Map of all articles and sections of the site

A-Class W168 (1997-2004)
General information
User manual
Control Panel
Instrument cluster and information display
Checking the engine oil level using a dipstick
Indication of maintenance period
Heater control
Air Conditioning Control
Removal ice
Removal internal fogging of glass
Removal external fogging of glass
Rear window defroster
Adjusting the position of the steering wheel
Heated seats
Airbags
Interior Light Switches
Interior rear view mirror
Cup holders on console and armrest
Using the socket
Window lift control
Headlight leveling regulator
Light switch
Steering column switches
Rear Window Wiper Switch
Locking the car locks
Opening and locking the rear hatch
Emergency opening of the fuel filler flap
Security alarm switch with indicator light on the center console
External rear view mirror switches
Folding mirrors
Cars with a spare tire
Cars equipped with TIREFIT tire sealant
Tire sealant TIREFIT
Hood release handle
Windscreen washer
Location of fuses
Purpose of fuses and relays
Ignition switch
Manual transmission
Automatic transmission
Tempomat (cruise control)
Cruise control with Speedtronic speed limiter
Technical data of cars
Maintenance
Vehicle care
Starting the engine using an auxiliary battery
Towing a car
Jacking up a car
Maintenance — list of works
Maintenance — works
Engine bay — visual inspection
Engine Oil and Oil Filter — Replacement
Coolant — Checking the Level
Coolant — Checking Concentration
V-belt — checking condition
Exhaust system — visual inspection
Spark plugs — removal and installation
Fuel filter — removal and installation
Air filter — replacing the filter element
Gearbox. Main gear
Gearbox — visual inspection for leaks
Suspension and steering
Steering Cuffs — Check
Ball joint caps — check
Power Steering — Checking Fluid Level
Rear Suspension Trailing Arm Support Play — Check
Brakes, tires, wheels
Brake fluid — checking the level
Brake pads — checking residual thickness
Drum brake shoes — checking the remaining thickness
Parking brake — checking operation, running-in and adjustment
Brake fluid — replacement
Wheels and tires
Body — interior equipment
Seat belts — visual inspection
Dust/Combination Filter — Replacement
Towing hitch — checking, cleaning, lubrication
Electrical equipment — maintenance
Windscreen wipers — checking the rubber bands of the brushes
Battery — Checking the Electrolyte Level
Service notification and control device
Troubleshooting
Identifying and troubleshooting engine faults
Identifying and troubleshooting engine cooling system faults
Possible malfunctions of the heating system, their causes and methods of elimination
Identifying and troubleshooting gasoline injection system faults
Identifying and troubleshooting diesel engine fuel system faults
Identifying and troubleshooting brake system faults
Identifying and troubleshooting battery problems
Identifying and troubleshooting generator faults
List of starter faults and their elimination
Identifying and troubleshooting windshield wiper problems
Power unit
Engine repair
Engine specifications
General information about engines
Vehicle and engine identification
Engine — removal and installation
Cylinder head — removal and installation
Cylinder Head Cover — Removal and Installation
V-belt — removal and installation
Engine — Start
Engine lubrication system
Oil — circulation
Oil pressure — check
Oil level sensor — removal and installation
Oil pan — removal and installation
Cooling and heating
Coolant circulation
Coolant
Coolant — Replacement
Thermostat — removal and installation
Thermostat — check
Checking the tightness of the cooling system
Water pump — removal and installation
Radiator Blower Fan — Removal and Installation
Radiator — removal and installation
Heater and air conditioner
Interior air deflectors — removal and installation
Heater and Air Conditioner Switches — Removal and Installation
Light bulb on air conditioner temperature switch
Heater Fan Motor — Removal and Installation
Additional resistance of the cabin air blower
Injection system (gasoline)
General description and precautions
The principle of operation of the fuel injection system
Fuel injectors — checking
Fuel distribution line — removal and installation
Engine control unit emergency program function
Fuel system (diesel)
How a diesel engine works
Glow Plugs — Checking
Glow Plugs — Removal and Installation
Fuel injectors — removal and installation
Fuel system
General description of the fuel system
Fuel System — Pressure Relief
Fuel pump and fuel gauge sensor
Fuel injection pump — removal and installation
Fuel Shut-Off Solenoid Valve — Removal and Installation
Air filter — removal and installation
Accelerator pedal stop — adjustment
Intake manifold — removal and installation
Intake Manifold Module — Removal and Installation
Crankshaft Position Sensor — Removal and Installation
Camshaft Position Sensor — Removal and Installation
Exhaust system
General information about the exhaust system
Operating principle of the catalyst
Exhaust gas turbocharger
Intake pipe with catalytic converter — removal and installation
Intake pipe with main muffler — removal and installation
Lambda probe — removal and installation
Front catalytic converter — removal and installation
Rear catalytic converter and main muffler — removal and installation
Turbocharger — removal and installation
Ignition system
General description of the ignition system
Spark plugs — removal
Spark plugs — checking
Spark plugs — installation
Transmission
Clutch
General description of the clutch
Clutch — removal
Clutch — check
Clutch — installation
Clutch drive — bleeding air and replacing fluid in the hydraulic drive
Automatic clutch
Transmission
Manual Transmission Specifications
Manual gearbox — removal and installation
Gear shift mechanism — removal and installation
Clutch — removal and installation
Differential, primary and secondary shafts — removal and installation
Automatic transmission — removal and installation
Gear Selector Cable — Removal and Installation
Gearbox parking lock mechanism
Gear Selector Cable — Adjustment
Chassis
Brake system
Brake system specifications
General description of the braking system
Disc brake pads — removal, inspection and installation
Support — removal and installation
Front Brake Disc — Removal and Installation
Rear Brake Disc — Removal and Installation
Brake disc — check
Parking brake pads — removal and installation
Parking brake — adjustment
Front Parking Brake Cable — Removal and Installation
Rear Parking Brake Cable — Removal and Installation
Brake shoes of drum brake mechanism — removal and installation
Brake fluid — safety precautions
Brake system — bleeding
Brake hoses — removal and installation
Brake booster vacuum — check
Brake Light Switch — Removal and Installation
Parking Brake Indicator Light Switch Sensor
Suspension
General information about the suspension
Front suspension — device
Shock absorber strut — removal and installation
Shock absorber strut — disassembly
Shock absorber — check
Front axle beam — removal and installation
Drive shafts — removal and installation
CV joint seals — removal and installation
Rear suspension — device
Rear shock absorber — removal and installation
Rear suspension shock absorber spring — removal and installation
Lower trailing arm — removal and installation
Flange on the tailpiece of the cross beam — removal and installation
Steering
Steering — device
Airbags — Safety Precautions
Steering Wheel Airbag Unit — Removal and Installation
Steering wheel — removal and installation
Contact spiral — removal and installation
Tie Rod End — Removal and Installation
Steering gear cuff — removal and installation
Body
Interior (all models)
Interior trim
Interior rear view mirror — removal and installation
Front seat — removal and installation
Armrest above the center console — removal and installation
Additional brake light cover — removal and installation
Rear Ceiling Crossmember Trim — Removal and Installation
Central lock
Central lock microswitch — removal and installation
Central lock actuator — replacement
Central lock pump — replacement
Interior (since 1997)
Driver's side wind deflector trim — removal and installation
Passenger Side Deflector Trim — Removal and Installation
Glove box — removal and installation
Glove box lid — removal and installation
Glove box lid — fit
Driver's Side Dashboard Lower Cover — Removal and Installation
Lower Instrument Panel Cover Passenger Side — Removal and Installation
Center console cover — removal and installation
Front Center Console — Removal and Installation
Rear of the center console — removal and installation
Gear Shift Boot — Removal and Installation
Ashtray on the center console — removal and installation
Front pillar trim — removal and installation
Interior (since 2001)
Glove box — removal and installation
Glove box lid — removal and installation
Driver's Side Lower Instrument Panel Trim — Removal and Installation
Center console cover — removal and installation
Front Center Console — Removal and Installation
Ashtray on the center console — removal and installation
Rear of the center console — removal and installation
Front pillar trim — removal and installation
Instrument panel — removal and installation
Exterior
Body — General Description and Precautions
Mudguard (protection) of the bottom — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Protective bumper pads — removal and installation
Front wheel fender liner — removal and installation
Rear wheel arch liners — removal and installation
Front wing — removal and installation
Hood — removal and installation
Hood — fit
Hood Lock Drive Rod — Removal and Installation
Hood lock — removal and installation
Moldings — removal and installation
Outside rear view mirror — removal and installation
Outside rear view mirror glass — removal and installation
Exterior Mirror Cone Trim — Removal and Installation
Outside Mirror Motor — Removal and Installation
Dimensions of A-class cars
Doors and windows
Front door — removal and installation
Door trim — removal and installation
Rear side door — window lift handle removal and installation
Front door window lifter — removal and installation
Window lifter motor — removal and installation
Door glass — removal and installation
External door handle — removal and installation
Door lock — removal and installation
Rear Tailgate — Removal and Installation
Rear Tailgate — Fitting
Rear Door Trim — Removal and Installation
Rear Door Lock and Switch — Removal and Installation
Gas-filled strut — removal and installation
Electrical equipment
Equipment and devices
General description and precautions
Additional electrical equipment — installation
Troubleshooting electrical equipment
Switches — Checking for Current Flow
Checking the relay
Ignition Key and Remote Control — Replacing Batteries
Disconnecting plug connections
Rear Window Defogger — Check
Sound signal — removal and installation
Fuses — replacement
Fuse box locations
Relay — removal and installation
Instrument cluster — removal and installation
Steering column switches — removal and installation
Cigarette lighter — removal and installation
Air Conditioner and Heater Switches — Removal and Installation
Lower Switch Block on the Center Console — Removal and Installation
Switches on the rear of the center console — removal and installation
Hazard warning light switch — removal and installation
Outside Air Temperature Sensor — Removal and Installation
Radio receiver — removal and installation
Speakers — Removal and Installation
Roof Radio Antenna — Removal and Installation
Power devices
Battery — Removal and Installation
Battery — Check
Battery — charging
Checking the generator voltage
Generator — removal and installation
Starter — removal and installation
Traction relay — removal, installation and testing
Windshield wipers and washers
Windscreen wiper — removal and installation
Windscreen washer jets — removal and installation
Rear Window Washer Nozzle — Removal and Installation
Windshield Wiper Arm — Removal and Installation
Windscreen wiper — removal and installation
Windshield Wiper Motor — Removal and Installation
Rear Window Wiper Blade Holder — Removal and Installation
Rear Window Wiper Motor — Removal and Installation
Washer Pump Motor — Removal and Installation
Windscreen wiper arm angle — checking and adjusting
Headlights and lighting
Lighting fixtures — general provisions
Headlight bulbs — replacement
Side turn signal repeater bulbs — replacement
Rear Headlights — Bulb Replacement
Additional brake light — replacement of lamps
License Plate Light Bulbs — Replacement
Interior Lighting — Replacing Bulbs
Headlights — removal and installation
Headlight Diffuser — Removal and Installation
Rear lights — removal and installation
Electrical circuits
Scheme 1. Engine control unit
Scheme 2. Engine control unit
Scheme 3. Fuel system of diesel engine before 31.08.2000
Scheme 4. Fuel system of a diesel engine
Scheme 5. Starter, generator
Scheme 6. Data bus for switching cabin control devices
Scheme 7. Automatic transmission
Scheme 8. Fuses and relays
Scheme 9. Diagnostic connector
Scheme 10. Window lifters
Scheme 11. Central lock
Scheme 12. Outdoor lighting
Scheme 13. Interior lighting
Scheme 14. Special signals
Scheme 15. Windscreen wiper
Scheme 16. Heater
Scheme 17. Air conditioner
Scheme 18. Airbags
Scheme 19. Instrument panel

C-Class 190 (W201) (1982-1993)
General information
Introduction to the guide
Dimensions and weights
Purchase of spare parts
Vehicle identification
Repair — general provisions
Tools and accessories
Checking the technical condition of the car
Technical condition checks performed from the driver's seat
Technical condition checks performed on a vehicle standing on the ground
Technical condition checks performed on a raised vehicle with freely rotating wheels
Checking the exhaust system of a car
Lifting the car with a jack and placing it on supports
Car Radio Theft Prevention System
Dictionary of technical terms
Operation and care
Mercedes 190: Introduction
Your Mercedes 190 Owner's Manual
Main dangers
Specific hazards
If the engine does not start
Starting the engine from an external battery
Wheel replacement
What do the smudges mean?
Towing a car
Weekly Checks: Introduction
Check points under the hood
Engine oil level
Brake fluid level
Power Steering Fluid Level
Coolant level
Windscreen wiper blades
Windscreen washer fluid level
Tire condition and pressure
Types of tire wear
Battery checks
Lamps and fuses
Operating materials
Choosing Oil for Your Car
Tire pressure
Maintenance (gasoline)
Technical data of service
Maintenance intervals
Location of vehicle maintenance points
Maintenance Procedures — Introduction
Regular maintenance
Engine oil and filter change
Replacing spark plugs
Lubrication of the throttle linkage
Checking the fluid level in the automatic transmission
Underhood/Underneath Vehicle Parts and Hoses — Check for Leaks
Accessory Drive Belts — Checking, Replacing and Adjusting
Checking the air conditioning system
Checking the carburetor damper oil level — Stromberg type carburetor
Setting the idle speed and mixture quality — checking and adjusting
Steering and Suspension Parts — Condition and Reliability Check
Drive shafts and drive shaft covers — checking the condition
Checking the front brake pads
Checking the rear brake pads
Parking brake — checking operation
Exhaust system and fastenings — condition and reliability check
Checking the oil level in a manual transmission
Final Drive Oil — Check Level and Replacement
Rubber coupling of the cardan shaft — checking the condition
Checking seat belts
Lubricate all hinges, locks and electrical antenna
Headlight adjustment
Windshield and Headlight Washer System — Checking Condition
Testing in motion
Front Hub Bearings — Checking
Clutch — Checking Action
Valve timing clearance (pre-1984 models) — checking and adjusting
Ignition system — checking the condition and adjusting the ignition timing
Air Cleaner Filter Element — Replacement
Replacing the fuel filter
Automatic Transmission Fluid and Filter — Replacement
Clutch Driven Disc — Checking Wear
Replacing the carbon absorption filter — models with a gasoline vapor absorption system
Replacing brake fluid
Replacing the coolant
Maintenance (diesel)
Technical data of service
Types and intervals of service
Location of vehicle maintenance points
Diesel Models: Introduction
Regular maintenance
Engine oil and filter change
Lubrication of the throttle linkage
Checking the fluid level in the automatic transmission
Underhood/Underneath Vehicle Parts and Hoses — Check for Leaks
Accessory Drive Belts — Checking, Replacing and Adjusting
Checking the air conditioning system
Idle speed — checking and adjustment
Steering and Suspension Parts — Condition and Reliability Check
Drive shafts and drive shaft covers — checking the condition
Checking the front brake columns
Checking the rear brake pads
Parking brake — checking operation
Exhaust system and fastenings — condition and reliability check
Checking the oil level in a manual transmission
Final Drive Oil — Check Level and Replacement
Flexible coupling of the cardan shaft — checking the condition
Checking seat belts
Lubricate all hinges, locks and electrical antenna
Headlight adjustment
Windshield and Headlight Washer System — Checking Condition
Testing in motion
Front Hub Bearings — Checking
Clutch — Checking Action
Air Cleaner Filter Element — Replacement
Fuel Filter and Pre-Filter — Replacement
Automatic Transmission Fluid and Filter — Replacement
Clutch Driven Disc — Checking Wear
Replacing brake fluid
Replacing the coolant
Troubleshooting
Troubleshooting: Introduction
Engine malfunctions
Cooling system malfunctions
Clutch faults
Manual Transmission Malfunctions
Automatic transmission faults
Differential and propeller shaft faults
Brake system malfunctions
Suspension and steering system faults
Electrical system faults
Power unit
Petrol engine I4
Technical data
Basic information
Compression — checking and analyzing the results
Engine and Timing Marks — Basic Information and Use
Camshaft Cover — Removal and Installation
Crankshaft Pulley/Vibration Damper and Hub — Removal and Installation
Timing Chain Cover — Removal and Installation
Camshaft Drive Chain — Checking and Replacing
Timing chain tensioner, sprockets and guides
Auxiliary shaft — removal, inspection and installation
Timing sprocket, valve lifters and camshaft
Cylinder head — removal, inspection and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Flywheel/Drive Plate — Removal, Inspection and Installation
Crankshaft Oil Seals — Replacement
Crankshaft Centering Bearing — Replacement
Powertrain Mounts — Checking and Replacing
Petrol engine V6
Technical data
Basic information
Compression — checking and analyzing the results
Engine and Timing Marks — Basic Information and Use
Camshaft Cover — Removal and Installation
Crankshaft Pulley/Vibration Damper and Hub — Removal and Installation
Timing Chain Covers — Removal and Installation
Camshaft Drive Chain — Checking and Replacing
Timing chain tensioner, sprockets and guides
Camshaft, Tappet and Sprocket — Basics, Checking and Installation
Cylinder head — removal, inspection and installation
Pallet — removal and installation
Oil pump and drive chain — removal, inspection and installation
Flywheel/Drive Plate — Removal, Inspection and Installation
Oil seals — replacement
Crankshaft Centering Bearing — Replacement
Powertrain Mounts — Checking and Replacing
Diesel engines
Technical data
General information
Compression and Leak Testing — Description and Analysis of Results
Timing marks — basic information and application
Camshaft Cover — Removal and Installation
Crankshaft Pulley/Damper and Hub — Removal and Installation
Timing Chain Cover — Removal and Installation
Camshaft Drive Chain — Checking and Replacing
Tensioner, sprockets and guides for the camshaft drive chain
Camshaft and valve lifters — removal, inspection and installation
Cylinder head — removal, inspection and installation
Oil pan — removal and installation
Oil pump and drive chain — removal, inspection and installation
Flywheel/faceplate — removal, inspection and installation
Crankshaft seals — replacement
Crankshaft centering bearing
Powertrain mounts
Oil radiator — removal and installation
Engine overhaul
Basic information on engine repair
Engine repair — basic provisions
Removal the power unit — methods and precautions
Four cylinder petrol engines — removal and installation
Six-cylinder petrol engines — removal and installation
Diesel engines — removal and installation
Engine Repair — Disassembly Sequence
Technical data
Cylinder head — disassembly
Cylinder head and valves — cleaning and checking
Cylinder head — assembly
Pistons and connecting rods — removal
Crankshaft — Removal
Cylinder Block/Crankcase — Cleaning and Inspection
Pistons and connecting rods — condition check
Crankshaft — Checking the condition
Main, connecting rod bearings and bearing cap mounting bolts — inspection and defect detection
Engine Repair — Assembly Procedure
Piston rings — installation
Crankshaft — installation and checking of clearance in main bearings
Pistons and connecting rods — installation and checking clearance in the lower head bearings of the connecting rods
Cooling and heating
Technical data
Basic information and precautions
Coolant Hoses — Disconnecting and Replacing
Radiator — removal, inspection and installation
Thermostat — Removal, Checking and Installation
Radiator Fan — Removal and Installation
Electrical Cooling System Switches — Removal and Installation
Water pump — removal and installation
Heater/Ventilation Parts — Removal and Installation
Air Conditioning System — Basics and Precautions
Power system (carburetor)
Technical data
Basic information and precautions
Air cleaner and filter element — removal and installation
Air Cleaner Temperature Control System — Checking and Replacing Parts
Fuel pump — removal and installation
Fuel level indicator sensor — removal and installation
Gas tank — removal and installation
Throttle Cable — Removal, Installation and Adjustment
Stromberg 175 CDT Carburetor — Basic Information and Parts Replacement
Pierburg 2E-E carburetor fuel system — basic information and replacement of parts
Carburetor — removal and installation
Intake manifold — removal and installation
Intake Manifold Heater — Removal and Installation
Injection system (gasoline)
Technical data
Basic information and precautions
Fuel injection system — leak
Air cleaner and filter element — removal and installation
Fuel pump(s) — removal and installation
Fuel level indicator sensor — removal and installation
Gas tank — removal and installation
Throttle Cable — Removal, Installation and Adjustment
Fuel accumulator — removal and installation
Throttle body — removal and installation
Bosch KE-Jetronic Fuel Injection System Parts — Removal and Installation
Intake manifold — removal and installation
Injection system (diesel)
Technical data
General information and precautions
Air cleaner — removal and installation
Low pressure fuel pump — removal and installation
Fuel Level Gauge Sensor Unit — Removal and Installation
Fuel tank — removal and installation
Throttle Control Cable — Removal, Installation and Adjustment
High pressure fuel pump — removal and installation
Injection timing control device and high pressure fuel pump sprocket
Fuel injection timing of the high pressure fuel pump — checking and adjustment
Injectors and high pressure fuel lines — removal and installation
Fuel thermostat — removal and installation
Electronic Idle Speed Control (ELR) — Parts Removal and Installation
Electronic Anti-Rapidity Control (ARA) — Component Removal and Installation
Electronic Diesel System (EDS) — Removal and Installation
Engine Overload Protection System — Removal of Components and Installation
Intake manifold — removal and installation
Exhaust system
Technical data
Exhaust system: basic information
Fuel vapor recovery system
Crankcase ventilation system — basic provisions
Exhaust manifold — removal and installation
Exhaust Gas Recirculation (EGR) System
Turbocharger — removal and installation
Exhaust system — basics and replacement of parts
Catalytic Converter — Basic Information and Precautions
Additional Air Supply System — Parts Removal and Installation
Charge and start system
Technical data
General information and warnings
Battery — control and charging
Battery — Removal and Installation
Generator/Charging System — On-Vehicle Testing
Generator — removal and installation
Generator — Voltage Regulator Brush Holder Replacement
Engine Starting System — Check
Starter — removal and installation
Starter — repair
Ignition system (I4)
Technical data
Basic information about the ignition system
Checking the ignition system
High Voltage Ignition Coil — Removal and Installation
Distributor — removal and installation
Runner — removal and installation
Ignition timing — checking and adjustment
Ignition Control System Parts — Removal and Installation
Ignition system (V6)
Technical data
General Provisions
Checking the ignition system
High Voltage Coil — Removal and Installation
Distributor and runner — removal and installation
Ignition timing — checking and adjustment
Ignition Control System Parts — Removal and Installation
Diesel heating system
Technical data
General Provisions
Glow Plug Control Unit — Removal and Installation
Spark Plugs — Checking, Removing and Installing
Coolant Temperature Sensor — Removal and Installation
Transmission
Clutch
Technical data
General Provisions
Clutch — removal, inspection and installation
Release bearing and lever — removal, inspection and installation
Clutch slave cylinder — removal, disassembly and installation
Main hydraulic cylinder — removal, disassembly and installation
Bleeding the hydraulic system
Clutch pedal — removal and installation
Mechanical gearbox
Technical data
General information
Manual Transmission Oil — Draining and Filling
Gearshift Mechanism Parts — Removal, Installation and Adjustment
Oil seals — replacement
Reverse Light Switches — Checking, Removing and Installing
Manual gearbox — removal and installation
Gearbox Repair — Basics
Automatic gearbox
Pressure control cable — adjustment
Technical data
Basic information about automatic transmission
Gear Selector Lever — Removal and Installation
Shift Lever Rod — Adjustment, Removal and Installation
Starter Lock/Reverse Light Switch — Removal, Installation and Adjustment
Automatic transmission — removal and installation
Cardan shaft and axle shafts
Technical data
Basic information
Main gear — draining and filling with oil
Main gear — removal and installation
Main gear oil seals — replacement
Half shafts — removal and installation
Protective half shaft covers — replacement
Cardan transmission — removal and installation
Rubber couplings of the cardan transmission — inspection and replacement
Cardan shaft support bearing — inspection and replacement
Universal joint of the cardan transmission — inspection and replacement
Chassis
Brake system
Technical data
Basic provisions about the braking system
Bleeding air from the hydraulic system
Hydraulic system tubes and hoses — replacement
Front brake pads — replacement
Rear brake pads — replacement
Front brake disc — inspection, removal and installation
Rear brake disc — inspection, removal and installation
Front Brake Caliper — Removal, Repair and Installation
Rear Brake Caliper — Removal, Repair and Installation
Master Cylinder — Removal, Repair and Installation
Vacuum brake booster — checking, removal and installation
Brake booster vacuum valve — removal, inspection and installation
Parking brake — adjustment
Parking brake shoes — removal and installation
Parking brake cable — removal and installation
Brake Light Switch — Removal and Installation
Anti-lock braking system (ABS) — basic provisions
ABS System Parts — Removal and Installation
Brake Vacuum Pump (Diesel Models) — Checking, Removing and Installing
Car suspension
Technical data
Basic information
Front Hub Bearing — Checking and Adjusting
Front hub — removal, disassembly and installation
Front steering knuckle — removal and installation
Front suspension shock absorbers — removal, disassembly and installation
Front suspension spring — removal and installation
Lower control arm of the front suspension — removal, disassembly and installation
Front suspension anti-roll bar — removal and installation
Rear Hub Holder — Removal and Installation
Rear Hub Bearing — Replacement
Rear shock absorber — removal, inspection and installation
Rear suspension spring — removal and installation
Rear suspension rods — removal and installation
Lower arm of the rear suspension — removal, disassembly and installation
Rear suspension anti-roll bar — removal and installation
Rear anti-roll bar connecting link — removal and installation
Steering
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Ignition Switch/Steering Lock — Removal and Installation
Steering column rubber coupling — removal and installation
Steering gear — removal, repair and installation
Steering knuckle — removal and installation
Lower Steering Gear Seal — Replacement
Power Steering Pump — Removal and Installation
Power Steering — Air Bleed
Steering shock absorber — removal and installation
Longitudinal steering rod — removal and installation
Intermediate steering arm — removal and installation
Steering Tie Rod Ball Joint — Removal and Installation
Steering rod — removal and installation
Wheel and steering angles — basics
Body
Exterior (external elements)
General information
Body and subframe maintenance
Minor body damage — restoration
Restoration of serious body damage
Hood — removal and installation
Adjusting the hood
Hood hinge — removal and installation
Bonnet Strut — Removal and Installation
Hood release cable — removal and installation
Hood lock — removal and installation
Radiator grille — removal and installation
Emblem on the hood — removal and installation
Front and rear bumpers — removal and installation
Bumpers — disassembly and assembly
Interior (internal elements)
Carpet and Upholstery Care
Front seats — removal and installation
Rear seat — removal and installation
Seat belts — removal and installation
Central control panel — removal and installation
Glove Box — Removal and Installation
Instrument panel — removal and installation
Doors, locks and windows
Trunk lid — removal and installation
Trunk lid lock — removal and installation
Interior door trim — removal and installation
Front door window lifter — removal and installation
Front door glass — removal and installation
Rear door window lifter — removal and installation
Rear Door Glass — Removal and Installation
Fixed rear door glass — removal and installation
Front Door Lock Outer Handle — Removal and Installation
Front door lock — removal and installation
Rear Door Outside Handle — Removal and Installation
Rear Door Lock — Removal and Installation
Door lock electromagnets (central locking system) — removal and installation
Front and rear doors — removal and installation
Windshield and rear glass — removal and installation
Door Mirror Glass (Manual) — Replacement
Door mirror assembly (with manual adjustment) — removal and installation
Door Mirror Assembly (Electric) — Replacement
Door mirror assembly (electric) — removal and installation
Roof hatch — general information
Vacuum pump for central locking system — removal and installation
Electrical equipment
Equipment and devices
Technical data
Basic information and precautions
Electrical Circuit Troubleshooting — Basics
Fuses and Relays — Basics
Central mounting: block — removal and installation
Steering Column Switch Block — Removal and Installation
Instrument panel and central console switches — removal and installation
Interior Light Switches — Removal and Installation
Instrument cluster — removal and installation
Instrument cluster parts — removal and installation
Speedometer Cable — Removal and Installation
Lamps (outdoor lighting fixtures) — replacement
Interior Lighting Bulbs — Replacement
Outdoor lighting fixtures — removal and installation
Headlight glass — removal and installation
Headlight adjustment
Headlight beam height adjustment system — description
Windscreen wiper blades and arms — removal and installation
Windscreen wiper motor and linkage — removal and installation
Windscreen wiper motor — removal and installation
Windshield Washer System — Removal, Installation and Adjustment
Sound signals — removal and installation
Audio equipment — removal and installation
Front and rear speakers — removal and installation
Radio antenna — removal and installation
Constant Speed Drive System Parts — Removal and Installation
Security alarm system — general provisions
Airbags — Basic Information and Precautions
Security System Parts — Removal and Installation
Electrical circuits
Symbol Designations on Schematics, Grounding Points and Fuses
Engine start and battery charging circuit
Radiator motor, magnetic clutch and downshift switch
Typical engine management system
Indicator lights and instruments (typical diagram)
Exterior lighting devices — side lights, rear lights, fog lights and headlights
Exterior lighting (continued) — turn signals, hazard lights, brake lights and tail lights
Standard interior lighting and windshield wiper
Headlight/windscreen washer and cleaner, rear window defroster, heater fan
Horn, cigarette lighter, sunroof and windows

