07.

2-110 Testing, adjusting engine

Operation no. of operation texts and work units or

standard texts and flat rates 07-1100

Test sheet complete.

Testers (see ill.) connect.
Coolant level check, adjust to correct level.
Engine oil level check, pay attention to condition of oil (visual
inspection).
Oil level in automatic transmission check.
Air filter remove, install.

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 1/16
Accelerator control check ease of movement and condition,
lubricate bearing points, relay levers, ball
sockets.
Full throttle stop check from accelerator pedal lever, adjust.
Battery no-load and starting voltage check.
Ignition coil: voltage (terms. 1 and 15) test.
Resistance trimming plug for 2 E-E carburetor test pin assignment (KAT/RÜF).
Engine oil temperature raise to approx. 80 °C.
Firing point, total vacuum
advance check, adjust.
Firing point with simulated throttle
valve actuator fault check.
Oscilloscope image analyse.
Function test of 2 E-E carburetor perform.
2nd carburetor stage test full opening.
Float chamber vent valve check.
Output system test for leaktightness by spraying.
Intake air preheater test, flap position (visual inspection).
Idling speed test.
Lambda control (KAT) test, adjust.
Idle exhaust emissions level (RÜF) test, adjust.

Test and adjusting data

Firing point
Engine/ Ignition control Engine Firing point in ° CA before TDC1)
Version unit EZL speed in
part no. rpm
Resistance w/o vacuum with vacuum
trimming plug
position

102.922 004 545 79 32 3200 S 22-26 38-42

102.924 004 545 81 32 N 15-19
KAT/RÜF 006 545 40 32 Idling S and N 11-15 11-15
006 545 41 32
006 545 52 322) 3200 S 19-23 38-42
006 545 53 322) N 14-18
Idling S and N 11-15 11-15

1
) If readout varies, test ignition system (15-540).
2) Ignition control unit with fault control in the event of throttle valve actuator faults.

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 2/16
Idle speed

Engine Version Idle speed in rpm Idle exhaust emissions Lambda control
level % CO (RÜF) range %
102.922 RÜF 700-800 1.5 0.5 -
102.924 1 50 10
KAT )

1
) For special exhaust emissions test (ASU) 0.5 %.

Battery voltages

No-load voltage 12.2 Volts

Starting voltage, minimum 10 Volts

Voltages at ignition coil(engine not running, ignition switched on)

Terminal 15 to ground Battery voltage

Between terminal 1 and terminal 15 0 Volts

Choke actuator (VD)

Test condition:
Coolant temperature +20 °C (simulated with test res istor)
Ignition: On Choke gap max. 1.5 mm

Special tools

Commercial testers

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 3/16
Revolution counter
Engine tester with oscilloscope e. g. Bosch,
MOT 002.02
Hermann MO 941
Sun, DMA 1000
Lambda control tester e.g. Hermann, L 115
Multimeter e.g. Sun, DMM-5
CO tester

Note
Do not detach crankcase breather for setting
idle speed!

Idle speed must not be adjusted when engine

is hot, e. g. immediately after driving car
sharply or after measuring engine output on
the performance tester.

Adjusting engine
1 Complete test sheet.

2 Connect testers:
Engine tester with oscilloscope
CO tester
Lambda control tester
Oil telethermometer

3 Check coolant level, adjust to correct level.

4 Check engine oil level, paying attention to

condition of oil (visual inspection).

5 Check oil level in automatic transmission.

6 Switch off air conditioning or automatic

climate control. Move selector lever into
position "P".

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 4/16
7 Take off air filter.
Unscrew nut (arrow) before removing the air
filter body.

8 Check ease of movement and condition of

accelerator control linkage and throttle valve.
Lubricate all bearing points and ball sockets.

9 Check adjustment of accelerator linkage,

correct. Retract throttle valve actuator plunger
fully (decel fuel cutoff position!). This is done
by detaching hose at air admission connection
of throttle valve actuator. Run engine and
switch off again.

