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    Manual de Servicio W111 de Mercedes Benz

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    w111-service-manual-180-to-220se

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    Manual de Servicio W111 de Mercedes Benz

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    267 views628 pages

    w111 Service Manual 180 To 220se

    Uploaded by

    pescrich
    Manual de Servicio W111 de Mercedes Benz

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 628
    Service Manual Models 180 to 220 SE : Merecdes-Benz _ service MERGEDES-BENZ OF NORTH AMERICA, ING. Sa 1201 eRUNDED IV USA ny DELMIRERSAE Aeinageelchol, fs fcr um nteisath per moh PREFACE This manusl wes doveloped az 9 supplementary mmanal ty thie Workshop Manual Modal 140-10 extend the covernge 19 atgdek, 1A, 1AOe, 164b, 18Ic, 189D, 18CDb. 1800c, 1900, 1 90Db, 190SL, 9200, 919. 2205 ond BIOSE. The ind wdual repoie procedures are described in detail anly if they do rot correspard ts these ot Modal 165, When thore is no differanea, reference is made to the besig Model 170 Werkshap Marucl. this means that for a voinplete desciption of vorious reacie procedures. both monuals, the Workshop Manual Model 190 ard the Workshop Manuel 180 to 2705k, must be svoilile. Nev covered are the side-velve engine of made! 180. dtasel enuives OM ATA Oi 621 of modal 1300, 1860, 1800, 1990 and 160De, the fuel injec ficn spstem of Modal 7705E, the Sydrou ie-oursmatic transmission, and the dawdlnjcanted rear exle of model 7BO ond 1800, These units are rnvered sv othar workshop meriuuls. The entire conlonts of this Workshos Manual sre arranged by groups. Tht grup index serves ‘a locate Oy Dértituiar group. Eoch group ls preceded by 3 comprehensive fisting a its cantents. Muivedes-Benr of North Amer ca, Inc., “ecomrrends Ikat repairs to, ond’ maintenance cf, Mercedes Benz obtamosiles pesformed only by Mercedes: Benz trained personael 1 cutaerized Mercedes Benz repair stations, The infer-norion combined in this speciul aublicacion wos arginaly issued by DounfersBez AG in con|uncion with supp-smemary service literoluie only lo its cuthorized dealers. The vorious repair and mamtédiond ® pte redures outlined feret ore praredures tn be used by iainsd Mercedes: Beng service onl rapoir s-atio7 persennel. Supplementary service lileohue 4g ng longer owciloble ‘or th * Mercedes Benz of North America, Inc., aasumas ao liability for ary dauncnge fa person or property occasioned by the utihaatior of th's publicanion te effort maintenance sr -epoi- work on Morcedes-Bonz autamobiles. Reorintad by MERCEDES-BENZ OF NORTH AMERICA, INC. Location of Model Plate, Engine, Chassis, and Body Numbers Apnit Pom exceptions Isied balow, Ihc lacaton of the Model Plate and the Plates giving the Ene tine, Chassis, and Jody Numbers ond the Typa of Gar Finish. 1s, for Models TBD 4e 720 5E, the some as on Model 190, Os Models TEO ond 180 B the Engite Kumber Plate is Incated on top of the liming gear cover On Medel 190 Sl the Chassis Numbar Flare ond the Pinte giving cha Type of Car Fins are localve or tha roa of the fira wall behind the battery. Cin Model 220a thera is a: yat ne plate indigating the type of Cor Finish. Te ensure prompt aad céract execution of your orders end attention te your inquiries, please let Us hove the fallowing details: L. Complete Chassis Nueber 2, Complete Engine Number % Complet® Body Numbe~ 4. Mileage covered Location of Unit Number Io your inquiricx ond erders referring 19 specific car units such a5 fromr exile, stearing gest, Irene cristion, end regi nein. plense quote tha Unit Numbers as well, For Madels 180 10 220SE these Numbers con be found tn thy some ploce as @n Medel 170, vl Group Index General Engine ond Engina Suipansion Clutch Tronuninien Comma System Springs and Shack Absorbers ping Froat Aula Rear Arie ‘Wheele ond Tirm, Adjyuimem of Wieals Propeller Shatt Broker Steering Asarably Fun! System Exhaurt Sytem Redlator Elnettieal Syston oni dewreraion tact oe Accelerator pedel adivitmert me Acid lnvel ard acid cenaity af tallory 54-1171 Adivrhtent came, deaburer zat ‘Aiken, eos, sa, a0 i iighe silane ‘angie of cinsure. dit beba> eowincie “Antiiraere salutiors 