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Daimler AG · Technical Information and Workshop Equipment (GSP/OR) · D-70546 Stuttgart Introduction of the New A-Class AMG with Engine M 133 Model Series 176 AMG Introduction into Service Manual – This printout will not be recorded by the update service. Status: 02 / 2013 –  Mercedes-Benz Service Introduction of the New A-Class AMG with Engine M 133 Model Series 176 AMG Daimler AG · Technical Information and Workshop Equipment (GSP/OR) · D-70546 Stuttgart Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 1 – This printout will not be recorded by the update service. Status: 02 / 2013 – Information and copyright Product Portfolio You can also find comprehensive information on our complete product portfolio in our Internet portal: Link: http://aftersales.mercedes-benz.com Questions and suggestions If you have any questions or suggestions concerning this product, please write to us. Email: customer.support@daimler.com Phone: +49 (0) 69-95 30 73 76 © 2013 by Daimler AG This document, including all its parts, is protected by copyright. Any further processing or use requires the previous written consent of Daimler AG, Department GSP/OR, D-70546 Stuttgart. This applies in particular to reproduction, distribution, alteration, translation, microfilming and storage and/or processing in electronic systems, including databases and online services. Image no. of title image: P00.01-4344-00 Image no. Poster: P00.01-4359-00 Order no. of this publication: HLI 000 000 11 86 2 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Contents Preface4 Overview5 Brief description 5 Models and major assemblies 6 Equipment7 Overall vehicle 13 Exterior13 Technical data 14 Interior16 Maintenance19 Maintenance intervals 19 Powerplant20 Brief description 20 Engine data 21 Engine views 23 Crank assembly 27 Aluminum crankcase 28 Oil pan 31 Cylinder head 32 Chain drive and camshaft adjustment 33 Engine lubrication 35 Injection system 37 Forced induction 41 Vacuum system 47 Charge air cooling 48 Air supply 49 Belt drive 50 Engine cooling 51 Fuel system 55 Exhaust system 57 Engine management 61 Transmission66 Transmission data 66 4MATIC68 Chassis74 Steering74 Axles and suspension 75 Brake system 76 Wheels and tires 77 Annex78 Abbreviations78 Keywords79 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 3 – This printout will not be recorded by the update service. Status: 02 / 2013 – Preface Dear Reader, This Introduction into Service manual presents WIS is updated continuously. Therefore, the information the A 45 AMG 4MATIC in model series 176. available there reflects the latest technical status of our ve- hicles and major assemblies. The purpose of this brochure is to acquaint you with the tech- nical highlights of this new vehicle in advance of its market This Introduction into Service manual presents initial infor- launch. This brochure is intended to provide information for mation relating to the A 45 AMG 4MATIC in model series people employed in service or maintenance and repair as 176 and, as such, is not stored in WIS. The contents of well as for aftersales staff. It is assumed here that the reader this brochure are not updated. No provision is made for is already familiar with the Mercedes-Benz/AMG engines supplements. currently on the market. We will publicize modifications and new features in the re- This Introduction into Service manual is not intended as an levant WIS documents. The information presented in this aid for repairs or for the diagnosis of technical problems. For Introduction into Service manual may therefore differ from such needs, more extensive information is available in the the more up-to-date information found in WIS. Workshop Information System (WIS) and Xentry Diagnostics. All information relating to technical data is valid as of the copy deadline in February 2013 and may therefore differ from the current production configuration. Daimler AG Technical Information and Workshop Equipment (GSP/OR) bbNote Information about the vehicles and about operating the vehicle functions can also be found in the interac- tive owner's manual on the internet at: www.mercedes-benz.de/betriebsanleitung 4 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Brief description Overview Vehicle concept/highlights The powerful top-of-the-range new A-Class from Mercedes- The high-tech package tailored by Mercedes-AMG is a prere- Benz ushers in a new era for the performance brand AMG. quisite for emotional power delivery. As already used in the For the first time in the 45 years of its corporate history, M 157, AMG again employs the advantages of spray-guided AMG will offer a fascinating high-performance vehicle in the gasoline direct injection with piezo injectors in the M133. compact class. The greater thermodynamic efficiency of this technology provides better fuel economy and leads to lower exhaust The new A 45 AMG 4MATIC stand together with other, future emissions. Optimum power transmission is ensured by the high-performance compact cars for exclusive dynamism and AMG SPEEDSHIFT DCT 7-speed sport transmission with dual the “AMG Performance 50” growth strategy. clutch technology and the performance-oriented all-wheel drive. The best preconditions for high cornering speeds and Mercedes-AMG GmbH introduces the first 4-cylinder gasoline remarkably nimble handling are provided by the AMG sports engine of its own to feature direct injection and turbochar- suspension with independently developed front and rear ging. The engine sets new standards in its displacement axles, electromechanical AMG Sport speed-sensitive power class and will be launched on the modular front-wheel-drive steering, the AMG high-performance brake system and the architecture platform (MFA) with the W 176. 