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 5/16
Detach accelerator control rod (1) and ball
head (2). The accelerator control lever should
now be resting against the stop (arrow) and
there should be no clearance at the driver
compression spring. (If not, perform basic
setting of accelerator control 30-300.)

If the accelerator control lever is resting

against the stop, attach accelerator control rod
(1) and adjust so that the idle travel (arrows) is
approx. 0.2 mm.

1 Accelerator control rod,

1st version

If accelerator control rod 2nd version (flat rod)

is fitted, adjust rod so that the hole in the rod is
half-visible.

Accelerator control rod

2nd version

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 6/16
Adjusting full throttle stop
This is done by depressing the accelerator
fully on cars fitted with manual transmission,
and as far as the stop on the kickdown switch
on cars with automatic transmission
(do not operate kickdown switch).

The throttle valve lever (27) must now be

resting against full throttle stop (28); adjust
Bowden cable with the adjusting screw (21), if
necessary.

10 Check cruise control setting, adjust if

necessary. Detach connecting rod (1) at
carburetor with the plunger of the throttle
valve actuator fully retracted. Press lever of
actuator in direction of engine as far as the
stop.

Now adjust connecting rod (1) so that the lever

of the actuator must be pulled back approx.
1 mm from the engine for attaching.

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 7/16
Tempomat/cruise
control
M16 Tempomat/cruise
control actuator
1 Connecting rod
3 Ball head

Remove clip on the hose of the air admission

valve of the throttle valve actuator.

11 Adjust control pressure Bowden cable

(automatic transmission).

Run engine at idle speed when performing this

step. Detach ball socket (2), push back fully,
then pull forward again until a slight resistance
is felt.

It must now be possible to attach the ball

socket to the ball head free of tension; alter
setting of adjusting screw (22), if necessary.

12 Test battery no-load and starting voltage.

a) Battery no-load voltage

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Connect voltmeter to battery, paying attention
to polarity, and take reading of voltage.
Specification: 11 - 14 Volts.

b) Battery starting voltage

Plug protective connector 102 589 02 21 00 to
diagnostic socket, or detach connector for
position sensor signal at ignition control unit.

Operate starter and take reading of voltage.

Specification: minimum 10 Volts.

Unplug protective connector.

13 Test voltages at ignition coil.

Engine not running. Switch on ignition. Test

voltage, terminal 15 to ground at contact 5 of
diagnostic socket (3).
Specification: battery voltage.

Test difference in voltage between terminal 15

and terminal 1 between contacts 4 and 5 of
diagnostic socket (3).
Specification: 0 Volts.

(If reading varies from specification,

additionally test ignition system 15-540).

14 Test resistance trimming plug (arrow) for

2 E-E carburetor.

KAT cars= Connector with inscription

"KAT"
RÜF cars= Connector with inscription
"ECE"

15 Raise engine oil temperature to approx.

80 °C.

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16 Test firing point and total vacuum advance
(15-515).

At the same time, also test firing point with

simulated throttle valve actuator fault.

This is done by detaching vacuum hose at the

evacuation port (92) of the throttle valve
actuator with the ignition switched off. Run
engine at idle speed and test firing point.
Specification: approx. 12° after TDC.

Re-fit vacuum hose with engine idling and test

firing point.
Specification: 11 - 15° before TDC.

If variation from specification exists,

additionally perform test step 14 (07.2-114,
Section "I").

17 Analyze oscilloscope image (15-525).

18 Perform function test of 2 E-E

carburetor.
This is done by simulating +20 °C coolant
temperature with ignition switched off, using a
2.5 k test resistor.

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 10/16
Switch on ignition and check chocke gap
(arrows).
Specification: max. 1.5 mm.

If variation from specification exists,

additionally perform test steps 1 - 4 (07.2-114
Section "I").

19 Check 2nd carburetor stage for full

opening.
This is done by applying full throttle and, as
soon
as engine speed has risen to 4000 - 5000 rpm,
holding both carburetor mixing chambers
closed
with your hands far enough for the engine to
still be running at approx. 2500 rpm.
The actuating rod (89) must be fully retracted
(if necessary, check vacuum supply and
leaktightness of vacuum cell (3)).