7] of crankshott onesie ot wieely with fires Fited an Soll cup coraeciar ol steering. asiemly at ef steering wheel hit cyte 246-27, Tia Bove bare 10 crankeass ma Bevery ‘tld lace] ancl osid densiny sea general Se femowel ond inwelloton sum aecting attembly For stenting ‘wheel “it eyetem removal aut instollation wae pair Melt Hearing bushing ‘ar Falical gear was Fa lng) rar chet ea Bearing pity oF comcham 5 fF connaig soe cos f cranks ose Blower tome ewich Bt? Body number, location ¥ Brake cable center, reploormert rear, fenincam art Brake ‘drums, recendéhning rake ‘ede OF pata gris hand beak brake lines, checking ao Aral linings, laceirant ond condoning, jam maser cylinder jembly ord reassembly 24 with thid reservar attochad oi Femeval and insia laFon a¥ Brake shoes ediettmect dizzsvambly ond rasszerbly ot ‘puramatic od jvsinun! atch front, remaval snd inllotice dies rear, rereval oud insts!latior nm index rake system bleeding and flushing-oat a7 na os 4 A iatewat an ith Piechewi¢al ninemet an ies sign Coble hornacs ‘tom genetahor fa realetot ss fe rormrsing light wich a5 for thecting abe 58 Sante op bucky edjustinem oot rast whnsels, aejustmen ae Cemshait ing. mensurements Bsa beotng play uta checking tHe oduerment wae aradfag asa aendiag daemon an ra Bedding oe “emeval and incrllation oe Cor radia mat Crburerne clude oc justment [rsa te dlscmembly ond ceatvenEly Pat idle adjustment cea Lakes edi cag reasuremenl and adhuetmant ‘f njetion ameunt oe removal ane istalfalion Oban tathaienl spactcatane e010, arid ea 032, tavblesshomting hints aan Laster on Carter adjustment m4 Laer fesiee 4 Chain ast Chae guide ip eyineer na aaa Canin. tensioner, belé-bleoding rameval ond iastlletian oan retbag ToS Change-aver switch for slearance ight Ber? Chargirg of battery soe Charging light, removal acd inslaFation — 1S—iS hans sumer, Fosation vl vil eck platen far cracksha"t ‘Choke centol, raroval ond iastliotion ieuit diagrams Glegtonce light sbange-aver switch ‘Clack, removal and instellaan Claivre enmle, cieriby ter contacts Clute ogjustment data isacsombty, Caching, and seastemaly — 95—4:1 reeset ond encllatian 5 Cid seeing mechonian = 36-19, 1) Chui, driven plate ad (Clue ace of “hawheel grinding eas Ghuiet haveing mms Clutch ecal ‘ae play eajustmenk Bo removal gag installaven aoa ‘une vedal shaft ol, FO Ciunch pressure plats me ‘Clutas ipeinge por Clutch rew-out bearing, Pree Compo and cese-dra carkeretor woe Compound dovndrafs cerbyratr oes Campression chamha® Daag, os Compression eneacurement ole Comprassian -aife 1-34, 150 Connecting tals ra retenditioning and ee-bushirg Sed Central sien mo Gottral levar os Conte) lishage oe justmant oace ernovel ard mstadot'an au Conical shaft won Cooling satu capacity 1B, U5, tleentag os oF engine: Piast ‘Seeling water antiis7e separation and | end fastaflarion aes Disickutar contacts, meaueeenent ond agjuttment of gops and ang'es of Cosure AUS Cinrinutce ative seesteal nd inata lation ean reper mu Double downdraf sabyrator aos CDaundna't sarhpeeers ra Dive For oi! puma, punter, cng ‘ajuehen pum cheno, evolves oa0, 1 Drive tha’ for trorsricsion tes Drizen plote af zhtch ms Dey cir Sher wrasa vertical sysem sssserrbligs and inirurments ste ee bac I ersine Bi end ploy of camsha® Bsa DF cronkthef a8 Ergin aoliog ystems aos strsprcambly ond #0414embl a4 tele edjustment cr lubiicotion 1954 rerovel aed jtlallarion logather with transaiio bt side nt naa le0ing ond rezciing asd eahng om tule teal wend on 93 suo oa Feqire beara, fr! ma ng ne auwiter, loention ‘ “bone Eshaust-305 test volues Fehaoat mewtold ond in-ake pie re1av3! and ‘nile lot.on nt oF sampee scr Japlacananl AF neater wale and sheft raplacamen of heating ‘ir Brhoust ave Fan inlovse baterds fan end redionar 321 femoval and ivtoltiun na en hell lansien, ¢hacking ond anjustment 5—51 Figen sical rai ae sigan! mackonisrs for fas signal, reenove! ead insallolwr 34! er uppe beam Flos» signel spataan, Temaral cad inst=ilotion a? Je ignal twiten Far upper bro se h signal rym suk hy seahnecnaR ots oleae af engine (ated Wade Flreherl ‘grinding sureh Face at remgeg! and rialievion hats ‘eplaceme nt of ring ea a ‘uti, bplendiag mest Fg Nigars, acjustmert te Foot dinar swith ou tons =e half Crething