3-stage ESP® with Sport Handling Mode. In terms of power and consumption, the M 133 raises the bar Other highlights are the sand-cast all-aluminum crankcase and assumes pole position among its competition. From its with NANOSLIDE barrel technology, air/water intercooling, 2.0 l displacement, the M 133 develops a maximum output of alternator management and the ECO start/stop function. 265 kW and a maximum torque of 450 Nm. bbNote Further information on the electrical systems in model series 176 (e.g. function descriptions and locations of electrical components) is available in the Workshop Information System (WIS) under Basic Knowledge/ Functions (GF). Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 5 – This printout will not be recorded by the update service. Status: 02 / 2013 – Models and major assemblies Overview Model series Model Engine FDCT Market launch A 45 AMG 4MATIC 176.052 133.980 724.015 06/13 P00.00-4959-00 Mercedes-Benz A 45 AMG 4MATIC (model series 176) 6 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Equipment Overview Edition 1 special equipment model (code P19): Interieur components: The ultra exclusive equipment features of the Edition 1 un- • Edition 1 badge on the AMG DRIVE UNIT derscore the fascinating esthetics and the individuality of • Sport multifunction steering wheel flattened at the bot- the A 45 AMG 4MATIC in impressive fashion. The Edition 1 tom, in nappa leather with 3-spoke design and perforated will be produced for 6 months from the market launch until grips December 2013 and will consist of specially matched equip- • Nappa leather gearshift lever ment packages for the exterior and interior. • DINAMICA microfiber door center panels • Black inner headliner Exterieur components: • Sports pedal assembly made of brushed stainless steel • Red accents (foil) for the AMG radiator grille, outside mir- with rubber nap rors and rear wing • Aluminum front and rear door sills • AMG light alloy wheels, 48.3 cm (19") in multi-spoke de- • Multifunction holder in center console sign (code 694), matt black finish with 235/35 R 19 on • Cover above stowage compartment in center console 8J x 19 ET 48 • 12 V socket at the rear • AMG wheel hub covers with center lock effect in red- • Infrared receiver in the driver door (summer opening/ black with chrome star closing) • Paintwork cirrus white (code 650) or cosmos black (code • Comfort locking system (infrared) with convenience 191) closing via key for side windows and panoramic sliding • AMG Aerodynamics Package consisting of AMG rear wing sunroof (code U47), additional flics (4 each) and larger front split- • Instrument panel upper section in ARTICO imitation lea- ter in the front skirt ther with red contrasting stitching • AMG sport stripes at the sides, on the engine hood and roof in matt graphite gray (foil) Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 7 – This printout will not be recorded by the update service. Status: 02 / 2013 – Models and major assemblies Overview Other components of Edition 1: Equipment packages • AMG Aerodynamics Package (code B26) The equipment packages listed below to the A 45 • AMG Night Package (code P60) AMG 4MATIC enable the customer to design the interior and • Brake calipers finished in red (code U70) exterior of the vehicle to meet individual requirements. • ARTICO imitation leather and DINAMICA microfiber upholstery in black with contrasting red stitching (code AMG Exclusive Package (code P39) 651A) The AMG Exclusive Package includes the following • AMG Performance seats (code 555) components: • AMG Performance steering wheel in nappa leather/ • Heated leather seats in black with red stitching and 4-way DINAMICA microfiber and selector lever with embossed lumbar support AMG emblem and electronic master key with AMG emb- • Seating Comfort Package lem (code 281) • 3-spoke leather steering wheel with 12 function keys incl. • AMG floor mats (code U26) leather gearshift lever and red stitching • PRE-SAFE® system (code 299) • Carbon fiber effect trim pieces • Seat heaters for driver and front passenger (code 873) • Distinctively sporty instrument cluster • Automatic child seat recognition ACSR (code U18) • Upper part of instrument panel with red stitching, head- lamp switch with silver chrome ring and nozzle ring and cross piece of air outlets in silver chrome • Longitudinally adjustable armrest with red stitching on center console • Trim piece in silver chrome and red stitching on door armrests • Door center panel with red stitching • Black inner headliner • Sports pedal assembly made of brushed stainless steel with rubber nap • Floor mats in black with AMG lettering • Aluminum front and rear door sills • Multifunction holder in center