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

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Mercedes-Benz
	G-class
		Introduction
		Controls and operation receptions
		Current care and maintenance
		Engine
			Check compression pressure assessment cylinders
			Checking the engine by means of the vacuum gauge
			Replace accessory drive belt and its tension elements of the mechanism
			Checking the motor oil pressure
			Calculating the oil flow
			Check and adjust the basic position of camshafts
			Checking the reference position of the balancing shaft (only engines M112 and 628)
			Checking the timing chain on the engine M628
			Verifying the installation of ignition timing on the petrol models
			Removal and installation of the power unit
			Removal and installation of supports of the suspension of the power unit
		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

printable version

Engine

Specifications

The following are the parameters used when performing the described procedures in this chapter. Detailed regulatory information can be found on branded service stations service station Mercedes-Benz. Separate characteristics are resulted also in the text of the Head and in case of compulsion of their performance are highlighted in bold.

Listed below are the only values that are typical for all engines considered series.

Petrol models

Common parameters

engine's type
M112	V-shaped, 6-cylinder, DOHC, water-cooled, timing chain drive and microprocessor control
M113	V-shaped 8-cylinder, DOHC, water-cooled, timing chain drive and microprocessor control
Lineup use
G320 (463.945)	112,945
G500 (463.249)	113,962
G55 AMG (463.246)	113,982
Engine volume, l
M112	3.2
M113
113,962	50
113,982	5.5
Number of valves per cylinder	3
Compression ratio	10.0: 1
Pressure compression bar
Nominal value	12 ÷ 14
The minimum allowable value	9.0
The maximum allowable difference in readings between cylinders	15
Operating procedure of cylinders
M112	1-5-3-6-2-4
M113	1-5-4-8-6-3-7-2
Valve clearance	Automatic adjustment - lifters

Cylinder head

Casting

Classification of cylinder head gaskets for engines
Symbol
chenie
telya to move in!
Volume
tsilind ditch l
The diameter of the cylinder
moat (C), mm
Marking
heads (A / B)

112,945
3.2
92.00
A
1120160320/0420

113,962
50
97.00
A
1130100220/0320
113,982
5.5
No data available
No data available
No data available

Dimensions of the cylinder head bolts

Thread M11
The length (L), mm
New bolt
141.5
The limit value
144.5

Valve guides

Driving landing valve guides


1 - Guides intake valve 2 - Guides exhaust valve	A - The landing depth of the sleeve L - Full-length sleeve

Valve guides

The diameter of the nest under landing of the valve guide, mm
Standard size	12.500 ÷ 12.511
The standard size of I (blue)	12.520 ÷ 12.531
Repair size I (red)	12.700 ÷ 12.711
Repair size II (yellow)	13.100 ÷ 13.111
The outer diameter of the valve guide, mm
Standard size	12.540 ÷ 12.551
The standard size of I (blue)	12.560 ÷ 12.571
Repair size I (red)	12.740 ÷ 12.751
Repair size II (yellow)	13.140 ÷ 13.151
The length of the valve guide, mm
The inlet and outlet valves	50
The geometrical characteristics of the guide sleeve, mm	A 14.3 ?� 0.2

Details of the installation and the geometric parameters of valve seats (motors 112 and 113 series)


D1 - Nest for planting inlet valve seat D2 - jack for planting saddle valve	a - The operating angle of the bevel chamfer b - Upper correction angle g - Lower correction angle A - width of a working facet of a saddle

Valve seats

Engines series 112 and 113

A - The diameter of the rod
B - Length
C - height plate
D - diameter dish
a - The angle of the bevel

The geometrical parameters of the valve (see. Conjugated. Illustration)
D, mm
M112
The intake valves	36 ?� 0.1
The exhaust valves	41 ?� 0.1
M113
The intake valves	38 ?� 0.1
The exhaust valves	43 ?� 0.1
C (for the new valve), mm
The intake valves	12
The exhaust valves	16
And, mm
The intake valves	6.975
The exhaust valves	6.970
In mm
M112
The intake valves	119.40 ?� 0.2
The exhaust valves	122.25 ?� 0.2
M113
The intake valves	119.10 ?� 0.2
The exhaust valves	121.80 ?� 0.2