C-Class W202 (1993-2000)
General information
User manual
Driver's seat and instrument panel
Periodic care and maintenance
Car keys
Opening and closing doors
Seats — adjustment
Seat belts
Airbag
Safety instructions
Ignition switch
Light rotary switch
Adjusting the light range
Combination switch
Rear view mirrors
Sun visors
Automatic lighter
Interior lighting of the salon
Sliding sunroof
Rear window heating
Electric window lifters
Engine hood — opening and closing
Ventilation unit, air conditioner
Some tips when buying a car
Re-punched numbers
Buying an old car
Durability of the car
About parallelism of vehicle and trailer axles
Preparing your car for winter
Driving a car
Parking brake
Starting off and changing gears
Installing the gear selector lever
Driving mode selection switch
Vehicle motion control
Cruise control
Oil and fuel consumption
Starting the engine from an auxiliary battery
Towing a car
Jacking and lifting the car
Car care
Car body wash
Care of painted surfaces
Care of plastic parts
Care of glass and rubber seals
Caring for alloy wheels
Seat belts
Anti-corrosion protection of the underbody
Preservation of the engine compartment
Caring for upholstery of chairs
Maintenance
Maintenance intervals
After 12 months or 15,000 km
Additionally, every 60,000 km
Every 2 years
Every 3-4 years
Maintenance work
Engine and exhaust system
Engine oil change
Checking the condition of the V-belt
Replacing spark plugs
Checking electrical connections
Lubrication of the throttle control system
Checking the coolant level
Air Conditioner: Checking the Refrigerant Level
Replacing the fuel filter / coarse filter
Replacing the air filter element
Checking the exhaust system
Gearbox / final drive
Visual inspection of tightness
Checking the oil level in the differential
Checking the driveshaft joint discs
Checking the rubber seals of the axle shafts
Front axle / steering
Checking the front axle joints
Checking the steering wheel free play
Tightening the mounting bolts on the steering gear
Checking the oil level in the steering gear
Brakes / tires
Checking the thickness of the brake pad friction linings
Checking the brake fluid level
Checking the brake fluid level indicator light
Visual inspection of brake lines
Replacing brake fluid
Checking the tread pattern of a tire (tire)
Checking the valve of an air tube or tire
Checking the pressure in inflated tires
Body / interior lighting
Replacing the dust filter nozzle
Lubrication of the bonnet
Checking seat belts
Lubricating the sunroof
Tools used for maintenance
Power unit
Gasoline engines
Technical characteristics of gasoline engines
Engine Identification Number
Removal the engine
Engine installation
Engine ventilation
Engine removal (cars with air conditioning)
Lower Engine Compartment Cover — Removal and Installation
Casting Port Covers (6 Cylinder Engine)
Chain tensioner — removal and installation
Cylinder Head Cover (4-cylinder engine)
Cylinder head cover (6-cylinder engine)
Cylinder head (4-cylinder engine)
Cylinder head (2.2L engine)
Cylinder head (6-cylinder engine)
Camshafts (4-cylinder engine)
Camshafts — Main Position Adjustment (4 Cylinders)
Camshafts (6-cylinder engine)
Hydraulic disc tappets
Valve stem seals — removal and installation
Valves — removal and installation
Directional valves
Valve seats in the cylinder head
Checking the compression in the cylinders
V-belt (4-cylinder engine)
V-belt (6-cylinder engine)
Diagnostics of malfunctions of gasoline engines
General notes on engine overhaul
Repair work without engine dismantling
Engine overhaul
Alternatives to Engine Overhaul
Engine dismantling
Engine disassembly sequence
Diesel engines
Technical characteristics of diesel engines
Removal and installation the engine
Engine ventilation
Engine removal (cars with air conditioning)
Lower Engine Compartment Cover — Removal and Installation
Chain tensioner — removal and installation
Camshaft (2.0 L engine)
Camshaft (2.2/2.5L engine)
Cylinder head (2.0L engine)
Cylinder head (2.2/2.5L engine)
Oil-reflecting caps (2.0 L engine)
Valve stem seals (2.2/2.5L engine)
Cylinder head cover (2.2 / 2.5L)
Hydraulic disc tappets
Valves — removal and installation
Directional valves
Valve seats in the cylinder head
Cylinder head and engine block
Checking the compression in the cylinders
V-ribbed belt — removal and installation
Tensioner for V-ribbed belt
Diagnostics of diesel engine faults
Lubrication system
Lubrication system — general description
Motor oil specification
Oil application area/viscosity class
Oil consumption
Oil circulation circuit (diesel)
Oil pressure reducing valve — removal and installation
Oil pan (petrol engine) — removal and installation
Oil pan (diesel 2.0) — removal and installation
Oil pan (diesel 2.2/2.5) — removal and installation
Oil level indicator — removal and installation
Oil/coolant heat exchanger
Diagnosing faults in the oil circulation circuit
Cooling system
Coolant circulation circuit
Coolant (petrol engines)
Coolant (diesel engines)
Coolant (cars with air conditioning)
Antifreeze for radiator
Coolant thermostat (thermostat)
Checking the cooling system
Hydraulic fan clutch — removal and installation
Liquid Cooling System Pump — Removal and Installation
Radiator — removal and installation
Fan shroud — removal and installation
Diagnostics of cooling system faults
Diagnostics of malfunctions of the liquid level indication system
Engine overheating
Heating and ventilation
General information about heating and ventilation
Air Conditioner — General Description
Additional resistances — removal and installation
Heating Fan — Removal and Installation
Heating service device — removal and installation
Diagnostics of heating system faults
Air conditioning: not only pros, but also cons
Air Conditioner Maintenance Rules
Ignition system
General description of the ignition system
Safety precautions when repairing an electronic ignition system
Ignition coils — removal and installation
Spark plugs — removal, installation, inspection
Kalilny number Index
Checking the diesel preheating device
Incandescent lamp — check
Heating control relay
Glow Plugs — Removal, Checking and Installation
Coolant temperature sensor
Intake air temperature sensor — removal, inspection and installation
Self-diagnosis of the diesel heating device
Fuel system
Safety precautions and refueling
Fuel tank — design description
Fuel level sensor — removal and installation
Fuel pump — removal and installation
Fuel filter — removal and installation
Air filter — removal and installation
Air Filter Cross Pipe — Removal and Installation
Intake manifold — removal and installation
Throttle Cable/Throttle Lever (Petrol)
Gasoline Control Cable — Removal and Installation
Diesel engine fuel circuit
Pre-heating of diesel fuel
Fuel thermostat — removal and installation
Hydraulic valve body — removal and installation
Throttle Cable/Throttle Lever (Diesel)
Gas control cable (diesel) — removal and installation
Injection system (gasoline)
Engine Management Systems PMS and HFM
How PMS works
How the HFM system works
Self-diagnosis of the ignition and fuel injection system
Air flow meter — removal and installation
Coolant Temperature Sensor — Removal, Checking and Installation
Intake Air Sensor — Removal, Checking and Installation
Vacuum piping system
Fuel distributor with valve injectors
Valve injectors — removal and installation
Oxygen sensor (lambda probe) — removal and installation
Diagnostics of faults of the petrol injection system
What should an owner of a car with an injection engine know?
Turbocharger repair and replacement
Injection system (diesel)
Injection system with exhaust gas recirculation
Checking/setting the start of fuel delivery by the pump
Injectors — removal and installation
Technical data of the diesel injection and fuel system
Diagnostics of faults in the injection and power supply system
Exhaust system
Design and description of the exhaust system
Exhaust system (petrol) — removal and installation
Exhaust system (diesel) — removal and installation
Main and middle mufflers
Cars with a catalytic converter
Diesel vehicle exhaust gas neutralization device
Three in one — or how to protect the catalyst
Transmission
Clutch
Clutch design and description
Checking the thickness of the clutch disc in the mounted state
Clutch — removal, inspection and installation
Clutch release bearing
Bleeding the Clutch Control System
Clutch slippage
Diagnosis of clutch system faults
Car gearbox
Gearbox design
Gearbox — removal, installation and adjustment
Automatic transmission
Towing of vehicles equipped with automatic transmission
Checking the oil level in an automatic transmission
Transmission oil and filter — replacement
Control pressure cable
Gear shift rod
Features of operation of automatic transmission
Chassis
Suspension, wheels and tires
Front suspension design
Shock absorbers — removal and installation
Checking and recycling shock absorbers
Front springs — removal and installation
Setting the clearance in the front bearings
Anti-roll bar — removal and installation
Rear suspension design
Rear shock absorbers — removal and installation
Rear springs — removal and installation
Half shafts — removal and installation
Removal axle shafts / replacing rubber seals
Why do you need a shock absorber?
Types of shock absorbers
Additional protection for ball joints of steering rods
Secret bolts for securing external elements
Technical characteristics of wheels
Wheel and tire maintenance
Diagnosis of tire faults
Steering
Design and description of steering
Steering wheel airbag unit
Steering wheel — removal and installation
Steering linkage — removal, inspection and installation
Steering linkage joint cuffs — removal and installation
Power steering pump — removal and installation
Installing camber-wheel convergence
Power steering — easy and effortless
Maintenance of the steering system
Diagnosing steering system faults
Brake system
Design and description of the brake system
Anti-lock braking system — ABS
Additional equipment — ASR system
Technical data of the brake system
Front Brake Pads — Removal and Installation
Rear Disc Brake Pads — Removal and Installation
Checking the thickness of brake discs and their lateral runout
Support — removal and installation
Front brake disc — removal and installation
Rear brake disc — removal and installation
Brake fluid
Bleeding the brake system
Brake lines / hoses
Replacing brake lines
Parking brake pads — removal and installation
Adjusting the parking brake
Brake light switch — removal and installation
Brake fault diagnostics
Body
Exterior (external elements)
General information about the body and safety precautions
Exterior mirror / mirror glass — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Inner wing of the car — removal and installation
Car wing — removal and installation
Mercedes radiator grille/emblem — removal and installation
Engine hood rod — removal and installation
Windshield Cover — Removal and Installation
Air supply device for heating the passenger compartment
Water collector — removal and installation
Paintwork — Damage Repair
Corrosion of body metal
Car body care products
Finding and eliminating creaks and vibrations
Purpose and types of roof hatches
Interior (internal elements)
Glove box — removal and installation
Gear Shift Knob Protective Cover
Front ashtray — removal and installation
Middle console — removal and installation
Heating service panel — removal and installation
A-pillar interior trim — removal and installation
C-Pillar Interior Trim — Removal and Installation
Front seat — removal and installation
Rear seat — removal and installation
Central lock
Under Dashboard Cover — Removal and Installation
Doors and windows
Front door — removal and installation
Rear door — removal and installation
Front door handle — removal and installation
Rear Door Handle — Removal and Installation
Door lock — removal and installation
Interior door trim — removal and installation
Front window lifter — removal and installation
Front window glass — adjustment
Rear window lifter — removal and installation
Front door glass — removal and installation
Window lift motor — removal and installation
Electrical equipment
Equipment and devices
General description of electrical equipment
Measuring instruments
Measurement technique
Electrical equipment checks
Sound signal — removal and installation
Replacing fuses
Instrument panel — removal and installation
Instrument cluster bulbs — removal and installation
Light switch — removal and installation
Radio receiver — removal and installation
Antenna — removal and installation
Automatic Antenna Telescope — Removal and Installation
Speakers — Removal and Installation
Rubber Windscreen Wiper Blades — Removal and Installation
Diagnosing Windscreen Wiper Blade Faults
Windscreen washer jets
Headlight Washer Nozzles
Windscreen wiper and its motor — removal and installation
Protect your car yourself
Anti-theft «immunodeficiency»
Checking the operation of alarms/external lighting
Power devices
Battery — Removal and Installation
Maintenance free batteries
Checking the battery
Self-discharge of the battery
Charging the battery
Storage of the battery
Diagnosis of battery malfunctions
Generator — Description and Safety
Generator — removal and installation
Checking the generator charging voltage
Replacing and checking the generator/voltage regulator carbon brushes
Generator fault diagnostics
Starter — General Description
Starter — removal and installation
Starter fault diagnostics
Traction relay — removal, testing and installation
Main faults of starter and generator
Lighting system
Lighting system — description and table of lamps
Low beam, high beam and fog lamps
Front turn signal light bulb
Lamp in the rear light
Lamp in the license plate light
Interior light — removal and installation
Turn signal lamp — removal and installation
Headlight — removal and installation
Headlight adjustment
Tail light — removal and installation
Why do headlights dim?
Increasing the service life of halogen lamps
About correct headlight adjustment
Electrical circuits
Using electrical diagrams
Abbreviations in electrical circuits
Electrical equipment — starter, generator, battery (BD 111 HFM / PMS)
Outdoor lighting (BD, DD)
Interior lighting (BD, DD)
Instrument cluster (BD 111 HRM / PMS / 104 HFM)
Instrument panel (DD 601/604/605)
Electrical diagram of starter, generator, battery (DD 601 / 604 / 605)

C-Class W203 (2000-2007)
General information
Introduction to guide
Vehicle Identification Numbers
Purchase of spare parts
Car maintenance technology
Workplace tools and equipment
Jacking and towing a car
Starting the engine using an auxiliary battery
Automotive chemicals, oils and lubricants
Car fault diagnostics
User manual
Vehicle specifications
Main Controls and Panels
Locks, keys and bolts. Single lock
Protecting your car from theft
Making it easier to get in and out of the car
Adjusting seats and headrests
Security systems
Steering wheel, rear view mirrors
Memory for seat, steering wheel and exterior mirror positions
Dashboard
Multifunctional steering wheel, universal display
Headlight and windshield wiper switches
Automatic heater and air conditioner, ventilation, independent heater
Rear window defroster
Power windows, sunroof
Salon equipment
Vehicle control and auxiliary systems
Warning lights, warning lights, and fault messages
First aid kit, fire extinguisher, tools, warning triangle and spare tire compartment
Maintenance
General description of current maintenance
Maintenance Specifications
Scheduled maintenance due date indicator
Maintenance schedule
General information about the setup
Checking fluid levels, leak monitoring
Checking tire condition and pressure. Wheel identification. Wheel rotation and replacement
Changing engine oil and oil filter
Checking the brake system, adjusting the parking brake
Checking the fuel system
Checking the condition and replacing engine compartment hoses, localizing leaks
Checking the condition of the ribbed belts of the serpentine drive of auxiliary units
Checking the functioning of the cooling system and frost resistance of the coolant
Checking the condition of the exhaust system
Checking the Automatic Transmission Oil Level
Visual inspection of the gearbox for oil leaks
Checking the condition of suspension and steering components
Checking the condition of the protective covers of the drive shafts
Checking the power steering fluid level
Checking the clearance control fluid level
Checking the air conditioning system
Cleaning the sunroof sliding panel mechanism
Visual inspection of the seat belt and airbag unit
Checking the functionality of headlights and horn
Checking the condition, adjusting and replacing windshield wiper blades
Checking battery condition, care and charging
Tele-Aid Emergency Call System Battery Replacement
Replacing the cabin air filter element / carbon air filter
Checking, cleaning and lubricating the coupling device
Replacing brake fluid
Checking the flexible coupling of the cardan shaft
Checking and replacing spark plugs, condition of high-voltage wires
Replacing the engine air filter element
Replacing the fuel filter
Power unit
Gasoline engines
Petrol and Diesel Engine Specifications
Checking the compression in the engine cylinders
Checking the engine with a vacuum gauge
Removal and installation the engine compartment cover from the bottom side
Construction of 4-cylinder petrol engines
Removal and installation the cylinder head (I4)
Removal and installation the cylinder head cover (I4)
Removal and installation the chain tensioner (I4)
Replacing the timing chains and setting the valve timing (I4)
Checking the camshaft timing (I4)
Removal and installation the V-belt (I4)
Construction of 6-cylinder petrol engines
Removal and installation the cylinder head (V6)
Replacing the timing chains and setting the valve timing (V6)
Removal and installation the V-belt (V6)
Engine lubrication system
Checking oil pressure
Removal and installation the oil level sensor
Diesel engines
Diesel engine design
Removal and installation the top engine cover
Setting the piston of the first cylinder to the TDC position
Removal and installation the cylinder head cover
Removal and installation the cylinder head
Removal and installation the front cover
Removal and installation the upper chain guide
Replacing the timing chains and setting the valve timing
Removal and installation camshafts
Removal and installation the intermediate sprocket
Removal and installation the chain tensioner
Removal and installation the V-belt
Oil filter design
Cooling system
Cooling and Heating System Specifications
General description of the cooling system
Antifreeze is a means of protection against freezing
Replacing the coolant
Removal and replacing cooling system hoses
Removal and installation the thermostat
Checking the Thermostat
Checking the cooling system under pressure
Removal and installation the coolant pump
Removal and installation the fan (models with manual transmission)
Removal and installation the radiator (models with manual transmission)
Ventilation and heating
Design of ventilation, heating and air conditioning systems
Removal and installation ventilation deflectors
Removal and installation of electric motors for damper drives
Removal and installation the heater and air conditioner control unit
Removal and installation the electric motor of the heater or air conditioner fan
Removal and installation the electronic fan controller of the heater or air conditioner
Removal and installation air conditioner sensors
Supply system
Power and exhaust system specifications
Fuel system of petrol and diesel engines
Relieving pressure in the fuel system
Removal and installation the fuel pump and fuel level sensor
Removal and installation the air filter
Injection system (gasoline)
Safety precautions when working with the injection system
Functioning of the control and injection system
General check of the injection system
Removal and installation the air mass meter
Checking the injectors
Removal and installation of fuel distribution line and injectors
Checking idle speed / ignition timing / CO concentration
Injection system (diesel)
Elements of the fuel injection system of a diesel engine
Functional diagram of fuel injection control
Location of Common Rail Injection Control System Components
General description of the diesel engine injection system
Removal and installation injectors
Bleeding air from the low pressure fuel circuit
Fuel injection system checks
Exhaust system
Exhaust system — general information
Removal and installation of the exhaust system
Checking the tightness of the exhaust system
Emission Control Systems — General Information
Catalytic converter
Turbocharger — General Information and Precautions
Belt driven blown air compressor
Intercooler — General Information
Ignition and control system
Ignition and Engine Management System Specifications
Diagnostics of faults in the ignition and engine management system
Design of ignition and engine control system
Removal and installation ignition coils
Checking the ignition and injection control system
Troubleshooting and Preliminary Checks
Checking and adjusting the ignition timing angle
Spark plugs — condition determination
Diesel engine preheating system
Checking diesel glow plugs
Removal and installation glow plugs
Diagnostics of electronic control systems and diagnostic equipment
Diagnostics of electronic engine control systems, injection, ignition and auxiliary brake systems
Controller for interfacing a personal computer with the on-board self-diagnostic system OBD II
Diagnostics of the electronic system of automatic air conditioning (A/C)
Using an Oscilloscope to Monitor Signals in Control System Circuits
Charge and launch systems
General description of charging and starting systems
Battery — Basic Information and Purchase
Checking and charging the battery
Replacing the battery
Storage of the battery
Charging system — general information and safety precautions
Checking the charging system
Generator — removal, inspection and installation
Removal and installation the voltage regulator and replacing the brushes
Engine Starting System — General Information and Precautions
Removal and installation the starter
Removal and installation the starter traction relay
Checking the engine starting system
Transmission
Mechanical gearbox
Design and description of manual gearbox
Manual Transmission Specifications
Removal and installation of a manual transmission
Adjusting the manual transmission control drive
Automatic gearbox
Automatic transmission design
Automatic Transmission Specifications
Hydraulic control elements of the Sequentronic automated gearbox
Electronic controls and signals of the Sequentronic automated gearbox control unit
Automatic transmission design 722.6
Troubleshooting — General Information
Electronic control unit tasks and control signals
Removal and installation of AT with a torque converter
Electrohydraulic control unit AT
Disassembly and assembly of the electrohydraulic control unit
Disassembling and assembling the gear shift plate
Transmission housing and torque converter
Multi-disc brakes B2, B3 and locking gear in «Parking»
Disassembly and assembly of the rear hollow shaft with the rear freewheel clutch
Removal and installation the B1 multi-disc brake and oil pump
Disassembly and assembly of the oil pump
Disassembly and assembly of the B1 multi-disc brake
Disassembly and assembly of the B2 multi-disc brake
Disassembly and assembly of the output shaft with the central and rear planetary gear block
Removal and installation of multi-plate clutches K1, K2 and K3
Disassembly and assembly of the K1 clutch
Disassembly and assembly of the drive shaft with clutch K2 and front block of planetary gears
Disassembly and assembly of the K3 clutch
Parking locking mechanism
Removal and installation the gear selector lever
Clutch and drive shafts
Clutch and Drive Shaft Specifications
Clutch design and description
Clutch — removal, inspection and installation
Bleeding the clutch drive, replacing the hydraulic fluid
Removal and installation the propeller shaft
Design and description of wheel drive shafts
Removal and installation wheel drive shafts
Disassembling drive shafts and replacing protective covers
Differential
Disassembling and assembling the differential
Disassembly and assembly of the main gear reducer and adjustment of gear clearances
Determining the thickness of the adjusting shim and installing it in the gearbox housing
Checking and adjusting the flange clearance
Disassembling and assembling a differential with automatic locking
Chassis
Brake system
Design and description of the brake system
Brake system specifications
Replacing the front disc brake pads
Removal and installation the front caliper
Replacing rear brake pads
Removal and installation the rear caliper
Removal and installation the brake disc
Checking the brake disc
Dual master cylinder
Replacing the parking brake pads
Removal and installation the parking brake cable
Removal and installation the brake light switch
Bleeding the brake system
Removal and installation the brake hose
Checking the brake booster
Car suspension
General description of suspension and steering
Suspension and steering specifications
Design and description of front wheel suspension
Removal and installation the front shock absorber strut
Repair of front wheel suspension strut
Adjusting the clearance in the front wheel bearings
Design and description of rear wheel suspension
Removal and installation the rear shock absorber
Removal and installation the rear spring
Car Wheel Alignment Angles — General Information
Conditions for checking wheel alignment angles
Front wheel alignment
Rear wheel adjustment
Checking the vehicle body clearance
Steering
Steering and airbags — general information
Safety precautions when working with an airbag
Removal and installation the airbag unit on the steering wheel
Removal and installation the steering wheel
Removal and installation the steering rod end
Removal and installation the steering gear protective cover
Body
Exterior (external elements)
General information and safety precautions when performing bodywork
Cleaning and care of the body and underbody
Repair of minor damage to body panels
Repair of significant body damage
Windshield damage due to stone impacts
Replacing windshield wipers
Removal and installation the windshield washer nozzle
Removal and installation the rear window jet
Removal and installation the windshield wiper arm
Removal and installation the rear wiper arm
Removal and installation the water collector
Removal and installation the hood
Removal and installation the hood trim
Adjusting the hood
Removal and installation the hood lock
Disconnecting the drive cable from the hood lock
Removal and installation the spoiler grille
Removal and installation the bumper
Removal and installation the rear bumper
Removal and installation the front wing
Removal and installation the protective strip on the wing
Removal and installation the protective strip on the bumper
Removal and installation the protective strip on the door
Removal and installation the front wing liner
Removal and installation the rear part of the wing liner
Removal and installation the front door
Checking and adjusting the door
Removal and installation the front door trim
Removal and installation the triangular overlay
Removal and installation the outer door handle
Removal and installation the exterior rearview mirror trim
Removal and installation the outside mirror
Removal and installation mirror glass
Removal and installation the trunk lid
Removal and installation the trunk lid trim
Removal and installation the trunk lock retainer
Removal and installation the tailgate lock
Removal and installation the tailgate lock mechanism
Removal and installation the trunk and tailgate lock cylinder
Removal and installation the tailgate
Tailgate adjustment
Removal and installation the tailgate trim
Removal and installation the rear spoiler — removal and installation
Removal and installation the cargo compartment plug
Specifications and body sizes
Interior (internal elements)
Notes on carrying out work with salon equipment
Removal and installation the expansion clamp
Removal and installation the cover under the instrument panel
Removal and installation the lower part of the instrument panel
Removal and installation the glove box
Removal and installation the cover under the glove compartment
Removal and installation the center console
Removal and installation the upper center console cover
Removal and installation the interior mirror
Removal and installation trim in the cargo compartment
Removal and installation the front seat
Removal and installation the rear seat
Removal and installation the shelf
Removal and installation the A and B pillar trim
Removal and installation the C-pillar trim
Electrical equipment
Equipment and devices
General description of on-board electrical equipment
Electrical Equipment Specifications
Diagnostics of faults of on-board electrical equipment
Checking the windshield wiper motor
Checking the heated rear window
Relays and Fuses — Location and Replacement
Ignition Key/Remote Control Battery Replacement
Removal and installation the windshield wiper motor
Removal and installation the rear window wiper motor
Removal and installation the water tank and pump motor
Removal and installation the rain sensor
Removal and installation the horn
Removal and installation parking sensors
Removal and installation the outside air temperature sensor
Removal and installation the instrument panel
Removal and installation the steering column switch
Removal and installation the front ceiling light switch
Removal and installation a group of switches to the left of the control panel
Removal and installation the center console switch
Removal and installation switches in doors
Removal and installation interior door light switches
Removal and installation parking assistant warning signs
Removal and installation the cigarette lighter
Removal and installation the radio
Removal and installation the loudspeaker
Digital data bus CAN
Single Lock — General Information
Installation of additional electrical and electronic devices
Purpose and location of electrical connectors
Lighting system
Replacement of incandescent lamps for outdoor lighting devices
Replacement of incandescent lamps for interior lighting devices
Removal and installation the daylight sensor
Removal and installation headlights
Removal and installation fog lights
Removal and installation the fog lamp diffuser
Removal and installation the rear light
Electrical diagrams (2000)
Designations and abbreviations on electrical equipment diagrams
Power distribution electrical circuit
Grounding layout
Electrical diagram of the charging system
Electrical diagram of the starting system
Electrical diagram of the cooling system fan
Electrical diagram of the tempostat
Electrical diagram of the engine management system 2.3 l
Automatic air conditioner wiring diagram
On-board computer wiring diagram
DLC diagnostic connector wiring diagram
Anti-lock braking system (ABS) wiring diagram
CAN bus wiring diagram
Electrical diagram of the anti-theft system
Electrical diagram of outdoor lighting fixtures
Wiring diagram of xenon headlights
Wiring diagram of headlights with DRL
Wiring diagram of headlights (without xenon)
Electrical diagram of the instrument panel
Wiring diagram for interior lighting when doors are opened
Instrument lighting wiring diagram
Parktronic System (PTS) Wiring Diagram
Single lock wiring diagram
Electrical diagram of the glass heater
Reverse Light Wiring Diagram
Wiring diagram for automatic dimming interior rear view mirror circuit
Electrical diagram of the electric drive for adjusting the outside rearview mirrors
Electrical diagram of the rear headrests
Electric Convertible Top/Sunroof Wiring Diagram
Wiring diagram for the release drive of the trunk lid lock latch
Seat heating wiring diagram
Horn wiring diagram
Electrical diagram of the electric drive for adjusting the driver's seat
Electrical diagram of the electric drive for adjusting the passenger seat
Electrical diagram of the electric drive of the window regulators
Electrical diagram of a radio receiver with an amplifier and a D2B data bus
Electrical diagram of a radio receiver with an amplifier and without a D2B data bus
Electrical diagram of a radio receiver without an amplifier and with a D2B data bus
Electrical diagram of a radio receiver without an amplifier and without a D2B data bus
SRS Additional Restraint System Wiring Diagram
Automatic transmission wiring diagram
Transmission Shift Lock Wiring Diagram
Windshield Wiper/Washer Wiring Diagram
Wiring diagram for headlight lens wipers/washers
Electrical diagrams (since 2001)
Designations and abbreviations on electrical equipment diagrams
Electrical diagram of the control system of the gasoline engine 111
Electrical diagram of the control system of the gasoline engine 112
Electrical diagram of the control system of the gasoline engine 271
Electrical diagram of the diesel engine control system
Fuel pump wiring diagram
Electrical diagram of the ignition switch control unit
SAM module electrical diagram
Electrical diagram of the instrument panel
Automatic heater wiring diagram
Automatic air conditioner wiring diagram
Automatic transmission control unit wiring diagram
Electrical diagram of the automated gearbox control unit
Electrical diagram of the AT selector control unit
Speed-sensitive power steering circuit diagram
ESP anti-skid system wiring diagram
Brake light wiring diagram
Wiring diagram of the tire pressure control unit
Electrical diagram of the Distronic system
Electrical diagram of the Comand system
D2B bus wiring diagram
Cell phone wiring diagram
Wiring diagram of CD changer

