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
+ Cooling system and heating
- Power supply system and release
   + Power supply system of the petrol and diesel engine
   + System of injection of fuel of the petrol engine
   - System of injection of fuel of the diesel engine. Turbocompressor
      Removal and installation of nozzles
      Removal of air from a contour of low pressure of fuel
      Checks of system of injection of fuel
   + Systems of release and decrease in toxicity of the fulfilled gases. Turbocompressor
+ Engine electric equipment
+ Manual transmission
+ Automatic transmission
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment







System of injection of fuel of the diesel engine. Turbocompressor

System of production of the fulfilled gases - general information

Elements of system of injection of fuel of the diesel engine

1 — the Sensor of position of the camshaft
2 — the Sensitive element of the sensor of temperature of the soaked-up air
3 — the Glow plug
4 — the Sensor of provision of a bent shaft
5 — the Sensor of the index of level of oil, the diesel engine

The function chart of management of injection of fuel from the general toplivoraspredelitelny Common Rail highway (on the example of the engine 611)

A1 — the Control panel
A1e43 — the Control lamp of failures of the system of electronic control by the power (EPC)
B2/5 — the Film MAF sensor
B4/6 — pressure Sensor in the highway
B6/1 — Hall's Sensor of the camshaft
B11/4 — the Sensor of temperature of cooling liquid
B17 — the IAT Sensor
B28 — pressure Sensor
B37 — the Sensor of provision of a pedal
CAN — the Tire of data
L5 — the CKP Sensor
M55 — the Electric motor of a cut-off of inlet port
N2/7 — the SRS Control unit
N3/9 — the Control unit CDI
N10/1 — the Forward SAM block with a box of the relay and safety locks
N14/2 — the Output cascade of candles of preheat
N15/3 — the ETC Control unit (models with AT)
N22 — the Control unit of the press button of automatic air conditioning system (AAS)
N33/2 — the heater fan Control unit
N47 — the traction control system Control unit
N73 — the Control unit of the sensor switch of electronic ignition (EIS)
S40/3 — the coupling pedal Sensor switch (models with RKPP)
Y31/1 — Transdyuser of EGR vacuum
Y31/5 — Transdyuser of vacuum of management of pressure of the pressurization/gate of control of pressure
Y74 — pressure regulator Valve
Y75 — the Electric locking valve
Y76y1-y4 — Nozzles of cylinders 1-4
62 — the Vacuum tank
63 — the Control valve
101 — the EGR Valve
104 — the Vacuum pump
110 — the Turbocompressor
110/2 — a pressurization air Cooler
110/10 — Vacuum assembly of management of pressurization pressure
112/1 — the Filter
120/1 — the Oxidizing catalytic converter (is closer to the engine)
120/2 — the Oxidizing catalytic converter (under a floor)

Arrangement of elements of a control system of Common Rail injection

(on the example of the engine 611)
A1e16 — the Control lamp of preheat
A1e43 — the Control lamp of refusals of EPC
B17 — the Sensor of temperature of the soaked-up air (IAT)
B28 — pressure Sensor
N14/2 — the Output cascade of candles of an incandescence
N10/1 — the Forward SAM control unit with a box of safety locks and the relay
N3/9 — the Control unit CDI
Y31/1 — Transdyuser of EGR vacuum
Y31/5 — the Vacuum transdyuser of the gate of management of pressure/management of pressurization pressure

Arrangement of elements of a control system of Common Rail injection

B37 — the Sensor of provision of a pedal
S40 — the Sensor switch of a tempostat
S40/3 — the coupling pedal Sensor switch

TNVD, the toplivopodkachivayushchy pump, the fuel filter and cooler of fuel (1 of 2)

1 — a shutdown valve Cover, 200CDI/220CDI
2 — a nozzle Cover, 270CDI
3 — the Valve of cutoff of fuel, 8 Nanometers
4 — the Intermediate element
5 — the Holder of an intermediate element, 9 Nanometers
6 — TNVD, 14 Nanometers
7 — the Holder of the pipeline
8 — the Sealing ring
9 — the Toplivopodkachivayushchy pump, 9 Nanometers
10 — the Lead
11 — the Sealing ring

TNVD, the toplivopodkachivayushchy pump, the fuel filter and cooler of fuel (2 of 2)

