Mercedes-Benz Series 176 Introduction Into Service Manual Download Page 5

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Contents

Introduction of the New A-Class, Model Series 176

Drive

Engine data for gasoline engines

Engine data for diesel engines

Description of engine M 270

Description of engine OM 651

Description of engine OM 607

Exhaust system

Fuel system

Transmission

Manual transmission FSG 310

Automatic transmission 7G-DCT

Suspension

Steering

Axles and suspension

Brake system

Wheels and tires

– This printout will not be recorded by the update service. Status: 06 / 2012 –

Summary of Contents for Series 176

Page 1: ...ction into Service Manual Daimler AG GSP OR HPC R 822 70546 Stuttgart Order No 6516 1393 02 HLI 000 000 08 06 Printed in Germany 06 12 Introduction of the New A Class Model Series 176 This printout wi...

Page 2: ...nz Service Daimler AG Technical Information and Workshop Equipment GSP OR 70546 Stuttgart Introduction of the New A Class Model Series 176 This printout will not be recorded by the update service Stat...

Page 3: ...ent including all its parts is protected by copyright Any further processing or use requires the previous written consent of Daimler AG Department GSP ORS HPC R822 W002 70546 Stuttgart This applies in...

Page 4: ...Overview Models and major assemblies 8 Brief description 9 Equipment 15 Overall vehicle Exterior 24 Dimensions 25 Technical data 27 Panoramic sliding sunroof 29 Interior 30 Maintenance ASSYST PLUS 34...

Page 5: ...of engine M 270 38 Description of engine OM 651 41 Description of engine OM 607 43 Exhaust system 61 Fuel system 63 Transmission Manual transmission FSG 310 64 Automatic transmission 7G DCT 65 Suspen...

Page 6: ...y and alternator 76 Energy management 77 Lights Exterior lights 78 Safety Active safety 80 Passive safety 81 Driving assistance systems Active Parking Assist 83 Comfort Climate control 84 Audio and co...

Page 7: ...8 Force progression during an accident 90 Aftersales Information CO2 Efficiency Classes 91 Special tools Bodywork 92 Engine OM 607 93 Workshop equipment Body repair systems 101 Annex Abbreviations 102...

Page 8: ...WIS is updated continuously Therefore the informa tion available there reflects the latest technical status of our vehicles The Introduction into Service Manual provides initial information on the on...

Page 9: ...CDI BlueEFFICIENCY 176 012 607 951 711 642 09 12 A 200 CDI BlueEFFICIENCY 176 001 651 901 711 642 724 003 09 12 A 220 CDI BlueEFFICIENCY 176 003 651 930 724 003 12 12 A 180 BlueEFFICIENCY 176 042 270...

Page 10: ...m while the vehicle height has been reduced by 160 mm Innovations New engine mounting concept with improved NVH characteristics Noise Vibration and Harshness i e minimization of noise and vibrations N...

Page 11: ...ps Sportier engine sound Interior components Sport seats in front in ARTICO man made leather upholstery DINAMICA microfiber with red stitching Seating comfort package Red 3 point seat belts except cen...

Page 12: ...esign with 225 45 R17 on 7 5 J x 17 ET 52 5 code 44R Interior components Leather steering wheel in 3 spoke design with alpaca gray stitching 12 function keys incl leather gearshift lever with stitchin...

Page 13: ...th silver colored dial type gauges and red pointers Longitudinally adjustable armrest with red contrast stitching on center console Armrests in doors with chrome trim piece and red contrast stitching...

Page 14: ...xclusive package code P34 The exclusive package includes the following components Front sport seats heated in leather upholstery with stitching and 4 way lumbar support Seating comfort package Trim pi...

Page 15: ...nly A 180 and A 180 CDI Interior Exterior EXCLUSIVE PACKAGE Code P34 AMG SPORT Code 950 NIGHT PACKAGE Code P55 STYLE Code P27 SPORT Code P84 Includes AMG SPORT range BASIC VEHICLE AMG EXCLUSIVE PACKAG...