E-Class W123 (1976-1985)
General information
Introduction to the guide
Preface to the Car Repair Manual
Vehicle Passport Data
Lifting and towing a car
General requirements for car repair
Vehicle specifications and dimensions
Power unit
Engine device
General information about engines
Cylinder head design and specification
Design and specification of valves
Cylinder Block Design and Specification
Design and specification of the crank mechanism
Design and specification of the valve timing mechanism
Design and specification of engine lubrication system
Design and specification of the cooling system
Power supply system design and specification
Design and specification of carburetor engines
Design and specification of fuel injection system
Ignition system design and specification
Repair M102 engines
Checking and adjusting clearances in the valve drive mechanism on M102.920 and M102.939 engines
Checking clearances in the valve drive mechanism on M102.980 and M102.982 engines
Complex operations without removing the engine from the car
Complex operations only on the engine removed from the vehicle
Removal auxiliary units
Valve timing mechanism of 4-cylinder engines
Replacing the camshaft drive chain
Removal and installation the cylinder head
Disassembly and assembly of the cylinder head
Removal the power unit
Installation of the power unit
Disassembling the engine
Checking the technical condition and repairing the engine
Repair M110 and M123 engines
Checking and adjusting clearances in the valve drive mechanism on M123 and M110 engines
Removal engines M110 and M123
Removal the cylinder head
Removal the camshaft
Disassembling the cylinder head
Replacing the camshaft chain
Removal the intermediate sprocket and shaft
Removal the flywheel (drive disk)
Replacing the front crankshaft oil seal
Removal the oil pump
Removal connecting rods and pistons
Removal the crankshaft and main bearings
Replacing the oil filter
Engine mount replacement
Description and maintenance of the crankcase ventilation system
General instructions for engine inspection and restoration
Inspection and restoration of the crankshaft and its bearings
Inspection and restoration of connecting rods and bearings
Inspection and restoration of pistons and piston rings
Inspection and restoration of cylinders in the block
Inspection and restoration of distribution mechanism parts
Inspection and restoration of the flywheel (drive disk) and flywheel ring gear
Inspection and restoration of the oil pump
Cleaning of carbon deposits, grinding of valves and restoration of cylinder head
Engine assembly
Installing the crankshaft and its bearings
Installing connecting rods and bearings
Installing an oil pump
Installing the flywheel (drive disk)
Installing the intermediate sprocket and shaft
Cylinder head assembly
Installing the camshaft
Installing the cylinder head
Removal and installation the intake manifold and exhaust manifold
Cooling and lubrication (M102)
Design of the lubrication system
Removal and installation the oil pump
Checking oil pressure
Cooling system design
Draining the coolant
Filling and bleeding the cooling system
Removal and installation the water pump
Removal, installation and tension adjustment of the generator drive V-belt
Removal and installation a multi-groove accessory drive belt
Setting and adjusting the belt tension
Cooling (M110 and M123)
Cooling system — general information
Draining the cooling system
Flushing the cooling system
Filling the cooling system
Removal, inspection, cleaning and installation of the radiator
Removal, checking and installation the thermostat
Removal and installation the water pump
Water pump repair
Checking, replacing and adjusting the water pump and generator drive belt
Checking the cooling fan drive clutch
Ignition system
Adjusting the breaker contacts
Replacing breaker contacts
Installing the ignition distributor
Setting the ignition timing using a stroboscope
Setting the ignition timing using a test lamp
Features of the contactless ignition system
The operating principle of a contactless ignition system
Removal and installation the distributor sensor
Replacing the contactless ignition distributor sensor
Checking the ignition distributor sensor
Removal and installation the TDC sensor
Setting the ignition timing
Power system «Stromberg»
Features of the Stromberg 175 CDT carburetor
Operating principle
Adjusting and checking the carburetor
Removal and installation the electromagnetic shut-off valve
Removal and installation the fuel pump
Power system «Solex 4A1»
Main parts of the Solex 4A1 carburetor
Adjusting engine idle speed
Cleaning the carburetor
Removal and installation the carburetor
Replacing the needle valve and setting the fuel level in the float chamber
Checking and adjusting the automatic starting device
Adjusting the pneumatic drive of the throttle valve of the 1st chamber
Checking the additional starting device
Checking and adjusting the accelerator pump
Checking electromagnetic shut-off valves
Removal and installation the bimetallic spring housing of the automatic starting device
Removal and installation the fuel pump
Valve timing adjustment (V6)
Fuel injection «K-Jetronic»
Description of the K-Jetronic fuel injection system
Air flow meter
Fuel dispenser and dispenser
Injectors — General Description
Checking the injection system
Adjusting engine idle speed
Possible malfunctions of the L-Jetronic system, their causes and methods of elimination
Fuel injection «L-Jetronic»
Description of the L-Jetronic fuel injection system
Checking the injectors
Adjusting engine idle speed
Checking the additional fuel supply valve
Checking the thermal valve
Checking the thermoelectric switch
Checking the thermal time relay
Possible malfunctions of the L-Jetronic system, their causes and methods of elimination
Transmission
Clutch
Clutch design and specifications
Removal and installation the clutch
Removal and installation the clutch slave cylinder
Removal and installation the clutch master cylinder
Bleeding the Clutch Hydraulic Drive
Clutch malfunctions and methods of their elimination
Mechanical gearbox
Design and technical characteristics of mechanical transmission
Removal and installation the gearbox
Disassembling the gearbox
Disassembling the primary and intermediate shafts
Disassembly and assembly of the secondary shaft
Disassembling and assembling the gearshift cover
Gearbox assembly
Assembly of a four-speed gearbox
Assembly of a five-speed gearbox
Assembly of four-speed and five-speed gearboxes
Adjusting the gear shift drive (from the lever on the body floor tunnel)
Automatic gearbox
Design and specifications of automatic transmission
Changing oil and oil filter, checking oil level
Removal and installation of automatic transmission
Removal and installation of the transformer
Transformer flushing
Flushing the oil radiator
Adjusting the control pressure rod
Adjusting the gear selection rod
Checking gear shift points
Checking and adjusting the modulating pressure
Checking the working pressure
Checking the pressure in the centrifugal regulator
Adjusting the starter interlock switch
Cardan and rear axle
Design and technical characteristics of the cardan shaft and axle
Removal and installation the cardan transmission
Replacing the intermediate support of the drive shaft
Replacing the elastic coupling and centering bushings
Rear axle and shaft design
Removal and installation the rear wheel drive shaft
Replacing the rear wheel drive shaft protective cover
Removal and installation the rear axle
Replacing the rear axle pinion seal
Replacing the rear wheel drive shaft seal
Replacing the rear axle suspension bracket
Chassis
Front suspension
Design and technical characteristics of the front suspension
Removal and installation front suspension springs
Checking, removing and installing shock absorbers
Removal and installation the front anti-roll bar
Removal and installation the front suspension assembly
Removal, installation and adjustment of the hub and front wheel bearings
Removal, disassembly and installation of the steering knuckle
Removal and installation the upper suspension arm
Removal and installation the lower arm of the front suspension
Removal and installation the front suspension auxiliary rod
Checking and adjusting the front wheel alignment angles
Rear suspension
Design and technical characteristics of the rear suspension
Removal, inspection and installation of shock absorbers
Removal and installation the rear anti-roll bar
Removal and installation the rear suspension spring
Removal and installation the rear suspension assembly
Removal and installation the rear suspension diagonal arm
Removal, installation and adjustment of the hub and rear wheel bearings
Replacing the front rear suspension mount
Automatic body position control system
Steering
Steering design and specifications
Removal and installation the steering wheel
Removal, disassembly and installation of the steering column
Removal and installation the coupling and the steering column deformable shaft
Removal and installation the steering column lock
Removal, disassembly and installation of the steering gear without power steering
Removal, disassembly and installation of the pendulum arm
Removal and installation of transverse and longitudinal steering rods
Checking and replacing the tie rod joints
Removal and installation the power steering mechanism
Bleeding the hydraulic steering system
Removal and installation the power steering pump
Checking and adjusting the front wheel alignment angles
Brake system
Design and technical characteristics of the brake system
Checking and replacing disc brake pads
Removal, disassembly and installation of the brake caliper
Inspection, removal and installation of the brake disc
Removal, disassembly and installation of the master brake cylinder
Bleeding air from the master cylinder
Bleeding the brake system
Replacing brake fluid
Flexible Hoses — Checking and Replacing
Steel Brake Lines — Checking and Replacing
Vacuum brake booster — removal and installation
Removal and installation the brake light switch
Removal and installation the brake pedal
Parking brake — general description
Adjusting the parking brake
Checking and replacing the parking brake pads
Body
Exterior (external elements)
Body and its equipment — general description
Removal and installation the hood
Removal and installation the hood lock drive cable
Removal and installation the trunk lid
Removal and installation the trunk lid lock
Outside rear view mirror
Removal and installation the fuel tank filler flap
Removal and installation bumpers
Removal, adjusting and installing windshield washer jets
Interior (internal elements)
Removal and installation seats
Removal and installation the instrument panel
Removal and installation the glove box and its cover
Removal and installation the center console
Removal and installation the rear storage compartment (sedan models)
Removal and installation the heater electric motor
Removal and installation the heater
Removal and installation the heater radiator
Air conditioning system maintenance
Doors, locks and windows
Removal and installation the tailgate (station wagon models)
Removal and installation the rear door glass (station wagon models)
Removal and installation gas-filled tailgate struts (station wagon models)
Removal and installation the interior door trim panel
Removal and installation a mechanical door window lifter
Removal and installation an electric window lifter
Removal and installation the front door drop glass
Removal and installation the rear door drop glass
Removal and installation fixed rear door glass
Removal and installation the door
Removal and installation the door opening limiter
Removal and installation the outer front door handle
Removal and installation the outer rear door handle
Removal and installation the front door lock
Removal and installation the rear door lock
Adjusting the sunroof
Removal and installation of windshield and rear window
Removal and installation rear side window glass
Removal and installation the rear side window regulator
Central locking system
Electrical equipment
Equipment and devices
Design and technical characteristics of electrical equipment
Fuses and relays
Removal and installation the combination switch
Removal and installation the interior door light switch
Removal and installation the light switch
Removal and installation instrument panel and console switches
Removal and installation the instrument cluster
Removal and installation the flexible speedometer drive shaft
Removal and installation instrument cluster indicators
Headlight/Fog Light Adjustment
Removal and installation of headlights and their lamps
Replacing lamps
Replacing Windshield Wiper Blades
Removal and installation the windshield wiper arm
Removal and installation windshield wiper drive rods
Removal and installation the headlight washer drive
Windshield washer
Power devices
Removal and installation the battery
Adding electrolyte to the battery
Charging the battery
Generator Maintenance and Special Precautions
Removal and installation the generator
Checking the generator and voltage regulator on the car
Removal, inspection and installation of generator brushes
Removal and installation the starter
Starter repair
Electrical circuits
Electrical diagram of the model «250» with engine 123.026
Electrical diagram of the model «280E» with engine 123.033
Electrical diagram of the model «280E» (engine 123.033) and «280CE» (engine 123.053)
Electrical diagram of the model «280TE» with engine 123.093
Electrical diagram of the model «280TE» with engine 123.093, starting with chassis No. 007 619
Models «280» with engine 123.030

E-Class W124 (1984-1995)
General information
Governing bodies
Controls and instruments
Instrument cluster
Control lights
Heating and ventilation
Examples of temperature control and air flow distribution
Independent heating system
Air conditioning system
Automatic air conditioning system
Car keys
Closing and locking door locks
Child lock rear door lock
Manual adjustment of the front seat position
Electric front seat adjustment
Adjusting the position of the steering wheel
Adjusting the position of the lower part of the front seat backrest
Front seat armrest
Rear seat armrest
Rear seat headrest
Adjusting headrests
Rear window defroster
Seat belts
Airbag
Steering column lock / ignition switch
Light switch
Headlight corrector
Multi-function steering column switch
Rear view mirrors
Cigarette lighter in the passenger compartment
Sun visors
Interior lighting
Sunroof
Electric window control
Parking brake
Vehicle identification
Main dimensions of the car
Control dimensions of the car
Driving and operation
Starting and stopping the engine
Driving Instructions
Manual transmission
Automatic transmission
Automatic transmission mode switch
Cruise control system
Four-wheel drive (4 MATIC)
Opening and closing the hood
Exhaust gas system
If the engine does not start
Wheel replacement
Checking the tightness of connections
Towing a car
Weekly care
Weekly inspection locations
Coolant level
Brake fluid level
Fluid level in the power steering system
Windscreen washer fluid level
Rechargeable battery-care
Tires and checking tire pressure
Windscreen wiper blades
Light bulbs and fuses
Maintenance (gasoline)
Engine bay and maintenance intervals
Maintenance Specifications
Primary and secondary maintenance actions
Maintenance every 9,000 km
Maintenance every 18,000 km
Maintenance every 58,000 km
Maintenance every 118,000 km or once every 4 years
Maintenance every 12 months
Maintenance every 3 years
Maintenance (diesel)
Maintenance Specifications
Engine bay and maintenance intervals
Primary and secondary maintenance actions
Maintenance every 9,000 km
Maintenance every 58,000 km
Maintenance every 12 months
Maintenance every 3 years
Troubleshooting
Engine diagnostics and troubleshooting
Diagnostics and troubleshooting of the cooling system
Diagnostics of fuel and exhaust system faults
Diagnosis and troubleshooting of clutch problems
Diagnostics of faults of a manual transmission
Automatic transmission fault diagnostics
Diagnostics of differential and propeller shaft faults
Diagnostics and troubleshooting of the brake system
Diagnosis of suspension and steering faults
Diagnostics of electrical equipment faults
Power unit
I4 petrol engine
Engine specifications
General engine data
Repair operations on the engine installed in the vehicle
Checking the compression pressure
Top dead center (TDC) of the piston of the first cylinder
Cylinder Head Cover — Removal and Installation
Crankshaft Pulley/Vibration Damper and Hubs
Timing Chain Cover — Removal and Installation
Checking and replacing the drive chain
Drive chain tensioning mechanism
Camshaft Sprocket — Removal, Inspection and Installation
Crankshaft Sprocket — Removal, Inspection and Installation
Lower chain guide for single-row drive chain models
Lower chain guide for double-row chain models
Upper chain guide
Tensioner shoe for single row drive chain models
Tensioner shoe for models with double-row drive chain
Intermediate shaft — removal, inspection and installation
Valve train, tappets and camshaft
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Flywheel/Drive Plate — Removal, Inspection and Installation
Replacing the crankshaft sealing rings
Replacing the bearing at the end of the crankshaft
Checking and replacing the powertrain support
V6 petrol engine (SOHC)
Engine specifications
General engine data
Repair operations on the engine installed in the vehicle
Top dead center (TDC) of the piston of the first cylinder
Cylinder Head Cover — Removal and Installation
Crankshaft Pulley/Vibration Damper and Hubs
Timing Chain Covers — Removal and Installation
Lower timing chain cover — removal and installation
Drive chain — checking and replacing
Drive chain tensioning mechanism
Camshaft and crankshaft sprockets
Drive chain tensioner and shoe
Valve train, tappets and camshaft
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Replacing the oil pump drive chain
Replacing the sealing rings
V6 petrol engine (DOHC)
Engine specifications
General engine data
Repair operations on the engine installed in the vehicle
Top dead center (TDC) of the piston of the first cylinder
Cylinder Head Cover — Removal and Installation
Crankshaft Pulley/Vibration Damper and Hubs
Timing Chain Covers — Removal and Installation
Upper timing chain cover (HFM fuel injection models)
Lower timing chain cover — removal and installation
Checking and replacing the drive chain
Drive chain tensioning mechanism
Camshaft and crankshaft sprocket
Chain Tensioners — Removal, Checking and Installation
Tensioner Shoe — Removal, Checking and Installation
Camshaft adjustment mechanism
Camshafts and tappets — removal, inspection and installation
Checking and adjusting the position of the camshafts
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump chain and drives — removal, inspection and installation
Replacing the sealing rings
Oil radiator — removal and installation
Diesel engines
Engine specifications
General engine data
Repair operations on the engine installed in the vehicle
Checking the compression pressure
Top dead center (TDC) of the piston of the first cylinder
Cylinder Head Cover — Removal and Installation
Crankshaft Pulley/Vibration Damper and Hubs
Timing Chain Cover — Removal and Installation
Drive chain — checking and replacing
Drive chain tensioning mechanism
Camshaft and crankshaft sprocket
Chain Tensioners — Removal, Checking and Installation
Camshafts and tappets
Checking hydraulic tappets
Camshafts — Installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump and drive chain — removal and installation
Replacing the crankshaft sealing rings
Engine overhaul
Specifications and repair dimensions of engines
General techniques for disassembling the cylinder head
Recommendations for engine removal
Removal and installation of 4-cylinder petrol engines
Removal and installation of 6-cylinder petrol engines
Removal and installation of diesel engines
Engine disassembly sequence
Disassembling the cylinder head
Cleaning and inspection of the cylinder head
Valves — Checking and grinding
Cylinder head assembly
Removal pistons with connecting rods
Removal the crankshaft
Engine cylinder block
Pistons and connecting rods — removal and installation
Crankshaft — Check
Inspection of main and connecting rod bearings
Sequence of engine assembly during major repairs
Installing piston rings
Selection of crankshaft main bearings
Checking the main bearing clearance
Installing the crankshaft
Installing pistons with connecting rods
Starting the engine after major repairs
Cooling system
Technical characteristics of the cooling system
General information about the cooling system
Cooling system hoses
Radiator — removal, inspection and installation
Thermostat — Removal, Checking and Installation
Radiator Fan — Removal and Installation
Fan with electromagnetic clutch — removal and installation
Electrical sensors — removal and installation
Water pump — removal and installation
Water pump (models with six-cylinder petrol engines)
Water pump (diesel engine models)
Heating and ventilation
Heating and ventilation system — general information
Heating system elements — removal and installation
Heater radiator — removal and installation
Heater Control Panel — Removal and Installation
Heater Fan Motor — Removal and Installation
Internal temperature sensor — removal and installation
Heater Radiator Temperature Sensors — Removal and Installation
Air distribution and cable switch
Air flow regulator — removal and installation
Air conditioning system — general information
Fuel system (carburetor)
Technical characteristics of the fuel system
General information about carburetors
Air filter and filter element — removal and installation
Engine air inlet temperature control unit
Fuel pump — removal and installation
Accelerator cable — removal and installation
Carburetor STROMBERG 175 CDT
Replacement of carburetor elements STROMBERG 175 CDT
Carburetor PIERBURG 2E-E
Replacement of carburetor elements PIERBURG 2E-E
Removal and installation the carburetor
Intake manifold — removal and installation
Intake Manifold Heater — Removal and Installation
Injection system «Bosch CIS-E»
Technical characteristics of the Bosch CIS-E (KE-Jetronic) fuel injection system
General information about the Bosch CIS-E (KE-Jetronic) fuel injection system
Accelerator cable — removal, installation and adjustment
Air filter — removal and installation
Air Filter Housing — Removal and Installation
Fuel filter — removal and installation
Pressure accumulator — removal and installation
Fuel level sensor — removal and installation
Fuel pump — removal and installation
Fuel tank — removal and installation
Throttle body — removal and installation
Intake manifold — removal and installation
KE-Jetronic fuel injection system components
Fuel distributor — removal and installation
Air flow sensor — removal and installation
Air pump (models with six-cylinder engines)
Cold start valve — removal and installation
Coolant Temperature Sensor — Removal and Installation
Throttle position switch
Electronic Control Unit (ECU)
Fuel injectors — removal and installation
Pressure regulator — removal and installation
Additional air device
Lambda sensor — removal and installation
Relieving pressure in the fuel system
Adjusting idle speed and CO content in exhaust gases
Injection system «Bosch HFM»
Technical characteristics of the Bosch HFM fuel injection system
General information about the Bosch HFM fuel injection system
Accelerator cable — removal, installation and adjustment
Air filter — removal and installation
Air Filter Housing — Removal and Installation
Throttle body — removal and installation
Intake manifold — removal and installation
Air flow meter — removal and installation
Coolant Temperature Sensor — Removal and Installation
Lambda sensor — removal and installation
Electronic Control Unit (ECU)
Fuel injectors and fuel line
Fuel pressure regulator — removal and installation
Relieving pressure in the fuel system
Adjusting idle speed and CO content in exhaust gases
Diesel fuel system
Technical characteristics of the diesel fuel system
General information about the diesel fuel system
Air filter — removal and installation
Intake manifold — removal and installation
Accelerator cable — removal, installation and adjustment
High pressure fuel pump — removal and installation
Fuel lift pump — removal and installation
Injection timing adjustment mechanism, fuel pump sprocket
High pressure fuel pump injection timing
Fuel injectors — removal and installation
Electronic Idle Speed Control (ELR)
Electronic anti-knock system ARA
Electronic control system of diesel engine
Engine overload protection system
Fuel thermostat — removal and installation
Supply system
Turbocharger technical characteristics
General information about the power supply system
Fuel vapor recovery system
Crankcase ventilation system
Exhaust manifold — removal and installation
Exhaust Gas Recirculation (EGR) System
Turbocharger — removal and installation
Exhaust system — removal and installation
Catalytic converter
Starting and charging system
Technical characteristics of the starting and charging system
General information about the starting and charging system
Battery Care Rules
Checking the battery
Charging the battery
Battery — Removal and Installation
Charging system
Generator — removal and installation
Replacing the voltage regulator unit and brush holder
Engine starting system
Starter — removal and installation
Ignition system (I4)
4-Cylinder Ignition System Specifications
EZL Ignition System
Ignition system TFZ
Checking the ignition system
Ignition coil — removal and installation
Ignition distributor — removal and installation
Distributor rotor — removal and installation
Ignition timing angle
Ignition Control System Components — Removal and Installation
Ignition system (V6)
Ignition System Specifications for 6-Cylinder Engines
General information about the ignition system
Checking the ignition system
Ignition coil — removal and installation
Ignition distributor and distributor rotor
Checking and adjusting the ignition timing angle
Ignition Control System Components — Removal and Installation
Preheating
Technical characteristics of the pre-heating system
General information about the pre-heating system
Glow Plug Control Unit — Removal and Installation
Glow Plugs — Removal, Checking and Installation
Coolant Temperature Sensor — Removal and Installation
Transmission
Clutch
Clutch specifications
General information about the clutch
Clutch assembly — removal, inspection and installation
Release bearing — removal, inspection and installation
Clutch release lever — removal, inspection and installation
Clutch slave cylinder — removal and installation
Clutch Master Cylinder — Removal, Repair and Installation
Adjusting the Clutch Master Cylinder Pusher
Bleeding the hydraulic clutch system
Clutch pedal — removal and installation
Mechanical gearbox
Technical characteristics of a manual gearbox
General information about manual transmission
Gearbox oil change
Gear shift mechanism — removal and installation
Replacing the sealing rings
Reverse Light Switch — Removal, Checking and Installation
Removal and installation the gearbox
Gearbox repair
Automatic gearbox
Technical characteristics of automatic transmission
General information about automatic transmission
Selector lever — removal and installation
Gear Selector Rod — Removal and Installation
Adjusting the pressure control cable
Starter and reverse light interlock switches
Removal and installation of automatic transmission
Automatic transmission repair
Drive shafts
Technical characteristics of drive shafts
General information about drive shafts
Changing the oil in the rear final drive
Removal and installation the rear final drive
Replacing the rear final drive sealing rings
Drive shafts — removal and installation
Replacement of protective covers of CV joints of the drive shaft
Cardan shaft — removal and installation
Rubber elastic coupling of the cardan shaft
Central bearing of the propeller shaft
Universal joint of the cardan shaft
Chassis
Brake system
Technical characteristics of the brake system
General information about the brake system
Bleeding the hydraulic brake system
Brake lines and hoses
Replacing the front brake pads
Replacing rear brake pads
Front brake disc — removal, inspection and installation
Rear brake disc — removal, inspection and installation
Front brake caliper
Caliper repair
Rear Brake Caliper — Removal and Installation
Master Brake Cylinder — Removal and Installation
Vacuum brake booster — removal, inspection and installation
One-way valve of the brake booster
Adjusting the parking brake
Parking brake pads — removal and installation
Parking brake pedal — removal and installation
Parking brake cables — removal and installation
Brake light switch — removal and installation
Anti-lock braking system (ABS)
Anti-lock braking system components — removal and installation
Models with Automatic Speed Regulator (ASR)
Vacuum pump on diesel engine models
Car suspension
Technical characteristics of suspension and steering
General information about suspension and steering
Front Hub Bearing — Checking and Adjusting
Front Wheel Hub — Removal and Installation
Steering knuckle — removal and installation
Front suspension shock absorber — removal and installation
Front suspension spring — removal and installation
Lower control arm front suspension — removal and installation
Front anti-roll bar
Rear Hub Fastener — Removal and Installation
Replacing the rear hub bearing
Rear shock absorber — removal and installation
Shock absorber (models without self-leveling rear suspension)
Rear suspension spring — removal and installation
Rear suspension arms — removal and installation
Lower arm rear suspension — removal and installation
Rear suspension anti-roll bar
Stabilizer bar connecting link
Self-leveling rear suspension system on Estate models
Self-leveling rear suspension components
Steering
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Steering column lock / ignition switch — removal and installation
Ignition switch contact group — removal and installation
Steering shaft rubber coupling — removal and installation
Steering gear — removal and installation
Steering knuckle — removal and installation
Replacing the lower steering gear seal ring
Power Steering Pump — Removal and Installation
Bleeding the power steering system
Steering shock absorber — removal and installation
Central steering rod — removal and installation
Intermediate steering arm — removal and installation
Transverse steering rod — removal and installation
Wheel alignment angles
Body
Exterior (external elements)
Tightening torques for threaded connections
General information about the body
Car body care
Caring for upholstery and carpets
Repair of minor body damage
Repair of severe body damage
Front bumper — removal and installation
Rear bumper — removal and installation
Hood — removal, installation and adjustment
Hood Lock Release Cable — Removal and Installation
Hood lock — removal and installation
Exterior rear view mirrors
Exterior body parts
Interior (internal elements)
Front and rear seats — removal and installation
Front seat belt tensioner mechanism
Seat belt components
Front seat belt on Coupe models
Seat belt height adjustment mechanism
Front seat belt buckle
Rear seat side belt on Sedan models
Rear seat side belt on station wagon models
Central rear seat safety belt
Interior finishing — removal and installation
Center console — removal and installation
Instrument panel — removal and installation
Doors, locks and windows
Doors — removal and installation
Door trim — removal and installation
Door handles and locks
Door glass and window lifters
Trunk lid — removal and installation
Trunk lid lock — removal and installation
Rear door — removal and installation
Rear Door Lock — Removal and Installation
Central locking elements — removal and installation
Windshield and rear glass
Sunroof in a car
Electrical equipment
Equipment and devices
Technical characteristics of electrical equipment
General information about electrical equipment
Electrical circuits
Detecting a faulty electrical circuit
Fuses and relays
Instrument cluster — removal and installation
Elements of the instrument cluster
Speedometer Drive Cable — Removal and Installation
Cigarette lighter illumination — removal and installation
Sound signal — removal and installation
Windscreen wiper arm — removal and installation
Windscreen wiper drive — removal and installation
Rear Door Wiper — Removal and Installation
Windshield and headlight washer system components
Sound reproducing equipment
Loudspeakers — Removal and Installation
Cruise control system components — removal and installation
Airbag system
Airbag Components — Removal and Installation
Switches
Multi-function steering column switches
Headlight corrector — removal and installation
Light switch — removal and installation
Front center console switches
Rear center console switches
Electric Sunroof Switch — Removal and Installation
Parking brake indicator light switch
Seat position adjustment switch
Rear Door Window Switches
Interior Light Switch — Removal and Installation
Trunk Light Switch — Removal and Installation
Headlights and lighting
External Light Bulbs — General Information
Headlights — removal and installation
Front side light
Front fog light
Front direction indicator
Side turn signal repeater — removal and installation
Rear lights — removal and installation
License plate light
Indoor Lighting Bulbs — General Information
Front interior lighting
Rear interior lighting
Trunk light lamp
Instrument cluster lights
Glove compartment light
Heater control panel illumination lamp
Switch illumination lamps
External lighting devices
Headlight adjustment
Electrical circuits
General information, electrical diagram of the charging and starting system
Electrical diagram of the engine management system
Electrical diagram of the instrument cluster and sensors
External lighting wiring diagram
Interior lighting, windscreen wipers and washers
Washers, heated glass, fan, horn, cigarette lighter
Mirrors, radio, central locking, seat belt mechanism
Heating system, electric windows