1 — the Fuel filter
2 — the Holder
3 — the Fuel pipeline, the toplivopodkachivayushchy pump to the shutdown valve
4 — the Holder, the fuel pipeline to the pump of cooling liquid
5 — the Fuel pipeline
6 — the Hose
7 — the Fuel pipeline, the fuel filter to the toplivopodkachivayushchy pump
8 — the Fuel pipeline, TNVD to the valve of adjustment of pressure
9 — the Isolated hose for the drainage pipeline
10 — the Drainage pipeline
11 — the Ring element, the drainage pipeline to the fuel filter
12 — the Hollow bolt, the drainage pipeline to the fuel distributive highway
13 — the Hose, the fuel highway to a fuel cooler
14 — the Cooler of fuel, 14 Nanometers
15 — Laying internal
16 — the fuel Heat exchanger
17 — the Cover
18 — the Fuel filter with the holder
19 — the Hose
20 — Laying lower
21 — the fuel heat exchanger Case
Only engine of 2.7 l
30 — the Fuel pipeline, the fuel filter to the toplivopodkachivayushchy pump
31 — the Fuel filter
32 — the Pipeline
33 — the Sealing ring
34 — the Filtering element

Vacuum lines. Engine 611.692

1 — To the right and left converter of pressure
2 — Working vacuum, atmospheric pressure, the operating vacuum
3 — the Hose to a turbocompressor
4 — — the Vacuum box for adjustment of the directing turbocompressor shovels
5 — the Isolated hose
6 — pressure Converter, the left adjusting valve
7 — the Filter left, right
8 — the Protective ring
9 — the Connecting element
10 — Tightening an element
11 — the Holder of the device of recirculation of the fulfilled gases
12 — the Holder on a longitudinal beam
13 — the Connecting hose
14 — the Tank
15 — pressure Converter, management of pressurization

The fuel system of the diesel engine copes an electronic control system of the engine. It has the following advantages:

· Self-diagnostics of a control system of the engine allows to run for bystry troubleshooting.
· Exact dispensing of amount of injectable fuel provides reduction of content of harmful substances in the fulfilled gases and low fuel consumption.
· Regulation of turns of idling and restriction of turns is made automatically.

During the operation of the diesel engine in its cylinders clean air which contracts to high pressure is soaked up. At the same time air temperature rises to 700 °C, the exceeding temperature of ignition of diesel fuel. Fuel is injected into the cylinder with some advancing and ignites. Thus, spark plugs for ignition of fuel are not used.

Fuel moves the toplivopodkachivayushchy pump under pressure of 3.5 atm. to the fuel pump of high pressure (FPHP). In TNVD already on low turns the constant pressure of compression over 1300 atm is created.

From TNVD there is the general fuel distributive highway (Common Rail) to separate cylinders. The general highway serves as the accumulator of pressure and distributes fuel with constant pressure on nozzles. The amount of injectable fuel is dosed with a necessary accuracy the control unit of the engine by means of electromagnetic nozzles. If the microprocessor of the control unit of the engine closes, for example, electromagnetic valves, the injection of fuel stops. In other words creation of pressure and injection of fuel happen independently from each other. Advantage of it is that the injection can optimum happen depending on requirement and composition of the fulfilled gases, but irrespective of engine speed.

For fuel combustion optimization multiple-jet nozzles open in two steps. At first the preliminary injection of a small amount of fuel is made that creates favorable conditions for conditions of ignition of the main amount of injectable fuel. As a result it leads to soft and silent combustion of fuel mix. When opening a nozzle a small part of fuel gets on internal components of a nozzle, greasing them, and comes back to the fuel tank.

Before intake of fuel in the toplivopodkachivayushchy pump and TNVD it undergoes cleaning in the fuel filter of pollution and water. Therefore is important to make regular replacement of the filter within carrying out maintenance.

The Toplivopodkachivayushchy pump and TNVD do not demand service. All mobile parts of pumps are greased with diesel fuel.

Air in the engine is sucked in or arrives from a turbocompressor and passes through the air filter. The turbocompressor compresses air which then comes to the intercooler where it is cooled after heating as a result of compression in a turbocompressor. Cooling promotes the best filling of cylinders with the forced air that in turn increases torque and engine capacity.

