Maintenance of the lubrication system (Mercedes-Benz M-Class W163)

1. The installation details of the oil filter liquid heat exchanger on the 612 series engine are shown in the illustration to which all references in the text refer.

2. Open the hood and fix it in a vertical position.

3. Remove the trim panels (1 and 2).

4. Remove the cover (3) of the oil filter housing, remove the filter element and drain the oil into a prepared container.

5. Remove the lower section of sound insulation.

6. Drain the cooling system (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).

7. Disconnect the cooling tract hose (12) from the EGR heat exchanger (11).

8. Remove the fuel cooler.

9. Remove the bolts securing the EGR heat exchanger (11) to the cylinder head.

10. Separate the EGR heat exchanger from the air distribution pipe (110/1).

11. Remove the pipeline (110/1).

12. Remove the fuel line (21) (see Chapter Removal and installation of fuel distribution line and injectors).

13. Disconnect the cooling system hose (7) from the liquid cooler (8).



14. Disconnect the ATF lines (9) from the heat exchanger (8) - be prepared to collect any leaking fluid.

15. Disconnect the heat exchanger (8) from the timing drive cover.

16. Installation is carried out in reverse order.

17. Check the coolant level and make adjustments if necessary (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).

18. Finally, start the engine and check for signs of developing leaks.

19. Warm up the engine to normal operating temperature, turn it off and after approximately 2 minutes check the engine oil level. If necessary, make the appropriate adjustments (see Chapter Changing engine oil and oil filter).

Removal and installation the oil pan

1. The details of the oil pan installation on the 612 series engine are shown in the illustrations to which all references in the text refer.

2. Open the hood and fix it in a vertical position.

3. Disconnect the negative cable from the battery.

4. Remove the lower section of sound insulation.

5. Drain the engine oil (see Chapter Changing engine oil and oil filter).

6. Drain the cooling system (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).

7. Remove the trim panels (1 and 2).

8. Disconnect the cooling system hose (3) from the connecting element (4).

9. Disconnect the hose (3) from the EGR (5).

10. Disconnect the fuel hose (7) from the fuel preheater (9).

11. Remove the device (9) from the EGR (5), - prepare a new gasket.



12. Remove the expansion tank of the cooling system (11) (see Chapter Cooling, heating and air conditioning systems).

13. Remove the air intake (12).

14. Remove the air hose (13), - prepare a new sealing ring (6).

15. Disconnect the air hose (15) from the mixing chamber.

16. Remove the cooling system fan (17).

17. Disconnect the hose (18) from the radiator (19).

18. Disconnect the electrical wiring from the engine oil level sensor (B40).

19. Loosen the clamp securing the primary catalytic converter (120/1) to the TWC (111).

20. Remove the torsion bar mounting clamps (24).

21. Loosen the nuts (23) of the front powertrain suspension supports.

22. Hang the engine on a winch.

23. Loosen the mounting bolts (26 and 27) and drain the oil from the oil pan (28).

24. Completely unscrew the bolts and remove the pan.

25. Remove the sealing gasket (29).

26. Carefully clean the mating surfaces of the pan and block.

27. Installation is carried out in the reverse order. Remember that all sealing elements must be replaced without fail. Make sure that all fasteners are tightened with the required force.

28. Finally, start the engine and check for signs of developing leaks. Also clear the memory of the on-board diagnostic module (see Chapter Engine electrical systems).

Removal and installation the oil level sensor

1. The installation details of the 612 Series Engine Oil Level Sensor are shown in the illustration to which all references in the text refer.

2. Open the hood and fix it in a vertical position.

3. Remove the lower section of sound insulation.

4. Drain the engine oil (see Chapter Changing engine oil and oil filter).

5. Disconnect the electrical wiring and remove the oil level sensor (B40).

6. Installation is carried out in reverse order.

7. Start the engine and check for signs of developing leaks.

Removal and installation oil sprayers

Note: Servicing oil sprayers involves dismantling the crankshaft and should be performed by car service specialists.

1. The details of the installation of the oil sprayers on the 612 series engine are shown in the illustration to which all references in the text refer.

2. Remove the oil pan (see above).

3. Remove the crankshaft.

4. Remove the oil sprayers (22).

5. Installation is carried out in reverse order.

Removal and installation the oil pump

1. The installation details of the 612 Series engine oil pump are shown in the illustration to which all references in the text refer.

