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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mercedes-Benz G-Class (W463, 1999 issue)

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Mercedes-Benz G-class
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Mercedes-Benz
G-class
Introduction
Controls and operation receptions
Current care and maintenance
Specifications
The active warning system Maturity planned TO (ASSYST)
The routine maintenance schedule
General information about the settings,
Check fluid level, leakage control
Checking the condition of tires and pressure in them, the designation of tires and wheel rims, wheel rotation
Replacing the motor oil and oil filter
Check the brake system
Check the power supply system, replacement of the fuel filter
Check and replacement of hoses of an impellent compartment, localization of leaks
Checking the multirebernyh accessory drive belt
Check the functioning of the cooling system and frost coolant fluid replacement
Checking the exhaust system
Replacement ATF and filter AT
Visual check of tightness automatic transmission
Checking the suspension components and steering
Checking the status of anther drive shafts
Check the air conditioning system
Grease limiters door locks and cylinders
Visual inspection of safety belts and airbag modules
Verifying the headlights and horn
Check and replace wiper blades
Checking the status of the battery, care it and gymnastics
Replacing the cabin filter
Replacing the drive fluid differential lock
Replacing brake fluid
Check and replacement of spark plugs, check the status of high-voltage wires (petrol models)
Replacing the glow plugs (diesel models)
Engine
System of cooling, heating, ventilation and air conditioning
The power supply system and exhaust
Systems of an electric motor
Automatic Transmission
Transmission Line
Brakes and auxiliary systems
Suspension and steering
Body
Onboard electric
Wiring
 


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Check the functioning of the cooling system and frost coolant fluid replacement



Refer also to the materials of Section Check and replacement of hoses of an impellent compartment, localization of leaks.

Hoses, as well as belts, tend to fail at the most inopportune moment - in order to avoid the hassles associated with the rupture of a radiator or heater hoses, carefully inspect them, as shown in the illustration


PERFORMANCE ORDER

  1. Many serious violations in the work related to the engine cooling system fault. If the car is equipped with an automatic transmission, its function and service life are also directly related to the operation of the cooling system.
  2. Check the cooling system must be done when the engine is cold, so it's best to do it before the first day of the current trip or not earlier than three hours after the engine is switched off.
  3. Slowly, being careful in case the engine is still not completely cooled, remove the reservoir tank cover. Thoroughly rinse the inside and outside with clean water. Also rinse the tank filler neck. The presence of traces of corrosion in the filler neck means that the coolant must be replaced (see. Below). The coolant within the expansion tank must be relatively clean and transparent. If it has a brownish color, empty the system and fill it with new coolant.
  4. Carefully inspect radiator hoses, heater hoses and which have a smaller diameter. Check the coolant hoses over the entire length, the detection of cracks, swellings and signs of aging are changing the material. Cracks are easier to detect by squeezing the hose. Pay special attention to location of the fastening clamps which may cut or pierce the pipes that lead to the development of leakage of coolant.
  5. Make sure of reliability of fastening of all hose connections. Coolant leaks usually occur in the form of white or rust-colored deposits in breach of the seal. If your car uses a wire-type clamps, it makes sense to replace them with collars of screw type.
  6. Use compressed air or a soft brush, clean the front of the radiator (and the air conditioning condenser, where it is available). Remove all insects, leaves and other foreign objects that fall on the fins - be very careful not to damage the edges and do not cut your fingers on them.
  7. If the coolant level is constantly falling, and you do not find any leaks, you should make a check of the cooling system pressure conditions HUNDRED Mercedes-Benz.

Checking coolant frost

Do not suppose antifreeze hit on your skin and the painted surfaces of the vehicle. In case of contact rinse immediately with plenty of water. Antifreeze is extremely toxic and deadly when ingested. Do not leave antifreeze in an open container or spilled on the floor; its sweet smell can easily attract children or pets. Consult local regulations for disposal of spent antifreeze. In many areas, there are special centers for its acceptance.


PERFORMANCE ORDER

  1. Before the start of the winter season, it is imperative to check the antifreeze concentration in the coolant, especially if the system during operation filled with clean water - use a hydrometer with graduation on frost.
  2. Slightly warm up the engine so that the upper radiator hose is hot. When measuring the concentration of antifreeze fluid temperature should be approximately + 20 ?� C.
  3. Carefully unscrew the bottle.

When the engine is hot plug the expansion tank should be opened with caution. There is a risk of burns! It is necessary to put on a cloth cap. The stopper is only open at a liquid temperature not more than + 90 ?� C.

  1. Dial liquid with a blower hydrometer.
  2. In our latitudes, a sufficient concentration of antifreeze that protects the system to a temperature of -25 ?� C, in particularly cold climates to -35 ?� C.

Substitution coolant

PERFORMANCE ORDER

  1. Prepare a drain container suitable volume.
  1. Remove the expansion tank cap.
  1. Open the tap adjusting heater.
  2. Remove protection crankcase.
  1. Alternately, first drain the coolant from the radiator (see. Conjugated. Illustration of a and b), then from the crankcase (see. Conjugated. Illustration c).

    and - Location of the drain valve radiator - tighten the valve on the hose inner diameter of 12 mm (petrol models)
    b - Location radiator drain valve - tighten the valve on the hose inner diameter of 12 mm (diesel models)
    c - Location drain plug of the water jacket of the engine crankcase, - if necessary, use the hose inner diameter of 14 mm

a.

b.

c.

  1. Check patency of the cooling channels open areas tract, in case of need make their cleaning.

  2. Assess the sealing washers drain plugs, replace faulty washers.
  3. After the surge tank fill neck in the required amount of fresh cooling liquid. When driving in conditions of temperature up to -25 ?� C antifreeze concentration in the coolant should be about 40%. When the thermometer is lowered to the level of -35 ?� C concentrations should be increased to 50% (see. Specifications).