and rapa aon diaze-vbly ond ruawenbly ze remoeet and inst lstion Boa Frant aie nwriber, Inston “ Franl wale 1-9pen, cheecing, 4 rast soring al aie code 2a Sardar, for bed vod condibians me fumovel end allotion Ea] vert ra'ves Bwe Frant thee. bearings can Faal eae semorian fascarding fo Germen Stardard DIN PUNE O14. M41. for owetnge h.gharay Pave W=1.146, 129 rote a WL ¥6 uF wer sr Fuel roncumpton curret woe arial land 4 Fuel dberioulor ftiags, removal ois: isellatiar ana Fuel saad pump checking oo dicasiembly ed cwueie Ca dutepeook wertinn wang meaiwaiagat ood odjusrment cf pressure E1—BE ssmmaval ane instal Ae, AIP Fuel gage Toul sroctoa als a removal and initollohan sone Ful ie aclion system, remcvst ond ingollation cart Sever Tama condo. twkoge oan fo dakibu-os Files an nyseton pume ans jecton «oles gan enturi central unl ae unl level in cerburalor ansgnas, mesures gal adjusment 8 Fal lave: iedientor remave! end insiareian vesing eel gored Fel fork sheeting end -epci as far Weal indicntn Femevel ond instalation ear tering oe removal one | xanlotian aon Tose bam, covmechons 2 ae Goatalise inition system Gene ski machonism, 2drusiment ms Genee=tar fsausambly and reassembly um mourting “wpeart] eo femeval sce instellt on aT varoing feats wt seat voluns sr esting mor hronbla shooting hints wT Bereroiot nat regulator, ok a wl wp ‘Stow plug slerie- ard tia teoteh ea, Sew ely syle 1M Senate anal jen, fer oslo ‘rem, far feerove ‘and installation oa Srourd feod oF diskihatoe 04% Gvide ula, shift tobe yeas Guide spracke! Oe Hora trace aot ratchet gad broke ‘aver shel Hendlight lnwer Lew Hd signal system STP lawnilgh apoar bear cch sigral seteh STE Headly: adjesinent remawal an) iowallarian raptncerent cf bln Heoher bloner water mech Anica geor For Aitrinatos drive Horn Hart exserbly ole aeystmere ment {dle adustrent knob ard 225 aie Iole oduct rene oman lle nine ditt oma? lang geo ho? for tbeier deve O10 Igniian © 2 Igrifion earrot zo pars Ugeitiae wad, tesh6g 13-24 Igetign tesd exmettor, taxing iota 3 Ipition sei by rains ef faut evabnastoe ot hr means of sing ight ra larition. wwiteh we Tgniion seaen, anriplion 7 sition van comral on ievkon aroun in corcucelar wm mmsoeuremant Rud aciustmend i) Injection purme sdjusinent mags -inwel| gue nstatotian nas nyectior pump drive emouul and ingcllarion Ibiecien eter Saiustnenr of ental ncoge Sinking ana ily odiaatment “eedjuttinget cf speed able stuuble-shesting Fils Ingestion univae Intrummars etustar Inteammens Highton, il_yurtch one immer resistance inaaiating Flange ef sa Infoke Bice voce. ensues Ino wpa end exhaust exofatd eewuva: and instal elon replocemen| ot dame? prions repleeamart of hiwly~ waive and chet replace-nem i beatirg spina iecteonare supprensinn to! tack rinting ase of sieermg couphig Kicene plete light Cocatieg bearing ef cronkshall ower beom flaeh sige! system wou Modan ef cylinder haar Wan salt af ranamietion Manieurs eneed ih Meusurieg tuna Wisalignmert af rent rele Shin'ng rahe, ae i} Sheds. rate, loeetine Neate sesrings tere rire aarti cama ws sha if bor we flee . Gil capzeity oraune “sates pup tow Gil consumption test ria OW Fiter Siensemby, clecatna, ore reassam ely TANS remvava! and inslellatine oar Oat ut aa ‘Sal pressure sat Git pum removal anz installation oe tazeit es Di Due Arve ermal wax) snstallalion aay faunir “en El list vole cleaning ord cheewing teas in erankeawe, remaval and ivataletian M—arid pening preemure wos il thew on conkshoH ov asar Qvashu cl ateges earthelt cathe bearing, rrankens rreauthott valve ouides ole seat ring Portia sed fsel conception wrayer Pori:ion ole, ceakense Oe Sino" hurd brake, that neat brake lev 8 atom pie kuzkina di m5 Naew on pey ma? ister riage cas Pistons Tring, lager sone nage, ite eytiniers 02515 remove nn “netaliat om 7 Five bearing for stewing relay on eo Fisat int Wslane asa Plate valve af radinssr m1 Hoa the . ‘emtyya! and irslallalinn ates aay eae Bf crankenee as of erlinear hud m1-52 Propeller sho fhsvege aly ant teense ly Lae remeval end ineallatian sin ssiverval ais Aimee Pulley 2 e-nakthot mouse wo wir Restirur 0 oo renova] end satellasion a thusremaiar wna vecum sole m4 aaa che athe uso incerierence srppression gain Roller uf pala -grn Fad broke welt