Maintenance of throttle actuator components (Mercedes-Benz M-Class W163)

1. The design of the throttle lever drive is shown in the illustrations, if necessary, remove the air cleaner (see Section Removal and installation air intake tract components).

2. Lubricate the drive mechanism hinge joints.

3. Slowly press the gas pedal all the way down, then release it - if you find signs of play or jamming, replace the throttle cable (see below).

Checking and adjusting the throttle actuator

Models 163.136

Illustrative material for checking and adjusting the throttle actuator on models 163.136 (111 series engine) is presented in the illustration, to which all references in the text refer.

Examination

1. Turn off the ignition.

2. Release the cover on the support plate (2) of the throttle actuator.



3. Check the smooth movement of the connecting rod (32/4) of the throttle cable (32), replace obviously faulty components (see below).

Adjustment

With the throttle valve closed

1. Release the connecting rod (32/4) on the throttle actuator lever (32/5) and assess the condition of the idle speed limiter.

2. Turn the lever (32/5) clockwise until it stops against the idle speed limiter.

3. By rotating the spherical socket, freely adjust the position of the connecting rod (32/4) on the throttle actuator lever support (32/5).

4. Place the rod (32/4) into the spherical bearing of the lever (32/5) and secure it with the lock nut.

5. Fully release the gas pedal (24) - the roller (32/8) of the support lever (32/6) should freely rest against the idle speed limiter.

With the throttle fully open

1. Turn left and release the maximum throttle opening limiter (38).

2. Press the gas pedal (24), open the throttle valve so that the drive lever (32/5) rests against the activator stop (arrow).

3. Turn to the right and fix the stop (38) in the adjusted position.

Evaluation of adjustment results

Make sure the throttle valve travels fully.

Disassembling and assembling the throttle actuator

1. Construction of the throttle actuator used on models 163.136 (111 series engine) shown in the illustrations, to which all references found in the text refer.

2. During disassembly, try to remember the installation positions of the removed components in as much detail as possible, paying particular attention to the torsion spring (5) and the lever roller (6). Replace defective parts.

3. When installing the axial screws (8) during assembly, ensure that both levers (4 and 3) have axial play within 0.1÷0.3 mm.

4. After completing the assembly, make sure that the regulator is functioning properly

Models 163.154/157/172/174/175

Illustrative material for checking and adjusting the throttle actuator on models 163.154/157172/174/175 (engines of series 112 and 113) is presented in the illustration, to which all references in the text refer.

Examination

Check the smooth running and condition of the shift lever position sensor (31/1) and drive cable (32). Replace defective components.

Adjustment

1. Press the gas pedal (24) until it stops against the kickdown switch (S16/6), but without activating the latter.

2. Turn the adjusting screw (32/3) until the throttle position sensor (31/1) rests against the maximum throttle opening limiter (b).

3. When the gas pedal is released, the sensor should rest against the idle speed limiter (a) - achieve this requirement by turning the adjusting nut (32/2) - alternatively, you can use the same nut to completely select the free travel of the pedal.

4. Make sure the throttle valve travels fully.

Removal and installation the throttle cable Model 163.136

1. Throttle cable installation details on 163.136 models (111 series engine) are shown in the illustration, to which all references found in the text refer.

2. Remove the throttle actuator cover.

3. Using your hands, move the support lever (32/6) to the position corresponding to the full opening of the throttle valve (arrow) and, holding it, release the drive cable (32) from the guide element (32/6).

4. Disconnect the guide element (32/5) from the support arm (32/6) and remove the latter together with the drive cable (32).

5. Squeeze the plastic retainer (30/4) and release it from the support plate (2) together with the drive cable (32).

6. Disconnect the cable end (arrow) from the gas pedal (24).

7. Push the cable from the passenger compartment into the engine compartment, making sure that the bushing remains in place in the bulkhead.

8. Remove the cable assembly from the engine compartment.

9. Installation is carried out in the reverse order - lubricate the open section of the cable between the guide element (30/5) and the tip with an anti-corrosion compound, ensure that the fastening pin (24/1) is securely seated.

10. Finally, check the correct adjustment of the cable and make the necessary adjustments if necessary.

Models 163.154/157/172/174/175

1. Details of installation of gas cable on models 163.154/157172/174/175 (engines of series 112 and 113) are shown in the illustration, to which all references found in the text refer.

2. Disconnect the drive cable (32) from the ball head.

3. Squeeze the plastic retainer (30/4) and disconnect it from the fixed lever (10) assembled with the drive cable (32).

4. Remove the cover installed on the left under the instrument panel.

5. Disconnect the cable end (arrow) from the gas pedal (24).

6. Push the cable from the passenger compartment into the engine compartment, making sure that the bushing remains in place in the bulkhead.

7. Remove the cable assembly from the engine compartment.

8. Installation is carried out in the reverse order - make sure that the mounting pin (24/1) is securely seated.

9. Finally, check the correct adjustment of the cable and make the necessary adjustments if necessary.

Removal and installation the idle speed control (ISC) actuator - model 163.136

1. ISC activator installation details on 163.136 models (111 series engine) are shown in the illustration, to which all references found in the text refer.



2. Remove the air cleaner bypass hose (see Section Removal and installation air intake tract components).

3. Remove the crankcase ventilation hose.

4. Remove the mounting screw and remove the ISC activator.

5. Installation is carried out in the reverse order - do not forget to replace the sealing ring (35/3), make sure the ventilation hose is connected correctly.

Removal and installation of the electronic accelerator actuator, - models 163.154/157/172/174

1. Installation details of the electronic accelerator actuator on models 163.154/157/172/174 (engines of series 112 and 113) are shown in the illustration, to which all references found in the text refer.

2. Remove the cylinder head cover trim panel/air cleaner.

3. Remove the air duct with the built-in MAF sensor (see Section Removal and installation air intake tract components).

4. Disconnect the vent line (1/2) from the intake manifold (19).

5. Disconnect the electrical wiring connector (arrow)

6. Unscrew the bolts (8/1) and remove the actuator (M16/6).

7. Installation is carried out in the reverse order - do not forget to replace the sealing ring (8/2), ensure that the contact connector is securely fixed (arrow).

Removal and installation the gas pedal

1. The details of the gas pedal installation are shown in the illustration, to which all references in the text refer.

2. When assembling, ensure that the pin (24/1) is securely seated.