).
Prevention Rings of round section (12) between a head of the block of cylinders and a case of camshafts have to be replaced with new always. Fix two bolts (11) with m 15 N.' moment.
19. Install the top directing tire of a chain of management, hammer persistent fingers.
20. Install camshafts and a cover of a head of the block of cylinders.
21. Establish a hose of the air filter.
22. Put on 2 hoses of depression a tank of depression of the gate of the regulator of pressure and the valve of recirculation of flue gases.
23. Put on a wire the temperature switch on the left side of a head of the block of cylinders on a flange of cooling liquid.
	24. Put on hoses of depression (2, 3) the vacuum pump (5) and a detail of the distributor (shooter), fix hoses by collars.
25. Put on a hose of deaeration of cooling liquid (1) and a hose of cooling liquid (4) and fix by collars.
26. Establish maple a ridge belt.
27. Hang and adjust a cable of management of gas.
28. Install the hydraulic coupling of the fan.
29. Screw a forward exhaust pipe on a collector and side holders.
30. Fill in cooling liquid.
31. Connect the weights cable (–) to the battery. Prevention If there was defective a sealing laying of a head of the block of cylinders, then it is necessary to replace engine oil and an oil filter.
32. Bring the engine to working temperature and check tightness of all subconnecting elements.
33. Establish the lower cover of a motor compartment and fasten bolts. Prevention Pulling up of bolts of a head of the block of cylinders is forbidden.
34. To close an engine cowl, press an unblocking key on the left arm.

Bolts of a head of the block of cylinders

DIAMETER OF THE CARVING	LENGTH IN NEW SITUATION	MAXIMUM LENGTH
M 10	102,0 mm	104,0 mm
M 10	115,0 mm	117,0 mm