For reduction of a share of harmful substances in the fulfilled gases diesel engines have the diesel oxidizing catalytic converter. At the same time the system of recirculation provides essential decrease in the fulfilled gases the content of oxides of nitrogen. It is reached thanks to supply of the fulfilled gases to the air which is soaked up by the engine that provides decrease in concentration of oxygen in the air coming to engine cylinders. It leads to a delay of ignition and to lower temperature of combustion that as a result reduces formation of NOx. Process of recirculation of the fulfilled gases has to be dosed however precisely, otherwise the maintenance of a soot increases in the fulfilled gases. For this purpose the amount of the sucked-in air is defined by the measuring instrument that allows the electronic device to operate recirculation process.

The injection of fuel is made directly in the combustion chamber.

The engine is operated the electronic system similar to a control system of petrol engines. The system operates operation of the engine, analyzing information arriving from a large number of sensors.

Information on position of the crankshaft and speed of rotation of the engine comes to the control unit from the sensor of position of the crankshaft. The inductive head of the sensor is located opposite to a flywheel and constantly scans the special tags applied on its surface. When passing a tag by a sensor head it sends an impulse to the control unit. Tags are evenly applied on a flywheel surface, but one tag is passed. It has to settle down in 90 ° to VMT of the first cylinder. At the time of passing by a flywheel of this point the sensor does not send an impulse to the control unit. Blok distinguishes this pause and precisely defines VMT moment. Duration of this pause is used for determination of speed of rotation of the engine.

Information on quantity and temperature of the air coming to the engine arrives from the sensor of absolute pressure in the inlet pipeline and air temperature sensors. The sensor of absolute pressure is connected to the pipeline a vacuum hose and measures pressure in it. Two sensors of air temperature are installed. One is established before a turbocompressor, and another — after the intercooler. Temperature and pressure of air are used for calculation of exact amount of fuel which it is necessary to fall to nozzles.

The sensor of temperature of cooling liquid takes temperature and sends the obtained information to the control unit. Analyzing this information, the control unit corrects structure and the moment of injection of fuel mix, and also operates system of warming up of the cold engine.

The switch of stoplights and the sensor of a pedal of a brake informs the control unit on the current provision of a pedal of a brake. When receiving signals from these sensors the control system instantly transfers the engine to idling until receives a signal from the sensor of provision of a pedal of an accelerator.

The cable of an accelerator is absent. Instead of it on the sensor of provision of a pedal of an accelerator is installed. The sensor constantly informs the control unit on the provision of a pedal which, in turn, precisely counts injection parameters. Single turns are also regulated by the control unit and cannot be adjusted manually. Analyzing information arriving from various sensors, the control unit counts the size of turns of idling, correcting them depending on load of the engine and its temperatures.

The system of injection of fuel is system of direct injection. In the bottoms of pistons there are vortex cameras providing a turbulence of the fuel coming to combustion chambers.

Control of warming up of the cold engine is exercised of the control unit of the engine. At the cold engine the moment of injection is displaced by the control unit. The control unit of the engine, in turn, operates work of candles of an incandescence. Glow plugs are installed in each cylinder and join before start of the engine, I work during an engine provorachivaniye with a starter and some time after start of the engine. Candles considerably facilitate start of the cold engine. After inclusion of ignition on the control panel the lamp (address the Head the Operation manual) signaling about inclusion of candles of an incandescence lights up. As soon as the lamp goes out, you can start the engine. If air temperature very low, candles continue to work still some time after start of the engine. It reaches stable operation of the engine and decrease in harmful impurity in the fulfilled gases.

Owing to high starting qualities of the engine with direct injection in a cold state preliminary heat is required only at a temperature below -10 °C.

Fuel passes through the fuel filter. In the filter fuel separates from water and pollution. Therefore it is important to delete water from fuel and to make timely replacement of the filtering element.

Operation in the winter

At decrease in temperature of external air the fluidity of diesel fuel owing to paraffin loss decreases. Diesel fuel on the fluidity becomes similar to honey and can hammer the filter. For this reason the additives increasing the fluidity of fuel and providing a possibility of start of the engine at a temperature of external air to – 22 °C can be entered into diesel fuel in the winter.

To exclude clogging of the fuel filter at a low external temperature, fuel goes to the heat exchanger.