If a higher degree of protection against freezing, it is possible to increase the concentration of antifreeze up to 60% (this concentration will provide protection against freezing at temperatures down to -40 ?� C). Further increase in the content of the antifreeze coolant reduces the efficiency of its operations as if the heat removal, and in the protection of the engine against corrosion.

  1. Start the engine and bleed the cooling tract air pockets (see. Below).
  2. Attach the lid of the expansion tank with a label indicating the concentration of the brand of antifreeze and the date of its replacement. Any subsequent replenishment system (up to the planned replacement) should be performed only liquid of the same composition, or distilled water

Removal of air pockets

PERFORMANCE ORDER

  1. If the replacement fluid motor overheats, the cause is likely in the presence of air pockets in the system. Traffic jams usually occur as a result of haste when filling the system does not violate the serviceability of coolant.
  2. The presence of the rubber hoses of the cooling system of air pockets usually simply taped to the touch. After replacing the coolant air pockets usually disappear when you first start the engine.
  3. When running to warm up to normal operating temperature of the engine and turn on the heater fan, - the warm air should flow into the interior in sufficient quantities. One reason for the lack of warm air may be present in the path of cool air pockets.
  4. The appearance in the cooling path of air pockets sometimes fraught with serious consequences, not only reduces the efficiency of the heater return. Enough volume plug may prevent the circulation of the liquid inside the water jacket of the engine. In order to make sure that there are no traffic jams inside the engine, feel the upper radiator hose: when the engine is running it should be hot. Insufficient heating hose may indicate the presence of air pockets in the jacket, and the possible failure of the thermostat.

Petrol models

PERFORMANCE ORDER

  1. If after the first engine start after replacement procedure coolant system will airlocks, switch off the engine and wait until it cools, then remove the reservoir tank cover and poszhimayte cooling hoses. In the worst case, the cooling system will have to completely empty and refill with fresh coolant (see. Above).

Diesel models

G270 CDI (M612)

Preparing to remove air pockets from the path of the cooling system turbo engine (1 of 4)

Preparing to remove air pockets from the path of the cooling system turbo engine (2 of 4)

Preparing to remove air pockets from the path of the cooling system turbo engine (3 of 4)

Preparing to remove air pockets from the path of the cooling system turbo engine (4 of 4)

N90 - The control unit cooler air pressurization


PERFORMANCE ORDER

  1. Set the AT selector lever to position "P" and turn off the ignition.
  2. Remove the mounting bolts (1), pull down the cover (2) under the instrument panel on the right, turn the screws (3) and remove the cover (4).

On the models equipped with an emergency call TELE AID (code ET2), disconnect the wiring from the corresponding speaker right front door.

  1. Open the right front door and release the latches of the side cover (5) to the right on the instrument panel to facilitate access to the control module supercharging air cooler (N90).
  1. Remove the module and N90 Jumper between themselves plugs ?��?�� 2 and 5 contact pads for the purpose of closing the loop supply circulating pump (M44).

Be careful: the numbering of the terminals in the connector block and the module does not match!

  1. Open the expansion tank cap and turn on the ignition, - activation of the circulation pump will remove the plugs from the path of the cooling system.
  2. After checking the completeness of removal of air, turn the ignition off and replace the components acting in film.

G400 CDI (M628)

During the procedure constantly watch the liquid level in the expansion tank, if necessary, make the appropriate adjustments! When the coolant temperature reaches 60-70 ?� C reservoir tank cover should be closed.


PERFORMANCE ORDER

  1. On models equipped with engine series 628 bleed the cooling path is also produced by the activation of the electric motor of the circulating pump (M44).
  2. Connect the reader and activate STAR DIAGNOSIS (proceed in accordance with the instructions given in the device manufacturer's instructions).
  3. Make the choice of model of the car indicating the type of engine and steering gear.
  4. Enter the main group of control units and select the required driver.
  5. Specify the type of power supply system (CDI-V1).
  6. Select activation mode, as the target point specifying the electric motor of the circulating pump (M44).
  7. To activate the pump, press the function key ?�F3?�, - the pump will operate only when the key is pressed.

The key must be pressed physically and virtually not using the mouse!

Removal of oil from cooling and heating paths diesel engines

Do not open the expansion tank cap as long as the coolant warms up to a temperature of 90 ?� C. When opening the lid, be careful - do not scald!

Removing oil from the cooling / heating path of the diesel engine

1 - Expansion tank
2a - The drain valve of the radiator
2b - Drain plug crankcase
3 - overflow tank (in these models is not used)

1 - 8 Radiator
20 - Thermostat
A - The supply and return flow heater

PERFORMANCE ORDER

  1. Remove protection crankcase. Drain the cooling system (see. Above).
  2. Remove the thermostat cooling system (see chap. System of cooling, heating, ventilation and air conditioning).
  1. Using pliers, remove the retaining plate (6), and then pulling down and simultaneously turning, remove the casing (4) thermostat operating element (5). Further cover may be used as a tool for the removal of the oil cooling system.
  1. Turn on the heater for maximum performance (see. Some devices provide comfort), with appropriate equipment activate an additional heater (ibid.).
  2. Pour in a special cooling the wash solution (5% concentrate, 95% water).
  3. Run the engine at moderate speeds warm it to a temperature of 80 ?� C (take about 5 minutes).
  4. Stop the engine and let it cool down to a temperature of about 50 ?� C.
  5. Drain the solution from the cooling system (see. Above).
  6. Fill the cooling system with clean water for 5 minutes, start the engine and then shut off again and drain the water.
  7. Fill the cooling system with fresh coolant, remove the cooling air path (See above.) And inspect the system components for signs of leaks.




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