Feted Fuel consuptee roova, 4, Rear ovla creciing and repat Bo cto gee sic #01 ‘haaembly end recesemely 5S hemor uni ay ioten su Rear axle “icalig rer aot oxle awabe-, teeatior Bear cale snersion ales sede Fevcer remeval arz instalstier val be lena deer pia ryeyol ond ineallation Raley snake Raversing Har aunt pdjutment ta exble herrest fer ss Rerolulies cewrler, ‘emaval aad instelll on soe Rovalutian = a Yat ennumpiion “ar overuye [inqh-wor oes. 1 REIS 32123 ‘eparae | Ferl _ sgul: . | . burpert Z Sid comrespording dreq in nuypur x * eich f ner I Gaeta tbe a wa ge tt sete“ apie eee, id ver ar agar sees nee ae Tw nian ae yest cari a th cag" om 3 le‘ iy te, ARealga Ra ewoatetn Fy lel bee momar 2% af tos std OD Ante = 2 Aesatretcnne ha, sretioale Fie teeny 9 Guna Re Seen bos Models 180 0, 120 Db, 184 .De, 190 Band 190 Bb Models Car Moc! j= 1a ob a 9b | WW Ub hone Tye | vay) en tama val} ali Enns Medel \ owas | owamn | oman | oma | Omani Engine Typ ex940 Pare aso Engine con i 1se8 ee Cperotion DoimerBen= corstaat How principle preccenvaisn choméer Number af ovinners 4 BoresSt-2ee bn : sata wits wala | var 15 80 | Wet na Injecran onda Hy carey ae - ! 2 Mas eed (Fm 0 on i Engite cer'armorce inmaric he atramace 901%] enor et yerumn ingr-HE #1 7eA ace "2 SAE wit i sectein Suu i argue mc : frigid pn weer IN 1x70 nae econ in Figen eve te EAE initio waren vat : Coumesbell Bearings 4 cwxpouad plaia brorings with steaborbert shals Connecsang rad busting VaiNn neaegement Comshoit lacgrian irte-al owacheod | Gel costing - ‘ilwoter hect wachongar ing arate ‘eeolar circulation ay menos of avitee “hermesint wih by-pess pp, lan Forced teed lob-icotion hy mans af gé6y-MRa Dump ss ssa is ely wl ol he coy tga 98 poste us Em eine DEANNA Hak ey Sounded oo-1a woe 18 wIDe Made! Pd Eledtrieal Equipment owary— Vallage (¥ | Ie 2 a Yana Ati at a, a Dimensions “vernal rack from herl rn rT vs | Mes) ap | 103 Fete ele load (ig! Frawsmar . renee Cepecities Tea. Span with hecting for} Water ey wd Feet nk fuel vauane (hn Foal sa Gorkcose fhe] Engine ol ioe Gil Filter (16) Cagine at ~ Sr rome witsion hr] Autor, Tranar, Fil 1 fear onde fie) Hyped ol SAE % Tas! ‘Sreering [1 Mraeid 21 SEA a ~~ Broke cyan (FH) ATE bine been Bud a oF 7 ‘wheat hie front ig) anabicien beovin= greeze Bonn Web dae 0 ne sate dnd rr ante TL es i aa eT eal bene Zn 7 Langh of weiter) ee Wid ct ahic Ford 18 | Height of wekice, vay far eivng Gord eppron 15) | Grand cecanca, coring 2 pers in) marron WS | Weights Diy valle ot vain byl thou Fl enn hea wed eet waa | na Used aah of hii aed ge gen, th TEPLAT ER pow whee toc Seal 7a Fev ot wtih al 14 Engine atl consomption [4/100 ke Goclings worer warking temparature {* C) Tal nts + 148 WP an mi er 40 aaa ae eeu 31 wn 1 Made! woo | rapes | rane | i950 | 19008 Speeds, Gonsumplion Figuies and Operating Coaditions Ar seer ave rata of f= | haa 1290 lava ‘az sowed in the ind'vidwa: poor: ad] ! Smeg il gear i 8 » 2ig pea 8 3 £5 geo ! 5 ee ; ee dent : approx. 110% anerar THM Climbing ein (5 ~ Te ave { Fy x % Bad gear { 8 5 is 5id Beer " i " sh 5a i és ‘ ‘AGERE A Lyra >, 4 geo om SING ec a so # seoed of 100 hints én 4th gor Ire} zy an! am Ful eaunpen for svropn High ove se8 aman i spa “ eoagumaticn acc. ta DIN 70MM sn 2 nm 16S tn areggtmh — LBREkmh aE kev Diss hye "VS> Sewn watn'a tne speed oF keen fit eh ab Steam! ba Sead ae FL Modots 220 a, 219, 220 5, und 220 5E ur anode [om tow Toms [ase Chonis wwe | vee | nom om ean | “tT _ | Engine rode Pmvzun | wison [aceon mim _ _ I A. Engine l Roarecgcle Ope ton foe-eyie cube ot j Tpecine Nymhee F eynan ‘ Bare! thats pant ALPS j Total cHlect~s piskre gipince mani nes i Conprout: var forest rpresion rain « wa | ove we © psinum REM | oe rains aeTumuron os site HP et! i T ami ' 1 eure | i cede eae | scvaney | sccm fsoneeen 12mg) rcs] noe ovinum tn j : ee exe. oth rans | tag.z4c0 ee4 hy cana) 9 3°2n0 | es in mld of RM SAE rating | veseaian Weis [evar er abnor Crarketiofl Veriva: | 4 Compocnd gloir bearings with stesbbocked shel’: Feast vod Wena | Sowoaved sic beorags wh eehbochd shal | ' a Vale wnangae Ova | Carat lacoren | Ten : _ poe / : ; ater erecahon sash pop, there wh acting open ! Mt ae atta tt J abrizatior 1 Torce-Feed leomoten ce mem oF Rep LU [Thy watig