S-class W202 Mercedes

1993-2000 of release

Repair and car operation

W202 Mercedes
+ 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. Bottom 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 tarelchaty pushers
   3.1.12. Maslootrazhatelnye caps
   3.1.13. Valves
   3.1.14. Directing valves
   3.1.15. Saddles of valves in a head of the block of cylinders
   3.1.16. Compression
   + 3.1.17. Klinovy belt
   3.1.18. Diagnostics of malfunctions (DB)
   3.1.19. General comments
   3.1.20. Repair work without engine dismantle
   + 3.1.21. Major maintenance of the engine
   + 3.2. Diesel engine (DD)
   3.2.3. Cars with the conditioner
   3.2.4. Bottom 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. Engine in volume of 2,2/2,5 l
   + 3.2.9. Maslootrazhatelnye caps
   3.2.10. Cover of a head of the block of cylinders (2,2/2,5 l)
   3.2.11. Hydraulic tarelchaty pushers
   3.2.12. Valves
   3.2.13. 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. Tense device of a maple ridge belt
   3.2.19. Diagnostics of malfunctions (DD)
+ 4. Greasing system
+ 5. Cooling system
+ 6. Heating, ventilation
+ 7. Ignition system
+ 8. Fuel system
+ 9. Transmission
+ 10. Running gear
+ 11. Steering
+ 12. Brake system
+ 13. Body
+ 14. Electric equipment
+ 14.2. Electroschemes

3.2.8.2. Engine in volume of 2,2/2,5 l

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

Drawing belongs to the engine in volume of 2,5 l (22 bolts). For the engine in volume of 2,2 l 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. Branches of 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 "weight" of the battery (–). Prevention The anticreeping code of radio is thus erased.
3. Raise the car in front and remove the bottom 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 lateral holder.
7. Unscrew the hydraulic coupling of the fan.
8. Weaken and remove maple a ridge belt.
	9. Disconnect depression hoses (2, 3) from the vacuum pump (5) and a detail of the distributor (shooter). If necessary previously weaken and remove back collars of fastening of hoses.
10. Remove a hose of removal of air from system of cooling (1) and a hose of cooling liquid, previously having weakened collars of fastening of hoses.
11. Remove a hose connecting the air filter.
	12. Disconnect hoses of depression (7) and (8) from a tank of depression, a zaslonka of a regulator of pressure and the retsirkulyatsionny 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 cooling system.
14. Remove camshafts.
	15. Take the top fingers (14) directing tires of a chain of management (15) by means of a pusher (2) and hairpins М6.
If such tool is not present, it is possible to take fingers by means of a chain asterisk with ten teeths (length of a tetrahedron = 1/2 inches) and bolt М6 having approximately threefold length of an asterisk, and a lock-nut. For this purpose screw a lock-nut on bolt М6 and insert from above a bolt a prokladochny washer. Get on a finger an asterisk, screw in bolt М6 in a carving of a finger and twirl a lock-nut before contact with an asterisk surface. The Prokladochny 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. As take the bottom fingers of the directing tire located below a podsoyedinitelny element of cooling liquid.
	17. Unscrew a case of camshafts (10) and remove it. Pushers it is not necessary to take out Tarelchatye: they will not drop out, thanks to the bottom ledges.
Prevention Pay attention to two adjusting sleeves (13). (12) at repeated installation it is necessary to replace a ring of round section new.
18. Remove nozzles with топливопроводами.
	19. Unscrew directing tube of a measuring instrument of level of oil (10) for an automatic transmission (if it is) from a head of the block of cylinders behind on the right.
20. Unscrew directing tube masloizmeritelny щупа (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 топливопроводы (90/1) and (90/2) from the device of preliminary heating of fuel.
Prevention For simplification of the subsequent installation designate топливопроводы a sticky tape. The poured-out fuel collect a rag.
23. Disconnect the cable channel (22) from the device of preliminary heating of fuel.
	24. Unscrew electricity cables from candles of an incandescence (R9), previously having marked wires a sticky 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 the cable channel (1) from the fuel (60) heat exchanger.
27. Disconnect a thick hose of cooling liquid behind a head of the block of cylinders, having completely opened 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 attached топливопроводами.
29. Remove directing tire in a chain case in the same way, as well as the top tire.
	30. Unscrew two bolts М8 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 sequence, their return numbering, i.e. from 22 to 1 (see fig. Bolts of a head of the block of cylinders (engine of 2,5 l)). Thus at first weaken all bolts on 1/2 turns, and then completely turn out, using a face nozzle on a wrench, for example, HAZET 2751.
32. The head of the block of cylinders is better for lifting together. In repair shops screw the holder (17) instead of an external cover of the bearing of camshafts and hang полиспаст for lifting of a head of the block of cylinders.