console • Cover above stowage compartment in center console • 12 V socket at the rear 8 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Models and major assemblies Overview Night Package (code P60) AMG Exterior Carbon Package (code 773) The AMG Night Package includes selected items of equip- The AMG Exterior Carbon Package enhances the vehicle with ment, such as the front splitter and outside mirror housings high-quality carbon fiber details such as the trim piece in the in high gloss black, as well as black chrome-plated tailpipe rear apron or the front splitter. finishers for an unmistakable and expressively sporty vehicle character. The AMG Exterior Carbon Package includes the following components: The Night Package includes the following components: • Front splitter • Elements in high gloss black: • Rear apron trim piece • Front splitter • Inserts in rocker panel trim • Rear apron trim pieces • Double slats in AMG radiator grille in silver shadow • Inserts in rocker panel trim • Outside mirror housings AMG Driver's Package (code 250) • Privacy windows The AMG Driver's Package increases the top speed of the • Tailpipe finishers in black chrome vehicle to 270 km/h. In addition, the driver may take part • Black anodized waistline trim strip in a one-day training course at the AMG Driving Academy in • Double slats in AMG radiator grille in silver shadow which he will learn safe and sporty driving under professional instructors and experience an unforgettable event in like- AMG Aerodynamics Package (code B26) minded company. A functionally tuned, larger front splitter, an AMG rear wing and more flics on the front skirt provide an additional incre- ase in the downforce of the sports car on the road. This also improves handling characteristics at high speeds, particularly lateral acceleration, driving stability and braking distance. The AMG Aerodynamics Package includes the following components: • Larger front splitter in high gloss black • Additional flics in high gloss black • AMG rear wing in high gloss black Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 9 – This printout will not be recorded by the update service. Status: 02 / 2013 – Models and major assemblies Overview A 45 AMG 4MATIC Special equipment model Edition 1 Code P19 Equipment packages AMG Exclusive Package Code P39 Night Package Code P60 AMG Aerodynamics Package Code B261 AMG Exterior Carbon Package Code 773 AMG Driver's Package Code 250 Brakes AMG high-performance brake system with internally ventilated and Standard perforated brake disks Powerplant AMG SPEEDSHIFT DCT 7-speed sport transmission with dual clutch technology Standard Steering AMG Sport steering with speed-sensitive Standard steering assistance Suspension AMG Performance suspension Code 492 AMG sports suspension Standard AMG axles with independent steering knuckles at the front and AMG- Standard specific elastokinematics 10 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Models and major assemblies Overview A 45 AMG 4MATIC Technical equipment packages AMG Sport exhaust system Standard AMG Performance exhaust system Code U21 AMG cooling with additional wheel arch cooler Standard AMG DRIVE UNIT Standard Exterior equipment packages 4MATIC lettering on left of luggage compartment door Code 259 AMG lettering on luggage compartment door Standard TURBO AMG lettering on front fenders Standard AMG Carbon outside mirrors Code B28 AMG front skirt with front splitter in matt titanium gray and Standard black flics AMG rear wing Code U47 AMG rear apron with diffuser look and trim piece in matt titanium gray Standard AMG radiator grille with double slats in designo magno matt titanium gray Standard AMG rocker panel trim with inserts in matt titanium gray Standard Brake calipers finished in red with AMG lettering in black Code U70 Wheel bolt cover for 45.7 cm (18") AMG light alloy wheels in “5 double-spoke Code B58 design” (code 649) in black including AMG wheel hub cover with center lock ef- fect in silver chrome Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 11 – This printout will not be recorded by the update service. Status: 02 / 2013 – Models and major assemblies Overview A 45 AMG 4MATIC Interior equipment packages AMG door sills of brushed stainless steel with AMG lettering Standard AMG floor mats Code U26 AMG instrument cluster Standard AMG Performance steering wheel in black nappa leather/Alcantara® Code 281 AMG Performance seats Code 555 Wheels, tires, light alloy wheels 45.7 cm (18") AMG light alloy wheel Standard “5 double-spoke design” - titanium gray finish and burnished Code 649 235/40 R18; 8J x 18 ET 48 48.3 cm (19") AMG light alloy wheel Code 6942 “Multi-spoke design“ - matt black finish 235/35 R19; 8J x 19 ET 48 48.3 cm (19") AMG light alloy wheel Code 780 “Multi-spoke design” - titanium gray finish and burnished 235/35 R19; 8J x 19 ET 48 48.3 cm (19") AMG light alloy wheel Code 787 “Multi-spoke design” - matt black finish and rim flange burnished 235/35 R19; 8J x 19 ET 48 Tire pressure loss warner (ECE only) Standard TIREFIT with tire inflation compressor Standard 1 Only in combination with AMG Night Package 2 Standard on the optional Edition 1 12 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Exterior Overall vehicle