Cylinder block

Crankcase

Bore, mm
M112
Standard size
Marking X	89.900 ÷ 89.915
Marking D	89.950 ÷ 89.965
Repair size	90.150 ÷ 90.165
M113
Standard size
Marking X	97.000 ÷ 97.015
Marking D	97.050 ÷ 97.065
Repair size	97.250 ÷ 97.265

Crankshaft

Dimensions bolts connecting rod bearing caps (see. Conjugated. Illustration)
Thread	M8x1
Length mm
New bolt	47
The limit value	47.6

Legend persistent half rings of a cranked shaft

Block
cylinders
The pin crankshaft
Persistent half rings
The magnitude of the axial
backlash shaft, mm
Symbol.
Inscription
Symbol.
Marking
-focusing
Code
N
O
N
Lettered-digit code
0,10 ÷ 0,266
Code
N1
1
N1
Lettered-digit code
0,10 ÷ 0,266

Balancer shaft (112 series)

Maximum permissible length of the bolt fastening the counterweight, mm

50.7

The connecting rod-piston assembly

Bore mm
M112
Standard size
Marking X	89.872 ÷ 89.902
Marking D	89.872 ÷ 89.902
Repair size	90.122 ÷ 90.152
M113
Standard size
Marking X	96.972 ÷ 97.000
Marking D	97.022 ÷ 97.050
Repair size	97.222 ÷ 97.250
The maximum permissible amount of movement of the pistons, mm	0.043
The size of the connecting rod bearing radial play (new bearings), mm	0.026 ÷ 0.054

Axial backlash of rods
Color-coded liner
The magnitude of the axial rod, mm
Upper ear (rods)
Lower liners (cover)
Yellow
Yellow
0,026 ÷ 0,054
Blue
Red
0,026 ÷ 0,054
Red
Blue
0,026 ÷ 0,054

The dimensions of the piston rings, mm
Compression rings
M112 83.2x1.5x3.1
M113
113,982
97.0x1.2x3.5
113,962
97.0x1.5x3.1
Scraper ring
M112 83.2x3.5x3.5
M113
113,982
97.0x1.5x4.0
113,962
97.0x3.5x3.5