hartegaier apetcligs ¢ getanliy ownrnble at che chock, since the sever (eed be the exgiae cceanictier boy nbpeey bews deracted, » Chere tyne for Cenreriny BOE ond Coupe & lane M Crete Nee far Canvereble AWZ80H ew! Saupe A TARO. 0.17 va | Medel m | ME 0S B. Elacireal Equipment voltage {¥) ; Sener oF 2 opi Ie IAM] g , Dimansi Track iment Fal in un What tot nat e ae ater R 3 Mom tucning cele epee Wheel Bove ey a __|_Sedon 7650] os xa) | aa Tr | Height of sahieie car candi on (ra _| bead won 15 | appr id Grand, chegravce - ‘oon Sotrying ? bavsens fw) coor 5 | eer 8 aS D. Weights Dy wuligh ul sahicle gi wthove lve meen, MEY see tue Cee | Sol Eom Gm -y waighs ol eabicle Iasi wither foe, aa alt? Vasa 1700 1785) 1320 1 pone hea! anal Eaaie swwom coon [YEE VS Ba | 2 ~ “eutcs : efecen weight cl vehice, wile 4 vag IY | rans Ves 1980 toes vac 17a Tiel tos pore wheel and ets (eg Tie [400 1305 13e0 1D 1398 i o 4 as 0) unl at i je ope a 8 os us on te Faamanbie vorar weight rap TH iz Tate Porm nin eee Ea tro ize | eo 220 zur ste 50 a Coating syarem with healing Oe] na Fuel tenk J fuel reserem 3 I sos [ae a sure lec : ‘ypoic' on SAE 4 4 Teaserision [7 Jctemalig ror tission uid MM ‘zor cle, de __Hipeid She 90 _ . 25 Seng 1 Hyped al SAE $0 oa Beshe sestna (Fi APE lie broke Th us | Wheel Bb Front igh Aatifeiginn beurety yreuse —_| po-ve eet 1 ithe | ar] ams | ms F. Spoods, Carsumpiion Figuras, and Oparoting Canditigns Meuinin, egeety ip de Iedindoa | eal uf 8 2 (og | 8 x x oof bag ub is jemi | ae erie) | appt ten yaar ® a [ES] Mader 3 go) 8 a] f wae q BOR) gH] wie OW Ss we | Ms i] ie 1 Aciale-alion tme in th gror [ran S-PEV esa Mea) eB, Migr rs ine} 2 ea Me | gaging tend el 120 arn cs gear | om [wn aoa | ae ~ | 1 ea . Furl =suumsken inant et Fd gantumpliee for average _ rin roast Alghevcy breve! [llr?LO9 err i aa 729 a—t ighey he! I | son | Eu. i j rom i ee hy Fast eoncamoten aeemudng c esl SHR — | Bie! beni Leia a ~ i vlad TER pow fl corso rete | va) vi - | fnaing 0 corsunaron restoa em) | is Teging wor wate emptor 1 95 ee Peemine 2 berlin ul Ancagee catag june ag Total wid Had oT] aT ee ee eee “I [satu er eak etm PO 8 # 2 nl] oom YP Deteresienrl 3° ct hw rreaimcen speed ov emuaseey sf 1 Okench wily a 10% incre ee 4 Determined «: ALE magmas af Akash with 10% wntreooe 4) the gesobae sngines are odjured at our warks ath, gemmarcist ly of “he anti-heotk ‘cling aver, above 9 (RecRoscd'In octorcorce sate tne taomieh wear, ROFL Wawa Hels of g ower ects rol @ a (ohn mel ha enjeted Seeordoghy- In Mods 15 urd 2205 wn comprantian nl gai # = 4307 jaminngl outta, see dob.Ne BI-3f%, Section the mmewrsurn elvan Folang #2 1 8 0-1:7 Meosuring Runs 0+ The directions giver in thy Model 190 Workshop Maqual fr measuring fuel consumption, aif con- sumption, oceslasatian, and rtaximum s@ecd, apply, with the necessory modificalians, olso ta Madals 180 to 29036 The preserbed weights [ualaden weigh! and total weight oF vehicle} of these Models are listed in thy Section “Technical Specifications” (sea Job No. O0-1], and ihe velver for pertiullone fyel consumption aad for acceleration sre divea it the grophs on the fallowing poges 00-47 la oa op.an A. Partial Load Fuel Consumption Curvas fend: Two parsons and full fucl tok veto "CL 1 8 i t i | i fede 160 ye t se 4 ee a oF ‘op ew as Model 18) Model 120b ‘e100 me at | a ITH a oc, te aD The Models 180 J ond 180 1 Models 1901D ond 199 Db ona om m an in i eo BD Modal 190SL nweaga ke Model 219 with compesssion ratio » = 7 048 ee ane compression ratio «= 76:1 ° was eH een co Model 2905 with compresiion ratia e — 37:1 and Mode! 720 SE o0.e8 B. Acceleration Curves Load: Twa persons and full Fuel tank ir gear re Be. on ea gene sal al zane os i Sa es Cary 1 act Model 1801 renin ame yo 6 ye ww Monde 180 7 4 Eid gear wo 1 teed Medel 1800 amit ewe bm ae auf | 9 = nee! EE gaaTr 1 ar ny 0 ie ar «Pe Miepa) y wf a Tt ‘ “ a : : 4 I | r, z- 4 : I L oT o shaw oe SE 1st tee so ew 1 heel U eet Model 1909 Medled 1998 00-05 kwon eon 10] 129] sao} © a - " 1 aI oe ae to ab we a a Sd ae Mode! 22a t 1 = 6/30 Es Soe we ew Madel 217 fe — 3.721} amt ante os 0 Bm 2s a as ce ue 0 tb fat Medel 2008 (6 — 8.701 00-46 6 1 foe} os Pst Medel 219 ry ie SS eS Tal} om te oh an as 1S 0 Ss Madel 208 je = 7.8:1) 6 