Page 16: ...592 Equipment packages Night package Code P55 Exclusive package Code P342 AMG Exclusive package Code P39 Dynamic handling package Code 483 Stowage package Code 30P Brakes Electric parking brake Standa...

Page 17: ...able steering force assis tance and variable steering ratio Component code 483 Dynamic handling package Standard with code 950 AMG Sport Suspension Comfort suspension Standard Comfort suspension with...

Page 18: ...45 R17 7 5J x 17 ET 52 5 Code R11 43 2 cm 17 light alloy wheel 225 45 R17 7 5J x 17 ET 52 5 Code 44R 45 7 cm 18 light alloy wheel 225 40 R18 7 5J x 18 ET 52 Code R10 45 7 cm 18 light alloy wheel 225...

Page 19: ...R16 6 5J x 16 ET 49 Code 3R7 Code 3R7 Winter wheel and tire assy M S 4 wheels 43 2 cm 17 light alloy wheel 205 50 R17 6 5J x 17 ET 49 Code 2R9 Winter tires M S 4 wheels instead of summer tires Code 64...

Page 20: ...t skirt Compo nent code 4U3 Light and vision package Code U62 Round front fog lamp Code U37 Safety and theft protection Left and right rear sidebag Code 293 PRE SAFE system Code 299 Theft protection p...

Page 21: ...de 22P DISTRONIC PLUS Code 239 CRUISE CONTROL with SPEEDTRONIC Standard in combination with code 429 Automatic transmission Code 440 Standard Comfort systems Multifunction steering wheel as 3 spoke st...

Page 22: ...d front passenger Code U22 Seat heater for driver and front passenger Code 873 Folding center armrest in rear incl through loading feature and cup holder Code 400 Stowage compartment under loading flo...

Page 23: ...audio and communications Audio 5 USB Standard Audio 20 CD Standard in combination with code P84 Sport 523 Audio 20 CD with integrated 6 disk CD changer Code 510 Cradle for iPhone Code B22 COMAND Onlin...

Page 24: ...7 surround sound system Code 810 Preinstallation for Becker MAP PILOT Code 508 Becker MAP PILOT Code 509 i Note Some of the individual equipment codes can only be selected and combined with each other...

Page 25: ...b Vehicle views The new A Class for model series 176 presents itself as a sporty 5 door car with well balanced proportions and innovative design P00 00 4822 00 Front and rear view P00 00 4823 00 Side...

Page 26: ...25 Introduction of the New A Class Model Series 176 b P00 10 5189 00 Vehicle dimensions shown here on A180 BlueEFFICIENCY W 176 Dimensions under no load This printout will not be recorded by the upda...

Page 27: ...lass Model Series 176 b P00 10 5190 00 Vehicle dimensions shown here on A180 BlueEFFICIENCY W 176 Dimensions under no load 1 At permissible gross vehicle weight 2 With trailer hitch SA This printout w...

Page 28: ...y to drive mm 1551 1552 1 Front overhang ECE mm 675 906 231 Rear overhang ECE mm 640 687 47 Height of trunk sill over road surface mm 523 561 38 Luggage compartment floor length mm 723 707 16 Turning...

Page 29: ...f rear backrest Capacity 341 liters V 214 2 Open luggage compartment behind rear seat Loading up to roof Capacity 400 liters V 211 1 Open luggage compartment behind rear seat Rear backrest folded down...

Page 30: ...s the switch is operated If the switch is operated beyond the first notch the automatic mode is activated and the panoramic sliding sunroof and roller sun blind are each moved to their respective end...

Page 31: ...the new A Class includes the electric parking brake which in turn means that the hand brake lever between the front seats is no longer installed The space gained by this measure enabled the stowage co...

Page 32: ...Anti lock braking system indicator lamp A1e18 Rear fog light indicator lamp A1e32 ESP ASR OFF warning lamp A1e38 Standing light indicator lamp A1e41 Electronic Stability Program warning lamp A1e51 Bra...