Efforts of a tightening of carving connections, Nanometer

Drain plug sump (M14)	30/32
The cover casing of the oil filter	25
Self-tapping bolt tensioner to cover timing
The thread does not cut	35
The thread is cut	25
Bolts damper belt tensioner
accessory drive
Tensioner	25
To the water pump	35
Bolts tensioner	25
The socket assembly connected to the fuel pipe feeding fuel line	38
Flanged reception pipe exhaust system with exhaust manifold	20
Bolts starter against the crankcase	42
Bolts pads front support to the subframe	35
M8 bolts fastening the torque converter to the drive disk	42
AT bolts to the engine
M10x40 and M10x90	40
M12	-
Mounts hydraulic lines to the steering pump
Pressure line
M14x1.5	-
M16x1.5	45
Return line	2
Tighten the screws on the compressor K / V to the support bracket	20
Cover bolts GRMk drive block and the cylinder head	20
Bolt M8x78 mounting idler belt K / V and auxiliary agregatovk cover timing	68
Bolts of fastening of the water pump
Self-tapping
M6
The thread does not cut	14
The thread is cut	10
M8
The thread does not cut	35
The thread is cut	25
Standard (M7)	10
Fixing water pump pulley	10
Thermostat housing bolts (M6)	10
Bolts steering pump
Self-tapping
The thread does not cut	35
The thread is cut	20
Standard	25
Bolts intake manifold to the cylinder heads (M8)	20
Chain tensioner in the timing cover	80
Bolt stars camshaft (M12x45)
Step 1	50
Step 2	To hold a 90 ?� angle
The Hall sensor of a camshaft in the cylinder head	8
Bolts camshaft bearing bridge to golovkamxilindrov
M7x45
Step 1	15
Step 2	-
M7x84
Step 1	10
Step 2	To hold a 90 ?� angle
Bolts of asterisks of camshafts (M12x45)
Step 1	50
Step 2	To hold a 90 ?� angle
Cylinder head bolts
To the engine block (inside TORX)
Step 1	10
Step 2	thirty
Step 3	To hold a 90 ?� angle
Step 4	To hold a 90 ?� angle
To cover timing	20
Bolts cylinder head covers	10
Nut connecting pipe to the EGR valve	40
Flanged reception pipe exhaust system with exhaust manifold	20
Nuts of fastening of a final collector	16
Bolts of fastening of the end cap of the engine	10
The central bolt of vibration damper
Step 1	200
Step 2	To hold at an angle of 95 ?�
Bolts disk drive to the crankshaft
Step 1	45
Step 2	To hold a 90 ?� angle
Bolts main bearing caps
M8
In addition to the side
Step 1	20
Step 2	To hold a 90 ?� angle
Side	thirty
M10
Step 1	thirty
Step 2	To hold a 90 ?� angle
Bolts of fastening of covers of the bottom heads of rods
Step 1	5
Step 2	25
Step 3	To hold a 90 ?� angle
Bolt M7x16.5 fixing the lock plate to the balancer shaft (M112)	15
Bolt counterweight to the balancer shaft (M112)
Step 1	20
Step 2	To hold a 90 ?� angle
Bolts / nuts cushion back support suspension of the power unit
By the transmission housing	35
By crossmember	35
Nuts of fastening of the crossbeam to the vehicle frame	35
Bolts left and right side supports the suspension of the power unit to the crankcase
Step 1	20
Step 2	To hold a 90 ?� angle
Bolts airbags Front Mount power unit
The subframe	35
To support arm	65
The cover casing of the oil filter	25
Bolts of the oil filter housing assembly	70
Fixing liquid heat exchanger oil filter	eleven
Drain plug oil pan (M14)	thirty
Self-tapping screws the lower section of the sump to the top
The thread does not cut	14
The thread is cut	10
Bolts of fastening of the top section of the oil pan to the cylinder block
M6	9
M8	20
Bolts oil level sensor
to the upper section of the oil pan	10
Bolts lubricators	15
Oil pump bolts (M8x30)	20

Diesel models

Listed below are the only values that are typical for all engines considered series.

Common parameters

engine's type
M612	Row (R), 5-cylinder, DOHC, turbocharged, water-cooled, timing chain
M628	V-shaped 8-cylinder, DOHC, turbocharged, water-cooled, timing chain
Lineup use
G270 CDI (463.323)	612,965
G400 CDI (463.333)	628,962
Engine volume, l
M612	2.7
M628	4.0
Number of valves per cylinder	4
Pressure compression bar
Nominal value	29 ÷ 35
The minimum acceptable value (approx)	18
The maximum allowable difference in readings between cylinders	thirty
Operating procedure of cylinders
M612	1-2-4-5-3
M628	1-5-4-8-6-3-7-2
Valve clearance	Not regulated as used hydraulic lifters

Cylinder head

M612

Casting

Dimensions of the cylinder head bolts

Thread M12
Length mm
Also M612.990
New bolt
102
The limit value
104
M612.990
New bolt
107
The limit value
-

Details of the installation of valves in the cylinder head (612 series engines)


and - Planting new valve with a new saddle	H - height of the cylinder head

The total height of the cylinder head, mm
Nominal value	126.85 ÷ 127.15
The limit value	-

Valve seats

Boring valve seats (612 series engines)


b - width of a working facet a - The angle of a working facet	g - correction angle

The geometrical characteristics of the valve seat
All valves
a	45 ?� (-30 ')
b, mm	1.0 ÷ 1.5
g	30 ?� (?� 15 ')
And, mm	0.9 ÷ 1.1
The maximum allowable ovality mm	0.03