E-Class W210 (1996-2002)
General information
Vehicle description
Structure of the repair manual
Maintenance and control
Working symbols
General description of the body
Lightweight body design concept
Exterior of the E-class model
Mercedes-Benz E-Class Models
E-class car model range
T-model with station wagon body
Correct seating position in the car
Seating arrangements
Airbags
Luggage compartment capacity
Dimensions of Mercedes E-class cars
Engines — General Information
Diesel 4-cylinder engines: E220D, E200CDI and E220CDI
Common Rail direct fuel injection
Diesel 5-cylinder engines: E250D and E290TD
Diesel 6-cylinder engine E300D
Diesel 6-cylinder engine E320CDI
Petrol 4-cylinder in-line engines E200, E230
Petrol 6-cylinder in-line and V-shaped engines E240, E280, E320
Petrol 8-cylinder V-engines E420, E430, E50AMG, E55AMG
Manual transmission
Automatic transmission
Safety when driving and cornering
Improved driving dynamics
Brake system
Passive safety system
Side impact protection
Frontal collision protection
Technical data and characteristics of the car
Working conditions and tools
Auto mechanic's workplace
Purchase of spare parts
Essential tool for car repair
Special tool for car repair
Safety precautions when repairing a car
Lifting a car with a jack
Techniques of a mechanic
Submitting a car for repair
Car care
Cleaning the car interior
Car body wash
Checking the cleanliness of the car
Car wash area
If you wash your car yourself
Engine wash
Lubrication of moving body parts
Windscreen wiper and washer
Filling the windshield washer fluid
Replacing the wiper blade
Windscreen washer nozzles
Removal the windshield wiper arm
Removal and installation the windshield wiper motor reducer
Windscreen wiper motor terminals
Removal the rear window wiper arm (T-model)
Removal and installation the rear window wiper motor (T-model)
Possible malfunctions of the windshield wiper system, their causes and methods of elimination
Possible malfunctions of the windshield wiper, their causes and methods of elimination
Paintwork care
Repairing paintwork damage
Mercedes E-Class Maintenance Schedule
Diesel engines
Engine repair
Four-cylinder diesel engines
Five-cylinder diesel engines
Six-cylinder diesel engines
Cranking the engine crankshaft
Hydraulic tappets — checking and adjustment
Possible malfunctions of the hydraulic tappet, their causes and methods of elimination
Camshaft drive chain
Checking the compression in the cylinders
Checking the accessory drive belt
Replacement of auxiliary drive belt
Cylinder head gasket
Possible malfunctions of the cylinder head, their causes and methods of elimination
Possible engine malfunctions, their causes and solutions
Knocking in the engine
Lubrication system
Lubrication system — general description
Oil pump
Oil pressure
Motor oil
Automatic oil level control
Checking the operation of the oil level sensor
Checking the condition of the engine oil
Oil and oil filter change
Lubrication system filling volumes
Checking the tightness of the oil system
Possible malfunctions of the lubrication system, their causes and methods of elimination
Cooling system
Cooling system — general information
Overpressure and radiator fan
Cooling liquid
Checking the cooling system for leaks
Coolant level indicator
Checking the level and topping up the coolant
Replacing the coolant
Cooling system filling volumes
Possible malfunctions of the hydraulic tappet thermostat and their causes
Possible malfunctions of the cooling system, their causes and methods of elimination
Thermostat — Removal and Checking
Fan — Checking the serviceability
Replacing cooling system hoses
Radiator — removal and installation
Air filter — removal and installation
Injection system
Diesel engine injection system — general information
Main elements of the Electronic Diesel System (EDS)
Engine operating modes
Idle system
Automatic Shift Assist (ARA)
Variable length intake manifold
Injectors — General Description
Turbocharger — description and maintenance
Possible turbocharger malfunctions, their causes and troubleshooting methods
Engine shutdown
Injection system maintenance
Removal injectors
Disassembling injectors
Accelerator pedal drive
Possible malfunctions of the diesel engine fuel system, their causes and methods of elimination
Supply system
Fuel tank
Fuel pump
Fuel system heat exchanger
Fuel filter — removal and installation
Fuel supply system
Fuel — specifications and description
Draining fuel from the fuel tank
Removal fuel supply system pipes and hoses
Fuel pump malfunctions
Pre-heating device
Exhaust system
Exhaust system — general description
Service life of the exhaust system
Reducing toxicity of exhaust gases
Checking the condition of the exhaust system
Replacing the exhaust system
Replacing the muffler
Gasoline engines
Engine repair
Petrol engines — general information
Hydraulic tappets — checking and adjustment
Possible malfunctions of hydraulic tappets, their causes and methods of elimination
Checking the compression in the cylinders
Auxiliary drive belt
Removal and installation the engine (4-cylinder in-line engine)
Removal and installation the cylinder head cover
Possible engine malfunctions, their causes and solutions
Lubrication system
Lubrication system — general description
Oil circulation
Oil pressure — check
Motor oil — classification and selection
Engine crankcase ventilation
Engine oil consumption
Oil level control system
Checking the condition of the engine oil
Oil and oil filter change
Possible malfunctions of the lubrication system, their causes and methods of elimination
Cooling system
Coolant circulation
Excessive pressure in the cooling system
Features of the cooling system of 6- and 8-cylinder engines
Additional electric fan
Checking the tightness of the cooling system
Cooling liquid
Thermostat — Removal, Installation and Checking
Removal and installation the radiator (for 2.0 and 2.3 l engines)
Possible malfunctions of the cooling system, their causes and methods of elimination
Control system
Engine Management Systems — General Description
Safety precautions when working with the engine management system
Operation of the engine management system
Removal and installation ignition coils
Removal and installation the fuel distributor
Removal and installation fuel injectors
Checking the technical condition of fuel injectors
Possible malfunctions of the injection system, their causes and methods of elimination
Power and exhaust system
Power supply system — general description
Fuel tank ventilation system
Draining fuel from the fuel tank
Removal fuel lines and hoses of the fuel system
Removal and installation the fuel level sensor
Removal and installation the fuel pump
Removal and installation the air filter
Exhaust gas system
Catalytic converter
Checking the exhaust system
Removal and installation of the exhaust system
Transmission
Clutch
Torque transmission
Hydraulic clutch drive
Clutch wear
Checking the clutch
The clutch is jerking
Checking the wear of clutch components
Visual inspection of the clutch hydraulic drive
Bleeding the clutch hydraulic drive
Clutch repair
Possible clutch malfunctions, their causes and solutions
Mechanical gearbox
Manual transmission — general description
Adjusting the gear shift mechanism
Checking the gearbox oil level
Checking the tightness of a manual gearbox
Automatic gearbox
Automatic transmission — general description
How an automatic transmission works
Torque Converter — General Description
Selector lever positions
Checking the automatic transmission
Possible malfunctions of automatic transmission, their causes and methods of elimination
Drive shafts
Cardan shaft — general description
Removal the propeller shaft
Purpose of differential
Checking the oil level in the differential
Rear Wheel Drive Shafts — General Description
Noise in the rear wheel drive shafts
Checking the condition of the rear wheel drive shaft mudguards
Removal and installation the rear wheel drive shaft
Disassembling the drive shaft and replacing the mudguards
Matic all-wheel drive system
Chassis
Car suspension
General information about the suspension
Front suspension — design description
Rear suspension — design description
Chassis of the T-model with a station wagon body
Ground clearance adjustment
Checking the wheel installation
Checking the condition of shock absorbers
Checking mudguards and play in steering rod ends
Checking mudguards and ball joint play
Checking the wheel hub bearing play
Setting the front hub bearing clearance
Removal the front shock absorbers
Checking the removed shock absorbers
Removal the front wheel suspension spring
Removal the rear wheel suspension shock absorber (without clearance adjuster)
Removal the rear suspension spring
Steering
Steering — General Description
Power steering system
Checking the steering play
Checking the power steering fluid level
Checking the tightness of the power steering
Checking the steering rack mudguards
Replacing tie rod ends
Checking the steering rod mudguards
Possible steering malfunctions, their causes and solutions
Tires and wheels
Structure of a multilayer tire
Mercedes E-class wheels
Information indicated on the tire
Important information about tires
Checking tire pressure
Wheel replacement
Checking the condition of the tires
Wheel imbalance
Possible tire malfunctions, their causes and solutions
Brake system
Brake system — general description
Service brake system
Anti-lock braking system (ABS)
Traction control system (ASR)
Electronic throttle control
BAS (Brake-Assist) system
Electronic Stability Program (ESP)
Operation of ABS/ASR/BAS/ESP systems
Checking the brakes
Parking brake system
Checking the brake fluid level
Checking the brake system for leaks and damage
Checking the brake booster
Checking the thickness of the pads
Checking the condition of the brake discs
Replacing the front brake pads
Replacing rear brake pads
Removal the brake caliper
Removal the brake disc
Removal the brake hose
Removal brake pipes
Bleeding the brake system
Replacing brake fluid
Adjusting the parking brake
Removal the parking brake pads
Replacing the parking brake cables
Possible malfunctions of the brake system, their causes and methods of elimination
Body
Exterior (external elements)
Car body — general description
Setting the hood to a vertical position
Removal the hood
Adjusting the hood
Removal the radiator grille
Removal the Mercedes emblem
Replacing the hood release cable
Removal the wing
Removal the mudguards
Removal the side trims
Front and rear bumpers
Removal the outside rearview mirror
Interior (internal elements)
Car interior — general description
Instrument cluster and switches in the cabin
Troubleshooting window lifters
Repair of window lifts on the road
Electric window switches
Removal the power window switch
Central locking with pneumatic drive
Troubleshooting the Central Locking System
Adjusting the rear view mirrors
Checking the electric drive for rear view adjustment
Disassembling the rear view mirror
Cigarette lighter — replacement
Checking the rear window defroster
Removal the radio
Removal the speakers
Replacing interior lighting bulbs
Replacing the remaining lamps in the cabin
Removal the front seats
Removal the rear seat
Removal the rear headrests
Heated seats
Checking seat belts
Removal the glove compartment
Removal the gearshift lever trim on the center console
Removal the ashtray
Removal the center console
Removal the heater control unit trim
Removal the B-pillar trim
Removal the rear pillar trim
Removal the rear shelf
Removal the trim under the dashboard
Removal the upholstery in the pedal area
Doors and windows
Removal the trunk lid
Adjusting the trunk lid
Doors — General Information
Removal the front door
Front door adjustment
Removal the rear door
Rear door adjustment
Removal the door trim
Removal the door glass
Removal the outer door handle
Removal the door lock
Windshield and rear glass
Sunroof
Heating and ventilation
Heating and ventilation — general description
Elements of the automatic heating system (HAU)
Checking the operation of the heating and ventilation system
Replacing the cabin air filter
Supply air fan
Troubleshooting a Fan
Removal the fan motor
Possible malfunctions of the heating system, their causes and methods of elimination
Air Conditioner — General Description
How an air conditioner works
Electrical equipment
Equipment and devices
Electrical equipment — general information
Control devices — general description
Checking control devices
Instrument cluster — general description
Removal the instrument cluster
Tempomat (cruise control)
Airbag system and seat belt pretensioners
Wires and fuses
Color coding of wires
Relay and fuse box mounting block
Fuses — Types and Locations
Replacing the fuse
Relay — purpose and fault finding
Combi relay — location
Power devices
Battery — General Description
Starter — design description
Generator — design description
Checking the electrolyte level in the battery, servicing the contacts
Checking the battery charge
Measuring battery voltage
Starting the engine from an external power source
Charging the battery
Removal the battery
Detection of a faulty consumer
Checking the voltage regulator
Possible battery malfunctions, their causes and solutions
Removal the generator
Removal and installation the starter
Possible starter malfunctions, their causes and solutions
Lighting and signaling
Headlights — General Description
Continuous monitoring of lighting devices
Replacing headlight bulbs
Replacing the fog light bulb
Removal headlights
Approximate headlight adjustment
Headlight adjustment
Adjusting fog lights
Replacing the bulb in the rear light
Removal the rear light
Replacing the bulb in the additional brake light
Replacing the license plate light bulb
Sound and light alarms — general description
Checking sound and light signaling devices
Replacing front turn signals
Replacing turn signal repeaters
If the turn signal relay is faulty
Checking and removing brake lights
Removal the sound signal
Checking the sound signal
Possible malfunctions of the sound signal, their causes and methods of elimination
Possible malfunctions of the brake light, their causes and methods of elimination
Possible malfunctions of hazard warning lights and direction indicators, their causes and methods of elimination
Electrical circuits
Electrical circuits — general description
Conventional symbols on electrical diagrams
Scheme 1. Starter and generator (engines 104, 111, 604, 605, 606)
Diagram 2. Front axle speed signal (GES) (engines 104, 111, 602, 604, 605, 606)
Diagram 3. Rear axle speed signal (GES) (engines 104, 111, 602, 604, 605, 606)
Diagram 4. Rear axle speed signal (GES) (engines 104, 111, 604, 605, 606)
Scheme 5. Automatic transmission (AG) (engines 104, 111, 119, 604, 605)
Scheme 6. Relay module (K40) (engines 602, 604, 605, 606)
Diagram 7. Electronic Throttle Positioning (EFP)/ Cruise Control (TMP)/ Idle Speed Regulation (LLR) (104 engines)
Scheme 8. Diesel engine injection system with high-pressure fuel pump (EVE) of distributor type and electronic regulation (engine 602)
Scheme 9. Diesel engine injection system with high-pressure fuel pump (EVE) of distributor type and electronic regulation (engine 604)
Scheme 10. Diesel engine injection system with in-line fuel injection pump (EVE) and electronic control (engine 605)
Scheme 11. Diesel engine injection system with in-line fuel injection pump (EVE) and electronic control (engine 606)
Scheme 12. Engine with CAN data bus
Diagram 13. Adaptive suspension control system (ADS)
Scheme 14. Anti-glare device of the interior rearview mirror
Scheme 15. Sound signal
Scheme 16. Parktronik parking system (PTS)
Scheme 17. Illumination of a cosmetic mirror
Scheme 18. Fuse and relay box (F1)
Diagram 19. Sliding/lifting sunroof drive (SHD)
Scheme 20. Windscreen wiper
Scheme 21. Interior lighting
Scheme 22. Infrared remote control
Scheme 23. Towing device contact connector
Scheme 24. Central locking
Scheme 25. Outdoor lighting
Scheme 26. Heating system automation (HAU)
Diagram 27. Fuse box in the rear of the car (F4)
Scheme 28 and 29. E320 petrol engine control system
Scheme 30. ABS system, models with traction control system
Scheme 31. Headlights with xenon lamps

G-Class W463 (1999-2019)
General information
Introduction to the guide
About this Guide
Mercedes-Benz G-Class Cars — Abstract
Vehicle Identification Numbers
Purchase of spare parts
Jacking up with a standard jack when changing wheels
Hanging the car
Transportation of a damaged vehicle
Starting the engine from an auxiliary power source
Car fault diagnostics
Controls and instruments
Vehicle specifications and dimensions
Instrument panel and center console — general information
Instrument cluster, gauges, control lamps and indicator lights
Interior controls and equipment
Replacing windshield wipers
Automated air conditioning system (Termatic)
Activation / deactivation of the service mode of the TELE AID emergency call system
Driving and operation
Running-in the first 1500 kilometers
Starting the movement and switching the automatic transmission
Transfer case shifts
Differential lock
Speed control systems (Tempostat / Speedtronic)
Parktronic system (PTS)
Emergency Brake Booster (BAS)
Anti-lock brake system (ABS)
Traction Control System (4-ETS)
Electronic skid control system (ESP)
Maintenance
Routine care and maintenance — general information
Maintenance Specifications
Active Maintenance Warning System (ASSYST)
Schedule of current maintenance
General information about settings
Checking fluid levels, leak control
Checking the condition of tires and their pressure, designating tires and wheel rims, rotating wheels
Changing engine oil and oil filter
Checking the brake system
Checking the fuel system, replacing the fuel filter
Checking the condition and replacing engine compartment hoses, localizing leaks
Checking the condition of multi-rib belts for auxiliary drive units
Checking the cooling system and coolant, replacing the liquid
Checking the condition of the exhaust system
Automatic transmission filter and fluid replacement
Visual inspection of automatic transmission for leaks
Checking the condition of suspension and steering components
Checking the condition of the drive shaft boots
Checking the air conditioning system
Lubrication of door stops and lock cylinders
Visual inspection of seat belts and airbag modules
Checking the functionality of headlights and horn
Checking the condition and replacing the windshield wipers
Replacing the cabin filter
Replacing differential lock fluid
Replacing brake fluid
Checking and replacing spark plugs, checking the condition of high-voltage wires
Replacing glow plugs (diesel models)
Power unit
Engine repair
Engine specifications
Checking compression pressure, assessing the condition of the cylinders
Checking the engine with a vacuum gauge
Replacement of the auxiliary drive belt and elements of its tensioning mechanism
Checking engine oil pressure
Calculating oil consumption
Checking and adjusting the basic position of the camshafts
Checking the basic position of the balance shaft (M112 and 628 engines only)
Checking the condition of the timing chain on the M628 engine
Checking the correct setting of the ignition timing on gasoline models
Removal and installation of the power unit
Removal and installation the powertrain suspension supports
Cooling system
Cooling, Heating and Ventilation System Specifications
Antifreeze is a means of protection against freezing
Coolant Replacement — General Notes
Checking the cooling system cap, replacing the hoses
Checking the Thermostat
Removal and installation the thermostat
Removal and installation the cooling system radiator
Removal and installation the expansion tank
Removal and installation the cooling system fan assembly
Removal and installation the water pump
Removal and installation low-temperature cooler (M612)
Removal and installation the engine block heater
Removal and installation of additional heater STH
Removal and installation the circulation pump of the additional heater STH
Heating and ventilation
General information and safety precautions
Removal and installation the control panel of the heating / ventilation / air conditioning systems
Removal and installation the heater/air conditioner fan and its control module
Removal and installation the heater heat exchanger
Removal and installation the heater circulation pump
Removal and installation rear ventilation flaps
Checking the refrigerant level in the working path of the A/C system
Removal and installation of sensors of the K/V system
Removal and installation the auxiliary fan assembly
Removal and installation the electric motor of the ventilation flap drive
Removal and installation the stepper motor of the air circulation mode switching flap drive
Removal and installation the electric motor of the mixing flap drive
Removal and installation of the air conditioning system evaporator and its casing
Removal and installation of the air conditioning system compressor
Removal and installation of the condenser of the K/V system
Removal and installation the expansion valve
Removal and installation the receiver-dryer
Power system (gasoline)
Power supply system specifications
General information and safety precautions
Checking and adjusting idle speed / ignition timing / CO concentration
Relieving pressure in the fuel system of a gasoline engine
The operating principle of the control and injection system of a gasoline engine
General check of the petrol engine injection system
Checking the injectors
Removal and installation air intake tract components
Maintenance of throttle actuator components
Emptying the fuel tank
Removal and installation the fuel pump
Removal and installation the fuel level sensor
Removal and installation of fuel distribution line and injectors
Removal and installation the fuel tank
Removal and installation the fuel injection control module (ECM ME-SFI)
Fuel system (diesel)
General information about the fuel system of diesel engines
Fuel injection system checks
Servicing air intake tract components
Removal air from the low pressure circuit of the fuel system
Removal and installation the fuel pre-pump
Removal and installation of high pressure fuel pump (HPFP)
Removal and installation of fuel distribution line and injectors
Removal and installation the fuel line pressure sensor
Removal and installation the fuel pressure regulator valve
Removal and installation the valve assembly
Removal and installation the fuel cooler
Removal and installation a low-temperature cooler
Removal and installation the fuel injection control module
Exhaust system
Exhaust and emission control systems
Tightening force of threaded connections, Nm
Removal and installation of the exhaust system
Removal and installation of exhaust manifolds
Removal and installation lambda probes
Removal and installation the air pump
Removal and installation the EVAP canister purge valve
Removal and installation the carbon canister (EVAP)
Removal and installation the EGR valve
Removal and installation the EGR cooler
Removal and installation EGR positioners
Removal and installation the coolant temperature sensor (CDI)
Ignition and control system
Engine Electrical System Specifications
Basic information and safety precautions
Checking the ignition and injection control system
Troubleshooting — General Information and Preliminary Checks
Checking and adjusting the ignition timing angle
Spark plugs — checking condition
Removal and installation ignition coils
Removal and installation the crankshaft position sensor (CKP)
Removal and installation the camshaft Hall sensor
Removal and installation knock sensors (KS)
Diesel engine preheating system
Checking diesel glow plugs
Removal and installation glow plugs
Diagnostics of electronic control systems and diagnostic equipment
Controller for interfacing a personal computer with the on-board self-diagnostic system OBD II
Using an Oscilloscope to Monitor the Performance of a Control System
Charging and starting system
General information about the charging and starting system
Battery — General information, maintenance recommendations
Charging system — general information and safety precautions
Checking the charging system
Removal and installation the generator
Engine Starting System — General Information and Precautions
Removal and installation the starter
Transmission
Automatic gearbox
General information about automatic transmission
Automatic Transmission Specifications
Troubleshooting — General Information
General principles of operation of the transmission control system, control signals
Adjusting the AT shift drive
Removal and installation the electro-hydraulic shift control unit
Removal and installation of AT with a torque converter
Removal and installation the selector module (ESM)
Removal and installation the AT output speed sensor
Removal and installation the ATF cooler
ATF Cooler and Oil Lines Flushing
Removal and installation the electronic transmission control module (TCM/ETC)
Transfer case
Transmission Line Specifications
Basic principles of organizing permanent all-wheel drive
Lubrication of cardan shaft hinge joints and sliding joints
Bleeding air from the hydraulic circuit of the differential lock drive
Changing the oil in the transfer case
Removal and installation the transfer case control module
Removal and installation the vacuum receiver of the differential lock control system
Removal and installation the differential lock drive vacuum pump
Removal and installation the transfer case servomotor
Disconnecting and connecting cardan shafts on the transfer case
Removal and installation the transfer case
Removal and installation transfer case suspension supports
Transfer case design
Replacing the transfer case seals
Removal and installation the slave cylinder of the interaxle differential lock drive
Removal and installation the front cover
Removal and installation the intermediate flange bearing cover
Disassembling and assembling the bearing cap
Removal and installation the intermediate flange cover
Removal and installation the intermediate flange
Removal and installation the center differential
Disassembly and assembly of the center differential
Removal and installation the input and intermediate shafts
Disassembling the input (drive) shaft
Disassembling the intermediate shaft
Removal and installation components of the center differential lock engagement mechanism
Removal and installation components of the transfer case mode switching mechanism
Axles front and rear
General information about bridges
Checking and adjusting the level / changing the oil in the bridge assemblies
Checking the grease packing of the pivot housings of the front axle pivot assemblies
Checking and adjusting the play of the front axle wheel bearing
Checking the concentricity of the seating of the connecting flanges of the main gear drives
Replacing the seals of the main gear drive pinions
Removal and installation of main gear drive pinions
Removal, installation and adjustment of actuator cylinders and components of the drive mechanism of the interwheel differential lock
Disassembly and assembly of the differential lock actuator cylinder
Removal and installation front wheel hubs
Disassembly and assembly of front wheel hubs
Removal and installation front axle drive shafts
Adjusting the bearings of the swivel units
Disassembly and assembly of the front axle hinge housing
Disassembly and assembly of the drive shaft
Removal and installation axle shafts
Disassembly and assembly of the axle shaft
Removal and installation of interwheel differential assemblies with driven gears of final drives
Disassembly and assembly of interwheel differentials
Checking the correct engagement of the main transmission gears
Chassis
Brake system
General information about the brake system and safety precautions
Brake system specifications
Checking the brake system for leaks
Checking the proper functioning of the brake booster
Removal and installation the brake fluid reservoir and the brake master cylinder (BMC)
Removal and installation the brake booster and the BAS diaphragm stroke sensor
Removal and installation a vacuum pump (diesel engines)
Removal and installation ABS/EBV/ESP control modules
Removal and installation of the ABS hydraulic modulator / 4-ETS
Removal and installation ABS wheel sensors
Removal and installation ABS wheel sensor rotors
Removal and installation the foot brake pedal
Removal and installation the parking brake cocking lever with the carrier bracket
Replacing brake hoses
Checking the condition and replacing brake pads
Replacing the parking brake shoes
Removal and installation of brake calipers
Fixed type caliper repair
Checking, removing and installing brake discs
Removal and installation components of the parking brake cable drive
Adjusting the parking brake drive
Bleeding the brake system
Front suspension
General information about suspension and steering
Suspension and steering specifications
General information about the front suspension
Removal and installation the front axle assembly
Removal, checking and installation front shock absorbers
Removal and installation front suspension springs
Removal and installation the front anti-roll bar
Removal and installation trailing arms
Replacing the rubber bushing of the trailing arm
Car Wheel Alignment Angles — General Information
Adjusting the front wheel alignment
Determining the required amount of run-out
Checking and adjusting the front wheel turning angle limits
Checking the wheelbase size
Rear suspension
General information about the rear suspension
Removal and installation of the rear axle assembly
Removal, checking and installation rear shock absorbers
Removal and installation front suspension springs
Removal and installation the rear anti-roll bar
Removal and installation trailing arms
Steering
General information about steering
Checking the steering pump pressure
Checking and adjusting the hydraulic limiter
Steering shaft adjustment
Evaluation of the condition of the steering drive components
Removal and installation the steering wheel
Removal and installation the steering wheel contact cable drum
Removal and installation the steering wheel angle sensor
Removal and installation the electronic steering column lock mechanism
Removal and installation a steering column with electric adjustment
Removal and installation the steering pump
Removal and installation of the power steering fluid cooling line
Removal and installation the steering gear
Steering mechanism design
Body
Exterior (external elements)
Specifications of the body and its elements
Removal and installation windshield wiper arms
Removal the front wiper drive
Removal and installation the hood
Removal and installation the hood lock
Removal and installation the hood latch release drive cable
Removal and installation the front grille
Removal and installation headlight covers
Removal and installation the engine compartment boot for the AMG package
Removal and installation side steps
Removal and installation bumpers
Removal and installation door rear view mirrors
Removal and installation the windshield washer fluid reservoir
Removal and installation the spare wheel holder
Removal and installation of wheel arch protection lockers
Removal and installation exterior trim panels of the A-pillars
Removal and installation front fenders
Interior (internal elements)
Removal and installation lower instrument panel covers
Removal and installation the instrument panel air duct deflectors
Removal and installation the glove box
Removal and installation the instrument panel handle
Removal and installation the front ashtray
Removal and installation the left lower section of the instrument panel trim
Removal and installation the knee support
Removal and installation the steering column end cover
Removal and installation the trim panel of the console section of the instrument panel
Removal and installation the center console
Removal and installation the instrument cluster
Removal and installation the instrument panel
Removal and installation interior rear view mirror
Removal and installation body pillar trim panels
Removal and installation of interior trim panels
Removal and installation the ceiling trim (station wagon models)
Removal and installation carpet floor panels
Removal and installation front seat assemblies
Removal and installation rear seat assemblies
Removal and installation seat backs
Removal and installation seat cushions
Doors, locks and windows
Removal, installation and adjustment of doors
Removal and installation the gas-filled tailgate strut (station wagon models)
Removal and installation exterior door handles
Removal and installation interior door handles
Removal and installation door locks
Removal and installation tailboard latches and locking wedges
Removal and installation interior trim of door assemblies
Removal and installation door window regulators
Removal and installation of window frames and door assemblies
Removal and installation of body glazing elements
Removal and installation the upper hatch cover trim panel
Removal and installation the top hatch cover
Removal and installation the sunroof drive cable
Removal and installation the upper hatch frame
Removal and installation the sealing element of the upper hatch and its fastening elements
Removal and installation the upper hatch drainage channel
Removal, installation and adjusting the upper hatch wind deflector
Electrical equipment
Equipment and devices
On-board electrical equipment specifications
General information and precautions
Search for causes of electrical equipment failures
Fuses — General Information
Circuit Breakers — General Information
Relays — general information and checking the correct functioning
Digital data bus CAN
Disconnecting and connecting electrical wiring of mounting blocks and control modules
Removal and installation fuse and relay mounting blocks
Removal and installation control modules
Removal and installation windshield wiper drive electric motors
Removal and installation single lock activators
Removal and installation electric motors for the front seat adjustment drive
Removal and installation sensors
Removal and installation of front airbag modules
Switches in salon
Removal and installation steering column switches
Group of switches on the left side of the instrument panel
Removal and installation the switch handle and actuators for adjusting the position of the headlights
Removal and installation of the upper switch group assembly of the console part of the instrument panel
Removal and installation the differential lock switch panel
Removal and installation the driver's door electric window switch panel
Removal and installation the overhead console panel
Headlights and lighting
Removal and installation of headlights, replacement of lamps, adjustment of the direction of optical axes
Removal and installation rear combination lights
Removal and installation turn signals
Removal and installation the high-level brake light
Removal and installation fog lights
Replacing interior lighting bulbs
Audio system and navigation
Removal and installation the radio
Removal and installation CD changer / TV tuner
Removal and installation of antenna amplifiers
Removal and installation of antenna units
Removal and installation the antenna splitter
Removal and installation speakers
Removal and installation of the transceiver of the Handsfree mobile telephone system
Removal and installation the mobile phone interface
Removal and installation a cell phone holder
Electrical circuits
List of symbols on electrical diagrams
ME-SFI control system for petrol engines 112.945 and 113.962
Diesel Engine CDI Control System 628.962
Transmission Control Module (ETC) (all models)
Electronic AT selector lever module (all models)
Transfer case (all models)
Front differential lock (all models produced from 01.09.01)
Starting system (all models produced 01.09.01)
Engine cooling system (all petrol models produced 01.06.99)
Anti-lock Brake System (ABS) (all models)
Steering column (all models)
Mounting block of fuses F1 (all models produced from 01.09.01)
Mounting block of fuses F2 (all models produced from 01.09.01)
Mounting block of preliminary fuses F32 (all models produced from 01.09.01)
Interior fuse box F34 (all models)
Mounting block relay K40 (petrol models)
Electronic Ignition Switch (EIS) (all models produced from 11/25/02)
Diagnostic connector DLC (all models produced from 01.09.01)
Instrument cluster without ASSYST system (all models produced from 01.09.01)
Instrument cluster with ASSYST system (petrol models)
Signal system (petrol models)
Driver Door Control Module (All Models)
Right Front Door Control Module (All Models)
Left Rear Door Control Module (All Models)
Single lock (petrol models)
13-pin connector for towing hitch wiring (petrol models, code E43)
Windscreen wipers (petrol models)
Headlight cleaners (petrol models)
Air conditioning system (AAC) (petrol models produced from 01.09.01)
Additional safety systems (petrol models)
Steering Column Contact Cable Drum (All Models)
Cigarette lighter (all models)
Power outlets (all models)
Ceiling console (all models produced from 01.09.01)
Rear reading lights (G 500)
Electric front seat adjustment (ESV) (all models produced from 01.09.01)
Anti-theft alarm system (ATA) (petrol models, code FZ5)