Medel 220 SE Running-In Instructions for New and Job No. Replacement Engines OT Shieh adherence Ia che -unaing-in ingructions is cf vitel inzartenee dor the vel able creation, sence life, erd eccnomical “unning sf avery eng ne Naw cad completely ivethauled engines ‘repozen=n! e-gires} ce given ineis initicl exnningsin mi ole warks be‘are they org itilalled ir a vabicle or arg shipped to a repair shop. Wie rotemmend, therefore, thot engines which have been repaired, 2g, by nelolling new hearings ar reve pislons, should ke wun ie for a shaet period ef line nefsve they are instulled in the vehicle Since in nest cases, hawaver, 9 lest stand and evoke will et be avgilcale, te fyllewing shut instructions stow her engires con be rur in en an ordi~ary test bench with cutside tooling ond ssithout & braking system Water tampomntuce Jaope. BO? C| ond 2! prnscure muet be chneked a sagulor intencals Running-in (nstructions brgire teed tem oth 180, 139:, Web. | biodels |905L, 22Cn, v0, cb ' HY B85 | i. nd re i wom: a i & i 2000, ! 0 a 0 | am i 5 : = auto | : 5 1 HT When the raping har beea su or wl 242 pri the aylireey mana aglewt ghoul mirsubben gid edeliar all screws and nubs Tar foal tld, the sterlar, 2nd Ihe qeacrote" should Be “cightened, -stightened ceneraing te -aur rg ne lace pipe, a cr bwrnoy, he ech mon Romningin has xe eddihonal advontago thot the caging, wile romoved lam Ine car, can be chedked for leckoge, o | protsure, auiet operatize, ond ule, urinermors itis advisable 1o mate en oil change directly offer -unn.ng -n tim eegine nd to clean Ine cir Eitee cl Ihe sume Hime, is @ coriapn =apevigiice thal very nany umpurvies oF [oH in she gorness end covilies of the nousing even if the engine compatonts are corctully etecnee before Gctembly, “hase smpurities ore lomnnné by the siroshing ail wnen fe engine 1s o2ing run in and sre camaved when the ail is drained oF Won the ovgine should bs ‘allowed, wlalted in she car, rac runing in inglewelions given sn the Ownars Menucd oo? Engine and Engine Suspension Engine and Engine Suspension Groups 01-24 Joa No. Grerano | | o ‘ | G11; Removal ond Installation of Engine together i wth Transmission war gia | Engine TuneUp ' onan A, Topps! Clearance Adj.stment a: B, Compression Maguyrement Iogae | j G. Gleanirg ane Testing of Saark Plugs aE D, Massurement ard Adjusinert af Dit-butor Centect Gans | Hl ond Angles of Cosure | oss E Ignition Satting O14 F, Cherking Camhatt Adjussmect olay G, Meoiurement ond Adjvstmont ef Precure 2f Pel Feed Pompe i ova H. Measurement and Adjustmant of fuic! Lmn! ene! Injection — | Amount oi Gasolire Ergines I ose | A Trnnble-Shanting Hints on Carburcior Syskem + ovana K._ Adjustment of Corbureto- Lirkuge ond lle 1 o1aee L. Testing Yotve Timing 1M. Maasorernen: of Inloke Pipa Yeet-um | N, Extous: Gos Tes! Valves Q. Engine Testing On the Roller Test Stand ® Adjustnent ot Gosoline injuctinn Pump in Matlel 220 56 Q. Checkiry Gasoline injection System af Model 290 5E | R. T-oubie-Shoating Hints on Goxolinc Irinctian Syston of Made! 2205E 8. Adjustment of Control Linkage, Idia Adjucimort, ond Rex adjustment of Speed Buitdllp of Gusaline Inject'on Engine | in Modal 220 SE ome Distr uembly ond Reassembly of Engine A, Removal cnd Inetullesion of Ca-hurerar ar Fuck Iniectiar System irel. Venturi Gorvel Writ end Gontral Lineage mar 8. Removal and tnstullatian wf flake Pige orel E&houst Me nial 430 ©. Removal ond Inuallutign af Cylinder Head, Yelves, Com- i sneHl, Chein Tensiones, Tension Sprocket Bearng, ond i Racker Arms eit | D. Removal gid Insialletion af Generator oad Storier o1ar33 ! E, Removel a-d Instollotign of Mote" Pump wviin Fon oa | 1 F. Remouel and Instellotion ef Distributor wih Rearing Oa |G. Removal ond Instalgtice af al Pug Drive, Distributor Drive, In ex! on Pump Deive, and Revolution Course Drive | 01-44) se na Job No cparatan Fage a i, Remavel and instal! aban of Fue Faod Pare 01-443 L Removo! end Installation of Oil Filler ois K, Remavel ond Installation at Gil Religf valve in Crankeoso | O1143 | L. Remavo! aed Installation of Gil Fan 1-445 Ak. Removal and installation of Oa umn 4a NA. Remove! ond Instaliniion nf Giusntersnight ard Vinratien Dumper on Crom kshcft «ar : @. Removal and Installation af