Page 33: ...er shadow finish frame and in combi nation with the light package special equipment it can be illuminated with ambient lighting The rear seats can accommodate three passengers although its sporty char...

Page 34: ...owage compartment is replaced by two adjustable air vents The second stowage compartment is available on request with a smoker element The special equipment includes Stowage compartment for eyeglasses...

Page 35: ...o a new interval of every 200 000 km 10 years for the gasoline engine M 270 OM 607 OM 651 For diesel engines OM 651 and OM 607 the service interval for the additional maintenance operations Replace co...

Page 36: ...pair costs The maintenance contract places cost transpar ency and projectability to the fore All the mainte nance costs for the agreed upon period are hereby covered The services include all maintenan...

Page 37: ...st pressure bar 0 6 1 0 1 2 Rated output at engine speed kW rpm 90 5000 115 5300 155 5500 Rated torque at engine speed Nm rpm 200 1250 4000 250 1250 4000 350 1250 4000 Performance Consumption Emission...

Page 38: ...1 Max boost pressure bar 0 7 1 65 1 8 Rated output at engine speed kW rpm 80 4000 80 3200 4600 100 3600 4400 125 3600 4000 Rated torque at engine speed Nm rpm 260 1750 2500 250 1400 2800 300 1600 300...

Page 39: ...stons connecting rod oil baffle and turbocharger have all been adapted to the larger displacement Vibration damper on front crankshaft instead of belt pulley Lanchester dynamic balancer bolted to cran...

Page 40: ...a pulse width modulated signal PWM signal of 1 kHz In the starting position both tappets are retracted The engine starts when the intake valves switch to large lift The initial switch to small lift e...

Page 41: ...d output at engine speed kW rpm 90 5000 115 5300 155 5500 Rated torque at engine speed Nm rpm 200 1250 4000 250 1250 4000 350 1250 4000 Compression ratio 10 3 1 9 8 1 P01 00 3361 00 Performance graph...

Page 42: ...egulates all sensors and actuator in the multiway exhaust gas recirculation system The engine exhaust gas recirculation actuator is actuated on the basis of a filed characteristics map with a pulse wi...

Page 43: ...ted output at engine speed kW rpm 80 3200 4600 100 3600 4400 125 3600 4000 Rated torque at engine speed Nm rpm 250 1400 2800 300 1600 3000 350 1600 3200 Compression ratio 16 2 1 P01 00 3362 00 Perform...

Page 44: ...nsumption Low level of CO2 emissions Low weight Comfortable Noise Vibration and Harshness characteristics NVH Special two mass flywheel Belt drive for alternator and A C compressor drive Toothed belt...

Page 45: ...a Unit OM 607 951 A 180 CDI Rated output at engine speed kW rpm 80 4000 Rated torque at engine speed Nm rpm 260 1750 2500 Compression ratio 15 4 1 P01 00 3363 00 Performance graph OM 607 951 80 kW M T...

Page 46: ...all sensor B50 Fuel temperature sensor B60 Exhaust pressure sensor G3 2 Oxygen sensor upstream of CAT M16 6 Throttle valve actuator N3 9 CDI control unit N14 3 Glow output stage R22 1 DPF heater boost...

Page 47: ...View of engine from front B40 6 Engine oil fill level sensor N3 9 CDI control unit N14 3 Glow output stage R22 1 DPF heater booster regeneration S43 1 Oil pressure switch Y77 1 Boost pressure positio...

Page 48: ...olant temperature sensor B19 9 Temperature sensor upstream of diesel particulate filter B28 8 DPF differential pressure sensor B157 2 EGR temperature sensor low pressure G3 2 Oxygen sensor upstream of...

Page 49: ...of a chain drive The camshaft coolant pump and the high pressure pump are all driven by a toothed belt i Note Repair instructions for changing the toothed belt are available in the Workshop Informati...

Page 50: ...n the charge air pipe The compressed and thereby heated air flows over the charge air pipe to the charge air cooler This cools down the charge air and routes it over the charge air pipe to the cylinde...