M-Class W163 (1997-2005)
General information
Introduction to the guide
Mercedes-Benz M-Class Cars (W163) — Abstract
Vehicle Identification Numbers
Purchase of spare parts
Jacking and towing a car
Starting the engine from an auxiliary power source
Car fault diagnostics
General information and vehicle specifications
Controls and instruments
Single lock for access to the car
Unlocking and locking doors
Access to the luggage compartment
Access to the fuel tank filler neck
Access to the underhood space
Access to the right front seat storage compartment
Anti-theft system
Elements of security systems — general information
Rules for the use of passive safety equipment for drivers and passengers
Seat adjustment
Supplemental Restraint System (SRS)
Risk of Carbon Monoxide (CO) Poisoning
Instrument panel and center console
Instrument cluster, gauges and control lamps and indicator lights
Interior controls and equipment
Luggage compartment equipment
Replacing windshield wipers
Automated air conditioning system (climate control)
COMMAND system, radio, telephone and radio
Driving and operation
Running in the car for the first 1500 km
Operating techniques and auxiliary systems
Running in a new car
Features of operation of vehicles equipped with a three-function catalytic converter
Car parking
Starting off and changing gears
Speed control systems (Tempostat / Speedtronic)
Parktronic system (PTS)
Emergency Brake Booster (BAS)
Anti-lock brake system (ABS)
Traction Control System (4-ETS)
Electronic skid control system (ESP)
Electronic Brakeforce Distribution (EBV)
Maintenance
Recommended lubricants and fluids
Active Maintenance Warning System (ASSYST)
Schedule of current maintenance
General information about settings
Checking fluid levels, leak control
Checking the condition of tires and their pressure, designating tires and wheel rims, rotating wheels
Changing engine oil and oil filter
Checking the brake system
Checking the fuel system, replacing the fuel filter
Checking the condition and replacing engine compartment hoses, localizing leaks
Checking the condition of multi-rib belts for auxiliary drive units
Checking the cooling system and frost resistance of the coolant, replacing the liquid
Checking the condition of the exhaust system
Replacement and checking of ATF level, replacement of AT filter
Visual inspection of automatic transmission for leaks
Checking the condition of suspension and steering components
Checking the condition of the drive shaft boots
Checking the air conditioning system
Lubrication of door stops and lock cylinders
Visual inspection of the seat belt and airbag unit
Checking the functionality of headlights and horn
Checking the condition and replacing the windshield wipers
Replacing the cabin filter
Replacing brake fluid
Checking and replacing spark plugs, checking the condition of high-voltage wires
Power unit
Gasoline engines
Engine specifications
Checking the compression pressure in the cylinders
Checking the engine with a vacuum gauge
Replacement of the auxiliary drive belt and elements of its tensioning mechanism
Removal and installation the engine
Removal and installation timing belt covers
Replacing the timing chain
Removal and installation of timing drive components
Setting the base position of the camshafts
Checking the balance shaft base position (112 series engines only)
Removal and installation of timing components
Removal and installation the cylinder head
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Removal and installation the end cover, replacing the rear crankshaft oil seal
Removal and installation the torsional vibration damper / drive belt pulley
Removal and installation the flywheel/drive disc
Removal and installation the powertrain suspension supports
Maintenance of the lubrication system
Diesel engines
Removal and installation the engine
Removal and installation timing belt covers
Replacing the timing chain
Removal and installation of timing drive components
Setting the base position of the camshafts
Checking the Balance Shaft Base Position (628 Series Engines Only)
Removal and installation of timing components
Removal and installation the cylinder head
Removal and installation the intake port shutoff motor (612 series engine)
Removal and installation the exhaust manifold
Replacing the front crankshaft oil seal
Removal and installation the rear end cover, replacing the rear crankshaft oil seal
Removal and installation the torsional vibration damper / drive belt pulley
Removal and installation the flywheel/drive disc
Maintenance of the lubrication system
Cooling system
Cooling, Heating and Air Conditioning System Specifications
Antifreeze is a means of protection against freezing
Coolant Replacement — General Notes
Replacing cooling system hoses
Checking the proper functioning of the thermostat
Removal and installation the thermostat
Removal and installation the cooling system radiator
Removal and installation the cooling system fan assembly
Removal and installation the water pump
Heating and ventilation
General information and safety precautions
Removal and installation the control panel of the heating / ventilation / air conditioning systems
Removal and installation the heater/air conditioner fan and its resistive assembly
Removal and installation the heater heat exchanger
Removal and installation the stepper motor of the air circulation mode switching flap drive
Removal and installation the electric motor of the mixing flap drive
Quick check of the air conditioning system operation
Removal and installation the auxiliary fan assembly
Removal and installation the intake fan of the cabin air temperature sensor
Removal and installation the outside air temperature sensor
Removal and installation the evaporator temperature sensor
Removal the air conditioner evaporator housing
Removal and installation the air conditioner evaporator
Removal and installation the air conditioner condenser
Removal and installation the expansion valve
Removal and installation the receiver-dryer
Removal and installation the air conditioning control module
Power system (gasoline)
Checking and adjusting idle speed / ignition timing / CO concentration
Relieving pressure in the fuel system of a gasoline engine
The operating principle of the control and injection system of a gasoline engine
General check of the petrol engine injection system
Checking the injectors
Removal and installation air intake tract components
Maintenance of throttle actuator components
Emptying the fuel tank
Removal and installation the fuel pump assembly with fuel level sensor
Removal and installation the fuel shut-off valve (US models only)
Removal and installation of fuel distribution line and injectors
Removal and installation the fuel line from the filter to the fuel line
Removal and installation the fuel tank
Fuel system (diesel)
Diesel Engine Fuel System — General Information
Fuel injection system checks
Servicing air intake tract components
Servicing Throttle Actuator Components
Removal and installation the fuel level sensor
Removal air from the low pressure circuit of the fuel system
Removal and installation the fuel pre-pump
Removal and installation of high pressure fuel pump (HPFP)
Removal and installation of fuel distribution line and injectors
Removal and installation the fuel line pressure sensor
Removal and installation an electric shut-off valve
Removal and installation the fuel pressure regulator valve
Removal and installation of valve assembly on models 163.128
Removal and installation the fuel cooler on models 163.113
Removal and installation the fuel injection control module
Replacing the parking brake shoes
Bleeding the brake system
Removal and installation the pedal assembly and brake light switch sensor
Removal and installation the parking brake pedal
Removal and installation the parking brake cable assembly
Adjusting the parking brake drive
Removal and installation of ABS/ETS/ESP wheel sensors
Exhaust system
Exhaust and emission control systems
Removal and installation of the exhaust system
Replacing the front sections of the exhaust system on gasoline models
Removal and installation catalytic converters on diesel models
Removal and installation lambda probes
Removal and installation the EGR valve — M112/113
EGR Cooler Removal and Installation — Diesel Models
Removal and installation the air pump — M112/113
Removal and installation the carbon adsorber — gasoline models
Removal and installation the fuel vapor accumulation expansion tank
Ignition and control system
Engine Electrical System Specifications
Basic information and safety precautions
Checking the ignition and injection control system
Troubleshooting — General Information and Preliminary Checks
Checking and adjusting the ignition timing angle
Spark plugs — checking condition
Removal and installation ignition coils — petrol models
Removal and installation the crankshaft position sensor (CKP)
Removal and installation the camshaft position sensor (CMP)
Removal and installation the camshaft Hall sensor
Removal and installation knock sensors (KS) — petrol engines
Diesel engine preheating system
Checking glow plugs
Removal and installation glow plugs
Removal and installation the coolant temperature sensor (ECT)
Diagnostics of electronic control systems and diagnostic equipment
Controller for interfacing a personal computer with the on-board self-diagnostic system OBD II
Using an Oscilloscope to Monitor the Performance of a Control System
Charging and starting system
Charging and starting systems — general information
Battery — General information, maintenance recommendations
Charging system — general information and safety precautions
Checking the charging system
Removal and installation the generator
Removal and installation the generator drive pulley
Removal and installation the voltage regulator
Engine Starting System — General Information and Precautions
Removal and installation the starter
Transmission
Mechanical gearbox
Manual Transmission Specifications
Adjustment of the gear shift drive RCPP 717.461
Removal and installation the manual transmission shift lever 717.461
Design features of the rod-cable gear shift drive for the 716.644 manual transmission
Removal and installation the manual transmission shift lever 716.644
Removal and installation of a manual transmission
Automatic gearbox
Automatic transmission specifications
Troubleshooting — General Information
General principles of operation of the transmission system, control signals
Adjusting the automatic transmission shift drive
Removal and installation the electro-hydraulic shift control unit
Removal and installation of AT with a torque converter
Removal and installation the selector module
Removal and installation the electronic ignition switch (EIS) interlock cable
Clutch
Transmission Line Specifications
Description of the clutch design
Assessing the degree of wear of the driven clutch disc
Removal, installation and testing of the clutch
Removal and installation the master cylinder
Removal and installation the clutch slave cylinder
Bleeding air from the clutch hydraulic circuit
Drive shafts and cardan
Removal and installation the front propeller shaft
Removal and installation the rear propeller shaft
Removal and installation the intermediate bearing of the rear crankshaft
Removal and installation of steering knuckle, replacement of ball joint
Removal and installation the front drive shaft flange and the front hub double-row radial thrust ball bearing
Removal and installation of the rear hub assembly, replacement of the ball joint
Removal and installation the rear drive shaft flange and the rear hub double-row radial thrust ball bearing
Removal and installation drive shafts
Replacement of drive shaft joint dust boots
Transfer case
Removal and installation the transfer case control module
Removal and installation the transfer case
Replacing the transfer case input shaft seal
Replacing the rear propeller shaft output flange seal
Replacing the front output shaft seal
Removal and installation the transfer case mode switching servomotor
Removal and installation of the planetary gear assembly of the transfer case center differential
Removal and installation of the transfer case bearing assembly
Removal and installation the transfer case oil pump
Removal and installation the transfer case shift mechanism
Removal and installation the transfer case reduction gear
Replacing the differential side seals
Replacing differential drive gear seals
Removal and installation differentials
Chassis
Brake system
Brake and auxiliary systems specifications
General information and safety precautions
Checking the brake system for leaks
Checking the proper functioning of the brake booster
Checking the non-return valve
Removal and installation the master brake cylinder
Removal and installation the brake booster and the BAS diaphragm stroke sensor
Removal and installation of the ETS/ESP hydraulic modulator
Removal and installation of hydraulic lines laid between the master cylinder and the ETS/ESP hydraulic modulator
Assessing the degree of wear and replacing brake pads
Replacing brake hoses
Removal and installation the caliper
Removal and installation the brake disc
Front suspension
Suspension and steering specifications
Removal and installation the front axle assembly
Removal, checking and installation front shock absorbers
Removal and installation the torsion bar
Removal and installation torsion springs
Removal and installation the lower wishbone, replacing the front axle bushing
Removal and installation the upper wishbone
Checking the condition of the ball joints of the steering knuckle
Rear suspension
Removal and installation of the rear axle assembly
Removal, disassembly and installation of rear struts
Removal and installation the torsion bar
Removal and installation the lower wishbone
Removal and installation the upper wishbone
Removal and installation the longitudinal stretcher
Steering
Filling and «bleeding» the steering pump
Checking the steering pump pressure
Replacing the clamp securing the power steering fluid cooling hose
Evaluation of the condition of the steering rod joints and rack and pinion housing boots
Removal and installation the steering pump
Replacing the steering gear housing dust boots
Removal and installation tie rod ends
Removal and installation of the steering gear input unit
Removal and installation the steering gear
Disassembling the mechanical steering column adjuster
Removal and installation the steering wheel and the steering column spiral contact drum
Removal and installation the ignition lock cylinder
Removal and installation the steering column lock
Removal and installation of the steering column jacket
Suspension geometry
Checking the geometric parameters of the bridge installation
Checking and adjusting the ride height
Car Wheel Alignment Angles — General Information
Checking and adjusting camber and runout
Checking and adjusting convergence
Checking the amount of front wheel divergence when turning
Body
Exterior (external elements)
Body specifications and dimensions
Removal and installation windshield wiper arms
Removal the front wiper drive
Removal and installation retractable telescopic headlight washer nozzles
Removal, installation and adjustment of the hood
Replacing hood hinges
Removal and installation the Mercedes emblem
Removal, installation and maintenance of bonnet lock components
Removal and installation a gas-filled bonnet locking stop in the open position
Removal and installation the washer fluid reservoir
Removal and installation the front bumper
Removal and installation the upper front cross member of the frame
Removal and installation lower engine compartment protection panels
Removal and installation the rear bumper
Removal and installation the outer spare wheel carrier
Removal and installation of wheel arch protection lockers
Interior (internal elements)
Removal and installation lower instrument panel covers
Removal and installation the instrument panel air duct deflectors
Removal and installation the central (console) section of the instrument panel
Removal and installation the main storage compartment
Removal, installation and adjusting the main glove compartment cover (models produced up to 31.08.99)
Removal and installation the lower and upper main sections of the instrument panel
Removal and installation the console storage compartment cover
Removal, disassembly and installation of the center console
Removal and installation the selector lever trim cover (using models produced up to 31.08.01 as an example)
Removal and installation body pillar trim panels
Removal and installation front footwell trim panels
Removal and installation door sill trims
Removal and installation carpet floor panels
Removal and installation front seat assemblies
Removal and installation the rear seat
Removal and installation seat backs
Removal and installation the folding armrest of the split rear seat
Doors and locks
Removal and installation doors
Removal and installation side door opening limiters
Removal and installation tailgate hinges
Removal and installation the gas-filled sliding tailgate stop
Removal and installation exterior door handles
Removal and installation interior trim panels of door assemblies
Removal and installation door locks
Removal and installation door rear view mirrors
Electrical equipment
Equipment and devices
Fuses and Relays Specifications
General information and precautions
Search for causes of electrical equipment failures
Fuses — General Information
Circuit Breakers — General Information
Relays — general information and checking the correct functioning
Digital data bus CAN
Removal and installation of mounting blocks
Removal and installation control modules
Removal and installation the CAN bus adapter
Removal and installation the instrument cluster
Replacing the lamp of the rotary push-button temperature selection module
Removal and installation on-board power sockets
Removal and installation the center console switch group
Removal and installation of individual switches for electric drive of rear door window regulators
Removal and installation front seat electric adjustment switches
Removal and installation the steering column switch assembly
Removal and installation the overhead console assembly
Removal and installation the switch for controlling the operation of the electric drive of the upper hatch
Removal and installation of the trip computer assembly (if equipped accordingly)
Removal and installation of front airbag modules
Removal and installation side airbag modules
Drive motors
Removal and installation of electric motor groups for the front seat adjustment drive
Removal and installation of electric motors for the door window regulator drives
Removal and installation electric motors for adjusting the position of door rear-view mirrors
Removal and installation the electric motor for the upper sunroof drive
Removal and installation of electric motors for adjusting the direction of the optical axes of the headlights
Removal and installation windshield wiper drive electric motors
Removal and installation of electric motors for the rear door lock actuators and fuel filler flap
Removal and installation of electric motors for exhaust vent drives
Lighting and signaling
Removal and installation horn horns
Removal and installation of headlights, replacement of lamps
Removal, installation and replacement of fog lamps
Removal and installation rear lights, replacing bulbs
Removal and installation the high-level central brake light
Removal and installation license plate lights
Replacement of interior lamp bulbs
Removal and installation the outside air temperature sensor
Removal and installation the rain sensor (if equipped)
Audio system
Removal and installation the radio
Removal and installation door speakers
Removal and installation the AM/FM amplifier
Removal and installation the antenna splitter
Removal and installation a CD changer (if equipped)
Removal and installation a subwoofer (if equipped)
Electrical circuits
Abbreviations and designations used in electrical circuits
Manual air conditioning system with cooling fan control module (ML 430)
Air conditioning system with manual control and without cooling fan control module (ML 430)
Anti-lock brake system (ABS) (ML 430)
Brake Booster System (ML 430)
Cooling system fan (ML 430)
Anti-theft system with additional siren (ML 430)
Anti-theft system without additional siren (ML 430)
General Activity Module (AAM) (ML 430)
Extended Activity Module (EAM) (ML 430)
Processor data lines (ML 430)
Tempostat or cruise control (ML 430)
Glass heating (ML 430)
Engine Management System (ML 430)
Engine Management System (ML 320)
Engine Management System (ML 500)
Reversing lights (ML 430)
Trip computer (ML 430)
Heated driver's seat (ML 430)
Outdoor lighting (ML 430)
Headlight adjustment (ML 430)
Horn (ML 430)
Headlights (xenon) (ML 430)
Headlights (not xenon) (ML 430)
Instrument cluster (ML 430)
Interior lighting when doors are opened (ML 430)
Instrument lighting (ML 430)
Driver's seat adjustment (with memory function) (ML 430)
Front passenger seat adjustment (with memory function) (ML 430)
Power Distribution (ML 430)
Electric door lock drive (ML 430)
Electric door mirrors (ML 430)
Electric driver's seat (ML 430)
Heated front passenger seat (ML 430)
Electric front passenger seat (ML 430)
Electric drive for two-panel upper hatch (ML 430)
Electric single panel roof hatch (ML 430)
Electric window lifts (ML 430)
Electric rear windows (ML 430)
Charging system (ML 430)
Headlight washers (ML 430)
Radio (basic, with emergency call system) (ML 430)
Radio (basic, without emergency call system) (ML 430)
Radio (upgraded, with emergency call system) (ML 430)
Radio (upgraded, without emergency call system) (ML 430)
AT Shift Lock (ML 430)
Starting system (ML 430)
All-wheel drive (4WD) (ML 430)
Supplemental Restraint System (SRS) (with seat position memory function) (ML 430)
Supplemental Restraint System (SRS) (without seat position memory function) (ML 430)
Automatic transmission (AT) (ML 430)
Windscreen wipers/washers (ML 430)
Rear window wipers/washers (ML 430)