Coonkshast with Goud terwelaht i cand Flywhons Lae : P. Removai and Installulion af Pislars awd ConnecEng Rods 1-450 @. Disassembly und Raustembly af Crankeose o1-4/50 R. Removal end lastallat‘on of Front Grease See! for Craak- shot with Fugit Installed ia Vehizie 18. emavp. und Instollerion of Flywhot I. Removel ard Installofion of Roller Cheia with Engina in i Vanicle 01-45] ' ; Testing ond Repsising Engine joan 01.5 | Cronkeazs and Cylinder Head | oan ‘A, Glaceing and Fretiure Tatting of Cronkeare and if neces vary. Surface-Grinding : | fieeng ond Han my atk Cplintn? Bare |G. Mothining and Presiure-Testirg of Cylinder Heod | 1D. Creckirg ond Replacing Yoive Guides i E Replacoment of Valve Snet Rings i | k Machining Valve Seats in Cyiinder Head i 35 A. Grinding of Srontshoft &. %-Bodding of Crankshaft C. Reconditiening and Ra-Buthing of Cornectirg Wek. 1D Fitting Figtons, tagether with Rings, into Cylinders 5 F G Raplacemers ef Srarer Ring (ocr inding Clutch hace of Fipwhas! Dynamic Balarcing of Counkshefl wilh Counte rvsight and Flywhee! Hy Stotic Bolarcing of New Flywhod! 1. Repair of Vibrations Comper O70 ‘Oeeraion Enging Timing A, Grinding and Testing Vales B, Teiting Valve Springs C. Sealing Yolve Shar: D. Grinding of CarshsH E. RaHedding ai Comshaft F, Teuting of Chain Tensicner (5. Repair at Tension Sprocket =nc Beoring H, Testing of Rocker Arm and Recker Avm Becring Description af Carburetors |. Downd:off Coraureters for Modeis 1B0, 18a, and 180 b Models 129 ond 1850 A. General B Start Macha C. Idle Mecha E. Moin Corburetion Sysiem E, Aecolocating Cump F. Lechinical Speciticetions at So.ex Downdeal Caraereto Typa 32 PCB Modal 180 9 A. Genaral E, Techrical Spc: Fications of Satex Downdeaf Curiereter Type 4 PICB II. Double Downdraft Curkurata’s far Models 2201 ond 217 A. Gensral B. Stark Mecfuntsr ©. Idle Mechavisi ©. Main Corburation Sye-em E Accelerating Pump F. Terknien! Specilicotinns of Soler Doune Downdral Corbuietar Tyee 22 RAAT {IL Corapeund Dewndroit Corberetor for Mode! 220 A General E. Arrangement ond Funckon of throttle Yolves ©, Sort Mechanism 0. Scovenging Devics fo Fuel System €. Techyicul Specifications of Solex Camposnd Bownlredt Carburoras Type 32 PAI Tv, Campoune Crass-BroF Corauretos for Meirel 1905. A. Genin D. Arrange-nent und Zunchon of Throitle Yalver © Sart Mechansm 0. dle Mechanism F Moin Cerbureen Sparen g 3 a Job te, 78 Ws nS a0 221 Yn? 240 1 Dperat en F. Accelerating Pame G. Fuol Exhaust Device H. Hol Start Machaniva 1, Indullation of Electrical idle Cut Qut Volves K. Technicel Specilicotans of Solex Ciompaund Geass-Draft Carburctar Fypa 44 PIM V. Allituée Adjustment uf Corburater A. Genera B. Seiecion of Ma C. Solex Altitude Car Disassembly und Atsombly of Carburetors 1 Downlroft Garuratzre for Made!s 180, 190 9, one 180 b 1, Double Downdrelt Carburetors tour Madals 2200 end 21° Ti, Compeund Bawndeeh Corburera: tor Mudel 720 § IV. Compound GrasseDra Carburetor far Model 2054 ir Intoke Silencer and Fyei Feed Pomp ‘A. Inioke Silencer B. Disassembly ond Repsir af Fuel Feed Pur Inake Pips and Exhoust Manifold A. Replocement of Henting Sairal B. Replacement «if Domger Sxcinas C Replocenent of Hester Valve and Shaft Oi Pump Drive, Distibutor Drive, Revelvtien Counter ond Injection Furip Orit: Engine Ubricating System & Generat B Repair al Oil Pure © Cleoning ond Checking (iii Revel Vole in thi: Moin Oil Flow 2. Bisossembly, Cleaning, ard Anserbty of Oil Fiter Engine Coofing System Front Engine Suspension Fomevel and Installation of Loft wt Right Rubbar Mavating ‘of Engine Swipension Removal and Installation of Front Engine Support Rear Engine Suspension A. Three-Point Engine Suspensicn in Models “80, 182.2, 120 b, 160 D. 180 Be, 190.8, "90 Db, 190 34, Zel9, and 215 B. Four-Foint Frgine Suspension in Adadele 190 34, 728, FASE, ond 219 with Hycravlie Avcomolic Chtch Romoval and lastaltetion af Reer Engine Sucpension AL Raber Mountings in Mocals with: Three-Point Engine Suspensio~ B, installstion af Stop Blode ih Reo: Rubber Mowaling ©. Rubber Mountings Laff or Right in Mariels with FaurePawn Engin Suspersiva o7.o:s7 7-059 07.059 ons? 7.0780 0731 ul raed mr 24-071 zea wala md 4.119 Removal and Installation of En together with Transmission On