Mercedes C-Class

W203 since 2000 of release

Repair and operation of the car



Mercedes-Benz
+ Mercedes-Benz cars of class C (W-203)
+ Operation manual
+ Routine maintenance
- Engine
   Check of a compression in engine cylinders
   Check of the engine by means of the vacuum gage
   Removal and installation of a cover of a motive compartment from the bottom
   + 4-cylinder petrol engines
   + 6-cylinder petrol engines
   - Diesel engines
      Removal and installation of the top cover of the engine
      Installation of the piston of the first cylinder in the provision of VMT
      Removal and installation of a cover of a head of cylinders
      Removal and installation of a head of cylinders
      Removal and installation of a forward cover
      Removal and installation of the top guide of a chain
      Replacement of chains of the GRM drive and installation of phases of gas distribution
      Removal and installation of camshafts
      Removal and installation of an intermediate asterisk
      Removal and installation of a natyazhitel of a chain
      Removal and installation of a maple belt
   + Engine lubrication system
+ Cooling system and heating
+ Power supply system and release
+ Engine electric equipment
+ Manual transmission
+ Automatic transmission
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment







Removal and installation of a head of cylinders

As the specified work demands existence of certain experience, the description only of basic provisions necessary for the skilled mechanic is provided. The description belongs to the diesel engine. Remarks concerning the petrol engine are provided in the end of the section.


Removal

 PERFORMANCE ORDER

1. Disconnect a negative cable (-) of the rechargeable battery at the switched-off ignition. It is previously necessary to remove a box of the filter of air of salon.

Before a detachment of a cable find out a protective code of the radio receiver if that is available, address the Section Replacement of the Rechargeable Battery

Lifting operation and installations of the car on supports is connected with danger! Therefore before carrying out operation study Poddomkrachivaniye's Section and towage of Introduction to the management.

2. Lift and install the car on supports.
3. Remove the lower cover of a motive compartment, address appropriate section.
4. Merge cooling liquid, address the Section Replacement of Cooling Liquid - general comments.
5. Disunite the generator socket.
6. Disconnect a turbocompressor at the lower holder.
7. Disunite the oil sensor socket.
8. Remove the top covers of the engine, address appropriate section.
9. Remove the air filter, address the Section Removal and installation of the air filter.
10. Disconnect the holder of the directing pipe of the index of level of oil behind to the right of a head of cylinders.
11. Disunite sockets of candles of an incandescence, the sensor of temperature of cooling liquid, the sensor of pressure of fuel and the valve of adjustment of pressure at a head of cylinders.
12. Disconnect a weight wire near the shutdown valve with electromanagement at a head of cylinders.
13. Disconnect the holder of a cable near the valve of adjustment of pressure at a head of cylinders.
14. Remove a thermostat casing, address the Section Removal and installation of the thermostat.
15. Remove nozzles, address the Section Removal and installation of nozzles.
16. Uncover a head of cylinders, address appropriate section.
17. Remove a natyazhitel of a chain, address the Section Removal and installation of a natyazhitel of a chain.
18. Install the piston of the first cylinder in the provision of VMT, address appropriate section.

Do not rotate the engine in the opposite direction. Do not rotate the engine for a bolt of fastening of an asterisk of the camshaft at all.

19. Remove a forward cover at a head of cylinders, address appropriate section.
20. Remove the top guide, address appropriate section.
21. Remove camshafts, address appropriate section.
22. Remove a casing of camshafts.
23. Remove TNVD.
24. Remove an intermediate asterisk, address appropriate section.
25. Remove the distributor of the forced air.
26. Remove the oil supply pipeline to a turbocompressor.
27. Remove a hose of cooling liquid to the generator.
28. Disconnect the preliminary catalytic converter at the block of cylinders.
29. Disconnect a turbocompressor from a final collector.

The final collector remains attached to a head of cylinders.

30. Turn out bolts of fastening of a head of cylinders to a gas distribution mechanism case cover.
31. Turn out bolts of fastening of a head of cylinders in the sequence, the return numbering, i.e. with 12 on 1
(The 4-cylinder engine) or with 14 on 1 (the 5-cylinder engine). At the same time at first turn off all bolts on Ѕ a turn and then turn out bolts.
32. By means of the assistant lift a head of cylinders. The head rises by HUNDRED by means of an elektrotala or the shop crane. For this purpose take cables for two eyes on a final collector.