Page 51: ...ssed air and there fore the boost pressure To act as protection against any thermal and mechanical overloading of the turbocharger the exhaust temperature is monitored by the CDI control unit using th...

Page 52: ...p i Note On engine 607 the fuel injectors are all coded with the IIC code from Continental which is located on the head of the injection nozzle This coding spec ifies the quantity characterization for...

Page 53: ...diesel particulate filter boosts the post injection volume far enough to increase the exhaust temperature and to ultimately trigger the diesel particulate filter s regeneration process The soot partic...

Page 54: ...he fuel preheating control unit is located under the battery box The fuel preheating control unit actuates the heating element for the fuel filter heater as and when required and it indicates the cond...

Page 55: ...nit reads in signals from the following components B2 5 Hot film MAF sensor Intake air temperature sensor Charge air pressure and temperature sensor Temperature sensor upstream of turbocharger Acceler...

Page 56: ...harge air cooler 2 Low pressure exhaust gas recirculation cooler B157 2 EGR temperature sensor low pressure M16 6 Throttle valve actuator Y27 7 Low pressure exhaust gas recirculation actuator Y27 8 Hi...

Page 57: ...uit exhaust gas recircu lation The exhaust gas recirculation actuator increases or reduces the volume of recirculated exhaust gas to match the degree of actuation by the CDI control unit The exhaust g...

Page 58: ...circuit schematic 1 Engine radiator 2 Exhaust gas recirculation cooler 3 Engine oil Coolant heat exchanger 4 Coolant expansion reservoir 5 Thermostat 6 Heater heat exchanger 7 Coolant pump 8 Restrict...

Page 59: ...bles a lower amount of energy to be used for the oil supply and it also reduces consumption CO2 levels The oil pan is made of an aluminum alloy to save weight P18 20 2111 00 Oil circuit diagram 1 Oil...

Page 60: ...oltage applied to the connections is measured at the start of current flow U1 and after a time period of t_1 U2 To ensure that the current flow is constant the measuring points have to be adapted acco...

Page 61: ...rmonization interface Exhaust gas recirculation Exhaust treatment The drivetrain control unit is located at the front left behind the instrument panel The drivetrain control unit on the OM 607 engine...

Page 62: ...ch has a shell design through a tailpipe which is located in a concealed position behind the bumper Depending on the equipment package involved a twin pipe exhaust system with two visible exhaust tips...

Page 63: ...ffler The rear end piece is formed by an invisible single pipe tailpipe basic model or two visible tailpipes with oval tip depending on equipment package P49 00 2146 00 Exhaust system for diesel engin...

Page 64: ...t hydrocarbon vapors The filling capacity of the fuel tank is 50 liters This includes a reserve of roughly 6 liters The fuel filler flap is located at the left rear No expansion reser voir is required...

Page 65: ...rods with babbit bearings The manual transmission main shifter shaft position sensor magnetic induction and a permanent magnet mounted on the main shifter shaft detect the transmission s neutral posit...

Page 66: ...DCT is characterized by rapid gear changes without interruption of tractive power and improved efficiency It provides sporty vehicle dynamics while also offering the convenience of an automatic transm...

Page 67: ...omatic parking in pulling out of a parking space Direct Steer system For vehicles with code 213 Direct Steer system a rack and pinion steering gear with variable gear ratio is used The toothed rack co...

Page 68: ...with separately arranged springs on the rear axle The sports suspension which is available in combi nation with the dynamic handling package and the AMG Sport Line is equipped with harder front and r...

Page 69: ...piston floating caliper Brake disk Internally vented Brake disk diameter mm 2951 280 295 320 Brake disk thickness mm 281 25 28 30 Pad area cm2 522 60 60 60 Brake system rear Type of brake 1 piston fl...

Page 70: ...ance System fault display Extended Traction Control XTC The ESP is equipped in all engines with the newly developed XTC Extended Traction Control which provides improved traction when accelerating out...