2. Remove the oil pan (1) (see above).

3. Unscrew the bolts securing the oil pump (2) to the engine crankcase.

4. Press the tensioner (4) and remove the chain (3) from the pump drive sprocket. Remove the pump assembly (2).

5. Thoroughly clean the mating surfaces of the pump and engine block.

6. Fill the pump assembly with fresh oil.

7. Installation is carried out in the reverse order - do not forget to clean the mesh filter of the oil intake.

Replacing the oil pump drive chain

1. The installation details of the oil pump drive chain on the 612 series engine are shown in the illustration to which all references in the text refer.

2. Remove the oil pan (see above).

3. Remove the oil pump (see above).

4. Using a special tool, disassemble the pump drive chain and remove it from the engine.

5. Installation is carried out in the reverse order - use a special device to connect the chain.

628 Series Engine

Removal and installation the oil filter housing

1. The oil filter installation details on 628 series engines are shown in the illustration to which all references in the text refer.

2. Remove the lower section of sound insulation.

3. Drain the cooling system (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).

4. Lift the power unit cover.

5. Remove the electric cooling fan.

6. Unscrew the cover (2) of the oil filter housing (11).

7. Remove the coolant hose from the radiator to the thermostat.

8. Disconnect the cooling (4) and ventilation (5) lines from the filter casing (11), release them from the support bracket (arrow).

9. Also disconnect the lines (7, 9 and 8) from the filter.

10. Remove the support bracket (15).

11. Remove the bolts (10).

12. Remove the oil filter housing (11)

13. Installation is carried out in reverse order.

14. Finally, start the engine and check the filter for signs of developing leaks.

15. Check the engine oil level and make adjustments if necessary (see Chapter Changing engine oil and oil filter).

Removal and installation the liquid heat exchanger of the oil filter

1. The installation details of the oil filter liquid heat exchanger on the 628 series engine are shown in the illustration to which all references in the text refer.

2. Open the hood.

3. Lift the power unit cover.

4. Unscrew the cover (1) of the oil filter housing (6) and remove the filter element (2).

5. Remove the left front wheel and wheel arch protection liner.

6. Remove the lower section of sound insulation.

7. Drain the cooling system (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).

8. Disconnect the cooling (3) and ventilation (4) lines from the oil filter housing (6).

9. Remove the liquid heat exchanger (8) from the oil filter housing (6).

10. Carefully clean the mating surfaces, prepare a new sealing gasket (9).

11. Installation is carried out in reverse order.

12. Finally, start the engine and check it for signs of developing leaks.

13. Check the engine oil level and make adjustments if necessary (see Chapter Changing engine oil and oil filter).

Removal and installation the oil pan

Bottom section of the pallet

1. The installation details of the lower section of the oil pan on the 628 series engine are shown in the illustration to which all references in the text refer.

2. Remove the lower section of sound insulation.

3. Disconnect the electrical wiring from the oil level sensor (B40).

4. Drain the engine oil (see Chapter Changing engine oil and oil filter).

5. Remove/lower the front axle assembly (see Chapter Suspension and steering).

6. Unscrew the bolts securing the support bracket of the lower sleeve of the air boost tract on the right wall of the lower section of the oil pan.

7. Unscrew the mounting bolts (2) and remove the lower section of the pan (1), if necessary, prying it off at the point indicated by the arrow.

8. Remove the oil level sensor (B40).

9. Carefully clean the mating surfaces of the lower and upper sections of the tray.

10. Installation is carried out in the reverse order - ensure that the sealant is applied correctly to the mating surface of the lower section of the tray.

Upper section of the pallet

1. The installation details of the upper section of the oil pan on the 628 series engine are shown in the illustration to which all references in the text refer.

2. Remove the lower section of the oil pan (2) (see above).

3. Remove the top section of the tray (1).

4. Clean the mating surfaces thoroughly.

5. Installation is carried out in the reverse order - make sure that the sealant is applied correctly.

Removal and installation the oil pump

1. The installation details of the 628 Series engine oil pump are shown in the illustration to which all references in the text refer.

2. Remove both sections of the oil pan (see above).

3. Remove the screw (7).

4. Unscrew the bolts (6) securing the oil pump (8).

5. Pull the tensioner (4) of the drive chain (3) away from the sprocket (5) of the pump drive (8). If necessary, remove the chain and replace it.

6. Remove the pump assembly (8).

7. Unscrew the bolts (9) and disconnect the cover with the oil line (10) from the pump.

8. Clean the oil intake mesh filter.

9. Clean the mating surfaces thoroughly.

10. Fill the pump assembly with fresh oil.

11. Installation is carried out in reverse order.