Valves

D - diameter dish
h - height of the cylindrical part of the plate (belt)
D1 - diameter of the rod
L - length of the valve

The diameter of the plates (D), mm
The intake valves	30.1 ÷ 30.3
The exhaust valves	28.3 ÷ 28.5
The height of the cylindrical part (corbel) plates (h), mm
All valves	1.7 ÷ 1.9
The angle of inclination of the operating chamfers (a)
All valves	45 ?� (+15 ')
Stem diameter (D1), mm
The intake valves	6.960 ÷ 6.975
The exhaust valves	6.955 ÷ 6.970
Surface reinforcement saddle
All valves	Absent
Sodium filling
All valves	Absent
The length of the valve (L), mm
The intake valves	104.7 ÷ 104.9
The exhaust valves	104.5 ÷ 104.9
Identification marking plates
The intake valves	611 E 01
The exhaust valves	A 611 May 1
The distance from the end of the valve stem to the base of the camshaft bearing (T) mm
All valves	17.1 ÷ 17.9
Planting of the new valve with the new seat (s), mm
The intake valves	1.1 ÷ 1.5
The exhaust valves	1.0 ÷ 1.4

Series 628

Casting

Dimensions of the cylinder head bolts

Thread M12
Length mm
New bolt
201.5
The limit value
203

Cylinder block

Series 612

Flywheel

Limit on cross beats the ring gear, mm	0.4
The diameter of the dowel sleeve ring gear, mm	276.05 (?� 0.05)

Crankcase

The diameter of the main bearing beds, mm	62.500 ÷ 62.519
The width of the bed of the thrust bearing, mm	19.979 ÷ 20.000
Maximum permissible value of roundness / taper beds of radical bearings, mm	0.02

Crankshaft

Dimensions bolt main bearing caps
Thread	M11
The length (L), mm
New bolt	61.8 ÷ 62.2
The limit value	63.8
The amount of movement of the crankshaft main bearing, mm
Radial clearance
Nominal value	0.03 ÷ 0.05
The limit value	0.08
End-play
Nominal value	0.10 ÷ 0.25
The limit value	0.3

Main bearing shells

The thickness of the main bearing shells (upper and lower liners) mm
Standard size (Ø 58.00 mm)
Blue mark (code 52)	2.255 ÷ 2.260
Yellow mark (code 54)	2.260 ÷ 2.265
Red mark (code 56)	2.265 ÷ 2.270
White markings (code 57)	2.270 ÷ 2.275
Purple mark (code 58)	2.275 ÷ 2.280

The connecting rod-piston assembly

The quantity of protrusion of the piston (a) a new sump, mm 0.38 ÷ 0.62
The magnitude of lateral play of the piston rings, mm
Groove 1
0.12 ÷ 0.16
The groove 2
0.05 ÷ 0.09
The recess 3
0.03 ÷ 0.07
The amount of backlash in the lock of piston rings, mm
Groove 1
0.22 ÷ 0.42
The groove 2
0.20 ÷ 0.40
The recess 3
0.20 ÷ 0.40

Bolts bottom heads of rods
The diameter of the threaded portion
8x1
Length (L) (see. Conjugated. Illustration), mm
New bolt
47 ?� 0.3
The limit value
48

1 - Rod
2 - Cover the bottom head
3 - Bush
4 - Guides
5 - Bolt
6 - balancing weights
7 - Marking area
8 - slots under the tab inserts
9 - Maslotok
10 - drilling oil spray