Vehicle views The emotional exterior design with new dynamic style, the The AMG rear apron with its implied air outlets at the side sculptured shaping and the character lines at the sides are features a diffuser element and a trim piece in matt titanium complemented by resolutely sporty and muscular accents of gray. The two angular, chrome-plated tailpipes of the AMG Mercedes-AMG. The front view of the A 45 AMG 4MATIC is Sport exhaust system with exhaust flap produce a dominant dominated by the AMG radiator grille and the front splitter, look. The optionally available AMG Performance exhaust both in matt titanium gray. Striking black flics flank the large system and the AMG rear wing with its specific design further cooling air intakes at the sides. Visual tension in the side underscore the car's sporty character. view is provided not only by the AMG light alloy wheels in double-spoke design and the optional multi-spoke light alloy wheels, but also by the rocker panel trim with matt titanium gray inserts. P00.00-4956-00 Front and rear view P00.00-4958-00 Side view Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 13 – This printout will not be recorded by the update service. Status: 02 / 2013 – Technical data Overall vehicle Dimensions Unit A 45 AMG 4MATIC Vehicle length (ECE) mm 4359 Vehicle width mm 1780 Vehicle width (with outside mirrors folded out) mm 2022 Vehicle height (curb condition) mm 1417 Wheelbase mm 2699 Front track width mm 1557 Rear track width mm 1561 Front overhang (ECE) mm 940 Rear overhang (ECE) mm 720 14 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Technical data Overall vehicle Dimensions and weights Unit A 45 AMG 4MATIC Curb weight as per EC kg 1555 Permissible gross vehicle weight kg 2050 Payload capacity as per EC kg 495 Trunk capacity l 341 Luggage compartment floor length mm 707 Turning circle m 11.04 Fuel tank/reserve l 56/8 Drag coefficient cw 0.34 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 15 – This printout will not be recorded by the update service. Status: 02 / 2013 – Interior Overall vehicle Interior design and color concept The interior of the AMG captivates with its typical Mercedes- AMG character features of dynamism and exclusivity. The multifunction sport steering wheel with shift paddles, the sport seats in ARTICO imitation leather and DINAMICA micro- fiber with contrasting red stitching and the AMG DRIVE UNIT set new standards in terms of both appearance and quality. The trim piece on the instrument panel has a carbon fiber fi- nish – perfectly complemented by the five air vents in black/ red or silver chrome depending on equipment), the red seat belts and the AMG door sills. P68.00-7188-00 Interior design 16 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Interior Overall vehicle Instrument cluster The AMG instrument cluster lends the interior a sporty look. It consists of two large dials each containing another smaller dial gauge. When idle, the needles are at 6 o'clock. The dials in the instrument cluster are finished in a carbon fiber effect. The AMG instrument cluster provides information by means of the central color display with the AMG main menu with RACETIMER. P54.33-2957-00 Instrument cluster, ECE version Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 17 – This printout will not be recorded by the update service. Status: 02 / 2013 – Interior Overall vehicle Seats The AMG Performance seats with the special design of the The seats are available in the following color variants: side bolsters on the seat cushions and backrest provide out- • Black standing lateral support and give the interior a unique sporty • Nut brown appearance and character. • Crystal gray In conjunction with the AMG Exclusive Package (code P39), the AMG Performance seats can be optionally combined with the AMG Performance steering wheel in RED CUT black lea- ther (code P34) and an optically enhanced silver chrome eat belt slot. When combined with the Stowage Package (code P30), the stowage boxes under the front seats are omitted as well as the nets on the driver and front passenger seat backs. P91.00-2324-00 AMG Performance seats 18 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Maintenance intervals Maintenance New technical features Predictable costs and reliable planning: Mercedes-Benz The AMG derivative of the A-Class is based on the pro- Passenger Car Service Contracts ven technology of the A-Class and is fully integrated into Which service contract suits me best? The vehicle-specific the ASSYST PLUS maintenance system of the Extended service contracts enable the car customer to choose indivi- Maintenance Strategy. dual protection while also allowing him to select the best of the different product variants available to him. New engine The AMG four-cylinder turbocharged engine M 133 is being The purchasable warranty extention as an entry-level pro- introduced in the A-Class. The extra maintenance operation duct is geared towards safety-oriented, price-conscious cus- “Replace air filter element” is performed at each service. All tomers. These customers are protected against unexpected the other unspecified service intervals of the AMG derivative repair costs in the long-term even after the manufacturer are the same as