1st and 2nd stage throttle valve mechanism

3 2nd stage aneroid cell 80 Torsion spring

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9 Carburetor housing 81, 82 Plastic element (for lock and 2nd stage
27 1st stage throttle valve lever positive return element)
42 1st stage throttle valve 83 Actuating lever for Tempomat/cruise control
46 2nd stage throttle valve 84 Idle stop screw
78 Stop screw (1st stage throttle valve 87 2nd stage actuating lever (with driving fork)
basic setting) 88 Torsion spring
79 Stop for deceleration 89 Actuating rod

20 Check float chamber vent valve. This is

done by detaching connector (arrow) with
ignition switched on, and re-fitting again. It
must be possible to hear and feel the switching
noise of the valve.

Detach hose for float chamber vent at

charcoal canister and suck at hose.

Ignition: On. There must not be any continuity.

Ignition: Off. There must be continuity.
If a variation from specification exists,
additionally perform remedy according to
test step 13 (07.2-114, Section "I").

21 Check intake system for leaks by spraying

with ISO-Octane DIN 51 756 or cleaning
naphtha.

Do not use commercial-grade fuel for spraying

(harmful vapors). Pay attention to risk of fire
and do not spray on hot parts or parts of the
ignition system.

A leak in the inlet manifold exists if:

a) KAT cars: the pointer of the lambda control
tester moves to the left.
b) RÜF cars: the idle exhaust emissions level
rises.

22 Test idle speed.

If a variation from specification exists,
additionally perform test steps according to
troubleshooting table 07.2-114, Section G.

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 12/16
23 Test idle exhaust emissions level of RÜF
cars and lambda control of KAT cars, adjust.

RÜF cars
Test idle exhaust emissions level at tail pipe.

KAT cars
Test lambda control.

Move selector lever switch on lambda control

tester to 100 % .

Take reading in idle control range. Pointer

should swing equally to both sides around the
50 % setting.

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 13/16
Adjust idle exhaust emissions level or lambda
control, respectively.

This is done by removing the security plug with

puller (028) and adjusting idle exhaust
emissions level or lambda control,
respectively, by turning the mixture adjusting
screw (arrow).

Screwing in = leaner = Lambda reading rises.

Unscrewing = richer = Lambda reading drops.

If on/off ratio reading is constant, it is essential

to refer to table "Fault readout with on/off ratio,
possible causes of faults, remedy according to
test table" (07.2-114, Section "F").

After performing adjustment, press in new

security plug (blue) with fitting mandrel (029).
Fit on air filter.

Move selector lever into drive position, switch

on air conditioning or automatic climate
control. Turn power steering to full lock. Engine
must run smoothly.

24 Test intake air pre-heater.

a) Intake air temperature below approx.

+20 °C

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 14/16
Determine by visual inspection in connection
fitting (12) whether the air flap (9) has fully
shut off the "cold air supply" (arrow A).

b) Intake air temperature above approx.

+30 °C

Determine by visual inspection in the

connection fitting (12) whether the air flap (9)
is fully opened to allow the "cold air supply"
(arrow A) to pass.

(If variation from specification or function fault

exists, replace thermocouple (5)).

Air flap in "warm air" position

5 Thermocouple 11 Intake manifold
6 Control rod 12 Connection fitting for warm air hose
7 Compression spring 13 Compensation opening with air guide pipe
8 Compression spring A Cold air supply
9 Air flap B Warm air supply
10 Air filter

© Daimler AG, 10/4/10, G/10/08 / ra07001020110x / 0110 - Testing and adjustment of the engine Engine 102 - 2 E-E Carburetor Page 15/16
Air flap in "cold air" position
5 Thermocouple 11 Intake manifold
6 Control rod 12 Connection fitting for warm air hose
7 Compression spring 13 Compensation opening with air guide pipe
8 Compression spring A Cold air supply
9 Air flap B Warm air supply
10 Air filter

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