Page 71: ...T 52 5 225 45 R17 Code R11 7 5J x 17 ET 52 5 225 45 R17 7 5J x 17 ET 52 5 225 45 R17 Code 44R Tremolite gray 7 5J x 17 ET 52 5 225 45 R17 7 5J x 17 ET 52 5 225 45 R17 Code R10 Black 7 5J x 18 ET 52 22...

Page 72: ...ight alloy wheel code R48 P40 10 6346 00 Light alloy wheel code R11 P40 10 6347 00 Light alloy wheel code 44R P40 10 6348 00 Light alloy wheel code R10 P40 10 6349 00 Light alloy wheel code R38 P40 10...

Page 73: ...eries 176 b P00 19 5222 00 Interior CAN Chassis CAN Drivetrain CAN Drivetrain CAN Drivetrain sensor CAN Front end CAN Diagnostic CAN LIN bus MOST Telematics CAN Overall network in model series 176 Thi...

Page 74: ...DI control unit OM607 18 Drivetrain control unit OM607 Front end CAN 13 Electronic ignition lock 29 Multifunction camera 30 Left rear radar sensor 31 Right rear radar sensor 32 Headlamp control unit 3...

Page 75: ...Audio COMAND operating unit 41 Navigation module 42 Navigation module cradle LIN bus 2 Left front door control unit 3 Right front door control unit 6 SAM control unit CBC 9 Interior protection tow awa...

Page 76: ...Transfer rate 500 kBit s Gateway function Control units with a gateway function can receive signals from more than one data bus and also relay signals via these particular data bus systems as they ar...

Page 77: ...d alternator Engine On board electrical system battery Alternator M 270 70 Ah 150 A OM 607 80 Ah 175 A OM 651 80 Ah 175 A P54 10 3768 00 Main components of on board electrical system A1 Instrument clu...

Page 78: ...transport mode is deactivated per diagnosis or by a combination of keys For deactivation per Xentry diagnostics the ignition key must be in the radio position and the diagnosis service RT_PNM_TraMode_...

Page 79: ...ght System The light functions are displayed for standing light parking lights and turn signal lights by LEDs The daytime running lamp on bi xenon headlamps or the ILS is integrated into the headlamp...

Page 80: ...he center high mounted stop lamp is located at the top in center of the spoiler on the liftgate and is designed with LED technology P82 10 7009 00 P82 10 7010 00 Left taillamp on vehicle equipped with...

Page 81: ...Blind Spot Assist and Lane Keeping Assist Traffic sign recognition only in combination with COMAND Online multi media system SA COLLISION PREVENTION ASSIST DISTRONIC PLUS SA Cruise control TPM with S...

Page 82: ...ses Improved structural geometry In addition the following safety systems are avail able Driver front passenger airbag dual stage adaptive Driver front passenger sidebags at front with new thorax pelv...

Page 83: ...eupon the injury risk during the impact is minimized The active engine hood is triggered in the event of a collision at a speed between 25 and 55 km h Pedestrian protection sensors are installed in th...

Page 84: ...miautomatic assistance in a curbside parking space beforehand This ensures that the vehicle is standing parallel to the edge of the road e g curb This precondition is required because the first thing...

Page 85: ...ew point temperature If there is a risk of fogging corresponding measures are authorized such as e g switching on the A C compressor or forcing the engine to start for the ECO start stop function A C...

Page 86: ...e Becker MAP PILOT navigation module extends the Audio 20 radio into a fully functional navigation unit and is available as special equip ment Bluetooth audio This new function in the A Class enables...

Page 87: ...external media devices Audio 5 USB with the option to connect an iPhone SA For the Audio 5 USB a preinstallation is available for the iPhone as special equipment The audio source is muted during a tel...

Page 88: ...ode 512 COMAND APS Online with integrated 6 disk DVD changer Code 527 COMAND APS Online with navigation P82 62 3863 00 harman kardon LOGIC 7 sound system A2 Radio A40 3 COMAND controller unit H4 3 Lef...

Page 89: ...Bodyshell 88 Bodywork Introduction of the New A Class Model Series 176 b P60 00 2946 00 Bodyshell for A Class model 176 This printout will not be recorded by the update service Status 06 2012...