for the current A-Class. warranty expires. Introduction of the dual clutch AMG SPEEDSHIFT DCT With the maintenance contract, the focus is on cost trans- 7-speed sport transmission parency and reliable planning. In this case, all maintenance The oil and filter change interval for the AMG SPEEDSHIFT costs are covered for the agreed term. The services include DCT 7-speed sport transmission with dual clutch technology all maintenance operations as per the service booklet in- is “50,000 km/ 3 years” for the M133 in the A-Class. cluding additional operations that are “subject to separate invoice”. As a premium product, the Full Service Contract combines the aforementioned maintenance and repair work with all wear-related operations. With this all-in-one protection pa- ckage, the customer can be sure that their Mercedes-Benz will stay in top form for a long time. The availability and product names for the Mercedes-Benz Service Contracts for cars are defined on a country-specific basis. Talk to your colleagues in sales or your contact person for the market. Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 19 – This printout will not be recorded by the update service. Status: 02 / 2013 – Brief description Powerplant The special features of the M 133 at a glance: • Highly supercharged gasoline engine with twin-scroll tur- • Viscous vibration dampers bocharging with max. 1.8 bar (relative) boost pressure • Two-mass flywheel with centrifugal pendulum • Fast-switching piezo injectors for multiple fuel injections • Advanced control and optimization of the oil circuit by • Combination of direct injection with turbocharging means of a governed engine oil pump • Boost pressure control via vacuum • ECO start/stop function with starter-assisted direct • Exhaust manifold with separate pipes starting • Damper filter with round filter with reduced pressure • On-demand multi-spark ignition losses • Sand-cast all-aluminum crankcase with NANOSLIDE bar- rel technology • Indirect charge air cooling with separate cooling circuit • Wide open throttle tank purging via venturi exhaust • Compliance with the EU 6 emissions standard with future potential P01.10-3137-00 M 133 AMG with 265 kW output from 2.0 l displacement 20 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Engine data Powerplant M 133 DE 20 LA Engine data Engine model designation 133.980 Displacement cm3 1991 Rated output kW at rpm 265 6000 Rated torque Nm at rpm 450 2250...5000 Compression ratio ε 8.6 : 1 Emissions standard EU 6 Cylinder configuration/ number 4 inline Valves per cylinder 4 Forced induction Twin-scroll turbocharger with indirect charge air cooling Boost pressure control Via vacuum Boost pressure (relative) bar 1.8 Bore mm 83 Stroke mm 92 Cylinder spacing mm 90 Connecting rod length mm 138.7 Injection Direct injection (DI) Performance/consumption/emissions Maximum speed km/h 250/2701 Acceleration s 4.6 0-100 km/h NEDC fuel consumption max. [l/100km] 7.1 min. [l/100km] 6.9 CO2 emissions max. [g/km] 165 min. [g/km] 161 Emissions class Standard EU 6 1 Only in combination with AMG Driver's Package Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 21 – This printout will not be recorded by the update service. Status: 02 / 2013 – Engine data Powerplant P01.00-3424-00 M 133 torque and power curve 22 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Engine views Powerplant P07.70-2466-00 View of engine from front 1 Air filter housing B6/16 Exhaust camshaft Hall sensor 19 Fuel system high-pressure pump B28/5 Pressure sensor downstream of air filter 50 Turbocharger G2 Alternator 50/2 Boost pressure control flap vacuum cell N3/10 ME-SFI [ME] control unit B4/4 Purging pressure sensor Y94 Quantity control valve B6/15 Intake camshaft Hall sensor Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 23 – This printout will not be recorded by the update service. Status: 02 / 2013 – Engine views Powerplant P07.70-2468-00 View of engine from rear A16/1 Knock sensor 1 M16/6 Throttle valve actuator A16/2 Knock sensor 2 N3/10 ME-SFI [ME] control unit B1 Engine oil temperature sensor S43 Oil level check switch B70 Crankshaft Hall sensor (with direction detection) Y130 Engine oil pump valve M1 Starter 24 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Engine views Powerplant P07.70-2467-00 View of engine from top right 11 Vacuum pump Y49/2 Exhaust camshaft solenoid T1/1 Cylinder 1 ignition coil Y76/1 Cylinder 1 fuel injector T1/2 Cylinder 2 ignition coil Y76/2 Cylinder 2 fuel injector T1/3 Cylinder 3 ignition coil Y76/3 Cylinder 3 fuel injector T1/4 Cylinder 4 ignition coil Y76/4 Cylinder 4 fuel injector Y49/1 Intake camshaft solenoid Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 25 – This printout will not be recorded by the update service. Status: 02 / 2013 – Engine views Powerplant P07.70-2469-00 Detail view from left rear B4/25 Fuel pressure and temperature sensor B28/7 Pressure sensor downstream of throttle valve B11/4 Coolant temperature sensor R48 Coolant thermostat heating element B17/9 Charge air temperature sensor downstream of throttle valve Y58/2 Partial load crankcase ventilation valve B28/6 Pressure sensor upstream of throttle valve Y77/1 Boost pressure control pressure transducer 26 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Crank