Dimensions rods
The distance between the centers of the connecting rod bearing and the hole for planting the piston pin (L), mm 148.970 ÷ 149.030
The width of the rod heads (B and b), mm 21.940 ÷ 22.000
The inner diameter of lower connecting rod (D1), mm 51.600 ÷ 51.614
Limit values roundness and taper bed shatunnogopodshipnika mm 0.02
Maximum allowable amount of twist in the rod length 100 mm 0.100
Maximum allowable amount of misalignment of the connecting rod head, mm 0.045
The inner diameter of the sleeve upper golovkishatuna (d), mm 30.018 ÷ 30.024
The base diameter of the sleeve of the little end (d1), mm 32.500 ÷ 32.525
The magnitude of backlash in a rod landing porshnevogopaltsa mm 0.018 ÷ 0.024
Maximum permissible difference weights connecting rod assemblies, g 2

Series 628

Crankcase

The diameter of the main bearing beds, mm
The base value	74.500 ÷ 74.519
Code 52 (first stage, blue)	74.500 ÷ 74.506
Code 54 (the second step, yellow)	74.506 ÷ 74.512
Code 52 (the third stage, red)	74.512 ÷ 74.519
The width of the bed of the thrust bearing, mm	25.29 ÷ 25.50
Maximum permissible value of roundness / taper beds of radical bearings, mm	0.02

Crankshaft

Dimensions bolts bottom section of the crankcase (bridge main bearing caps)
Thread M11
The length (L), mm
Short screws
New bolt
113
The limit value
115
Long bolts
New bolt
135
The limit value
137
The amount of movement of the crankshaft main bearing, mm
Radial clearance
Nominal value
0.03 ÷ 0.05
The limit value
0.08
End-play
Nominal value
0.10 ÷ 0.25
The limit value
0.3

Main bearing shells

The thickness of the main bearing shells (upper and lower liners) mm
Standard size (Ø 70.00 mm)
Blue mark (code 52)	2.252 ÷ 2.257
Yellow mark (code 54)	2.257 ÷ 2.262
Red mark (code 56)	2.262 ÷ 2.267
White markings (code 57)	2.267 ÷ 2.272
Purple mark (code 58)	2.272 ÷ 2.277

The connecting rod-piston assembly

Bolts bottom heads of rods
Thread	8x1
Length (L) (see. Conjugated. Illustration), mm
New bolt	47
The limit value	48
The magnitude of lateral play of the piston rings, mm
Groove 1	0.12 ÷ 0.16
The groove 2	0.065 ÷ 0.110
The recess 3	0.03 ÷ 0.07
The amount of backlash in the lock of piston rings, mm
Groove 1	0.40 ÷ 0.55
The groove 2	0.25 ÷ 0.50
The recess 3	0.20 ÷ 0.40