Installation

 PERFORMANCE ORDER

Before installation of a head and the block of cylinders remove with a shaber the sealant remains from the interfaced surfaces. You watch that the remains of sealant did not get to openings. Close openings rags. After cleaning remove rags.
1. Check a steel ruler planeness of surfaces of the block and a head of cylinders in the longitudinal and cross directions, if necessary process the planes (work HUNDRED).
2. Check a head of cylinders for existence of cracks, and the working surfaces of cylinders on existence of flutes.
3. Carefully clear openings under bolts of fastening of a head of cylinders of oil and other products. Blow openings compressed air or remove oil with the screw-driver which is wrapped up by a rag.

Openings under bolts of fastening of a head of cylinders have to be free from the remains of oil and cooling liquid. Otherwise at a vvorachivaniye of new bolts pressure which can lead to destruction of the block of cylinders or to incorrect assessment of the moment of an inhaling will be created.

4. Surely replace sealing laying of a head of cylinders.
5. Lay on the place new laying without sealant so that not to block any opening.
6. Put by means of the assistant into place a head of cylinders. You watch that the head of cylinders at installation did not warp.

The head of cylinders on the block of cylinders is aligned by the directing plugs.


7. Measure length of bolts of fastening of a head of cylinders. Length of new bolts makes 102 mm. At each inhaling bolts are extended. At achievement of length of 104 mm and more bolts it is necessary to replace.

8. Oil a carving and a basic surface of a head of bolts and screw by hand to a prileganiye to a head.

The inhaling of bolts of fastening of a head of cylinders should be carried out with special care. Before an inhaling it is necessary to check a dynamometer key for accuracy. The inhaling of bolts on the set corner has to be made with application of an angular washer, for example, of HAZET 6690. Not to overload a dynamometer key with the high moment, apply an angular washer with a usual key.


If the angular washer is unavailable, it is possible to estimate a corner differently. For this purpose put a rigid key so that the handle of a key settled down along the engine and turn a key at one time so that the handle reached position across the engine.

9. Tighten bolts of fastening of a head of cylinders in three steps, in the sequence established by Specifications with 1 on 10.

10. Tighten Torx (11) and (12) screws of fastening of a head of cylinders to a cover of the case of the mechanism of gas distribution the moment of 20 Nanometers.

11. Tighten bolts of fastening of a head of cylinders in five receptions, in the sequence established by Specifications.


12. Fix a turbocompressor on a final collector by the moment of 30 Nanometers.
13. Fix the preliminary catalytic converter on the block of cylinders.
14. Install the pipeline of cooling liquid going to the generator.
15. Fix the pipeline of supply of oil with new laying on a turbocompressor the moment of 30 Nanometers and on a head of cylinders the moment of 22 Nanometers.
16. Install the distributor of the forced air.
17. Establish an intermediate asterisk, address appropriate section.
18. Establish TNVD. Fix the pipeline of high pressure at TNVD and the highway by the moment of 22 Nanometers.
19. Install the case of camshafts.
20. Install camshafts, address appropriate section.
21. Establish the top guide, address appropriate section.
22. Establish a forward cover on a head of cylinders, address appropriate section.
23. Establish a natyazhitel of a chain with a new sealing ring, address the Section Removal and installation of a natyazhitel of a chain.
24. Establish a cover of a head of cylinders, address appropriate section.
25. Establish nozzles, address the Section Removal and installation of nozzles.
26. Establish a thermostat casing, address the Section Removal and installation of the thermostat.
27. Fix the holder of a cable near the valve of adjustment of pressure on a head of cylinders.
28. Fix a weight wire near the shutdown valve with electromanagement on a head of cylinders.
29. Join sockets of candles of an incandescence, the sensor of temperature of cooling liquid, pressure sensor in the fuel highway and the valve of adjustment of pressure on a head of cylinders.
30. Fix the holder of the directing pipe of the index of level of oil of the transmission behind on the right at a head of cylinders.
31. Install the air filter, address the Section Removal and installation of the air filter.
32. Establish the top covers of the engine, address appropriate section.
33. Join the oil sensor socket.
34. Fix the lower holder at a turbocompressor by the moment 30 Nanometers.
35. Join the generator socket.
36. Establish the lower cover of a motive compartment, address appropriate section.
37. Lower the car on wheels.
38. Check oil level in the engine.
39. Fill system with cooling liquid, address the Section Replacement of Cooling Liquid - general comments.
40. Attach a negative cable (-) to the rechargeable battery at the switched-off ignition. Establish into place a box of the filter of air of salon. Enter a code of the radio receiver and determine time on hours.
41. Check tightness of the engine concerning oil and cooling liquid. At the same time check the cooling system for tightness when the engine reaches working temperature.

Laying of a head of cylinders gains tightness only when the engine gets warm up to the working temperature, and laying as appropriate bulks up.

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