assembly Powerplant The recesses of the forged pistons have been adapted to suit the combustion method and the arrangement of the fuel injectors. The forged pistons are designed to withstand ignition pressures of up to 140 bar. For reasons of strength, the crankshaft is forged and carries eight counterweights. A viscous vibration damper effectively reduces vibrations in the very confined space that is available. bbNote The ignition pressure is the highest pressure acting on the piston during ignition in the internal combustion engine at operating temperature. P03.00-2050-00 Crank assembly 1 Pistons 3 Crankshaft 2 Counterweights 4 Viscous vibration damper Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 27 – This printout will not be recorded by the update service. Status: 02 / 2013 – Aluminum crankcase Powerplant The crankcase of the M 133 consists of an aluminum chill casting (with sand grains) and is a closed deck design. The cylinder barrels are lined with a twin-wire-arc-sprayed coating (NANOSLIDE) which is optimized in terms of manufacture and friction. The ventilation bores between the cylinders are embedded in the casting. Several transverse and longitudinal struts lend it extremely high rigidity. The crankshaft bearing caps are made of cast iron with nodular graphite (GGG 60). P01.40-2301-00 Explosionsdarstellung 1 Crankcase 4a Oil cooler 2 Timing case cover 5 Oil deflector 3 Crankshaft bearing cap 6 Crankshaft bearing cap bolts 4 Oil filter 30 Engine oil pump 28 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Aluminum crankcase Powerplant Ventilation The ventilation system of the M 133 operates via an oil se- The blow-by gases are removed via the parator and consists of partial load and wide open throttle oil separator vent line from the oil filler neck ventilation functions. In partial load operation the crankcase to the oil separator. is ventilated via a branch fitted with a check valve through the wide open throttle vent line in the opposite direction. It is vented from the oil separator to the charge air distribution line. In wide open throttle operation, venting occurs from the oil separator to the clean air line. P01.20-2323-00 Detail view of ventilation system 1 Oil separator B4/4 Purging pressure sensor 2 Wide open throttle vent line Y58/2 Partial load crankcase ventilation valve 3 Check valve (engine ventilation) A Partial load ventilation 4 Purge line B WOT ventilation 5 Tank vent connection C Ventilation 6 Oil drain line D WOT tank purging 7 Oil separator vent line Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 29 – This printout will not be recorded by the update service. Status: 02 / 2013 – Aluminum crankcase Powerplant Wide open throttle tank purging Turbocharging produces a boost pressure in wide open In order to verify whether wide open throttle purging can be throttle operation, which prevents the fuel vapors from being enabled, the purging switchover valve is opened quickly three drawn off through the partial load vent line. The partial load times. Pressure spikes in excess of 120 mbar must occur. check valve prevents a pressure buildup in the direction of The purging pressure sensor registers the pressures prevai- the activated charcoal canister. When boost pressure occurs ling in the WOT vent line and sends a signal to the ME-SFI in wide open throttle operation, the fuel vapors are extracted control unit. via the WOT check valve and the WOT vent line. The vacuum required for this is produced by a venturi. The fuel vapors are then carried through the WOT vent line, the turbocharger and the charge air cooler to the charge air manifold. P47.30-2264-00 Schematic of wide open throttle tank purging 1 Air filter housing 77 Activated charcoal canister 15 Partial load vent line 110/3 Charge air cooler 16 Wide open throttle vent line B4/4 Purging pressure sensor 50 Turbocharger Y58/1 Purging switchover valve 71 Partial load check valve A Intake air 71/2 Wide open throttle valve B Charge air 74 Venturi C Exhaust 75 Fuel tank D Fuel vapors 30 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Oil pan Powerplant The oil pan is made of diecast aluminum for a highly rigid switched between the two pressure settings 2 and 4 bar by structure. The ribbing on the oil pan is designed to reduce the ME-SFI control unit as required according to a characte- radiated noise and to guarantee the necessary strength for ristics map. bolting on ancillary equipment. The oil dipstick guide tube in the M 133 is located on the right. The oil level check switch is installed in the oil pan. The engine is supplied with oil by a regulated engine oil pump which is driven by the crankshaft via a chain. The valve of the engine oil pump regulates the engine oil pressure. This is P01.45-2403-00 Oil pan 1 Oil pan S43 Oil level check switch 2 Oil dipstick guide tube Y130 Engine oil pump valve 30 Engine oil pump Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 31 – This printout will not be recorded by the update service. Status: 02 / 2013 – Cylinder head Powerplant The cylinder head is made of a high-strength aluminum al- The gas exchange and the charge movement of the M 133 loy. The specially designed intake ports produce the charge are designed