Mercedes S-class W202

1993-2000 of release

Repair and car operation



Mercedes W202
+ 1.2. The general data
+ 2. Maintenance service
- 3. Engines
   3.1.2. Identification number
   + 3.1.3. The engine
   3.1.4. Cars with the conditioner
   3.1.5. The bottom cover of a motor compartment
   3.1.6. Covers of cast apertures
   3.1.7. Натяжитель chains
   + 3.1.8. A cover of a head of the block of cylinders
   + 3.1.9. A head of the block of cylinders
   + 3.1.10. Camshafts
   3.1.11. Hydraulic тарельчатые 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. A compression
   + 3.1.17. A klinovyj belt
   3.1.18. Diagnostics of malfunctions (DB)
   3.1.19. Broad-brush observations
   3.1.20. Repair work without engine dismantle
   + 3.1.21. Engine major repairs
   + 3.2. The diesel engine (ДД)
   3.2.3. Cars with the conditioner
   3.2.4. The bottom cover of a motor compartment
   3.2.5. Covers of cast apertures
   3.2.6. Натяжитель chains
   + 3.2.7. A camshaft
   - 3.2.8. A head of the block of cylinders
      3.2.8.2. The engine in volume of 2,2/2,5 l
   + 3.2.9. Maslootrazhatelnye caps
   3.2.10. A cover of a head of the block of cylinders (2,2/2,5)
   3.2.11. Hydraulic тарельчатые 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. A head of the block of cylinders and the motor block
   3.2.16. A compression
   3.2.17. Клиновой a ridge belt
   3.2.18. The pulling device клинового a ridge belt
   3.2.19. Diagnostics of malfunctions (ДД)
+ 4. Greasing system
+ 5. Cooling system
+ 6. Heating, ventilation
+ 7. Ignition system
+ 8. Fuel system
+ 9. Transmission
+ 10. A running gear
+ 11. A steering
+ 12. Brake system
+ 13. A body
+ 14. An electric equipment
+ 14.2. Electroschemes







3.2.8.2. The engine in volume of 2,2/2,5 l
THE GENERAL DATA

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

And – a bolt with the M fillet 10х115
In – a bolt with the M fillet 10х102
And – a universal bolt of M 8 х 50 (картер chains)
b – bolts of M 8 х 80 (for the fuel filter)


The prevention

Drawing concerns the engine in volume of 2,5 l (22 bolts). For the engine in volume of 2,2 l with 18th 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. Taps of final and soaking up pipes remain connected. Signs of defect of a sealing lining of a head of the block of cylinders same as of 2 l are described for the engine.

Removal


PERFORMANCE ORDER
1. Raise an engine cowl.
2. Disconnect a wire of "weight" of the battery (–).
The 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 hydraulic муфту the fan.
8. Ослабьте also remove клиновой a ridge belt.
9. Disconnect depression hoses (2, 3) from the vacuum pump (5) and details of the distributor (marksman). If necessary preliminary ослабьте also remove back collars of fastening of hoses.
10. Remove a hose of removal of air from system of cooling (1) and a hose of a cooling liquid, preliminary 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 depression tank, заслонки a regulator of pressure and рециркуляционного the valve of the final device.
13. Disconnect wires from temperature switches on a left-hand 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 tyres 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 about threefold length of an asterisk, and a counternut. For this purpose screw a counternut on bolt М6 and insert from above a bolt прокладочную a washer. Spread on a finger an asterisk, screw in bolt М6 in a carving of a finger and twirl a counternut before contact with an asterisk surface. The prokladochnaja washer serves for improvement of contact of surfaces. Extend a finger, keeping a head of a bolt a wrench and simultaneously turning a counternut a wrench concerning an asterisk.
16. As take the bottom fingers of the directing tyre located more low подсоединительного of an element of the cooling liquid.
17. Unscrew картер camshafts (10) and remove it. It is not necessary to take out tarelchatye pushers: they will not drop out, thanks to the bottom ledges.

The prevention

Pay attention on two adjusting sleeves (13). At repeated installation it is necessary to replace a ring of round section (12) new.


18. Remove atomizers 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 маслоизмерительного щупа (11) from a head of the block of cylinders.
21. Unscrew the shock-absorber (13) devices of a tension ridge клинового a 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.