Efforts of a tightening of carving connections, Nanometer

All engines
The cover casing of the oil filter	25
Bolt the fuel filter to the air
M612	14
M628	9
Screw clamp ring securing the fuel filter (M612)	9
Series 612
Tighten the screws on the trim panel of the cylinder head cover	10
Tighten the screws on the trim panel diffusers	10
Bolts support bracket sleeves supercharge air distribution	20
Mounts steering pump pressure line
M14x1.5	-
M16x1.5	45
Hollow screw couplings oil return line to the radiator	thirty
Bolts compressor K / V to cover timing	20
Bolts to the engine AT
M10x40 and M10x90	40
M12	-
Bolts front cylinder head cover	14
The cylinder head bolts to the timing cover (M8)	20
Bolts timing cover to the crankcase
M6	-
M8	20
Sump bolts
To the engine block
M6	9
M8	20
M10	-
To cover the timing (M6)	9
Side bolts	9
Drain plug oil pan (M14)	thirty
Central bolt of vibration damper
Strength class 8.8
Step 1	200
Step 2	To hold a 90 ?� angle
Class 10.9
Step 1	325
Step 2	To hold a 90 ?� angle
Bolts compressor K / V to cover timing	20
Bolts of fastening of covers of bearings of camshafts to the cylinder head	9
Bolt exhaust camshaft sprocket	18
Bolt pump idler sprocket	40
Bolt tensioning gas distribution chain to cover timing	80
Cylinder head bolts
M8	20
M12
Step 1	60
Step 2	To hold a 90 ?� angle
Step 3	To hold a 90 ?� angle
Nut pressure line fuel pump / fuel distribution pipe	20
The node connecting the front of the catalytic converter to the turbocharger	thirty
Bolt oil return line of the turbocharger	9
Bolts support bracket to the turbocharger	thirty
Bolts distribution charge air hoses tract
M5	-
M7	16
Yokes air path	3
Bolt the support bracket to the distribution arm of the charge air tract	20
Bolt the support bracket to the mounting bracket Engine	40
Bolts motor off the inlet port to the sleeve of the air distribution path of boost	9
Nuts of fastening of the exhaust manifold to the cylinder head	thirty
Bolts of fastening the rear end of the engine cover	9
Bolts flywheel / drive disc to the crankshaft
Step 1	45
Step 2	To hold a 90 ?� angle
The cover casing of the oil filter	25
Fixing liquid heat exchanger oil filter	15
Sump bolts
To the engine block
M6	9
M8	20
M10	-
By the transmission housing	40
To cover the timing (M6)	9
Bolts oil level sensor to the sump	14
Bolts of fastening of the oil pump	18
Bolts of fastening of covers of the bottom heads of rods (rod bearing)
Step 1	5
Step 2	25
Step 3	To hold a 90 ?� angle
Bolts main bearing caps of the crankshaft (M11)
Step 1	55
Step 2	To hold a 90 ?� angle
Series 628
Belt tensioner vspomogatelnyhagregatov in the crankcase	thirty
The node connecting the front of the catalytic converter to the turbocharger	15
Bolts torque converter to the drive disk (M8)	42
Union nuts / bolts hollow choke lines tract cooling ATF	35
Mounts steering pump pressure line
M14x1.5	-
M16x1.5	45
Hollow screw couplings oil return line to the radiator	thirty
Bolt refrigeration lines to the compressor K / V	20
Bolts to the engine AT
M10x40 and M10x90	40
M12	-
Bolts front cylinder head cover	14
The pins riveted links the gas distribution chain (approximate value)	28
Bolts of fastening of covers of bearings of camshafts to the cylinder head	9
Bolt exhaust camshaft sprocket	18
Bolt pump idler sprocket	40
Bolt tensioning gas distribution chain to cover timing	80
Cover bolts centrifuge to the crankcase	8
Bolts cylinder head
To cover the timing (M8)	20
To the engine block
Step 1	20
Step 2	60
Step 3	To hold a 90 ?� angle
Step 4	To hold a 90 ?� angle
Step 5	To hold a 90 ?� angle
Bolt oil return line of the turbocharger	9
Bolts support bracket to the turbocharger	thirty
Nuts of fastening of the exhaust manifold to the cylinder head	thirty
Bolts of fastening the rear end of the engine cover	9
Drain plug oil pan (M14)	32
Sump bolts
To the engine block
M6	19
M8	20
M10	-
By the transmission housing	40
To cover the timing (M6)	9
Bolts of fastening of the top section of the oil pan to the engine block (M6)	8
Central bolt of vibration damper
Step 1	275
Step 2	To hold a 90 ?� angle
Bolts 2-fold flywheel / drive disc to the crankshaft
Step 1	45
Step 2	To hold a 90 ?� angle
The cover casing of the oil filter	25
Fixing liquid heat exchanger oil filter	15
Fixing the vent line to the left of the inlet pipeline	eleven
Self-tapping screws the lower section of the sump to the top
The thread does not cut	12
The thread is cut	8
Oil pump bolts (TORX)	8
Fixing screws to assemble the oil pump cover with the oil pipe	10
Nut front support to the bracket	110
Bolts of fastening of covers of the bottom heads of rods (rod bearing)
Step 1	5
Step 2	25
Step 3	To hold a 90 ?� angle
Bolts lower section of the crankcase
M6	8.5
M8	20
M11
Step 1	20
Step 2	50
Step 3	To hold a 90 ?� angle
Step 4	To hold a 90 ?� angle

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