Page 90: ...ckage of NVH measures Noise Vibration and Harshness intended to improve acoustic and vibra tion related characteristics The flanges at the connecting points of the panels have been designed so as to c...

Page 91: ...0 Bodywork Introduction of the New A Class Model Series 176 b P60 00 2947 00 Force progression in a frontal impact P60 00 2948 00 Energy distribution in a side impact This printout will not be recorde...

Page 92: ...he absolute CO2 emis sion levels also chooses the vehicle mass as a rela tive reference value The vehicle mass is taken into consideration with a specific reference value To determine the efficiency c...

Page 93: ...ombination with W246 589 01 23 00 Engine M 270 Automatic transmission 7G DCT i Note Information about the special tools for the M 270 4 cylinder engine can be found in the Introduc tion of the New M 2...

Page 94: ...enger Car Basic Opera tions Mandatory No Exemptions Note Only in combination with load controller see GOTIS Chapter H Design Group 00 12 Topic 04 0 and the cantilever or overhead crane Drift P58 20 23...

Page 95: ...00 FG 01 Set B Category Mercedes Benz Passenger Car Basic Opera tions Mandatory Approved for Cooperation Note In combination with Engine hoist W246 589 00 62 00 Adapter cable 160 pin P58 20 2395 00 Us...

Page 96: ...3 589 00 21 00 MB number W607 589 01 91 00 FG 18 Set B Category Mercedes Benz Passenger Car Basic Opera tions Mandatory No Exemptions Note In combination with test equipment W103 589 00 21 00 consisti...

Page 97: ...ndatory No Exemptions Note Only in combination with Compression recorder W001 589 76 21 00 or W001 589 78 21 00 or Commercially available cylinder leakage test equipment and adapter W611 589 02 63 00...

Page 98: ...ic Opera tions Mandatory No Exemptions Note In combination with Test equipment W103 589 00 21 00 Insertion tool P58 20 2401 00 Use For mounting front radial shaft sealing ring into timing case MB numb...

Page 99: ...G 03 Set B Category Mercedes Benz Passenger Car Basic Opera tions Mandatory No Exemptions Note In combination with Insertion tool W607 589 03 43 00 Puller P58 20 2403 00 Use For removal of radial shaf...

Page 100: ...ring on flywheel side MB number W607 589 04 43 00 FG 03 Set B Category Mercedes Benz Passenger Car Special Opera tions Drift P58 20 2405 00 Use For locking camshaft MB number W607 589 01 15 00 FG 01...

Page 101: ...5 43 00 FG 03 Set B Category Mercedes Benz Passenger Car Special Opera tions Connecting adapter P58 20 2407 00 Use For leakage test of air intake diagnosis of air flow MB number W607 589 03 91 00 FG 0...

Page 102: ...utside Germany CELETTE FRANCE S A S 3 Avenue Marcelin Berthelot F 38200 Vienne France CAR BENCH International S p A Via Dorsale 22 I 54100 Massa Italy Car O Liner Box 7 S 73621 Kungs r Sweden Note Onl...

Page 103: ...diesel injection COMAND Cockpit Management And Data System CVT Continuously Variable Transmission DAB Digital Audio Broadcasting DCT Double Clutch Transmission DEH Direct injection homogeneous mode D...

Page 104: ...ME Motor Electronics ME SFI MP3 MPEG Audio Layer 3 MOST Media Oriented System Transport NVH NVH optimization Noise Vibration and Harshness ROZ Research octane number RON SA Special equipment SAM Sign...

Page 105: ...nt packages 12 Exhaust gas recirculation 54 F Fuel preheating 53 Fuses 75 H Halogen headlamps 78 Heater booster diesel particulate filter 53 Heater booster DPF regeneration control unit 52 I Injection...

Page 106: ...ction into Service Manual Daimler AG GSP OR HPC R 822 70546 Stuttgart Order No 6516 1393 02 HLI 000 000 08 06 Printed in Germany 06 12 Introduction of the New A Class Model Series 176 This printout wi...

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