Mrs UB a, 180 b, 190 SL, 720-0, 219, 220, ond 229 SE the removed and irstellativn ope rations far the cngina together with ske transmistion ara baticelly the soma os fos Model 190. Ia addition, the Faftowing anints require etlention Now the var'eus Model 1. Medel 190 SL ISee aso Session Il +o) Engine Hood Before removing the hond, mark the position ‘of the hiege bacring an the left side and unsere the binage Beoring. Tron puch the engine Swod toward the lefl uted cantare i ‘when epinsiglling the angive hood, nake sur fet the hood properly tected ond poy ottention to the mares ae she hinge braving mode ching temaval bj Air Intake Silencer Brtoch the Tlexible hose frome the out inloke pipe ond the ake hosa “ron. the vont tube. ‘and remors the covsr af the ait intoke silae, zac legsthar witk the “exible hose. Then lessen the thiee heaogan scenwee at the Botiem of tha silencer bese. Whan lifting the oir intzke dilencer, eheck tha damfirg piate Deneesn the soul aud the cit intake sifenrer, Bamaged domping plates shouid be replaced, The flesibla Ruse between the ai intaee Siler cer cud the oir intewe pip2 mus not ke Kirkod efor it hos agen installed. <} Fual Overflow Line Disconnect the rubber hose between the fual overflow ‘ing oar che pipe ot the oir scoce ‘ararkel on the cow! ‘On installation glign the wo pipes; fac rukber hose must net be kinked, In adation, moke sre tha: tha pipe an the ir croma bredker is “osrenad in such a Woy chat the distance belwien the lower =nd of the pine wna the drain “unset is appr. 1 man dj Hot-Stert Mechanise: Disconnadi the cortral rable for She hat stor raceFanism frou the sear corburelor Connection and discatnectian of the cantrci cobia avr dreeribad én Jos Na 30-6, €) Spesdamster Drive Gisconnect the Floriblo speedometer drive 0° the: front of the engine. Wiken connecting the drive, mcke sure thal the shaft is 4ot kiaked. ff Oil Filter Unsceevs thy ail diter 9) ing Hearn tha seank 056, nardar fa prevent dir fram getting inta sha oil possayes, cle the apeninys in the crankcase by means o° wooden plugs oF cover chem with lertile “ope. Use a raw gaske- when roinstolling *he &i tikes. 4a} Geor Shift Mechonism Removal: 1. Fold the rubber mot on tha t-ansimeicn unnel over to the led, Alor onscrawing Ine hexagen toapet remove the holding “be +yoke end in position. Then pell cot the shift ube tower the tear From thr splines in she yoke and Installati 4. Mave the shifting shaft agcins® *he reverse geo" tap, pur the gear shi lover vaniicii ‘nesen in the disection of trove’) nnd insert it in the splines of the shitling shaft yoke ond. {this pesiliva tha gaar chit Sever must Ee absolutely worliea’ (seer in tae tirectun of nawal and at right angle lo Then tighten thr: lmexayen nat of the glamp- ing screm cn the yoke end. aia Notes To gain betler accsss 19 tne hexogan ru, it is edtisable Im angege 1" gear withul, hiswnva’, dsplacing “he shift tube in the yoke end, aa ck tne gen shifl enachomistn, Tits ts, angeyy the various geor ond check wnether, whin Iie Gea 2 cegoged, there ig gelficien! cicorcnce bevweer the shiF lave end the upper siF fewer bearing. The shift lever mast ax ag occornt bute against the shifi fever beafng, since this moy tavse fhe goar to skp oul, Abwoy: declureh whan shiffing the imliviouet. yeers 8 Se-wwe nim Te cover plate for the geur stilt inkage ane put oa the rusher mat. UW, Models 180.6, 180, 190SL, 220%, 219, 2205, and 220 SE {For ficd| 990 SE sme oiler Se 1} Cylinder Head Cover Gr Models 719 ond 990 $ with hydraulic auamalic clurch il is advisaale to remove she c¥itder heod caver before liffing out the engine, [nit cnaéas i nach easier to remove fhe engine kngerher wilh toe lronsnnsinsn, 5 he encine car by lifted h’gher of the rar: ) Cluich Actuating Mechanism Madels 1798; Grd 776 m hows Ihrax dilfever versions af the cltch actuating mechaniaa, 3 Madels 180 c, 18Gb, 217, 7298, and hove only she latest versinn, which » slaFeed in Midel 192 The installation and vecnaval procedures for the Such acluatng sichorinn uve cienen: for the dhfferen| versions, Fos dotcile soe -2b Ro, 21-1 si Reversing Light Switch On the fist curs af Madel 226 0 the reversing ight swite’s wos moun-ed

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