to produce: movement in the combustion chamber that is required in an • High torque across a broad rpm range engine with direct injection. • High output • Low fuel consumption Each cylinder has four valves. The valves are timed by means • Low exhaust emissions of two camshafts: an exhaust camshaft and an intake cams- haft. Two retainers are installed for each camshaft. The cylinder head is specially designed to produce a sufficiently high turbulence to further improve the combustion process. P01.30-2420-00 Cylinder head 49/1 Intake camshaft adjuster A Camshaft retainer with lug 49/1a Intake camshaft 49/2 Exhaust camshaft adjuster 49/2a Exhaust camshaft 32 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Chain drive and camshaft adjustment Powerplant The camshafts are driven by the crankshaft via a chain. The bearings of the guide rail and tensioning rail on the timing case cover are entirely contactless. This significantly reduces noise levels. The engine oil pump is driven by the crankshaft via another chain. P05.10-2478-00 Chain drive 3 Upper chain guide rail 10 Chain guide rail 4 Tensioning rail 30 Engine oil pump 5 Hydraulic chain tensioner 49/1b Intake camshaft gear 6 Camshaft chain 49/2b Exhaust camshaft gear 7 Crankshaft gear Y49/1 Intake camshaft solenoid 8 Engine oil pump chain Y49/2 Exhaust camshaft solenoid 9 Engine oil pump chain tensioning rail Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 33 – This printout will not be recorded by the update service. Status: 02 / 2013 – Chain drive and camshaft adjustment Powerplant The camshaft adjustment system enables the intake cams- camshafts to be continuously adjusted depending on the duty haft to be “advanced” by up to 40 °CKA (crankshaft angle) cycle of the PWM signals. The position of the intake camshaft and the exhaust camshaft to be “retarded” by up to 40 °CKA, is registered by the intake camshaft Hall sensor and the po- allowing the valve overlap during the gas exchange to be sition of the exhaust camshaft by the exhaust camshaft Hall varied within broad limits. This optimizes the engine torque sensor, which transmit the positions to the ME-SFI control curve, reduces fuel consumption and improves exhaust cha- unit as voltage signals. racteristics. The intake camshaft solenoid and the exhaust camshaft solenoid are actuated to adjust the camshafts by the ME-SFI control unit with pulse width modulated (PWM) signals at 150 Hz. The system is actuated according to a characteristics map in the partial and wide open throttle ranges, and allows the P07.10-2023-00 Function schematic of camshaft adjustment B6/15 Intake camshaft Hall sensor 1 Engine load, signal B6/16 Exhaust camshaft Hall sensor 2 Camshaft Hall sensor, signal B11/4 Coolant temperature sensor 3 Coolant temperature sensor, signal B28/7 Pressure sensor downstream of throttle valve 4 Camshaft solenoid, actuation B70 Crankshaft Hall sensor (with direction detection) 5 Engine oil pump valve, actuation F58kN Circuit 87M relay 6 Engine speed, signal N3/10 ME-SFI [ME] control unit 7 Circuit 87, status Y49/1 Intake camshaft solenoid Y49/2 Exhaust camshaft solenoid Y130 Engine oil pump valve 34 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Engine lubrication Powerplant Regulated engine oil pump The engine oil pressure is regulated via the valve at the en- The engine oil pressure reported via the control duct is mo- gine oil pump. The ME-SFI control unit actuates the engine oil dulated at the pilot control valve and acts accordingly at the pump valve. This enables the oil pressure to be switched bet- set collar against the force of the opposite control spring. ween the two pressure settings of 2 and 4 bar according to The position of the set collar produces a corresponding ec- demand, optimally adjusting the supply of engine oil in the oil centricity relative to the axis of the rotor, and the delivery circuit of the engine to suit the current requirements. It also volume rises as the eccentricity increases. reduces the operating energy input of the engine oil pump and hence the power losses of the engine. The oil level check is performed by an oil level switch in the oil pan. P18.10-2207-00 Engine oil pump 30/1 Drive gear 30/7 Rotor with blade 30/2 Control spring 30/8 Set collar 30/3 Oil pump cover 30/9 Control duct 30/4 Oil intake tube 30/10 Oil pump housing 30/5 Oil strainer Y130 Engine oil pump valve 30/6 Pilot control valve Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 35 – This printout will not be recorded by the update service. Status: 02 / 2013 – Engine lubrication Powerplant P18.00-2334-00 M 133 oil circuit diagram 1 Crankcase 49/1 Intake camshaft adjuster 2 Cylinder head 49/2 Exhaust camshaft adjuster 3 Chain tensioner with oil spray nozzle 50 Turbocharger 4 Oil filter module with non-return lock and pressure differential valve a Engine oil return line 5 Engine oil/coolant heat exchanger with thermostat b Engine oil pressure line 6 Oil sump c Engine oil control pressure 11 Vacuum pump A Oil spray nozzle 30 Engine oil pump with 2 pressure settings (2 and 4 bar) B Hydraulic valve clearance compensation 36 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Injection system Powerplant High-pressure system High-pressure pump The high pressure