Installation

PERFORMANCE ORDER

1. Before installation a head of the block of cylinders clear a scraper of the hermetic remains. Track, that they did not get to openings.
2. The carving openings cleared of oil and water, blow the compressed air. If there is no compressed air, liquid in deaf openings absorb the rag which has been wrapped up round a small screw-driver.
3. Check a head of the block of cylinders and the block of cylinders on 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 hermetic so that it did not close an opening.
6. Establish a head of the block of cylinders (21). Prevention Head of the block of cylinders align by means of fixing sleeves (19) on the motor block.
	7. Measure length (L) bolts of a head of the block of cylinders. If the maximum length (see the table Bolts of a head of the block of cylinders) is exceeded, just in case replace a bolt.
8. Grease with engine oil a carving of bolts of a head of the block of cylinders, and also a place of their prileganiye to it, twist bolts and tighten manually (see fig. 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 prokladochny washers. Carefully tighten bolts of a head of the block of cylinders. Previously check accuracy of a dinamometrichesky key. Tighten bolts of a head of the block of cylinders in 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 are tightened in sequence from 1 to 22 or from 1 to the 18th. 1 stage: dinamometrichesky natural moment of 15 N of m. 2 stage: dinamometrichesky natural moment of 35 N of m. 3 stage: A rozhkovy wrench tighten bolts in the same direction on 90 °. Prevention In this place make a 10-minute pause for a precipitation of bolts. Then tighten bolts further, without weakening. 4 stage: turn bolts in the same direction on 90 ° a rozhkovy wrench. Prevention At a tightening of bolts estimate an angle of rotation. Arrange the wrench handle along the engine and tighten a bolt one effort while the handle of a key does not become across the engine (1/4 turns, 90 °).
9. 2 bolts М8 (and) in front of a head of the block of cylinders establish with spring washers and tighten a long face key of SW6 with the moment of 25 N of m.
10. Establish the fuel filter with the holder and twirl with the moment of 25 N of m, bolts (b).

	11. Establish the bottom directing tire of a chain of management in a case of a chain and insert persistent fingers. Thus establish directing tire so that elements of installation of the top persistent finger (And) and the bottom finger (In) were from above.
12. Put on a thick hose of cooling liquid a back branch pipe of cooling liquid and fix it a collar.
13. Connect electricity cables to glow plugs and sensors of temperature of cooling liquid.
14. Screw the cable channel on system of preliminary warming up of fuel.
15. Connect with the moment of 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 directing pipe masloizmeritelny щупа in the engine and in an automatic transmission on a head of the block of cylinders.
17. Establish nozzles.
	18. Establish a case of camshafts with tarelchaty 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 should be replaced with the new always. Fix two bolts (11) with the moment of 15 N of m.
19. Establish the top directing tire of a chain of management, hammer persistent fingers.
20. Establish 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 a zaslonka of a regulator of pressure and the valve of a retsirkulyatsiya 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 depression hoses (2, 3) on the vacuum pump (5) and a detail of the distributor (shooter), fix hoses collars.
25. Put on a hose of deaeration of cooling liquid (1) and a hose of cooling liquid (4) and fix collars.
26. Establish maple a ridge belt.
27. Hang and adjust a cable of management of gas.
28. Establish the hydraulic coupling of the fan.
29. Screw a forward exhaust pipe on a collector and lateral holders.
30. Fill in cooling liquid.
31. Connect a "weight" cable (–) to the battery. Prevention If there was defective a sealing laying of a head of the block of cylinders, it is necessary to replace engine oil and the oil filter.
32. Finish the engine to working temperature and check tightness of all podsoyedinitelny elements.
33. Establish the bottom 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