S-Class W116 (1972-1980, petrol)
General information
Introduction to guide
General Provisions: Introduction
Vehicle designation
General repair instructions
Working conditions and tools
Correct lifting of the car
Maintenance and care
General specifications of the car
Power unit
8-cylinder V8 engine
Removal and installation the engine
Cylinder head: removal and installation
Disassembly and assembly of the engine
Disassembling the cylinder head
Cylinder head repair
Camshaft Drive Cover: Removal and Installation
Pistons and connecting rods — removal
Pistons and Connecting Rods — Cylinder Measurements
Checking pistons and connecting rods
Assembly of pistons and connecting rods
Installing pistons and connecting rods
Cylinder block
Crankshaft and drive plates
Checking the crankshaft parts
Installing the crankshaft
Box drive discs
Damper and crankshaft pulley
Rear Crankshaft Oil Seal and Cover
Front crankshaft oil seal
Camshaft drive
Removal and installation the drive chain
Removal and installation the tensioner shoe
Removal and installation chain guides
Removal and installation the spark distributor drive sprocket
Removal and installation camshafts (without removing the engine)
Engine mounts
Exhaust system
Engine specifications
Tightening torques for threaded connections
6-cylinder I6 engine
Removal the engine
Engine installation
Disassembly and assembly of the engine
Removal the cylinder head
Disassembling the cylinder head
Cylinder head repair
Pistons and connecting rods — removal
Measuring cylinders, checking pistons and connecting rods
Assembly of pistons and connecting rods
Installing pistons and connecting rods
Cylinder block
Removal the crankshaft
Crankshaft and flywheel: checking the parts
Installing the crankshaft
Flywheel or drive discs (automatic transmission)
Damper and crankshaft pulley
Rear oil seal
Front oil seal
Camshaft drive
Removal and installation the chain tensioner
Removal and installation the drive chain
Removal and installation the tensioner shoe
Removal and installation chain guides
Removal and installation the guide sprocket
Removal and installation rocker arms
Removal and installation the camshaft housing
Removal and installation camshafts
Checking the valve timing
Adjusting the valve timing
Adjusting clearances in valve mechanisms of 6- and 8-cylinder engines
Engine mount
Cooling and lubrication system
Engine lubrication system — general information
Removal and installation the oil pump
Oil filter
Removal and installation the oil pan
Engine cooling system — general information
Draining and filling the cooling system
Cooling liquid
Radiator and fan
Removal and installation the coolant pump
Thermostat — General Information
Adjusting the tension of the coolant pump drive belts
Lubrication and Cooling System Specifications
Power system (carburetor)
Twin carburetor Solex 4A 1 — device
The principle of operation of a carburetor
Disassembly and assembly of the carburetor
Checking the carburetor
Air filter
Fuel pump
Power supply system specifications
Fuel injection system
The structure and functions of the main elements of the power supply system
Adjusting idle speed and CO content in exhaust gases
Removal and installation of individual components of the fuel injection system
Checking the fuel injection system components
Injection system specifications
Ignition system
Ignition system — brief description
Safety rules when working with the ignition system
Ignition distributor
Adjusting the ignition timing angle
Spark plugs
Ignition coil
Transistor ignition system for fuel injection engines
Speed limiter
Ignition System Specifications
Transmission
Clutch and cardan
Clutch — General Information and Removal
Clutch repair
Clutch installation
Clutch release drive
Checking the wear of the clutch driven disc linings (in assembled condition)
Removal and installation the master cylinder
Removal and installation the slave cylinder
Checking the free play of the clutch and suspension pedal
Bleeding the hydraulic drive
Disassembly and assembly of synchronizer of manual transmission
Removal and installation the cardan transmission
Removal and installation the intermediate support bearing of the cardan transmission
Adjusting the front wheel alignment
Clutch specifications
Tightening torques for threaded connections
Car gearbox
Removal and installation of a manual gearbox
Disassembly and assembly of a manual gearbox
Removal and installation the manual transmission gearshift mechanism cover
Removal and installation the front cover of the manual transmission
Removal and installation the rear cover of a manual gearbox
Removal and installation reverse gear of a manual transmission
Removal and installation of gears of a manual transmission
Disassembly and assembly of the driven shaft of a manual transmission
Disassembly and assembly of the intermediate shaft of a manual transmission
Adjusting the gear shift drive of a manual transmission
Mechanical gearboxes of the first releases
Automatic transmission — general information
Removal and installation of automatic transmission
Gearbox specifications
Tightening torques for threaded connections
Chassis
Front suspension
Removal and installation the shock absorber
Removal and installation the front suspension spring
Removal and installation the front suspension
Adjusting the axial clearance of wheel hub bearings
Removal and installation the hub
Replacing bearings in the hub
Removal and installation the steering knuckle
Replacing ball joints
Adjusting the camber and caster angle of the steering axis
Determining the difference in rotation angles
Front Suspension Specifications
Tightening torques for threaded connections
Wheel Specifications and Wheel Alignment
Rear suspension
Removal and installation the main gear (differential)
Replacing the pinion seal
Replacing seals in main gear bearing caps
Removal and installation the axle shafts as a whole
Removal and installation the rear wheel hub and adjusting the hub bearings
Adjusting the rear wheel hub bearings
Removal and installation the rear shock absorber
Checking the position of the car by the rear suspension
Replacing rear brake pads
Adjusting the parking brake
Rear Suspension Specifications
Tightening torques for threaded connections
Steering
Steering — removal and installation
Steering drive
Power Steering — Removal
Power steering pump
Steering Specifications
Tightening torques for threaded connections
Brake system
Brake system — general information
Replacing the front brake pads
Removal and installation the front caliper
Front caliper overhaul
Removal and installation the front brake disc
Rear caliper overhaul
Removal and installation rear brake discs
Master brake cylinder
Removal and installation parking brake pads
Brake force booster
Bleeding the brake hydraulic system
Brake specifications
Tightening torques for threaded connections
Electrical equipment
Power devices
Electrical equipment — general information
Rechargeable battery
Safety precautions when working with a generator
Checking the generator on the car
Removal and installation the generator
Generator repair
Checking, removing and installing the starter
Disassembling and assembling the starter
Electrical Equipment Specifications
Electrical circuits
Electrical diagram of the car «Mercedes 280 S»
Electrical diagram of the car «Mercedes 280 SE»
Electrical diagram of the car «Mercedes 350 SE»
Electrical diagram of the car «Mercedes 450 SE/450 SEL»

S-Class W126 (1979-1991, petrol)
Power unit
Engine repair
Vehicle Identification
Removal and installation the engine
Disassembling the engine
Engine assembly
Disassembling the cylinder head
Checking cylinder head parts
Installing the valve guide bushing
Cylinder head assembly
Checking pistons and connecting rods
Cylinder block (crankcase)
Crankshaft and flywheel
Camshaft and Drive Mechanism — General Information
Checking camshafts
Checking the valve timing
Adjusting the valve timing
Rocker arm — removal and installation
Checking and replacing the hydraulic valve clearance compensator
Chain tensioner — removal and installation
Engine specifications
Vehicle dimensions and fuel capacities
Tightening torques for threaded connections
Cylinder head cover of a six-cylinder engine
Cylinder head of a six-cylinder engine
Ignition system
General information about the ignition system
Operation of the transistor ignition system
Safety precautions for transistor ignition system
Checking the ignition system
Checking the ignition coil
Checking the ignition wires
Checking and adjusting the ignition timing
Ignition distributor — general information
Ignition distributor — removal and installation
Spark plugs — description and marking
Checking the distributor cap
Checking electrical connections
Checking spark plugs
Ignition system fault diagnostics
Lubrication system
Purpose and properties of motor oils
The structure and operating principle of the lubrication system
Oil pressure reducing valve — removal and installation
Oil pump — removal and installation
Oil filter — design description
Replacing the oil filter on a 110 engine with air conditioning
Oil pan — removal and installation
Oil Temperature Thermostat — Removal and Installation
Oil radiator — removal and installation
Changing engine oil
Diagnostics of lubrication system faults
Lubrication circuit of eight-cylinder engines
Cooling system
The design and operating principle of the cooling system
Removal and installation the coolant pump
Coolant pump repair
Thermostat — Removal, Installation and Checking
Drive belts — replacement and tensioning
Radiator — removal and installation
Fan Motor — Removal and Installation
Checking the coolant level
Antifreeze check
Visual inspection of the system for leaks
Replacing the coolant
Cooling system fault table
Engine Cooling and Lubrication System Specifications
Cooling system parts for eight-cylinder engines
Fuel system
Carburetor Solex 4A-1 — design description
Adjusting idle speed and CO content
Checking the idle shut-off valves
Air filter — removal and installation
Changing the air filter element
Checking the vacuum regulator
Checking the air piston damper oil level
Adjusting the tempomat
Checking the idle air cut-off valve
Checking the ground connection on the carburetor
Checking the idle speed cut-off valve relay
Idle Speed Control Valve — Removal and Installation
Adjusting warm engine speed and CO content in exhaust gases
Checking the Thermal Delay Valve / Pull-down Valve
Automatic start device — removal and installation
Fuel tank — general information
Fuel pump — check
Fuel pump — removal and installation
Carburetor fault diagnostics
Engine Fuel System Specifications
Fuel injection system
The principle of operation of the fuel injection system
Inspection, testing and adjustment of the fuel injection system
Checking the tightness of the injection system connections
Checking and adjusting idle speed and CO content
Adjusting the throttle linkage
Adjusting the full throttle limiter
Removal, installation and checking the cold start injector
Removal, installation and checking the thermal time switch
Checking the additional air damper
Checking and adjusting the air flow meter flap
Checking the cold start valve
Adjusting the tempomat
Checking the temperature sensor
Checking the fuel pump
Removal and installation the fuel pump
Diagnostics of injection system faults
Transmission
Clutch and cardan
Description of the clutch design
Removal, checking and installation the clutch
Bleeding the hydraulic clutch drive
Removal air using a special installation
Removal and installation the release bearing
Clutch Master Cylinder — Removal and Installation
Checking the thickness of the driven disk
Diagnosing Clutch Faults
Removal and installation the propeller shaft
Removal and installation the intermediate bearing of the propeller shaft
Propeller shaft specifications
Tightening torques for threaded connections
Cardan shaft parts
Mechanical gearbox
Removal and installation the gearbox
Gear shift cover
Removal and installation the front gearbox cover
Removal and installation the rear cover of the gearbox
Reverse gear — removal and installation
Adjusting the gear shift lever
Checking the oil level in a manual transmission
Manual Transmission Specifications
Tightening torques for threaded connections
Cross-section of a 5-speed manual transmission
Automatic gearbox
Automatic transmission — description
Automatic transmission — removal and installation
Checking the oil level in an automatic transmission
Oil change / cleaning the screen in the oil pan
Towing cars with automatic transmission
Automatic Transmission Specifications
Tightening torques for threaded connections
Chassis
Front suspension
Description of the front suspension design
Front shock absorber — removal and installation
Checking the shock absorber
Front Coil Springs — Removal and Installation
Removal, installation and checking front wheel bearings
Adjusting the axial clearance of wheel bearings
Front and rear suspension specifications
Tightening torques for threaded connections
Front suspension — design description
Wheel alignment and kingpin tilt
Rear suspension
Description of the rear suspension design
Rear Coil Springs — Removal and Installation
Rear shock absorber — removal and installation
The middle part of the rear axle (differential) with half shafts
Rear Axle Maintenance
Rear Axle — Design Description
Steering
General description of steering
Removal and installation the steering wheel
Removal and installation tie rod ends
Dust boot of the articulated joint of the connecting rod and steering rod
Power steering servo — removal and installation
Removal and installation the power steering pump
Power Steering Fluid Replacement
Removal and installation the articulated joints of the connecting rod
Tie rod/steering rod joint boots — check
Steering gear play — check
Checking the oil level
Steering system clamp bolts — tightening
Power steering hydraulic pump drive belt
Wheel alignment angles
Steering Specifications
Tightening torques for threaded connections
Brake system
General description of the braking system
Replacing rear and front disc brake pads
Replacing the front brake disc
Replacing the rear brake disc
Brake fluid — general information
Bleeding the brake system
Brake pipes and hoses — replacement
Handbrake — design description
Servo cylinder — checking operation
Replacing the front brake cable
Replacing the rear brake cable
Handbrake brake pads
Adjusting the handbrake
Anti-lock braking system (ABS system)
Checking the Low Brake Fluid Warning Light
Checking the thickness of brake pads
Checking the thickness of brake discs
Visual inspection of brake pipes
Replacing brake fluid
Checking the handbrake
Diagnostics of brake system faults
Brake system specifications
Tightening torques for threaded connections
Anti-lock braking system — design description
Electrical equipment
Power devices
Measuring devices
Methodology for conducting measurements
Battery — Removal and Installation
Battery charge
Checking the battery
Battery maintenance
Troubleshooting the battery
Alternating Current Generator — Design Description
Alternator — Removal and Installation
Replacing the alternator drive belt
Replacing Generator Carbon Brushes
Voltage Regulator — Check
Diagnosing faults in the alternator
Starter — design description
Starter — removal and installation
Starter fault diagnostics
Engine Electrical Specifications
Bosch Generator — Design Description
Bosch starter — design description
Electrical circuits
Electrical diagram of a 6-cylinder carburetor engine
Explanations for the electrical equipment diagram with a 6-cylinder carburetor engine
Electrical diagram of the 8-cylinder engine with injection
Explanations of the electrical equipment diagram with an 8-cylinder engine with injection

S-Class W140 (1991-1998)
User manual
Controls and instruments
Vehicle Identification Numbers
Purchase of spare parts
Jacking and towing a car
Starting the engine from an auxiliary power source
Car fault diagnostics
Main specifications of the car
Remote control and special functions
Unlocking the driver's door with the key
Access to the luggage compartment
Access to the fuel tank filler neck
Access to the underhood space
Access to main storage compartment and goggle compartment
Anti-theft system
Elements of security systems
Rules for the use of passive safety equipment for drivers and passengers
Seat adjustment
Supplemental Restraint System (SRS)
Risk of Carbon Monoxide (CO) Poisoning
Instrument panel — general information
Instrument cluster, gauges and control lamps and indicator lights
Interior controls and equipment
Luggage compartment equipment
Replacing headlight and windshield wiper blades
Installing a roof rack
Automated air conditioning system (climate control)
Independent heater
Driving and operation
Main caveats
Running in a new car
Car parking
Starting off and changing gears
Speed control systems (tempostat) and Speedtronic
Parktronic system (PTS)
Emergency Brake Booster (BAS)
Anti-lock brake system (ABS)
Anti-Slip Regulation (ASR)
Electronic skid control system (ESP)
Automatic damping suspension system
Recommendations for driving in adverse weather conditions
Operating a car in winter conditions
Towing a trailer
Maintenance
Routine Maintenance — General Information
Maintenance Specifications
Active Maintenance Warning System (ASSYST)
Schedule of current maintenance
General information about the setup
Checking fluid levels, leak control
Checking the condition of tires and their pressure, designating tires and wheel rims, rotating wheels
Changing engine oil and oil filter
Checking the brake system
Checking the fuel system, replacing the fuel filter
Checking the condition and replacing engine compartment hoses, localizing leaks
Checking the condition of the ribbed belts of the serpentine drive of auxiliary units
Checking the functioning of the cooling system and frost resistance of the coolant, replacing the liquid
Checking the condition of the exhaust system
Checking ATF level, replacing AT filter
Visual inspection of automatic transmission for leaks
Checking the condition of suspension and steering components
Checking the condition of the protective covers of the drive shafts
Checking the air conditioning system
Lubrication of door stops and lock cylinders
Visual inspection of the seat belt and airbag unit
Checking the functionality of headlights and horn
Checking the condition, adjusting and replacing windshield wipers
Checking battery condition, care and charging
Replacing the cabin filter
Replacing brake fluid
Checking and replacing spark plugs, checking the condition of high-voltage wires
Power unit
Petrol engine V6
Specifications of all engines
Checking the compression in the engine cylinders
Checking the engine with a vacuum gauge
Serpentine belt for auxiliary drive
Removal and installation the engine
Cylinder Head Cover — Installation Details
Removal and installation the intake manifold with resonator
Exhaust manifold — installation details
Removal and installation the cylinder head
Removal and installation the timing chain cover
Timing Drive — General Information, Component Maintenance
Crankshaft Sprocket — Installation Details
Removal and installation the camshaft adjuster
Removal and installation camshafts
Replacing valve guide bushings
Replacing valve seats
Removal and installation pistons
Replacing piston rings
Checking the condition of the connecting rods
Checking the condition of the crankshaft
Cylinder Block Maintenance
Removal and installation the engine oil pan
Oil pump — installation details
Oil Level Switch Sensor — Installation Details, Test Data
Petrol engine V8
Removal and installation the engine
Cylinder Head Covers — Installation Details
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Removal and installation cylinder heads
Removal and installation timing chain covers
Timing chain replacement
Checking the valve timing
Timing Drive — General Information, Component Maintenance
Removal and installation the valve timing regulator
Removal and installation camshafts
Checking and adjusting the control position of the camshafts
Removal and installation valves
Replacing valve guide bushings
Replacing valve seat rings
Removal and installation pistons
Piston designations and dimensions
Checking the condition of the connecting rods
Checking the condition of the crankshaft
Petrol engine V12
Removal and installation the engine
Air purifier — installation details
Cylinder Head Covers — Removal and Installation
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Exhaust Gas Recirculation Valve — Installation Details
Air supply pump — removal and installation
Removal and installation the upper front covers
Cylinder heads — removal and installation
Removal and installation the timing chain cover
Timing chain replacement
Timing Drive — General Information, Component Maintenance
Timing chain tensioner — removal and installation
Camshaft adjuster — removal and installation
Removal and installation camshafts
Checking the valve timing
Checking and adjusting the position of the camshafts
Replacing valve guide bushings
Removal and installation pistons
Removal and installation the crankshaft
Removal and installation the engine oil pan
Oil Level Switch Sensor — Installation Details
Oil pump — design and installation details
Diesel engine OM603
Removal and installation the engine
Air purifier — installation details
Replacing the alternator drive belt
Removal and installation the alternator drive belt tensioner
Exhaust manifold — installation details
Timing Chain Cover — Removal and Installation
Camshaft — Removal and Installation
Removal and installation the cylinder head
Checking the camshaft reference position
Timing chain replacement
Timing Drive — General Information, Component Maintenance
Timing Chain Tensioner — Installation Details
Removal and installation pistons
Checking the condition and replacing the connecting rods
Measuring cylinder diameters
Removal and installation of cylinder liners
Checking the condition of the crankshaft
Removal and installation the crankshaft sprocket
Oil Level Switch Sensor — Installation Details
Replacing the oil pump drive chain
Removal and installation the oil pump
Removal and installation the oil filter housing
Diesel engine OM606
Cylinder Head Cover — Installation Details
Removal and installation of pre-chambers
Removal and installation the camshaft housing
Removal and installation camshafts
Checking the control position of the camshafts
Removal and installation the cylinder head
Removal and installation the timing chain cover
Timing Chain Tensioner — Installation Details
Timing Drive — General Information, Component Maintenance
Checking the condition of the valves
Removal, inspection and installation of valve guide bushings
Replacing valve seats
Removal and installation pistons
Removal and installation piston rings
Removal, condition check and installation of connecting rods
Measuring cylinder diameters
Checking the condition of the crankshaft, replacing the seals
Removal and installation the engine oil pan
Removal and installation the oil pump
Oil Level Switch Sensor — Installation Details
Removal and installation the oil filter housing
Oil Cooler Fan — Installation Details
Cooling system
Cooling and Heating Systems — General Information
Cooling and Heating System Specifications
Antifreeze is a means of protection against freezing
Coolant Replacement — General Notes
Removal and replacing cooling system hoses
Checking the proper functioning of the thermostat
Removal and installation the thermostat
Removal and installation the cooling system radiator
Removal and installation the water pump
Ventilation, heating and air conditioning systems
Fan Shroud and Fan Assembly — Installation Details
Air Conditioning System — Information and Precautions
Location of the main components of the automatic air conditioning system
Power supply and injection system
Power and exhaust system specifications
Fuel injection and fuel supply system of a gasoline engine — general information
Safety precautions and rules for maintaining cleanliness when working with the fuel system
Relieving pressure in the fuel system of a gasoline engine
Checking and adjusting idle speed/ignition timing/CO concentration
Diesel Engine Fuel Injection System — General Information
Fuel injection system checks (diesel)
Emission Control Systems — General Information
Exhaust system — general information
Catalytic converter (petrol models)
Control system HFM-SFI
Removal and installation of fuel distribution line with injectors
Removal and installation of injectors — removal and installation
Replacing the air flow sensor
Removal and installation a diaphragm fuel pressure regulator
Removal and installation the air pump
Removal and installation the crankshaft position sensor (CKP)
Removal and installation the lambda probe
Removal and installation knock sensors
Control system LH-SFI
Removal and installation of fuel distribution line with injectors
Air Flow Meter — Installation Details
Diaphragm fuel pressure regulator
Lambda probes — installation details
Exhaust Gas Recirculation (EGR) Valve Installation Details
Knock Sensor Installation Details
Control systems ME-SFI
ME-SFI Fuel Injection and Ignition Control System Component Locations
Removal and installation of fuel distribution line with injectors
Diaphragm Fuel Pressure Regulator Installation Details
Air Flow Meter Installation Details
Lambda probe (oxygen sensor) installation details
Crankshaft Position Sensor (CKP) Installation Details
Knock Sensor Installation Details
Diesel control system
Functional diagrams of fuel injection systems (diesel engines of the OM603 series)
Removal and installation the high pressure fuel pump (OM603)
Fuel injection timing regulator installation details (OM603)
Removal and installation of turbocharger (OM603)
Location of components of the electronic engine management system (diesel engines OM606)
Glow Plug Installation Parts (OM606)
High pressure fuel pump (HPFP) (OM606)
Fuel Injection Timing Regulator Installation Details (OM606)
Intercooler (compressed air radiator) — installation parts (OM606)
Compressed Air Supply Tubes — Connection Diagram (OM606)
Turbocharger installation parts (OM606)
Turbocharging system — general information
Intercooler — General Information
Ignition system
Basic elements of a microprocessor control system
Checking the ignition and injection control system
Troubleshooting — General Information and Preliminary Checks
Checking and adjusting the ignition timing angle
Spark plugs — checking condition
Self-diagnosis of electronic control systems OBD
Diagnostics of the electronic system of automatic air conditioning (A/C)
Using an Oscilloscope to Monitor Control System Signals
Ignition Coil Installation Details
Removal, installation and adjustment of the camshaft position sensor (CMP)
Ignition distributor installation details
Engine Electrical System Specifications
Charge and launch system
Charging and starting systems — general information
Battery — Basics, Disconnecting and Buying a New Battery
Checking and charging the battery
Storage of the battery
Charging system — general information and safety precautions
Checking the charging system
Generator Installation Details
Engine Starting System — General Information and Precautions
Checking the engine starting system
Transmission
Mechanical gearbox 717.438
Manual Transmission Specifications
Removal and installation the gearbox
Gearbox Front Cover Installation Details
Removal and installation the rear cover of the gearbox
Removal and installation the vehicle speed sensor (VSS)
Removal and installation the intermediate crankcase
Checking the clearance of the drive and intermediate shafts
Disassembly and assembly of the driven shaft
Removal and installation drive and driven gears
Replacement of ball bearings of manual transmission with No. 6141001
Replacement of tapered roller bearings of gearbox up to No. 6141000
Gearshift mechanism installation details
Mechanical gearbox 717.454
Installation details of manual transmission 717.454
Removal and installation the vehicle speed sensor (VSS)
Removal and installation the front gearbox cover
Removal and installation the rear cover of the gearbox
Removal and installation the intermediate crankcase
Replacing the rear gearbox cover seal
Removal and installation gearbox shafts
Disassembly and assembly of the intermediate shaft
Checking the dimensional characteristics of the gearbox
Replacing tapered roller bearings of the intermediate shaft
Replacing the intermediate shaft ball bearings
Adjusting the gear shift mechanism
Automatic gearbox 722.5
Automatic transmission — general information
Automatic Transmission Specifications
Troubleshooting — General Information
Removal and installation of automatic transmission
Removal, condition check and installation of the torque converter
Removal and installation a centrifugal regulator
Removal and installation the starter lock switch sensor
Installation details of the AT vacuum unit
Removal, maintenance and installation of the secondary pump (AT up to No. 3652931)
Removal and installation the front cover with secondary pump
Removal and installation the LB3 piston
Removal and installation the rear transmission cover
Disassembly and assembly of the AT valve assembly
Disassembly and assembly of the transmission
Installation and clearance check in B3 multi-disc brake
Measuring the Brake Clearance B1
Overdrive clutch
Removal, installation and inspection of BS overdrive brake and KS clutch components
Disassembly and assembly of the freewheel clutch
Disassembly and assembly of planetary mechanisms
Disassembly and assembly of the K1 clutch
Clutch K2 — disassembly, assembly and inspection
Gear selector lever
Automatic gearbox 722.6
Removal and installation of AT with a torque converter
Removal and installation of the electro-hydraulic control unit AT (transmission installed)
Disassembly and assembly of the electrohydraulic control unit
Disassembling and assembling the gear shift plate
Disassembly and assembly of the transmission housing and torque converter
Disassembly and assembly of multi-disc brakes B2, B3 and transmission locking gear in position «P»
Disassembly and assembly of the rear hollow shaft with the rear freewheel clutch
Removal and installation the B1 multi-disc brake and oil pump
Disassembly and assembly of the oil pump
Disassembly and assembly of the B1 multi-disc brake
Disassembly and assembly of the B2 multi-disc brake
Disassembly and assembly of the output shaft with the central and rear planetary gear blocks
Removal and installation of multi-plate clutches K1, K2 and K3
Disassembly and assembly of the K1 clutch
Disassembly and assembly of the drive shaft with clutch K2 and front block of planetary gears
Disassembly and assembly of the K3 clutch
Removal and installation the transmission locking mechanism in the «P» position
Removal and installation the gear selector lever
Clutch and drive shafts
Clutch and Differential Specifications
Clutch — General Information
Removal and installation the clutch
Removal and installation the clutch master cylinder
Removal and installation the clutch slave cylinder
Removal and installation the propeller shaft
Drive shafts — general information
Removal and installation the drive shaft flange and radial thrust ball bearing
Removal, checking and installation the drive shaft
Removal and installation of CV joints of drive shafts and their protective covers
Differential
Disassembly, assembly and testing of the differential
Disassembly and assembly of the main gear reducer and adjustment of gear clearances
Determining the thickness of the adjusting shim and installing it in the gearbox housing
Checking and adjusting the flange clearance
Disassembly and assembly of the main gear reducer and adjustment of gear clearances (models up to 31.05.94)
Disassembling and assembling a differential with automatic locking
Replacing the differential cylinder with automatic locking (models up to 31.05.94)
Chassis
Brake system
General information and safety precautions
Brake system specifications
Location of ASR/ETS traction control system components
Location of Brake Assist System (BAS) components
Location of ESP system components
Disassembly and assembly of the main brake cylinder of the «Tandem» type (models 140.028/032/033/135)
Removal, installation and checking of the functioning of the brake booster servo drive
Removal and installation the brake caliper
Checking the thickness of the brake disc and brake pads
Removal and installation parking brake shoes
Removal and installation the front parking brake cable
Adjusting the parking brake
ABS Wheel Sensors — Installation Details
Steering
Suspension and steering specifications
Safety precautions when repairing suspension and steering
Wheel alignment angles, ground clearance
Removal and installation the steering gear
Removal and installation the steering pump (with engines 104, 119, 120 and 606)
Disassembling and assembling the power steering pump
Disassembly and assembly of the electronically adjustable steering column
Removal and installation the lower steering shaft
Removal and installation the steering column telescopic adjustment drive
Removal and installation the pipe stop
Disassembly and assembly of the inner tube
Installing the top pipe mounting bracket
Removal and installation the locking cylinder
Contact spring — removal, inspection and installation
Removal and installation the middle steering rod
Removal and installation the steering gear pendulum arm
Removal and installation the transverse steering rod
Front suspension
Removal and installation the front suspension
Adjusting the clearance in the front wheel bearing
Removal and installation the lower ball joint
Checking the condition of the upper ball joint
Replacing the upper control arm
Replacing the lower control arm
Removal, checking and installation the front wheel hub
Removal and installation the steering knuckle assembly
Removal and installation a coil spring
Removal and installation the anti-roll bar
Removal and installation the shock absorber
Front Suspension Clearance Adjuster — Installation Details
Rear suspension
Rear suspension design of a car
Design and installation details of the hub assembly
Removal and installation a coil spring
Anti-roll bar — installation details
Removal and installation the shock absorber
Removal and installation the rear shock absorber strut
Checking the hydraulic pump
Removal and installation the rear suspension hydraulic pressure accumulator
Removal and installation the rear suspension clearance control unit
Damper valves — installation details
Removal and installation the clearance adjustment valve
Rear suspension clearance adjuster
Body
Exterior (external elements)
Body specifications and dimensions
Safety precautions when performing bodywork
Bumpers — installation details
Combination Relay — Installation Details
Front doors — removal, installation and adjustment
Rear doors — installation details
Adjusting the hood
Headlights — installation details
Rear combination lights — installation details
Removal and installation the air conditioning compressor speed sensor (models up to 31.08.95)
Checking and adjusting the headlights
Adjusting the trunk lid
Front fenders and wheel arch protection liners — installation details
Decorative radiator grille — installation details
Mercedes emblem
Removal and installation exterior rearview mirrors
Front Direction Indicators — Installation Details
Reversing lights — installation details
Interior (internal elements)
Removal and installation the instrument panel
Removal and installation the combined steering column switch
Headlight Switch — Installation Details
Removal and installation the instrument cluster
Instrument cluster control lamps and indicator lights
Instrument cluster gauges — layout and installation details
Removal and installation the automatic air conditioning control unit
Removal and installation the push-button air conditioner control panel
Replacing the control lamps of the push-button control panel of the air conditioner
Checking the pneumatic headlight beam tilt regulator
Center Console Switches — Installation Details
Removal and installation the center console
Loudspeakers — Installation Details
Removal and installation interior door trim panels
Removal and installation seats
Removal and installation headrests
Instrument Panel Air Vent Deflectors — Installation Details
Glove Box Lid — Installation Details
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
Electrical Equipment Specifications
Diagnostics of faults of on-board electrical equipment — general information
Checking the windshield wiper motor
Checking the heated rear window
Replacing incandescent lamps
Electrical fuses
Installation of electrical and electronic devices
Location of the main electrical components of the car body electrical system
Electrical circuits
Designations on schematic diagrams
Engine Management System for 3.2L Models
Engine management system for 4.2 and 5.0L models
Launch system
Charging system
Automatic transmission
AT shift lock system
Electronic power steering system
Electronic suspension
Anti-lock brake system (ABS) on models equipped with traction control system (ASR)
Anti-lock brake system (ABS) on models equipped with electronic skid control (ESP)
Electrical diagram of the tempostat
Engine cooling system fan
Instrument cluster
Instrument lighting
Exterior lighting on Sedan models with conventional headlights
Exterior lighting on Sedan models with xenon headlights
Outdoor lighting fixtures
Standard type headlights
Xenon headlights
Daytime running lights (DRL)
Reversing lights on Sedan models
Reversing lights on Coupe models
Interior lighting when doors are opened
Automatic day/night switching of the interior rearview mirror
Parktronic system
Horn wiring diagram
Rear window heating
Windscreen wipers/washers
Headlight cleaners and washers
Heating of the washer fluid
Automatic air conditioning system in the cabin
Automatic air conditioning system in the rear compartment
Anti-theft alarm
Single lock
Door closing soft closing system
Trunk lid latch release drive
Electric window lifters
Electric driver's seat adjustment
Electric front passenger seat adjustment
Electric rear seat adjustment with solid structure
Electric adjustment of the four-seat split rear seat
Electric rear window sunblind
Electric convertible top/sunroof
Heated front seats
Heated rear seats
Electric rear headrests (Coupe)
Seat belt comfort position selection device (Sedan)
Seat Belt Extender (Coupe)
Supplemental Restraint System (SRS)
Electric antenna drive (except models with built-in cell phone and Bose audio system)
Electric antenna drive (models with built-in cell phone)
Electric Antenna (models with Bose audio system)
Processor data lines
Memory for adjustable rear view mirrors and telescopic steering column
Memory for adjustable seat positions
Radio receiver electrical circuit