is produced by a high-pressure pump (sin- The high-pressure pump is located on the top of the cylinder gle piston pump) with a quantity control valve integrated in head. The maximum delivery pressure of the high-pressure the pump module. pump is 200 bar. The high-pressure pump is driven mechani- cally via the drive plate of the intake camshaft. The delivery The fuel is directed via a high-pressure rail to the centrally rate of the high-pressure pump is rpm-dependent. As the arranged fuel injectors leading into the combustion chamber. pump unit moves upwards, the fuel volume in the pump cy- The newly developed fuel injectors with piezo actuators are linder is compressed. When the system pressure is reached, capable of delivering up to five highly accurate injections per the outlet valve of the high-pressure pump opens and the fuel cycle. is pumped through the high-pressure line to the rail. A pres- sure limiting valve protects the high-pressure pump against excessively high pressure buildup. P07.02-2142-00 High-pressure fuel system 19 High-pressure pump Y76/3 Cylinder 3 fuel injector 19/1 Drive plate (drive) Y76/4 Cylinder 4 fuel injector 20 Rail Y94 Quantity control valve B4/25 Fuel pressure and temperature sensor A Fuel low pressure (from fuel tank) Y76/1 Cylinder 1 fuel injector B Fuel high pressure (to rail) Y76/2 Cylinder 2 fuel injector Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 37 – This printout will not be recorded by the update service. Status: 02 / 2013 – Injection system Powerplant Rail Rail pressure regulation A soldered rail made of stainless steel is used in the M 133. The quantity control valve is located at the high-pressure It acts as a high-pressure reservoir for the fuel. The reservoir pump and is actuated according to demand by the ME-SFI function of the rail damps the oscillations that occur during control unit with a PWM signal. In this way the fuel quantity the injection process. reaching the pump unit is regulated. The high-pressure pump compresses only the fuel that the engine requires. The rail pressure is therefore regulated between 100 and 200 bar ac- cording to the operating state of the engine. The current rail pressure and the fuel temperature are sensed by the fuel pressure and temperature sensor, and are trans- mitted as voltage signals to the ME-SFI control unit. When the engine is switched off, the quantity control valve is no longer energized, so no more pressure can build up in the high-pressure chamber of the pump. The prevailing rail pres- sure is maintained for a long time even after the engine is switched off. bbNote The stainless steel high-pressure fuel line can be reused in the event of repair work. Corresponding test specifications can be found in WIS. 38 Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG – This printout will not be recorded by the update service. Status: 02 / 2013 – Injection system Powerplant Fuel injectors The fuel injectors spray a calculated quantity of finely ato- Via an integrated output stage the ME-SFI control unit gene- mized fuel into the intake port of selected cylinders at a rates the operating voltage of 140 to 210 V for the fuel injec- certain point in time. A coupler module in the injection nozzle tors and actuates the fuel injectors with a ground signal. The ensures that the nozzle module and the piezo actuator mo- lift of the nozzle needle measures approx. 35 μm. The piezo dule have not play in the longitudinal direction. The fuel injec- actuator module is a capacitive load for the ME-SFI control tors are designed without a fuel return. unit. When the injector opens, a current of approx. 8 A flows for a few microseconds. The ME-SFI control unit reverses the The fuel feed sealed in the rail on the high-pressure side with polarity to open and close the injector. a seal pack consisting of an O-ring and support rings. The fuel injector is sealed against the cylinder head by means of The short switching times of the piezo injectors allow multi- a teflon ring. ple injections to occur with very short breaks during a single combustion cycle for optimum mixture formation. The fuel injectors switch extremely rapidly and inject even very small amounts of fuel of less than 1 mg per injection. Due to the high pressure of the fuel, the outward-opening nozzle forms a stable hollow cone fuel jet under all operating conditions. bbNote BBCaution A 220 kΩ discharge resistor is located in parallel with The fuel injector will be damaged if the polarity of the the piezo actuator module. This value can be measu- lines from the fuel injector to the ME-SFI control unit red at the electrical connections of the fuel injectors. is reversed. Each fuel injector has two lines leading directly to the The ME-SFI control unit will be damaged if the lines ME-SFI control unit. Current and voltage measure- have a short circuit to ground. ments on these lines are only to be performed using potential-free clips. Every time a fuel injector is removed, both ends must be fitted with clean protective caps otherwise any contact with other components can result in damage. Introduction of the New A-Class AMG with Engine M 133 | Model Series 176 AMG 39 – This printout will not be recorded by the update service. Status: 02 / 2013 –