The prevention

For simplification of the subsequent installation designate топливопроводы a sticky tape. 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 накаливания (R9), preliminary having marked wires a sticky tape.
25. Disconnect штеккерные connections from the gauge of temperature of a cooling liquid for the conditioner (В10/8), the indication device (В11/4) and repeated накаливания (В11/8).
26. Unscrew the cable channel (1) from the heat exchanger of fuel (60).
27. Disconnect a thick hose of a cooling liquid behind a head of the block of cylinders, completely having 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 tyre in картере chains in the same way, as well as the top tyre.
30. Unscrew two bolts М8 of a head of the block of cylinders by means of long face key SW.
31. Unscrew bolts of a head of the block of cylinders in sequence, their return numbering, i.e. From 22 to 1 (fig. Bolts of a head of the block of cylinders (the engine 2,5 see). Thus at first ослабьте 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 rests. Track, that they have not got to apertures.
2. The carving apertures cleared of oil and water, blow compressed air. If there is no compressed air a liquid in deaf apertures absorb the rag which has been wrapped up round a small screw-driver.
3. Check up a head of the block of cylinders and the block of cylinders on absence of cracks and planeness by means of a steel ruler.
4. Necessarily replace a sealing lining of a head of the block of cylinders (20).
5. Impose a new sealing lining without hermetic so that it did not close an aperture.
6. Establish a head of the block of cylinders (21).
The 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 (Bolts of a head of the block of cylinders see the table) just in case replace a bolt is exceeded.
8. Grease with engine oil a carving of bolts of a head of the block of cylinders, and also their place прилегания to it, twist bolts and tighten manually (fig. Bolts of a head of the block of cylinders (the engine 2,5 see).
The prevention

Bolts of a head of the block of cylinders are mounted without прокладочных washers. Carefully tighten bolts of a head of the block of cylinders. Preliminary check up accuracy динамометрического a key.


Tighten bolts of a head of the block of cylinders in sequence with 1 on 22 and, accordingly, with 1 on 18, in 4 stages.
The 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 18th.


1 stage: динамометрическим a key with the moment 15 Н.м.
2 stage: динамометрическим a key with the moment 35 Н.м.
3 stage: рожковым a wrench tighten bolts in the same direction on 90 .
The prevention

In this place make a 10-minute pause for deposits of bolts. Then tighten bolts further, without weakening.


4 stage: turn bolts in the same direction on 90 рожковым a wrench.
The prevention

At a tightening of bolts estimate an angle of rotation. Arrange the handle of a wrench along the engine and tighten a bolt one effort while the key handle does not become across the engine (1/4 turns, 90 ).


9. 2 bolts М8 () in front of a head of the block of cylinders establish with spring washers and tighten long face key SW6 with the moment 25 Н.м.
10. Establish the fuel filter with the holder and twirl with the moment 25 Н.м., bolts (b).
11. Establish the bottom directing tyre of a chain of management in картере chains and insert persistent fingers. Thus establish directing tyre so that elements of installation of the top persistent finger () and the bottom finger () were from above.
12. Put on a thick hose of a cooling liquid a back branch pipe of a cooling liquid and fix its collar.
13. Connect electricity cables to candles накаливания and to gauges of temperature of a cooling liquid.
14. Screw the cable channel on system of preliminary warming up of fuel.
15. Connect with the moment 25 Н.м. The shock-absorber of the device of a tension клинового a ridge belt to a head of the block of cylinders.
16. Screw directing pipe маслоизмерительного щупа in the engine and in an automatic transmission on a head of the block of cylinders.
17. Establish atomizers.
18. Establish картер camshafts with тарельчатыми pushers and centre two unloading plugs (13).

The prevention

Rings of round section (12) between a head of the block of cylinders and картером camshafts should be replaced with the new always. Fix two bolts (11) with the moment 15 Н.м.


19. Establish the top directing tyre 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 depression tank заслонки a regulator of pressure and the valve рециркуляции departing gases.
23. Put on a wire the temperature switch on a left-hand side of a head of the block of cylinders on a flange of a cooling liquid.
24. Put on depression hoses (2, 3) the vacuum pump (5) and a detail of the distributor (marksman), fix hoses collars.
25. Put on a hose деаэрации a cooling liquid (1) and a hose of a cooling liquid (4) and fix collars.
26. Establish клиновой a ridge belt.
27. Hang and adjust a cable of management of gas.
28. Establish hydraulic муфту 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.
The prevention

If there was defective a sealing lining 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 up tightness of all подсоединительных elements.
33. Establish the bottom cover of a motor compartment and fasten bolts.
The 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 NEW POSITION
THE MAXIMUM LENGTH
M 10
102,0 mm
104,0 mm
M 10
115,0 mm
117,0 mm