S-Class W220 (1998-2005)
General information
Introduction to guide
Mercedes-Benz S-Class (W220) Cars — Abstract
Vehicle Identification Numbers
Purchase of spare parts
Service technology, tools and workplace equipment
Jacking and towing a car
Starting the engine from an auxiliary power source
Checking the vehicle's readiness for operation
Automotive chemicals, oils and lubricants
Car fault diagnostics
User manual
Vehicle specifications and dimensions
Main organs and control/monitoring panels
Locks, keys and bolts. Smart card. Single lock
Anti-theft protection
Assistance in getting in and out of a vehicle
Adjustment of front and rear seats
Security systems
Steering wheel, rear view mirrors
Seat position memory
Dashboard
Multifunctional steering wheel, multi-information display
Headlight and windshield wiper switches
Automatic air conditioning. Ventilation. Independent heater
Power windows, sunroof
Salon equipment
Vehicle control and auxiliary systems
Warning and indicator lights and messages on the multi-information display
First aid kit, fire extinguisher, warning triangle and spare tire compartment
Messages and inscriptions in foreign languages
Maintenance
General information about current maintenance
Maintenance Specifications
Active Maintenance Warning System (ASSYST)
Schedule of current maintenance
General information about the setup
Checking fluid levels, leak control
Checking the condition of tires and their pressure. Designation of tires and wheel rims. Rotation and replacement of wheels
Changing engine oil and oil filter
Checking the brake system
Checking the fuel system
Checking the condition and replacing engine compartment hoses, localizing leaks
Checking the condition of the ribbed belts of the serpentine drive of auxiliary units
Checking the cooling system operation and frost resistance. Liquid replacement
Checking the condition of the exhaust system
Checking the Automatic Transmission Oil Level
Visual inspection of automatic transmission for leaks
Checking the condition of suspension and steering components
Checking the condition of the protective covers of the drive shafts
Checking the power steering fluid level
Checking the air conditioning system
Lubrication of door stops and lock cylinder
Visual inspection of the seat belt and airbag unit
Checking the functionality of headlights and horn
Checking the condition, adjusting and replacing windshield wipers
Checking battery condition, care and charging
Replacing the cabin air filter element/carbon air filter
Replacing brake fluid
Checking and replacing spark plugs. Checking the condition of high-voltage wires
Power unit
Engine repair
Engine specifications
Checking the compression in the engine cylinders
Checking the engine with a vacuum gauge
Serpentine belt for auxiliary drive
Gas distribution mechanism and engine components
Replacing the timing chains and setting the valve timing
Location of the main sensors of the gasoline engine
Cooling and heating systems
General parameters of cooling and heating systems
General description of the cooling system
Antifreeze is a means of protection against freezing
Coolant Replacement — General Notes
Removal and replacing cooling system hoses
Removal and checking the thermostat
Ventilation, heating and air conditioning systems
Air Conditioning System — General Information and Precautions
Location of the main electrical components of the air conditioning system
Power and exhaust systems
General description of the power supply and exhaust systems
Description of the design of the fuel supply and injection system
Relieving pressure in the fuel system of a gasoline engine
Power Distribution Control — Description and Principle of Organizing the Cylinder Shutdown Function
Air blower
Checking and adjusting idle speed/ignition timing/CO concentration
Diesel engine fuel injection system
Diesel fuel injection system checks
Diesel turbocharger — general information, removal and installation
Diesel Intercooler — General Information
Emission Control Systems — General Information
Exhaust gas system
Catalytic converter
Ignition and control system
Engine Electrical Specifications
Basic elements of a microprocessor control system
Checking the ignition and injection control system
Troubleshooting — General Information and Preliminary Checks
Checking and adjusting the ignition timing angle
Spark plugs — checking condition
Self-diagnosis of electronic control systems of the second generation OBD II
Controller for interfacing a personal computer with the on-board self-diagnostic system OBD II
Using an Oscilloscope to Monitor Signals in Control System Circuits
Digital data bus CAN
Charge and launch systems
Charging and starting systems — general information
Battery — Basic Information and Buying a New One
Checking and charging the battery
Storage of the battery
Charging system — general information and safety precautions
Checking the charging system
Engine Starting System — General Information and Precautions
Checking the engine starting system
Transmission
Automatic gearbox
General description of automatic transmission
Electronic control unit tasks and control signals
Troubleshooting — General Information
Removal and installation of AT with a torque converter
Electrohydraulic control unit AT (AT installed)
Disassembly and assembly of the electrohydraulic control unit
Disassembling and assembling the gear shift plate
Transmission housing and torque converter
Multi-disc brakes B2, B3 and locking gear in «Parking»
Disassembly and assembly of the rear hollow shaft with the rear freewheel clutch
Removal and installation the B1 multi-disc brake and oil pump
Disassembly and assembly of the oil pump
Disassembly and assembly of the B1 multi-disc brake
Disassembly and assembly of the B2 multi-disc brake
Disassembly and assembly of the output shaft with the central and rear planetary gear block
Removal and installation of multi-plate clutches K1, K2 and K3
Disassembly and assembly of the K1 clutch
Disassembly and assembly of the drive shaft with clutch K2 and front block of planetary gears
Disassembly and assembly of the K3 clutch
Parking Lock Mechanism — Removal and Installation
Removal and installation the gear selector lever
Drive shafts
Drive shaft and differential specifications
Removal and installation the propeller shaft
Removal and installation the drive shaft flange and radial thrust ball bearing
Drive shaft — removal, inspection and installation
Removal and installation of CV joints and protective covers of drive shafts
Disassembling and assembling the differential
Disassembly and assembly of the main gear reducer and adjustment of gear clearances
Determining the thickness of the adjusting shim and installing it in the gearbox housing
Checking and adjusting the flange clearance
Disassembling and assembling a differential with automatic locking
Chassis
Brake system
Basic information about the braking system
Brake system specifications
Location of Emergency brake booster BAS components
Location of ESP system components
Dual master cylinder
Vacuum booster — removal, inspection and installation
Brake caliper — removal and installation
Checking the thickness of the brake disc and brake pads
Removal and installation brake pads
Removal and installation the front parking brake cable
Adjusting the parking brake
ABS anti-lock brake system, anti-skid system
Front suspension
Suspension and steering specifications
Safety precautions when working with suspension
Removal and installation the front suspension
Adjusting the clearance in the front wheel bearing
Front Wheel Hub — Removal, Inspection and Installation
Front steering knuckle — removal and installation
Front anti-roll bar
Pneumatic shock absorber — removal and installation
Rear suspension
Rear suspension design
Rear wheel hub
Transverse stabilizer
Rear shock absorber — removal and installation
Rear air shock absorber
Elements of the controlled air suspension system
Steering
Car Wheel Alignment Angles — General Information
Conditions for checking wheel alignment angles
Front wheel alignment
Rear wheel adjustment
Checking the vehicle body clearance
Removal and installation the steering gear
Power Steering Pump — Removal and Installation
Disassembling and assembling the power steering pump
Disassembly and assembly of the electronically adjustable steering column
Removal and installation the lower steering shaft
Removal and installation the drive for telescopic adjustment of the steering column
Removal and installation the pipe stop
Disassembly and assembly of the inner tube
Installing the top pipe mounting bracket
Removal and installation the locking cylinder
Contact spring — removal, inspection and installation
Body
Body elements
Control dimensions of the car body
Safety precautions when performing bodywork
Cleaning and car care
Repair of minor damage to body panels
Repair of significant body damage
Replacing windshield wipers
Orthopedic seats
Heated seats
Replacing the cabin air filter
Electrical system sensors
Fire extinguishing system
Electrical equipment
Equipment and devices
General information about on-board electrical equipment
On-board electrical equipment specifications
Diagnostics of faults of on-board electrical equipment — general information
Checking the windshield wiper motor
Checking the heated rear window
Replacing incandescent lamps
Backup light function
Electrical fuses
Installation of electrical and electronic devices
Elements of a single lock
Location of the main electrical components of the car body electrical system
Anti-theft alarm
Electrical circuits
Designations and purposes of electrical wiring, terminals and terminals
Power distribution
Grounding points
Charging system
Launch system
Engine Management System M112
Left Front Signal and Control Module (SAM)
Rear Signal and Management Module (SAM)
Right Front Signal and Control Module (SAM)
CAN data bus
Diagnostic connector DLC
Automatic air conditioning system
Automatic transmission
Transmission shift locks
Anti-lock braking system (ABS)
Electronic suspension
Anti-theft alarm system (ATA)
Tempostat (speed control system)
Distronic system
Parktronic system
Dashboard
Navigation system
Airbag System (SRS)
Glass heating (condensation removal)
Modular box fan
Cooling system fan
Reversing lights
Outdoor lighting
Headlights
Interior lighting
Driver's seat position memory
Rear view mirror position memory
Passenger seat position memory
Steering column position memory
Adjusting the comfort position of the seat belts, Sedan
Single lock
Electric mirrors
Rear headrests
Electric rear seats
Electric convertible roof/sunroof
Electric release of the luggage compartment lid lock latch
Electric window lifters
Electric rear sunblind
Horn wiring diagram
Radio receiver electrical circuit
Headlight glass/lens cleaners/washers

Mercedes Sprinter (1995-2000, diesel)
General information
Introduction to the guide
Description and characteristics of Mercedes Sprinter
Vehicle Identification
Disconnecting the battery
General rules for carrying out repair work
Working conditions and tools
Maintenance
Maintenance and care — general information
Checking the engine oil level
Checking the brake fluid level
Checking brake light bulbs
Checking the lighting
Checking the air pressure in the tires
Checking the level of liquid in the cooling system
Air filter element
Checking the Power Steering Fluid Level
Other maintenance work
Lubricants, sealants
Techniques for working with threaded connections, bolts, nuts
Vehicle Maintenance Chart
Tightening torques for threaded connections, Nm
Power unit
Engine repair
General description of engines
Dismantling the power unit
Installation of the power unit
Disassembling the engine
Cylinder head — general description
Removal and installation the cylinder head
Disassembling the cylinder head
Cylinder head repair
Pistons and connecting rods — removal
Measuring cylinder liners
Checking pistons and connecting rods
Assembly of pistons and connecting rods
Installing pistons with connecting rods into cylinders
Camshaft Drive Mechanism Cover
General Description — Cylinder Block
Removal and installation cylinder block plugs
Measuring the working clearance in pistons
Changes in the design of the cylinder block introduced as a result of modernization
Crankshaft and Flywheel — General Information
Removal the crankshaft
Checking the crankshaft
Installing the crankshaft
Flywheel or drive disc (automatic transmission models)
Belt pulley and torsional vibration damper of the crankshaft
Rear crankshaft oil seal and its holder
Front crankshaft oil seal
Camshaft Drive Mechanism — General Description
Removal and installation the camshaft drive chain tensioner
Dismantling and installation of the camshaft drive chain
Removal and installation the chain tension shoe
Dismantling and installation of drive chain dampers
Removal and installation the crankshaft sprocket
Removal and installation the camshaft
Gas distribution mechanism
Hydraulic valve lifter compensators — device
Checking the serviceability of hydraulic tappets
Removal and installation of hydraulic tappets
Diesel Engine Specifications
Lubrication system
Purpose of the engine lubrication system
Checking the oil level
Engine oil consumption
Selecting and replacing engine oil
Causes of sediment formation in oil
Oil change at the service
Do-it-yourself engine oil change
Brief description of the lubrication system
Removal and installation the oil pump
Removal and installation the oil pan
Removal and installation the oil filter
Oil radiator — removal and installation
Oil dipstick
Turbodiesel engine oil lines
Lubrication System Specifications
Cooling system
Cooling system — design description
Replacing the coolant
Antifreeze — General Information
Radiator — General Description
Radiator check
Removal and installation the radiator
Coolant pump — design description
Removal and installation the coolant pump
Drive belt — removal and installation
Viscous fan clutch
Thermostat — design description
Thermostat malfunction
Checking the Thermostat
Checking the cooling system
Checking the coolant level sensor
Engine overheating
Checking the density of the coolant
Cooling system hoses
Cooling system specifications
Power and exhaust system
General description of the diesel fuel injection system
Precautions when working with the injection system
Removal and installation of fuel injection pump
Checking the injection start timing
Injectors and injector bodies — troubleshooting
Removal and installation injectors
Repair and cleaning of injectors
Removal and installation the mixing chamber
Removal and installation the fuel filter
Removal and installation the air filter
Turbocharger — General Description
Possible turbocharger malfunctions
General instructions for operating a turbocharger
Removal and installation a turbocharger
General description of glow plugs
Removal and installation glow plugs
Possible malfunctions of glow plugs
Removal and installation the intake manifold
Removal and installation of the exhaust system
Recommendations for repairing the exhaust system
Idle speed adjustment
Diesel Engine Fuel System Specifications
Transmission
Clutch
General description of the clutch
Clutch Maintenance
Removal the clutch
Clutch repair
Clutch installation
Removal and installation the clutch release fork and clutch release bearing
Removal and installation the master cylinder
Removal and installation the slave cylinder
Checking the driven disk for wear (in installed condition)
Bleeding the clutch hydraulic drive
Possible clutch malfunctions
Mechanical gearbox
Manual transmission — general description
Removal and installation the gearbox
Gearbox repair
Replacing the primary (drive) shaft seal of the gearbox
Replacing the rear cuff
Removal and installation the gear shift lever
Checking the gearbox oil level and changing the oil
Manual Transmission Specifications
Automatic gearbox
Automatic transmission — general description
Starting the engine of a car with an automatic transmission by towing
Towing a car with an automatic transmission
Checking the automatic transmission
Removal and installation of automatic transmission
Working fluid level and its replacement
Removal and installation of the automatic transmission housing
Start blocker — general information
Automatic transmission specifications
Front axle
General description of the front axle
Front axle design
Removal the front axle
Installing the front axle
Removal the lower control arm
Installing the transverse arm
Replacing the ball joint
Replacing the silent blocks of the transverse levers
Removal and installation the steering knuckle
Adjusting the axial play of the wheel bearing
Removal and installation the front hub
Replacing the hub bearing
Front Axle and Suspension Specifications
Rear axle and cardan
Rear Axle and Propeller Shaft — General Description
Removal and installation the rear axle (for models without ABS)
Removal and installation the rear axle (for models with ABS)
Disassembling the rear axle
Removal and installation of drive axle shafts
Disassembling the drive axle shaft
Drive gear sleeve
Checking the oil level in the rear axle housing and changing the oil
Cardan shaft — removal and installation
Rear Axle and Suspension Specifications
Chassis
Car suspension
Adjusting the front wheel alignment angles
Ball joint maintenance
Checking the ball joint mudguards
Checking shock absorbers
Front and rear suspension — general information
Replacing the front spring
Removal and installation the front anti-roll bar
Rear spring mount
Removal and installation rear springs
Rear shock absorbers — removal and installation
Rear anti-roll bar
Steering
Steering — General Information
Power steering fluid reservoir
Removal the steering gear
Replacing tie rod ends and protective covers
Checking the steering play
Checking the play in the steering rod joints
Checking the steering gear protective covers
Filling the power steering system with fluid
Bleeding the power steering system
Checking the tightness of the power steering system
Power steering pump drive V-belt, belt replacement
Removal and installation the power steering pump
Front wheel alignment angles
Possible steering malfunctions and how to fix them
Brake system
Brake system — general information
Design of the brake system
Brake System Maintenance — General Information
General description of the various components of the braking system
Checking the brake fluid level
Replacing brake fluid
Checking the brakes
Checking the tightness and serviceability of the brake system
Checking brake pads
Front disc brakes with floating caliper — general information
Replacing the front brake pads
Removal and installation the front brake caliper
Front Brake Caliper Repair
Replacing rear brake pads
Installing and removing the rear caliper
Rear Brake Caliper Repair
Removal and installation the front brake disc
Removal the rear brake disc
Installing the rear brake disc
Master Brake Cylinder — General Information
Removal and installation the master brake cylinder
Repair of the main brake cylinder
Parking brake — general information
Removal and installation parking brake pads
Adjusting the parking brake shoes
Adjusting the parking brake cables
Replacing the front parking brake cable
Replacing the rear parking brake cables
Brake booster — general information
Removal and installation the brake booster
Bleeding brakes
Anti-lock braking system (ABS)
Vacuum pump — removal and installation
Brake system specifications
Tires and wheels
Tires and wheels — general information
Tire size
Speed and age designation of tires
Wheel rotation
Checking tire pressure
Extending the life of your tires
Wheel replacement
Checking the condition of the tires
Electrical equipment
Equipment and devices
Electrical Equipment System — General Information
Description of devices for measuring voltage, current and resistance
Checking the windshield wipers
Replacing the windshield wiper arm
Removal and installation windshield wipers
Removal and installation the windshield wiper motor and arms
Instrument cluster
Coolant temperature gauge
Fuel level indicator
Other devices
Control lamps
Windshield washer
Fuses — Description and Replacement
Headlights and lighting
Checking the lamps
Replacement of outdoor lighting lamps
Replacing the headlight housing
Replacing front turn signals
Headlight adjustment
Adjusting the headlight angle
Headlight cleaners
Rear lights
Rear lights of a different design
Direction indicators and hazard warning lights
Side turn signal repeaters
License plate light
Power devices
Battery — General Information
Description of battery characteristics
Checking and servicing the battery
Detection of a faulty consumer
Alternator — General Information
Precautions when working with the generator circuit
Checking the generator without dismantling
Removal and installation of the generator — removal and installation
Replacing the brushes and voltage regulator of the generator
Disassembly and repair of the generator
Starter — General Information
Checking the starter
Removal and installation the starter — removing and installing
Starter repair
Possible starter malfunctions
Electrical circuits
Scheme 1. Fuel injection system of a diesel engine with exhaust gas recirculation system
Scheme 2. Control system of a diesel engine with a distributor-type fuel injection pump
Scheme 3. Control system of a diesel engine with a distributor-type fuel injection pump
Scheme 4. Control system of diesel engine 602.980 with distributor-type fuel injection pump
Scheme 5. Rear window defroster
Scheme 6. Electrical supply and starting systems of engine 601.943 manufactured before April 1998.
Scheme 7. Electrical supply and starting systems of engine 602.980 produced since February 1998.
Scheme 8. Power take-off mechanism of a manual gearbox (engines 601 and 602)
Scheme 9. Instrument cluster with electronic tachometer
Scheme 10. Anti-theft system EDW
Scheme 11. Outdoor lighting system
Scheme 12. Direction indicators, hazard warning lights
Scheme 13. Interior lighting system
Scheme 14. Interior lighting system
Scheme 15. Electric windows
Scheme 16. Interior lighting system when doors are opened
Scheme 17. Interior heating system
Scheme 18. Electric drive of rear view mirrors
Scheme 19. ABS/ABD or ABS/ETS systems
Scheme 20. Sound signal

