Service process of MercedesBenz CLS-350 CGI

Overview
The basic service package consists of the following

processes:
Engine oil change
Oil filter change
Air filter clean/replace
Ac filter clean/replace
Battery test
Front and rear disc thickness check
Front and rear break pad check
Brake fluid change (Brake bleeding)
Miscellaneous

Engine oil change

Suction of oil
The car engine is switched on. The engine is kept running in idle till a

temperature of 80C is obtained inside engine. (appx 8 mins)

This heats the engine oil and lowers its viscosity such that oil can be

extracted easily.
To extract the oil, a pneumatic oil extractor is used. (1.1)
The hose is inserted in the dipstick tube (1.2), while pneumatic vaccum

pressure extracts oil (8.5 litres) from the engine. (appx 12 minutes)

(1.1) Pneumatic oil extractor

(1.2) Hose inserted in the dipstick tube

Oil filter replacement

Tools required:
Filter cap (28Nm) ( fig 2.1)
Ratchet (long)
27 size hex Box

(2.1) Oil filter cap

(2.2) Removal of oil

Procedure (fig 2.2)

Fit the filter cap on filter head
Use 27 size hex box to grip the
filter cap
Socket the ratchet on the hex box.
Set the ratchet to turn anticlockwise.
Loosen the oil filter completely and
allow it to stay for 2 minutes.
This is done to drain some quantity
of oil from the filter.

Oil filter replacement

Procedure:
After 2 minutes, remove the oil filter
assembly.
Care to be taken so as to not let drops
of oil drip on hands as it is hot.
extract the oil filter from the filter head.

Old oil filter

This is how the old oil filter looks.
Purifying engine oil from
contaminants such as specks of
dirt and metal powder clogs the
filter as is evident from the colour
Thus an oil filter protects the
engine from floating garbage,
which would other wise damage
the engine.

Oil filter replacement

(3.1) Oil filter element

(3.2) New oil filter fitted in

Procedure:
New oil filter is fitted in filter head as
shown. (fig 3.1)
New O rings are carefully fitted in
respective grooves.
The filter assembly is refitted In its
place using filter cap, ratchet and 27
size hex box.
The filter head is tightened to a torque
of 28Nm

(3.3) Filter assembly

Engine oil change

The oil grade used for
Mercedes 272
petrol
engines is 0W40.
8.5 litres of mobile
1/Mercedes oil brand is
poured inside the engine oil
entrance.
Care should be taken that oil
is not spilled else where.
Oil cap is fixed back on
(4.1), (4.2) 8 litres of 0W40 oil grade
completion of pouring
poured into engine

Hazard warning!
The engine should not be
started before the oil has be
poured completely, as doing
so may result in engine seize,
resulting from the heavy

Air filter
The CLS 350 petrol engine W272
comes with two air filters housed in the
engine cover(removable), each of them
breathing air into 3 individual cylinders,
forming a total of 6 cylinders or V6
A 25mm size tox driver is used to open
4 screws on each oh the housing. (fig
5.1)
(5.1) Opening Air filter
box
Depending on the condition of the
filter, it is either cleaned or replaced.

(5.2) Air filter element along

(5.3) Dust particles

Ac filter

(6.1) Ac filter

Purpose
Ac filter or cabin air filter purify the air
coming inside the seating cabin
through heating, ventilation or air
conditioning from dust or pollen.
Tool required
20mm tox is required to open 4
screws to slip out the Ac filter on the
front left side of engine, behind the
glove box.
Process
The filter is examined visually to
determine if it can be cleaned or
replaced
Usually the Air filter and Ac filter are
cleaned together in the service
process as shown in the fig 6.2, by a
pneumatic high pressure pipe.

(6.2) cleaning of Air , Ac

Brake pads Inspection

Process
In order to examine brake pads, the
wheels are to be removed first (fig
7.1).
Break pads inside caliper assembly
has to be visually inspected for wear
(fig 7.2).

(7.1) Removal of
wheels

Tools
A pneumatic gun coupled to a 17 mm
hex box is used to open 5 bolts of
wheel.
Pneumatic air flow of 300l/min is
sufficient to open the tightest bolts.
Caution
The pneumatic gun must be checked
to see if it has been set to anticlockwise turning only.

(7.2)Break pads, caliper and disc

Brake pad wear

Mercedes Benz standard calculation
Front Brake Pad

Rear Brake pad

1mm thickness = 6000kms

Minimum thickness required =
2mm
Thickness by inspection =
5mm (appx)
Brake pad life = (5-2)6000 =
18,000kms

1mm thickness = 6500kms

Minimum thickness required =
2mm
Thickness by inspection = 6mm
(appx)
Brake pad life = (6-2) 6500 =
26,000kms

(8.1) Front LH Brake pad

Disc Plate wear

Process
The front and Rear Disc plate are
subject to wear due to friction
between brake pads and the plate.
The Disc thickness is measured to
determine if it has to be replaced.
Tools required
Standard vernier caliper
Mercedes Benz Standard values:
Disc Position

Min
Requir
ed

Actual
value

Result

Front
Discs(LH,RH)

29.4mm 29.2mm

Change!

Rear
Discs(LH,RH)

19.4mm 19.6mm

Ok!

Break fluid change

(10.1) Brake bleeder

machine

(10.2) Pressure of minimum

Process
To replace brake fluid, an electric bleeder machine
is used as shown in fig 10.1.
The hose of bleeder is connected to the Brake
fluid box. 3 litre of brake oil is poured in bleeder.
Pressure is set a little more than 2 bar as shown in
fig 10.2. This pressure acts from the brake fluid box
and throught the circuit till the calipers
The brake bleeding process is carried from the
farthest to nearest caliper in circuit from fluid box.
for Eg: since the brake fluid box is located near
Front RH, bleeding process is started from Rear LH
> Rear RH > Front LH > Front RH

Brake bleeding process

Tools required
11mm Ring spanner
Flexible tube of 1m
Container
Process
Fix one end of the pipe to a container and
other end to the bleeding nozzle of caliper.
Use 11 mm ring spanner to turn nozzle
anti-clockwise such that it loosens
Loosen in to an extent where sufficient
quantity of Brake fluid is bleeding from
caliper to container.
Collect 600ml of fluid from each of the
rear calipers
Collect 900ml fluid from each of the front
calipers
Sufficiently tighten nozzle back.

(11.1) Bleeding
process

Other Miscellaneous
activities
Under Body Damage Check
Visual inspection revealed damage to Oil sump
Case and cracks to front Bumper.
Battery Inspection (starter battery) (fail)
Mid-tronics setup is used to measure battery
charge. The battery was charged.
Charg
e

Specif Min
Resul
c
capaci t
gravit ty
y

Min
12.0V
1.190
50Ah
Reqd
Tyre Groove depth Test (pass)
12.39V are1.225
12Ah
Actual
Depth of grooves
measured
by depthCharg
gauge
e
Front
Front
Rear
Rear
LH
RH
LH
RH
Min
Reqd

6mm

6mm

5mm

5mm

(12.1
)

(12.
2)

(12.3)

Other miscellaneous
activities
Star test
A wireless multiplexer is connect to the
car which records data from 38 different
sensor heads and shows the
recordings on a screen
If a sensor is malfunctioning, the
Result in front of the sensor will show a
fault code F
The technician can thus use Star test
as a tool for diagnosis of problems.
In case a Fault code is shown,
customer approval is taken to do the
necessary repairs.

Referrences

Thankyou.