Mercedes Vito 1 (1996-2003)
General information
User manual
Instrument panel
Control and measuring instruments, signal and indicator lights
Combination switch
Emergency light signaling
Rear fog light/fog lamp
Windscreen wiper switch
Watches — General Information
Total and daily mileage counter
Tempomat — general information
Ignition switch
Heating and ventilation
Air recirculation mode
Setting the heating and ventilation modes
Rear window heating
Heated seats
Air Conditioning — General Information
Engine residual heat utilization mode
Central lock
Central lock switch
Starter lock device (immobilizer)
Anti-theft system
Adjusting the position of seats and headrests
Adjusting the position of the steering wheel
Airbags
Additional heating
Hood — General Information
Fuel grades
Starting the engine
Manual transmission
Automatic transmission
Program switch positions
Brake systems
Anti-lock braking system ABS
Automatic brake and differential control (ABD) system
Electronic Ride Height Regulation (ENR)
Maintenance
Scheduled vehicle maintenance
Checking the drive belts
Replacing the alternator drive belt
Cooling system
Changing engine oil and oil filter
Replacing spark plugs (only on engines 111.948 and 104.900)
Replacing the fuel filter
Replacing the air filter element
Checking the operation of indicator and signal lights, horn, multi-function switch, windscreen wipers and washers
Changing oil in a manual transmission
Automatic transmission oil change
Checking the steering
Checking the brake system
Checking tire pressure
Front crankshaft oil seal
Petrol engines 2.0 l
Engine repair
Removal and installation the engine
Air filter
Cylinder head cover
Intake manifold
Exhaust manifold
Exhaust gas system
Front cylinder head cover
Cylinder head
Chain drive cover
Chain drive tensioner
Sliding chain drive lever
Chain drive tensioner lever
Chain tensioner
Drive chain
Camshafts
Crankshaft Groove Pulley
Crankshaft rear oil seal cover
Rear crankshaft oil seal
Crankshaft toothed pulley
Hydraulic compensators — removal, inspection, installation
Valve springs and valve stem retainers
Valves — removal and installation
Replacing valve seals
Lapping valve seats
Pistons — Removal and Installation
Piston rings
Checking and replacing connecting rods
Cylinder block
Flywheel — removal and installation
Crankshaft ball bearing
Replacing the crankshaft
Checking the axial clearance in the crankshaft main bearings
Checking the radial clearance in the crankshaft main bearings
Checking the radial clearance in the connecting rod bearings
Tightening torques of engine components and parts 111.948
Technical characteristics of petrol engines 111.948 and 111.978
Lubrication system
Lubrication system — device
Pallet — removal and installation
Oil level indicator guide tube
Oil pump
Replacing the oil pump drive chain
Oil level sensor
Pressure reducing valve
Oil pressure sensor
Checking oil pressure
Cooling system
Fan — removal and installation
Radiator — removal and installation
Cooling system pump
Thermostat — removal and installation
Oil radiator
Coolant temperature sensors
Air conditioner condenser
Coolant level sensor
Fan thermal switch
Power and control system
Engine management system
Ignition coils
Replacing spark plugs
Idle speed drive
Idle speed control valve
Control element of the device «Tempomat»
Inlet air temperature sensor
Oxygen sensor
Crankshaft position sensor
Diaphragm fuel pressure regulator
Fuel distributor with injectors
Generator — removal and installation
Starter — removal and installation
Petrol engines 2.8 l
Engine repair
Removal the engine with the subframe
Removal the engine with transmission
Air filter
Cylinder head cover
Intake manifold
Exhaust manifold
Exhaust gas system
Cylinder head
Upper timing belt cover
Lower timing belt cover
Chain tensioner
Replacing the drive chain
Checking the basic position of the camshafts
Camshafts
Valves — removal and installation
Replacing valve seals
Crankshaft Groove Pulley
Replacing the front crankshaft oil seal
Replacing the rear crankshaft oil seal
Flywheel / drive disk
Tightening torques of engine components and parts 104.900
Lubrication system
Engine sump
Oil level indicator guide tube
Oil filter housing
Oil pump
Oil pressure sensors
Oil radiator
Cooling system
Cooling system fan
Radiator of the cooling system
Cooling system pump
Thermostat housing
Thermostat — removal and installation
Coolant temperature sensors
Circulation pump
Power and control system
Ignition coils
Replacing spark plugs
Lambda probe (oxygen sensor)
Diaphragm fuel pressure regulator
Throttle body
Exhaust Gas Recirculation (EGR) Valve
Exhaust Gas Recirculation (EGR) Cut-off Valve
Air supply quantity check valve
Mass sensor for measuring air flow
Inlet air temperature sensor
Engine Crankshaft Speed Sensor
Camshaft speed sensor
Knock sensors
Checking engine compression
Injectors — removal and installation
Generator — removal and installation
Starter — removal and installation
Diesel engines 2.3 l
Engine repair
Removal and installation the engine
Cylinder head cover
Intake manifold
Exhaust manifold
Crankshaft Groove Pulley
Timing chain cover
Cylinder head
Prechamber — removal and installation
Camshaft
Timing chain sliding lever
Timing chain tensioner
Checking the hydraulic compensator
Front crankshaft oil seal
Rear crankshaft oil seal
Flywheel — removal and installation
Technical characteristics of diesel engines OM 601.942 and OM 601.970
Cooling system
Fan — removal and installation
Radiator — removal and installation
System pump
Thermostat — removal and installation
Coolant level sensor
Fan thermal switch
Lubrication system
Engine oil pan
Oil filter housing
Oil radiator
Oil level sensor
Oil pressure sensor
Checking oil pressure
Turbocharging and recycling
Exhaust Gas Recirculation System Vacuum Converter
Exhaust gas recirculation valve
Turbocharging — removal and installation
Turbocharger radiator
Turbocharger radiator fan
Compressed air distribution pipes
Power and control system
Incoming and compressed air pressure sensor
Electronic Fuel Injection Control System Temperature Sensor
Air flow meter
Electronic fuel injection control unit
Mixing chamber
Transmission overload protection valve
Vehicle speed sensor
Checking engine compression
High pressure fuel pump (HPFP)
Microswitch of fuel injection pump
Injectors — removal and installation
Glow plugs
Pre-heating relay
Pre-heating temperature sensor
Checking and adjusting the start of injection (digital tester method)
Checking and adjusting idle speed
Generator — removal and installation
Starter — removal and installation
Tightening torques of engine components and parts 601.970
Diesel engines 2.2 l
Engine repair
Removal and installation the engine
Decorative panel of the cylinder head cover
Cylinder head cover
Mixing chamber with exhaust gas recirculation valve
Intake manifold
Exhaust manifold
Crankshaft Groove Pulley
Front cylinder head cover
Timing chain cover
Timing chain sliding lever
Timing chain tensioner lever
Timing chain tensioner
Timing chain replacement
Camshafts
Checking the basic position of the camshafts
Cylinder head
Pistons — Removal and Installation
Crankshaft
Front crankshaft oil seal
Rear crankshaft oil seal
Cooling system
Fan — removal and installation
Radiator — removal and installation
Cooling system pump
Thermostat housing
Lubrication system
Pallet — removal and installation
Oil pump — removal and installation
Oil radiator
Oil level sensor
Turbocharging and recycling
Exhaust gas high pressure chamber
EGR system vacuum converter
Exhaust gas recirculation valve
Removal and installation turbocharger
Intercooler (compressed air cooling radiator)
Intercooler fan
Compressed air distribution pipes
Compressed air temperature sensor
Compressed air pressure sensor
Electronic fuel injection control system
Power and control system
Electronic Fuel Injection Control Unit CDI
Fuel injection system coolant temperature sensor CD1
Air flow meter
High pressure fuel pump intermediate gear
High pressure fuel pump
Vacuum pump
Fuel cut-off valve
Fuel pressure sensor in the distributor
Fuel pressure regulating valve
Fuel distributor
Crankshaft position sensor
Camshaft speed sensor
Injectors — removal and installation
Glow plugs
Pre-heating relay
Checking engine compression
Generator — removal and installation
Starter — removal and installation
Tightening torques of engine components and parts 611.980
Transmission
Clutch
Removal and installation the clutch
Clutch release lever
Clutch slave cylinder (only for vehicles with engines 111.948 and 601.970)
Clutch master cylinder
Clutch hydraulic lines (vehicles with engine 611.980)
Mechanical gearbox
Removal and installation the gearbox
Disassembly and assembly of the gearbox
Reverse light switch
Bearing caps
Clutch housing
Gearbox housing
Gearbox axle shaft seals
Drive shaft
Driven shaft
Reverse gear shaft
Disassembling and assembling the differential
Reverse gear lock
Adjusting the gear shift lever
Gear shift cables
Technical characteristics of mechanical gearboxes
Automatic gearbox
Removal and installation of automatic transmission
Replacing transmission fluid and oil filter of automatic transmission
Automatic transmission pan
Automatic transmission control unit
Electrohydraulic control unit
Gearshift Solenoid valves
Automatic transmission mode software switch (cars with engines 111.601 and 611.980)
Inductive sensor of rotation speed of the turbine of the GTR
Inductive sensor of the speed of the driven shaft of the automatic transmission
Radial seal of the GTR
Left axle shaft flange seal
Right axle shaft flange seal (vehicles with engine 104.900)
Rear cover of automatic transmission (on cars with engine 104.900)
Gear selector lever position sensor (vehicles with engines 111, 601.970 and 611.980)
Automatic transmission oil cooler (cars with engine 104.900)
Automatic transmission oil cooler fan (cars with engine 104.900)
Gear shift cable
Transmission Element Fastening Moments
Automatic transmission specifications
Chassis
Front suspension and wheels
Removal and installation the front suspension
Anti-roll bar
Lower suspension arm
Wheel hub
Steering knuckle
Half shaft — removal and installation
Central drive shaft with bearing
Left gearbox flange
Moments of fastening of suspension elements
Rear suspension
Removal and installation the rear suspension
Lower suspension arm
Anti-roll bar (cars 638.244 from 1.4.97 with air suspension of rear wheels)
Air suspension control unit
Removal the shock absorber
Air chamber (vehicles 638.0/1 and 638.2 with air suspension of rear wheels)
Checking and adjusting the vehicle level
Compressor — removal and installation
Lift height sensor (vehicles 638.0/1 and 638.2 with rear wheel air suspension)
Height sensor adjustment lever
Camber and longitudinal inclination of the front wheel kingpin
Front wheel alignment
Rear wheel alignment
Steering
Steering wheel (cars with airbags)
Steering gear
Steering shaft
Ignition lock cylinder
Ignition switch
Power steering pump
Checking the pressure in the power steering pump
Power Steering Pump Mounting Bracket
Ball joint
Driver's airbag
Passenger airbag
Airbag control unit
Fastening moments of steering elements
Brake system
Brake systems — general information
Master brake cylinder
Vacuum brake booster
Front brake caliper
Brake disc (ventilated) of the front brake mechanism
Front brake pads
Rear brake caliper
Rear brake disc
Rear brake pads
Parking brake drive mechanism
Brake pads of the parking brake system
Adjusting the parking brake system
Front parking brake cable
Rear parking brake cables
ABS/ABD system component locations, ABS/ABD system schematic diagram and ABS/ABD control unit wiring connector image
Hydraulic unit ABS/ABD or ABD/ETS
ABS Wheel Speed Sensors
Tightening torque of brake system components
Body
Exterior (external elements)
Radiator grille
Front bumper
Rear bumper
Hood — removal and installation
Front doors
Side door adjustment
Rear door adjustment
Installation distances of the hood, doors and covers
Basic dimensions for checking the relative position of body points
Interior (internal elements)
Instrument cluster center cover
Instrument panel
Instrument panel
Electrical equipment
Equipment and devices
Headlights — removal and installation
Headlight bulbs
Rear lights
Fog light switch
Windscreen wiper drive
Windscreen wiper link arms
Parktronic system sensors
Relay and fuse box (right side of instrument panel)
Heater and air conditioner
Heater housing
Heater fan drive
Additional heater control unit
Ignition sensor
Temperature and overheating sensors
Engine residual heat utilization system switch
Engine residual heat utilization system control unit
Air conditioning compressor
Air conditioner condenser
Air conditioner evaporator
Outside air temperature sensor
Cabin air temperature sensor
Air conditioning pressure sensor
Air conditioning control unit
Air conditioner switch
Outlet air temperature sensor
Electrical circuits
How to read and use electrical diagrams
Engine management system 111.948 and 111.978
Fuel injection and ignition control system HFM-SFI/MFI engine 104.900
Diesel fuel injection system CDI engine 611.980
Diesel fuel injection system with in-line fuel injection pump (IFI) and electronic control
Starting and charging system for engines 111.948 and 111.978
Engine starting and charging system 104.900 on model 638.244
Engine starting and charging system 104.900 on model 638.294
Engine starting and charging system 611.980 for model 638.094/194/294
Engine starting and charging system 601.970 on models 638.074/174/274 (up to 1.05.98)
Engine starting and charging system 601.970 on models 638.074/174/274 (from 23.04.98)
Manual transmission 503.018/06 (5-speed)
Automatic transmission 503.020 (up to 1.05.98)
Automatic transmission 503.020 (since 23.04.98)
Automatic transmission 503.020 with engines 111.948 and 601.970 (from 23.04.98)
Automatic transmission 503.020/04 on cars with engine 104.900
Direction indicators and hazard warning lights
Exterior lighting on models (with DLR system) 638.014
Exterior lighting on models 638.244 (before 1.05.98)
Exterior lighting on models 638.094/194/294
Engine cooling fan 111.948 and 601.970
Engine cooling fan 104.900 for model 638.244
Engine cooling fan 611.980 on models 638.094/194/294
Engine cooling fan 611.980 and 111.950/980 on models 638.094/194/294
Heating system on models 638.014-274 (before 01.05.98)
Heating system on models 638.014-274 (since 23.04.98)
ABS/ABD or ABS/ETS on models 638.014-274 (before 1.05.98)
ABS/ASR on models 638.094/194/294 with engine 611.980 (from 1.02.00)

Mercedes Vito 2 (2003-2014, diesel)
General information
User manual
Technical terms found in the manual
General overview — driver's workplace
Car key
Ignition switch positions
Seat adjustments
Steering wheel adjustment
Rear view mirrors
Seat belts
Starting the engine with a manual transmission
Starting an engine with an automatic transmission
Parking brake
External lighting control
Windshield wiper
Parking and locking the car
Systems that ensure traffic safety
Anti-theft protection
Multifunctional display (standard)
Multifunctional display (High-Line)
Features of using some functions
Cruise control systems TEMPOMAT and SPEEDTRONIC
Electronic Vehicle Body Level Control System (ENR)
PARKTRONIC system (PTS)
Options for organizing the luggage compartment
Self Help — Where to Look for What?
Emergency opening and closing
Lift and slide sunroof/panoramic sliding roof
Manual disengagement of the gearbox lock when parked
Replacing lamps
Removal the spare wheel
Electrical fuses
Front towing eye
Rear towing eye
Tires and wheels
Technical characteristics of the car
Maintenance
Inter-service maintenance intervals
Maintenance work
Changing engine oil and oil filter
Cooling system — checking, adjusting the concentration of antifreeze with anti-corrosion additives
Hydraulic brake drive
Car windshield washer
Replacing the air filter element
Checking the poly V-belt for wear and damage
Replacing the belt
Replacing the fuel filter
Replacing the filter element of the dust filter of the heating and ventilation system
Tire pressure: adjustment
Checking the thickness of the friction linings of the brake pads and the condition of the brake discs
Removal, installation and adjusting the parking brake pads
Checking for leaks and condition
Removal and installation ball ends of steering rods
ASSYST Service Computer — Updating Readings
Changing oil and oil filter in automatic transmission 722.680/682/683
Additional work at each maintenance
Towing hitch with removable ball pin and automatic locking
Additional work at every second maintenance
Additional work carried out every 2 years
Additional work carried out after 180,000 km
Additional work carried out every 10 years or after 300,000 km of mileage
Diesel engine OM646
Engine repair
General information
Vehicle option codes
Engine specifications
Removal and installation of the power unit
Units and assemblies in the front part of the engine
Removal and installation of the cylinder head (CH)
Checking the relative position of the camshafts
Checking the relative position of the crankshaft and camshaft system
Cylinder head repair
Removal and installation valves
Valve seats
Valve guide bushings
Processing of cylinder head for installation of valve guide bushings
Checking hydraulic valve clearance compensators
Disassembly and repair of the lower part of the engine
Removal and installation the crankshaft
Connecting rod and piston group of parts (CRP) — composition
Crank mechanism (CRM) — composition
Checking and repairing connecting rods
Connecting pistons to connecting rods and installing them in the cylinder block
Measuring the piston protrusion above the parting plane of a new cylinder block
Front cylinder block cover
Installing the rear cylinder block cover
Installing an oil pump
Installing the flywheel
Cooling and lubrication system
Lubrication system — general information
Oil pump
Oil sump pan
Oil filter and heat exchanger
Supply and return oil lines
Coolant circulation pump and thermostat
Cooling radiator
Cooling system fan
Connecting hoses and pipes
Power and exhaust system
Functional diagram of the air supply system
Turbocharger — purpose, control
Removal and installation a turbocharger
Removal and installation the intercooler
Elements of the air supply system
Low pressure circuit
High pressure circuit
High pressure fuel pump
Fuel injection pump drive
High pressure fuel manifold (HPFC)
High pressure fuel lines
Pressure regulating valve in the high pressure fuel system
Fuel injectors
High pressure pipe connection fitting to fuel injector
Exhaust gas system
Transmission
Clutch
Clutch mechanism
Clutch mechanism control
Operating principle of the hydraulic clutch release drive
Automatic clutch release system
Clutch release drive using pedal
Checking clutch parts during repairs
Removal the coaxial clutch slave cylinder
Removal and installation the clutch pedal
Clutch pedal bracket
Car gearbox
Gearbox designation and technical characteristics
Rear axle final drive gearbox
Manual transmission type 716.6
Hydraulic control unit
Mechanical gear shifting
Disassembly and assembly of the semi-automatic gearbox 716.6
Disassembly and assembly of the front part of the gearbox housing
Clutch release mechanism position sensor
Pressure sensor in the hydraulic drive of the gearbox control
Internal gear shift mechanism
Mechanical elements of the gearbox
Three-cone synchronizing mechanism
Double cone synchronizing mechanism
Single cone synchronizing mechanism
Intermediate shaft
Main shaft and primary shaft
Components of the rear axle final drive gearbox
Removal and installation the rear final drive
Removal and installation the propeller shaft
Removal and installation rear axle drive shafts
Removal the inner CV joint of the drive shaft from the rear axle final drive gearbox
Removal the outer CV joint from the drive shaft
Removal the inner CV joint from the drive shaft
Replacing the CV joint boot
Front axle gearbox
Chassis
Front suspension
Front wheel suspension
Front suspension arm
Front control arm and steering knuckle
Fastening the steering knuckle to the shock absorber strut
Anti-roll bar
Fastening the stabilizer bar
Shock absorber strut
General information on checking wheel alignment angles
Checking and adjusting the front wheel alignment
Checking and adjusting the camber and longitudinal tilt of the wheel pivot axis
Rear suspension
Rear suspension
Rear suspension with metal springs
Rear air suspension
Air suspension compressor
Rear air suspension lines
Rear stabilizer
Removal and installation the rear shock absorber
Checking the condition of the rear shock absorber
Removal and installation rear suspension arms
Removal and installation the rear hub bearing
Removal and installation the rear axle thrust rod
Replacing the rear gearbox oil seal
Checking and adjusting rear wheel alignment
Checking the rear wheel alignment
Removal and installation the steering gear
Steering
Hydraulic power steering (HPS
Steering column
Steering wheel
Removal and installation the steering wheel
Removal the rotating contact joint
Setting the average position of the rotating contact joint (RCJ)
Removal and installation the steering wheel angle sensor
Removal and installation the steering rod end
Removal and installation the steering rod
Adjusting the clearance of the gear engagement in the rack and pinion mechanism
Brake system
Elements of the braking system
Removal and installation the brake pedal
Removal and installation of the master brake cylinder (MBC)
Removal and installation the brake booster
Body
Body elements
Vito Viano car body
Removal and installation the hood
Removal and installation mudguards
Removal and installation the radiator grille
Removal and installation the front bumper
Removal and installation the upper bumper trim
Removal and installation the front panel support crossmember
Removal and installation the external rearview mirror
Removal and installation the front wing
Removal and installation the fuel tank flap
Removal and installation rear bumper corners
Disassembling and assembling the rear bumper
Removal and installation the bumper reinforcement
Removal and installation the side bumper mount
Removal and installation the side door step
Removal and installation front passenger seats
Removal and installation roof rails
Coupling device
Control data for clearances when installing removable body elements
Electrical equipment
Equipment and devices
Car control system
Operating principle of the CAN multiplex network
The principle of signal formation in a multiplex network
Block diagram of multiplex networks of Vito Viano cars
List of components of multiplex networks
Data exchange between data buses
Instrument cluster (A1)
Front universal switching unit
SAM Block Functions
Engine management system
Functions performed by the control system in different modes
Control of fuel supply to the injection pump
Controlling the amount of fuel injected
Fuel injection pressure control
Controlling the amount of fuel injected during engine start-up
Injection control in driving mode
Idle injection control
Fuel pre — injection control function
Main fuel injection control function
Final stage of injection
Glow plug preheating function
Post-start heating
Boost pressure control function
Air-fuel ratio definitions
Exhaust Gas Recirculation (EGR) Control
Air supply cut-off control
Air conditioning compressor shutdown control function
Fuel supply system
Functional diagram of engine control
Elements of the engine management system
Electronic Control Unit (ECU)
Accelerator pedal position sensor (B37)
Crankshaft Position Sensor (L5)
Camshaft Position Sensor (B6/1)
Coolant temperature sensor (B11/4)
Fuel temperature sensor (B50)
Inlet air mass sensor (B2/5), combined with inlet air temperature sensor (B2/5b1)
Discharge air temperature sensor (B17/9)
Boost pressure sensor (B5/1)
Fuel pressure sensor in the high pressure fuel system (B4/6)
Oil condition sensor (B40)
Input oxygen sensor on the EGR converter (G3/2)
Air filter outlet pressure sensor (B28/5)
CDI control system actuators
Glow plugs (R9)
Pressure regulating valve in the high pressure fuel pump (Y74)
Exhaust Gas Recirculation (EGR) Valve Actuator
Exchange Rate Stability System ESP
Interaction of systems
ABS Component Locations (for vehicles not equipped with ESP)
Wheel speed sensors
Lateral acceleration sensor
Angular velocity (yaw)sensor
Steering wheel angle sensor
Hydraulic brake force control unit
Functioning of the ESP system
Brake Assist System (BAS): Functional Description
Vehicle Maintenance and Condition Monitoring System (ASSYST)
Tire pressure monitoring system
Security systems
Passive safety system
Block diagram of the passive safety system
Elements of the security system
Precautions when servicing units containing elements of the passive safety system
Driver's airbag
Side airbags
Seat belt pretensioner
Construction of the UPN
Upper side airbags
Electrical circuits
Using Electrical Schematics
Scheme 1. Relay and fuse box
Scheme 7. Power supply to fuse box F34
Scheme 9. Power supply to fuse box F35
Scheme 10. Power supply to the fuse box located in the right seat frame
Scheme 11. Power supply to fuse boxes F4 and F5
Scheme 12. Electronic ignition control unit
Scheme 13. Electrical wiring couplings
Scheme 20. Starter and generator (for engines OM 646.982 and 646.983, before 28.02.2005)
Scheme 21. Starter and generator (for engines OM 646.980 and 646.981, from 01.03.2005)
Scheme 23. Electronic control unit of the CDI system (for engines OM 646.982 and 646.983)
Scheme 25. Electronic control unit of the CDI system (for engines OM 646.980 and 646.981)
Scheme 27. Fuel supply system
Scheme 28. Automatic gearbox
Scheme 29. Gear selector control unit
Scheme 30. Brake control (with ESP stability control system (VVZ equipment code))
Scheme 31. Brake control (without ESP stability control system)
Scheme 32. Electronic stability control system ESP up to s No. 195056
Scheme 33. Electronic stability control system ESP starting from No. 195057
Scheme 34. Multifunctional steering wheel
Scheme 35. Rear window heating
Scheme 36. Electric drive of the rear ventilation window
Scheme 37. Right sliding door control unit
Scheme 38. Rear wiper
Scheme 39. Electric drive of the driver's door window lifter
Scheme 40. Electric drive of the front passenger door window lifter
Scheme 41. Control unit of the front left door
Scheme 42. Control unit of the front right door
Scheme 43. Central lock
Scheme 44. Anti-theft alarm
Scheme 45. Outdoor lighting
Scheme 46. Internal sockets
Scheme 47. License plate lighting up to No. 094908
Scheme 48. Number plate lighting starting from No. 094909
Scheme 49. Direction indicators and hazard warning lights
Scheme 50. Brake light
Scheme 51. Interior lighting
Scheme 53. Controls illumination
Scheme 54. Sound signal
Scheme 55. Rear wiper
Scheme 56. Car windshield washers
Scheme 57. Heater diagram
Scheme 58. Passive safety system until 31.08.2005.
Scheme 59. Passive safety system since 01.09.2005.
List of electrical equipment elements

Mercedes Vario 814D (1996-2003, diesel)
General information
Maintenance
Brief history and characteristics of the truck
Instructions for performing maintenance
Scheduled maintenance
Checking the drive belts
Cooling system
Engine oil change
Replacing the air filter element
Fuel system
Checking the operation of windshield wipers and washers
Functional check of the heating and ventilation system
Manual transmission (MT)
Automatic transmission (AT)
Transfer case oil change 750.553/581
Changing the oil in the front axle gearbox
Changing the oil in the rear axle gearbox
Checking the brake shoe linings
Checking the steering
Power unit
Engines 602.984/985
Removal and installation the engine
Air filter
Intake manifold
Exhaust manifold
Cylinder head cover
Timing chain cover
Sliding lever
Timing chain tensioner
Timing chain tensioner lever
Timing chain replacement
Cylinder head
Camshaft
Valve springs and valve stem seals
Checking and grinding valves
Checking the valve spring
Checking and replacing the valve guide bushing
Replacing the ring and lapping the valve seat
Pistons — Removal and Installation
Piston rings — removal and installation
Connecting rods — removal, inspection and installation
Cylinder block liners
Flywheel — removal and installation
Crankshaft ball bearing
Crankshaft — Removal, Inspection and Installation
Cooling system pump
Radiator of the cooling system
Pallet — removal and installation
Oil pump pressure reducing valve
Oil pump — removal and installation
Oil filter housing
Turbocharger — removal and installation
High pressure fuel pump (HPFP)
Injectors — checking
Nozzle holder — removal and installation
Starter — removal and installation
Generator — removal and installation
Tightening torques for engine components and parts 602.984/985
Engines 904.908/914/923/936
Removal and installation the engine
Intake pipe — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Cylinder head cover
Cylinder head
Timing Belt Cover — Removal and Installation
Rocker arms and rocker arm axle
Camshaft — Removal and Installation
Checking valve lift
Adjusting the thermal clearance of the valves
Valves — removal and installation
Replacing valve seat rings
Replacing valve stem seals
Constant throttle — removal and installation
Pistons — Removal and Installation
Piston rings — removal and installation
Connecting rods — removal, inspection and installation
Crankshaft — removal and installation
Cylinder block sleeve
Crankshaft seals
Flywheel — removal and installation
Pallet — removal and installation
Oil pump — removal and installation
Oil filter housing
Oil radiator — removal and installation
Oil level sensor
Cooling system pump
Thermostat — Removal, Checking and Installation
Radiator of the cooling system
Turbocharger — removal and installation
Engine Brake Valve
Engine control unit
Pump-injector — removal and installation
Compressed air pressure sensor (engines 904.908 up to number 040 487)
Compressed air temperature sensor (engines 904.908 up to number 040 487)
Compressed air temperature/pressure sensor (engines 904.904/908, from number 040488: 904.923/936)
Starter — removal, installation
Generator — removal and installation
Diagnostic Trouble Codes for Engines 904.9
Tightening torques for engine components and parts 904.9
Transmission
Clutch
Removal and installation the clutch
Clutch slave cylinder
Checking the runout of the driven clutch disc
Manual gearbox 711.613
Removal and installation of manual transmission
Reverse light switch
Gearbox housing
Gearshift fork guide plate
Primary shaft — removal and installation
Gearbox cover
Secondary and intermediate shafts
Disassembly and assembly of the secondary shaft
Adjusting the axial clearance of the intermediate shaft
Gear shift lever
Lower part of the gear shift lever
Gear shift cylinder
Cardan transmission
Tightening torques for transmission components and parts
Manual gearbox 710.64/66
Removal and installation of manual transmission
Front of gearbox
Rear of the gearbox
Primary shaft
Intermediate shaft
Secondary shaft
Gear shift lever
Manual gearbox 715.051
Removal and installation of manual transmission
Front of gearbox
Rear of the gearbox
Primary shaft
Intermediate shaft — removal and installation
Secondary shaft — wear check
5th gear pinion — removal and installation
4th gear pinion — removal and installation
3rd gear pinion — removal and installation
2nd gear pinion — removal and installation
Gear shift mechanism
Automatic gearbox 723.345
Removal and installation of automatic transmission
Centrifugal regulator of automatic transmission
Automatic transmission modulator
Automatic transmission oil cooler
Gearbox valve shift
Power take-off box
Power take-off box (cars with manual transmission 711.613)
Disassembly and assembly of the power take-off box
Adjusting the axial clearance of the power take-off drive shaft
Power take-off output flange seal
Chassis
Front suspension
Removal and installation the front suspension
Front axle hub
Steering knuckle
Front suspension spring
Replacing the anti-roll bar
Front axle height adjustment valve
Rear suspension
Removal and installation the rear suspension
Rear axle hub
Rear suspension spring
Replacing the rear anti-roll bar
Rear axle height adjustment valve
Rear axle air chamber (models 668, 670 with rear air suspension)
Tightening torques for chassis components and parts
Steering
Removal and installation the steering gear
Power steering pump
Checking and adjusting the central position of the steering mechanism
Tightening torques for steering components and parts
Brake system
Brake booster vacuum
Telma retarder (on models 668.322/323/352/353, 670.322/323/324/352/373/374 with code BR3)
Brake pads — removal and installation
Brake caliper
Adjusting the parking brake system drive
Wheel speed sensors
ABS System Error Codes
Tightening torques for brake system components and parts
Body and electrical equipment
Interior (internal elements)
Instrument panel
Central part of the instrument panel
Upper instrument panel cover
Driver's airbag
Exterior (external elements)
Front wing
Front door
Hood — removal, installation and adjustment
Windscreen wiper arm
Heater and air conditioner
Heater housing
Air conditioning compressor
Air conditioner condenser
Air conditioning compressor electromagnetic clutch
Tightening torques for elements and parts of the car body and electrical equipment
Electrical diagrams
How to read and use electrical diagrams
Diesel fuel injection system for engines 904.908/914/923/936 on models 668, 670
Diesel fuel injection system and electronic engine control 602.984/985
Starting and charging system for engines 602.984/985 on models 667, 668, 670
Engine starting/charging system 602.984/985 on models 667, 668, 670 from 01.07.1999.
Starting and charging system for 602 and 904 engines with finger-type battery switch on 667, 668, 670 models
Starting and charging system for engines 904.904/908/923 on models 670.373/374 with battery switch
Engine starting/charging system 904.904/908/923 on models 668, 670 up to 30.06.1999.
Starting and charging system 904.904/908/923 on models 670.373/374 with emergency switch
Scheme of the starting and charging system of engines 904.904/908/923 on models 668, 670 from 01.07.1999.
Automatic transmissions 723.345/346 on models 668, 670
ABS anti-lock braking system on 667 models
Anti-lock braking system ABS on models 668, 670
Outdoor lighting system models 667, 668, 670 up to 30.06.1999.
Outdoor lighting system models 667, 668, 670 since 01.07.1999.
Instrument cluster for models 667, 668, 670 with 602 engines
Instrument cluster for models 667, 668, 670 with 904 engines
Air suspension models 668, 670 with engines 602.985
Air suspension of models 668, 670 with 904 engines from 01.07.1999.
Diagnostic connector for models 667, 668, 670 with 602 engines
Diagnostic connector for models 667, 668, 670 with 904 engines
Air conditioner — electrical diagram
Air conditioner models 667, 668, 670 from 01.07.1999.
Heater — electrical diagram
Direction indicators and hazard warning lights for models 667, 668, 670
Windscreen wipers — electrical diagram
Electrical center models 667, 668, 670 with engines 602 since 01.07.1999.
Electric center models 667, 668, 670 with engines 904

6007